Saurabh Mishra Training Report

7/30/2019 Saurabh Mishra Training Report

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(From 09th july 2012 to 24 sept 2012)

AT

Guided By: - Submitted By:-Mr. Arbind Singh Saurabh Mishra

(DGM Mechanical) Mechanical Engineering

O.I.M.T. Damoh


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ACKNOWLEDGEMENT

Every successful training requires a healthy atmosphere,

good presence of mind, co-ordination and several other resources

like energy and time through which a successful project can be

made. The credit of all these things that I had got partially in

completing my project approaches.

I must admit that I cannot take credit for all ideas and

information that this training comprises off. It is merely a

collection of ideas from various books and people.

I am very much thankful to Mr. Arbind Singh Sir and all other

who directly or indirectly supported me to bring my training to a

success.


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PROFILE OF THE COMPANY

Heidelberg Cement India Limited is a subsidiary of Cement

rum I.B.V. (a Company incorporated under the laws of The

Netherlands, which is 100% controlled by Heidelberg Cement

AG).

Heidelberg Cement India Limited, with its core products

being cement, ready mixed concrete, aggregates and related

activities, is one of the leading producers of building materials

worldwide, and it employs around 46,000 people in more than 50

Countries.

Heidelberg Cement India Limited is committed to supply

high quality products and provide best possible services to its

customers. Its emphasis is to continuously upgrade plant efficiency

by employing modern and latest technologies, reduce costs and

improve production.


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Heidelberg Cement India Limited (MCL), a Heidelberg

Cement Group Company, was promoted in 1958 by a Karnatakabased industrialist in technical and financial collaboration with

Kaisers of USA as a Public Limited Company.

The first one lac ton per annum dry process cement plant

with an investment of Rs.220 lacs at Ammasandra Dist. Tumkur,

Karnataka was commissioned in 1962. Immediately thereafter, an

expansion was planned which doubled MCL's capacity to 2 lac tpa

in 1966 at an investment of Rs.170 lacs Kaisers subsequently took

control of the Company. Late Shri.G.D. Birla became the

Chairman of the Company in 1966 and under his stewardship, the

Company again doubled its capacity from 2 lac tpa to 4 lac tpa in1968 at an investment of Rs.390 lacs MCL made steady progress

and increased the capacity at Ammasandra to 6 Lac tpa with an

investment of another Rs.230 lacs in 1978.


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MCL, to expand, looked for a location in the North which,

was then facing acute cement shortage. Damoh in Madhya Pradesh

was selected and a 5 lac tpa green-field cement plant was set up atan investment of Rs.2950 lacs, which commenced production in

1983. This was a state of art first 5 stage preheater based

technology plant in the Country which helped in maximising

thermal efficiency. Encouraged with its success MCL also

modernised its Ammasandra unit at an investment of Rs.3600 lacs,

which was successfully completed in January, 1989, and helped

not only in increasing the efficiency but also reduced cost of

production on account of savings in power and fuel consumption.

The Clinkerisation capacity at Damoh was further increased

to 10 lac tpa by installing another state of art 6 stage preheater Kilnat an investment of Rs.8000 lacs, which was commissioned in

1989,and becomes 5cr.per.month\60cr.per.annum which helped

not only in improving the operational efficiency but also in

reducing the coal consumption and enhanced productivity.


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A green field 5 lac tpa grinding unit was set up at Jhansi in

Uttar Pradesh at an investment of Rs.5900 lacs, which commenced

production in July 1989 to take advantage of the available fly ash

from the nearby located Paricha Thermal Power Plant. Jhansi wasconsidered an ideal location in view of the fact that Uttar Pradesh

is one of the biggest cement consuming state with very little

production capacity and even the available capacity then was only

from the State Govt. owned cement plants.

With this MCL achieved a total capacity of over 20 lac in

1989-90, with a presence both in Southern and Northern markets,

which at that time only ACC enjoyed. Subsequently with

upgradation and balancing at Damoh, the capacity increased to 23

lac tpa in 2004-05.

