Manufacturing of Cement

7/30/2019 Manufacturing of Cement

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ANJANI PORTLAND CEMENT LIMITED

A REPORT

ON

INDUCTION PROGRAMME

AS A PART OF

PRACTICE SCHOOL -1

Prepared for:

Prepared by:

28 MAY 2012


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Introduction:

This report outlines the results of my observation in various departments at

Anjani Portland cements Ltd during our induction programme. We went

through various departments, technical and non-technical, and have collected

detailed information on their respective functions and their impact on the

outcomes of the company. I have made an attempt to describe some of the

things I came across during the course of time.

Non-Technical:

We went to non-technical departments like P&A, Time office and weighbridge,

stores, A/C and sales.

In TO and WB, we learned they way the company keeps track of the in time

and out-time of their employees. We also learned the different shifts the

company follows and their respective timings. We also learned the conditions

for applying leave and different types of leaves an employee can have. Theweighbridge measures the loads of the trucks while coming in and going out

thus having an idea of input raw materials.

During our visit to P&A office we learned that they are responsible for

maintaining health and safety of employees, their recruitment and training for

increasing their potential and safety. Environmental safety also comes under

their supervision.

In stores they have the items that are constantly needed for the industry and

other regular items like nuts and bolts, bulbs etc... They always use standard

items so that they can have them for longer periods of time.

We also visited the accounts department which majorly deals with cash, banks,

and journals. They coordinate with all other departments and have a detailed

record of production parameters, number of workers, work completion, pay

sheet by personnel. Though the budget is prepared by HODs, this department

takes care of the effective implementation of the plans.


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Sales department deals with orders of the customers and supplies appropriate

amount of material to them will be a sales representative of the company for

each region.

Different stages involved in the process of cement manufacturing are alsocovered in the induction programme. We are also a brief description on the

different machines used in the process like crusher, raw mill, kiln etc...

We also visited different technical departments like mechanical, electrical and

instrumentation. We visited workshop in mechanical engineering department

and learnt different basic machines like lathe, shaper, grinding machine. In the

electrical department we were explained how the power distribution is done in

the plant.

Personnel and Administration (P&A) office:

P&A office ensures that whether all the activities in the

company are going on according to the schedule or not. Any deviations from

the programme are corrected by them.

Three ISOs are followed in the plant. They are:

1. Q.M.S : Quality Management System 9001 ISO


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2. E.M.S: Environmental Monitoring System 14001 ISO3. O.H.S: Organisational Health Safety 18001 ISO

The P&A department in the factory monitor these isos.

Other functions of the P&A department are briefly described below:

The department helps employees to maintain good behaviour byconducting programmes like yoga, counselling.

It makes sure that each and every employee in the organisation followssafety rules thereby prevents accidents.

P&A department maintains the employees insurance details and takesat most concern about the health of the employees.

P&A prepares the pay sheet and submits it over to the accountdepartment.

It prepares the vehicle bills. It conducts the welfare activates in the factory. It provides training to the employees to do their work efficiently. Training is provided for the career development of the employees.

Time Office and weigh bridge:

Time office: Time office mainly keeps a record of in/out timings of the

employees. Proper software is maintained for this in which the employees

have to scan their identity cards with the machine available in time office and

their in/out timings are loaded automatically. They will maintain the details of

only the employees who have their names in according to form25 muster roll.


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These employees will be having four types of shifts and the timings for

different shifts are stated below:

A shift:- 6:00am to 2:00pm

B shift:- 2:00pm to 10:00pm C shift:- 10:00pm to 6:00am General shift:-8:00am to 5:30pm (lunch break from 12:00noon to

1:30pm)

Employees working in A, B, C shifts should leave only after the entry of the

employee of the next shift. General shift employees will have weekend

holidays, national holidays, and public holidays.

Time office also keeps a record of the employees leaves. Leaves are classified

as

Sick leaves Casual leaves Personal leaves

Every employee has to submit a leave card in the time office after the approval

from the HOD of the concerned department.

