INPLANT TRAINING UNDERGONE

in

THE INDIA CEMENTS LTD

SANKAR NAGAR-WORKS
TIRUNELVELI 627357

Reported by

ESSAKKI RAJ.M
(01107153016)
B.Tech 2nd year PetroChemical Technology
ANNA UNIVERSITY
THIRUCHIRAPPALLI-620024

DECLARATION
 I am ESSAKKIRAJ.M hereby declare that the Training report

entitled “Mechanical Operations in cement

manufacture” is done by us under the permission of
Mr.Santhanamuthu, Dean & Mr.Saker, Head of
PetroChemical Department and
Mr.Kumaraguru(class inchare) ANNA UNIVERSITY,
THIRUCHIRAPPALLI-620024 to improve my technical knowledge in
BACHELOR OF TECHNOLOGY.

DATE :

PLACE:

SIGNATURE OF THE CANDIDATE

(ESSAKKIRAJ.M)
Mr.Antony (L..C.R unit)
Mr.Kasi (V.R.M unit)
Mr.Varatharajan (Coal mill)
Mr.Senthil (Cement mill)
Mr.Kailasam (Workshop)
Mr.Appadurai (Packing section)
 CONTENTS

S.NO TOPICS

1. INTRODUCTION

2. COMPANY PROFILE

3. POLICIES OF THE COMPANY

4. MANUFACTURING PROCESS

(i) Crusher

(ii) Vertical roller mill

(iii) Kiln
(iv) Coal mill
(v) Cement mill
(vi) Packaging

5. FUNCTIONAL AREAS OF MANAGEMENT

a. Maintenance management system
b. Information management system
c. Marketing management system
d. Quality analyzing system
c. Finance and account’s management system
d. Personnel management

6. CONCLUSION
 ICL - INTRODUCTION:
The India Cements, which is located in Sankarnagar, manufactures
cement, which fulfills the entire requirement of south Indian people.
The company was incorporated in 21st February 1946. On the starting
stage wet process technique was used which was converted to dry
process in the year 1990.

COMPANY PROFILE:
The India Cements, which is located in

Sankarnagar, manufactures cement, which fulfills the entire

requirement of south Indian people. The company was incorporated in

21st February 1946. The initial annual capacity of one lakh tones is

increased gradually reaching 463000 tones by 1959. In August 1990,

the wet process technique is converted to dry process and the existing

wet process kilns were replaced with a modern single dry process kiln

increasing the capacity of the plant to one million tone per annum. On

10th April, the Bureau of Indian Standards (BIS) granted ICL

Sankarnagar the license for quality systems certification “ IS/ISO

9001:2000 “ in respect of the manufacture and supply of the cement.

CEMENT
Cement may be defined as an adhesive substance capable of uniting

fragments or masses of solid matters to a compact mass. Cement is the

lifeline of construction industry and cement constitutes about 15% of the

construction cost.
 SUBSIDIARY COMPANIES OF
ICL :
ICL Foundary Ltd

ICL Securites Ltd

ICL International Ltd

ICL Financial Services

Industrial Chemicals and Monomers

Ltd

DIVISIONS :
• Shipping division

• Wind form division

• Real Estate , Property development

AWARDS WON:
1. Corporate excellence award from SEBI.

2 .Best presented accounts from institute of charted accounts.

3. CAP EXIL special award from Export from Port Trust.

4. Traffic promotion award from Port Trust.

GOLDEN JUBILEE:
ICL celebrated the Golden Jubilee on 21 st February 1996 for

that all workers received some gift. And the experienced employees

got special award by the chairman

COMPETITORS:
 MADRAS CEMENTS LTD

 ACC GROUPS

ULTRA TECH

GUJARAT AMBUJA

GRASIM INDUSTRIES

TYPES OF CEMENTS:
The ICL is producing three types of cements, which suits the

. customer requirement

Ordinary Portland Cement (53 Grade)

Ordinary Portland Cement (43 Grade)

Portland Pozzalona Cement

POLICIES AIM:
This plant is maintaining many policy for

* Environment

* Quality

* Safety

Environmental policy :
Protect the environment by the prevention of

pollution.

Compliance to relevant environmental regulations.

Continual improvement of environmental performance

energy conservation, waste minimization and

wherever practicable waste utilization.