Pursuant to the Share Subscription and Share Purchase

Agreement and Escrow Agreement Cementrum I B.V.(subsidiary

of HeidelbergCement AG) acquired Equity Shares from the S.K.

Birla Group and its affiliates. In addition, further Equity Shares

were acquired under the Open Offer giving Cementrum I B.V.

54.89% shareholding in HeidelbergCement India Limited.


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MANUFACTURING PROCESS

OF CEMENTS

The Plant incorporates the latest sophisticated dry process

technology from KHD, Germany.

The main raw material for the cement manufacturer is

limestone. Limestone from the mines is carried to the main

primary crusher by ropeway/dumpers after properly scrutinizing

the limestone quality.

The crushed limestone is brought to the pile by stacker

through conveyor belts. The stacked material is extracted from the

pile by reclaimer so as to get the uniform quality and brought to

the roller press by conveyors where the material is pressed to form

cokes with a size reduction upto 2-3% on 6.3 mm and 35% below

1mm.

The pressed material is fed into the ball mill along with the

appropriate quality of additives (fluxes) i.e. iron ore, bauxite and

laterite etc. to produce a fine raw meal (2% on 210 micron

sieve). Raw meal is transported by means of air slide and pumped

to the blending silos by the air lift. The material is again blended to

form uniform quality in silos.


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The raw mill is further extracted from the silos and conveyed

by pneumatic transport to first stage of suspension preheater.

Material attains a temperature of 850o C by the heat exchange

between the hot gases and material.With this temperature material

attains about 30% calcination.This materials then enters a

puroclone where because of the more retention of this material in

the hot gases stream and pulverized coal firing it attains 85-90%

calcination at the end and then the calcined material enters the last

cyclone for further separation of material from the gases. Here the

material attains a temperature 900-950 C.The meal from the last

cyclone enters the kiln burning zone where temperature of about

1400 C is maintained by pulverized coal firing, here the chain of

chemical reactions between the constituents of calcined raw meal

i.e.SiO2, Al2O3, Fe2O3, CaO and MgO takes place. In this phase

formation of nodules called clinker takes place. The hot air attains

a temperature of 1000-2000 Celsius with enters the kiln as

secondary air for coal combustion and balanced by cooler exhaust

fan and ph fan. The cooled clinker is transported by means of

bucket conveyor to the clinker yard or ropeway silos. The` clinker

is transported by ropeway to clinker yard/cement mill hopper.

The fine coal used for the firing purpose is ground in a ball

mill to a fineness of 10-12% on 90 micron sieve and stored in fine

coal silo.


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MANUFACTURING PROCESS FOR 33, 43 & 53

GRADE

33Grade ordinary Portland Cement is manufactured by

grinding clinker with about 2.0-4.0gypum to a fineness of 2800-

3000 cm2/gm in terms of Blaine 33 Grade OPC is manufactured as

per IS : 269 1989.

43Grade ordinary Portland cement is manufactured by

grinding clinker with about 3.0 5.00% gypsum to a fineness of

3000 3200 cm2/gm in terms of Blaine 33 Grade OPC is

manufactured as per IS : 8112 1989.

53Grade Ordinary Portland cement is manufactured by

grinding clinker with about 3.0 5.00 % gypsum to a fineness of

3300 3500 cm2/gm in terms of Blaine. 53 Grade OPC is

manufactured as per IS: 12269 1987.

PPC is produced by inter grinding clinker with about 20 24 % fly ash (pozzolana material) and 2.00 4.00 % gypsum to a

finess of 3500 - 3700 cm2/hr.PSC is produced as per IS : 455

1989 .

Cement produced is conveyed by pneumatic pumps to the

storage silos where from it is extracted and conveyed to the rotary

packer where it is packed is bags and dispatched.


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INTERMEDIATE CONTROLS

1. During cement manufacture, very stringent control is

exercised on quality of incoming raw materials and at every

stage of process products.

2. 100% consignments of raw materials are checked for their

quality.

