NOBLE ENGINEERING COLLEGE JUNAGADH

TRAINING REPORT AT GUJARAT SIDHEE CEMENT LIMITED (GSCL) VERAVAL (GUJARAT)

DURATION: 01/06/2011 to 15/06/2011

PREPARED BY: SONAGRA NIKUNJ K. (080350119055) MANDAVIYA SMIT H. (080350119023)

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GUJARAT SIDHEE CEMENT LIMITED - SIDHEEGRAM

A REPORT ON DEPARTMENTAL TRAINING PROGRAMME

Prepared By: MANDAVIYA SMIT H. (MECHANICAL)

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INDEX

Sr. No:

Topic Name

Page No

1 2 3 4 5 6 7 8

General layout of cement plant Production Department Mines Department Mechanical Department Instrument Department Quality Control Department Electrical Department Distribution Department
PREFACE

6 7 11 12 22 23 24 25

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I have gone through various departments training program from 01/06/2011 to 15/06/2011. Form this training I learnt basic function of various department, activity done by them, and what are the role of various department to increase productivity. Each and every department contributes to increase the productivity of plant. Every department stand as a column for organization. In this report I describe what I learn during training programme. First I describe function of department and various section covered by department. What are the responsibilities of department have that I cover. In electrical department I describe power circuit, various electrical motors and other electrical equipment used in plant. In production department I describe various process involve to make clinker and cement. In mechanical department I explain material flow diagram and various equipment uses, what kind of drive used to run machine etc. And basic function of various other departments I explain in this report.

ACKNOWLEDGEMENT

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I have started training in Gujarat sidhee cement limited from 01st June 2011 in mechanical department. Gujarat sidhee cement limited is a reputed mehta group company I thankful to company, which gives me this bright opportunity for my bright ahead future. I thankful to Mr. K.A. Zala who is sr. manager of P & HR department who give me this opportunity to make this report. I hearty thankful to Mr.Makwana sir who allow me to go anywhere in plant premises. I thankful to all HODs, Sr. manager, Manager and deputy manager who help me at site as well as in office for technical discussion that increase my knowledge and this knowledge help me in future also. All engineers help me lot to understand technical detail and various operations. I also thankful to mechanical department fitter who help me in practical aspects.

GENERAL LAYOUT OF CEMENT PLANT

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PRODUCTION DEPARTMENT

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I was in production department, I Shaw and understood various processes to make clinker and cement. Main reaction process occurs in kiln at 1400C to make clinker. To make cement grinding and rubbing processes take in cement mill. Main process is as below:

MINING:
They have two types of mining process: Conventional mining (Blast mining) and Ecofriendly surface mining. In blast mining, Drill a hole with the help of drilling machine and fill the explosive material into that hole, allow exposing and it will take limestone from earth. Second one is the surface mining. In the mining surface miner is used to extract the limestone from earth. Blast mining is dangerous for surrounding village because it creates shock. They have very rich captive mines. Two mines actually they have one is morasa mines and other ones is prasanavada mines. In this mines almost all grades of limestone is available and a very little quantity of additive is to be added from outside to prepare raw-mix.

CRUSHING:
The mined limestone is hauled through Dumpers to a rotary hammer - impact type crusher that crushes the limestone to a size of 80% up to - 75 mm size. Additive material is added to the crushed limestone through an additive hopper, which bypasses the crusher.

STACKING:
The material is passed on to the stacker via belt conveyors, which stacks the material in longitudinal layers. To perform this function they have chevron-stacking stacker, which was supply by Elecon Company.

RECLAIMING:
They having end reclaim type reclaimer. The stacked material is lifted by the reclaimer, which reclaims it by cutting transversely the longitudinal stacked layers ensuring perfect blending and homogenizing. The reclaim material is transported to raw mill through belt conveyors.

RAW MILL GRINDING:

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They having Atox-40 vertical roller mill. The desired material is drawn from lime stone reclaimer pile to the Box feeder and is fed to the vertical roller mill through chute. The vertical mill consists of a rotating table upon which 3 rotating rollers are hydraulically pressed. The material is dried and transported by the hot kiln exit gases. The size of the pulverized material is controlled by a static separator, which separates the oversized particles and sends it back on the table for further grinding. The pulverized material is transported to the C.F. Silo via energy efficient bucket elevators.

PROCESS IN C.F.SILO:
The pulverized material is stored and blended in the controlled flow silo. The blending action is achieved by extracting the material from the 7 outlets at a different flow rate. The extracted material is conveyed to a weighing bin were it is further blended. The operation of extraction is controlled by a PLC. The blended material is fed to the pre heater for preheating via bucket elevator.