Propagation of environmental policy to all employees

Quality policy :
♦ Maintaining consistent quality

♦ Maintaining cost effectiveness

♦ Ensuring customer satisfaction

♦ Ensuring continual improvement

Safety policy:
Some safety aspects are given below:

♦ There should be adequate natural

ventilation through doors, Windows and

♦ ventilators. Local exhaust ventilation

should be provided.

♦ Hazardous Process should be in closed

to prevent contamination of the air in

the workroom.

♦ Good house keeping should be

maintained.

♦ Workers should be provided with

approved Protective equipments like

masks (or) respirator goggles, aprons

etc.

♦ Adequate Protective clothing should be

given to workers where necessary like

aprons, gloves, books, caps and hoods.

♦ If necessary Protective ointments for

hands arms and face should be

provided.
 FLOW CHART OF MANUFACTURE OF
CEMENT

RAW MATERIALS
(LIME STONE + IRON ORE + BAUXITE

VRM(VERTICAL ROLLER MILL) - GRINDING - BLENDING SILO

FIVE STAGE Pre heaters - CLINKER - COOLERS - CLINKER

SILO

CEMENT MILL GRINDING

( CLINKER+GYPSUM ) ( CLINKER
+FLYASH+GYPSUM )
43,53 GRADE OPC PPC

CEMENT SILOS CEMENT SILOS

PACKING PACKING
(House 3 &4) (House 1,2, 5&6)
 STEPS INVOLVED:
The following are the various steps involved in the manufacture of

cement.

CRUSHER,STACKER&RECLAIMER

VRM
 KILN COALMILL
CEMENT MILL
PACKING
 CRUSHER FLOW DIAGRAM

L.S Hopper

CRUSHER

Stackar

Reclaimer

Chute
Additive
Chute
Hopper

Hoppers

CRUSHER:
There are two crushers (New and Old crushers).

OLD CRUSHER (HAMMERTONE CRUSHER):

 Limestones are brought through laminated conveyor from the

hopper.

 Laminated conveyor has high load capacity. It can be used only for

short distances.

 There is a membarane shaft, which connects the crusher to the

motor instead of belt.

 In crusher, there are 10 hammers, which breaks the incoming LS.

 The hammer arm which contains hammer is connected to the

flywheel and then to the motor.

 The broken LS comes out through grate bar to the belt conveyor.

 The capacity of the crusher is 150 TPH (tonnes per hour).

 The LS entering the crusher are limited to the size of 800 mm and

the out going particles are of the size 75mm.

 The power of the motor is 1000 hp.

NEW CRUSHER (IMPACT CRUSHER):

SPECIFICATIONS:

Crusher motor power : 448kW

Speed of the motor : 988rpm

Approximate speed of crusher : 400rpm

No. Of blades in the crusher : 6

Design capacity : 5020TPH

Motor power rating four apron conveyor : 55kW

 Apron drives are used to transfer LS to the crusher from mining.

 The centre rotating area is called rotor.

 There are 6 blow bars on the rotor, which rotates by a 3-phase

induction motor.

 These blow bar cuts the LS to 75 mm through no. Of stages from

300 mm.

 There are fixed blades called stator blades in the crusher whose

distance from the blow bar decides the diameter of the LS.

 The temperature of the blow bar is measured by using scanner.

 The LS from the crusher moves to the stacker through belt

conveyor.

TRANSFER OF LIMESTONE FROM CRUSHER TO STACKER:

1) By apron feeding mechanism LS are brought into the crusher.

2) There is a Grizzly filter in-between this, which separates LS less

than 95 mm into belt conveyor (1020).

3) The grinding particles (dust) from the crusher are brought into

1020 belt conveyor.

4) From 1020 the dust particles along with hot gas are taken to bag

filter system which absorbs the dust particles using bags. Bags

are inserted into a case. Air of capacity 30000 cu.m/hr is passed

inside and comes out through air vent. The timer is activated

once in 15-20 seconds. The bag bulges and retards due to the

entry of this air inside the bag the suspended dust particles fall

down to the dust hopper. Beneath the dust hopper there is a

sump and a rotary air lock. Rotary air lock is used to regulate the
 dust along the horizontal direction. In rotary air lock there is an

impeller and housing whose gap is very low (ie) 1-2 tou (1 tou =

1/1000 inches). Through these impeller vanes the dust particles

passes to the other side (ie) 1030 belt.

