A PRESENTATION ON A PRESENTATION ON PRACTICAL TRAINING ATPRACTICAL TRAINING ATUlTRATECH CEMENT LIMITEDUlTRATECH CEMENT LIMITED( KOTPUTLI )( KOTPUTLI )

SUBMITTED TOSUBMITTED TO : : PRESENTED BY: PRESENTED BY:

Mr. BUDDHI PRAKASH SIRMr. BUDDHI PRAKASH SIR Yogendra Singh Shekhawat Yogendra Singh Shekhawat

( ( Asst. Professor, MEAsst. Professor, ME) Mechanical engineering ) Mechanical engineering

P.G.I JaipurP.G.I Jaipur

ABOUT UlTRATECH CEMENT ABOUT UlTRATECH CEMENT

COMPANYCOMPANY India's leading manufacturer of cement India's leading manufacturer of cement

and amongst the top cement producers and amongst the top cement producers globallyglobally

India's largest producers of RMC and India's largest producers of RMC and the nation's largest producer of white the nation's largest producer of white cement cement

It employs a diverse workforce It employs a diverse workforce comprising of 1,20,000 employeescomprising of 1,20,000 employees

It belonging to 42 different It belonging to 42 different nationalities across 36 countries nationalities across 36 countries

ABOUT UNITS OF ULTRATECH CEMENT ABOUT UNITS OF ULTRATECH CEMENT

LTDLTD Ultra Tech Cement has 12 composite plantsUltra Tech Cement has 12 composite plants

1 white cement plant, 1 white cement plant,

2 wall care putty plants, 2 wall care putty plants,

1 clinkerisation plant in the UAE, 1 clinkerisation plant in the UAE,

16 grinding units (12 in India, 2 in the UAE and 1 each in Bahrain and Bangladesh), 16 grinding units (12 in India, 2 in the UAE and 1 each in Bahrain and Bangladesh),

six bulk terminals (5 in India and 1 in Sri Lanka) and six bulk terminals (5 in India and 1 in Sri Lanka) and

101 RMC plants – spanning India, UAE, Bahrain, Bangladesh and Sri Lanka. 101 RMC plants – spanning India, UAE, Bahrain, Bangladesh and Sri Lanka.

BACKGROUND OF THE COMPANYBACKGROUND OF THE COMPANY Ultra Tech Cement Limited is a part of Aditya Birla Group Ultra Tech Cement Limited is a part of Aditya Birla Group

The Cement Business of the Aditya Birla Group is today the 8th largest cement producer The Cement Business of the Aditya Birla Group is today the 8th largest cement producer globallyglobally

It has a total capacity of 52 mn tones It has a total capacity of 52 mn tones

US $ 29 billion corporation the Aditya Birla Group is in the league of Fortune 500 US $ 29 billion corporation the Aditya Birla Group is in the league of Fortune 500

In the year 2009, the group was ranked among the top six great places for leaders in the In the year 2009, the group was ranked among the top six great places for leaders in the Asia-Pacific region Asia-Pacific region

The group extends social welfare activities to communities, especially, around its The group extends social welfare activities to communities, especially, around its industrial units industrial units

PRODUCTS AND NATURE OF PRODUCTS AND NATURE OF BUSINESS BUSINESS

Products -

1. Ordinary Portland cement

2.Portland blast-furnace slag cement

3. Portland Pozzolana cement

4. Cement to European and Sri Lankan norms

1. Ordinary Portland cement Ordinary Portland cement is the most commonly used cement Ordinary Portland cement is the most commonly used cement

for a wide range of applications. These applications cover dry-for a wide range of applications. These applications cover dry-lean mixes, general-purpose ready-mixes and even high lean mixes, general-purpose ready-mixes and even high strength pre-cast and pre-stressed concrete.strength pre-cast and pre-stressed concrete.