PREHEATING:
Preheating process is done in the preheater and pre-calciner string having four stage cyclone. Approximately 40% of the total feed is given to the pre heater string where it get preheated by the hot kiln exit gases and gets calcined up to 30% approximately. The balance 60% feed is fed to the calciner string where coal is fired in the calciner and the 30% calcined feed from the pre heater string is also added to the calciner. Here, about 90% calcinations are achieved. Chemical formula of this process (at 900C) is as under: CaCO3 900c CaO + CO2

KILN PROCESS:
The material comes from ph and pc string is feed into the kiln where remaining 10% Calcinations process is done. This calcined feed is transferred to the kiln for the remaining 10 calcinations and sintering where the flux materials and silica melt and react with lime to form four clinker constituents. This is achieved by firing coal in the rotary kiln. Kiln capacity is 4000 TPD.

CHEMICAL REACTION PROCESS:

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Sr no.

Temperature

Chemical Reaction

I II

Below 800oC 900 - 1100oC

Decomposition of CaO.Al2o3 begins

limestone

&

formation of

III IV V

1. Decomposition of Calcium Carbonate is complete. 2. Formation & Decomposition of Gehlenite (2CaO+Al2O3+SiO2) 3. Formation of C3A, C4AF starts. Formation of C2S, C3A & C4AF is nearly complete.

1000 - 1200oC 1200 - 1300oC Liquid formation starts. 1200 1450oC Assimilation of CaO through solid-liquid reactions & formation of C3S

COOLING:
They have Folax type cooler. The clinker coming out of the rotary kiln is at a temperature of 1200 -1300 0C and hence cooling of it is required. This is achieved by pumping atmospheric air in the reciprocating grate cooler by 7 centrifugal fans. The clinker gets cooled and the air gets heated up and the excess air is vented out at a lower temperature.

CLINKER STORAGE & TRANSPORT:

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The clinker, which is cooled to 150 C, is stored in a silo, which has a capacity of 40,000 M.T. The clinker is transported to the silo by deep bucket conveyors. The silo for clinker is a salient feature of the plant, as the clinker does not get weathered. Another silo of 2000 M.T. Capacity is provided to store specified products/non conforming products. The clinker from the clinker silo is transported to the clinker silos of the cement mills for grinding.

CEMENT GRINDING:
The clinker is ground along with gypsum and slag at desired proportion in the highly efficient Cambodian mills. The cement mills are two compartment tube mills. In the first compartment, the grinding is done by impact with balls and in the second compartment; it is done by attrition with small grinding media cylinders called cyllpebs. The mill is swept with air, which transports the material through the mill. The cement is pumped to the cement silos with the help of airlifts. There are four silos for cement of 5000 M.T. capacities each for storing different grades of cement.

RAW COAL & FINE COAL PLANT:

Raw coal is also stacked and reclaimed by a stacker and reclaimer hence ensuring a perfectly blended Raw Coal. This is a unique feature of the plant. The Raw Coal is pulverized in a vertical roller mill, which is similar to that for the limestone. They have Atox-22.5 vertical coal mill. Pneumatic screw pumps fire the coal.

PRODUCT:
They make ordinary Portland cement of 43 grade and 53 grade. This grade indicates compressive strength of cement. They also make fly ash base pozzolona Portland cement. In ordinary Portland cement 95% clinker and 5% gypsum add in cement mill for grinding. In case of pozzolona Portland cement 75 to 80% clinker, 15 to 20% fly ash and 5% gypsum is added in cement mill. Gypsum helps to set setting time of cement. Fly ash is the waste product and it pollutes the environment so if it use in cement plant pollution reduces and it reduce the clinker consumption. It also works as filler material in this mixture.

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MINES DEPARTMENT
They have two captive mines namely prasanavada mines and morasa mines. These mines have all grade of limestone, which provide raw material for cement production. Two types of mining process are available namely surface mining and blast mining. In surface mining surface miner is used to extract the limestone and in case of blasting mining blasting is done with the help of explosive materials. Mines department have various HEM machineries to extract limestone and to transport it. Those are Excavator, Loader, Dumper, Dozer, Drill machines etc. Excavator is used to extract the lime from mines. Loader is used to load the dumper. Dumper is used to transport the material from mines to crusher, Dozer is used to level the ground surface and Drill machine is used to drill a hole for blasting mining.

MECHANICAL DEPARTMENT
I was in mechanical department for work distribution they are having 8 major sections from mechanical point of view they are as under: GUJARAT SIDHEE CEMENT LTD. Page 11

1. 2. 3. 4. 5. 6. 7. 8.