Weigh bridge: Their main function is to keep a record of amount of raw

materials, fuel that was taken into the company and also the amount of

cement leaving the plant.

For raw materials /fuel, they will note the weight of the loaded

truck, after unloading they will take the weight once again and calculates the

net weight of the raw material/fuel. They enter the net weights of different

raw materials and will save them. For cement first they will note down the


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Main costs and drains in production and respective measures to be taken to

reduce them even at the lowest level are taken care by accounts. For e.g., coal

makes up for around 50% of the total cost of production while the other raw

materials doesnt cost much so decreasing the cost for coal other means of

energy sources reduces the cost of cement by more than 10%.

They maintain records of each department separately and all the respective

costs are submitted to HO (Head Office).

Stores Department:

Stores department coordinate with purchase department to have an

effective transport from various vendors for clearance of goods at different

transports and unloads them after reaching the company. They cheques

quantities of goods physically with respect to document and moves them to

appropriate area where it is to be stored. They classify the materials according

to departments and stores at different places. They protect material against

deterioration and damage.

They will keep the material according to their consumption levels.

From their analysis only 5% of the total material contributes to 70% of total

annual consumption, 20% contribute to 25% of the value and 75% of the items

contribute only 5% to the consumption value. So, they separate the material

according to their consumption value and store them with relevant locations.

Stores department has to coordinate with different department in

their functioning. In planning the targets of production availability of the

materials plays a vital role. They will provide accurate quantities of the

materials available. It keeps a track on the receipt of the purchase goods and

avoids any delay in the receiving of the purchased goods. Wrong


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supply/rejections/damages are reported to purchase section. They submit the

receipts of various purchases to the purchase section daily.

It has to process the received goods through inspection andidentification marks are made ass advised by inspection department to avoid

mix up of rejected and accepted goods. It forwards the details of the receipt

and their inspection results to finance department for making payment the

suppliers, transporters, customs duty etc. They also inform the accounts

department about the results of stock verification of material for making

necessary book adjustments.

They also maintain the materials required by the personnel

department like stationary items, canteen furniture and others. They supply

the material needed in different areas to personnel department. They supply

the spares and material required by plant maintenance team and assists them

in maintaining the plant safely. The main objective of stores department is to

supply the necessary material required by the production department.

Materials have to be issued to the production department according to the

production programme released PPC within the shortest time to avoid any loss

of production time.

The stores department has to ensure that the materials which

have been carried into store are made available whenever they are required. It

follows the FIFO method for the issuing of the goods to the different

departments. It makes the storing facility in three types

Main store which keeps all new items only. Secondary Godown, keeps separately once used items with

identification tags and used only in emergencies.


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Scrap yard, once used the items will be scraped thorough intoscrap yard.

Disposal of scrap is also one of main functions of the storesdepartment. Once in 6 months advertisements are given for all items to be

scrapped for receiving tenders. Stores assistant prepares a competitive

statement from the tenders received and submits it to the superiors and a

contractor with higher price is awarded the contract. Stores in charge ensure

that the contractor lifts all the scrap within the scheduled time.

For the transportation of materials from one place to another

it uses different material handling equipment like

Fork link trunks Platform trailers Chain pulley blocks

Sales Office:

The main function of Sales department is to take orders from the

customers and supply accordingly. There will be a sales representative for each

district. There are four sales representatives for Hyderabad region. These sales

representatives take orders from the customers and send their details to the


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head office. Head office gives instructions to the production units in the

nearest places.

Sales office has to follow the instructions given by the headoffice and has to deliver the load at the particular within a given span of time.

They have to maintain the details of the load leaving from the plant and submit

them to the accounts office.

In the case of the bulk orders they have to properly coordinate

with the customers and should deliver the load in certain intervals of time as

the production unit cannot produce huge amounts in a short period of time.

They maintain proper records of the orders coming and the amount of the load

delivered and ensures that the orders are delivered properly.


