INDUSTRIAL TRAINING REPORT

BIRLA CORPORATION LIMITED, SCW, SATNA (M.P.)

TRAININGON

PRODUCTION OF CEMENT

GYAN GANGA INSTITUTE OF TECHNOLOGY AND SCIENCES, JABALPUR (M.P.)

SUBMITTED TO SUBMITTED BY DEPT. OF MECH ENGG. SUSHANT SIDDHEY GGITS, Jabalpur 0206ME131167 BRANCH - ME SEMESTER - 7th

ACKNOWLEDGEMENT

I sincerely express indebtedness to esteemed and revered guide of ‘HRD Department’, ‘Mechanical Engineers Department’, and ‘Electrical Engineers Department’ of SCW, Satna for their invaluable guidance and support throughout the industrial training.

I take the opportunity to express deep sense of gratitude to ‘Mr. B S Chouhan’ Officer HRD, ‘Mr. R Bhalla’, ‘Mr. V P Singh’, ‘Mr. B P Singh’, ‘Mr. Md. Alim Khan’ ‘Mr. Amit Halvi’, and ‘Mr. D P Singh’ Mechanical Engineers Department, and ‘Mr. Srivas’, HOD Workshop for Guidance and Support during training, and providing the best available facilities.

I owe thanks to all the Engineers in ‘Mechanical Engineers Department’ for their advice, and support time to time.

Date: 5 Aug 2016 Sushant Siddhey

Place: Satna, MP 0206ME131167

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ABSTRACT

This report covers the experience, which I got in ‘INDUSTRIAL TRAINING’ at Birla Corp. Ltd. (SCW, Satna). Firstly I was introduced in the Cement Mill & Packing Plant section. In operation of cement mill the clinker first come from the clinker storage piles to the clinker hopper through the deep bucket conveyor. Then transferred to the polycom, where it crushes and then fed to cement mill for further grinding and mixing. There is also a recirculation system, which again feed the coarse material to the polycom. The very fine material from cement mill is then stored in the cement silo. From the cement silo the cement is fed to the packers, where it filled in the bags of 50 kg.

Then I was introduced in the OHC section, Heavy Earth Moving Vehicle section and then Raw Mill & Coal Mill section. In Raw Mill & Coal Mill section I got the knowledge of various Instruments like pressure transmitters, temperature transmitters, pressure gauge, proximity switches, flow switches, level switches, temperature sensors like RTDs & thermocouples, weigh feeders, metal detector &metal separator etc. Then I was introduced to Kiln and Preheater section, WHRS and all others section one by one and learnt the processes and working of various machines and their significance.

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INDEX

SECTION SECTION NAME PAGE NO.

1. COMPANY PROFILE 06-14

2. INFRASTRUCTURE 15-17

3. ENVIRONMENTAL PROTECTION 18-19

4. DESCRIPTION OF ELECTRICAL ENERGY AND LINE DIAGRAM

20-21

5. PROCESS FLOW 22-25

6. INTRODUCTION OF THE TOPICS 26

A) WEIGH FEEDER 27-28

B) BELT WEIGHER 29

C) TEMPERATURE MEASURING INSTRUMENTS 30-31

D) PRESSURE MEASURING INSTRUMENT 32

E) LEVEL MEASURING INSTRUMENTS 33

F) ELECTRONIC SPEED SWITCH 34

G) METAL DETECTOR 35

H) OPACITY MONITER 36

I) VIBRATION MONITER 37

J) GAS ANALYSER 38

7. CEMENT MANUFACTURING PROCESS 39

A) QUARRYING 40-41

B) RAW MATERIAL PREPARATION 41

C) FUELS PREPARATION 42

D) CLINKER BURNING AND STORAGE 42-44

E) CEMENT GRINDING 45

F) MINERALS ADDITION PREPARATION 45

G) CEMENT DISPATCH 46

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H) CENTRAL CONTROL ROOM 46

8. SAFETY 47-48

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COMPANY PROFILE

INTRODUCTION OF THE COMPANY

Birla Corporation Limited

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Birla Corporation Limited, a renowned organization and a parent company to various industries is dedicated towards the progress and development of the country through its widespread undertakings both in India as well as abroad. The annual sales of the organization today are more than Rs. 1800 Crores. Birla Corporation Ltd. is the flagship company of the M.P. Birla Group.

Birla Corp. Ltd. formerly Birla Jute Manufacturing Co. Was started in the year 1919 by Late Shri Ghanshyam Das Birla which was the first Indian owned Jute Mill on the outskirts of Calcutta. It marked not only the birth of Indian Jute manufacturing industry but also the beginning of the Birla Industrial Group in India. Later the company grew steadily under the guidance of Late Shri Madhav Prasad Birla.

