ACC

FOUR WEEK INDUSTRIAL

TRAINING

AT ACC GAGAL CEMENT WORKS

BARMANA

PREPARED BY:- UNDER GUIDENCE

OF:-
AASHISH KUMAR, MR. P.K. SINGH

MANOJ KUMAR ASSIT. MGR. INSTRUMENTATAION

MAHENDER CHAND

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SUMMER TRAINING PROJECT REPORT

ON
PROCESS ASPECTS OF CEMENT
MANUFACTURING
(DIPLOMA IN INSTRUMENTATION)

SUBMITTED TO: SUBMITTED BY:

H.O.D. OF AASHISH KUMAR

INSTRUMENTATION MANOJ KUMAR

G.P.C. KANGRA MAHENDER CHAND

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ACKNOWLEDGEMENT

We express our deepest gratitude to Mr Atul Khosla (Director Plant) and

Human Resource Development Center ACC Barmana for providing me
the opportunity to undergo training in ACC.

I would like to thanks Mr. P.K SINGH (Assist. Manager Instrumentation)

and his staff for cooperative guidance & helping me to learn a lot about
different aspect of his company and under whose guidance I complete my
summer training program.

I also put my special thanks to my training guide

Mr.KHANNA, MR. MANI LAL, MR. BALWANT SINGH. who cared to give
out an ample amount of time to me, regardless of being extremely busy in
their work.

I would like to put forth my regardful thanks to all those who have and are
making it a remarkable attempt in guiding me and making me learn the
most during my short period of my training at ACC- GAGAL CEMENT
WORKS, BARMANA.

AASHISH KUMAR

MANOJ KUMAR

MAHENDER CHAND

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INDEX

Sr.No TOPIC Page No.

1 Introduction 4-6

2 Overview of cement manufacturing process

3 Steps in cement manufacturing-- 10-12

a. Quarrying
b. Raw meal preparation
c. Pyroprocessing
d. Cement grinding
4 Various instruments used in field 13-33

5 PLC , Preheater 34-36

6 Clinker Cooling,bag filter 37-38

7 Cement packing, storage &dispatch 39-40

8 Conclusion 41

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INTRODUCTION

ACC Limited, or ACC as it is popular known, is India‟s largest

manufacturer of cement and ready mix concrete, Formerly called “The Associated
Cement Companies Limited”, it was established in 1936 following a historic merger of
ten cement companies belonging to four business groups. ACC‟s operations are spread
throughout the country with 14 modern cement factories, 19 sales offices, and several
area offices. The company has over 9000 employees.

Corporate OFFICE :

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

Regional office:

Eastern Region Northern Region South West Region

Kolkata. New-Delhi. Pune.

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 )

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GAGAL CEMENT WORKS – AN OVERVIEW :

Gagal Cement Works a unit of the Associated Cement Companies Limited, has two
unites Gagal I and Gagal II. Gagal I was set up in the year 1984 and Gagal II was set up
in the year 1994. Clinker production of Gagal I is 2800 TPD and of Gagal II is 3300
TPD. The total annual capacity of the plant is around 6100 TPD. Both units are located
at 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 & ISO
14001.
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PORTLAND CEMENT

DEFINITION:

Cement is finely ground hydraulic binding medium for mortar and concrete,
consisting substantially of compounds of CaO with SiO2, Al2o3 and ferric
oxide which have been formed by sintering or fusion. „Sintering‟ means
burning at a temperature which cause partial fusion of the material. When
mixed with water cement hardens, both in air and under water and retains
its strength under water.

OR

Portland cement clinker is a hydraulic material which shall consist of at

least two-thirds by mass of calcium silicates (3CaO.SiO2 and 2CaO.SiO2),
the remainder consisting of aluminum- and iron-containing clinker phases
and other compounds. The ratio of CaO to SiO2 shall not be less than 2.0.
The magnesium content (MgO) shall not exceed 5.0% by mass.

Portland cement is manufactured by burning a calcareous material, such

as, limestone, chalk, shells or marl and an argillaceous material such as
clay, shale etc. at a high temperature of 1450-1500ºc and grinding the
resultant product called „Clinker‟ with the addition of the small quantity of
the Gypsum.

