REPORT ON INPLANT TRAINING AT DALMIA CEMENT(BHARAT) LTD ARIYALUR FROM 20.05.11 TO 26.05.

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by G.Lakshmi & S.Shree janani 3rd year Easwari engineering college Chennai

We thank Mr.RA.Krishnakumar, Unit head, Dalmia cement(Bharat) ltd for accepting the request from our college for implant training. We also thank Mr.S.K.Mukhopadhyay, Mr.B.C.Devaraju, , Mr.C.Basavaraj, Mr. Kanaga subramaniyam Mr.Vinod & Mr.P.Dhanpal for patiently guiding us in understanding the cement manufacturing process and various instruments associated with it. We also thank Mr.Nachiappan, GM-Captive power plant, Mr.Nandakumar, Mr.Sampath, Mr.Shivakumar for patiently guiding us in understanding the operation & automation associated with the steam power plant. This implant training gave us an industrial exposure & helped us to understand the practical application of the theoretical concepts that we studied during our coursework.

Firstly, an introduction to the cement manufacturing process & associated safety measures were given. We were briefed about the various sections of the plant, namely Crusher section, Circular stacker reclaimer section, Linear stacker reclaimer section, Raw mill & Coal mill section, Pre-heater & Kiln section, cooler section, cement mill section & packing section. We were then introduced to various parameters being monitored & the field instruments used to monitor them. Few of the critical parameters monitored include, pressure, temperature, weight, speed. Some of the instruments employed include DP transmitters & sensors, thermocouples, RTD, load cells, vibration sensors, tacho encoders, proxy pickups, metal detectors, zero speed detectors. The special equipments uniquely used in this plant include cross belt analyzers & nucleonic gauges. Various safety instruments like pull chords & sway switches are also employed here. This plant is automated using ABB distributed control system (DCS).Profibus communication system is used to communicate & control various analog & digital inputs & outputs from the CCR.All alarms in case of any tripping are conveyed to the personnel manning the CCR through a SIM card as message(SMS) connected to the server. First we were taken to the crusher section. There we were shown & explained as to how the raw material, i.e. Limestone ,is transported

from the mines to the hopper, mixed & fed to the crusher based on various parameters like LSF, alumina content etc. The operation of the primary & secondary crusher was explained & we were able to see the reduction of size of the limestone in this section. Any metal object present is removed using metal detectors & discarded before the limestone is fed into the secondary crusher. Next we were shown the circular stacker reclaimer section, where the crushed limestone from the crusher section brought in through conveyor belts & is built uniformly by a circular motion using the reclaimer. We then visited the raw mill & coal mill section. We learnt about the operation of VFD drives. Vibration sensors are used to sense the vibration to help smooth functioning of the mill. We also were acquainted with the linear & circular release gates used to stop or start the material flow. The compression system used includes a damper & supply arrangements. Next we visited the pre heater section. 5 cyclones were present in which raw meal was passed through for the kiln section. Opacity monitors is employed for dust monitoring. Various other gas analyzers, namely, CO, SOx, NOx, O2 are employed here. To remove blocks air blasters are used.

We then went to the kiln section where the coal from the coal mill section & raw material from the pre heater is calcined at a temperature of about 1200 deg C. The kiln is at an inclination of 4.1 deg to facilitate the easy flow of materials. In case of any material jam manual clearance is employed. CCTV cameras are employed to check the material flow from the CCR. The camera is up to half way through the kiln .The kiln is initially fired up using a diesel pump & burner set up After firing, the coal from the coal mill is used for continuous burning. Four drives along with limit switches & auto greasing facilities are employed to keep the kiln rotating at a speed of 4.4 r/min. Limit switches are used to limit the rotation of the drives in case of expansion of drives due to heat. The calcined material (clinker) is then sent to the cooler section where it is cooled using water spray from a condenser system. 4 LVDTs have been used to check material flow in this section. Air blasters are used to remove jamming of materials. The cooled clinker is transported to the clinker silo through deep pan conveyor whose speed is measured using tacho meters & proxy pick ups. Load cells are employed to measure the weight of the clinker. Sway switches & pull chords are employed for safety purpose. The clinker from the clinker silo is fed into the hopper. Weigh feeders are used to measure the materials in tones per hour & transport them to the cement mill section. The cement mill is