2. Portland blast-furnace slag cement 2. Portland blast-furnace slag cement Portland blast-furnace slag cement contains up to 70 percent of Portland blast-furnace slag cement contains up to 70 percent of

finely ground, granulated blast-furnace slag, a nonmetallic finely ground, granulated blast-furnace slag, a nonmetallic product essentially consisting of silicates and alumina-silicates product essentially consisting of silicates and alumina-silicates and alumina-silicates of calcium. Slag brings with it the and alumina-silicates of calcium. Slag brings with it the advantage of the energy invested in the slag making process. advantage of the energy invested in the slag making process. Grinding slag for cement replacement takes only 25 per cent of Grinding slag for cement replacement takes only 25 per cent of the energy needed to manufacture Portland cement.the energy needed to manufacture Portland cement.

3. Portland Pozzolana cement Portland Pozzolana cement is ordinary Portland cement blended Portland Pozzolana cement is ordinary Portland cement blended

with pozzolanic materials (power-station fly ash, burnt clays, ash with pozzolanic materials (power-station fly ash, burnt clays, ash from burnt plant material or siliceous earths), either together or from burnt plant material or siliceous earths), either together or separately. Portland clinker is ground with gypsum and separately. Portland clinker is ground with gypsum and pozzolanic materials which, though they do not have cementing pozzolanic materials which, though they do not have cementing properties in themselves, they combine chemically with Portland properties in themselves, they combine chemically with Portland cement in the presence of water to form extra strong cementing cement in the presence of water to form extra strong cementing material which resists wet cracking, thermal cracking and has a material which resists wet cracking, thermal cracking and has a high degree of cohesion and workability in concrete and mortar.high degree of cohesion and workability in concrete and mortar.

4. Cement to European and Sri Lankan norms UltraTech's bulk cement terminal in Sri Lanka is located at UltraTech's bulk cement terminal in Sri Lanka is located at

Colombo. Cement is received by specially-engineered, self-Colombo. Cement is received by specially-engineered, self-discharging bulk cement carriersdischarging bulk cement carriers. A sophisticated bulk cement A sophisticated bulk cement terminal (which subscribes to all environmental norms) terminal (which subscribes to all environmental norms) dispatches cement in bulk form to RMC and asbestos plants. dispatches cement in bulk form to RMC and asbestos plants.

UltraTech Concrete

1 Colourcon1 Colourcon

2 Fibercon 2 Fibercon

3 Thermocon 3 Thermocon

4 Hypercon 4 Hypercon

5 5 PerviousPervious

6 Pervious6 Pervious

1 Colourcon -1 Colourcon -

Ultra Tech Colourcon is colored concrete available in a wide palette Ultra Tech Colourcon is colored concrete available in a wide palette of colors, with customized shades being made available as per of colors, with customized shades being made available as per architectural requirements. architectural requirements.

2 Fibercon –2 Fibercon –

Ultra Tech Fibercon is an enhanced crack resistant and relatively Ultra Tech Fibercon is an enhanced crack resistant and relatively ductile concrete produced by using different types of fibers like ductile concrete produced by using different types of fibers like polyester, polypropylene, glass and steelpolyester, polypropylene, glass and steel etc., that minimize the etc., that minimize the problems of plastic shrinkage cracks in the green stage and problems of plastic shrinkage cracks in the green stage and substantially improve its static dynamic properties like flexural, substantially improve its static dynamic properties like flexural,

impact and tensile strength.impact and tensile strength.

3 Thermocon3 Thermocon It is produced with chilled water and ice flakes in a state-of-the-art, fully It is produced with chilled water and ice flakes in a state-of-the-art, fully

computerized RMC plant, which controls the temperature of the concrete computerized RMC plant, which controls the temperature of the concrete and maintains it within acceptable limitsand maintains it within acceptable limits

4 4 HyperconHypercon

Hypercon is produced by blending a combination of different cementitious Hypercon is produced by blending a combination of different cementitious materials along with advanced quality superplasticisers, in state-of-the-materials along with advanced quality superplasticisers, in state-of-the-art, fully computerized RMC plants.art, fully computerized RMC plants.