The ordinary Portland cement consists of four major components i.e.

 Tricalcium Silicate (C3S)

 Dicalcium Silicate (C2S)

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 Tricalcium Aluminate (C3A)

 Tetracalcium Alumino ferrite (C4AF).

OVERVIEW OF CEMENT MANUFACTURING
PROCESS

Cement manufacturing consists of raw meal grinding, blending, pre-

calcining, clinker burning and cement grinding. In short, limestone and
other materials containing calcium, silicon, aluminium and iron oxides are
crushed and milled into raw meal. This raw meal is blended and heated in
the preheated system to initiate dissociation of carbonate to calcium oxide
and carbon dioxide.The secondary fuel is fed into the preheater to keep the
temperature sufficiently high.Then meal is fed into the rotary kiln for
reaction between caclcium oxide and other elements to form calcium

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silicates and other aluminates at temperature upto 1450 degree

calcius.Primary fuel is used to keep temperature high enough in burning
zone to chemical reaction takes place.

PROCESS FLOW DIAGRAM OF CEMENT

MEANUFACTURING

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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 and
RAJASTHAN. Firstly we get the 70mm size limestone with the help of
crusher and stock it with the help of stacker through belt conveyor.

In Raw mill / VRM section, limestone, shale, quartzite & Iron ore are
fed in measured quantity through weigh feeders. In the mill the mixture
further reduces the size to the desired fineness. The finer product
separated by air separator is goes to the Electro-static precipitator & then
to the blending silos and coarse material is fed back into the mill Inlet. Raw
mill / VRM s controlled by central control room. The set point for chemical
composition of the raw meal and fineness of the material is given by the
Laboratory department.

From raw mill the raw meal is fed to the blending and the storage
silos .In the blending part of the silo, further homogenization of raw meal
takes place so that a constant quality is maintained. In storage part the raw
meal is stored so that it may be fed at the desired rate. From there the
material is fed to the low lift pumps (L.L.P.s) with the help of bucket
elevators. Low lift pumps feed the material or raw meal to the preheater
cyclone . 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 of
preheating zone. About 60%of the coal firing is done at pre-calciner section
itself . Raw meal which is almost calcined enters from the one end of the
kiln . From the other end of the kiln the pulverised coal is fired . Various
chemical reactions occurs as the raw meal progresses from feed end to the
burning zone , where intermediate phases consisting of CaO, Al2O3, Fe2O3
become liquid and because of the rotation of kiln CaO and silica combine
with liquid to form nodules called clinker.

At the lower end of the kiln the temperature reaches to about 1450
degree centigrade . Due to such high temperature the physical and the
chemical characteristics of the raw meal changes . Clinker that comes out
of the kiln is at a very high temperature and has to be cooled to facilitate

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handling and grinding . Hence, the clinker is passed through the cooler
where cooling takes place by means of fans. Hot air is used for combustion
inside the kiln and calciner. In cooler circuit the ESP has also been installed
to control the air pollution. With the help of the drag chains and bucket
elevators the clinker is fed to the clinker silos. .

STEPS IN MANUFACTURING OF PORTLAND CEMENT

Portland cement is manufactured in four step process.

STEP 1. Quarrying

The raw material for cement manufacture is rock mixture which is about
80% limestone (which is rich in CaCO3)and 20% clay or shale (source of
slica,alumina and ferrite ).These are quarried and stored separately.The
lime ind silica provide the main strength to cement,while the iron reduce the
reaction temperature and gives the cement its characterstic grey colour.

STEP 2. Raw Meal Preparation

It involves mixing the extract raw material to obtaine the correct chemical
composition,and grinding them to achieve proper particle size to ensure
optimal fuel efficiency in the kiln and strength in final concrete product.If the
dry process is used then raw material is dried by using dryers,Air
separaters before grinding.

STEP.3 Pyroprocessing or Clinkering

In this raw mix is heated to produced cement clinker(which is grey in

colour and in spherical nodules with diameter ranging 0.3-5cm).It involves
three steps preheating,calcining(in which CaO is formed)and burning. The
pyroprocessing takes place in kiln department.The raw mix is provided in
form of powder.In the rotary kiln temperature is ranging about 1400-1450°c.