3. Crushed limestone is tested every hour (with continuous

sampling at an interval of 5 minutes). Similarly raw mix, kiln

feed and fine coal samples are tested on hourly basis for theircomposition.

4. Clinkerisation is done at a temperature of more than 1400 oC

and clinker is checked every hour for its quality and burning

characteristics.

5. Cement produced is checked every hour for various

parameters like blains, setting time and So3 contents etc.

6. The quality control lab is equipped with sophisticated

equipments like X-ray and other testing equipments.


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SPECIAL EFFORTS MADE FOR

MANUFACTURE 53 GRADES

To cape up with the requirements of 53 grade OPC as per IS:

12269 1987, we have specially imported coal of low ash (13

15%) from Indonesia. with this coal of higher calorific value ash

absorption in clinker is very low thus even normal lime in raw

mix. The LSF and C3S of clinker is on higher side i.e., 0.92 0.94and 52.0 - 55.80 respectively. The mineralogy of clinker has also

improved. We ensure free lime of less than 1 % by maintaining

higher temperature in kiln burning zone. High purity gypsum is

used so that insoluble residue remains within limits.

We have increased fineness of cement and maintaining blainsof 3500 3800 cm2/gm. This helps in achieving higher strengths.

The entire operation of the kiln and mills is automatic and

controlled by sophisticated maintenance instruments through

programmable logic control (PLC).


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PLANT MAINTANANCE SYSTEM

The entire maintenance system is based on preventivemaintenance, planned repairs and conditioned monitoring. Each

section or stage will have maintenance plan indicating area,

responsibilities, frequencies and associated documents etc.

Broadly each sectional in charge will be responsible to carry out

preventive maintenance activities per the maintenance plan.

The section in charge will be responsible for arranging the

resources like man power, tools and tackles, spares and planes shut

down of the equipments for the maintenance. As and when

required he will also obtain necessary guide lines from his higher

authorities


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CRUSHER

INTRODUCTION:-

DOUBLE SHAFT HAMMER CRUSHER HDS are

successfully used for the reduction of limestone, marl, gypsum,

bauxite, chalk as well as similar materials with compression

strength of up to 2000 dn/cm2 mixing moistures in the feed of up to

20% H2O does not necessitate heating of the crusher housing. Forthe double shaft hammer crusher HDS the power spectrum of

throughout is in the range of 260 TPH to 2100 TPH related to the

crushing of medium hard limestone in one operation down to a

final grain size of 0-25mm.

Lumps sporadically occurring in the feed with a weight of up

to 8000 kg/s are reduced to the desired final grain size with in few

seconds, dependent on the size of crusher and motor output

installed.


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MODE OF OPERATION:-

The material fed to the HDS crusher is caught by the free

swinging hammers of the rotors running in opposite direction and

reduced by the resulting impact effect. Crushing mainly done

above the rotors. Fine crushing proper takes place on the anvil and

crushing grates which are adjustable so as to be at optimum height

relative to the striking circle of rotors. The above average energy

storing capacity reduces the speed drop of the rotors to a minimum

even in case of large feed lumps and largely diminished current

peaks. An overload protection circuit which depends on the rotor

speed protects the crusher and control the speed of the steel-plate

APRON FEEDER. This ensures optimum utilization of the HDS

crusher.

SPECIFICATIONS:-

TYPE: HDS 1600 * 2200

CAPACITY: 700 TPH

MAX. FEED SIZE: 1.3 m3

FINAL GRAIN SIZE: 0-50mm

ROTOR DIA.: 1600mm

MOTOR: 2 * 500KWNo. Of HAMMER: 2 * 36

WEIGHT OF HAMMER: 90 Kg


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WORKING OPERATION OF CRUSHER SECTION:-

The raw materials are coming in from quarry which are of size

(80mm-1.3mm) and are dumped into the crusher hopper

(V=150m3) by means of dumper.

From the crusher hopper, raw material comes to apron

conveyor (which is a belt) whose width is 2000 mm and

capacity 1650 TPH. It acts as a media for raw material from

hopper to H and B screen.

