By:-Deepesh Kumar Mishra11202732

Satna Cement WorksBirla Corp. Ltd.

Six Weeks Training Report

Satna Cement Plant

Introduction

Counted amongst the larger plants of the Cement Division, Satna Cement Works and Birla Vikas Cement at Satna (MP) along with Raebareli Cement Works (UP) have an installed capacity of 2.36 million tones at present, which is projected to rise to 2.84 million tones after the present expansion/modification.

Birla Cement Samrat and Birla Cement Khajuraho are already leading Brands and frontrunners of company’s activities. Riding on the glory of very high standards of quality, the company products are premierly priced in all the markets where it is available.

00. Limestone Quarry and Crushing plant 09. Cooler

01. Limestone Stockpile 10. Deep Bucket Conveyor

02. Additives Hopper 11/12. Clinker/Gypsum Storage

03. Additives Storage 13. Coal Mill Building

04. Raw Mill Building 14. Cement Mill and Bag House

05. Blending and Storage Silo 15. Cement Storage Silo

06. Preheater 16. Packing & Dispatch

07. Gas Conditioning Tower and ESP 17. Central Control Room

08. Kiln

Plant Layout

Process Flow Chart

00. Limestone Quarry and Crushing plant The major raw material for cement production is limestone. The limestone most suitable for cement production must have some ingredients in specified quantities i.e., calcium carbonates, silica, alumina, iron,etc Belt Conveyors The quarried raw material is transported to the cement plant, using mechanical conveying equipment such as ropeways or belt conveyors, or by vehicles like wagons and trucks.

There are mainly two types of crushers available - compression type or impact type crushers.

Imapct Crusher

01 Limestone Stock Pile

Circular or longitudinal stock piles are used to store the material.

A number of layers are stacked in circular or longitudinal piles and are reclaimed in transverse, cross-sectional slices.

02 & 03 Additives Storage Hopper

In order to get the required composition of raw material, certain additives such as iron ore, bauxite, laterite, quartzite and flourspar are added in required quantities.

These additives are stored at the plant in separate hoppers and are extracted using belt conveyors in conjunction with belt-weighing equipment.

04 Raw Mill Building

VRM

The raw material is finish-ground before being fed into the kiln for clinkering. This grinding is done using either ball mills or vertical roller mills (VRM).

VRM uses the compression principle to grind the raw material.

The main advantage of VRM is higher grinding efficiency and ability to accept material with higher moisture content.

Normally the energy consumption level in VRM is 10 to 20 percent lower than in ball mills.

05 Blending and Storage Silo

In order to blend and homogenize the raw materials properly, continuous blending silos are used.

As there are various sources of raw materials, it becomes necessary to blend and homogenize these different materials efficiently to counteract fluctuation in the chemical composition of the raw meal.

06 Preheater

Clinkering takes place in the kiln and the preheater system.Preheater systems offer heat transfer from the hot kiln gases.

07 Gas Conditioning Tower and ESP

The conditioning tower is used to reduce the temperature and to increase the moisture level of the dusty exhaust gas from the kiln, before it is passed through the bag house and ESPs.

The Electrostatic Precipitators are used in cement plants particularly for removal of dust from the exit gases of cement kilns and from the exhaust air discharged by dryers, combined grinding and drying plants, finishing mills and raw mills through water injection.

08 KilnA kiln is the heart of any cement plant.

It is basically a long cylindrical-shaped pipe, and rotates in a horizontal position. Its internal surface is lined by refractory bricks. Limestone and additives are calcined in this. The output of the kiln is called clinker.

09 Cooler

The clinker coming out of the kiln is hot. It is cooled in a set-up called a cooler. In the cooler, cold air is blown to effect heat exchange between hot clinker and cold air.

10 Deep Bucket Conveyor

The deep bucket conveyor is essentially an equipment to lift material vertically.

11 Clinker StorageThe output of the kiln is stored before it is fed to the cement mill for conversion to cement.

12 Gypsum Storage

The storage space is used for gypsum storage.

13 Coal Mill Building

The coal mill building houses the mill for grinding lumpy coals. This fine ground coal is used for burning in the kiln.

14 Cement Mill and Bag House

Clinker, along with additives, is ground in a cement mill. The output of a cement mill is the final product viz. Cement.

The term bag house is applied to large filters containing a number of tubular bags mounted in a usually rectangular casing. The dust laden air is drawn through them by suction.

15 Cement Storage Silo

The cement storage silo is used for storing the finished product – cement.

16 Packing and Dispatch

The cement is packed with the help of a rotary packer and finally dispatched to the market.

17 Central Control Room

It is the nerve center of the cement plant since all equipment is controlled from this place. It is the place from where all the process parameters are controlled.

Gantt Chart of 6 weeks Training

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