STEP.4 Cement Milling

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To produce the final product clinker is mixed with gypsum and other
additive is grinded in large tube mill.First grinding breaks up the material
and second grinds into fine powder.
The grinding process is controlled to obtain a powder with a broad particle
size range, in which typically 15% by mass consists of particles below 5 μm
diameter.

QUARRYING
Quarry operation consists of drilling,blasting,loading
crushing,hanhling,screening and storing.

The raw materials are usually quarried from local rock, which in some
places is already practically the desired composition and in other places
requires the addition of clay and limestone, as well as iron ore, bauxite or
recycled material.

BLASTING

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LOADING & HAULAGE

MINING, CRUSHING & HANDLING

Raw Material Crushing:

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HAMMER CRUSHER: - .

Description:-
These are used for the size reduction of hard to medium hard
limestone and for raw marl crushing. Reduction ratios are as high as 1:40.
Depending upon crusher feed this can be reduced to 1:60. Generally two
types of the hammer crushers are manufactured:

 Single shaft hammer crusher.

 Double shaft hammer crusher.

These work with the impact effect of the hammers according to the
formula, P=mv²/2. Mass of hammers in hammer mill was reduced to
minimum while increasing the velocity as far as possible, resulting in
greater impact force combined with reduced wear. Rim speed of the
hammers is in the range of 5000 to 7000 rpm. Power demand of single
hammer crusher is between 1.3 to 2.8 HP h/t.

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Pre - blending: stacking and reclaiming

The blending bed consists of two equal material stockpiles which are
arranged in line. These material stockpiles are used both for storing and
also for prehomogeniation of the material to be stacked. The material
stockpile of one pile can be reclaimed while the other stockpile is stacked.

Stacking of the blending bed:-

Stacking of the blending bed is carried out in the „Chevron method‟ by

means of a stacker with loop car. The stacker with loop car is moved into
its starting position in „manual mode‟ with the boom raised its highest
position. The boom is lowered to its lowest position after reaching the
starting position.

The stacker starts the operating process after the commands for automatic
mode of stacking are given from a central control room. The stacker now
throws off the incoming material to the yard as it travels from one end of the
stockpile to the other, until a material probe which is mounted to the boom
tip sends a singal „material height reached‟. Then a command is given to
the luffing gear to lift the boom by one lifting step. This process is repeated
until the boom, after 20 lifting steps, has reached its maximum lifting height

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and the stockpile is stacked to its maximum

volume.

The material is reclaimed from the stockpile by the forward movement

of the scraper travel gears in connection with the reversible rake car on the
scraper bridge, the rakes mounted to the car on the scraper bridge, the
rake mounted to the rake car and the material discharge by the scraper
chain drive.

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RAW MEAL PREPARATION

The raw materials are usually quarried from local rock, which in some
places is already practically the desired composition and in other places
requires the addition of clay and limestone, as well as iron ore, bauxite or
recycled materials. The individual raw materials are first crushed, typically

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to below 50 mm. In many plants, some or all of the raw materials are then
roughly blended in a "prehomogenization pile." The raw materials are next
ground together in a rawmill. Silos of individual raw materials are arranged
over the feed conveyor belt. Accurately controlled proportions of each
material are delivered onto the belt by weigh-feeders. Passing into the
rawmill, the mixture is ground to rawmix. The fineness of rawmix is
specified in terms of the size of the largest particles, and is usually
controlled so that there are less than 5%-15% by mass of particles
exceeding 90 μm in diameter. It is important that the rawmix contains no
large particles in order to complete the chemical reactions in the kiln, and to
ensure the mix is chemically homogenous. In the case of a dry process, the
rawmill also dries the raw materials, usually by passing hot exhaust gases
from the kiln through the mill, so that the rawmix emerges as a fine powder.
This is conveyed to the blending system by conveyor belt or by a pump.

RAW MILL

Activity of Raw mill department start from feeding the raw materials
(Limestone, Shale, Quartzite and Iron ore) to the mills and ends at filling
the raw meal to silos.

RAW MILL – CIRCUIT FLOW DIAGRAM :

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RAW MILL CIRCUIT CONSISTS OF:

1.Feed Hoppers(to feed lime stone &corrective materials).

