SUMMER TRAINING REPORT

“CEMENT MANUFACTURING PROCESS”

At

JK CEMENT LTD.

Submitted to
Mewar University, Chittorgarh
Towards the partial fulfillment of
The degree of
Bachelor of Technology In
Chemical Engineering

Session: - 2019-2020

Guided By Submitted By:

Mr.Ankit Mathur Anupam Kumar Thakur
GENERAL MANAGER MUR1600032
JK Cement LTD. Roll No:160100090001

Faculty of Engineering&Technology
Department of Chemical Engineering
Mewar University,
Chittorgarh (Raj)
July 2020
i
 STATEMENT OF ORIGINALITY
In accordance with the requirements for the degree of Bachelor of Technology in
Mewar University, in Faculty of Chemical Engineering, I present this report Entitled
“CEMENT MANUFACTURING PROCESS” This report is completed under the
guidance of Mr.Ankit Mathur I declare that the work presented in the report is
my own work except as acknowledged in the text and foot notes, and that to my
knowledge this material has not been submitted either in whole or in part, for a degree
at this University or at any other such Institution.

Date:- / /2020 Anupam Kumar Thakur

Faculty of Engineering&Technology
Department of Chemical Engineering
Mewar University
Chittorgarh (Raj.)
July 2020
 RECOMONDATION
This training entitled “CEMENT MANUFACTURING PROCESS” submitted by
Anupam Kumar Thakur to Chemical Department of Engineering of Mewar
University Chittorgarh is a satisfactory account of his training report and is
recommended for the award of marks sheet.

Signature of Guide Signature of Head

Mr.Ankit Mathur Mr.Deepak kohali
GENERAL MANAGER HEAD OF DEPT.
JK CEMENT LTD DEPT.OF CHEMICAL
ENGG.

Date:- / /2020. Date:- / /2020

Faculty of Engineering & Technology

Department of Chemical Engineering
Mewar University
Chittorgarh (Raj.)

iii
July 2020

iv
 CERTIFICATE
This is to certify that Anupam Kumar Thakur Roll No. 160100090001 has
submitted the summer industrial training report entitled “CEMENT
MANUFACTURING PROCESS” in partial fulfillment of the award of the degree
of BACHELOR OF TECHNOLOGY (CHEMICAL ENGINEERING). The
report is
up to my satisfaction and as per the formats prescribed for the writing of the report.
His report is approved for presentation.

INTERNAL EXAMINER EXTERNAL EXAMINER

DATE. DATE.

Faculty of Engineering&Technology

Department of Chemical Engineering

Mewar University,

Chittorgarh (Raj.)
July 2020
 DECLARATION
In accordance with the requirements for the degree of B-tech. Program in Chemical
Engineering and technology, I present this report Entitled “CEMENT
MANUFACTURING PROCESS”. This report is completed under the guidance of
Ms. Shekhawat.

I declare that the work presented in the report is my own work expect as
acknowledged in the text and foot notes, for a degree at this university or at any other
such institution.

Date :- / /2019 Anupam Kumar Thakur

Faculty of Engineering & Technology

Department of Chemical Engineering

Mewar University

Chittorgarh (Raj.)
July 2019
 ACKNOWLEDGEMENT
I am deeply indebted to our Chancellor, Dr. Ashok Kumar Gadiya, Mewar
University, and Chittorgarh for providing us the infrastructural facilities to complete
our project work

I would like to express my sense of gratitude of my guide Ms Shekhawat, General

Manager, for his valuable guidance, suggestion, and continuous support throughout in
preparing the one-month industrial training report.

I also express my thanks to my Head of Department Ms. Shalinee Gupta and other
faculty member for providing me an opportunity to present the training report on
“CEMENT MANUFACTURING PROCESS”.

Date: - / /2019 Anupam Kumar Thakur

Enrollment MUR1600063

Faculty of Engineering & Technology

Department of Chemical Engineering

Mewar University

Chittorgarh (Raj.)