5) From 1030 belt they are transferred to transit hopper which has

40 tonne capacity.

6) Then it is move on to variable speed conveyor 1035 & 1035A.

7) From there it is brought to 1180A which is a cross belt analyzer

(CBA).

Cross belt analyzer passes gamma rays beneath the source and the LS

particles are exposed to these rays. These constituents are seen in

Quality control lab and LSF (lime saturation factor) is tested. Due to

variation in LSF high or low grade LS are mixed to compensate the

variation. There is a load cell to determine weight per umit time

according to the speed. Soad cell is commected to 1035 in a closed

loop.

8) From CBA, it passes to the stacker.

STACKER:

SPECIFICATIONS:

Motor used : bidirectional AC motor

Travel drive : 11kW

Thyristor brake : 0.2kW

Hydraulic pumps motor : 4kW

 It is used for arranging LS into several layers called pile.

 It has a boom. The LS from 1180 belt conveyor move on to the belt

conveyor of the boom and the pile is formed as several layers (12

layers normally) of thickness 105 cm. The length of the pile is 100

m, the intermediate gap between two piles is 15-30 m.

 Stacker is a moving part in-between two truck.

 One end of the stacker has a boom and the other end is

compensated by concrete to balance the boom.

 The length of the pile is determined by the magnetic sensors (ie)

there is a sensor on the wheel of the stacker and the magnet

placed on the rails determines the length to which the pile

RECLAIMER:

SPECIFICATIONS:

Travel drive : 7.5kW

Thyristor brake : 0.2kW

Scrapper chain : 75kW

Harrow drive : 15kW

 It is used to transfer the LS from pile to the bucket conveyor.

 There are two harrows on the either side of the reclaimer.

  The harrows are used to scrap the LS from the pile. After

scrapping, the LS are dropped down, which are collected by

bucket conveyer system.

 Chains connect the buckets.

 From reclaimer, the LS (low-grade) passes to the Raw mill

through belt conveyor.

VRM:
Limestone, high grade lime stone, iron ore, bauxite are mixed and

brought to Vertical Raw Mill through belt conveyors. It is grinded finely by

the roller mill. The roller mill contains four rollers. The powder is then

sucked by the ESP fan through to Dynamic seperator. Here the fine

particles are separated and coarse particles are fed back again into the mill.

The separated particles are feed to the blending silo.

 Vertical Roller Mill Flow
Stack
          
Bag Filter
E.S.P    
 

T
o

DING SILO
P
.

BLIN
A

GC
T
230

r
olle
alR
rtic
Ve l
M i l

Reject
Hopper.

VERTICAL ROLLER MILL:

SPECIFICATIONS:

Capacity of VRM : 275TPH

Power of VRM : 1900kW

Size of VRM : 46/23

Speed of VRM : 25.4rpm

CHEMICAL SUBSTANCE IN RAW MILL:

LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, LSF, S.R., A.R.

DYNAMIC SEPERATOR:

 In the top of VRM, there is a dynamic seperator. It is a rotating

device. The dusts are sucked by air through dynamic seperator. The

stator blades are fixed. The blade angles determine the fines of

dust particles. A rotor rotates rotor blades. Fluid coupling is used in

drive to rotate rotor blades. The dusts are vent through pipe to

ESP and coarse particles get down to VRM.

 The coarse particles are brought through bucket elevator to reject

chute and they are feeded in seperator. The cone like structure in

seperator feeds coarse particles to VRM. With this recycling

process, there will be no wastage of LS.

ELECTROSTATIC PRECIPITATOR (ESP):

• The dusts seperated by seperator are send to ESP, to separate hot

gas and dust.

• In ESP, 4 sets of electrode are used. They are connected with

themselves.

• Power supplied is 40000V. Dust coming inside ESP are charged and

settled in positive electrode. Positive electrode is collecting

 electrode and emitting electrode is negative. The emitting

electrode supplied area is called carona. The rapping method is used

to collect dust from ESP. The rapping rods hit electrodes and dust

fall down.