2.Weight Feeders(to feed material in different rates).

3.Bucket Elevator(to carry raw material & product discharge from mill to air
separator).

4.Air Separator(to separate out coarse and fine particles).

5. A multi bag dust collector (for precipitating fine dust from mill draft)

1.Function of Ball mill:

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A ball mill is a type of grinder used to grind materials into extremely fine
powder for use in many industries. The ball mill allows grinding of the
harder limestone that are more common than chalk. A ball mill consists of a
horizontal cylinder that rotates on its axis. It holds spherical, cylindrical or
rod-like grinding media of size 15–100 mm that may be steel or a variety of
ceramic materials, and occupy 20–30% of the mill volume. The shell of the
mill is lined with steel or rubber plates. Grinding is effected by impact and
attrition between the grinding media.

The ball mills are two chamber tube mill lined with Mn steel liners,
chambers are separated by intermediate diaphragms and charged with
Hyper steel balls. The compartments are separated by double diaphragm
for improving the retention time and transfer of material in second chamber
for further grinding. Size reduction of the mill feed is performed by motion of
the grinding media. Rotation of the mill cylinder raises the pile of mill feed
and grinding media to an optimum height, necessary for grinding operation.

2. TERTIARY CRUSHER (REVERSIBLE IMPACTOR TYPE)

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It is a impactor type crusher employing a high speed rotating disc to

which no. of hammers are fixed whose swung towards with centrifugal
force. the hammers are made up of mild steel. The material is fed at top of
the crusher and it is thrown out centrifugally and crushed by being between
hammers and periphery of cylindrical casing. Since the the hammer bars
are hinged, in case of any hard material does not cause damage to
equipment. The bars are readily replaced when they are worn out.

Hammer crusher

3.AIR SEPARATOR

Principle of operation: Action of air current of a certain velocity upon a

mass particle is prortional to surface presented by this particle to the air
current. Materials leaving the distributing plate are acted upon by various
forces. The action of force Fg &Fc

Upon a particle is proportional to its volume since volume is function of

diameter cube.

It is an industrial machine which sorts materials by a combination of size,

shape, and density. It works by injecting the material stream to be sorted
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into a chamber which contains a column of

rising air. Inside the separation chamber, air
drag on the objects supplies an upward force
which counteracts the force of gravity and lifts
the material to be sorted up into the air.

Three forces acted upon particles are:

VERTICAL ROLLER MILL

With the continual increasing demand for Portland cement and constant
pressure for reduced energy consumption, producers are exploring a wide
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variety of cost-saving manufacturing options. One option is vertical roller

mill technology for raw material grinding.

VRM-
CIR

CUIT FLOW DIAGRAM :

DESCRIPTION: It has same way of working as of raw mill, but it is more

economical then raw mill. The raw material from hoppers goes to the
vertical raw mill where material is grinded and fines are through to CF silo

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and to bag house. Fines from bag house go to the blending silo and stack
to vent off.

VRM

RAW MEAL HOMOGENISATION

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Ground raw meal is stored in large blending silos. These silos are air
activated to promote homogenization of the raw meal, reducing chemical
variation and promoting a stable sintering process in the rotary kiln.. These
may work continuously or batch-wise, in multi-stage systems, and in
combination with air agitation. In modern plants, the trend is large,
continuously operating silos. It follows that the silos, working as continuous
blending systems, have to be full in order to have a blending effect. If the
silos are only partially full, the variations in the raw mix composition from
the raw mill will go directly to the kiln. The efficiency of a blending system
can be characterized by the ratio, H, between variations in composition of
the incoming and the outgoing material. An example is the ratio between
the standard deviation of CaO in the raw meal before and after the kiln feed
silos.
Homogenization is the final opportunity to affect the raw meal chemistry
and quality before introduction to the pyroprocessing phase.

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VARIOUS TYPE OF FIELD INSTRUMENT USED IN GAGAL

CEMENT WORKS

 TEMPRATURE MEASUREMENT

 Resistance temprature measurement (RTD)

 Thermocouple

 Optical pyrometer

 FLOW MEASUREMENT

 Head type flow meter like orifice,venturi,pitot tube.