divided into 3 sections namely, feeder section, recirculation section & transport section. Along with the clinker, various additives like wet/dry fly ash & gypsum is transported. Before the clinker is fed into the hopper, it is passed via metal detectors. In the feeder section the clinker is fed into the hopper along with gypsum & fly ash for PPC & gypsum alone for OPC. In the recirculation section, metal detectors are employed again to check for metals. Any metal detected is sent into the reject bin through gates. The clinker is now passed through a pump where the fine materials are further passed & coarse materials are filtered out & re-circulated in order to reduce their size. From the hopper, the cement so obtained is sent through air slides to the cement silos. Bucket elevators are used to transport the cement to the respective silo (OPC or PPC). To prevent material accumulation in the bucket elevator system, boot blocks are used. Sway switches & zero speed detectors are used for safety purpose. In order to start the cement mill, an initial temperature of 90 deg C is required. This temperature is obtained by the hot gas generated in the kiln, if the kiln is operational. This way any wastage of hot gas inside the plant is prevented. All the above mentioned units are controlled & monitored from the CCR. The cement from the cement silo is sent to the packing unit via bucket elevators. Vibrators are used to prevent the settling of

cement. The packer unit fills the bags up to 50kgs of cement. The packed cement is transported via conveyor belts to the trucks. The packing unit is separately controlled from a control station as the functioning of this unit depends upon the cement demand. QUALITY CONTROL The quality of the cement is checked at four stages. Samples from various parts of the plant are sent as capsules periodically as per requirement. The capsule container is emptied by the robot & the container is sent back to the sample drawing site. This robot has been programmed to operate on the samples of analysis. The samples are compressed as disks and are analyzed for 5 various elements, namely calcium, alumina, silica etc. using the XRF analyzer. Based on periodic monitoring of quality by this way the ratio mix of the raw materials is controlled.

CAPTIVE POWER PLANT

The captive power plant has a capacity of 27MW. We were first given an overview of the power plant and the automation employed. The power plant uses GE OCK 4000 DCS system. Two sets of Ethernet cables namely master and slave are used. Optical fiber cables are also used. The speed is 100 Mbps with a response time of about few seconds. 5 controllers along with respective backups are connected to the Ethernet cables. In case of any failure the backup controllers are used. The parameters controlled here include temperature, pressure, capacity & vibration. The field measuring instruments include DP transmitter, thermocouples & RTDs etc. The power plant consists of three main sections namely, the boiler section, turbine section & condenser section. The boiler section consists of furnace, economizer and air pre heater. The boiler used in this plant is CFDC water tube boiler. In the furnace, 400mm of sand is maintained in the bottom. Hot air from the air pre-heater section is blown into the furnace through primary air heater fan & secondary air pre-heater fan. This results in heating of the sand bed. Now the coal is sprayed from the coal hopper which results in combustion. A temperature of about 800 deg C is obtained. Water from the DM (De-mineralization) plant & condenser is stored in the steam drum at a pressure of 107 kg/cm2.This is supplied to the water tubes inside the boiler. Before

supply, various parameters like pH, temperature & presence of minerals in water are analyzed & a de-aerator is used to remove O2. Due to combustion, steam is generated in the water tubes. The temperature of the steam is 540 deg C. The steam from boiler is sent to turbine section for expansion. In the turbine section, governor is used to guide the steam into turbine blades. The turbine employed here is impulse/reaction turbine. The shaft of turbine is coupled to the alternator through gear box. The speed of turbine is 7500 rpm while the speed of alternator is 1500rpm. The expanded steam is sent to the condenser where it is condensed using 6 fans. The water hence obtained is circulated along with the makeup water to the water drum. The alternator is cooled using air through condensers. The power generated through the alternators is connected to the power grid after synchronization. This power generated is used to run the cement mill.