• The hot gases are sucked by ESP fan.

TRANSFER OF DUST FROM ESP TO BLENDING SILO

1) The dusts are passed through a hopper to rotary air lock. It is

used to remove any false air or gas going with dust.

2) Through aeropol conveyor using a blower, dusts are sent to

blending silo.

3) Blending silo temperature is nearly 100 degree. Raw meal is

present here. It is constructed in a way to set uniform mixture

to preheater. It is 80-m height, but only 48 m is effective.

Nearly, 16000 ton of raw meal is stored here.

HOT GAS SUPPLY TO VRM

1) VRM is effective only operating at nearly 350 degree.

2) The hot gas from kiln is generally utilised by sending it to VRM.

3) Gas conditioning tower is used. In gas conditioning tower, water-

cooling is done to reduce the high temperature to nearly low as

needed by VRM.
PREHEATER:

 From blending silo, dust is fed to preheater. There are 5 stages in

preheater.

 The flow of feed and gases are clearly shown in figure. The gas

escapes by cyclone seperators. At each stage, feed comes down to

next stage and hot gases goes up to next stage and escapes from

cyclone seperators.

 The hot gases are fed to VRM (ie) by use of gas conditioning tower.

 60% of coal from fine coal hopper goes to preheater by pfister.

 This process of preheating is called pyro process.

 Preheater fan provides suction.

PREHEATER FAN:

Capacity : 170cu.m/sec

Power : 2360kW

 Calcination occurs in precalcinator (i.e) dust is preheated to 900

degrees.

 In this stage, Caco3 ---------> Cao + Co2, reaction occurs moisture is

also removed.

 From here, feed goes to kiln. The entry temperature to kiln is

nearly 900 degrees.

 Autoloop system with PID (proportional integral derivative) is used

for temperature control in preheating.

KILN:
Kiln is the place where the limestone powder is changed into clinker.

The materials are fed into the Preheater through the top while the

hot gas is passed through the bottom. As the material passes down it

absorbs heat from the gas and reaches the bottom with a high

temperature. Then it passes through the Kiln which is at 1400 degree

Celsius. Thus the heated material is cooled to nearly 100 degree

Celsius. Then clinker is obtained. The hot Clinker from the Kiln is

discharged onto perforated in the Grate cooler. The cold Air

penetrates the perforation of the plate and pas through the clinker,

thus cooling it. Thus the obtained clinker is stored in silo. The Air

that gains heat from the clinker is taken through tertiary Air duct to

the Pre-haeter, VRM & Coal dryer.

DEEP BUCKET CONVEYOR:

Materials conveyed : clinker

Capacity : 140TPH

Conveying speed : 220TPH

Inclination of conveyor : 40 degrees

Width of bucket : 1000mm

Pitch of bucket : 630mm

Shaft centres : 110.5m

No. Of buckets/rollers : 3 each

 Kiln Flow Diagram
From
P.H.Fan.
To Coal Mill

GCT
W.Bin

Bucket Elevator

Bag House

Vent Fan

Grate Cooler
A B C
P.H.Fan. Clinker
Silo

Booster Fan.

CHEMICAL SUBSTANCES IN CLINKER:

LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, SO3, CaCO3, C3S, C2S, C3A,

C4AF, I.R., LSF, S.R., A.R.

GRATE COOLER:

The hot Clinker from the Kiln is discharged onto perforated in the Grate

cooler and is present as a bed of uniform height. The whole cooler is

mounted at a slope of 3 deg. The grate cooler has three chambers into

which Air is blown through fans. The cold Air penetrates the perforation of

the plate and pas through the clinker, thus cooling it. The Air that gains

heat from the clinker is taken through tertiary Air duct to the Pre-haeter,

VRM & Coal dryer. Variable speed control (AC drives) are used to control

the speed of the fans. Airflow transmitter controls the flow of air.

Pressure transmitters and thermocouples are also present to measure

pressure and temperature respectively.

 Air from exit of kiln goes by PA duct to preheater. It is supplying

oxygen required for burning in precalcinator.

 Also, remaining air and air from cooler are sent to heat exchanger.

Heat exchanger reduces temperature to 100 degrees and sent to

bag house.

 From bag house gases escape to atmosphere through chimney by

vent fan.

