Yogiraj Institute Of Technology ,Kota

Topic: CHEMICAL PROCESS TECHNOLOGY

PRESNT BY: IRSHAN KHANPOLYTECHNIC 2ND YEAR

MANGALAM CEMENT-AT A GLANCE(AN ISO9001:2000-COMPANY) Mangalam Cement Limited belongs to the B.K. Birla group companies. it is a professionally manage and well-established cement manufacturing company enjoying the confidence of consumers because of its superior quality product and excellent Customer Service. The Company has added one more feather to its cap by commissioning its state-of-the-art new Cement Plant with German Technology for producing 7 lacs tones per annum at the existing site at Morak, Dist, kota Rajasthan under the name of Neer Shree Cement. Krupp Polysius, Germany and their counter parts Krupp Industries India. Ltd,have joined hands with Mangalam Cement Ltd, to produce Birla Uttam Premium, 33, 43 & 53 Grade Portland Cement using ultra modern technology with unique features like Vibrating Screen.Stacker Reclaimer. X-Ray Analyzers. Computerized Central Control Room, Vertical Roller Mills & Precalcinator Kiln. Roll Press Electronic Packing with automatic Truck and Wagon Loading Machincs. Now the cement manufacturing capacity is over 1 Million tones per annum.

Location :Morak 65 km From Kota

Registered office and plant : P.O. Adity nagar Morak

Dist-Kota(raj.)• Head Office : 9/1 R.N. Mukherjee

RoadCalcutta-700001

Brand Name :Birla UttamProduct Man. :PPC,OPC 43 Grades

Awards & certificatesCompany of the year award for

year 1988-89.D.S.A. Excellence Award For year

1991-92Received ISO 9000 In Year 1996.Renewal of certificate to ISO

9001:2000 in Year 2000.IS/ISO:14001 EMS(environment

management system)IS/ISO:18001 OHS (Occupational

Health & Safety Management)

Introduction:- Generally speaking crushing denotes the size

reduction process that breaks down the material to particle size suitable as feed for the next main stage i.e. grinding. In present day cement manufacturer with due regard to the possibilities of the reduction machineries. Employed crushing is taken to mean reducing the particle size to between 80 mm to 20 mm.

Presently there are two units at mangalam cement Ltd. And a third unit is proposed Mangalam Unita Neer Shree Unita

A brief comparision of both units is given in the following table:-Mangalam Unit Neer Shree Unit

Estblished In the Year 1978.

Estblished In the Year 1992.

Limestone is Taken from mining site to the crushing unit which is at the plant on dumpers.

Limestone is crushed at mining site it self and then it is brought to the plant through 1.5 K.m. long coveyor belt.

After Crushing limestone is sent to crane-gantry.

Blending of crushed limestone is done by means of Stacker & Reclaimer.

Raw materials are powdered in a rolling ball mill

Raw materials are powdered using VRM(vertical raw mill)

Rated capacity of mangalam unit is 1200 tones per day and average production is 1500 tones per day.

Rated capacity of Neer Shree unit is 2200 tones per day and average production is 3500 tones per day after due modification.

Concept of Cement The word CEMENT may be defined as a substance, which can join two or

more pieces of same other substance together to form a unit mass. Cement

is a fine powder which when mixed with water and allow to set and harder

can join different components together to give a strong structure

mechanically. Thus cement can be used as founding material for bricks or for

founding solid particles of different sizes (rubble masonry ) to form a

monolish.

It was about 150 years ago or so that Cement as we know and use it today

was invented or prepared . Mr Joseph Aspadin of England first of all patented

the manufacture of an improvement type of cementations material for

construction of buildings in the year 1824 and gave it the name Portland

Cement. This was because of the fact that hardened stone from the cement;

Joseph Aspadine invented resembled Portland Stone found in England.

However some other persons also claimed that they had made similar

cement. Each of them adopted a different process of his own. It is however at

the end of Nineteenth Centhury that the process of manufacturing Portland

Cement was adopted on modern lines as we know it today. 

Product and Raw Material For the manufacturing of cement limestone is

a basic raw material. At mangalam cement Ltd. This Limestone is procuring from their captive Morak Lime Stone Mines,Which is situated adjacent with factory premises.Beside the Morak lime stone small quantity of other additive and corrective material are also being used for cement making process Which are as follow:

1. High grade lime stone 2. Blue dust 3. Bauxite 4. Gypsum 5. Fly Ash

MINES Prospecting-it is the process to

find the potential at a place from where useful and bulk quantity of LS can be extracted

Drilling-the place is drilled with the drilling machine for inserting DYNAMITES

Blasting-the DYNAMITES breaks the huge rocks into pieces.

CRUSHERVibration sensorsSecondary crusherSizer Wagon loadersScarp conveyor

STACKER

It make the stacks of the different raw materials and collect the material at a place to be used further.