 Electromegnatic flow meter

 Rotameter

 PRESSURE MEASUREMENT

 Diaphragm, bourdon tube

 LVDT type transducer

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LEVEL MEASUREMENT

 Capacitor level measurement

 RF type level measurement

 Ultra sonic level measurement

 Vibrating folk type level measurement

 Float type level switch

 Bin level measurement

 Radar type level measurement

WIEGHING SECTION (STRAIN GAUSES)

 Solid flow meter

 Weigh feeder

 Rotor scale

 Multi core

 Belt weigher

 Weigh bridge

 Poldos system

GAS ANALYZER

 CO analyzer

 Oxygen analyzer

 NOX analyzer

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OTHER MISCELENIOUS INSTRUMENT

Zero speed sensor and transmeter

VVVF drives (variable frequency variable speed drives)

Dc drive (10 nos ranging from 2.2 kw -1250kw)

Metal detector (10 nos)

CCTV kiln camera (4 nos)

Bag filter timer panel (100 n0s)

Electronic packer (7 nos)

Electronic ear (sound level)

Girth gear lubrication system ( nos)

Field bus control (10 nos)

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TEMPERATURE MEASUREMENT

Resistance Temperature Detectors (RTD)

RTDs commonly use Platinum, Nickel and Copper to form the sensors. The
relation ship between the Resistance of these metals and Temperature is as
shown below. Platinum is used very widely in the Industry for measuring the
temperature of moderate range between 0–300 Deg. C.

R
e
Nickel
s

t
Copper
a
n
c
e

Platinum

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RTD Characteristics

Platinum RTD’s are used widely in industries because it is resistant to corrosion

and oxidation, malleable, has a very high melting point. As shown in the graph
plots the relation ship between resistance and temperature is linear over a wide
range of temperature from 250 – 800 deg C.

Metals are basically crystalline in structure comprising metal ions and free
electrons in equilibrium. The application of DC potential across the metallic
elements results in directional flow of these electrons. During their movement
they collide with themselves and with the ions comprising the crystal lattice, thus
restricting its flow, which results in an electrical resistance. As the metal is heated,
temperature rises and the mean free length between collision decreases due to
the increase in amplitude of oscillation, resulting in an increase in electrical
resistance.

The range of temperature over which this phenomenon is valid is decided by the
temperature coefficient of resistance, chemical inertness, and its crystal structure
which should not undergo permanent changes within this range. In general, the
resistivity of metals increases with an increase in temperature (i.e.: The Temp.
coefficient is positive), where as in some semiconductors the resistance decreases
with the increase of temperature. (i.e.: Temp. coefficient is negative). Such
variation in the temperature can be measured with the suitable electrical circuits
like Wheatstone’s bridge or Muller’s bridge.

Platinum wire

Mica

R1 R2 R3 R4

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Resistance Temperature Detector (Four Wire)

Calendar’s interpolating equation for temperature above 0 deg C for Platinum

(PT100) sensor is as given below.

Platinum resistance elements (PT100) fabricated with high purity wires or

foils are excellent for high precision temperature measurements. Coiled platinum
wire elements are used on board aircraft’s for outside air temperature
measurements.

Application: Measurement of bearing temperatures and motor winding

temperatures. Apart from it RTDs are used in the Coal mill circuit and other low
temperature applications.

Problems faced: Damage to element of RTD due to vibration in bearings.

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Thermocouples

Thermocouples are perhaps the most widely and commonly used sensor’s for
temperature measurements of higher ranges in any industrial application. The
sensing is based on the principle that current flows in a closed circuit made up of
two dissimilar metals if the junction of the two metals kept at different
temperature. In each lead, the concentration of the valence electron is
proportional to the temperature, and at the point of contact, the electrons diffuse
through the boundary layer between the two leads, resulting in one lead
becoming positive and the other becoming the negative. Thus the EMF generated
is proportional to the temperature difference in a predictable manner. This
phenomenon is known as SEEBECK Effect.