5. Pervious5. Pervious

It It is a special concrete with high porosity, which is a special concrete with high porosity, which is used for concrete flatwork application that is used for concrete flatwork application that allows water from precipitation or other sources allows water from precipitation or other sources to pass through, thereby reducing the runoff and to pass through, thereby reducing the runoff and ensuring recharge of ground waterensuring recharge of ground water . .

6 Décor6 Décor –– Ultra Tech Décor is colored textured imprinted concrete Ultra Tech Décor is colored textured imprinted concrete

available in different shadesavailable in different shades. .

7 Free Flow 7 Free Flow – –

Ultra Tech Free Flow is a special concrete, Ultra Tech Free Flow is a special concrete, produced by using high-quality ingredients produced by using high-quality ingredients including the latest fourth generation acrylic-including the latest fourth generation acrylic-based super plasticizers and viscosity modifying based super plasticizers and viscosity modifying agentsagents

8 Stainless 8 Stainless ––

Ultra Tech Stainless is a concrete that uses high quality, Ultra Tech Stainless is a concrete that uses high quality, corrosion inhibiting corrosion inhibiting agents. agents.

MARKET STRENGTHMARKET STRENGTH It was predicted to grow at between 8.50% and 9% in 2014/15 It was predicted to grow at between 8.50% and 9% in 2014/15

and company got success to achieve this goal.and company got success to achieve this goal. Despite strong and stable cement-demand growth in India Despite strong and stable cement-demand growth in India

over the past fifteen years, per capita consumption remains a over the past fifteen years, per capita consumption remains a low 173 kilograms as compared with a global average of 423 low 173 kilograms as compared with a global average of 423 kilograms. kilograms.

For China, consumption is at an impressive 1038 kilograms, For China, consumption is at an impressive 1038 kilograms, which indicates the growth opportunity in Indiawhich indicates the growth opportunity in India

A growing population, increasing nuclearization of families, A growing population, increasing nuclearization of families, rising incomes and better financing avenues all contribute to rising incomes and better financing avenues all contribute to boosting demandboosting demand..

The company reported revenues of INR “ 66,643.30 “ million The company reported revenues of INR “ 66,643.30 “ million during the fiscal year Ended march 2014 an increase of “ during the fiscal year Ended march 2014 an increase of “ 16.43 %” over 2013. 16.43 %” over 2013.

COMPANY INFRASTRUCTURECOMPANY INFRASTRUCTURE UltraTech Cement, India's leading manufacturer of cement and amongst UltraTech Cement, India's leading manufacturer of cement and amongst

the top cement producers globally.the top cement producers globally. It is nation's largest producer of white cement has been instrumental in It is nation's largest producer of white cement has been instrumental in

India’s rapid infrastructural growth. India’s rapid infrastructural growth. UltraTech Cement is part of the US $40 billion Aditya Birla Group. UltraTech Cement is part of the US $40 billion Aditya Birla Group. The company has an installed capacity of 62 MTPA .The company has an installed capacity of 62 MTPA . It provides a range of products that cater to all the needs from laying the It provides a range of products that cater to all the needs from laying the

foundation to delivering the final touches. The range includes foundation to delivering the final touches. The range includes Ordinary Portland Cement Portland Blast Furnace Slag CementOrdinary Portland Cement Portland Blast Furnace Slag Cement Portland Pozzalana Cement White Cement Portland Pozzalana Cement White Cement Ready Mix ConcreteReady Mix Concrete White cement is manufactured under the brand name of ‘White cement is manufactured under the brand name of ‘Birla WhiteBirla White’.’. Ready mix concretes under the name of ‘Ready mix concretes under the name of ‘UltraTech ConcreteUltraTech Concrete’ .’ . New age building products under the name of ‘New age building products under the name of ‘UltraTech Building UltraTech Building

Products DivisionProducts Division’’..