UNIT NAME:- STACKER EQUIPMENT STACKER:- Boom Belt, CRD, Bogie, Loop car, etc.TACHNICAL DATA FOR STACKER 

RECLAIMER

IT reclaims the materials in definite amount from the pile and provide to conveyor belt with the help of scrapper chain and harrows.UNIT NAME:- RECLAIMER EQUIPMENT RECLAIMER: Bogie, Power, CRD, Control, CRD Harrow, Rack Car. Bucket, etc.TECHNICAL DATA FOR RECLAIMER

BELT CONVEYOR FROM RECLAIMER TO R.M.HOPPER

RAW MILL HOPPER

Transporation of raw material from one place to their respective storage hopper is also done with the help of belt conveyor. The hopper are made of concrete having pin gates and weigh feeders at lower side. They are also equipped with load cell and gamma ray instruments to defect quantity of material of hopper.Process 

The material comes through reclaimer by the help of belt conveyor (232BC2) and goes to raw mill hopper High Grade Lime Stone,Bauxite and Blue Dust are transported to respected feed hopper. In this section we have 4 nos. hopper as mentioned below.

1. Morak limestone hopper

2 & 3 Blue Dust and Bauxite Hopper  

High Grade Lime Stone (HGLS) hopper

TECHNICAL DATA FOR RAW MILL HOPPER

Weigh feeder Belt: Equipment: weigh feeder Length: 1000 mmOil Quantity:5 ltr. Feed hopper Fr. Of change in two year IN RCC CONSTRUCTIONGear Box Stroage Capacity: 500T,200 T&100 TMake Red Icon Material Stored: Low Grade lime, High Grade Lime Stone & LateriteSize: A337 Feed Hopper in Steel ConstructionRatio: 60:1 Storage Capacity:100 T &100 TREDUCER Scrapper ChainMake: Gyrox Material Storage Bauxite & GypsumRatio:4:15. VERTICAL RAW MILL

RAW MIX GRINDING, BLENDING AND STORAGE 

VERTICAL RAW MILL (VRM) 

The Krupp Polysius Roller Mills belong to the category of Vertical Mill and are particularly suitably for the grinding of medium-hard to soft minerals but may yet be used for grinding comparatively hard substances. This roller mill is ideally suited for combined grinding and drying.

RAW MILL BAG HOUSE AND RAW MILL CYCLONE

Raw mill bag house is used to collect the waste particle i.e. dust

RAW MILL SILO

This actually acts as a raw meal storage with a very fine opening in conical shape.

ROTARY KILN

KILN

The rotary kiln is designed for the burning of pulvernulent, small size or sludgy feed material .For this purpose the kiln hood at the outlet of the rotsry kiln accommodating a special rotary kiln burner. The hot secondary air coming from the down stream cooler and entering the rotary kiln hood is mixed with the primary air of the primary air of the rotary kiln burner and passed through the rotary kiln in counter flow to the feed material.The inclination and rotation of the rotary kiln make the feed material fed in at the kiln inlet flow towards the outlet. The down stream kiln hood serves as an air seal and as a connection to the cooler.For the protection of the rotary kiln shell and the attached parts a well as far the prevention of incisive heat losses, the rotary kiln is provided with a special refractory lining which is adjusted to the requirements of the individual zones. 

COOLER

Introduction:-The hot cement clinker discharged from the kiln is further treated in clinker cooler. What all types of cooler have is common is that the cooling air flows directly-in counter current or cross-current-through the clinker and that some or the heated air from the cooler is fed as combustion air to the kiln.The reciprocating grate cooler serves for the cooling of small sized or granulated burned material. An excellent cooling effect is achieved in that cold air is blown through the cooler grate and through the burned material lying on grate. 

PYRO COOLING SECTION

In this section, hot clinker coming out from kiln is fed.

This hot clinker is cooled from air stream produced by various cooler fans.

CLINKER SILOS

This cooled clinker is stacked in clinker stock piles. The clinker is then fed to Cement mill for further processing.

The clinker silos is used to collect the clinker

Material which is to be send to the cement mill.

Gypsum is added to the cement mill to enhance the setting time.

CEMENT MILL

This mill is similar to the raw mill where hydraulic gates are used to control the overfeeding of the material.

The horizontal rollers crushes the clinker into finely pulverized powder known as CEMENT.

PACKING PLANT

Introduction:What type of packaging is chosen for the dispatch of cement will depend on local circumstance and on the most favorable transport facilities available Road, Rail or Water (Ship or Barge).In principal, there are three possibilities packing in sacks or bags, dispatch in bulk and Big Big. Packing Plant is the important part of Cement Industry. NSC plant, two sources are used to send the cement on a particular place.1. Truck loading:- In this process the cement bags are transported by Truck/Trolla.2. Wagon Loading:- In this process the cement bags are transported by Railway wagon rakes from works to required place.

Lime Stone (MINES)

Size: Up to 1M

Clay storage & handling

StackerMakes stockpile

Lime Stone CrusherSize: Up to 50mm

By

Dumpers

Red ochre storage& handling

ReclaimerReclaim Material

Raw Mill Hoppers

LS LS Clay Red ochre

Laterite

Laterite storage& handling

By Belt Conveyor

RAW MILL(It Grinds material)

Control FEED by

WEIGHFEEDERS

Raw Mill Cyclones

Blending Silo(Raw Meal Storage)

By Separator

By

Bucket Elevator

PREHEATER Double String

6 Stages, 12 Cyclones

Precalcinator(Before Last Stage

of Preheater)

Rotary KILN(Burn Pulverized

small size material)Coal

Storage

Coal Mill Section(Mill, Classifier,

& Bag Filter)

By Stacker

Reclaimer &

Belt Conveyor

Coal Firing System

(CORLIOUS SYSTEM)

By Air Slides

Pyro Floor Cooler

Clinker SiloStorage

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