It was Madhav Prasad Birla who with his strong sense of enterprise and clear- sighted vision transformed it from manufacture of jute goods to a leading multi-product corporation with widespread activities and the name of the company was changed from Birla Jute Mfg. Co. to Birla Jute & Industries Ltd. which ranked among the top thirty companies in the country with products that range from jute and synthetic yarns to cement, calcium carbide, industrial gases, linoleum & Auto trim. Under the chairmanship of Mrs. Priyamvadaji Birla, the company crossed the rupees 1300 crores turnover mark and name was changed to Birla Corporation Ltd in 1998.

After the demise of Mrs. Priyamvadaji Birla, the company continues to consolidate in terms of profitability, competitiveness and growth under the leadership of Mr. Rajendra Singh Lodha, late chairman of the M. P. Birla group. Under his leadership company posted its best results in the year ended 31.3.2006 to 31.3.2007 and thereafter once again in year 2008.

Thereafter, under the leadership of Shri Harsh V. Lodha, Chairman, once again the company recorded an impressive result and highest ever turnover Rs.2400 crores and profit of Rs. 550 crores in the year ended 31.03.2009.

Apart from normal Ordinary Portland cement & Pozzolana Portland cement, The Company is also making special grades of cement such as high strength cement for Railway Sleepers, low alkali cement for dams and power projects. Now the name of “Birla Jute Industries Ltd.” has changed to “Birla Corporation Ltd”.

Birla Corporation Ltd., cement division has six plants in following places

Satna (M.P.) - Two Plants

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1. Satna Cement Works

2. Birla Vikas Cement

Raibareli (U.P.) - One Plant

Chittorgarh (Raj) - Two Plants

Durgapur (W.B.) - One Plant

These plants manufacture various type of cement like

Ordinary Portland Cement (OPC)

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Portland Pozzolana Cement (PPC)

Low Alkali Cement

Portland Slag Cement

The cement is branded under the name of Birla Cement are

Khajuraho

Samrat

Chetak

Durgapure

Premium

BIRLA CORPORATION LIMITED SENIOR MANAGEMENT TEAM

1. Shri Harsh V. Lodha

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Chairman2. Shri B.R. Nhar

MD & CEO3. Shri P.k. chand

CFO4. Shri KK Sharma

Jt President Management Audit5. Shri P.S Marwah

President Satna Cement Works & Birla Vikas Cement

6. Shri VK Hamirwasiya President Birla Cement works & Chittor Cement Works

7. Shri PC Mathur Jt President Durgapur Cement Works.

SATNA CEMENT WORKS

Satna Cements Works / Birla Vikas Cement are industries of cement Division of Birla Jute & Industries Ltd., are situated in North East corner of Satna City about 5 km from Satna.

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Satna Cement Works was the first cement plant in the house of Birla’s and the plant itself was of production capacity exciting in our country at that time.

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History

1959 – Commissioning of satna cement works with a single well process kiln of TPD. 1964 – Capacity raised to 1750 TPD with two additional wet process kilns. 1982 – Commissioning of Birla Vikas cement, a dry process kiln with 2500 TPD. 1989 – Conversion of Satna Cement Works wet process kiln into a single dry process

kiln with 2250 TPD.

Present Status

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Plant Layout

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

“The present operating capacity of Satna Cement Works and Birla Vikas cement are 2750 and 2650 TPD respectively”.

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 tonnes at present, which is projected to rise to 2.84 million tonnes 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 primarily priced in all the markets where it is available.

Earlier Birla Cement was available with the name “KHAJURAHO” (OPC) & “SAMRAT” (PPC) but now the cement is available in the market with the name “Birla Cement SAMRAT”, which owing to the good quality has a brand name in the market. Cement is being regularly exported to Nepal and Bangladesh under the brand name "CAMEL" & "ROYALTIGER"

Company Details and Achievement

All cement plants are ISO 9001:2000 Certificated, covering the entire range of production and marketing. SCW & BVC have received the IS/ISO 14001 certificate, an international recognition for "Implementation of Environmental Management System". (SCW has been awarded GREENTECH Safety Silver Award 2009 and GREENTECH Environment Excellence Award 2008 by GREENTECH Foundation, New Delhi. It has also received the First Prize for Maximum Reduction in KWH/ton of cement in M.P. from FLS Energy Award, Bhopal, in 2008. The Satna units received the Quality Circle Excellence Award from Quality Circle Forum of India, Durgapur Chapter; Quality Circle Excellence Award and Quality Circle Distinguish Award from Quality Circle Forum of India, Kanpur Chapter, both in 2008, and Quality Circle Forum of India, Baroda. SCW has received the National Award for Excellence in Water Management from CII, Hyderabad and First Prize for Lowest Thermal Energy Consumption K. Cal/kg clinker under the 10th FLS Energy Award 2007.