Now in H and B SCREEN, the material coming from apron

conveyor is separated out from foreign materials like clay etc.

with this some small size raw materials (5-10mm) goes to the

washer where raw materials with clay washed out such that

limestone is recycled to crusher hopper.

SPECIFICATIONS OF H & B SCREEN:-

TYPE: DSS 2100 * 1600

CAPACITY: 1100 TPH

MAX. : 1650 TPH

MOTOR: 55 KW, 1500 RPM


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From H and B SCREEN, the material coming to crusher

where they are crushed to a size of 0-50mm.

From crusher, the limestone is coming to stacker through V-

belts. In between, we use two packet filters. First pocket filter,

blows away the dust which sticks to the small sized limestone

and second is to attract the small natural iron pieces from belts,

if any (it works as magnet).

SPECIFICATIONS OF FIRST POCKET FILTER:-

TYPE: LGAB 23

CAPACITY: 3240 m3/hr

FILTER AREA: 22.5 m2

FAN TYPE: HCCB 025-47

FAN MOTOR: 5.5 KW

SPECIFICATIONS OF SECOND POCKET FILTER:-

TYPE: LGAB 23

CAPACITY: 4320 m3/hr

FILTER AREA: 22.5 m2


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Now, with the help of stacker we stock the limestone pieces on

form of heaps for future use if there come any problem in

crusher.

After reclaiming the limestone goes to the roller press hopper

through belts (W = 1000 mm, capacity= 500 TPH).

Now in roller press, there are two rollers one is fixed and other

is movable.

When the limestone of -50mm goes in between the roller, then

due to movable roller the coming limestone presses in between

them, and then we get the burn-cake type of limestone which is

brittle in nature and due to we get the limestone of size of about

0-20mm.


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SPECIFICATIONS OF ROLLER PRESS

TYPE: RPB 115 100

ROLLER DIA & WIDTH: 1150 mm X 1000 mm

MOTOR: 2 X 500 KW

MOTOR SPEED: 1000 RPM

V-BELT PULLY DIA.: 710 mm

MOTOR V-BELT PULLY DIA.: 600,670

BELT: SPC X 13

From the roller press, the pressed lime moves to raw mill by V

belts.

WEIGHT = 1000 mm

CAPACITY = 500 TPH

SPEED = 1.5 m/sec.

The similar process also takes place for bauxite and iron which

are mixed limestone to improve the quality of cement.


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RAW MILL

INTRODUCTION:

I. The tandems grading plant is a combined drying and grinding

mill system with IMPACT HAMMER MILL preceding for

grinding cement raw mill material.

SPECIFICATION OF RAW MILL:

AREA: 4.2* 6.75m

CAPACITY: 200TPH

SPEED: 15.24/min

MOTOR: 1700 KW


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IMPACT HAMMER MILL

INTRODUCTION:

The HUMBOLT IMPACT HAMMER MILL is used as

primary reducing unit in tandem grinding plants. It shall further

open up the raw material discharge by the primary crusher thus

relieving the following raw mill. Not gas is fed in to the impact

hammer mill along with the raw material which means that

material is dried during and after comminuting procedure.

MODE OF OPERATION

Depending on the characteristic of the discharge products, the

IMPACT HAMMER MILL may be classified as medium or fine

comminuting machine continuous flow of material with an adequate amount

of air required for discharging the product will be the precondition for an

optimum throughout of the machine.


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FIGURE OF OPERATING PRINCIPLE

It represents the impact hammer mill in which the moist raw

material is fed by a mechanically lock.

Which sets as air seal ,over stepped deflecting and distributing

plates

The moist raw material comes into the contact with drying

gasses

Already before entering the impact hammer mill .The length of

pre drying section has matched to the maximum moisture

contact of the raw material.

The pre dried raw material and the drying gasses jointly enter

the impact hammer mill which operates at a circumferentially

speed of approx 40m/min

The raw material which has a size up to 5.mm approx is reduced

between the rotor, the arm one plates of inlet and the mill

bottom.

The fraction 10mm approx. Is entertained with the gas stream

in the riser pipe.

