Lucky cement factory internship report

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LUCKY CEMENT COMPANY LIMITED

PREPARED BY MOHAMMAD YOUNUS (08IN70)

SUHAIL AHMED (08IN36) &

MANSOOR ALI SOLANGI (08IN106)

1

(Internship Program Report)

LUCKY CEMENT LIMITED , KARACHI

Date : 22-06-2011 To 30-07-2011

Submitted To: HUMAN RESORCE DEPARTMENT

Submitted By:

MOHAMMAD YOUNUS (08IN70)

SUHAIL AHMED PALIJO (08IN36)


DEPARTMENT OF

MEHRAN UNIVERSITY OF ENGINEERING & TECHNOLOGY, JAMSHORO

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PREFACE This report has been give by the authors to convey the information about different departments of lucky cement limited , which has been visited during our industrial training. We have discussed the different specifications , processing and production of the department we visited. We have tried to give some history of the processes , literature , survey and importance of the processing as well. MOAHAMMD YOUNUS (08IN70) SUHAIL AHMED PALIJO (08IN36) & MANSOOR AHMED SOLANGI (08IN106)

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ACKNOWLEDGEMENT

First of all we would like to thanks Al-mighty Allah , The Most Beneficent and Merciful . We are very happy to avail this golden opportunity of getting training at lucky cement plant . We are thankful to General Manager of Lucky cement plant at Karachi Mr. Mashkoor Ahmed who provided us such a valuable opportunity. A lot of thanks to MECHANICAL Manager M.K PASHA who provided us assistance in such a friendly environment.

We are Also thankful to

ASSISTANCE MANAGER SHAHID ZAMAN ASSISTANCE MANAGER SAAD SENIOR ASSISTANCE MANAGER HAFEEZ SHAHAB

For providing us information about the plants. This report is a result of handwork of not a single person but many persons have aided by volunteering their services to create this text . Their kindness thus improving this report with their Additional technical knowledge has contributed mightly to the quality of this work. We got much practical knowledge which was not possible to gain in the university during studies. Overall , we are thankful to all the Officers & the workers of Lucky cement Overall , we are thankful to all the Officers & the workers of Lucky cement Overall , we are thankful to all the Officers & the workers of Lucky cement Overall , we are thankful to all the Officers & the workers of Lucky cement

Ltd.Ltd.Ltd.Ltd.

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CONTENTS

UNIT’S

DISCRIPTION

PAGE

UNIT NO. 1

INTRODUCTION • INTRODUCTION TO CEMENT.

• TYPES OF CEMNT

• LUCKY CEMENT LIMITED

CONCRETE PROGRESS,

KARACHI.

• PRODUCTS.

• Quality policy , vision , mission &

values.

• Overall flow diagram of lucky

cement plant.

7 to 11

UNIT NO. 2

RAW MATERIAL USED…

• Limestone

• Clay

• Laterite

• Bauxite

• Slag

• Gypsum

• Coal

• Furnance oil

12 to 16

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UNIT NO. 3

LABORATORY • Coal testing

• Limestone sample

• Latirite sample

• Bauxite sample

• Clay sample

17 to 23

UNIT NO. 4

CRUSHER • Hammer crusher

• Production of crusher

• Limestone yard

•

24 to 27

UNIT NO. 5

PROPORTIONING TOWER

• Way feeder

• Decision of percentage of raw

material

28 to 29

UNIT NO. 6

GRIDING OF COAL

• Coal grinding

• Pulverize coal

• Coal mill

• Coal storage bin

• Fire extinguisher system

• Coal transportation to

• Pre-calciner

• main burner (klin)

30 to 31

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UNIT NO. 7

GRIDING OF RAW MATERIAL • Transportation of ingredients

• Rotary valve

• I.D fan

• System fan

• Vertical raw mill

• Inlet of hot Air

• Outlet of Air

• Cyclones

• Air slides

• Bag house

• Bag house fan

• Outlet of extra gases

• Storage of powder grinded raw

material to the Silo

• Homogenization of grinded raw

material

32 to 36

UNIT NO. 8

CALCINATION AND HEAT

EXCHANGER • Pre-heater

• Inlet of feed to pre-heater

• Construction of feed silo

• Rizor

• Cyclones of pre-heater

• Pre-calciner burner

• Pre-calcination

• Heat exchange

• Primary duck

37 to 39

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UNIT NO. 9

KILN AREA • Introduction to kiln

• Ignition of kiln

• Reaction at kiln

• Formation of clinker

• Hard burning and soft burning

• Outlet of clicker

40 to 48

UNIT NO. 10

COOLING AND STORAGE

OF CLINKER • Construction of cooler

• Cooler crusher

• Pan conveyer

• Storage of clinker

UNIT NO. 11

CEMENT MILL • Proportionating tower

• Flow diagram of cement mill

• Roller crusher

• Crushing Separator

• Storage bin

• Ball mill

• Grinding aid

• Storage of cement

UNIT NO. 12

PACKING PLANT • Loose cement

• Packed cement

• Loose cement storage and ship

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loading terminal at Berth – 25

west wharf , Karachi Port

UNIT NO. 13

QUALITY CONTROL LAB • Collection of sample

• Testing of sample at different stages

UNIT NO. 14

POWER GENERATION • Furnace oil generator

• Natural gas generator

• Dual fuel generator

• Generation of power house

UNIT NO. 15

OVER ALL PERFORMANCE OF

LUCKY CEMENT FACTORY

• Aims and missions

UNIT NO. 16

ENVIRONMENTAL SAFETY

• Global warming and the dangers

of GHG

UNIT NO. 17

CONCLUSION

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INTRODUCTION TO CEMENT

Cement is the non metallic bonding material used for construction

Or

Cement is binding material which is used in construction

HISTORY OF CEMENT History of cement is very old as human civilization. Romans

used volcanic tuff mixed raw material for their construction .Egyptians

used it for the construction of PYRAMIDES.

In 1824 English man Joseph Aspdin, patented artificial

cement made by the calcinations of an argillaceous lime stone. He cal

edit “Portland” because concrete made from it resembles with a famous

building stone obtained from land near England

TYPES OF CEMENT ASTM C150

There are five types of Portland cements with variations of the first three

according to ASTM( AMERICAN SOCITY OF TESTING MATERIAL )

C150.

1.COMMON or GENERAL PURPOSE CEMENT

It is generally assumed unless another type is specified. It is

commonly used for general construction especially when making precast

and precast-prestressed concrete that is not to be in contact with soils or

ground water. The typical compound compositions of this type are:

55% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 2.8% MgO, 2.9% (SO3),

1.0% Ignition loss, and 1.0% free CaO.

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A limitation on the composition is that the (C3A) shall not exceed fifteen

percent.

2. SULPHATE RESISTANCE CEMENT

Type II is intended to have moderate sulfate resistance with or without

moderate heat of hydration. This type of cement costs about the same as

Type I. Its typical compound composition is:

51% (C3S), 24% (C2S), 6% (C3A), 11% (C4AF), 2.9% MgO, 2.5% (SO3),


A limitation on the composition is that the (C3A) shall not exceed eight

percent which reduces its vulnerability to sulfates

3. RAPID HARDENING CEMENT

Type III is has relatively high early strength. Its typical compound

composition is:

57% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 3.0% MgO, 3.1% (SO3),


This cement is similar to Type I, but ground finer. Some manufacturers

make a separate clinker with higher C3S and/or C3A content, but this is

increasingly rare, and the general purpose clinker is usually used, ground

to a specific surface typically 50-80% higher. The gypsum level may also

be increased a small amount

4.LOW HEAR OF HYDRATION CEMENT

Type IV Portland cement is generally known for its low heat of hydration.