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INFRASTRUCTURE

INFRASTRUCTURE

Plants: Satna Cement Works & Birla Vikas Cement Capacity 1.73 Million Tonnes / Year Range of Products

1. OPC Grade 432. PPC (Fly ash based)

Process – Dry Process Salient Features

1. Mine planning through computer based system.2. 4.5 Kms long bi-cable ropeway between mines and the plant.3. Stacker and reclaimer for limestone blending.

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4. Vertical roller mill and ball mill with high efficiency separator.5. Blending silo for Raw Mill.6. Four / Five stage Preheater with calciner.7. Modern energy saving Grate cooler.8. Online X-ray analyzer.9. State – of – the- art control system.10. Alkali-By Pass system.11. Electronic Packing Machines.12. Facilities for Transportation 13. Rail Broad Gauge14. Road Trucks, Trailors15. Packaging – Packed in PP bags – 50 Kg each

Captive Mines

Lease Area 10 Sq. Km.

Mining Area 06 Sq. Km.

THERMAL POWER PLANT

27 MW Capacity

One 27 MW Capacity Steam Turbine Two 65 TPH each capacity ‘F’ grade coal based and Bio mass fired AFBC Boilers. Equipped with DCS controlled system and modern RO based water treatment plant. Latest pollution control equipments and monitoring system. Dedicated fuel handling system. Advance communication system.

12 MW Capacity

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3 sets of 4 MW capacity steam turbines. 3 FBC ‘F’ grade coal fired boilers of capacity 32, 22 & 22 TPH. Latest pollution control equipments and monitoring system. Water treatment plant with de-mineralizing unit.

7.5 MW Capacity

One set of 5 MW and one 2.5 MW capacity steam turbines. 3 FBC ‘F’ grade coal fired boilers of capacity 25, 25 & 15 TPH. Latest pollution control equipments and monitoring system. Water treatment plant with de-mineralsing unit.

Diesel / Power Plant

2 sets of 6 MW HFO based 1 set of 4 MW HFO / Diesel based

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ENVIRONMENT PROTECTION

ENVIRONMENT PROTECTION

Satna Cement Works is committed to provide clean environment to the society and constantly endeavors to keep Air, water and noise pollution well below the stipulated levels. In recognition of its commitment to and implementation of environmental improvement measures, Bureau of Indian Standards awarded IS/ISO – 14001 Certification to Satna Cement Works, Birla Vikas Cement and Sagmania Limestone Mines in Sept.1999. Some of the major activities that are being carried out and a continuous basis are listed below:

Pollution Control Equipments in use: Electrostatic Precipitators = 15 Nos. Bag Dust Collector = 58 Nos.

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Pocket Filter = 60 Nos.

Plantation in the Factory and Quarry as on date 411290 Nos. Recycling of wastewater through treatment in oxidation pond and used for gardening

etc. Sludge oil generated from DG set being reused for firing in the Kiln. Water sprinkling inside the factory for controlling fugitive dust. Installed dust suppression system on coal belt/ Clinker belt and Iron ore crushing belt

conveyors, to suppress dust emission. Fly ash transportation from Thermal Power stations by pneumatic conveying system in

closed tankers.

ENVIRONMENTAL FRIENDLY PRODUCTION & PROCESS

IS/ISO-14001 Certification for Environment Management System by BIS, New Delhi since 1999 both for SCW & BVC.

ENVIRONMENTAL POLICY

The Birla Corporation Limited, Satna is engaged in the Manufacturer of different varieties of Cement using dry process having two plants with an installed capacity of 2.50 Million Tones per annum.