July 2019
 ABSTRACT
This study evaluates cement manufacture, Cement any substance which binds together
other materials by a combination of chemical processes known collectively as setting.
Cements are dry powders and should not be confused with concretes or mortars, but
they are an important constituent of both of these materials, in which they act as the
'glue' that gives strength to structures, Cement is an extremely important construction
material, Cements used in construction can be characterized as being either hydraulic
or non-hydraulic.

The first step in the manufacture of cement is to combine a variety of raw ingredients
so that the resulting cement will have the desired chemical composition. These
ingredients are ground into small particles to make them more reactive, blended
together, and then the resulting raw mix is fed into a cement kiln which heats them to
extremely high temperatures.

The basic mixture of cement industry consists of Chalk Lime stone Clay Calcium
carbonate Silicon oxide Aluminum oxide and iron (II) oxide.

Portland cement is by far the most common type of cement in general use around the
world. This cement is made by heating limestone (calcium carbonate) with other
materials (such as clay) Raw Materials processing included: Setting and curing and
cement manufacturing process , Process Discretion: Wet process, Semi-dry process,
Dry process and Finish process.

The environmental impact of the cement production and its variations between
different cement plants, using Life Cycle Impact assessment. For that purpose, details
of the cement production processes are investigated in order to show the respective
part of raw materials preparation and clinker production using
 TABLE OF CONTANT
STATEMENT OF ORIGINALITY...............................................................................ii

RECOMONDATION...................................................................................................iii

CERTIFICATE.............................................................................................................iv

DECLARATION...........................................................................................................v

ACKNOWLEDGEMENT............................................................................................vi

ABSTRACT.................................................................................................................vii

CHAPTER 1:.................................................................................................................1

INTRODUCTION OF CEMENT INDUSTRY.........................................................1

1.1 Background About Study.................................................................................1

1.1.1 Background about Cement............................................................................1

CHAPTER 2...................................................................................................................2

RAW MATERIALS FOR CEMENT MANUFACTURE.........................................2

2.1 Raw Materials For Cement Industry................................................................2

2.2 The Materials Of Which Is Made Up Of Cement............................................3

2.3 Description of Raw Materials of Cement.........................................................3

2.4 Lime stone........................................................................................................5

2.5 Pure limestone uses..........................................................................................5

CHAPTER 3………………………………………………………………………… 8

RAW MATERIALS PROCESSING.........................................................................8

3.1 About raw Material & processing....................................................................8

3.2 Setting and curing............................................................................................8

3.3 Cement manufacturing process........................................................................9

CHAPTER 4.................................................................................................................10

PROCESS DESCRIPTION.....................................................................................10

4.1 Wet Process....................................................................................................10

4.2 Semi-Dry Process...........................................................................................10

 4.3 Dry Process....................................................................................................10

4.4 Finish Process.................................................................................................11

CHAPTER 5.................................................................................................................13

ENVIRONMENTAL IMPACT FOR CEMENT.....................................................13

5.1 Environmental impact caused by emissions into the air................................13

5.3 Environmental impact resulting from the disposal of solid waste.................13

CHAPTER 6.................................................................................................................15

PLANT LAYOUT...................................................................................................15

6.1 Storage Facilities...........................................................................................16

6.2 Spacing Of Items............................................................................................16

6.3 Processing Area.............................................................................................17

6.4 Placing Of Equipment....................................................................................17

6.5 Maintenance...................................................................................................18

6.6 Construction And Building............................................................................18

6.7 Railroads, Roadway And Pipe Racks.............................................................19

6.8 Planning For Expansion And Imprements.....................................................19

6.9 Processing Buildings....................................................................................19

6.10 Warehouse....................................................................................................20

6.11 Sanitary Water..............................................................................................21

6.12 Utility Water.................................................................................................21

CONCLUSION........................................................................................................22

REFERENCE...........................................................................................................23
 LIST OF FIGURES
Figure 1.Location map of chalk depodite in jorden..............................................................................................4
Figure 2.location map of kaoline deposite in jorden.............................................................................................6
Figure 3. Cement raw material processing...........................................................................................................8
Figure 4The wet Process of Cement...................................................................................................................10
Figure 5.Cement Roasting flow sheet.................................................................................................................11
Figure 6. Cement production flow sheet by the dry process...............................................................................12

xi
v
 LIST OF TABLE
Table 1: Raw ingredients used to provide each of the main cement elements..............2