Crusher section including stacker and reclaimer Raw mill section Kiln and cooler section Coal mill section including stacker and reclaimer Cement mill section Packing plant section Utility section MIPS section (Monitoring, Inspection, Planning and scheduling)

CRUSHER SECTION:

IMPACT TYPE CRUSHER As shown in above figure the material comes from mines are fed to the feeder hopper then it is passed to the approan feeder, which regulate the material flow into the crusher. Approan feeder is control from the crusher operator room. From approan feeder material is fed into the crusher where it crushes in 75 mm size. Approximately 80 to 85% materials is crushed in this impactor. Crushing action takes places at front impact arm, rear impactor arm and in grinding path but now due to surface mining this grinding path is remove from it. In single rotor impactor there are six evenly distributed blow bars, which crush the materials. At the timing of maintenance care should be taken that approximately same weight of blow bar is replaces at that place. Wear of blow bars depend upon the material comes from mines. In case of high grade limestone wear is low because in this kind of limestone sio2 present in less quantity. And in case of low-grade GUJARAT SIDHEE CEMENT LTD. Page 12

limestone due to sio2 present in higher percentage wear of blow bar is more. To run the single rotor impactor 1200kw motor is used which has 990rpm. Power is transmitted from motor to impactor shaft through belt drive. Speed of rotor is approximately 319 rpm. Capacity of impactor is 900TPH. During monsoon problem of coating in chute and other parts of impactor occur to remove this coating Pressurize air is purge from cylinder. After the material crushed in impactor it is conveyed through belt conveyor up to stacker. Various belt conveyors like BC-1 transport the material from crusher to BC-2. And BC-2 discharged the materials in BC-3, which takes the materials at stacker.

STACKER:

Stacker makes the piles of materials, which are come from crusher. With the help of BC-3 material rich at stacker which makes longitudinal piles. Boom belts are there to do this function. Rail track is there for the movement of stacker. To run the stacker on rail gear drive is used. For boom belt position, wire rope is provided. To prepare homogeneous mixture of material stacker is used. They make two piles of material.

RECLAIMER:

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RECLAIMER Reclaimer is used to cut the longitudinal layers prepared by stacker in transverse direction. It is important device to prepare homogeneous mixture. It also moves on rail track by gear drive. Material is transport to belt conveyor through bucket of reclaimer. Some teeth buckets are also provided to remove hard material from ground. Harrow is used to down the material from pile. Movement of harrow is done by hydraulic oil. Piston cylinder type hydraulic system is used to move the harrow.

BELT CONVEYOR :
There are three belts conveyors which transport the material from reclaimer to raw mill. Namely BC-4, BC-5 and BC-8.To run the Belt conveyor Fluid coupling and gearbox are used in between motor and head drum shaft. To run BC maintenance of fluid coupling and gearbox is necessary. To join belt three types of joint are there: Hot joint, Cold joint and fastener joint. They have another belt conveyor BC-4A for additive materials. Magnetic separator is provided to separate the metal particles.

SPECIFICATION
BC-1

WIDTH (mm)
1400

CAPACITY (TPH)
900

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BC-2 BC-3 BC-1A

1200 1200 1400

1000 1000 150

RAW MILL:
The function of raw mill is to grind the limestone material comes from reclaimer. To perform this function they have vertical mill that is atox-40 mill. In this mill one rotating table is there which is rotate by 2000kw motor through gearbox and hydraulic system. Grinding action take place between roller and table. In mill there are three roller arranged at 120C on the table. Roller move up and down to crush the materials this movement is achieved by hydraulic accumulator. Hydraulic cylinder is attached with roller through push rod at joint head and another arm that is torque arm with roller. All three rollers are connected at center by yoke joint. Main two parameters on which output of mill depend on air nozzle gap and dam ring height. Water spray is also done into the raw mill to control the output of mill. Material flow takes place due to hot air circulation with the help of ph and pc fan. After grinding of material, this material is transported in to the cyclone with help of booster fan. To run the booster fan 2000kw motor is provided. The function of cyclone is to separate the air and material from mixture. After this air is pass through ESP where all material is recovered and this material is transported through screw conveyor and drag chain in bucket elevator.

