Inplant Training Undergone in

India Cements Ltd; Sankarnagar- 627 357.

Tirunelveli – Dist.

Submitted by
1) I. Charles
2) C.Hari Krishnan
3) S.Sugumar
4) S.Panisathish
5) M.Sathishkumar
Department of 2nd Year Diploma Mechanical Engineering
Sankar Polytechnic College, Sankarnagar, Tirunelveli- 627 357

INPLANT TRANING REPORT

As we are very thankful for giving this in plant training. This training is
useful for our feature plans. From this training we can know that about the
machine, parts and their specification. This can understand by those who
given the explanation about this given by schedule.
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. 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 10 th
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.
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
 MANUFACTURING PROCESS OF CEMENT:

RAW MATERIALS

(LIME STONE + IRON ORE + BAUXITE)

VRM (VERTICAL ROLLER MILL)

GRINDING

RAW MILL

BLENDING SILO

FIVE STAGE Pre heaters

CLINKER

COOLERS

CLINKER SILO

CLINKER+GYPSUM CLINKER +FLYASH+GYPSUM

43,53 GRADE OPC PPC
CEMENT SILOS CEMENT SILOS
PACKING PACKING

STEPS INVOLVED:
The following are the various steps involved in the manufacture of cement .
CRUSHER
VRM
KILN COALMILL
CEMENT MILL
PACKING
CRUSHER:
Crusher is the region where large limestones are broken into small
stones. The Limestones which are brought from various mines through
lorries are fed into the Crushing machine. The crushed stones are brought
through the Conveyor belts and then they are stacked. Then they are
reclaimed. The reclaimed Limestones are brought to the Weigh feeder.
The Weigh feeder is used to weigh the input with the load cell. Cross belt
Analyzers are present in which gamma rays are passed through the
substance to find the Chemistry of the Lime Stone (ie. to control the
quality of Lime Stone.)

VRM:
Limestone, HG 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 into the mill. The separated
particles are feed to the blending silo. The bearings in the Rawmill are
cooled by oil. The level of the oil is measured using capacitance high level
sensor. The temp. are measured using RTD. The inlet and outlet
pressures are measured using pressure transducers.
CHEMICAL SUBSTANCE IN RAW MILL:
LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, LSF, S.R., A.R.
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 1700 degree Celsius. Thus the heated
material is cooled to nearly 100 degree Celsius. Then clinker is obtained.
Thus the obtained clinker is stored in
silo. Low temp. are measured using RTD while high temp. are measured using
Thermocouple.

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.

CHEMICAL SUBSTANCES IN CLINKER:

LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, SO3, CaCO3, C3S, C2S, C3A, C4AF,
I.R., LSF, S.R., A.R.
COAL MILL:
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 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.
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.
PACKING :
The cement which is brought from silo is packed by three Mechanical
packers and one Electronic packer. Then it is transferred to lorries or
trains and transported to various places.
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. A complete picture of the entire plant, the
various temperatures, pressures, flow rates, feed rates, vibrations of the
rollers of the VRM etc. Can be seen and these variables can be controlled
accordingly.

CONCLUSION:
The India Cements, Sankarnager is the largest Cement plant in TamilNadu
and The Cement is being manufactured by Dry process. The entire process
and the various machineries involved have been explained along with its
working. India Cements Limited with its eight Plants is becoming one of
the leading producers of the basic construction material, Cement.
 Sankarnagar
16/05/2009
From
V.Abirami
B.C.M.W.G Polytechnic College
Ettayapuram -
Tuticorin- Dist

To
The Sr. Manager ( Personnel),
India Cements Ltd,
Sankarnagar.

Through:
The A.G.M( Inst.)
India Cements Ltd,
Sankarnagar.

Respected Sir,

As I have completed my “INPLANT TRAINING” from 11-05-2009

to 16-05-2009, I kindly request you to issue me the certificate for
Inplant Training in Instrumentation department.
Thanking you,

Yours Sincerely,

V.Abirami
 V.Durgamageswari

Sankarnagar
10/01/2009
From
C.SHUNMUGAM,
IYER.V.KAILASAM,
S.KALIAPPAN @ SUBRAMANIAN,
Francis xavier engg.College,
Vannarapettai,
Tirunelveli- 627 003.

To
 The Sr. Manager ( Personnel),
India Cements Ltd,
Sankarnagar.

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

Respected Sir,
As we have completed my “PROJECT WORK” from 10.12.2008 to
10.01.2009, we kindly request you to issue the certificate for Project work in
Mechanical department.
Thanking you,

Yours Sincerely,