Its typical compound composition is:

28% (C3S), 49% (C2S), 4% (C3A), 12% (C4AF), 1.8% MgO, 1.9% (SO3),


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The percentages of (C2S) and (C4AF) are relatively high and (C3S) and

(C3A) are relatively low. A limitation on this type is that the maximum

percentage of (C3A) is seven, and the maximum percentage of (C3S) is

thirty-five.

5. SULPHATE RESISTANCE

Type V is used where sulfate resistance is important. Its typical compound

composition is:

38% (C3S), 43% (C2S), 4% (C3A), 9% (C4AF), 1.9% MgO, 1.8% (SO3),


This cement has a very low (C3A) composition which accounts for its high

sulfate resistance. The maximum content of (C3A) allowed is five percent

About YUNUS Brothers Group

Lucky Cement Limited has been sponsored by Yunus

Brothers Group (YB Group) which is one of the largest business groups of

the Country based in Karachi and has grown up remarkably over the last

50 years. The YB Group is engaged in diversified manufacturing activities

including Textile, Spinning, Weaving, Processing, Finishing, Stitching and

Power Generation. The Group consists of a number of industrial

establishments other then Lucky Cement Limited, they include:

1. Lucky Textile Mills

2. Fazal Textile Mills Limited

3. Gadoon Textile Mills Limited

4. Lucky Energy (Private) Limited

5. Yunus Textile Mills

Lucky Textile Mills - established in 1983

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- Fully computerized weaving and stitching unit

- Consists of 3 weaving plants comprising of 800 looms, 250 stitching

machines, 3.4 million meter/month Grey fabric capacity, 83 million

meters/ annum processing and 15 million meters/ annum made ups

capacity

- Power generation capacity 6.20 MW

- Expertise in ready-made curtains and accessories for foreign markets

Fazal Textile Mills Limited - established in 1987

- One of the top spinning mill in the country with 59,508 installed spindles

- Produces 100% Grey Cotton Ring Spun Yarn and wide range of Blended

and Heather Yarns?

- ISO – 9001:2000 certified

Gadoon Textile Mills Limited - established in 1988

- First of the only two mills in the world producing Compact Core Spun

yarn

- 194,392 installed spindles. Produces high quality Compact yarn, Murata

Jet Spinning yarn, Core Spun yarn and 100% Grey Cotton Ring Spun yarn

- Also has a power plant of 34 MW

- OKO – Tex Standard 100 certified

Lucky Energy (PVT) Limited - established in 1993

- Captive power unit

- Supplies uninterruptible power to Lucky Textiles, Fazal

- Textiles & Lucky Knitwear

- Generation capacity of 17.4 MW

Yunus Textile Mills Limited - established in 1998

- State of the art machinery for weaving, printing and dyeing

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- Self power generation capacity of 14 MW

- 250 Air Jet looms installed

- Completely vertically integrated textile mill

- Major Player in home textile and garment exports

BUSINESS STRATEGY

To be the leading exporter of cement from Pakistan for the

regional countries as well as to explore other potential export markets. Our

future strategy is to explore investment possibilities outside Pakistan in the

cement industry to become a leading global producer.

EXPLORING AND ESTABLISHING EXPORT MARKETS

We have a firm commitment in exploring new markets for

sustainable business growth. Lucky Cement has been successful in

establishing its brand in several export markets including Middle East,

India, Sri Lanka and East and South African countries. We are also

planning to setup some offshore facilities to further strengthen our export

business on regular basis.

ABOUT LUCKY CEMENT LIMITED CONCRETE

PROGRESS, KARACHI. Founder Mr. Abdul Razzak Tabba

Lucky cement limited concrete progress is Sponsor by well

known “Yunus Brothers Group” – one of the largest export houses of

Pakistan, Lucky Cement Limited currently has the capacity of producing

25,000 tons per day of dry process Cement.

Lucky Cement came into existence in 1996 with a daily

production capacity of 4,200 tons per day, currently is an omnipotent

cement plant of Pakistan, and rated amongst the few best plants in Asia.

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With production facilities in Pezu (Production capacity: 13,000 Tons per

day) as well as in Karachi (Production capacity: 12,000 tons per day), it

has the tendency to become the hub of cement production in Asia. Lucky

Cement Limited has been sponsored by Yunus Brothers Group (YB

Group) which is one of the largest business groups of the Country based in

Karachi and has grown up remarkably over the last 50 years.

PRODUCTS PF LUCKY CEMENT Lucky Cement aims at producing cement to suit every user. The

following types of cement are available:

1. Ordinary Portland Cement

2. Sulphate Resistant Cement

3. Slag Cement

ORDINARY PORTLAND CEMENT (OPC) Ordinary Portland cement is available in darker shade as well as

in light shades in Lucky Star with different brand names to suit the

requirement of users.

It is used in all general constructions especially in major

prestigious projects where cement is to meet stringent quality

requirements; it can be used in concrete mortars and grouts etc. Ordinary

Portland cement is compatible/consumable with admixture/ retarders etc.

SULPHATE RESISTANT CEMENT (SRC) Sulphate resistant Cement’s best quality is to provide effective

and long lasting strength against sulphate attacks and is very suitable for

constructions near sea shores as well as for canals linings. It provides very

effective protection against alkali attacks.

SLAG CEMENT Slag cement is also available for specific user requirements.

Slag cement, has been incorporated into concrete projects for over

a century to improve durability and reduce life cycle costs. Among its

measurable benefits in concrete are better workability and finish ability,

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higher compressive and flexural strengths, and improved resistance to

aggressive chemicals.

BRANDS AVAILABLE AT LUCKY CEMENT

• Lucky CEMENT (REGULAR) Lucky STAR

• Lucky GOLD Lucky SULPHATE RESISTANT CEMENT (SRC)

QUALITY POLICY

Quality of cement

ISO CERTIFICATION Lucky's Cement plant is one of the best maintained plants of

Pakistan and is managed by qualified and expert cement field specialists.

The Company has also got ISO 9001:2000 certifications, for

manufacturing and sales of cement by UKAS Quality Management,

Pakistan National Accreditation Council and Moody International.

QUALITY MANAGEMENT Lucky Cement always gives major emphasis in manufacturing

high quality cement through stringent quality control techniques and

computerized control systems using state of the art sophisticated

equipments like Distributed Control System (DCS), Programmable Logic

Controllers (PLCs) and on line X-Ray Analyzers. The Company has got

one of the best equipped laboratories, having all facilities for the analysis

of raw material, semi furnished product, furnished product and fuel, to

ensure the supply of high quality product to market.

The quality of Company’s cement has been tested and found to be superior

in many respects to the specifications mentioned in Pakistan and British

Standards.

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SUPERIOR STRENGTH, OPTIMUM SETTING TIMES AND

MINIMUM EXPANSION These are the three benchmarks adopted by Lucky Cement

Limited which is emerging to be the largest cement plant of Asia and

committed to provide the best quality cement to its customers around the

globe through stringent quality control and application of most modern

quality control techniques.

SUPERIOR STRENGTH The compressive strength is a very important factor of cement.

The Ordinary Portland Cement achieves its maximum strength in 28 days.

The Pakistan standard PSS 232-1883 (R) & British Standard EN 197 Class

42.5 N provides for 28 days strength of 5000Psi and 5950 Psi respectively

for mortar cubes. As compared to this Lucky Cement has a 28 days

compressive strength of more than 7,000 psi to bear heavy loads.

OPTIMUM SETTING TIME Optimal initial & final setting times are ensured by adopting

special production parameters using most modern control techniques.

SOUNDENESS By using most modern Kiln feeding system, it is ensured that

lime entering into the Kiln should be in such a shape that it should totally

combine with oxides during the burning process. The result is that the

frees lime content is very low and soundness of Lucky Cement is less than

1 mm which is far better than 10 mm prescribed by Pakistan Standard PSS

232-1983 ( R) and / or British Standard EN 197 Class 42.5 N.