UltraTech’s subsidiariesUltraTech’s subsidiaries Dakshin Cements LimitedDakshin Cements Limited

Harish Cement LimitedHarish Cement Limited

Gotan Limestone Khauj Udyog Private LimitedGotan Limestone Khauj Udyog Private Limited

Bhagwati Limestone Company Private LimitedBhagwati Limestone Company Private Limited

UltraTech Cement Lanka (Pvt.) (Ltd.)UltraTech Cement Lanka (Pvt.) (Ltd.)

UltraTech Cement Middle East Investments LimitedUltraTech Cement Middle East Investments Limited

UltraTech Mining Indonesia and PT UltraTech Investments IndonesiaUltraTech Mining Indonesia and PT UltraTech Investments Indonesia

Plants of UltraTechPlants of UltraTechUltraTech Cement has -UltraTech Cement has - 12 composite plants12 composite plants

1 white cement plant1 white cement plant

2 wall care putty plants2 wall care putty plants

1 clinkerisation plant in the UAE1 clinkerisation plant in the UAE

16 grinding units (12 in India, 2 in the UAE and 1 each in 16 grinding units (12 in India, 2 in the UAE and 1 each in Bahrain and Bangladesh)Bahrain and Bangladesh)

six bulk terminals (5 in India and 1 in Sri Lanka) and six bulk terminals (5 in India and 1 in Sri Lanka) and

101 RMC plants – spanning India, UAE, Bahrain, Bangladesh 101 RMC plants – spanning India, UAE, Bahrain, Bangladesh and Sri Lanka.and Sri Lanka.

Cement Production LayoutCement Production Layout

1 Mining 1 Mining " " Cement manufacture, like many other manufacturing processes, begins Cement manufacture, like many other manufacturing processes, begins

at the mine, where the raw materials like at the mine, where the raw materials like limestone, silica, aluminates, limestone, silica, aluminates, ferric mineralsferric minerals and others are obtained. and others are obtained.

Some typical materials used for calcium carbonate in cement Some typical materials used for calcium carbonate in cement

manufacturing are manufacturing are limestone, chalks, marbles, marls, and oyster shelllimestone, chalks, marbles, marls, and oyster shell. .

Some typical materials used for alumina in the cement manufacturing are Some typical materials used for alumina in the cement manufacturing are shale, clay, slags, fly ash, bauxite, alumina process waste, and graniteshale, clay, slags, fly ash, bauxite, alumina process waste, and granite..

The general mining methods are surface mining, while some The general mining methods are surface mining, while some silicatessilicates, ,

such as such as sandsand, are commonly mined using dredges, from lakes, rivers , are commonly mined using dredges, from lakes, rivers

and waterways. and waterways.

CrushingCrushing Crushing is a process of breaking a large particle into very small particles.Crushing is a process of breaking a large particle into very small particles.

All these crusher are of impact type.All these crusher are of impact type.

All these crushers are Larsen and turbo make.All these crushers are Larsen and turbo make.

All crushers use impact for crushing rather than pressure .All crushers use impact for crushing rather than pressure .

The material is contained within a cage with opening on bottom end or on The material is contained within a cage with opening on bottom end or on the desired side.the desired side.

The type of crusher is usually used with soft and non – abrasive material The type of crusher is usually used with soft and non – abrasive material such as coal, lime stone, gypsum, or soft metallic ores.such as coal, lime stone, gypsum, or soft metallic ores.

Raw material handlingRaw material handling

It includes It includes HomogensationHomogensation – It is process of mixing the crushed material very well– It is process of mixing the crushed material very well

with cement additives for better and desired result.with cement additives for better and desired result.

Stacker and Reclaimer Stacker and Reclaimer - These are used to make homogeneous - These are used to make homogeneous mixture.mixture.

- After crushing the lime stone is transported by belt conveyer to form - After crushing the lime stone is transported by belt conveyer to form stock pile which is done by stacker.stock pile which is done by stacker.

