gujarat sidhee cement limited-smit

7/31/2019 Gujarat Sidhee Cement Limited-smit

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GUJARAT SIDHEE CEMENT LTD. Page 1

NOBLE ENGINEERING COLLEGE

JUNAGADH

TRAINING REPORT AT

GUJARAT SIDHEE CEMENT LIMITED (GSCL)

VERAVAL (GUJARAT)

DURATION: 01/06/2011 to 15/06/2011


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INDEX

Sr. No: Topic Name Page No

1 General layout of cement

plant

6

2 Production Department 7

3 Mines Department 11

4 Mechanical Department 12

5 Instrument Department 22

6 Quality Control Department 23

7 Electrical Department 24

8 Distribution Department 25


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I have gone through various departments training program from 01/06/2011 to15/06/2011. Form this training I learnt basic function of various department, activity doneby them, and what are the role of various department to increase productivity. Each and

every department contributes to increase the productivity of plant. Every departmentstand as a column for organization. In this report I describe what I learn during trainingprogramme. First I describe function of department and various section covered bydepartment. What are the responsibilities of department have that I cover. In electricaldepartment I describe power circuit, various electrical motors and other electricalequipment used in plant. In production department I describe various process involve tomake clinker and cement. In mechanical department I explain material flow diagram andvarious equipment uses, what kind of drive used to run machine etc. And basic functionof various other departments I explain in this report.


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I have started training in Gujarat sidhee cement limited from 01 st June 2011 inmechanical department. Gujarat sidhee cement limited is a reputed mehta groupcompany I thankful to company, which gives me this bright opportunity for my brightahead future. I thankful to Mr. K.A. Zala who is sr. manager of P & HR department whogive me this opportunity to make this report. I hearty thankful to Mr.Makwana sir who

allow me to go anywhere in plant premises. I thankful to all HODs, Sr. manager, Managerand deputy manager who help me at site as well as in office for technical discussion thatincrease my knowledge and this knowledge help me in future also. All engineers help melot to understand technical detail and various operations. I also thankful to mechanicaldepartment fitter who help me in practical aspects.


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I was in production department, I Shaw and understood various processes to make

clinker and cement. Main reaction process occurs in kiln at 1400 C to make clinker. Tomake cement grinding and rubbing processes take in cement mill. Main process is asbelow:

MINING:They have two types of mining process: Conventional mining (Blast mining) and Eco-

friendly surface mining. In blast mining, Drill a hole with the help of drilling machine and fillthe explosive material into that hole, allow exposing and it will take limestone from earth.Second one is the surface mining. In the mining surface miner is used to extract thelimestone from earth. Blast mining is dangerous for surrounding village because it createsshock. They have very rich captive mines. Two mines actually they have one is morasa minesand other ones is prasanavada mines. In this mines almost all grades of limestone is availableand a very little quantity of additive is to be added from outside to prepare raw-mix.

CRUSHING:The mined limestone is hauled through Dumpers to a rotary hammer - impact

type crusher that crushes the limestone to a size of 80% up to - 75 mm size. Additivematerial is added to the crushed limestone through an additive hopper, which bypassesthe crusher.

STACKING:The material is passed on to the stacker via belt conveyors, which stacks thematerial in longitudinal layers. To perform this function they have chevron-stacking

stacker, which was supply by Elecon Company.

RECLAIMING:They having end reclaim type reclaimer. The stacked material is lifted by the

reclaimer, which reclaims it by cutting transversely the longitudinal stacked layersensuring perfect blending and homogenizing. The reclaim material is transported to rawmill through belt conveyors.

RAW MILL GRINDING:


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They having Atox-40 vertical roller mill. The desired material is drawn from limestone reclaimer pile to the Box feeder and is fed to the vertical roller mill through chute.The vertical mill consists of a rotating table upon which 3 rotating rollers arehydraulically pressed. The material is dried and transported by the hot kiln exit gases.The size of the pulverized material is controlled by a static separator, which separates the

oversized particles and sends it back on the table for further grinding. The pulverizedmaterial is transported to the C.F. Silo via energy efficient bucket elevators.

PROCESS IN C.F.SILO:The pulverized material is stored and blended in the controlled flow silo. The

blending action is achieved by extracting the material from the 7 outlets at a differentflow rate. The extracted material is conveyed to a weighing bin were it is further blended.The operation of extraction is controlled by a PLC. The blended material is fed to the preheater for preheating via bucket elevator.