Lucky Power Generators is one of the best maintained power

generation facilities of the country and is maintained and operated round

the clock by expert engineers and technicians.

VARIETY TO SUIT EVERYONE

Lucky Cement aims at producing cement to suit every user. At

present, it is producing Grey Portland Cement and also Sulphate Resistant

cement. The customers are able to get Portland Cement both in dark shade

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as well as in light shade with different brand names to suit the requirement

of user. The Portland cement specifically made for prefabrication industry

with a lower setting time is also available. In addition, the plant also

produce Slag cement for specific users.

Overall flow diagram of lucky cement plant.

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Schematic explanation of Portland cement production

There are three fundamental stages in the production of Portland cement:

1. Preparation of the raw mixture

2. Production of the clinker

3. Preparation of the cement

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RAW MATERIAL’S

Cement is manufactured into two stages

First stage : from crusher to kiln

Second stage : from clinker yard to cement mill

That’s why raw material is also divided into two stages

First stage raw material Second stage raw material

Lime stone Clinker

Clay or Lucky clay Gypsum

Latirite Slag

Bauxite

Following basic raw materials are generally used in the manufacture of

cement

� LIMESTONE

Limestone is a sedimentary rock composed largely of the mineral calcite

(calcium carbonate: CaCO3). The deposition of limestone strata is often a

by-product and indicator of biological activity in the geologic record.

Calcium (along with nitrogen, phosphorus, and potassium) is a key

mineral to plant nutrition: soils overlying limestone bedrock tend to be

pre-fertilized with calcium. Limestone is an important stone for masonry

and architecture, vying with only granite and sandstone to be the most

commonly used architectural stone. Limestone is a key ingredient of

quicklime, mortar, cement, and concrete. The solubility of limestone in

water and weak acid solutions leads to important phenomena. Regions

overlying limestone bedrock tend to have fewer visible groundwater

sources (ponds and streams), as surface water easily drains downward

through cracks in the limestone. While draining, water slowly (over

thousands or millions of years) enlarges these cracks; dissolving the

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calcium-carbonate and carrying it away in solution. Most well-known

natural cave systems are through limestone bedrock.

uses include:

• The manufacture of quicklime (calcium oxide) and slaked lime

(calcium hydroxide);

• Cement and mortar;

• Pulverized limestone is used as a soil conditioner to neutralize acidic

soil conditions;

• Crushed for use as aggregate—the solid base for many roads;

• Geological formations of limestone are among the best petroleum

reservoirs;

• As a reagent in desulphurization;

• Glass making, in some circumstances;

• Added to paper, plastics, paint, tiles, and other materials as both

white pigment and cheap filler.

• Toothpaste

• Suppression of methane explosions in underground coal mines

• Added to bread and cereals as a source of calcium

� SEDIMENTARY ROCK

Sedimentary rock is one of the three main rock types (the others being

igneous and metamorphic rock). Sedimentary rock is formed by deposition

and consolidation of mineral and organic material and from precipitation

of minerals from solution. The processes that form sedimentary rock occur

at the surface of the Earth and within bodies of water. Rock formed from

sediments covers 75-80% of the Earth's land area, and includes common

types such as limestone, chalk, dolostone, sandstone, conglomerate, some

types of breccia, and shale.)

� CLAY

Clay is a naturally occurring material composed primarily of fine-grained

minerals, which show plasticity through a variable range of water content,

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and which can be hardened when dried and/or fired. Clay deposits are

mostly composed of clay minerals (phyllosilicate minerals), minerals

which impart plasticity and harden when fired and/or dried, and variable

amounts of water trapped in the mineral structure by polar attraction.

Organic materials which do not impart plasticity may also be a part of clay

deposits.

� LATRITE

Latrite is redish brown color and it contains iron content ,

.It is less harder than gypsum but harder than limestone.

� BAUXITE Bauxite is the most important aluminium ore. It consists largely of the

minerals gibbsite Al(OH)3, boehmite γ-AlO(OH), and diaspore α-

AlO(OH), together with the iron oxides goethite and hematite, the clay

mineral kaolinite and small amounts of anatase TiO2. It was named after

the village Les Baux in southern France, where it was first discovered in

1821 by the geologist Pierre Berthier.

� SLAG Slag is the mixture of iron and some metallic impurities. It is obtained

from steel mills. The cement made from slag is full of strength.

� GYPSUM (Ca SO4)

It is obtained from the N.W.F.P

And 5% is added with clinker obtained from kiln in cement mill and then

grinded to get cement.

It is used for refresh ness of cement.

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MANUFACTURING AIDS • COAL

In lucky cement industry coal is the major source of fuel, for this

purpose coal is imported from

1. south Africa

2. Indonesia

Some time lucky also uses a mixture of south African and Indonesian coal.

• FURNANCE OIL

Furnace oil is also used in cement industry for burning the kiln initially.

It help us to maintain the temperature of the kiln.

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LABORATARY

When plant is designed it is decided that which type and

quality of raw material is used for the manufacture of desired product.

So a laboratory is established that take care of the raw material which is

suitable for the plant.

For this purpose the samples of raw material is checked

at the time of purchasing. For ensuring the good quality of the product.

� TITRATION

Laboratory also decide the titration or ratio of raw material

used in the plant . In practice, the raw material for rawmix is controlled

by frequent chemical analysis (hourly by X-Ray fluorescence analysis,

or every three minutes by prompt gamma neutron activation analysis).

The analysis data is used to make automatic adjustments to raw

material feed rates.

� TESTING

In lucky cement industry a laboratory is also working

for the same purpose that every sample of raw material is checked

before and After purchasing the raw material. Fuel used for burning in

the kiln is also tested because of some safety reasons.

� TESTING OF COAL Coal is the main fuel in cement industry that why it is tested

very .

Testing of caol has been didvided into three stages

• Presence of moisture

To find the moisture in coal a coal sample is get from the fresh

supply or last day or present morning truck

Then sample is divided into two categories

1. Crushed coal

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2. Grinded coal

Crushed coal is used to find the RM (Received Moisture) by using

moisture analyzer

Powdered or Grinded coal is used to find the TM (Total Moisture) by

using moisture analyzer

Air moisture is find by taking the coal in a glass dish and weight and place

it in decicator to remove moisture with the help of silica gel and after 30

minutes put out the dish and weight it .

Inherent moisture is the moisture which is possessed by the coal it self so

it can be calculated as follows

Total moisture - Air moisture = Inherent moisture

• Loss on ignition

To calculate the loss on ignition we have to first calculate the volatile

matter

Then by using formula we can calculate loss on ignition

• Presense of sulphur

� TESTING OF RAW MATERIAL

Following basic raw materials are used in the lucky cement industry to

check this thing that the purchased raw material is suitable or not for plant

raw materials are tested .

• Limestone

• Bauxite

• Latrite

• Clay

• Gypsum

• Slag

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For testing the above raw material X-Ray Flourescence Spectrometry

method is used it is a Computer operated machine in which a ring sample

is introduced .

This machine takes few minutes and give as two things

1. name of compound or element present in the sample

2. concentration of the element or compound

some X-Ray Flourescence Spectrometry results are given

below

� lime stone at crusher

L.O

.I

SiO

2

Al2

O3

Fe2

O3

Ca

O

Mg

O

SO

3

Na2

O

K2

O

Cl LS

F

S

M

A

M

42.

69

3.8 0.77 0.92 52.