Copper

Measuring Measuring

Junction Instrument

Constantan Reference Junction

Fig: Typical construction of Thermocouple Element

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FLOW MEASUREMENTS

Electromagnetic Flow Meters

The Operation of this type of flow meters are based on the Faradays laws of
electromagnetic induction principal. The law states that the relative motion of a
medium flowing at right angles to a pair of electrodes and a magnetic field will
develop an emf across the electrodes.

Electrode

North South

Fig : Principle of electromagnetic flow meter

In this device the fluid passing through the pipe has to be conductive. The
schematic arrangement of the Electromagnetic flow meter is as shown in figure.
The flow tube lies in the uniform magnetic density B.

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The two electrodes are inserted in the tube, their surfaces being flushed with the
inner surface of the tube and in contact with the liquids. As the conductive liquid
passes through the insulated tube with an velocity v, it may be considered as flat
conductor disks passing through the magnetic field, inducing an emf e across the
electrodes. This is expressed as following equation.

e = B X d X v X 10 -8 V Where, e is the induced

voltage,

B is the flux density in tesla,

d is the distance between the two electrodes in meter,

v is the average velocity in met/sec

V is the constant to care of Units.

The main advantage of this flow meter is, it does not obstruct the flowing fluid
and it do not have any moving part.

Application: VRM internal water spray flow measurement.

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Rotameters

A Rotameters consists of a vertical tube with a tapered cone in which a float

assumes a vertical position corresponding to each flow rate through the tube. The
conical tube is made of glass, stainless steel or Monel and the floats are made up
of brass, stainless steel, monel or special plastics. The Rotameters are sometimes
referred as constant pressure drop, variable area or variable aperture meters.

Flow

PRESSURE MEASUREMENTS:

Pressure is defined as the force acting per unit area, measured at a given
point or over a surface. This can be in absolute, gauge or differential units,
depending on the reference taken.

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Pressure Transducers can be classified into gravitational and elastic types. In

gravitational type, the familiar Manometer is the simplest device. In elastic
transducer the pressure exerts a force over the area of an elastic device. The
force responsive member is in the form of diaphragm, capsule, bellows or
Bourdon tube as shown in figure.

Membrane

P Corrugated

Stretched Diaphragm

Diaphragm

A B

pointer

Manometer Bourdon Gauge

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The resultant displacement or strain developed is measured with an

appropriate electrical sensor. The conversion of this mechanical phenomenon
to an equivalent electrical signal is achieved by a variety of linkage
mechanisms. The transduction principles used are deflection measurements
with resistive, inductive, and capacitive principles or measurement of change in
natural resonance frequency of a stretched member.

In all transducer energy from the measurand is converted to energy

proportional to the measurand. Conventional pressure transducers achieve this
by converting the pressure to a mechanical displacement.

The pressure measuring transducers can be of two types. They are Direct and
Indirect type of measurement.

The direct types of measuring devices are, Manometer, barometers etc. The
Indirect types of devices are, based on the elastic elements which deflects
under pressure, such as diaphragms, bellows and tubes. Instruments of this
group can be coupled to the mechanical to electrical transducers of suitable
type.

Elastic Element Mechanical

Pressure to
Fluid

Energy Input Transducer Electrical Transducer

Mechanical Electrical
Energy Output Energy

Fig : Basic Principle for Pressure Transduce

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PROGRAMMABLE LOGIC CONTROLLER

CONCEPTUAL DIAGRAM OF A PLC:

PROCESS OR MACHINE
SERIAL OR
TO BE CONTROLLED BY
PLC PARALLEL I/O PROCESSOR

RACKS

The inputs to PLC come from the process connected devices or sensors such as:

 Limit Switches/Inductive proximity Switch

 Push buttons
 Thermocouple Couples
 RTD
 Transmitters like 4 to 20 mA current source
 P to E converters

The Output from PLC are given to the devices and final control elements such as:

 Lamps
 Indicators
 Relays
 Solenoids
 Motor contactors
 4-20 mA signals to operate control valves

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The processor part of the PLC contains a Central Processing Unit (CPU), Program
Memory, and Data Memory. The operation of the PLC starts with execution the
control program stores in the program memory. This program reads the status of
all input devices connected to it and stores it in input status table of the data
memory. It then executes the instructions used for process or machine control
and calculates output conditions as per the program logic. These output
conditions are stored into the output status table of the Data Memory. The
output devices connected to the I/O racks are updated as soon as the CPU
calculates the outputs. This operation of PLC; called as ‘PLC Scan’; is cyclic and
continues unless interrupted by an external command. The Time taken by the
processor to complete one PLC Scan is called “ Scan Time “.