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DESCRIPTION OF ELECTRICAL ENERGY

DESCRIPTION OF ELECTRICAL ENERGY OF PLANT

Contract Demands = 21500 KVA (For both plants)

Single Line Diagram (Electrical) with details of supply voltage and current of SCW

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PROCESS FLOW

Process flow chart of Satna Cement Works

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Quarry Pre blending yard Stacker

Crusher Raw mill

KilnCoal supply

Coal Crushe

r

Raw coal

Hopper

Coal mill

Quarry CrusherPre blending yard Stacker

Reclaimer

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Cooler

Gypsum

Fly ash

Cement mill

hoppers

Cement mill

Cement silos

PackingMarket

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20

V R M

MINES & CRUSHER

COOLER CEMENT MILL

PACKING PLANT

DESPATCH

SILO & P H CEMENT SILO

ROTARY KILN

HIGH LEVEL FLOW DIAGRAM

FLOW DIAGRAM

OF CEMENT PLANT

PROCESS

COAL MILL

INTRODUCTION TO TOPICS

A) WEIGH FEEDER

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As the name suggests it feeds material to the next process while weighing the material in proper quantity. It is just like any conveyor belt but the belt speed is varied by weighing the material so as the feed to the next process remains constant. The material on the belt is weighed by load cell under the belt and the speed is varied by the speed control of dc motor. The signal from the load cell and speed (measured by Tachometer) are multiplied in microprocessor card. The resultant shows the feed in TPH. Further this TPH is compared by a set point given externally. Now the microprocessor controller generates the error which is amplified and given to the Thyristor controller, which controls the power fed to the DC motor which in accordance varies the speed of the belt with the gear box and hence control the feed.

INPUT, OUTPUT & MARKER

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These are one bit variable that can have LOW or HIGH status. Inputs are signal from outside to the control program, and outputs are signal from the control program to the external system. Markers are internal variable and serve asmemory

within the control system. They are available outside the control system when they have been copied onto outputs. This diagram depicts the basic process of cement blending and storage.

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B) BELT WEIGHER

It is a system used to measure the feed of material to any m/c through belt conveyor. We are using it in many location. In Raw mill it is being used.

PRINCIPLE OF OPERATION

Mass of material flowing on BC is sensed by load cells. Load cells are located under the belt in such a way that the force acting on the load cell is equal to amount of material on the 1/2 meter of the belt, hence it is represented in Kg/m. The belt speed is sensed by a speed transducer which is calibrated to give belt speed in m/sec. The integration of belt loading and belt speed will give you total material, whereas multiplication of two gives instantaneous flow rate in Kgs/sec. Various indicators totalizers, alarms and control signals can be generated from flow rate signal.

Flow rate = Belt loading*Belt speed= Kg/m*m/sec = Kg/sec

Flow rate in tones/hours = Kg/sec*(3600/1000)

Total material conveyed= Int. of (f/v)dt from 0 to l

f = Belt loading

l = distance between rollers

v = belt speed It comprises of following

1. Transom assembly

2. Load cell

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3. Speed transducer 

4. Main processing unit

C) TEMPERATURE MEASURING INSTRUMENTS

I. THERMOCOUPLE

The thermocouples are based on Thermo-electric effect is known as Seeback effect. A thermocouple consists of a pair of dissimilar metal wires joined together at one end (sensing or hot junction) and terminated at the other end (cold junction or reference), which is maintained at a known constant temperature (reference temperature).When a temperature difference exists between the sensing junction and reference junction an EMF is produced that causes the current to flow in the circuit. When the reference junctions terminated by a meter, the meter indication will be proportional to the temperature difference between the hot junction and the reference junction. Various types of thermocouples are:

TYPE MATERIAL USED

J Iron-constantan K Cromel-Alumel R/S Platinum-Rhodium E Chromel-ConstantanTo ensure long life in its operation environment a thermocouple is protected in an open or closed metal protecting tube or well. Since thethermocouples usually in a location remote from the measuring instrument, connections are made using special extension wires called compensating lead.

 

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THERMOCOUPLES IN CEMENT PLANT

II. RESISTANCE TEMPRATURE DETECTOR (RTD)They employ a sensitive element of extremely pure Platinum, Copper or Nickelwire that provides a definite resistance value at each temperature with in its range R(t)=R(ref) (1+ $t)R (t)= Resistance of conductor at temperature "t"R (ref)= Resistance at reference temperature$= Temperature coefficient.Almost all metals have a positive temp. Coefficient of resistance so thattheir resistance increases with an increase in temperature. Some materials such ascarbon and germanium have negative temperature coefficient of resistance, whichsignifies that their resistance decreases with increase in temperature. PT100 is anexample of RTD that has 100 ohms resistance at zero degree resistance.Type of RTD -- PT-100.