68

1.1

7

0.0

1

0.19 0.1

3

0.0

5

4.3

3

2.2

4

0.8

3

� Clay

SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O K2O Cl LSF SM AM

68.57 12.48 4.29 4.3 1.48 0.01 0.84 2.43 0.14 0.02 4.09 2.91

74.06 11.29 5.15 2.82 1.39 0.02 0.89 2.16 0.16 0.02 4.51 2.19

� Latrite

SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O K2O Cl LSF SM AM

17.81 7.41 48.51 7.79 0.51 0.11 0.34 0.08 0.05 0.09 0.32 0.15

29.22 9.25 45.05 4.32 0.47 0.04 0.35 0.11 0.36 0.03 0.54 0.21

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CRUSHER

HAMMER CRUSHER

In lucky cement industry hammer crusher are used for crushing the lime

stone

The hammer crusher contain 5 rows and 9 hammers in each row it means

that hammer crusher has 45 hammers.

A hammer mill is a machine whose purpose is to shred material into fine

particles. They have many sorts of applications in many industries,

including:

WORKING AND CONDITION

The basic principle is straightforward. A hammer mill is essentially a steel

drum containing a vertical or horizontal rotating shaft or drum on which

hammers are mounted. The hammers are free to swing on the ends of the

cross, or fixed to the central rotor. The rotor is spun at a high speed inside

the drum while material is fed into a feed hopper. The material is impacted

by the hammer bars and is thereby shredded and expelled through screens

in the drum of a selected size.

Small grain hammer mills can be operated on household current. Large

automobile shredders can use one or more 2000 horsepower (1.5 MW)

diesel engines to power the hammer mill.

The Screen less hammer mill uses air flow to separate small particles from

larger ones. It is designed to be more reliable, and is also claimed to be

much cheaper and more energy efficient than regular hammer mills.

PRODUCTION OF CRUSHER

In lucky cement industry two lime stone crusher are Assembled both are

hammer crusher

Hammer mill at lucky reduces the size of I meter stone into 70 to 80 mm

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The crushing capacity of hammer mill is 800 to 900 ton/hour .

The weight of each hammer is 120 kg .

LIMESTONE YARD A yard is made for the storage of crushed limestone in form of

piles .

A limestone pile being built by a boom stacker and prehomogenization of

pile is made with the help of reclaimer.

Crushed limestone is transported by a 90 m long belt to the storage yard

then it drop the material on chand belt then chand belt drop on boom belt

then with the help of boom stacker piles are made then after

prehomogenization the lime stone is transported to the proportionating

building by buckets then on long belt .

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PROPORTIONATING TOWER

INTRODUCTION

In lucky cement there is a Proportionting tower. It is a building which

store raw material Silos of individual raw materials are arranged. It has

hoppers which provide feed to weigh-feeder. Accurately controlled

proportions of each material are delivered onto the belt by weigh-feeders.

The proportion of raw material is decided by Laboratory usually luck

cement industry works on following titration .

• limestone 75 to 85 %

• purchase clay 6 to 7 %

• lucky clay 5 to 6 %

• bauxite 1 to 2 %

WEIGH FEEDER

Weigh feeder is a machine which weigh’s the material according to the

defined composition and supply to the conveyer belt which take the

material to the work place.

Decision of proportion of raw material for grinding.

. In practice, the raw material for rawmix is controlled by frequent

chemical analysis (hourly by X-Ray fluorescence analysis in the

laboratory, or every three minutes by prompt gamma neutron activation

analysis). The analysis data is used to make automatic adjustments to raw

material feed rates.

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VERTICAL RAW MILL or RAW MILL

These are the standard form in modern installations, occasionally called

vertical spindle mills. In a typical arrangement, the material is fed onto a

rotating table, onto which steel rollers press down. A high velocity of hot

gas flow is maintained close to the dish so that fine particles are swept

away as soon as they are produced. The gas flow carries the fines into an

integral air separator, which returns larger particles to the grinding path.

The fine material is swept out in the exhaust gas and is captured by a

cyclone before being pumped to storage. Feed size can be up to 100 mm.

Roller mills are efficient, using about half the energy of a ball mill, and

there seems to be no limit to the size available. Roller mills with output in

excess of 800 tonnes per hour have been installed. Unlike ball mills, feed

to the mill must be regular and uninterrupted; otherwise damaging

resonant vibration sets in.

. In the case of a dry process, the rawmill also dries the raw materials,

usually by passing hot exhaust gases from the kiln through the mill, so that

the rawmix emerges as a fine powder. This is conveyed to the blending

system by conveyor belt or by a powder pump.

VRM section in Lucky cement plant

In lucky cement plant the Vertical raw mill is used for the grinding

of Raw material and coal.

Approximately 180 to 210 tons of feed per hour is provided to the

VRM . According to the introduction of VRM there are some rollers in the

mill. VRM at lucky has 4 rollers weight of each roller is 22 ton.

Inlet temperature of VRM is 287 C for 230 ton/h feed acorrding

to design capacity

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35

VRM (Vertical Raw Mil) or Roller Mill.

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36

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37

GRIDING OF COAL COAL MILL

In Lucky Coal mill is the place where coal is grinded into fine powder for

this purpose a small Roller mill or VRM (Vertical Raw Mill) is used.

COAL GRINDING Grinding of coal Also take place in a small roller mill or VRM (Vertical

Raw Mill) but it has only two Stationary Rollers other working is same as

define above for the VRM .

Coal mill design capacity is 25 tons/h and its inlet temperature is 92 C .

PULVERIZE COAL

Fine powdered coal is called Pulverize coal. The coal is grind to fine

powder because the fine coal is very easy to burn in the kiln or PC (pre-

calciner)

COAL STORAGE BIN

After Grinding the coal is stored in a bin whose capacity is 100 tonn but in

lucky cement only 25 to 30 % bin is filled because coal can catch fire from

the surrounding.

FIRE EXTINGUISHER SYSTEM

A latest fire extinguisher system is installed in the Coal mill area which is

fully automatic and can Also be control through the PLC(Programmable

Logic Controller).

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38

COAL TRANSPORTATION TO 1. Pre-calciner (PC)

2. main burner (kiln)

The Grinded coal is used as a fuel in PC and kiln so it is transported to

them through the Delta Blowers.

In Lucky 4 Delta Blowers are used , 2 are used for transportation of coal to

the PC and 2 are used for the transportation of coal to the main Burner at

kiln

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39

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40

GRINDING OF RAW MATERIAL

After deciding the ratio of raw material at proportioning tower the next

step is grinding of raw material.

In Lucky cement Industry Vertical Raw Mill is used for Grinding the raw

material.

VERTICAL RAW MILL USED FOR GRINDHING THE

RAW MAERIAL

The raw materials are next ground together in a rawmill.

VRM used here is consisting of 4 continuously moving Rollers. The

fineness of rawmix is specified in terms of the size of the largest particles,

and is usually controlled so that there are less than 5%-15% by mass of

particles exceeding 90 µm in diameter. It is important that the rawmix

contains no large particles in order to complete the chemical reactions in

the kiln,

TRANSPORTATION OF INGREDIENTS The Silos of individual raw materials are arranged (Proportionting tower)

over the feed conveyor belt. Accurately controlled proportions of each

material are delivered onto the belt by weigh-feeders. Passing into the

rawmill, the mixture is ground to rawmix.

ROTARY VALVE

Rotary valve is a valve which control the flow of feed at raw mill and

helps in maintaining the pressure in the mill.

I.D FAN

I.D fan or induce Draft fan is the fan which provides hot air to the VRM

from the preheater. It also produces negative pressure in the kiln and

preheater.

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41

SYSTEM FAN

System fan is also an I.D fan but it is used for the suction of air from the

VRM through the cyclones. It sucks the hot air from the VRM and send it

to Bag house. It also works for maintaining the negative pressure into the

VRM.