Table 2: Chemical and physical properties of the studied areas....................................5

xv
 CHAPTER 1:

INTRODUCTION OF CEMENT INDUSTRY

1.1 Background About Study

1.1.1 Background about Cement
Cement is any substance which binds together other materials by a combination of
chemical processes known collectively as setting. Cements are dry powders and
should not be confused with concretes or mortars, but they are an important
constituent of both of these materials, in which they act as the 'glue' that gives
strength to structures. Mortar is a mixture of cement and sand whereas concrete also
includes rough aggregates; because it is a major component of both of these building
materials, cement is an extremely important construction material. It is used in the
production of the many structures that make up the modern world including buildings,
bridges, harbors, runways and roads. It is also used for facades and other decorative
features on buildings. The constant demand for all of these structures, increasingly
from the developing world, means that cement is the second most consumed
commodity in the world after water (Francesca, 2010).

Cements used in construction can be characterized as being either hydraulic or non-

hydraulic, depending upon the ability of the cement to set in the presence of water
(Blezard, 2004).

Non-hydraulic cement will not set in wet conditions or underwater; rather, it sets as it
dries and reacts with carbon dioxide in the air. It can be attacked by some aggressive
chemicals after setting (Blezard, 2004).

Hydraulic cements (e.g., Portland cement) set and become adhesive due to a chemical
reaction between the dry ingredients and water. The chemical reaction results in
mineral hydrates that are not very water-soluble and so are quite durable in water and
safe from chemical attack.

1
 CHAPTER 2
RAW MATERIALS FOR CEMENT MANUFACTURE

2.1 Raw Materials For Cement Industry

The first step in the manufacture of cement is to combine a variety of raw ingredients
so that the resulting cement will have the desired chemical composition. These
ingredients are ground into small particles to make them more reactive, blended
together, and then the resulting raw mix is fed into a cement kiln which heats them to
extremely high temperatures (Kosmatka et.al, 2002)
Since the final composition and properties of cement are specified within rather strict
bounds, it might be supposed that the requirements for the raw mix would be similarly
strict. As it turns out, this is not the case. While it is important to have the correct
proportions of calcium, silicon, aluminum, and iron, the overall chemical composition
and structure of the individual raw ingredients can vary considerably. The reason for
this is that at the very high temperatures in the kiln, many chemical components in the
raw ingredients are burned off and replaced with oxygen from the air. Table1 lists just
some of the many possible raw ingredients that can be used to provide each of the
main cement elements (Kosmatka et.al, 2002).
The cement industry is considered of strategic industries. It is so simple with the
industry compared to major industries, and depend on the availability of the necessary
raw materials for it.