III. KILN SHELL TEMPRATURE SCANNERIt is used for precise evaluation of the refractory's condition at all times.Evan if a single brick falls out its location can be identified as a hot spot. It uses principles of non-contact temperature measurement. It measures an objectnaturally emitted infrared radiation to determine its temperature. Infraredradiation enters through a sensor window. A mirror rotating at 19.6 Hz receivesinfrared energy and reflects it on to a lens, which focuses it on to athermoelectrically cooled detector. The detector receives energy from the targetfor every 90 degrees of rotation of the mirror. Rest remaining 270 degrees of rotation are used to self calibrate the instrument by reflecting infrared energy of two internal temperature indicators on to the detector.The incoming signal is sampled at 20 kHz, converted from analog to digital andtranslated by an internal microprocessor into temperature. For every rotation of mirror 256 measured values are possible which can be averaged to 128 or 64measured signals.For data transmission an RS232 interface with switchable baud rate is availableand allows transmission of pre-processed data to a PC.

IV. RADIATION PYROMETERIt is also detects the heat radiation emitted from the object. These radiation arefinally converted into temperature using the necessary optics and electroniccircuitry.

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D) PRESSURING MEASURING INSTRUMENTS

PRESSURE TRANSMITTER 

Pressure is transmitted to a silicon pressure sensor through a diaphragm and aliquid filling. The pressure causes the sensors measuring diaphragm to distort.The resistance of four doped pizeo resistors in a bridge circuit in the measuringdiaphragm changes. The change in resistance generates an o/p voltage in bridgecircuit that is proportional to the measured pressure. The voltage is converted into periodic signal by an amplifier in a voltage/frequency convertor. A microcontroller evaluates the signal, correct it with respect to linearity and temperature before passing it on to D/A convertor which gives 4 to 20 mA.Differential pressure is transmitted to a silicon pressure sensor through adiaphragm and a liquid filling. The differential pressure causes sensors measuringdiaphragm to distort. The electronic circuit is same as that of pressure transmitter.The differential capacitance between the sensing diaphragm and capacitance plateis converted electrically to 4 to 20 mA.The process pressure is transmitted through an isolating diaphragm and oil fluidto a sensing diaphragm. The reference pressure is transmitted similarly to theother side of sensing .The displacement of sensing diaphragm is proportional to pressure difference across it. The position of the sensing diaphragm is detected bythe capacitance plate on both sides of the sensing diaphragm. This capacitance isfurther treated to give 4 to 20 mA.

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E) LEVEL MEASURING INSTRUMENTS

I. NUCLEONIC LEVEL SENSOR These provide noncontact method of level monitoring. It utilizes theattenuation principle of gamma rays transmission. Since it does not come incontact with material so it is not affected by the physical conditions.Such type of level sensors have a source of gamma radiations and adetector. The source and detector are mounted opposite to each other. The sourceutilizes Ceasium137 or Cobalt 60 as a source of gamma radiations. The gammaradiation sees through the vessel wall and detector converts nuclear gamma rayradiations into electrical quantities related to level (generally in form of a counter)When the level of the material in the vessel exceeds the height of thegamma beam the beam is attenuated and the output relay switches.Intensity of the radiation received by the detector varies(1) in proportion to the thickness of the material between source and the detector.(2) inversely proportion to the square of the distance between the source and thedetector.

II. ULTRASONIC LEVEL SENSOR The emitter in the sensor is excited electrically and it sends an ultrasonic pulse inthe direction of the surface of the product which partially reflects the pulse. Theecho is detected by the same sensor and then converted back into electrical signal.The time between transmission and reception of pulse is directly proportional tothe distance between the sensor and product suface. The distance is determined bythe velocity of sound "c" and the run time "t" using the formulad=c.t/2 (where c=320mtr/sec)

III. RF TYPE LEVEL SENSOR It includes an electronic unit and a probe. The electronic unit consists of anoscillator, a detector and a output relay which is controlled by the detector . The probe contains an inner(active)section and outer section(shield),insulated fromeach other

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and from the vessel ground.The oscillator generates low power RF signal which is used to providesignals equal in frequency, amplitude and phase to both, active section and theshield section of the probe.The signals provided to shield held constant. The detector is then used tocompare the fixed shield signal with the active signal which varies with thedielectric constant of the material in contact with the probe .Difference in signalscompared by the detector cause the output relay to activate.IV. CAPACITANCE TYPE LEVEL SENSOR Capacitance is formed between the sensing probe and the vesselwall/ground. When the material level changes there is corresponding change inthe value of this capacitance because of the difference in the dielectric constant of the material and that of air. The electronic circuit converts the capacitance intoDC signal which causes the relay to operate.