TRAVELING OG HOT AIR

In the plant area or VRM area the hot Air flows from one place to another

through the Ducts.

Ducts are pipe lines of very big dia which are used for transportation

purpose.

CYCLONE

A cyclone is a conical vessel into

which a dust-bearing gas-stream is

passed tangentially. This produces a

vortex within the vessel. The gas leaves

the vessel through a co-axial "vortex-finder".

The solids are thrown to the outside edge

of the vessel by centrifugal action, and leave

through a valve in the vertex of the cone.

Cyclones were originally used to clean up

the dust-laden gases leaving simple dry

process kilns.

In lucky cement plant 4 cyclones are used in the VRM area which purify

the hot gas which is coming from VRM .

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42

AIR SLIDES

Air Slides is a mean of transportation in the cement plant it take the

material from one place to another with the help of air. Bags and blowers

are used in air slides. Air slides are normally used at the bottom of

cyclones.

BAG HOUSE

Bag house is a collective name of many bag filters. Bag house has 20

chambers and each chamber contains 104 bags. It is also known as Dust

Collector or Fabric filters.

In lucky the most common type of bag filters are used which operates with

a velocity of about 0.01 m/s across the bag surface.

BAG HOUSE FAN

Bag house fan is a suction fan which helps the bag house in filtering the

hot air from cyclones. If it does not work properly then there is a need to

shutdown the plant because it also helps in producing the negative pressure

and prevention of atmosphere from pollution.

OUTLET OF EXTRA GASES

The bag house remove fine raw mix particles from the hot air then

remaining extra gases containing SOx , NOx , CO and CO2 released in the

atmosphere.

STORAGE OF POWDER GRINDED RAW MATERIAL TO

THE SILO Raw material in required ratio is grinded by the Vertical Raw mill is

separated by the cyclones is sent to the __65__ m silo having capacity

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43

__3300___ tons with the help of air slides, screw conveyers and bucket

elevators . This silo is also used to give feed to the pre-heater

HOMOGENIZATION OF GRINDED RAW MATERIAL

As the raw mix is stored in the silo that’s why its need to homogenize it

for this purpose heavy compressor are used which through's air from the

downward due to which a continuous motion occurs in the material and

Homogenization of grinded raw material takes place.

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44

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45

CALCINATION & HEAT EXCHANGE

Raw material enters the pre heater for pre heating before sending to the

rotatary kiln it is also known as four stage tower it is about 87m high

,consisting of cyclones , riser duct (gas duct) and pre calciner,(pc).

To conserve energy most modern cement plants pre heat raw material

before they enter the kiln using the exhaust gases from kiln itself.

In Lucky cement plant a 5 stage pre-heater is used.

Pre-heater is divided into two section

• Cyclones of pre-heater .

Where heat exchange takes place between the feed (raw mix) and hot

air .

• Precalciner (P.C)

Where calcinations takes place . In pre calciner abut 75-80% calcination

(formation of cao) take place by decomposition of CaCO3 into CaO &

CO2.

CaCO3___________CaO+CO2 (calcination)

To understand a pre-heater completely I have given a 4 stage pre-heater

description with diagram.

Gas-suspension preheaters Cutaway view of cyclone showing air path

The key component of the gas-suspension

pre-heater is the cyclone and the precalciner.

A cyclone is a conical vessel into which a

dust-bearing gas-stream is passed tangentially.

This produces a vortex within the vessel.

The gas leaves the vessel through a co-axial

"vortex-finder". The solids are thrown to the

outside edge of the vessel by centrifugal action,

and leave through a valve in the vertex of the cone. Cyclones were

originally used to clean up the dust-laden gases leaving simple dry process

kilns. If, instead, the entire feed of raw mix is encouraged to pass through




MANSOOR ALI SOLANGI (08IN106

the cyclone, it is found that a very efficient heat exchange takes place: the

gas is efficiently cooled, hence producing less waste of heat to the

atmosphere, and the raw mix is efficiently heated. This efficiency is

further increased if a number of cyclones are connected in series.

4-Stage preheater, showing path of feed

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sphere, and the raw mix is efficiently heated. This efficiency is


Stage preheater, showing path of feed

46



sphere, and the raw mix is efficiently heated. This efficiency is


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47

The number of cyclones stages used in practice varies from 1 to 6. Energy,

in the form of fan-power, is required to draw the gases through the string

of cyclones, and at a string of 6 cyclones, the cost of the added fan-power

needed for an extra cyclone exceeds the efficiency advantage gained. It is

normal to use the warm exhaust gas to dry the raw materials in the raw

mill, and if the raw materials are wet, hot gas from a less efficient

preheater is desirable. For this reason, the most commonly encountered

suspension preheaters have 4 cyclones. The hot feed that leaves the base of

the preheater string is typically 20% calcined, so the kiln has less

subsequent processing to do, and can therefore achieve a higher specific

output. Typical large systems installed in the early 1970s had cyclones 6 m

in diameter, a rotary kiln of 5 x 75 m, making 2500 tones per day, using

about 0.11-0.12 tonnes of coal fuel for every tones of clinker produced.

A penalty paid for the efficiency of suspension preheaters is their tendency

to block up. Salts, such as the sulfate and chloride of sodium and

potassium, tend to evaporate in the burning zone of the kiln. They are

carried back in vapor form, and re-condense when a sufficiently low

temperature is encountered. Because these salts re-circulate back into the

rawmix and re-enter the burning zone, a recirculation cycle establishes

itself. A kiln with 0.1% chloride in the rawmix and clinker may have 5%

chloride in the mid-kiln material. Condensation usually occurs in the

preheater, and a sticky deposit of liquid salts glues dusty raw mix into a

hard deposit, typically on surfaces against which the gas-flow is

impacting. This can choke the preheater to the point that air-flow can no

longer be maintained in the kiln. It then becomes necessary to manually

break the build-up away. Modern installations often have automatic

devices installed at vulnerable points to knock out build-up regularly. An

alternative approach is to "bleed off" some of the kiln exhaust at the kiln

inlet where the salts are still in the vapor phase, and remove and discard

the solids in this. This is usually termed an "alkali bleed" and it breaks the

recirculation cycle. It can also be of advantage for cement quality reasons,

since it reduces the alkali content of the clinker. However, hot gas is run to

waste so the process is inefficient and increases kiln fuel consumption.

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48

Cement plant pre heater Designed by Polysius, this new plant includes a

four-stage precalciner with a 158-foot (48-meter) long by 13-foot (4-

meter) diameter two-station kiln to produce 2,500 tons per day of clinker.

Air Cannons were not included in the design of this new plant. But based

on his 25 years in the cement industry, Production Manager Tom Messer

knew they would be required to avoid shutdowns due to blockages of the

material flow through the kiln pre-heater. “I’ve seen the problems that can

arise from plugs and choking of the pre-heater,” Messer explains. “I’ve

seen the high labor costs and the production losses that come from having

to shut down the tower to break up a blockage.”

Messer and Martin Engineering developed a plan for the installation of 45

big blasters and air canons on the brand new pre-heater. Crews from

Martin Engineering’s Martin Services group installed the pre-heater air

cannon system. Feed is entered from feed silo to risor of cyclone 2.