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RAW MILL OPERATION

OPERATION:
Material is grinding due to shear force and impact force of roller and table. Weight of one roller is approximately 25 ton. Grind material is sucked by the booster fan material and air is separated in the cyclone. Air which is separated in cyclone is further passed through the ESP to recover the material from air. Hot air coming from PH and PC string helps to dry up the material and transport it. DP is one of the most critical parameter for raw mill. It is the differential pressure of inlet gas and outlet gas. To get desire output of mill it is important and up and down movement of roller is governed by this DP. Fine grinding material is transported to C.F. silo through air slide and bucket conveyor. In air slide two parts is there, in down side air is flow with help of blower and at upside material is flow. Due to movement of air material is transported in air slide. Material comes from air slide is transported through bucket elevator into the C.F. silo. Capacity of raw mill is 280 TPH. GUJARAT SIDHEE CEMENT LTD. Page 16

 C.F.SILO:
The function of continues flow silo is to store the material and provide homogeneous mixture to the PH and PC string. This provides continues flow to the kiln feed. C.F. silo has a capacity of 20000MT.The diameter of it is 22.4 mtr and height is 44.2 mtr. At the bottom of silo seven outlet is there which gives materials flow at different rate and this seven outlet is merge at weigh bin to provide homogeneous mixture. From C.F. silo material is transported through bucket elevator into the PH and PC string.

Bucket elevator

C.F.silo

Weigh bin

Air slide

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 PH AND PC STRING:
To utilize the kiln hot gases and for calcinations process material is passed through PH and PC string. They have two string for calcinations process, in this process CO2 remove from limestone at 900C this is achieved in PH and PC string. Four stages are there in one string material is passed through these four stages of one string for this calcinations process. In this two string hot kiln gases is used which is sucked by PH fan and PC fan. To remove coating from this string high-pressure air cylinder is provided at regular interval. In PC string coal firing is done to achieve 900C temperature.

KILN:

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Kiln is used to form clinker from limestone. In kiln main process to make C3S, C2S, C3A and C4AF is occur. Kiln length is 75mtr and Diameter of it is 4.35mtr. Inclination of kiln is 4%. To run the kiln DC motor is used to get high torque and gear drive is also used. Gear teeth are mounted on the circumference of kiln and pinion is attached with motor shaft. Kiln is supported on three-tire and roller assembly. Kiln is divide into three zones: 1. Cooling zone 2. Burning zone 3. Calcination zone

COOLER:
The clinker is coming from kiln is at 1200 to 1300C temperature so cooling of it is necessary. It is cooled in cooler with the help of atmospheric air. 8 cooling fans are used to perform this task. In cooler there are three grate plates on which clinker is cooled. Grate plate arrangement is such that one moving plate raw and second stationary plate raw. These plates are supported on beam, which is run by electric motor through connecting rod and roller. Air is pumped from atmosphere to cool the clinker. Heat transfer take place in between clinker and air so air becomes hot which is passed in many area. This area is listed below: 1. Kiln as secondary air 2. Coal mill 3. Tertiary air duct 4. ESP This distribution of hot air is depending on the pressure difference. Hammer crusher crushes clinker at the last stage of cooler. This clinker is transported to the clinker silo, which has 45000 MT capacities with the help of deep bucket conveyor.

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 COAL MILL:
They use two type of coal namely coal and pet coke. These coals are crushed in hammer crusher and then it transported to stacker. The function of stacker and reclaimer is same as limestone stacker and reclaimer. Coal is transported into coal hopper through belt conveyor. After that coal is fed into the rotating coal table and then it is enter into the coal mill for fine grinding. Coal mill grind the coal into the fine form with the help of three rollers and table assembly same as raw mill. Fine coal is sucked with the help of ESP fan and sends it to cyclone where it separates from air. The air is then passed through the ESP to recover fine coal from air. With the help of screw conveyor it is send to ground bin from here it send to the LO2 and LO5 with PS pump. Then this coal is transported in the kiln burning in pipe and also for PC vessel firing.

CEMENT MILL:
In cement mill there are two units for grinding of clinker. They have two-clinker silo, two gypsum silo and two fly ash silo. Clinker is transported through belt conveyor at cement mill. In cement mill, two chambers are there for grinding and rubbing action. In first chamber spherical balls are there to grind the clinker and to rubbing it cyllpel are there in second chamber. Cement mill is run with the help of 3600kw motor. Cement mill efficiency is only 1% other power is lost in other auxiliary. For ideal condition 70% material and 30% media load is required. To ensure perfect grinding diaphragm is there in between two chamber. Cement mill is 14 mtr long and 4.2 mtr in diameter. Its capacity is 105 TPH. For the proportion of clinker and gypsum and in case of PPC fly ash also speed control motor is provided. Grinding cement is pass through belt conveyor and air lift to rich at cement silo.