Here stacker and reclaimer are of Here stacker and reclaimer are of “ Mesto Minerals Pvt. Ltd. ““ Mesto Minerals Pvt. Ltd. “ Capacity of lime stone stacker – 1800 TPH.Capacity of lime stone stacker – 1800 TPH. Type – Slewing and Type – Slewing and LuffingLuffing Capacity of coal stacker – 500 TPH ( Capacity of coal stacker – 500 TPH ( Slewing and Luffing Slewing and Luffing )) Capacity of additives stacker – 500 TPH (Capacity of additives stacker – 500 TPH (non - Slewing and Luffing non - Slewing and Luffing ))

Raw material grindingRaw material grinding

The desired raw mix of crushed raw material and the additional The desired raw mix of crushed raw material and the additional components required for the type of cement, e.g. silica sand and iron components required for the type of cement, e.g. silica sand and iron ore, is prepared using metering devices.ore, is prepared using metering devices.

Roller grinding mills and ball mills grind the mixture to a fine powder at Roller grinding mills and ball mills grind the mixture to a fine powder at

the same time as drying it, before it is conveyed to the raw meal silos the same time as drying it, before it is conveyed to the raw meal silos for further homogenization.for further homogenization.

Preprocess -Preprocess -It includes – It includes –

Preheating - Preheating - Raw meal stored in the raw mill silo should be preheated Raw meal stored in the raw mill silo should be preheated

before feeding it to the kiln sectionbefore feeding it to the kiln section..

Burning - Burning - The burning of the raw meal at approx. 1,450°C . The burning of the raw meal at approx. 1,450°C . It is carried out in Lepol or preheater kilns. It is carried out in Lepol or preheater kilns. The main difference being in the preparation and preheating of the kiln feed. The main difference being in the preparation and preheating of the kiln feed.

By chemical conversion, a process known as sintering, a new product is By chemical conversion, a process known as sintering, a new product is

formed: clinkerformed: clinker..

Cooling of clinkers - Cooling of clinkers - The clinker is cooled down and stored in clinker The clinker is cooled down and stored in clinker silos. silos.

From there the clinker is conveyed to ball mills or roller presses, in which it From there the clinker is conveyed to ball mills or roller presses, in which it is ground down to very fine cement, with the addition of gypsum and is ground down to very fine cement, with the addition of gypsum and anhydrite.anhydrite.

Clinker storage Clinker storage

We supply silos with storage We supply silos with storage capacities ranging up to 100,000 capacities ranging up to 100,000 tones. tones.

Company install steel hall or Company install steel hall or circular structures, dome silos, circular structures, dome silos, hybrid-construction silos or pure hybrid-construction silos or pure concrete silos. concrete silos.

Finish GrindingFinish Grinding

After burning, the clinker is cooled down and stored in clinker silos. After burning, the clinker is cooled down and stored in clinker silos.

From there the clinker is conveyed to ball mills or roller Presses.From there the clinker is conveyed to ball mills or roller Presses.

In roller presses , it is ground down to very fine cement.In roller presses , it is ground down to very fine cement.

This fine cement then mix with the addition of gypsum and anhydrite, as This fine cement then mix with the addition of gypsum and anhydrite, as well as other additives, depending on the use to which the cement is to well as other additives, depending on the use to which the cement is to be putbe put

Packing and Dispatch -Packing and Dispatch -

The finished cement is stored in separate silos, depending on type and The finished cement is stored in separate silos, depending on type and strength class. strength class.

From there it is mainly loaded in bulk form from terminals onto rail or From there it is mainly loaded in bulk form from terminals onto rail or road vehicles as well as onto ships.road vehicles as well as onto ships.

Only a small proportion of the cement reaches the customer in the form Only a small proportion of the cement reaches the customer in the form

of bags that have been filled by rotary packers and stacked by of bags that have been filled by rotary packers and stacked by automatic palletizing systems.automatic palletizing systems.

For more visitFor more visitwww.studyhubz.comwww.studyhubz.com Thank you Thank youYogendra Singh Shekhawat Yogendra Singh Shekhawat RajnotaRajnota