The portion of minus 0.09mm amount to much smaller

dimensions.


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Fairly large volume of at this stage already but its quantity is

determned exclusively by the type of fed material. And then else also discharge pneumatically .To large particles

that have not been crushed at the adjustable impact plate.

Either is recirculated through the hammer mill.

SPECIFICATIONS OF IMPACT

HAMMER MILL

TYPE: PHM 2200* 2200

CAPACITY: 200TPH

FEED SIZE: 0- 50 MM

PRODUCT SIZE: 10MM

ROTOR DIA: 2200MM

ROTOR SPEED: 355RPM

WEIGHT OF HAMMER: 29KGS

NO. OF HAMMER: 108

MOTOR: 300KW, 1000RPM


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PROCESS DESCRIPTION OF

RAW MILL:-

The cement raw materials is discharged by proportioning

divides from the mill storage bins .via a conveyor belt and a

double flap box preventing air from being entertained into the

grinding system, the raw materials fed into the impact hammer

mill.

The gases required for drying the raw materials will be

sucked by the circulating air fan either from the pre heater or from

the gas generator via impact hammer mill tube mill. If the moisture

content of the materials will be found too high waste gas from the

pre heater and hot gas generator may be used.

Distribution of the gases volume rates is regulated by flaps.

The materials are dis will be combined in the riser pipe and

conveyed by gas stream to the separator. In the separator the

finished product and rejects are separated from each other.


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The rejects are passed through respected separator materials

are recycled to impact hammer mill. The residual rejects are

passed through a belt conveyor with rejects weight device on to the

mill for reground.

The finished products are conveyed with the gas stream to

the cyclone collectors. Here, the finished product is separated from

the gas stream. The finished raw mill is withdrawn from the

separator by pressure and by subsequent conveyor unit passed on

to the silo. Gas stream carrying the dust residual load is divided

behind the circulating air part of it is conveyed to the grinding (to

the inlet and outlet of the tube mill and to the impact hammer mill)

the other part of the gas stream is conveyed to the E.S.P

(ELECTRO STATIC PRECIPITATOR) for being deducted.

The collected dust is conveyed by pressure worms to the

subsequent conveyed unit and transported to the silos.


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COAL MILL:-

INTRODUCTION:-

The air swept coal grinding plant is a grinding and drying

plant for grinding the materials being conveyed through the system

by the gas flow.

The grinding plant mainly plant mainly consists of a chamber

tube mill with drying chamber, a air separator, a cyclone dust

separator , a circulating air fan , a motor controlled down flap

valve , as well as two shut off slide valves , an electrical circular

dust collector with rotary lock and a hot gases from the . In the

cases of feed rises up to maximum approx. 30mm the shell lining

of the mill may be designed as a lifter lining.

The special design of the drying chamber permits to grind

material with high contents the trunnion and slide shoe bearings

are sized so that the gas velocity in the bearing journal are kept

with normal ranges .The mill is drawn by a single pinion driver


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PROCESS DISCRIPTION:-

The coal is discharged from the entire mill feed bin with the

aid of a propertionating system and fed to the mill by a double flap

valve which serves as a air seal and the inter bland. In the mill the

coal is ground and dried at the same time.

The heat which is required to drying the most coal is

supplied to the mill in the form of hot waste gas by separating

cyclone and the hot gas fans.

The hot gases are distributed in the system by the adequate

flap positioning.

The ground coal is discharged from the mill with the gas

flow and conveyed to the separator through the rising pipe.In the

separator the pulverized coal is separated which the fineness set at

the separator by the reects outlet which is sealed with flap valve,

the rejects are recycled to the mill by the throughout screw

conveyor.

The pulverized al is transported to the C.D.S (CYCLONE

DUST SEPARATOR) with gas flow and separated from the

carrier gas.


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The carrier gas which is still laden with residual amount of

dust is sucked by the mill inlet as a circulating gas flow the other

portion which is composed of the hot gases supplied to the plant,

the water stream driven out of the run-of -mine coal and false air is

passed through the filter and largely discharged into the

atmosphere after deducting. The pulverized coal separated into the

filters is also conveyed to the final coal pin via a rotary lock and a

throughout screw conveyor.