 Bag house contains bags, where dust in air is removed. Polyurethane

and Acriclic bags are used.

TRANSFER OF COAL:

1) Coal used is Indonesia coal, which has high calorific value. They

are brought to plant by transportation.

2) Then they are fed to stacker area by belt conveyors.

COAL STACKER:

♦ Coal pile is formed using the stacker.

♦ Coal piles formed has 10000 X 3 T capacity.

♦ The stacker can be rotated to any angle along the fixed axis. There

are 3 piles. The boom, which drops the coal from stacker to pile,

can be moved upto 10th position. Each position has a certain height.

There are 10 different speeds available.

♦ Magnetic sensors and limit switches are available to maintain length

of pile and to drop coal exactly over the pile.

♦ The stacker is rotated by a motor drive using pinion and gear

mechanism. The bull gear rotates entire stacker. Angle of rotation

is determined by length of pile. Grease lubrication system is

available.

♦ Manual and automatic operations are also possible. In case of automatic

operation, they are controlled by CCR. The coal mill is a Ball mill

containing steel balls of different sizes. The coal mill is a two-

compartment mill one for drying and the other for grinding. The coal

gets pulverized in the air swept mill. The pulverized

COAL MILL:

coal passes through a coarse separator where coarse particles are separated

and fed back into the mill through a Screw conveyor. The pulverized coal is

collected in the twin cyclones and is stored in the fine coal bin after it

passes through an ESP, where the coal in the air stream is collected and sent

to the fine coal bin. From here appropriate amounts of coal are fed to both

ends of the Kiln by pfisters, three in number for the Kiln precalcinator and a

standby and the coal gets fired in the already hot Kiln. The proximity

inductance sensor measures the speed of the drive. The low temperatures

are measured using RTD.

COAL STACKER:

♦ Coal pile is formed using the stacker.

♦ Coal piles formed has 10000 X 3 T capacity.

♦ The stacker can be rotated to any angle along the fixed axis. There

are 3 piles. The boom, which drops the coal from stacker to pile,

can be moved upto 10th position.

♦ Magnetic sensors and limit switches are available to maintain length

of pile and to drop coal exactly over the pile.

♦ The stacker is rotated by a motor drive using pinion and gear

mechanism. The bull gear rotates entire stacker. Angle of rotation

is determined by length of pile. Grease lubrication system is

available.

♦ Manual and automatic operations are also possible. In case of

automatic operation, they are controlled by CCR.

 COAL MILL Diagram

FD
Fan
ESP
Mill Fan Fan

E.S.P

Separator Fine
Coal
Bin.

From P.H. Pfisters

COAL MILL

To P.C To Kiln Main

EMERGENCY FEEDING:

1) In case of emergency, coal is feeded manually in a hopper

available above apron conveyor. From lorries, coal is feeded in a

steel structure above hopper, size of coal is controlled by this

steel structure.

2) Then, from apron conveyor they are sent to raw coal hopper.
COAL RECLAIMER:

♦ The coal from pile is transferred into 5170 belt conveyor by means

of a reclaimer.

♦ Harrow in reclaimer is used to scrap the material in pile to belt

conveyor.

♦ The belt conveyor drains the coal into a hopper, located at centre

of stacker.

♦ From this hopper, the coal is transferred to raw coal hopper

through apron conveyor.

♦ Chain drive is available for harrow movement and sensors are

available to determine the length to which it should move. Harrow is

supported by means of a rope and can be moved to any angle.

♦ The reclaimer can reach pile by a mechanism available, which moves

over circular fails. The speed mechanism can be controlled in

control mill. There are 10 speeds available. Depending on step,

speed is maintained. This determines the load supplied.

POLYSIUS CIRCULAR BLENDING BED:

SPECIFICATIONS:

Stacking rate : 100T/hr

Reclaiming rate : 100T/hr

Material handled : Coal/Lignite/Coal+Lignite mix

Bulk density, coal/lignite : 0.8T/cu.m

1.1 T/cu.m

Size of material : 50mm

Live storage capacity : 10000T

RAW COAL HOPPER:

 From apron conveyor, feed is given to raw coal hopper.

 Capacity of raw coal hopper is 200tonnes.

 Coal of size upto 35mm is fed into the inlet of coal mill.