F) ELECTRONIC SPEED SWITCH The electronic speed switch is ideally suited to monitor any repetitivemotion, whether rotational or translational. In fact it is best suited for the speedmonitoring of critical element of any material handling system, such as belt/screw conveyor, elevators, crushers, drag chain, rotary feeders etc. It senses theunder speed /over speed conditions in the systems by non contact method and provides out put contacts for protection, control and interlock purposes.Application include ,detection in jamming in feeders, sequential interlocking onconveyors, detection of blade breakage in reclaimer chain, motion detection, fanspeed monitoring etc.The speed switch comprises of a sensor probe and a monitor unit. A sensor probe is a non contact type inductive proximity switch, which picks up speedinformation, evalutes it and provides necessary outputs. The proxi potted probe isdust and water tight and the monitor in steel sheet or cast Alluminium, epoxi printed housing is dust tight pulses are clearly visible through the transparentwindow on cover. The terminal strip which can accept conductor up to 2.5 squaremm, speed setting knob, the range switch and the bypass trip setting knob all areaccessible only after opening the cover. Proper markings are provided for test points and external conditions. Different housings are available to suit individualrequirements. The sensor probe are available suit individual requirements. Thesensor probe is available in threaded housing, either thermoplastic or metallicwith two clamping nuts, maving size as per selection table.

 With the unit connected the "SUPPLY ON" and "RELAY ON" LED lightup as the supply is switched on During the initial bypass time, which is initiated by supply on the output relay remains picked, independent of speed. It is further held only. if the speed reaches the set value, before expiry of the bypass. Therelay then drops whenever the speed falls below the set value. it can again pick up, if the system speed picks up to healthy running condition. The pulses LED onand off in response to the actuation and deactuation of the probe.

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G) METAL DETECTOR

In our plant LS is queried from mines. So it may happen that some metal pieces can come together with .If these metal pieces allowed to pass throughmachinery it could damage machinery. So to detect metal, detecting device isused on the belt weigher which senses the metal and divert the material to rightside for short duration.

DESIGNThe metal detecting device consists of two components the probe and theamplifier, both which are interconnected with one coaxial cable. The probe will be furnished to match your conveyor belt width. There is a single probe and atendom probe available. The planer single probe will usually be mountedunderneath the conveyor belt. The tendom probe consists of two planer probesone of which will be mounted underneath the conveyor belt while the other probewill be held above the belt by special support.

FUNCTION

A high frequency AC voltage is fed from the amplifier to a coil in the probe via a75 ohms coaxial cable. This generates an electromagnetic field. If a metal piececomes into this field, induction currents will be generated that drain power fromoscillator.

If depending upon the selected sensitivity an unwanted metal piece in theconveyed material is identified by the electronics. In the amplifier, the o/p relaywill switch to its other state for about 0.5 seconds.The o/p relay has two potential free NO/NC contacts that are wired to theterminal strip. These contacts can be used to stop the conveyor belt or to activatean injection device.

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H) OPACITY MONITOR

Opacity refers to the amount of light being scattered or absorbed by particles in the light beam path. An Opacity or dust density monitor measures the particulate level of stack emissions. One of the most common reasons for measuring opacity is comply with Environment protection (EPA) or the nationalrequirement. A transmissometer is used to ensure that the stack opacity does notexceed these prescribed limits.

SYSTEM DESCRIPTIONThe OPM 2000A Opacity/Dust monitor consists of a transmitter receiver (transceiver) module, a retroreflector module and a control room unit (CRU). Thetransreceiver and retroreflector modules are mounted on the stack directlyopposite each other. The transceiver projects a controlled beam of light across thestack. Particles in the gas stream cause a certain amount of light to be scatteredand absorbed. This amount varies depend upon the particulate content of the gasstream an the type and the size of the particles. The corner tube bounces the light back along a parallel path to the transreceiver. The light then strikes a detector,which converts the light into a voltage that can be processed. The detector signalis amplified by an independently powered detector/amplifier board. The amplifiedsignal is then digitized and transmitted to the CRU calculates opacity, sendscommands to the transceiver, and provides an operator interface for the system.Because the beam passes through the stack twice (once in each direction) theresulting value is double - pass transmitted measurement. By passing through the smock twice, sensitivity to opacity level is increased and alignment of themodules is made easier. The measurement value is compared to a reference value previously determined with no smoke in the light path. The resulting ratio is atransmittance value for the measurement path. This ratio can then be converted tounits of optical density and stack exit opacity and dust concentration.

TRANSCEIVER MODULE

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The main component of transceive module of optical assembly air lens assemblyand blower motor. The three components are mounted to monitoring plate andenclosed in weather housign. The optical assembly contents all transceiver opticaland electronic components.