PREHEATING:Preheating process is done in the preheater and pre-calciner string having four

stage cyclone. Approximately 40% of the total feed is given to the pre heater string whereit get preheated by the hot kiln exit gases and gets calcined up to 30% approximately. Thebalance 60% feed is fed to the calciner string where coal is fired in the calciner and the30% calcined feed from the pre heater string is also added to the calciner. Here, about90% calcinations are achieved. Chemical formula of this process (at 900C) is as under:

CaCO3 CaO + CO2

900c

KILN PROCESS:The material comes from ph and pc string is feed into the kiln where remaining

10% Calcinations process is done. This calcined feed is transferred to the kiln for theremaining 10 calcinations and sintering where the flux materials and silica melt and reactwith lime to form four clinker constituents. This is achieved by firing coal in the rotarykiln. Kiln capacity is 4000 TPD.

CHEMICAL REACTION PROCESS:


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COOLING:They have Folax type cooler. The clinker coming out of the rotary kiln is at a

temperature of 1200 -1300 0C and hence cooling of it is required. This is achieved bypumping atmospheric air in the reciprocating grate cooler by 7 centrifugal fans. Theclinker gets cooled and the air gets heated up and the excess air is vented out at a lowertemperature.

CLINKER STORAGE & TRANSPORT:

Sr

no.

Temperature Chemical Reaction

I

II

III

IV

V

Below 800o

C

900 - 1100oC

1000 - 1200oC

1200 - 1300oC

1200 - 1450oC

Decomposition of limestone & formation ofCaO.Al2o3 begins

1. Decomposition of Calcium Carbonate iscomplete.

2. Formation & Decomposition of Gehlenite(2CaO+Al2O3+SiO2)

3. Formation of C3A, C4AF starts.Formation of C2S, C3A & C4AF is nearly complete.

Liquid formation starts.

Assimilation of CaO through solid-liquid reactions& formation of C3S


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The clinker, which is cooled to 150 C, is stored in a silo, which has a capacity of40,000 M.T. The clinker is transported to the silo by deep bucket conveyors. The silo forclinker is a salient feature of the plant, as the clinker does not get weathered. Another siloof 2000 M.T. Capacity is provided to store specified products/non conforming products.The clinker from the clinker silo is transported to the clinker silos of the cement mills for

grinding.

CEMENT GRINDING:The clinker is ground along with gypsum and slag at desired proportion in the

highly efficient Cambodian mills. The cement mills are two compartment tube mills. Inthe first compartment, the grinding is done by impact with balls and in the secondcompartment; it is done by attrition with small grinding media cylinders called cyllpebs.The mill is swept with air, which transports the material through the mill. The cement ispumped to the cement silos with the help of airlifts. There are four silos for cement of

5000 M.T. capacities each for storing different grades of cement.

RAW COAL & FINE COAL PLANT:Raw coal is also stacked and reclaimed by a stacker and reclaimer hence ensuring a

perfectly blended Raw Coal. This is a unique feature of the plant. The Raw Coal ispulverized in a vertical roller mill, which is similar to that for the limestone. They have

Atox-22.5 vertical coal mill. Pneumatic screw pumps fire the coal.

PRODUCT:They make ordinary Portland cement of 43 grade and 53 grade. This grade

indicates compressive strength of cement. They also make fly ash base pozzolonaPortland cement. In ordinary Portland cement 95% clinker and 5% gypsum add in cementmill for grinding. In case of pozzolona Portland cement 75 to 80% clinker, 15 to 20% fly

ash and 5% gypsum is added in cement mill. Gypsum helps to set setting time of cement.Fly ash is the waste product and it pollutes the environment so if it use in cement plantpollution reduces and it reduce the clinker consumption. It also works as filler material inthis mixture.


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They have two captive mines namely prasanavada mines and morasa mines. Thesemines have all grade of limestone, which provide raw material for cement production.Two types of mining process are available namely surface mining and blast mining. In

surface mining surface miner is used to extract the limestone and in case of blastingmining blasting is done with the help of explosive materials.