Pre calciners

% of North American Capacity using Precalciners





Mean Daily Output (tonnes) of North American Kilns

In the 1970s the precalciner was pioneered in

become the equipment of choice for new large installations world

The precalciner is a development of the suspension preheater. The

philosophy is this: the amount of fuel that can be burned in the kiln is

directly related to the size of the kiln. If part of the fuel necessary to burn

the rawmix is burned outside the kiln, the output of the system can be

increased for a given kiln size. Users of suspension p

output could be increased by injecting extra fuel into the base of the

preheater. The logical development was to install a specially designed

combustion chamber at the base of the preheater, into which pulverized

coal is injected. This is referred to as an "air

the combustion air for both the kiln fuel and the calciner fuel all passes

through the kiln. This kind of precalciner can burn up to 30% (typically

20%) of its fuel in the calciner. If more fuel were

the extra amount of air drawn through the kiln would cool the kiln flame

excessively. The feed is 40

The ultimate development is the "air

hot combustion air for the calciner arrives in a duct directly from the

cooler, bypassing the kiln. Typically, 60

precalciner. In these systems, the feed entering the rotary kiln is 100%

calcined. The kiln has only to raise the fee

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In the 1970s the precalciner was pioneered in Japan, and has sub

become the equipment of choice for new large installations world


e amount of fuel that can be burned in the kiln is



increased for a given kiln size. Users of suspension preheaters found that




is referred to as an "air-through" precalciner, because



20%) of its fuel in the calciner. If more fuel were injected in the calciner,


excessively. The feed is 40-60% calcined before it enters the rotary kiln.

The ultimate development is the "air-separate" precalciner, in which the

ustion air for the calciner arrives in a duct directly from the

cooler, bypassing the kiln. Typically, 60-75% of the fuel is burned in the


calcined. The kiln has only to raise the feed to sintering temperature. In

49


, and has subsequently

become the equipment of choice for new large installations world-wide[7].


e amount of fuel that can be burned in the kiln is



reheaters found that




through" precalciner, because



injected in the calciner,


60% calcined before it enters the rotary kiln.

separate" precalciner, in which the

ustion air for the calciner arrives in a duct directly from the

75% of the fuel is burned in the


d to sintering temperature. In

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50

theory the maximum efficiency would be achieved if all the fuel were

burned in the preheater, but the sintering operation involves partial melting

and nodulization to make clinker, and the rolling action of the rotary kiln

remains the most efficient way of doing this. Large modern installations

typically have two parallel strings of 4 or 5 cyclones, with one attached to

the kiln and the other attached to the precalciner chamber. A rotary kiln of

6 x 100 m makes 8,000–10,000 tonnes per day, using about 0.10-0.11

tonnes of coal fuel for every tones of clinker produced. The kiln is dwarfed

by the massive preheater tower and cooler in these installations. Such a

kiln produces 3 million tonnes of clinker per year, and consumes 300,000

tones of coal. A diameter of 6 m appears to be the limit of size of rotary

kilns, because the flexibility of the steel shell becomes unmanageable at or

above this size, and the firebrick lining tends to fail when the kiln flexes.

A particular advantage of the air-separate precalciner is that a large

proportion, or even 100%, of the alkali-laden kiln exhaust gas can be taken

off as alkali bleed (see above). Because this accounts for only 40% of the

system heat input, it can be done with lower heat wastage than in a simple

suspension preheater bleed. Because of this, air-separate precalciners are

now always prescribed when only high-alkali raw materials are available

at a cement plant.

TARGET OF PRE-HEATER

Pre-heater is used for heat exchange and calcinations .

In lucky cement plant Pre-heater’s inlet temperature is 800 to 1000 C and

out let temperature is 250 to 280 C .

The raw material is burned in the pre-heater for 52 seconds and then it is

sent to kiln . 75-80 % calcination is done..

It increases the production capacity, it reduces the specific heat

consumption also reduces specific power consumption.

ADVANTAGE OF PRE-HEATER

• Improved kiln operation efficiency.

• Reduced production cost.

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51

• Environmental protection.

INLET OF FEED TO PRE-HEATER

Feed is entered through the feed silo in the risor of cyclone 2 with help of

bucket elevators.

CONSTRUCTION OF FEED SILO

The capacity of this silo is mentioned above here I want to tell u that

below the silo there is a bin where feed to pre-heater is homogenized and

weighed the capacity of this bin is 100 ton .

This bin is connected to 8 gates of air slides which opens in the opposite

pair of two and provide feed to the main air slide on the rate of 215 Ton/h.

BIN STORAGE AND SILOS

Bins are cylindrical or rectangular vessels of concrete or metals .a silo is

tall and relatively small in diameter .a bin is not so tall and usually fairly

wide .silos and bins are loaded from top by some kind of elevator.

Discharging is done from the bottom .

PRESSURE IN BINS AND SILOS

When solid or semi solids are placed in a bin or silo the lateral pressure

exerted On the wall at any point is less than predicted from the head of

material above that point .there usually is friction between walls and

solids. The friction Force at the wall tends to off set the weight of solid

and reduces the pressure exerted by mass on the floor of container .in

general when height of solids column is greater than about 3 times

diameter of the container ,additional solids have no effect on the pressure

at the base.

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52

FLOW OUT OF BINS

solids tend to flow out of any openings near the bottom of bin but are best

discharged through an opening in the floor .flow through a side openings

tends to be un certain an increase the lateral pressure on the other side of

bin while the solids are flowing.

When out let at bottom of a bin containing free flowing is opened , the

material immediately above the opening begins to flow . one of two flow

pattern will develop , depending on steepness of the walls in the bottom

section of the bin and on the coefficient of friction between the solids and

the bin walls. tunnel flow develops in the bins with a shallow cone angle

or with vertical walls and central opening in the floor. here a vertical

column of solids above the openings moves downward with out disturbing

the material at the sides. eventually lateral flow begins ,first from the top

most layer of solids.

The rate of flow of solids by gravity through a circular opening in the

bottom of a bin depends on the diameter of the openings and on the

properties of the solid

With cohesive solids it is often hard to start flow .once flow does start,

however, it again begin in the material directly above the discharge

opening. sticky solids and even some dry powder adhere strongly to

vertical surfaces and have enough shear strength to support a plug of

considerable diameter above an open discharge .thus to get flow started

and to keep the material moving , vibrators on the in walls , internal plows

near the bin floor, or jets of air in the discharge opening are often needed.

PRE-CALCINER BURNER

Pre calciner burner is composed of two chambers vortex chamber and

reaction chamber ,the vortex chamber is situated at the end of tertiary air

duct ,close to the entry to the kiln gases , they can therefore get

preliminarily mixed. the tertiary air is drawn from the middle part of the

burner and is therefore of medium temperature about 750 to 850 C. in

these conditions a condensations of volatile components of the feed occurs

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53

on the grains of raw material and they are recycled to the kiln ,which

allows the formations of accretions on the walls of precalciner to be

avoided. the raw mix is fed to side upper part of reaction chamber, while

in lower part 2 burners are arranged readily round the shaft of the chamber.

Due to vortex motion of the gases in the of the gases in the axis of

reaction chamber negative pressure is developed, facilitating the

introduction of the grains of the fuel and meal to the fuel and meal to the

inside chamber.

PRE- CALCINATIONS

A first principle model of cement precalcination system is developed for

the purpose of controller’s design and synthesis. The dynamic model is

based on the mass and energy balance principle and consists of a set of

ordinary differential equations. Based on some logical assumptions, the

model not only considers the reaction mechanisms but also reduces the

complexity of precalciner system. The model is divided into a preheater

sub model and a calciner sub model. Separate sub model for preheater and

calciner are initially developed and coupled together to build an integrated

model. The model takes the gas content into account and can obtain the

values of all key output variables in precalcination process.