SPECIFICATION OF COAL MILL:-

AREA: 3.4m * 4.5m

DRYING CHAMBER: 2M

CAPACITY: 23TPH

SPEED: 5RPM

MOTOR: 580 KW, 986RPM.


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ROTARY KILN:-

INTRODUCTION:-

The most essential data for production operation starting and

stopping, locating and eliminating operational defects and

servicing of the plant exactly observing the instruction given shall

avoid production interruption. The special operating instruction for

a individual machinery shall be observed. Following completion of

commissioning revised operating instruction will be prepared by

us who will consider the experienced gained during

commissioning.

NORMAL OPERATION

Switch on the dust transporting system of E.S.P including

mill air lift

Switch raw material transporting.

Switch cooler fan


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It is taken for granted that the shock blowers in the pre heater

Start the E.S.P fan and regulating the draught to-10mm we

down stream the pre heater fan

Start the pre heater fan and opening the flap in front of the

pre heater fan while observing the down stream the pre

heater fan.Closing the fresh air socket raising the draught in

front of the pre heater fan to 500mmwc.

Increasing the quantity of the pulverized coal for the klin

burner lance to 4-4.5tph.

The raw mill branch in the raw meal line underneath cyclone

has been set such that no raw mill will penetrate to the

production

The kiln speed has been kept at 1.51min this ensuring that

the kiln is not choking fed with raw mill.

After first raw mill feeding the pre heater inlet chamber,

fresh air socket and kiln head assembly shall again be

checked if necessary immediately be carried out during

operation ingress of false air should be reduced to a

minimum checking the kiln inlet and outlet seal at regular


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intervals shall be implied.

The cooler grates are operated at mean number of strokes.

The kiln head pressure, the total cooler control as well as the

number of strokes and air volume control systems are

manually adjusted during the plant starting phase.

Up an correct draught condition , inside the kiln and pre

heater fan will adjust to 2.5 - 3.5 % after a certain period and

the 02 content of the kiln inlet some what later to 1 -2%.

The tertiary air flap is gradually opened as soon as a clinker

belt has built up and hot secondary air is available as soon as

the hot gas down stream of the pryoclon section has reached

a temperature of more than 760 degree Celsius., the

pulverized coal firing system can be stared upon

simultaneous feeding of raw meal to the pyroclon section.

With the tertiary air reaching higher temp. An increased raw

meal feed rate, the control ekt for keeping the temperature

down stream of the pyroclon section and downstream of the

gas riser pipe between the inlet chamber and cyclone is set to

automatic operation. Nom possible to run kiln up to rated

capacity with in a short period the time of 4 - 6 hrs is been


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taken for first raw meal feeding for the rated output.

Subject to proper heating of the kiln and pre heater system ,

clinker will be found inside the sintering zone after a short

period on observing the KW recorder for the main kiln drive,the kiln speed must be raised by 25/min each as soon as the

KW requirement shows an upward tendency.

Upon increasing the temperature inside the pre heater, the

raw meal feed rate is increased by 10 TPH.

Rapid heating of the plant due a excessive addition of

pulverized coal in to the system in the danger of excessive

clinkers burning and agglomerating in the coolers.

SPECIFICATION OF ROTARY KILN

AREA: 4.0 m *54.0 m

FLOW: 3.5%

CAPACITY: 100 TPH

MOTOR: 340 kW; 1500-2500 RPM


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WORKSHOP

DIFFERENT TYPES OF MACHINE IN

WORKSHOP:-

Planner Machine

Lathe Machine

Drilling Machine

Shearing Machine Hydraulic Machine

Rolling Machine or Plate bending roller press

Shaper Machine

Grinder Machine

Milling Machine

Hack saw

Planner Machine

This Machine is used for machining the big job.

Lathe Machine

This Machine is used for machining the job drilling, boring,

threading and making of shaft and bush.

Documents

Saurabh Mishra Training Report