Mines department have various HEM machineries to extract limestone and totransport it. Those are Excavator, Loader, Dumper, Dozer, Drill machines etc. Excavatoris used to extract the lime from mines. Loader is used to load the dumper. Dumper isused to transport the material from mines to crusher, Dozer is used to level the groundsurface and Drill machine is used to drill a hole for blasting mining.

I was in mechanical department for work distribution they are having 8 majorsections from mechanical point of view they are as under:


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1. Crusher section including stacker and reclaimer2. Raw mill section3. Kiln and cooler section4. Coal mill section including stacker and reclaimer5. Cement mill section6. Packing plant section7. Utility section8. MIPS section (Monitoring, Inspection, Planning and scheduling)

CRUSHER SECTION:

IMPACT TYPE CRUSHERAs shown in above figure the material comes from mines are fed to the feeder

hopper then it is passed to the approan feeder, which regulate the material flow into thecrusher. Approan feeder is control from the crusher operator room. From approan feedermaterial is fed into the crusher where it crushes in 75 mm size. Approximately 80 to 85%

materials is crushed in this impactor. Crushing action takes places at front impact arm,rear impactor arm and in grinding path but now due to surface mining this grinding pathis remove from it. In single rotor impactor there are six evenly distributed blow bars,which crush the materials. At the timing of maintenance care should be taken thatapproximately same weight of blow bar is replaces at that place. Wear of blow barsdepend upon the material comes from mines. In case of high grade limestone wear is lowbecause in this kind of limestone sio2 present in less quantity. And in case of low-grade


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limestone due to sio2 present in higher percentage wear of blow bar is more. To run thesingle rotor impactor 1200kw motor is used which has 990rpm. Power is transmitted frommotor to impactor shaft through belt drive. Speed of rotor is approximately 319 rpm.Capacity of impactor is 900TPH. During monsoon problem of coating in chute and otherparts of impactor occur to remove this coating Pressurize air is purge from cylinder.

After the material crushed in impactor it is conveyed through belt conveyor up tostacker. Various belt conveyors like BC-1 transport the material from crusher to BC-2. AndBC-2 discharged the materials in BC-3, which takes the materials at stacker.

STACKER:

Stacker makes the piles of materials, which are come from crusher. With the helpof BC-3 material rich at stacker which makes longitudinal piles. Boom belts are there todo this function. Rail track is there for the movement of stacker. To run the stacker onrail gear drive is used. For boom belt position, wire rope is provided. To prepare

homogeneous mixture of material stacker is used. They make two piles of material.

RECLAIMER:


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RECLAIMER

Reclaimer is used to cut the longitudinal layers prepared by stacker intransverse direction. It is important device to prepare homogeneous mixture. It alsomoves on rail track by gear drive. Material is transport to belt conveyor through bucket ofreclaimer. Some teeth buckets are also provided to remove hard material from ground.Harrow is used to down the material from pile. Movement of harrow is done by hydraulicoil. Piston cylinder type hydraulic system is used to move the harrow.

BELT CONVEYOR :There are three belts conveyors which transport the material from reclaimer to raw

mill. Namely BC-4, BC-5 and BC-8.To run the Belt conveyor Fluid coupling and gearboxare used in between motor and head drum shaft. To run BC maintenance of fluidcoupling and gearbox is necessary. To join belt three types of joint are there: Hot joint,Cold joint and fastener joint. They have another belt conveyor BC-4A for additivematerials. Magnetic separator is provided to separate the metal particles.

SPECIFICATION WIDTH (mm) CAPACITY(TPH)

BC-1 1400 900


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BC-2 1200 1000

BC-3 1200 1000

BC-1A 1400 150

RAW MILL:The function of raw mill is to grind the limestone material comes from reclaimer.

To perform this function they have vertical mill that is atox-40 mill. In this mill onerotating table is there which is rotate by 2000kw motor through gearbox and hydraulicsystem. Grinding action take place between roller and table. In mill there are three rollerarranged at 120C on the table. Roller move up and down to crush the materials thismovement is achieved by hydraulic accumulator. Hydraulic cylinder is attached withroller through push rod at joint head and another arm that is torque arm with roller. Allthree rollers are connected at center by yoke joint.

Main two parameters on which output of mill depend on air nozzle gap and damring height. Water spray is also done into the raw mill to control the output of mill.Material flow takes place due to hot air circulation with the help of ph and pc fan. After

grinding of material, this material is transported in to the cyclone with help of boosterfan. To run the booster fan 2000kw motor is provided. The function of cyclone is toseparate the air and material from mixture. After this air is pass through ESP where allmaterial is recovered and this material is transported through screw conveyor and dragchain in bucket elevator.


