TABLE OF CONTENT

1. COMPANY PROFILE
2. LISTS OF CEMENT PLATS
3. GAGAL CEMENT WORKS AN OVERVIEW
4. OVERVIEW OF CEMENT MANUFACTURINGPROCESS

 Company Profile
1. ACC (ACC Limited) is India's foremost manufacturer of cement and concrete.
ACC's operations are spread throughout the country with 17 modern cement
factories, more than 50 Ready mix concrete plants, 21 sales offices, and several
zonal offices. It has a workforce of about 9,000 persons and a countrywide
distribution network of over 9,000 dealers.

2. Since inception in 1936, the company has been a trendsetter and important
benchmark for the cement industry in many areas of cement and concrete
technology. ACC has a unique track record of innovative research, product
development and specialized consultancy services. The company's various
manufacturing units are backed by a central technology support services centre
- the only one of its kind in the Indian cement industry.

3. ACC has rich experience in mining, being the largest user of limestone. As the
largest cement producer in India, it is one of the biggest customers of the
domestic coal industry, of Indian Railways, and a considerable user of the
countrys road transport network services for inward and outward movement of
materials and products.

4. Among the first companies in India to include commitment to environmental

protection as one of its corporate objectives, the company installed
sophisticated pollution control equipment as far back as 1966, long before
pollution control laws came into existence. Today each of its cement plants has
state-of-the art pollution control equipment and devices.

5. ACC plants, mines and townships visibly demonstrate successful endeavours in

quarry rehabilitation, water management techniques and greening activities.
The company actively promotes the use of alternative fuels and raw materials
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and offers total solutions for waste management including testing, suggestions
for reuse, recycling and co-processing

6. ACC has taken purposeful steps in knowledge building. We run two institutes
that offer professional technical courses for engineering graduates and diploma
holders which are relevant to manufacturing sectors such as cement. The main
beneficiaries are youth from remote and backward areas of the country.

7. ACC has made significant contributions to the nation building process by way
of quality products, services and sharing expertise. Its commitment to
sustainable development, its high ethical standards in business dealings and its
on-going efforts in community welfare programmes have won it acclaim as a
responsible corporate citizen. ACCs brand name is synonymous with cement
and enjoys a high level of equity in the Indian

Corporate OFFICE
CEMENT HOUSE, 121, Maharshi. Karve . Road, Mumbai 4000 020

Regional office:
Eastern Region ,Northern Region, South West Region
Kolkata
New-Delhi
Pune

 LIST OF CEMENT PLANTS

Cement Plants:
1. Bargar Cement Works Distt. Bargarh ( Orissa )
2. Chaibasa Cement Works Distt. Singhbhum ( Jharkhand )
3. Chanda Cement Works Distt. Chanderapur ( Maharashtra )
4. Damodar Cement Works Distt. Purulia ( West Bengal )
5. Gagal Cement Works Distt. Bilaspur ( Himachal Pradesh )
6. Jamul Cement Works Distt. Durg ( Chhattisgarh )
7. Kymore Cement Works Distt. Katni ( Madhya Pradesh )
8. Lakheri Cement Works Distt. Bundi ( Rajasthan )
9. Madukkarai Cement Works Distt. Coimbatore ( Tamil Nadu )
10. Sindri Cement Works Distt. Dhanbad ( Jharkhand )
11 Tikaria Cement Works Distt. Sultanpur ( Utter Pradesh )
12. Wadi Cement Works Distt. Gulbarga ( Karnataka

GAGAL CEMENT WORKS AN OVERVIEW

Gagal Cement Works a unit of the Associated Cement Companies Limited, has twounites
Gagal I and Gagal II. Gagal I was set up in the year 1984 and Gagal II was set upin the year
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1994. Clinker production of Gagal is 2800 TPD and of Gagal II is 3300TPD. The total annual
capacity of the plant is around 6100 TPD. Both units are locatedat BARMANA in District
BILASPUR of H.P

 KIND OF PRODUCT

Ordinary Portland Cement (OPC) in different grades i.e. 33GR, 43GR, 53GR and
Portland Pozzolona Cement (PPC).BIS (Bureo of Indian Standard).
The company has registration to
ISO 9002 & ISO14001
Tricalcium Aluminate (C3A)
Tetracalcium Alumino ferrite (C4AF).

 OVERVIEW OF CEMENT
MANUFACTURINGPROCESS
Cement manufacturing consists of raw meal grinding, blending, pre-calcining, clinker burning
and cement grinding. In short,limestone andother materials containing calcium, silicon,
aluminium and iron oxides arecrushed and milled into raw meal. This raw meal is blended and
heated inthe preheated system to initiate dissociation of carbonate to calcium oxideand carbon
dioxide.The secondary fuel is fed into the preheater to keep thetemperature sufficiently
high.Then meal is fed into the rotary kiln forreaction between caclcium oxide and other
elements to form calcium

silicates and other aluminates at temperature upto 1450 degreecalcius.Primary fuel is used to
keep temperature high enough in burningzone to chemical reaction takes place.
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The raw materials used are lime stone, shale, iron ore and gypsum.The lime stone provided by
nature and Iron-ore comes from BIHAR andRAJASTHAN. Firstly we get the 70mm
size limestone with the help ofcrusher and stock it with the help of stacker through belt
conveyor.In Raw mill / VRM section, limestone, shale, quartzite & Iron ore arefed in
measured quantity through weigh feeders. In the mill the mixturefurther reduces the size to
the desired fineness. The finer productseparated by air separator is goes to the
Electro-static precipitator & thento the blending silos and coarse material is fed
back into the mill Inlet. Rawmill / VRM s controlled by central control room. The
set point for chemicalcomposition of the raw meal and fineness of the material is
given by theLaboratory department.From raw mill the raw meal is fed to the blending
and the storagesilos .In the blending part of the silo, further homogenization of raw
mealtakes place so that a constant quality is maintained. In storage part the
rawmeal is stored so that it may be fed at the desired rate. From there thematerial is fed to the
low lift pumps (L.L.P.s) with the help of bucketelevators. Low lift pumps feed the
material or raw meal to the preheatercyclone . To reduce the requirement of heavy
coal injection in the kiln ,95%of the calcination occurs in the M.F.C., D.D.F.
vessels and cyclones ofpreheating zone. About 60%of the coal firing is done at
pre-calciner sectionitself . Raw meal which is almost calcined enters from the one
end of thekiln . From the other end of the kiln the pulverised coal is fired .
Variouschemical reactions occurs as the raw meal progresses from feed end to theburning
zone , where intermediate phases consisting of CaO, Al2O3, Fe2O3 become liquid
and because of the rotation of kiln CaO and silica combinewith liquid to form nodules
called clinker.At the lower end of the kiln the temperature reaches to about 1450degree
centigrade.
Due to such high temperature the physical and thechemical characteristics of the
raw meal changes . Clinker that comes outof the kiln is at a very high temperature
and has to be cooled to facilitate.