Calcium Silicon Aluminum Iron

Limestone Clay Clay Clay

Marl Marl Shale Iron ore

Calcite Sand Fly ash Mill scale

Aragonite Shale Aluminum Shale

Shale Fly ash Blast furnace dust

Sea Shells Rice hull ash

 Cement kiln dust Slag

Table1:-Raw ingredients used to provide each of the main cement elements

2.2 The Materials Of Which Is Made Up Of Cement

The basic mixture of cement industry consists of: (Taylor, 1997).
• Chalk
• lime stone
• Clay
• Calcium carbonate
• Silicon oxide
• Aluminum oxide
• Iron (II) oxide
2.3 Description of Raw Materials of Cement.
2.3.1 Chalk
Chalk is a fine-grained white limestone or micrite. On average, it consists of 97.5 –
98.5% calcium carbonate. Clay and quartz are the most common impurities. Most
chalk is soft friable rock that does not required explosives in mining (Fadda, 1996).
Mining Underground mining within the Chalk outcrop of southern and eastern
England has taken place over a long-time span. Some of the earliest mine workings
date from the Neolithic period. The scale of mining may differ according to purpose,
comprising for example a single small-scale mine working covering an area of
<100m² (Fadda, 1996). Uses: - Chalk as a form of carbonate rocks containing high
calcium carbonate can be used in many industrial applications such as: - Chalk can be
used as a building stone, and chalk rubble is often used in road construction. - When
heated, chalk becomes lime, which has a great many applications, Lime is used in the
production of steel, Aluminum, Glass, Paper, Sugar, Cement, and Fertilizer.
Location: - Chalk deposits exposed over an area extend from east of Zarqa to the area
of Al Azraq are shown in Figure (1) (AbuQudera, 1998).
 Figure 1.Location map of chalk depodite in jorden

Location: (AbuQudera,1998)
1. Al – Umary (Abar Al Hazim) / Dahikiya Area.
This area is located about 45km south east of Al- Azraq.
2. Wadi Al-Ghadaf Area.
This area is located about 35km south of Al-Azraq.
3. Qaser Al-Harrana Area.
This area is located about 50km east of Amman.
4. Wadi Al- Dha'abi Area
This area is located about 60km east of Amman.
Chemical and Physical Properties
The Chemical and Physical Properties listed in table (1)
 Area CaO% Brightness

Al – Umary – Dahikiya 38.9 – 49.6 74.8 – 81.7%

Wadi Al-Ghadaf 43.6 – 52.6 79.5 – 81.4%

Qaser Al-Harrana 47.9 – 52.6 76.6 – 83.5%

Wadi Al- Dha'abi 51.59 – 53.15 1.6 – 85%

Table 2:-Chemical and physical properties of the studied areas. (H.F.W. Taylor 1997)

2.4 Lime stone

Pure limestone is among the most important non-metallic raw material used for
industrial and agricultural purposes (Technostone, 1984).
Mining:- Sedimentary limestone deposits can be extensive, covering hundreds of
square miles, and can be relatively uniform in thickness and quality. Therefore,
limestone quarries can be large and long lived, mining limestone layers that can be
hundreds of feet thick over areas of several square miles. Many quarries produce
multiple products, and crushed rocks that are not pure enough for certain uses may
still be suitable as road aggregate. Marble quarries can also be very large.

However, these rocks that were once regularly bedded have been metamorphosed into
irregularly shaped bodies that are more difficult and costly to mine
(Technostone,1984).

2.5 Pure limestone uses

• In the metallurgical industry as a fluxing agent for the smelting and refining of iron,
aluminum and copper .

• In the chemical industry in the production of lime, calcium carbonate, alkali

compounds, calcium carbide, magnesium oxides

• In industries of white cement, iron and steel, glass, paper, sugar-refining, water
purification, sewage and waste treatment, and gas desulphurization.

• Agricultural uses in soil condition, fertilizers and animal feeds.

• As a filler material in paints, rubber, paper, ceramics, floor tiles, tooth paste, medicine.

• Cement industry.

2.6 Location:
Location map of Pure Limestone deposits in Jordan show in figure 2.
 Figure 2.location map of kaoline deposite in jorden

Cement industry:- In white cement industry pure limestone should have CaO >52%.
The insistent need for pure limestone deposit are due to the increasing prices of
cement and the development of construction industries, so the investment opportunity
will be increased in this industry (Teimeh and Hiyari,1978).
Clay Defination and Uses:-
Kaolin is white, soft, plastic clay mainly composed of the fine grained platy mineral
kaolinite; a white hydrous aluminum silicate, Al2Si2O5(OH)4, containing 23.5%
alumina, 46.5% silica It is used in the manufacturing of white-ware ceramics and in
filling and coating of paper. It is also used as filler in paints, rubber, plastics and many
OTHER productions (Ajlouni and Gharaybeh, 1986).
 2.7 Mining
The mining and processing of kaolin begins with exploration. Geologists study the
earth’s surface, research literature and other data to identify land with potential kaolin
deposits.