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RAW MILL OPERATION

OPERATION:Material is grinding due to shear force and impact force of roller and table. Weight

of one roller is approximately 25 ton. Grind material is sucked by the booster fan materialand air is separated in the cyclone. Air which is separated in cyclone is further passedthrough the ESP to recover the material from air. Hot air coming from PH and PC string

helps to dry up the material and transport it. DP is one of the most critical parameter forraw mill. It is the differential pressure of inlet gas and outlet gas. To get desire output ofmill it is important and up and down movement of roller is governed by this DP. Finegrinding material is transported to C.F. silo through air slide and bucket conveyor. In airslide two parts is there, in down side air is flow with help of blower and at upside materialis flow. Due to movement of air material is transported in air slide. Material comes fromair slide is transported through bucket elevator into the C.F. silo. Capacity of raw mill is280 TPH.


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C.F.SILO:The function of continues flow silo is to store the material and provide

homogeneous mixture to the PH and PC string. This provides continues flow to the kilnfeed. C.F. silo has a capacity of 20000MT.The diameter of it is 22.4 mtr and height is 44.2

mtr. At the bottom of silo seven outlet is there which gives materials flow at different rateand this seven outlet is merge at weigh bin to provide homogeneous mixture. From C.F.silo material is transported through bucket elevator into the PH and PC string.

Bucket

elevator

C.F.silo

Weigh bin Air slide

C.F.SILO


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PH AND PC STRING:To utilize the kiln hot gases and for calcinations process material is passed through

PH and PC string. They have two string for calcinations process, in this process CO2

remove from limestone at 900C this is achieved in PH and PC string. Four stages arethere in one string material is passed through these four stages of one string for thiscalcinations process. In this two string hot kiln gases is used which is sucked by PH fanand PC fan. To remove coating from this string high-pressure air cylinder is provided atregular interval. In PC string coal firing is done to achieve 900C temperature.

KILN:


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COAL MILL:They use two type of coal namely coal and pet coke. These coals are crushed in

hammer crusher and then it transported to stacker. The function of stacker and reclaimeris same as limestone stacker and reclaimer. Coal is transported into coal hopper through

belt conveyor. After that coal is fed into the rotating coal table and then it is enter intothe coal mill for fine grinding. Coal mill grind the coal into the fine form with the help ofthree rollers and table assembly same as raw mill. Fine coal is sucked with the help of ESPfan and sends it to cyclone where it separates from air. The air is then passed through theESP to recover fine coal from air. With the help of screw conveyor it is send to ground binfrom here it send to the LO2 and LO5 with PS pump. Then this coal is transported in thekiln burning in pipe and also for PC vessel firing.

CEMENT MILL:In cement mill there are two units for grinding of clinker. They have two-clinker

silo, two gypsum silo and two fly ash silo. Clinker is transported through belt conveyor atcement mill. In cement mill, two chambers are there for grinding and rubbing action. Infirst chamber spherical balls are there to grind the clinker and to rubbing it cyllpel arethere in second chamber. Cement mill is run with the help of 3600kw motor. Cement millefficiency is only 1% other power is lost in other auxiliary. For ideal condition 70%

material and 30% media load is required. To ensure perfect grinding diaphragm is therein between two chamber. Cement mill is 14 mtr long and 4.2 mtr in diameter. Its capacityis 105 TPH. For the proportion of clinker and gypsum and in case of PPC fly ash also speedcontrol motor is provided. Grinding cement is pass through belt conveyor and air lift torich at cement silo.

Diaphragm

Motor Coupling Chamber-2 Chamber-1 Inlet

LINE DIAGRAM OF CEMENT MILL


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CEMENT MILL

PACKING PLANT:To store the cement they have four cement silos. In silo no-1, 3,and 4 OPC cement

is stored and in silo no-2 PPC cement is stored. It is then pass into the air slide to bucketelevator Bucket elevator transported the cement in hopper that is then feed into therotary packer. They have for rotary packers that have a capacity of 95 TPH. After Bag ispack in packer it is directly transported into the truck with the help of belt drive.