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Manufacturing of cementProcess description

1) Mines:

Anjani Portland Cement Ltd took a land of 142.14 acres for lease from

the Government. There are four benches in the mining area. Breadth of each

bench is 15m and its height is 3m. As we go down that means as the depth

increases the concentration of limestone increases. Holes are made using

drilling machines. Explosives are used to blast the mines. Depth of drilling can

be up to 5m.Drilling is made in such a way that the size of the limestone should

not be more than 1m.Mining area is at a distance of 8km from the plant.

2) Limestone crusher:

The crusher is meant for crushing the limestone from one

meter size to less than 10mm.Crushing process consists of Primary Crusher

followed by secondary crusher. Primary crusher and secondary crusher consist

of vibrating screens. They act as sieves. Primary crusher crushes the limestone

from one meter size to 70mm.Secondry crusher is meant for further crushing

of the limestone from 70mm to less than 10mm.

The capacity of the crusher is 40TPH.The crushing unit

consists of buildings, control room, feeding hoppers, feeding equipment,

conveyors, galleries, platforms, hand railing, de-dusting equipments,

foundations etc...


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3) Limestone stock pile and transportation:

The crushed limestone of size less than 10mm is

transported through conveyor to the Limestone Stock Pile to stack under

covered shed through Tipper conveyor. From the Limestone stock pile material

with uniform quality will be transported to Hopper through Belt conveyor.

This entire process consists of Control room, Feeding and

Transport conveyors, Galleries, Platforms, Hand railings, Bag filters at all

transfer points to control dust emissions etc.

4) Additives crusher and transportation:

The crusher is meant for crushing the Laterite an Iron ore

to less than 10mm size and it will be stored in Additives stock pile under

covered shed. From additive stock pile material is conveyed to Additive

hoppers through belt conveyers.

5) Raw mill & raw meal preparation:

Raw mill is a Ball mill meant for grinding the limestone,

Laterite, and iron ore of size below 10mm to less than 212 micron size. Thispowdered material is called Raw meal and is transported to storage silo.

The Raw meal preparation process is consisting of feed

hoppers, weigh feeders, conveyers, supports for conveyers, control room,

Bucket elevators, Cyclone separator, coarse and fine particles separation

equipment, pollution control equipment, foundations, platforms, railings and

metal detectors, separators etc..


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6) Blending silo & kiln feed extraction system:

Storage silo is of concrete construction meant for storage of

the raw meal powder produced by raw mill and also to facilitate blending

through aeration system to homogenize and maintains consistent quality of

raw meal. Homogenized raw meal from the silo transported to kiln feed bin.

From the kiln feed bin, the raw meal conveyed to the top of pre heater

through bucket elevator.

This entire process consists of silo, kiln feed storage bin, level

indicators, solid flow feeder to know the feed rate, bucket elevators, air slides,

bucket elevator support tower, feeding and transport conveyors, galleries,

hand rails, aeration blowers, compressors, pollution control equipment and

foundations.

7) Coal crushing and Transportation:

Coal is main fuel for manufacturing the clinker from RAW MEAL. The raw coal

from the coal hopper is conveyed to coal crusher through series of belt

conveyors. The coal crusher is meant for crushing the raw coal of size less than

200mm to less than 10mm.Crushed coal is conveyed to Coal Mill hopperthrough belt conveyers.

This entire process consists of covered sheds, feeding hoppers, crusher, control

room, platforms, feeding and transport conveyers, galleries, hand railing,

pollution control equipment, foundations etc.


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8) Coal mill, Fine coal preparation & Fine coal transportation

to Kiln and Calciner:

Coal mill is meant for pulverizing the crushed coal of size

less than 10mm size to below 212 micron size. Pulverized coal is called fine

coal. It is transported to fine coal bins. Fine coal pneumatically conveyed by FK

pumps and is fed to kiln and Pre-calciner.

Entire process consists of Ball mill, Grit separator for

separating fine and coarse material, building with control room, bins, blowers,

weigh feeders, FK pumps, pollution control equipment etc.