2.8 Location
Location of Kaoline deposits in Jordan shown in Figure (3)
• Batn el-Ghoul area
• Mudawwara area
 CHAPTER 3
RAW MATERIALS PROCESSING

3.1 About raw Material & processing

Portland cement is by far the most common type of cement in general use around the
world. This cement is made by heating limestone (calcium carbonate) with other
materials (such as clay) to 1450 °C in a kiln, in a process known as calcinations,
whereby a molecule of carbon dioxide is liberated from the calcium carbonate to form
calcium oxide, or quicklime, which is then blended with the other materials that have
been included in the mix to form calcium silicates and other cementitious compounds.
The resulting hard substance, called 'clinker', is then ground with a small amount of
gypsum into a powder to make 'Ordinary Portland Cement', the most commonly used
type of cement (often referred to as OPC). Portland cement is a basic ingredient of
concrete, mortar and most non-specialty grout. The most common use for Portland
cement is in the production of concrete. Concrete is a composite material consisting of
aggregate (gravel and sand), cement, and water.

Setting and curing

Cement starts to set when mixed with water which causes a series of hydration
chemical reactions. The constituents slowly hydrate and the mineral hydrates solidify;
the interlocking of the hydrates gives cement its strength. Contrary to popular
perceptions, hydraulic cements do not set by drying out; proper curing requires
maintaining the appropriate moisture content during the curing process.

Figure 3. Cement raw material processing

3.2 Cement manufacturing process
a) The quarry
Cement plants are usually located closely either to hot spots in the market or to areas
with sufficient quantities of raw materials. The aim is to keep transportation costs low.
Basic constituents for cement (limestone and clay) are taken from quarries in these
areas (Hahn, et.al 1997).
 A two-step processes
Basically, cement is produced in two steps:
first, clinker is produced from raw materials. In the second step cement is produced
from cement clinker. The first step can be a dry, wet, semi-dry or semi-wet process
according to the state of the raw material.
b) Making clinker
The raw materials are delivered in bulk, crushed and homogenized into a mixture
which is fed into a rotary kiln. This is an enormous rotating pipe of 60 to 90 m long
and up to 6 m in diameter. This huge kiln is heated by a 2000°C flame inside of it.
The kiln is slightly inclined to allow for the materials to slowly reach the other end,
where it is quickly cooled to 100-200°C (Hahn, et.al 1997).
Four basic oxides in the correct proportions make cement clinker: calcium oxide
(65%), silicon oxide (20%), alumina oxide (10%) and iron oxide (5%). These
elements mixed homogeneously.
(called “raw meal” or slurry) will combine when heated by the flame at a temperature
of approximately 1450°C. New compounds are formed: silicates, aluminates and
ferrites of calcium. Hydraulic hardening of cement is due to the hydration of these
compounds (Hahn, et.al 1997).
The final product of this phase is called “clinker”. These solid grains are then stored
in huge silos.
 CHAPTER 4

PROCESS DESCRIPTION

Wet Process

This process is make by cylindrical type kiln the length for it = 40times of the shell’s
inner diameter it is using to help dry the slurry see figure 4.

Figure 4The wet Process of Cement

4.1 Semi-Dry Process

It example to dry process and uses a Lepol kiln : in the lepol kiln the pellets are dried
and preheated once by the movable grate (Mahasenan, et.al 2008).
4.2 Dry Process
The Cement Roasting Machine is the device to heat and dry materials. The Materials
in the coaxial type roasting machine are roasted through retracing and raising between
the helical lobe and the intermittent spiral plate. The sleeve structure of the machine
can severalfold shorten the length of dryer, hereby the radiating surface and heat
consumption are significantly reduced, while the increased heat exchange surface
greatly enhance thermal efficiency. As to the materials that could not contact smoke,
the multi drum cement roasting machine is equipped with inside smokestacks and
ringlike smokestacks, and each smoke tube linked through radial flue, consequently,
reaching the effect of high efficiency and energy saving see Figure 5 (Mahadevan,
et.al 2008).
 Figure 5.Cement Roasting flow sheet

In this case there are three types of kilns to uses:

• long kiln, the short kiln with boiler, the SP kiln and the NSP

• the long kiln is use in the Near and Middle East (it used because rain falls less

It can be seen that the wet process is rapidly replaced by the dry process the cause it
for energy conservation (Mahadevan, et.al 2008).