OVERALL PRE-HEATER PROCESS

In lucky cement plant feed is entered in the risor of cyclone 2 than hot air

take the feed to Cyclone 1A and 1B,

outlet of cyclone 1A and 1B drop the material in risor R-3 than hot air

take the material to C-2 ,

out let of C-2 drop the feed into R-4 than hot air takes the material to C-3 ,

outlet of C-3 drop the material into R-5 than hot air takes the feed into C-4

,

the outlet of C-4 drops the material in P.C. where calcinations of raw mix

take place . here two burners are used for this purpose fresh air is also

given to the burners. Burners use pulverize coal for burning . the

temperature of P.C is 850 to 900 C and has an pressure of -813 pascal ,

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54

After the calcinations hot air takes the material in C-5 through the goose

neck of P.C. ,

This reaction takes place in the calcination zone

CaCO3 → CaO + CO2 (lime stone) (lime)

The outlet of C-5 drops the material into KILN INLET OR SMOKE

CHAMBER OR INLET CHAMBER .

S:NO STAGES TEMP

PRESSURE

1 Klin 900-950

2.6-3.6

2 Riser duct 10-

11

3 P.C 900-930 8-

10

4 Cyclone -4 810-850

18-12

5 Cyclone-3 750-770

30-35

6 Cyclone -2 550-600

40-55

7 Cyclone -1 350-380

55-65

8 I.D fan 350- 370

65-70

9 Secondry 1100-1150 ---

---

10 Tertiary 630-670 --

----

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PRIMARY DUCT

A method and apparatus for controlling the combustion of fuel

modules charged into a preheater or precalciner kiln above the transition

shelf, typically into the riser duct, is described. The apparatus includes a

sensor for providing signals indicative of the status in the region of

combustion of the fuel modules, and a controller for a fuel module feed

mechanism is provided to receive signals indicative of the status of the

combustion region and adjust the rate of delivery of the fuel module into

the combustion region responsive to the sensed conditions in the

combustion region.

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57

KILN AREA

INTRIDUCTION TO KILN

Cement kilns are used for the pyroprocessing stage of manufacture of

Portland and other types of hydraulic cement, in which calcium carbonate

reacts with silica-bearing minerals to form a mixture of calcium silicates.

Over a billion tonnes of cement are made per year, and cement kilns are

the heart of this production process: their capacity usually define the

capacity of the cement plant. As the main energy-consuming and

greenhouse-gas–emitting stage of cement manufacture, improvement of

their efficiency has been the central concern of cement manufacturing

technology.

Kiln is consist of 4 zones ;

• Calcinations zone

• Transition zone

• Burning zone

• Cooling zone

Kiln used at Lucky cement plant is

• 64 meter in length ,

• total dia of kiln is 4.3 meter and effective dia is 3.9 meter .

• Slop of kiln is 3.5 %.

• Migration of kiln is 4-5 rpm.





General layout of a rotary kiln

The rotary kiln consists of a tube made from steel plate, and lined with

firebrick. The tube slopes slightly (1

between 30 and 250 revolutions per hour. Rawmix is fed in at the upper

end, and the rotation of the kiln causes it gradually to move downhill to the

other end of the kiln. At the other end fuel, in the form of gas,

pulverized solid fuel, is blown in through the "burner pipe", producing a

large concentric flame in the lower part of the kiln tube. As material moves

under the flame, it reaches its peak temperature, befo

kiln tube into the cooler. Air is drawn first through the cooler and then

through the kiln for combustion of the fuel. In the cooler the air is heated

by the cooling clinker, so that it may be 400 to 800 °C before it enters the

kiln, thus causing intense and rapid combustion of the fuel.

Kiln are typically stopped only for a few days once or twice a year for

essential maintenance.

IGNITION OF KILN

Some time once or twice in a year kiln is shutdown for

maintenance purpose . after the the completion of maintenance the kiln

is again ignited.

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THE ROTARY KILN

General layout of a rotary kiln


. The tube slopes slightly (1–4°) and slowly rotates on its axis at



other end of the kiln. At the other end fuel, in the form of gas,



under the flame, it reaches its peak temperature, before dropping out of the




thus causing intense and rapid combustion of the fuel.


IGNITION OF KILN



58


on its axis at



other end of the kiln. At the other end fuel, in the form of gas, oil, or



re dropping out of the







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59

For the ignition of kiln first of all furnace oil is used

because it has higher calorific value 9760 cal Furnace oil used for kiln

main burner is first treated in a boiler to decrease its viscosity at

minimum level due to which it flows very well. when the required

initial temperature of kiln is maintained than kiln is burned on pulverize

coal whose calorific value is 5800 cal .

As we know that oxygen is necessary for ignition that’s

why blowers are used which provides fresh air to the main burner.

KILN PROCESS

IN LUCKY CEMENT PLANT

After pre heating and pre calcinated material enters in burning and clinker

zone of kilns where temp ranges from 1000C-1350C. Here CaO reacts

with other oxides to form cementeous materal. Burning of kiln involves

the following steps ;

1. evaporation of free water at temperature upto 100 C

2. removal of absorbed water in clay material 100-300 C

3. removal of chemically bounded water 450-900 C

4. calcinations of carbonate materials 700-850 C

5. formation of C2S, Aluminates and ferrite’s 800-1250 C

6. formation of liquid phase melt > 1250 C

7. formation of C3S 1330-1450 C

8. cooling of clinker to solidify liquid phase 1300-1240 C

9. final clinker microstructure frozen in clinker < 1200 C

10. clinker cooled in cooler 1250-100 C

the final product as it comes out the kiln is known as clinker .

REACTION AT KILN

Following major reactions take place inside the kiln. )

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60

2CaO + SiO2 → 2CaO.SiO2 (Dicalcium silicate)

3CaO + SiO2 → 3CaO.SiO2 (Tri Calcium Silicate)

3CaO + Al2O3 → 3CaO.Al2O3 (TRI CALCIUM ALUMINATE)

.

4CaO+AlO3+Fe2O3 → 4CaO.Al2O3.Fe2O3 (Tetra Calcium Aluminum Ferrate)

FORMATION OF CLINKER

At about 1280 0C And above clinker is formed which is in the form of

compound that is known as cement compound. The composition of clinker

is as followed .

COMPOSITION OF CLINKER

C3S 55-56%

C2S 21-22%

C3A 5-6(FOR OPC)

C3A <3.5(FOR SRC)

C4AF 12-13(FOR OPC)

C4AF 16-17(FOR SRC

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OUTLET OF CLINKER

AT ABOUT 1280 C And above clinker is formed which is in the form

of compound that is known as cement compound . hot clinker is dropped

into the cooler.

OUTER VEIW OF KILN

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63

COOLING AND STORAGE OF CLINKER

In lucky cement a grate cooler is used to cool the clinker . These coolers

have two main advantages: they cool the clinker rapidly, which is desirable

from a quality point of view, and, because they don't rotate (rotating

coolers used in early ages) , hot air can be ducted out of them for use in

fuel drying, or for use as precalciner combustion air.

FAN FOR COOLER.

8 Fans are also used to force air through the cooler bed or grates.

CONSTRUCTION OF COOLER

This consists of a perforated grate through which cold air is blown,

enclosed in a rectangular chamber. A bed of clinker up to 0.5 m deep

moves along the grate. The grates are moved with the help of a hydraulic

system.

COOLER CRUSHER

Rotary crushers are used at the out let of a cooler. These crushers crush the

big pieces of cooled clinker into small ones.

PAN CONVERYER

Pan conveyer is the medium used for transportation of material in heavy

amount. It consist of a chain of pan joined with each other in the form of a

belt. Motors are used to run them.

STORAGE OF CLINKER Cooled clinker from the cooler is transported to the clinker storage yard

with the help of pan conveyer.

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CEMENT MILL

Cement mill is the area where finally cement is manufacture by the

addition of second stage raw materials (Slag , Gypsum and clinker) it

consist of following parts

Diagram of CEMENT MILL

Flow diagram of cement mill

Roller press or crusher

Crushing Separator

Storage bin

Ball mill

In lucky cement plant the cement mill is used is actually a ball mill.

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The length of ball mill is 13 meter . it is divided into two chambers .

