Upload
essakkirajm
View
5
Download
1
Embed Size (px)
Citation preview
INPLANT TRAINING UNDERGONEINPLANT TRAINING UNDERGONE
in
THE INDIA CEMENTS LTDTHE INDIA CEMENTS LTDSANKAR NAGAR-WORKSSANKAR NAGAR-WORKS
TIRUNELVELI 627357TIRUNELVELI 627357
Reported by
ESSAKKI RAJ.M (01107153016)
B.Tech 2nd year PetroChemical TechnologyANNA UNIVERSITY
THIRUCHIRAPPALLI-620024
DECLARATION DECLARATION
I am ESSAKKIRAJ.M hereby declare that the Training
report entitled “Mechanical Operations in cement
manufacture” is done by us under the permission of
Mr.Santhanamuthu, Dean & Mr.Saker, Head of
PetroChemical Department and
Mr.Kumaraguru(class inchare) ANNA UNIVERSITY,
THIRUCHIRAPPALLI-620024 to improve my technical knowledge in
BACHELOR OF TECHNOLOGY.
DATE :
PLACE:
SIGNATURE OF THE CANDIDATE
(ESSAKKIRAJ.M)
Mr.Antony (L..C.R unit)
Mr.Kasi (V.R.M unit)
Mr.Varatharajan (Coal mill)
Mr.Senthil (Cement mill)
Mr.Kailasam (Workshop)
Mr.Appadurai (Packing section)
CONTENTS
S.NO TOPICS
1. INTRODUCTION
2. COMPANY PROFILE
3. POLICIES OF THE COMPANY
4. MANUFACTURING PROCESS
(i) Crusher
(ii) Vertical roller mill
(iii) Kiln
(iv) Coal mill
(v) Cement mill
(vi) Packaging
5. FUNCTIONAL AREAS OF MANAGEMENT
a. Maintenance management system
b. Information management system
c. Marketing management system
d. Quality analyzing system
c. Finance and account’s management system
d. Personnel management
6. CONCLUSION
ICL - INTRODUCTION:
The India Cements, which is located in Sankarnagar, manufactures cement, which fulfills the entire requirement of south Indian people. The company was incorporated in 21st
February 1946. On the starting stage wet process technique was used which was converted to dry process in the year 1990.
COMPANY PROFILE: The India Cements, which is located in
Sankarnagar, manufactures cement, which fulfills the entire
requirement of south Indian people. The company was
incorporated in 21st February 1946. The initial annual capacity of
one lakh tones is increased gradually reaching 463000 tones by
1959. In August 1990, the wet process technique is converted to
dry process and the existing wet process kilns were replaced with
a modern single dry process kiln increasing the capacity of the
plant to one million tone per annum. On 10th April, the Bureau of
Indian Standards (BIS) granted ICL Sankarnagar the license for
quality systems certification “ IS/ISO 9001:2000 “ in respect of
the manufacture and supply of the cement.
CEMENT
Cement may be defined as an adhesive substance capable of
uniting fragments or masses of solid matters to a compact mass.
Cement is the lifeline of construction industry and cement constitutes
about 15% of the construction cost.
SUBSIDIARY COMPANIES OF
ICL :
ICL Foundary Ltd
ICL Securites Ltd
ICL International Ltd
ICL Financial Services
Industrial Chemicals and
Monomers Ltd
DIVISIONS : Shipping division
Wind form division
Real Estate , Property
development
AWARDS WON:1. Corporate excellence award from SEBI.
2 .Best presented accounts from institute of charted
accounts.
3. CAP EXIL special award from Export from Port Trust.
4. Traffic promotion award from Port Trust.
GOLDEN JUBILEE:
ICL celebrated the Golden Jubilee on 21st February 1996
for that all workers received some gift. And the experienced
employees got special award by the chairman
COMPETITORS: MADRAS CEMENTS LTD
ACC GROUPS
ULTRA TECH
GUJARAT AMBUJA
GRASIM INDUSTRIES
TYPES OF CEMENTS:
The ICL is producing three types of cements, which suits the
. customer requirement
Ordinary Portland Cement (53 Grade)
Ordinary Portland Cement (43 Grade)
Portland Pozzalona Cement
POLICIES AIM: This plant is maintaining many policy for
* Environment
* Quality
* Safety
Environmental policy : Protect the environment by the prevention of
pollution.
