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)