Diaphragm

Motor Coupling

Chamber-2

Chamber-1

Inlet

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CEMENT MILL

PACKING PLANT:
To store the cement they have four cement silos. In silo no-1, 3,and 4 OPC cement is stored and in silo no-2 PPC cement is stored. It is then pass into the air slide to bucket elevator Bucket elevator transported the cement in hopper that is then feed into the rotary packer. They have for rotary packers that have a capacity of 95 TPH. After Bag is pack in packer it is directly transported into the truck with the help of belt drive.

PACKING PROCESS

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INSTRUMENT DEPARTMENT
I was in instrument department, i leant various instrument used by this department for the measurement of various quantity like thermocouple for temperature measurement, pressure transmitter for pressure measurement etc. I Shaw logical programme language, PLC, SCADA and some information about the fuzzy logic and opto22 system used by them. For the measurement of any quantity almost same circuit is used which are shown below:

Measurement device (e.g. thermocouple)

Transducer (which convert input signal into desire signal)

Transmit in PLC

On screen Measurement device measures the signal in its measurable form suppose in thermocouple it produces the mili volt signal and it convert in degree centigrade with the help of transducer. Then its signal is given to PLC (Programmable Logic Control) and its shown on screen in CCR.

TEMPERATURE MEASUREMENT DEVICE:

1. Thermocouple 2. RTD (Resistance Temperature detector) 3. Radiation pyrometer According to temperature range this equipment are used in the plant. Two cameras are provided at crusher section and kiln section to see situation on screen. Various interlocking given at different place on the basis on right path of material transport and to save power consumption.

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QUALITY CONTROL DEPARTMENT

Quality control department check the quality of raw material, limestone, clinker and cement at various stages. This department has four laboratory namely testing lab, physical lab, chemical lab, X-ray lab. In testing lab, Sample is bringing from various section at hourly basis. Sample is taken from Raw mill, Kiln feed, Clinker, Cement grinding and cement packing. Here all sample come first and then it send to correspondence lab. In chemical lab they test raw material, limestone extracted from mines. They test following raw material to check total moisture, intermediate moisture, volatile matter, ash and sulphure. 1. 2. 3. 4. 5. 6. Coal and pet coke Bauxite Red soil Gypsum Basalt Sand stone Fly ash

To measure above parameter they do titration test in chemical lab. In Physical lab they do Blaine test, Compressive strength, Expansion test, and Setting time test. In Blaine test they have Blaine apparatus to check the Blaine of materials. This test gives the fineness of material. In compressive strength test they make block with 200gm fine sand, 200gm medium sand, 200gm course sand and 200gm cement. This block is kept at some define temperature. Then it kept in water for setting it. At 1st. 3rd, 7th and 27th day it compressive strength is measure with the help of compressive strength apparatus. On the basis of this strength grade of cement is given. Expansion test is also done in physical lab. To measure the expansion of cement for that circular tab late is made and is kept in between two wires. Setting time or Water consistency test is done with the help of needle apparatus. There are three apparatus for this test. At last only one ring should be shown on sample. In mines sample test various parameter are checked like silica, Alumina, Iron, lime etc. if among this anyone found in less percentage then it add from additive belt. Sand stone, bauxite, basalt, red soil, high-grade limestone is added in the material. For cement test they take sample at grinding and packing also.

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ELECTRICAL DEPARTMENT

ELECTRIC MOTORS:
In motor two main parts are Rotor and stator. Supply voltage is given to stator and due to law of electromagnetic induction rotor is rotate about its axis. Motor frame is provided to enclose the rotor and stator generally it is made up of cast iron. Motor failure occurs due to any one of following reason. 1. 2. 3. 4. 5. Protection Relay not operated. Motor running hot winding overheated. Water entry inside motor. Very old motors. Insulation failure.

Main motor capacity and rpm: LOCATION Crusher main drive Raw mill main motor Raw mill buster fan Raw mill ESP fan Pre-calciner fan Pre-heater fan Kiln main motor (DC) Coal mill main motor Coal mill ESP motor Cement mill main motor RATING (KW) 1200 2000 2000 875 2000 1315 496 550 550 3600 RPM 990 980 980 990 990 990 1000 988 988 594

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DISTRIBUTION DEPARTMENT
They have two markets: Local market and Export market. Order of export market is receive at Mumbai market office. Order of local market is receive at their market branches, which is area wise divided. Local market branches are at Ahmedabad, Rajkot, Surat, Baroda, Junagadh, Bhavanagar etc. They have Ramco system limited with the help of this system they are online with market branches. They prepare dispatch advice slip as per order receive and it is given to transporter. They have area wise transporter for local market.

DISTRIBUTION PROCESS

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REFERENCE

www.sidheecement.com
GUJARAT SIDHEE CEMENT LTD

Off Veraval Kodinar Highway Sidheegram 362 276 Gujarat

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