Compliance to relevant environmental
regulations.
Continual improvement of environmental performance
energy conservation, waste minimization and
wherever practicable waste utilization.
Propagation of environmental policy to all
employees
Quality policy : Maintaining consistent quality
Maintaining cost effectiveness
Ensuring customer satisfaction
Ensuring continual improvement
Safety policy: Some safety aspects are given below:
There should be adequate natural
ventilation through doors, Windows
and
ventilators. Local exhaust
ventilation should be provided.
Hazardous Process should be in
closed to prevent contamination of
the air in the workroom.
Good house keeping should be
maintained.
Workers should be provided with
approved Protective equipments like
masks (or) respirator goggles,
aprons etc.
Adequate Protective clothing should
be given to workers where
necessary like aprons, gloves,
books, caps and hoods.
If necessary Protective ointments
for hands arms and face should be
provided.
FLOW CHART OF MANUFACTURE OF
CEMENT
RAW MATERIALS
(LIME STONE + IRON ORE + BAUXITE
VRM(VERTICAL ROLLER MILL) - GRINDING - BLENDING
SILO
FIVE STAGE Pre heaters - CLINKER - COOLERS -
CLINKER SILO
CEMENT MILL GRINDING
( CLINKER+GYPSUM ) ( CLINKER
+FLYASH+GYPSUM )
43,53 GRADE OPC
PPC
CEMENT SILOS CEMENT
SILOS
PACKING PACKING
(House 3 &4)
(House 1,2, 5&6)
STEPS INVOLVED:
The following are the various steps involved in the
manufacture of cement.
CRUSHER,STACKER&RECLAIMER
VRM
KILN COALMILL
CEMENT MILL
PACKING
CRUSHER:
Chute
Chute Additive Hopper
L.S Hopper
Stackar
CRUSHER FLOW DIAGRAMCRUSHER FLOW DIAGRAM
CRUSHER
Reclaimer
Hoppers
There are two crushers (New and Old crushers).
OLD CRUSHER (HAMMERTONE CRUSHER):
Limestones are brought through laminated conveyor from the
hopper.
Laminated conveyor has high load capacity. It can be used
only for short distances.
There is a membarane shaft, which connects the crusher to
the motor instead of belt.
In crusher, there are 10 hammers, which breaks the incoming
LS.
The hammer arm which contains hammer is connected to the
flywheel and then to the motor.
The broken LS comes out through grate bar to the belt
conveyor.
The capacity of the crusher is 150 TPH (tonnes per hour).
The LS entering the crusher are limited to the size of 800 mm
and the out going particles are of the size 75mm.
The power of the motor is 1000 hp.
NEW CRUSHER (IMPACT CRUSHER):
SPECIFICATIONS:
Crusher motor power : 448kW
Speed of the motor : 988rpm
Approximate speed of crusher : 400rpm
No. Of blades in the crusher : 6
Design capacity : 5020TPH
Motor power rating four apron conveyor : 55kW
Apron drives are used to transfer LS to the crusher from
mining.
The centre rotating area is called rotor.
There are 6 blow bars on the rotor, which rotates by a 3-phase
induction motor.
These blow bar cuts the LS to 75 mm through no. Of stages
from 300 mm.
There are fixed blades called stator blades in the crusher
whose distance from the blow bar decides the diameter of the
LS.
The temperature of the blow bar is measured by using
scanner.
The LS from the crusher moves to the stacker through belt
conveyor.
TRANSFER OF LIMESTONE FROM CRUSHER TO STACKER:
1) By apron feeding mechanism LS are brought into the
crusher.
2) There is a Grizzly filter in-between this, which separates LS
less than 95 mm into belt conveyor (1020).
3) The grinding particles (dust) from the crusher are brought
into 1020 belt conveyor.
4) From 1020 the dust particles along with hot gas are taken
to bag filter system which absorbs the dust particles using
bags. Bags are inserted into a case. Air of capacity 30000
cu.m/hr is passed inside and comes out through air vent.
The timer is activated once in 15-20 seconds. The bag
bulges and retards due to the entry of this air inside the bag
the suspended dust particles fall down to the dust hopper.