9) Pre-Heater:

Pre-heater is a 7 storey building with Pre-calciner,

cyclones, mixing chamber, feed pipes and ducts. Kiln feed enters at a duct

connected between 2nd and twin cyclones. This kiln feed is heated from 70

degrees to 1000 degrees in pre heater itself. Hot gases from the kiln and fine

coal fired in pre calciner will be utilized to heat the kiln feed to 1000 degrees

before it enters into the kiln. In the pre-calciner up to 92% of calcinations of

kiln feed takes place. Calcination is dissociation of limestone into lime and

carbon dioxide.

The pre heater consists of 7 storey building, steel cyclones,

steel ducts, steel chutes, flap valves, gates, doors, bucket elevator, platforms,

hand railing, de dusting equipment, refractory bricks, blowers, compressors,

fans, RCC floors and foundations.


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10)Rotary Kiln:

Kiln is a long, steel tubular structure with refractory lining

and is placed on support rollers to rotate at required speed. The hot material

which is heated in pre-heater up to 900 degree centigrade enters in to kiln

inlet. The kiln will be in rotating condition with controlled speed and with

pumping of fine coal and air from outlet of the kiln. The entered hot material is

converted at 1350-1400 degree centigrade to clinker after passing through

various phases. The hot clinker is discharged in clinker cooler for further

cooling.

This process consists of steel shell, supporting rollers, and

refractory bricks, drive motors, gear boxes, burner pipe, shell cooling blowers,

gas analyzers, panels and control room.

11) Grate cooler and ESP:

The cooler is meant for cooling hot clinker which is

discharged from kiln with 1100 to 150 degree centigrade by centrifugal fans.

Ambient air is pumped in to cooler through fans at bottom side of grate pass

through hot clinker bed. During the process the ambient air gains heat because

of heat exchange between hot clinker and ambient air. Part of hot air enters in

to kiln as secondary air at 1000 degree centigrade and tertiary air at 800

degree centigrade in to pre calciner and remaining hot air passes through ESP

to ID fan. The clinker moves on grate plate mechanism and by the time it

reaches clinker discharge, the hot clinker cools down. The cooled clinker passes

through a clinker breaker and transported to clinker stock pile by means of

conveyors. The cooler exit gas containing clinker dust passes through ESP


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(Electro Static Precipitator), where clinker dust is separated and clean air is

exhausted by ID fan through Chimney.

This process consists of grate plates, moving mechanism,fans, hydraulic power pack, drive motors, gear boxes, refractory lining, clinker

breaker, air blasters, deep pan conveyor, bag filters, ESP etc.

12) RABH & Bag Filters:

RABH (Reverse Air Bag House) is de-dusting equipment which

separates dust from pre-heater exhaust gases. The kiln exhaust gas passes

through pre-heater and pre-heater fan and then it enters in to RABH. Here dust

gases are separated and clean gas went out where as the dust collected taken

back in to process.

The entire process consists of control room, building, steel

structures, bin, steel casing, conveyors, filter bags, fans, blowers and drag

chain.

Clinker Stock Pile (CSP):

Clinker stock pile is a closed shed, where clinker is stored. It

is also useful for protecting clinker from rain and to reduce the dust emission

while handling. Clinker discharged from cooler is transported to CSP by

conveyors further the clinker i transported to cement mill hoppers through

underground conveyors.

CSP consists of civil structures, steel structures, conveyors

and pollution control bag filters fans and clinker extraction chutes.


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Fly ash & Gypsum storage and handling:

Fly ash stored in a closed silo having MS hopper where as

gypsum is stored in covered shed to protect from rain. These materials are

added to clinker as per required percentage in the process of cement grinding.

Gypsum is conveyed to cement mill hoppers by Terex as and when required.

This system consists of shed, conveyors, and hoppers.

Cement mill hoppers:

Cement mill hoppers are of concrete structures and is meant

for storage and feeding of clinker and gypsum to facilitate consistent feeding

to mills through weigh feeders and conveyors.

Cement Mills:

Cement mill is meant for grinding the clinker, fly ash and

gypsum to a powder form around 320Sq.m/Kg. This fine powder is called

cement and it is transported to storage silo through conveyors.