4.3 Finish Process

The second phase is handled in a cement grinding mill, which may be located in a
different place to the clinker plant. Gypsum (calcium sulphates) and possibly
additional cementations (such as blast furnace slag, coal fly ash, natural pozzolanas,
etc.) or inert materials (limestone) are added to the clinker. All constituents are
ground leading to a fine and homogenous powder. End of phase two. The cement is
then stored in silos before being dispatched either in bulk or bagged see figure 6
(Mahasenan, et.al 2008).
Figure 6. Cement production flow sheet by the dry process
 CHAPTER 5

ENVIRONMENTAL IMPACT FOR CEMENT

5.1 Environmental impact caused by emissions into the air

• Atoms dirt: these atoms to permeate ready lung and caused great damage to the
respiratory tract (diseases such as asthma and chronic cough and inflammatory coral
aerobic). And these emissions consist of ash and soot and carbon components, which
are often resulting from incomplete combustion process (Chandak, Shobhit, 2011).
• Sulfur Oxides: The air pollution caused by the pollutants sulfur and one of the most
dangerous air pollutants, which cause sulfur compounds in major problems for the
animals and plants, as well as for the building, because the acid rain causing corrosion
of metals, limestone, and other materials. For example but not limited to (Chandak,
Shobhit, 2011).
• NOx: nitrogen monoxide has the same harmful effect of the environment as the first
carbon dioxide, which can combine with hemoglobin cells to limit the ability of blood
to carry oxygen, and nitrogen dioxide causes inflammation of coral bronchial
pneumonia (Chandak, Shobhit, 2011).
• Carbon dioxide: and it is one of the six greenhouse gases that cause global warming
phenomenon where these gases absorb heat radiation and store them, which
contributes to increase the surface temperature (Chandak, Shobhit, 2011). 5.2
Environmental impact resulting from the liquid waste
In the case of access to the dust furnace systems fluid exchange, it may lead to the
formation of clay which can lead to clogged sewage pipes (Berkes, Howard, 2011).
As well as form oils and lubricants resulting from garages and workshops and a great
danger in the case discharged into the sewage system, where Tzb in gluing pipes
which lead to many difficulties in maintenance operations. And also if the discharge
of such effluent into water bodies, they can interfere with aquatic life in this body of
water or can be a great oily and lead to serious pollution of the environment
surrounding spots (Berkes, Howard, 2011).

5.3 Environmental impact resulting from the disposal of solid waste

Arise atoms dirt minute of crushing and milling operations and confused in addition to
the dust sedimentation resulting from the process of electrolysis in the last milling
stage
before packing. It is worth mentioning that the disposal of such waste by dumping in
buried outside the factory area requires the addition of stabilizing agents to reduce the
harm and that may lead to serious risks to the population surrounding environment in
case of high proportion of these pollutants in the air.
 CHAPTER 6
PLANT LAYOUT

The laying out of a plant is still an art rather than a science. It involves the placing

Equipment so that the following are minimized

a) Damage to persons and property in case of a fire, explosion, or toxic release

Maintenance costs

b) The number of people required to operate plant

c) Other operating costs

d) Construction costs

e) The cost of the planned future revision or expansion

The first thing that should be done is to determine the direction of the prevailing wind
this can be done by consulting Weather Bureau records. Wind direction will
determine the general location of many things. All equipment that may spill
Flammable materials should be located on the downwind side. Then if a spill occurs
the prevailing winds are not apart to carry any vapors over the plant, where they
could be ignited by an open flame, spark, or a hot surface.