Beneath the dust hopper there is a sump and a rotary air
lock. Rotary air lock is used to regulate the dust along the
horizontal direction. In rotary air lock there is an impeller
and housing whose gap is very low (ie) 1-2 tou (1 tou =
1/1000 inches). Through these impeller vanes the dust
particles passes to the other side (ie) 1030 belt.
5) From 1030 belt they are transferred to transit hopper which
has 40 tonne capacity.
6) Then it is move on to variable speed conveyor 1035 &
1035A.
7) From there it is brought to 1180A which is a cross belt
analyzer (CBA).
Cross belt analyzer passes gamma rays beneath the source and
the LS particles are exposed to these rays. These constituents are
seen in Quality control lab and LSF (lime saturation factor) is
tested. Due to variation in LSF high or low grade LS are mixed to
compensate the variation. There is a load cell to determine
weight per umit time according to the speed. Soad cell is
commected to 1035 in a closed loop.
8) From CBA, it passes to the stacker.
STACKER:
SPECIFICATIONS:
Motor used : bidirectional AC motor
Travel drive : 11kW
Thyristor brake : 0.2kW
Hydraulic pumps motor : 4kW
It is used for arranging LS into several layers called pile.
It has a boom. The LS from 1180 belt conveyor move on to the
belt conveyor of the boom and the pile is formed as several
layers (12 layers normally) of thickness 105 cm. The length of
the pile is 100 m, the intermediate gap between two piles is
15-30 m.
Stacker is a moving part in-between two truck.
One end of the stacker has a boom and the other end is
compensated by concrete to balance the boom.
The length of the pile is determined by the magnetic sensors
(ie) there is a sensor on the wheel of the stacker and the
magnet placed on the rails determines the length to which the
pile
RECLAIMER:
SPECIFICATIONS:
Travel drive : 7.5kW
Thyristor brake : 0.2kW
Scrapper chain : 75kW
Harrow drive : 15kW
It is used to transfer the LS from pile to the bucket
conveyor.
There are two harrows on the either side of the reclaimer.
The harrows are used to scrap the LS from the pile. After
scrapping, the LS are dropped down, which are collected by
bucket conveyer system.
Chains connect the buckets.
From reclaimer, the LS (low-grade) passes to the Raw mill
through belt conveyor.
VRM:
Limestone, high grade lime stone, iron ore, bauxite are
mixed and brought to Vertical Raw Mill through belt conveyors. It is
grinded finely by the roller mill. The roller mill contains four rollers.
The powder is then sucked by the ESP fan through to Dynamic
seperator. Here the fine particles are separated and coarse particles
are fed back again into the mill. The separated particles are feed to
the blending silo.
VERTICAL ROLLER MILL:
SPECIFICATIONS:
Capacity of VRM : 275TPH
Power of VRM : 1900kW
Size of VRM : 46/23
Speed of VRM : 25.4rpm
E.S.P
GC
2300
BL
IN
Stack
Bag Filter
To P.H
Reject Hopper.
A
Vertical Roller Mill Flow Vertical Roller Mill Flow DiagramDiagram
Vertical Roller
Mill
CHEMICAL SUBSTANCE IN RAW MILL:
LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, LSF, S.R., A.R.
DYNAMIC SEPERATOR:
In the top of VRM, there is a dynamic seperator. It is a rotating
device. The dusts are sucked by air through dynamic
seperator. The stator blades are fixed. The blade angles
determine the fines of dust particles. A rotor rotates rotor
blades. Fluid coupling is used in drive to rotate rotor blades.
The dusts are vent through pipe to ESP and coarse particles
get down to VRM.
The coarse particles are brought through bucket elevator to
reject chute and they are feeded in seperator. The cone like
structure in seperator feeds coarse particles to VRM. With this
recycling process, there will be no wastage of LS.
ELECTROSTATIC PRECIPITATOR (ESP):
The dusts seperated by seperator are send to ESP, to separate
hot gas and dust.
In ESP, 4 sets of electrode are used. They are connected with
themselves.
Power supplied is 40000V. Dust coming inside ESP are charged
and settled in positive electrode. Positive electrode is
collecting electrode and emitting electrode is negative. The
emitting electrode supplied area is called carona. The rapping
method is used to collect dust from ESP. The rapping rods hit
electrodes and dust fall down.