PACKING PROCESS


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I was in instrument department, i leant various instrument used by this

department for the measurement of various quantity like thermocouple for temperaturemeasurement, pressure transmitter for pressure measurement etc. I Shaw logical

programme language, PLC, SCADA and some information about the fuzzy logic and opto-22 system used by them. For the measurement of any quantity almost same circuit is usedwhich are shown below:

Measurement device (e.g. thermocouple)

Transducer (which convert input signal into desire signal)

Transmit in PLC

On screen

Measurement device measures the signal in its measurable form suppose inthermocouple it produces the mili volt signal and it convert in degree centigrade with thehelp of transducer. Then its signal is given to PLC (Programmable Logic Control) and itsshown on screen in CCR.

TEMPERATURE MEASUREMENT DEVICE:1. Thermocouple2. RTD (Resistance Temperature detector)3. Radiation pyrometer

According to temperature range this equipment are used in the plant. Twocameras are provided at crusher section and kiln section to see situation on screen.Various interlocking given at different place on the basis on right path of materialtransport and to save power consumption.


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Quality control department check the quality of raw material, limestone, clinkerand cement at various stages. This department has four laboratory namely testing lab,

physical lab, chemical lab, X-ray lab.

In testing lab, Sample is bringing from various section at hourly basis. Sample istaken from Raw mill, Kiln feed, Clinker, Cement grinding and cement packing. Here allsample come first and then it send to correspondence lab.

In chemical lab they test raw material, limestone extracted from mines. They testfollowing raw material to check total moisture, intermediate moisture, volatile matter,ash and sulphure.

1.

Coal and pet coke2. Bauxite3. Red soil Gypsum4. Basalt5. Sand stone6. Fly ash

To measure above parameter they do titration test in chemical lab.

In Physical lab they do Blaine test, Compressive strength, Expansion test, and Settingtime test. In Blaine test they have Blaine apparatus to check the Blaine of materials. This

test gives the fineness of material. In compressive strength test they make block with200gm fine sand, 200gm medium sand, 200gm course sand and 200gm cement. Thisblock is kept at some define temperature. Then it kept in water for setting it. At 1st. 3rd, 7thand 27th day it compressive strength is measure with the help of compressive strengthapparatus. On the basis of this strength grade of cement is given. Expansion test is alsodone in physical lab. To measure the expansion of cement for that circular tab late ismade and is kept in between two wires. Setting time or Water consistency test is donewith the help of needle apparatus. There are three apparatus for this test. At last only onering should be shown on sample.

In mines sample test various parameter are checked like silica, Alumina, Iron, limeetc. if among this anyone found in less percentage then it add from additive belt. Sandstone, bauxite, basalt, red soil, high-grade limestone is added in the material. For cementtest they take sample at grinding and packing also.


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ELECTRIC MOTORS:In motor two main parts are Rotor and stator. Supply voltage is given to stator and

due to law of electromagnetic induction rotor is rotate about its axis. Motor frame isprovided to enclose the rotor and stator generally it is made up of cast iron. Motor failureoccurs due to any one of following reason.

1. Protection Relay not operated.2. Motor running hot winding overheated.3. Water entry inside motor.4. Very old motors.5. Insulation failure.

Main motor capacity and rpm:LOCATION RATING (KW) RPM

Crusher main drive 1200 990

Raw mill main motor 2000 980

Raw mill buster fan 2000 980

Raw mill ESP fan 875 990

Pre-calciner fan 2000 990

Pre-heater fan 1315 990

Kiln main motor (DC) 496 1000

Coal mill main motor 550 988

Coal mill ESP motor 550 988

Cement mill mainmotor

3600 594


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They have two markets: Local market and Export market. Order of export market is receive at Mumbai market office. Order of local market is receive at their market branches, which is area wise

divided. Local market branches are at Ahmedabad, Rajkot, Surat, Baroda, Junagadh,

Bhavanagar etc.

They have Ramco system limited with the help of this system they are online withmarket branches.

They prepare dispatch advice slip as per order receive and it is given totransporter.

They have area wise transporter for local market.

DISTRIBUTION PROCESS


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REFERENCE

www.sidheecement.com GUJARAT SIDHEE CEMENT LTD

Off Veraval Kodinar HighwaySidheegram 362 276Gujarat

gujarat sidhee cement limited-smit

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