Apart from the processor and I/O Racks, a programming device is also required to
enter the user program. The programming device is a personal computer, which is
connected to the processor only while loading and testing the program.

TYPES OF PLC USED AT GAGAL CEMENT WORKS

 Seimens S5 100U PLC in all Stacker Reclaimers Coal as well as Limestone

 Allen Bradley SLC500 PLC in Bag House of K2 and Packing House of Gagal I
 Tata Honeywell LCS 620 PLC in Gagal Packing House
 Compton Greaves PLC in Gagal II Packing House, and for air blasters.K1 and
K2.

HONEYWELL LCS 620 PLC

The Honeywell LCS 620 programmable controller is a modern state of the art
PLC. The LCS (Logic Control System) Series consists of 620-12, 620-16, 620-36
and 620-35 processors.

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PREHEATER

All the three processes drying,preheating and calcinations are done in the
preheater.

The key component of the gas-suspension preheater is the cyclone. A

cyclone is a conical vessel into which a dust-bearing gas-stream is passed
tangentially. This produces a vortex within the vessel. The gas leaves the
vessel through a co-axial "vortex-finder". The solids are thrown to the
outside edge of the vessel by centrifugal action, and leave through a valve
in the vertex of the cone. Cyclones were
originally used to clean up the dust-laden
gases leaving simple dry process kilns. If,
instead, the entire feed of rawmix is
encouraged to pass through the cyclone, it is
found that a very efficient heat exchange
takes place: the gas is efficiently cooled,
hence producing less waste of heat to the
atmosphere, and the rawmix is efficiently
heated. This efficiency is further increased if a
number of cyclones are connected in
series

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Heat Transfer in preheater:

Raw meal is fed to the top of the preheater and it flows down in feed
pipe,while the hot gases coming from kiln flows in upward direction due to
upward force applied by Id fan.As the hot gase going up through riser duct
and raw meal coming down comes in intimate contact the heat transfer
take place due to which hot gase transfer the heat to the raw material and
heat it up in the preheater and gases cool down.

As we see in the graph between temperature and stages,temperature of

exhaust gas decrease as it flows from 5th stage 1st stage and on other sides
temp. of raw meal increases as it comes down from 1st to 5th stage.

Precalciner ;

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ROTARY KILN
A Rotary kiln is a pyroprocessing device used to raise materials to a high
temperature (calcination) in a continuous process. The rotary kiln consists
of a tube made from steel plate, and lined with firebrick. The tube slopes
slightly (1–4°) and slowly rotates on its axis at between 30 and 250
revolutions per hour. Rawmix is fed in at the upper end, and the rotation of
the kiln causes it gradually to move downhill to the other end of the kiln.

The temperature of the burning zone is 1400-1500 0C.

FUNCTIONAL DESCRIPTION :

The feed material enters the rotary kiln

through the inlet housing. The inclination and
the rotation of the kiln cause the material to move in counter-flow to the hot
gases towards the outlet and from there into the cooler.

In this process the feed material passes through the following

reaction zones :

1. Preheating zone (subject to kind of preheater )

2. Calcining zone (subject to the kind of preheater )
3. Clinkering zone
4. Cooling zone

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The presence and the length of these zones is mainly dependent on

the composition of the material to be burnt , the preheater and the
downstream cooling system Diameter and the length of the rotary kiln
depends upon the desired output and are considerably influenced by the
chosen preheater and cooling. The quality of the refractory lining of the
rotary kiln pipe is adjusted to the length of the reaction and temperature
zone and is specifically determined for every individual plant.

The heat quantity required for different reaction stages is generated

by the rotary kiln burner at the rotary kiln outlet. The combination air is high
temperature secondary air coming from the cooler section. The hot gases
flow through the rotary kiln and reach the inlet housing via the rotary kiln
inlet. The heat is transmitted to the feed material by the contact between
the hot gases and the material and by its contact with the refractory brick
lining.