OPTICAL SYSTEM

The light source for the optical system is a special long -life incandescent lamp.The lamp contains a built-in that directs light forward to a 1/8-inch diameter cross-haired aperture. Two liquid crystal windows (LCW) function as shuttersthat either block or transmit light. The LCWs are made of a normally translucentfilm when an electric current is applied to the file, the LCWs becomestransparent, allowing light to pass. The sequence and duration that the LCWs turnon or off are under software control. Each of four-voltage measurement is produced by a different combination of LCWs being on or off during themeasurement cycle. Each measurement cycle consists of four different light pathmodes, each of which produces different voltages. The four measurement modesSTACK, AMBIENT, DARK and LAMP.

I) VIBRATION MONITOR

VIBROCONTROL 1000 Vibration monitoring system is used to monitor andmeasure machines vibrations. The system measures the rms value of vibrationvelocity in accordance.

PRINCIPAL OF OPERATIONElectrodynamic vibration sensors converts mechanical motion into an analogeelectrical signal. The o\p voltage supplied by the sensor is proportional to thevibratoion velocity. The ac signal supplied by the sensor is amplifired rectifiedand adapted to the measuring span in the measuring or monitoring amplifier.At the o/p of these ciruits, a dc voltage of 0 to 10 volts or a dc currentsignal of 4-20 ma is available, which can be fed to field mounted i/o cards, whichis given to PLC system, further it is displayed on coros monitor. Each system has5 calibrated measuring ranges for vibration velocity or vibration displacement. Inaddition the measuring amplifier enables 2 alarm limits to be set, a power relay is provided for each of the alarm limits, the throw-over contacts of which can beused to trip an alarm or shut-down the machine concerned.A supplementary ok relay monitors the power supply and the sensor circuit by means of a dc current passing through sensor coil.

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J) GAS ANALYSER

PRINCIPLE

O2 MEASUREMENT - PARAMAGNETIC TYPECO MEASUREMENT - INFRARED TYPEDUAL CHANNELSAMPLE (1) SAMPLE SOV 2-5 ONSAMPLE (1) EXHAUST SOV 2-4 ONSAMPLE (1) CLEAN SOV 2-2 &2-1 ON

DEFINITION

In order to obtain accurate results the analyser must be callibrate d with a gas of accurately known concentration of zero callibration gas as given or specified onthe Test Certificate of Gas Cylinder supplier.ZERO GAS :100% Nitrogen CALLIBRATION GAS: COO2Bal.

Nitrogen Channel 1: OxygenChannel 2: Carbon Mono Oxide

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CEMENT MANUFACTURING PROCESS

CEMENT MANUFACTURING PROCESSThere are four main process routes In the manufacturing of cement – the dry,semi-dry, semi-wet and wet process.Common to all these processes are the following sub-processes - _ Quarrying. _ Raw materials preparation. _ Fuels preparation. _ Clinker burning. _ Mineral additions preparation. _ Cement grinding. _ Cement dispatch

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A) QUARRYING

Natural (“primary”) raw materials

such as limestone/chalk, marl, andclay/shale are extracted from quarries which, in most cases, are located close tothe cement plant. After extraction, these raw materials are crushed at the quarrysite and transported to the cement plant for intermediate storage, homogenizationand further preparation.

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Belt Conveyors Impact Crusher

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Limestone Stock Pile Additives Storage Hopper

Corrective materials

such as bauxite, iron ore or sand may be required toadapt the chemical composition of the raw mix to the requirements of the processand product specifications. The quantities of these corrective materials are usuallylow compared to the huge mass flow of the main raw materials.To a limited extent, “secondary” (or “alternative”) raw materials originating fromIndustrial sources are used to substitute for natural raw materials and correctives.In the same way as traditional raw materials, they may be fed to the quarry crusher or – more commonly – directly to the cement plant’s raw material preparation system.

Today, modern computerised methods are available to evaluate the rawmaterial deposits and to optimise the long-term and short-term productionschedule.

B)RAW MATERIALS PREPARATION

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.

Raw Mill Building, VRM

After intermediate storage and pre-homogenisation, the raw materials are driedand ground together in defined and well-controlled proportions in a raw mill to produce a raw meal For the dry (and semi dry) process. In the wet (and semi-wet) process, the raw materials are slurried and ground with addition of sufficientwater to produce a raw slurry. Depending on the technological process applied, additional steps may berequired such as preparing raw meal “pellets” from dry meal (semi-dry process)or “filter

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cake” by dewatering of the slurry in filter presses (semi-wet process).The resulting intermediate product – i.e. raw meal or raw slurry (or their derivatives) – is stored and further homogenised in raw meal silos, storage bins or slurry basins to achieve and maintain the required uniform chemical composition before entering the kiln system.As a rule of thumb, approximately 1.5 – 1.6 tons of (dry) raw materials arerequired to produce one ton of  the burnt product clinker. More detailed figures onraw.