 Through draconic belt conveyor and apron feeder, they are then

fed into coal mill.

COAL MILL:

GENERAL SPECIFICATION:

Type : Air swept mill

Size : 4m diameter & 9m long

Material to be used : Coal/Lignite/Coal+Lignite mix

Feed size : 0-50mm

Mill capacity : 40T/hr

DESCRIPTION:

1) Coal mill is driven by caution shaft.

2) Hot air from ESP and from kiln is fed to coal mill to maintain a

temperature of 200 degree.

3) There are 2 chambers in coal mill.

4) First chamber consists of plates used to dry the coal.

5) There are 2 slideshoe bearings at one end. There is a high and

low speed pump utilised in lubrication of slideshoe. Slideshoe

bearing is a white metal bearing. There is a cylindrical drum for

which lubrication is done, when rotating. High-speed pump first

produces a gap of 0.4mm. Then slow speed pump lubricates. Oil

and water are used for lubrication. Oil used is SERVO 320.

6) Steel balls of diameter 15mm to 50mm are present in 2nd

chamber. It fills 1/3rd area capacity is 40T/hr.

7) There is a diaphragm blade in between 2 chambers. This serves

for purpose of flow of coal in one direction only.

8) At the right, there is a pinion with girth gear.

9) Girth gear lubrication is carried out with grease. Grease used is

MOLUBALLOY 8031/6000. Multi service lubricant. It can

withstand very high temperatures.

10) After Girth gear, there is a trunnion bearing. It is made of

Tungsten steel. It has less load carrying capacity.

11) The balls revolve in a speed, so that coal particles are grinded

and required fineness is achieved.

4) COAL MILL TO KILN:

1) Coal from coal mill pass into static seperator. There, the coal,

which is not ground to required fineness, are again sent to coal

mill. Return coal feed to mill occurs.

2) From there, it passes to a cyclone seperator at top. The blade

angle is such that to get fine coal.

3) Fine coal is again passed to cyclone seperators.

4) The feed goes through two more cyclone seperators for extra

cooling. From there, it goes to ESP. ESP removes fine coal and

hot gas, then the fine coal moves to fine coal hopper by screw

worm conveyor.

5) From the cyclone seperators, feed directly goes to screw worm

conveyor.

6) Through screw worm conveyor fine coal is fed to fine coal silo. It

has 200T capacity.

7) From fine coal silo, it goes to kiln or precalcinator accordingly.

There are three pfisters available for this purpose. Kiln main,

stand by, and precalcination pfister. Pfister serves for

measuring and conveying of coal accordingly.

8) Air is also passed in and gets out in pfister. Load cell connected

sets speed according to load needed. Stand by is used when

problem occurs in others. The valve is opened and it operates

either for kiln or precalcinator.

CEMENT MILL:
The Clinker is brought to the Cement mill and feed into the chamber

along with gypsum. Here it is grinded using balls. Then it is transferred to

air slider, after which it is brought to Seperator through Bucket elevator.

Here fine cement is separated and stored in silo. The coarse particles are

fed back into Cement mill. Sound level transducers are used to sense

grinding level inside the mill. Weigh feeder are used to weigh the substance

and tachometers are used to measure the speed. Thus when combined

produce Tonnes /Hour of the substance passing out.

CHEMICAL SUBSTANCES IN OPC53, PPC: LOI, CaO, MgO, SO3, I.R.

Cement Mill Flow Diagram

E.S.P

To
Cement
Silo
CEMENTMILL
CEMENT MILL:

• The clinker silo stores clinker. From there. Through 6461 belt

conveyor. It is taken to a hopper with deflector.

• There are two deep pan conveyors at bottom. In one belt the

gypsum and clinker for old cement mill are added. Where as in

case of new mill one belt carries gypsum and the other carries

the clinker. There is a weigh feeder which senses the quantity

added according to the speed. Deflector serves for feed in two

conveyors accordingly.

• Gypsum 5% is added to 95% clinker. Gypsum increases the

setting time of cement, hence high strength.

• With the help of two belt conveyors feed is given to cement mill.

• In new cement mill, there are two chambers. It is a ball mill type.