Successive chemical reactions take place in the kiln:

 70 to 110 °C - Free water is evaporated.

 400 to 600 °C - clay-like minerals are decomposed into their
constituent oxides; principally SiO2 and Al2O3. Dolomite
(CaMg(CO3)2) decomposes to calcium carbonate, MgO and CO2.

.650 to 900 °C - calcium carbonate reacts with SiO2 to form belite

(Ca2SiO4).

Cement
clinker

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CLINKER COOLING

The reciprocating grate cooler serves for the cooling of the small sized or
granulated burned material. An excellent cooling effect is achieved in that.
The cold air is blown through the cooler grate and through the burned
material lying on the
grate.

Cooling principle:

The burned material discharged from the kiln falls through the inlet
shaft of the cooler onto the entry to the grate . Due to the special design to
the grate entry the material to be cooled forms a uniform bed. Over the
stationary and movable grate plate rows, the burned material is transported
by the forward movement of the movable grate plate rows to the end of the
cooler.

The oscillating frame with the movable grate plate rows is driven on
both the sides; the number of the strokes per minute is infinitely variable.
The cooling air is generated by the several fans. Normally, one fan is
allocated to each air chamber, thereby providing the targeted aeration to
the grate and the material to be cooled.

The heated up cooling air is captured in the upper section of the

cooler and is available for the further use as secondary air for the kiln or as
the tertiary air.
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CEMENT GRINDING

Final processing step in the manufacture of the cement is cement

grinding.It is the grinding of mixture of clinker and additives into a finished
product Object is to create a particular fineness of the product to achieve
some predetermined physical characteristics in the cement. When in
concrete, Main ingredient used in cement is the clinker. Clinker is ground
with gypsum to produce Portland cement. Grinding mill is the main
component used in finish grinding system. A ball mill is horizontal
cylindrical drum with two compartments having steel balls of the different
diameter. as grinding media . Clinker is ground by a closed circuit grinding
system where mill product is routed through the dynamic air separator and
the material coarser than the required grain size is returned to the mill.
Thus, separator removes the coarser and the fine particles, which are fed
back to the mill.

Cement mill

Cement clinker is usually ground using a ball mill. This is essentially a large
rotating drum containing grinding media - normally steel balls. As the drum
rotates, the motion of the balls crushes the clinker. The drum rotates
approximately once every couple of seconds.The drum is generally divided
into two or three chambers, with different size grinding media.

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As the clinker particles are ground down, smaller media are more efficient
at reducing the particle size still further. Grinding systems are either 'open
circuit' or 'closed circuit.' In an open circuit system, the feed rate of
incoming clinker is adjusted to achieve the desired fineness of the product.
In a closed circuit system, coarse particles are separated from the finer
product and returned for further grinding.

BALL MILL INTERNAL

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Ball mill

Function of gypsum in cement:

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DUST COLLECTORS
1.Cyclone
Separator:

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2.Bag
Filter

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3.Electrostatic Precipitator:

CEMENT STORAGE,PACKAGING & DISPATCH

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Packing Plant is the place where cement is stored, packed and

dispatched to various destinations.

Gagal Cement Works Packing Plant has seven cement silos.

All the packers have the truck loading facility because the cement
from Gagal is transported to different destinations by road only.

The different varieties of cement handled are :

 33 Grade OPC (Ordinary Portland Cement) as per IS : 269

 43 Grade OPC (Ordinary Portland Cement) as per IS : 8112
 PPC (Portland Pozzolana Cement) as per IS : 1489(part II)
 PPC (Portland Pozzolana Cement) super Separate bags Godown is
available in Gagal plant I and Gagal plant II, Where up to 40 lakhs and
80 lakhs can be stored respectively. Packing plant is close liason with
cement Dispatch section and Laboratory.

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Cement packing and dispatch is done through road transported by trucks

only.

Cement dispatch section receives order from RMO and accordingly

they place demand of trucks to the truck unions, destinations wise. Then
the trucks are placed in accordance to demand for loading of cement. The
silo from which the cement is to be extracted for loading depends upon the
type of cement and type of cement filled in the silos.

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Thank you

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