C) FUELS PREPARATION Conventional (fossil) fuels

used in the cement industry are mainly coal(lignitie and hard coal), petcoke (a product from crude oil refining), and heavy oil(“bunker C”). Natural gas is rarely used due to its higher cost.

Alternative fuels

 – i.e. non-fossil fuels derived from industrial (“waste”)sources .

Fuels preparation

 – i.e. crushing, drying, grinding, and homogenising – usually takes place on site. Specific installations are required such as coal mills, silos andstorage halls for solid fuels, tanks for liquid fuels, and the correspondingtransportand feeding systems to the kilns.The thermal fuel consumption is largely dependent on the basic process designapplied in the burning of clinker.

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.

Blending and Storage Silo

D) CLINKER BURNING

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

Preheater

A 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.

Kilm speed is 3.5 RPM

Kiln

The prepared raw material (“kiln feed”) is fed to the kiln system where it issubjected to a thermal treatment process consisting of the consecutive steps of drying/preheating, calcination (e.g. release of CO2 from limestone), and sintering(or “clinkerisation”, e.g. formation of clinker minerals at temperatures up to1450° C). The burnt product “clinker” is cooled down with air to 100-200° C andis transported to intermediate storage.The kiln systems commonly applied are rotary kilns with or without so-called“suspension preheaters” (and, in more advanced systems, “precalciners”)depending on the main process design selected. The rotary kiln itself is aninclined steel tube with a length to diameter ratio between 10 and 40. The slightinclination (2.5 to 4.5%) together with the slow rotation (0.5 – 4.5 revolutions per minute) allow for a material transport sufficiently long to achieve the thermalconversion processes required.Exhaust heat from the kiln system is utilised to dry raw materials, solid fuels or mineral additions in the mills. Exhaust gases are dedusted using either electrostatic precipitators or bag filter systems before being released to theatmosphere.

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The output of the kiln is stored before it is fed to the cement mill for conversion to cement.

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.

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

Deep Bucket Conveyor

Clinker Storage

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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.

This storage space is used for gypsum storage.

Gypsum Storage

E) CEMENT GRINDING Portland cement

It is produced by intergrinding cement clinker with a few percentof natural or industrial gypsum (or anhydrite) in a cement mill.

Cement Mill and Bag House

Blended cements

Blended cement (or “composite” cements) contain other constituents in addition such asgranulated blast-furnace slag, natural or industrial pozzolana (for example,volcanic tuffs or fly ash from thermal power plants), or inert fillers such aslimestone.Mineral additions in blended cements may either be interground with clinker or ground separately and mixed with Portland cement.Grinding plants may be located remotely from the clinker production facility.The different cement types have to be stored separately in cement silos prior to bagging and dispatch.

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

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

F) MINERALS ADDITION PREPARATION Mineral additions from natural or industrial sources intended to be used in blended cements may need to be dried, crushed or ground in separate installationson site. Separate “grinding plants” where mineral additions and blended cementsonly are produced may also be located remote from the clinker production facility.

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

Cement Storage Silo

G) CEMENT DISPATCHCement may be shipped as bulk cement or – usually to a lesser extent – packedinto bags and palletised for dispatch. Transport methods used (i.e. road, railway,waterways) depend on local conditions and requirements.

Packing and Dispatch

H) CENTRAL CONTROL ROOM

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SAFETY

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.

SAFETYSafety is utmost requirement for any plant because by taking proper measuresagainst accident we can increase the profit of company and can save manpower from injury.Safety is totally an Egineering system. According to Bell Telephone inotto“ No job or service is so urgent that we cannot take time to perform our work safely”. “Safety an attitude, a state of mind that must be sustained in work environment”.

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ACCIDENT

Unwanted undesirable events which has potential to hit injury to a person or aloss of property”

CAUSE OF ACCIDENT

Unsafe act - 85-90% Unsafe condition 10-15%

UNSAFE ACT: UNSAFE CONDITION:

•Lack of knowledge No provision of safety attachment

•InattentionLeakage of oil, water, steam etc

•HurryDust fumes & temperature

•Violating safetyCondition of ladder/scrapped/stair 

•Overconfidence

•Worry & hypertension

•Lack of experience

HOW TO PREVENT ACCIDENTS?

•Use of proper safety devices 

•Toxic & inflammable materials store process to be isolated

•Preventive & periodically maintenance of equipment

•By training of employees through video, audio , lectures etc

•To motive the people to make active part for creating awareness in the plant

•Use of personal protective equipment

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