Here balls move upward due to centrifugal force. At critical

speed, they roll inside without falling down and hence no crushing

occurs. Hence to grind efficiently, cement mill rotates at 65-

70% of critical speed.

• First chamber contains 90-60mm balls. Balls are made of high

chromium steel.

• Second chamber contains 50-15mm balls. The grinded particle in

first chamber enters second chamber through diaphragm blade.

• The coarse grinding occurs in first chamber and fine grinding

occurs in second chamber.

• There are two slideshoe bearings one at each end. High speed

and low speed pump lubricate them.

• Cement mill capacity is 130T, for one shift of load.

• Drive is from DC motor. Girth gear driven by pinion is used.

Grease lubrication is done for girth gear.

• The output from cement mill passes by elevator to dynamic

seperator. Seperator is present at centre and four cyclone

seperators are surrounding it. Seperator seperates cement and

passes it to a belt conveyor. The gas particles are sucked by

cyclone seperators and sent out through chimney. The ESP fan

connected provides suction. Coarse particles are again feed to

mill, by seperator.

• The clinker passing through deep pan conveyor is inspected by

quality control lab, and accordingly grades are divided.

• In old cement mill, there are four mills. Each has 40T capacity.

Two of them have belt conveyors. Two have fluxo system, using

compressor and pneumatic setup. This consumes high power than

new cement mill.

• No slideshoes are present here. They are ground and sent to

packing through conveyors.

• Output from new cement mill is sent through belt conveyors to

cement silo.
PACKING:

Packing Section utilizes the mechanical counterpart for the

packing of Powder Cement. Manual labors are used to connect the

plastic/paper pack with the Cement Valve and the mechanical lock is

provided to fill the pack with fine cement powder. A counterbalance

of 50Kg connected in the top compares the pack weight with 50

kilograms and closes the cement outcome valve only when the pack is

filled with 50kg. The pack is designed such that fine cement powder

has only one way to enter into the pack and cannot escape. The packed

50kg Cement Pack is passed through Belt Conveyors and transported

by Roadways and Railways.

THE CENTRAL CONTROL ROOM (CCR):

The CCR is situated near the kiln area. From here the hopper weigh

feeders, VRM, blending silo, kiln, grate cooler, coal mill and cement mill

can be controlled. The CCR is the main control room for the entire

plant. Depending upon the requirements, of the feed rate, volumetric

flow rate for the gases and the water etc. The CCR operators control

the dampers and the other equipment provided for the

control of the control of these variables. The CCR control has been

provided for the new cement mill which is driven by two drives.
 PERSONNAL DEPARTMENT
MAIN FUNCTIONS OF THE PERSONNEL :

It is responsible for maintaining cordial relationship between the

employees and management. It trains and develops the employees to

that they work effectively. It motivate the workers and keeps in them

good morale. It looks after workers. Employees bonus compensation

leave availed etc.

shift timings : There are 3 shifts in a day

6.30 am – 2.30 pm

2.30 pm – 10.30 pm

10.30 pm -6.30 am

general shift timings :

07.30 am – 04.00 pm

Subsidized canteen :

Free tea and coffee was given to all the staff

members during the shift timings . The lunch can be provided at a

confessional rate .
 conclusion
The main aim of institutional training system in

INDIA CEMENTS LTD is to improve the skill and knowledge of

students about the product of the industry and to improve the

efficiency of institution.
I thank all the staff in the ICL for their kind co-operation

this training was helpful for us to carry further study in future. And

we learnt many thing through the training. This training is a golden

opportunity given for us. Through this training we gain knowledge about

they hope with this situation.

 Sankarnagar

24/01/2009

From
ESSAKKI RAJ.M (01107153016),
B.Tech 2nd year PetroChemical Technology,
ANNA UNIVERSITY,
THIRUCHIRAPPALLI-620024.

To

The Sr. Manager ( Personnel),

India Cements Ltd,
Sankarnagar.

Through:
Chief Manager Mech.)
India Cements Ltd,
Sankarnagar.

Respected Sir,
As I have completed my “INPLANT TRAINING” from 19.01.2008 to

24/01/2009, I kindly request you to issue me the certificate for Inplant

Training in Mechanical department.

Thanking you,

Yours Sincerely,

ESSAKKI RAJ.M
(ESSAKKI RAJ.M)