The hot gases are sucked by ESP fan.
TRANSFER OF DUST FROM ESP TO BLENDING SILO
1) The dusts are passed through a hopper to rotary air lock. It
is used to remove any false air or gas going with dust.
2) Through aeropol conveyor using a blower, dusts are sent to
blending silo.
3) Blending silo temperature is nearly 100 degree. Raw meal is
present here. It is constructed in a way to set uniform
mixture to preheater. It is 80-m height, but only 48 m is
effective. Nearly, 16000 ton of raw meal is stored here.
HOT GAS SUPPLY TO VRM
1) VRM is effective only operating at nearly 350 degree.
2) The hot gas from kiln is generally utilised by sending it to
VRM.
3) Gas conditioning tower is used. In gas conditioning tower,
water-cooling is done to reduce the high temperature to
nearly low as needed by VRM.
PREHEATER:
From blending silo, dust is fed to preheater. There are 5 stages
in preheater.
The flow of feed and gases are clearly shown in figure. The gas
escapes by cyclone seperators. At each stage, feed comes
down to next stage and hot gases goes up to next stage and
escapes from cyclone seperators.
The hot gases are fed to VRM (ie) by use of gas conditioning
tower.
60% of coal from fine coal hopper goes to preheater by pfister.
This process of preheating is called pyro process.
Preheater fan provides suction.
PREHEATER FAN:
Capacity : 170cu.m/sec
Power : 2360kW
Calcination occurs in precalcinator (i.e) dust is preheated to
900 degrees.
In this stage, Caco3 ---------> Cao + Co2, reaction occurs
moisture is also removed.
From here, feed goes to kiln. The entry temperature to kiln is
nearly 900 degrees.
Autoloop system with PID (proportional integral derivative) is
used for temperature control in preheating.
KILN:
Kiln is the place where the limestone powder is changed into
clinker. The materials are fed into the Preheater through the top
while the hot gas is passed through the bottom. As the material
passes down it absorbs heat from the gas and reaches the
bottom with a high temperature. Then it passes through the Kiln
which is at 1400 degree Celsius. Thus the heated material is
cooled to nearly 100 degree Celsius. Then clinker is obtained.
The hot Clinker from the Kiln is discharged onto perforated in the
Grate cooler. The cold Air penetrates the perforation of the plate
and pas through the clinker, thus cooling it. Thus the obtained
clinker is stored in silo. The Air that gains heat from the clinker is
taken through tertiary Air duct to the Pre-haeter, VRM & Coal
dryer.
DEEP BUCKET CONVEYOR:
Materials conveyed : clinker
Capacity : 140TPH
Conveying speed : 220TPH
Inclination of conveyor : 40 degrees
Width of bucket : 1000mm
Pitch of bucket : 630mm
Shaft centres : 110.5m
No. Of buckets/rollers : 3 each
CHEMICAL SUBSTANCES IN CLINKER:
LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, SO3, CaCO3, C3S, C2S, C3A,
C4AF, I.R., LSF, S.R., A.R.
Clinker Silo
To Coal Mill
From P.H.Fan.
GCT
Booster Fan.
A B C
Grate Cooler
W.Bin
Bag House
Vent Fan
Bu
cke
t E
lev
ato
r
P.H.Fan.
Kiln Flow DiagramKiln Flow Diagram
GRATE COOLER:
The hot Clinker from the Kiln is discharged onto perforated in the
Grate cooler and is present as a bed of uniform height. The whole
cooler is mounted at a slope of 3 deg. The grate cooler has three
chambers into which Air is blown through fans. The cold Air penetrates
the perforation of the plate and pas through the clinker, thus cooling it.
The Air that gains heat from the clinker is taken through tertiary Air
duct to the Pre-haeter, VRM & Coal dryer. Variable speed control (AC
drives) are used to control the speed of the fans. Airflow transmitter
controls the flow of air. Pressure transmitters and thermocouples are
also present to measure pressure and temperature respectively.
Air from exit of kiln goes by PA duct to preheater. It is
supplying oxygen required for burning in precalcinator.
Also, remaining air and air from cooler are sent to heat
exchanger. Heat exchanger reduces temperature to 100
degrees and sent to bag house.