Plant Offices Electrical substation

 Central Laboratories Water treatment plant

 Mechanical and other shops Cooling tower
 Office building Air Compressors
 Cafeteria Parking lot
 Store house Main water pumps
 Medical Building Warehouses that contain non-hazardous
 Change house Non-explosive and
 Fire station Non-flammable materials
 Boiler house Fired heaters
 All ignition sources
 Electrical Power house
 Equipment’s that may spill inflammable materials
 Blown down tanks
 Burning Flares Setting ponds
For a similar reason the powerhouse, boilers, water pumping, and air supply facilities
should be located 250 ft (75 m) from the rest of the plant, and on the upwind side.
This is to minimize the possibility that these facilities will be damaged in case of a
Major spill. This is especially important for the first two items, where there are
usually open flames. Every precaution should be taken to prevent the disruption of
utilities, since this could mean the failure of pumps, agitators, and instrumentation.
For this reason, it may also be wise to separate the boilers and furnaces from the other
utilities. Then, should Fire equipment explode, the other utilities will not be damaged.

Other facilities that are generally placed upwind of operating units are plant officers,
Mechanical shops and central laboratories. All of these involve a number of people
who need to be protected also, shops and laboratories frequently that are used
primarily for quality control are sometimes located in the production area.

6.1 Storage Facilities

Tank farms and warehouses that contain non-hazardous, non-flammable, and non-
explosive materials should be located upwind of the plant. Those that do not fit this
Category should not be located downwind of the plant, where they could be damaged
and possibly destroyed by a major spill in the processing area. Nor should they be
Located upwind of the plant where, if some of their contents are spilled. The
processing Area might be damaged. They should be located at least 250 ft (75 m) to
the side of any processing. Some authorities suggest this should be 500 ft. The same
reasoning Applies to hazardous shipping and receiving areas. Sometimes, storage
tanks are located on a hill, in order to allow the gravity feeding of Tank cars. Care
must be taken under these circumstances to see that any slop over cannot flow into the
processing, utilities, or services areas in case of a tank fir. When liquefied petroleum
gases are used, the areas for containing spills are always below grade because the
gases are denser than air. The gases will accumulate in the Low areas will also not be
asphyxiated.

6.2 Spacing Of Items

The OSHA has standards for hazardous materials that give the minimum distances
between containers and the distances between these items and the property line,
Public roads and building. These depend on the characteristics of the material, the
Type and size of the container, whether the tank is above ground or buried and the
type of protection provided. Specific details are provided for compressed gas
equipment
Containing acetylene-air, hydrogen-oxygen and nitrous oxide, as well as liquefied
Petroleum gases. They also prohibit the storage and location of vessels containing
Flammable and combustible materials inside buildings, unless special precautions are
Taken. Again, the major reason for including the layout in the preliminary plant
design is that the transporting equipment and buildings may be sized to make certain
that no needed Equipment is omitted and that the chosen Plant site will be large
enough. At this Point, since most of the energy transfer again, the major reason for
including the layout in the preliminary plant design is that the transporting equipment
and buildings may be sized to make certain that no needed Equipment is omitted and
that the chosen plant site will be large enough. At this Point, since most of the energy
transfer equipment has not been sized, only its approximate location can be given.

6.3 Processing Area

There are two ways of laying out a processing area. The grouped layout places all
similar pieces of equipment adjacent. This provides for ease of operation and
Switching from one unit to another. For instance, if there are 10 batch reactors, these
would all be placed in the same general area and could be watched by minimum of
Operators; if they were spread out over a wide area, more operators. Might be added.
This scheme is best for large plants. The flow line layout uses the train or line System,
which locates all the equipment in the order in which it occurs on the flow Sheet. This
minimizes the length of transfer lines and therefore reduces the energy needed to
transport materials. In industries, it is used mainly for small volume Products. Often,
instead of using the grouped or flow line layout exclusively, a Combination that best
suits the specific situation is used.