The cement mill circuit consists of ball mill, building, control

room, bucket elevator, classifier, cyclones, bag filters, fans, supporting

structures, hand rails, blowers, compressors etc.

Cement silos:

Cement silo is a concrete structure and meant for storing

the cement. The cement is transported from silo to packing plant for bagging.

It consists of aeration system blowers, compressors, bucket

elevators, air slides, supporting structures and bag filters etc.


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Packing Plant:

Packing plant is meant for packing the cement into bags

and transports the packed bags in the trucks.

The packing plant circuit consists of rotary packing

machine, buildings, control room, bucket elevator, air slides, belt conveyors,

screen, bin, fans, level indicators, supporting structures, bag filters etc.

Bulk loading system:

Bulk loading system is meant for loading cement to bulk

tankers. It consists of Hopper, Air slides, blowers, supporting structures etc.


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TECHNICAL DEPARTMENTS:

Electrical & Instrumentation department:

Electrical department mainly deals with

distribution of power in the industry and the operating conditions of various

electrical machines. Anjani Portland Cement Ltd. receives three phase power

of 132kV from the Government power substation. Three phase power of 132kV

from the Government substation directly reaches the SWITCH YARD of the

company. In the switch yard it is stepped down to 6.6kV. This 6.6kV is directly

given to the various substations present in the industry. From the substations

power supply is given to the LOAD CENTRES.

Transformers of various ratings are used in the power distribution. These

transformers give maximum efficiency at 50-65% of maximum load.

Depending on the requirement of the load 6.6kV can be further stepped down

to 3200V or 440V or 110V etc. using step-down or step-up Transformers. At

each and every sub-station, load centre, and at switch yard CT (Current

Transformer) and PT (Potential Transformer) are used to measure the supply

current and supply voltage. Special wire is being used to prevent surges in the

Transformers which are caused due to lightning, thundering etc. Transformers

are being earthed to prevent shocks. In general LV (Low Voltage) side of the

Transformer is earthed.

Special devices like relays are being used to detect the surges (high currents

and high voltages). Mostly Induction Motors are being used in the industry.

Even DC Motors are being replaced with Induction Motors. Capacitive banks

are used to improve the PF (power factor) of the motors. Maximum power

factor reached is around 0.997.


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LRR (Liquid Rotor Resistor) is used to vary the speed of the motor in starting

condition. VVVFD (Variable Voltage Variable Frequency Device) is used to

change the speed of the motor in running condition.

WORKSHOP:

Workshop mainly deals with repairing the damaged parts that were used in

machines and also designing the new parts according to the requirements.

There are all basic machines that should be present in a workshop and some

work specific machines that are specially used in a cement industry. The

following are the machines present in workshop here in Anjani Cements.

Grinding machine Drilling machine Bench vice Lathe Pipe Vice Shaper machine Power axe-saw Bending machine

The most important machine used in workshop is a Gear Motor. It is a

combination of Gear box and a normal motor. It is used to vary the speed of

the motor depending on the requirement of the machine. The input rpm given

to the motor is called drive and the output taken is called driven. The ratio

of the gear motor is calculated by dividing drive with driven. We can even

change the direction of rotation of resultant driven by using ODD or EVEN

number of gears. By using even numbers of gears we can reverse the direction

of driven to that of drive and vice versa.


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There are also rotary feeders which help in locking air. Also there are different

types of drives such as belt, chain, gear drives etc Gear drives are used for no

loss condition and depending on required output belt and chain drives are

used.

Acknowledgement:

The following people helped us in respective areas in completion of this report.

P&A Mr.Varma

TO & WB Ramaiah

Stores, A/C, Sales Sr. Mgr Stores, Mgr A/c, Dy. Mgr Sales

Crusher Mr. M.purushottam, Mech eng

Mines Mr. Ramachandram, sr.Mgr

Workshop Mr. PSN Raju

Raw Mills, Kilns, Mills Mr. Subbarao

Packing Plant Mr. P.Subbaraju

ELE & INST Mr. DV Subbaraju

Documents

Manufacturing of Cement