From bag house gases escape to atmosphere through chimney
by vent fan.
Bag house contains bags, where dust in air is removed.
Polyurethane and Acriclic bags are used.
TRANSFER OF COAL:
1) Coal used is Indonesia coal, which has high calorific value.
They are brought to plant by transportation.
2) Then they are fed to stacker area by belt conveyors.
COAL STACKER:
Coal pile is formed using the stacker.
Coal piles formed has 10000 X 3 T capacity.
The stacker can be rotated to any angle along the fixed axis.
There are 3 piles. The boom, which drops the coal from stacker
to pile, can be moved upto 10th position. Each position has a
certain height. There are 10 different speeds available.
Magnetic sensors and limit switches are available to maintain
length of pile and to drop coal exactly over the pile.
The stacker is rotated by a motor drive using pinion and gear
mechanism. The bull gear rotates entire stacker. Angle of
rotation is determined by length of pile. Grease lubrication
system is available.
Manual and automatic operations are also possible. In case of
automatic operation, they are controlled by CCR. The coal mill is
a Ball mill containing steel balls of different sizes. The coal mill is a
two-compartment mill one for drying and the other for grinding.
The coal gets pulverized in the air swept mill. The pulverized
COAL MILL :
coal passes through a coarse separator where coarse particles are
separated and fed back into the mill through a Screw conveyor. The
pulverized coal is collected in the twin cyclones and is stored in the
fine coal bin after it passes through an ESP, where the coal in the air
stream is collected and sent to the fine coal bin. From here
appropriate amounts of coal are fed to both ends of the Kiln by
pfisters, three in number for the Kiln precalcinator and a standby and
the coal gets fired in the already hot Kiln. The proximity inductance
sensor measures the speed of the drive. The low temperatures are
measured using RTD.
COAL STACKER:
Coal pile is formed using the stacker.
Coal piles formed has 10000 X 3 T capacity.
The stacker can be rotated to any angle along the fixed axis.
There are 3 piles. The boom, which drops the coal from stacker
to pile, can be moved upto 10th position.
Magnetic sensors and limit switches are available to maintain
length of pile and to drop coal exactly over the pile.
The stacker is rotated by a motor drive using pinion and gear
mechanism. The bull gear rotates entire stacker. Angle of
rotation is determined by length of pile. Grease lubrication
system is available.
Manual and automatic operations are also possible. In case of
automatic operation, they are controlled by CCR.
COAL MILL DiagramCOAL MILL Diagram
EMERGENCY FEEDING:
1) In case of emergency, coal is feeded manually in a hopper
available above apron conveyor. From lorries, coal is feeded
in a steel structure above hopper, size of coal is controlled
by this steel structure.
2) Then, from apron conveyor they are sent to raw coal
hopper.
E.S.P
COAL MILLCOAL MILL
From P.H.
Fine Coal Bin.
To Kiln MainTo P.C
FD Fan
Mill Fan
ESP Fan
Separator
Pfisters
COAL RECLAIMER:
The coal from pile is transferred into 5170 belt conveyor by
means of a reclaimer.
Harrow in reclaimer is used to scrap the material in pile to belt
conveyor.
The belt conveyor drains the coal into a hopper, located at
centre of stacker.
From this hopper, the coal is transferred to raw coal hopper
through apron conveyor.
Chain drive is available for harrow movement and sensors are
available to determine the length to which it should move.
Harrow is supported by means of a rope and can be moved to
any angle.
The reclaimer can reach pile by a mechanism available, which
moves over circular fails. The speed mechanism can be
controlled in control mill. There are 10 speeds available.
Depending on step, speed is maintained. This determines the
load supplied.
POLYSIUS CIRCULAR BLENDING BED:
SPECIFICATIONS:
Stacking rate : 100T/hr
Reclaiming rate : 100T/hr
Material handled : Coal/Lignite/Coal+Lignite
mix
Bulk density, coal/lignite : 0.8T/cu.m
1.01 T/cu.m
Size of material : 50mm
Live storage capacity : 10000T
RAW COAL HOPPER:
From apron conveyor, feed is given to raw coal hopper.
Capacity of raw coal hopper is 200tonnes.