Its 1st chamber is 3 meter long and 2nd chamber is 10 meter long .

The efficiency of ball mill depends on the size and weight of media or

grinding medium.

Media size in 1st chamber is 30,40,50 and 60 mm and in 2nd chamber is 10

x12 , 12x14 mm .

Weight of media in ball mill is 180 ton .

Grinding aid

Glycol is used as grinding aid in ball mill . due to high temperature

gypsum under goes hydration so lumps form in the mill which chock the

out let of ball mill so glycol stops this phenomena

Storage of cement

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PACKING PLANT LOOSE CEMENT

Lucky cement also export loose cement by loading it into through

bunker. Daily it export ton per day.

loose cement storage and ship loading terminal at berth -25 west

wharf karachi port

PACKED CEMENT

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QUALITY CONTROL LAB

COLLECTION OF SAMPLE

For quality management samples of material and cement is taken from

following places ,

• Query

• Limestone yard

• Proportionating building

• Vertical Raw mill Air slide

• Raw mix silo

• Preheater

• Cooler

• Ball mill

Testing of sample at different stages

ANALYSIS OF COAL

In order to access the quality of the coal the following two types of

analyses are made.

• PROXIMATE ANALYSES

• ULTIMATE ANALYSES

PROXIMATE ANALYSIS

It is the analyses on compound basis which involves the following

determinations.

1.moisture

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2.volatile matter

3.ash

4.fixed carbon

1. MOISTURE: about 1gm of finaly powdered air dried coal sample is weighed in a

crucible . the crucible is placed inside an electronic hot air oven

maintained at 105_110 0C the crucible is allowed to remain in oven for 1

hour and then taken out. (with the help of pair of tongs) cooled in a

desecator and weighed .

loss in weight is reported as moisture on % basis.

FORMULA FOR FINDING MOISTURE

% of moisture =( loss in weight / weight of coal taken )*100

2.VOLATILE MATTER

the dried sample of coal left in a crucible in crucible in (1) is then covered

with a lid and placed in an electric furnace(muffle furnace) maintained at

925+25oC or 925-25oC .the crucible is taken out of the oven after 7

minutes heating. The crucible is cooled 1st in air then inside dedicator and

weighed again loss in weight is reported as volatile matter i,e

Formula For Finding Volatile Matter

volatile matter (v m) = loss in weight due to removal of volatile matter x

100

wt of coal sample taken

3.ASH the residual coal in the crucible in (2) is then heated without lid in a

muffle at about 500C for half an hour .the crucible is taken out cooled 1st

in air then in desiccators and weighed ,heating, cooling and weighing is

repeated till a constant weight is obtained the residue is reported as ash on

%basis.

FORMULA FOR FINDING % OF ASH The % of ash = wt of ash left x 100

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wt of coal taken

4.FIXED CARBON

% of fixed carbon = 100 -% of (moisture + volatile matter +ash)

ULTIMATE ANALYSIS

It is the analysis on elemental basis which involves the following

determinations.

1. carbon and hydrogen

2. Nitrogen

3. sulpher

4. oxygen

1. CARBON AND HYDROGEN; about 0.2gms of accurately weighed coal sample is burnt in a

current of oxygen in a combustion apparatus .C and H of the coal are

converted into CO2 and H2O respectively. The gaseous products are

absorbed respectively in KOH and CaCl2 tubes of known weights, the

increase in weight of these tubes are then determined

C + O2 → CO2

2KOH + CO2 → K2CO3 + H2O

CaCl2 + 7H2O → CaCl2 .7H2O

% OF C = Increase in weight of KOH tube x 12 x 100

Weight of coal sample taken x 44

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% of H2= increase in weight of CaCl2 tube x 2 x 100

weight of coal sample taken x 18

1. NITROGEN

About 1 gm of accurately weighed powdered coal is heated with

concentrated H2SO4 along necked flask called kejeld’s flask, after the

solution becomes clear it is treated with excess of KOH and LIBERATED

AMMOUNT is distilled over and absorbed in a known volume of standard

acid solution. The unused acid is then determined by lack titration with

standard NAOH FROM the volume of acid by ammonia liberated % of N

in coal is calculated as follows

% OF N =volume of acid used x normality x14 x 100

weight of coal taken

3.SULPHER Sulpher is determined from washings obtained from the

known mass sample of coal used in a bomb calorimeter for

determination of calorific value during determination. Sulpher is

converted into sulphate , the washings are with barium chloride solution

BaCl2, when BaSO4 is precipitated this filtrate washed and heated to

constant weight.

% of sulphur in coal = wt of bariam sulphate obtained x 32 x 100

233 x wt of coal sample taken in bomb

4.Oxygen

Oxygen determined by

% of oxygen = 100 - % of (C + S + H + N + Ash

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POWER GENERATION

There is also a power generation plant in lucky cement industry. 11

generators are used some of them required furnace oil and some Natural

gas.

Furnance oil generator or Dual fuel generator

There are 2 dual fuel or furnace oil generators are used. Dual fuel

generators are those which uses furnace oil and natural gas as fuel for

power generation. Each generator produces 7.4 Mega Watt electricity.

Natural gas generator

There are 9 other generators used to generate electricity by natural gas.

• 5 of them is of CAT MAC company and has an efficiency of

generating electricity nearly 5.9 Mega Watt.

• 3 of Roll Royce company having efficiency of 6.9 Mega Watt.

• 1 of Roll Royce company having efficiency of 8.5 Mega Watt

Generation of power house

In lucky cement industry total power consumption is 48.5 Mega Watt .

Power house can generate 75 Mega Watt electricity.

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OVERALL PERFORMANCE OF LUCKY CEMENT

LIMITED

� Aims and missions

� F uture plan

� Expansion plan

Our Company has emerged as the largest exporter of cement in Pakistan.

We have been able to capture new markets where our brand is now very

well established and known for its high quality of cement produced by us.

The location of our Karachi project is ideal for exports by sea for which

we have already setup state-of-the-art infrastructure at Plants & Karachi

Port.

Currently the total production capacity of Lucky Cement is 25,000 tons

per day. Our Company has adopted the same hybrid technology experience

for this expansion plan which was earlier used for the existing production

lines by acquiring the latest technology fuel consuming components from

European suppliers with the combination of Chinese plant and machinery

which helps to minimize expansion cost. It will ensure great efficiency for

producing cement at lower cost.

The power requirement for the expansion lines will be met through captive

gas based power generation for which additional supply of gas has been

arranged.

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ENVIRONMENTAL SAFETY

GLOBAL WARMING AND THE DANGERS OF GHG

WASTE HEAT RECOVERY

Lucky Cement, being aware of Global warming and the dangers of GHG,

has decided to play an active role in participating in reduction of global

warming and creating an environmental friendly atmosphere. In this regard

Lucky cement has taken a step to contribute in this Global effort to control

carbon emission.

Lucky Cement Limited is now in the process of installing a waste heat

recovery system which will utilize the waste heat generated during clinker

production into electrical power with zero emission of carbon and without

consuming any fuel. This effort of producing 25 MW electricity, although

a costly effort , but looking at the circumstances both nationally and

internationally will help in contributing in production of electricity in a

nation where the power generation sector is in crisis and in a world which

feels the dangers to environment and global warming.

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CONCLUSION

Lucky cement industry is a day by day growing industry and counted in

Pakistan’s most biggest and popular industry.

We have observed all units process and operations used in a chemical

industry and got good working experience in lucky.

Internship is most important for the engineering students as it develops

confidence and practical knowledge in students during their studies.

As far as the production of lucky concrete progress plant is concerned,

it is in very huge quantity and of good quality.

Lucky is famous for manufacturing OPC of very good quality.





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Business

Lucky cement factory internship report