Coal of size upto 35mm is fed into the inlet of coal mill.
Through draconic belt conveyor and apron feeder, they are
then fed into coal mill.
COAL MILL:
GENERAL SPECIFICATION:
Type : Air swept mill
Size : 4m diameter & 9m long
Material to be used : Coal/Lignite/Coal+Lignite mix
Feed size : 0-50mm
Mill capacity : 40T/hr
DESCRIPTION:
1) Coal mill is driven by caution shaft.
2) Hot air from ESP and from kiln is fed to coal mill to maintain
a temperature of 200 degree.
3) There are 2 chambers in coal mill.
4) First chamber consists of plates used to dry the coal.
5) There are 2 slideshoe bearings at one end. There is a high
and low speed pump utilised in lubrication of slideshoe.
Slideshoe bearing is a white metal bearing. There is a
cylindrical drum for which lubrication is done, when
rotating. High-speed pump first produces a gap of 0.4mm.
Then slow speed pump lubricates. Oil and water are used
for lubrication. Oil used is SERVO 320.
6) Steel balls of diameter 15mm to 50mm are present in 2nd
chamber. It fills 1/3rd area capacity is 40T/hr.
7) There is a diaphragm blade in between 2 chambers. This
serves for purpose of flow of coal in one direction only.
8) At the right, there is a pinion with girth gear.
9) Girth gear lubrication is carried out with grease. Grease
used is MOLUBALLOY 8031/6000. Multi service lubricant. It
can withstand very high temperatures.
10) After Girth gear, there is a trunnion bearing. It is made of
Tungsten steel. It has less load carrying capacity.
11) The balls revolve in a speed, so that coal particles are
grinded and required fineness is achieved.
4) COAL MILL TO KILN:
1) Coal from coal mill pass into static seperator. There, the
coal, which is not ground to required fineness, are again
sent to coal mill. Return coal feed to mill occurs.
2) From there, it passes to a cyclone seperator at top. The
blade angle is such that to get fine coal.
3) Fine coal is again passed to cyclone seperators.
4) The feed goes through two more cyclone seperators for
extra cooling. From there, it goes to ESP. ESP removes fine
coal and hot gas, then the fine coal moves to fine coal
hopper by screw worm conveyor.
5) From the cyclone seperators, feed directly goes to screw
worm conveyor.
6) Through screw worm conveyor fine coal is fed to fine coal
silo. It has 200T capacity.
7) From fine coal silo, it goes to kiln or precalcinator
accordingly. There are three pfisters available for this
purpose. Kiln main, stand by, and precalcination pfister.
Pfister serves for measuring and conveying of coal
accordingly.
8) Air is also passed in and gets out in pfister. Load cell
connected sets speed according to load needed. Stand by is
used when problem occurs in others. The valve is opened
and it operates either for kiln or precalcinator.
CEMENT MILL:
The Clinker is brought to the Cement mill and feed into the chamber
along with gypsum. Here it is grinded using balls. Then it is
transferred to air slider, after which it is brought to Seperator through
Bucket elevator. Here fine cement is separated and stored in silo. The
coarse particles are fed back into Cement mill. Sound level
transducers are used to sense grinding level inside the mill. Weigh
feeder are used to weigh the substance and tachometers are used to
measure the speed. Thus when combined produce Tonnes /Hour of the
substance passing out.
CHEMICAL SUBSTANCES IN OPC53, PPC: LOI, CaO, MgO, SO3, I.R.
CEMENT MILL:
The clinker silo stores clinker. From there. Through 6461
belt conveyor. It is taken to a hopper with deflector.
There are two deep pan conveyors at bottom. In one belt
the gypsum and clinker for old cement mill are added.
Where as in case of new mill one belt carries gypsum and
the other carries the clinker. There is a weigh feeder which
senses the quantity added according to the speed. Deflector
serves for feed in two conveyors accordingly.
Gypsum 5% is added to 95% clinker. Gypsum increases the
setting time of cement, hence high strength.
E.S.P
CEMENTMILL
To Cement Silo
Cement Mill Flow DiagramCement Mill Flow Diagram
With the help of two belt conveyors feed is given to cement
mill.
In new cement mill, there are two chambers. It is a ball mill
type. Here balls move upward due to centrifugal force. At
critical speed, they roll inside without falling down and
hence no crushing occurs. Hence to grind efficiently,
cement mill rotates at 65-70% of critical speed.
First chamber contains 90-60mm balls. Balls are made of
high chromium steel.
Second chamber contains 50-15mm balls. The grinded
particle in first chamber enters second chamber through
diaphragm blade.
The coarse grinding occurs in first chamber and fine
grinding occurs in second chamber.
There are two slideshoe bearings one at each end. High
speed and low speed pump lubricate them.
Cement mill capacity is 130T, for one shift of load.
Drive is from DC motor. Girth gear driven by pinion is used.
Grease lubrication is done for girth gear.
The output from cement mill passes by elevator to dynamic
seperator. Seperator is present at centre and four cyclone
seperators are surrounding it. Seperator seperates cement
and passes it to a belt conveyor. The gas particles are
sucked by cyclone seperators and sent out through
chimney. The ESP fan connected provides suction. Coarse
particles are again feed to mill, by seperator.
The clinker passing through deep pan conveyor is inspected
by quality control lab, and accordingly grades are divided.
In old cement mill, there are four mills. Each has 40T
capacity. Two of them have belt conveyors. Two have fluxo
system, using compressor and pneumatic setup. This
consumes high power than new cement mill.
No slideshoes are present here. They are ground and sent
to packing through conveyors.
Output from new cement mill is sent through belt conveyors
to cement silo.
PACKING:
Packing Section utilizes the mechanical counterpart for the
packing of Powder Cement. Manual labors are used to connect
the plastic/paper pack with the Cement Valve and the mechanical
lock is provided to fill the pack with fine cement powder. A
counterbalance of 50Kg connected in the top compares the pack
weight with 50 kilograms and closes the cement outcome valve
only when the pack is filled with 50kg. The pack is designed such
that fine cement powder has only one way to enter into the pack
and cannot escape. The packed 50kg Cement Pack is passed
through Belt Conveyors and transported by Roadways and
Railways.
THE CENTRAL CONTROL ROOM (CCR):
The CCR is situated near the kiln area. From here the hopper
weigh feeders, VRM, blending silo, kiln, grate cooler, coal mill and
cement mill can be controlled. The CCR is the main control room
for the entire plant. Depending upon the requirements, of the
feed rate, volumetric flow rate for the gases and the water etc.
The CCR operators control the dampers and the other equipment
provided for the
control of the control of these variables. The CCR control has
been provided for the new cement mill which is driven by two
drives.
PERSONNAL DEPARTMENTMAIN FUNCTIONS OF THE PERSONNEL :
It is responsible for maintaining cordial relationship between
the employees and management. It trains and develops the
employees to that they work effectively. It motivate the workers
and keeps in them good morale. It looks after workers.
Employees bonus compensation leave availed etc.
shift timings : There are 3 shifts in a day
6.30 am – 2.30 pm
2.30 pm – 10.30 pm
10.30 pm -6.30 am
general shift timings :
07.30 am – 04.00 pm
Subsidized canteen :
Free tea and coffee was given to all the
staff members during the shift timings . The lunch can be
provided at a confessional rate .
conclusion The main aim of institutional training system in INDIA
CEMENTS LTD is to improve the skill and knowledge of students
about the product of the industry and to improve the efficiency of
institution.
I thank all the staff in the ICL for their kind co-
operation this training was helpful for us to carry further study in
future. And we learnt many thing through the training. This
training is a golden opportunity given for us. Through this training
we gain knowledge about they hope with this situation.
Sankarnagar
24/01/2009
From
ESSAKKI RAJ.M (01107153016), B.Tech 2nd year PetroChemical Technology, ANNA UNIVERSITY, THIRUCHIRAPPALLI-620024.
To
The Sr. Manager ( Personnel),India Cements Ltd,Sankarnagar.
Through:Chief Manager Mech.)India Cements Ltd,Sankarnagar.
Respected Sir, As I have completed my “INPLANT TRAINING” from 19.01.2008
to 24/01/2009, I kindly request you to issue me the certificate for
Inplant Training in Mechanical department.
Thanking you,
Yours Sincerely,
ESSAKKI RAJ.M
(ESSAKKI RAJ.M)