6.4 Placing Of Equipment

Once a general scheme is decided upon, the processing area is divided into unit areas.
The units should be grouped so that the number of operating personnel is minimized.
The maximum loss concept must also be considered. Some companies place a limit in
the maximum loss that can be expected if a fire or explosion occurs. This permits
those watching the controllers to quickly investigate and determine the cause of any
Problems that might arise. It may be desirable to have two or more processes
Controlled from one location, this could reduce the number of operations required. In
This case, the control room should be located in a relatively unexposed area near the
Edge of the processing area, but away from fired heaters. This is to protect both the
Employees and the equipment.

6.5 Elevation
If there is no special reason for elevating equipment it should be placed on the ground
Level. The superstructure to support on elevated piece of equipment is expensive. It
Can also be a hazard should there be an earthquake, fire or explosion. Then it might
Collapse and destroy the equipment it is supporting as well as that nearby. Some
Pieces of equipment will be elevated to simplify the plant operations. An example of
this is the gravity feed of reactors from elevated tanks. This eliminates the need for
some materials-handling equipment. This especially true for solids and slurry feed.

6.6 Maintenance
Maintenance costs are very large in the chemical industry. In some cases, the cost of
Maintenance exceeds the company’s profit. The engineer must design to reduce these
Costs. The easiest way to reduce maintenance costs is to allow lots of extra space and
to construct everything at ground level for easy access. However, this may increase
Construction and operating expenses and the ease of operability. The engineer should
determine what type of equipment need to be serviced by mobile cranes. These Pieces
of equipment will need to be located on the perimeters of the plant or on a Roadway.
The roadways along which the crane will travel must have adequate Overhead and
horizontal clearness. Adequate space must be left around all equipment So that it can
be easily serviced and operated. For instance, a floating-head heat Exchanger must
have enough space so that the tube bundle can be removed from the Shell and taken
elsewhere for repairs. For tanks containing coils and agitators, enough Headroom
must be provided so that these can be removed.

6.7 Construction And Building

Proper placing of equipment can result in large savings during the construction of the
Plant. For instance, large columns that are field-erected should be located at one end
of the site so that they can be built, welded, and tested without interfering with the
Construction of the rest of the plant.
6.8 Railroads, Roadway And Pipe Racks
The main purpose of railroads is to provide an inexpensive means for obtaining raw
Materials and for shipping products. This means that they should be close to raw
Materials and or/ product storage. Buildings and loading docks should be set back 8
ft. (2.4m) from the centre of the railroad track. Spurs and switches should be laid out
with a 100 ft (30m) radius. Roads are used not only for these purposes but to provide
Access for fire fighting equipment and other emergency vehicles, and for maintenance
equipment. This means that there should be a road around the perimeter of the site No
road should be dead-end. For safety there should be two ways to reach every
Location. All major traffic should be kept away from the processing areas.

6.9 Planning For Expansion And Imprements

Obviously, if the equipment has been over designed to meet the anticipated future
Expansion, no extra space needs to be provided. If, however, additional equipment
will be required, space should be allocated for it. The net result will be an increase in
these initial costs of construction and some increase in material transfer costs, because
the transfer lines will be longer.

6.10 Building
Building with the layout of the plant is the direction as to what types of buildings are
to be construction, and the size of teach. When laying out buildings, a standard size
Bay (area in which there are no structural supports) is 20ft x 20ft (6m x 6m). Under
Normal conditions a 20-ft (6m) span does not need any centre supports. The extension
of bay in one direction can be done inexpensively. This only increases the amount of
Steel in the long girders, and requires stronger supports. Lavatories, change rooms,
Lunch rooms and medical facilities is dictated by OSHA. It depends on the number of
Workers employed. Research laboratories and office buildings usually not included in
the preliminary cost estimate. However, if they are contemplated, their location
should be indicated on the pilot plan.

6.11 Processing Buildings

Quality control laboratories are necessary part of any plant, and must be included in
all cost estimates. Adequate space must be proved in them for performing all tests,
And for cleaning and storing laboratory sampling and testing containers. Packaging
equipment generally must be in enclosed buildings, and is often located at one end of
the warehouse. If the material being packaged is hazardous, either this Operation will
be performed in a separate building, or a firewall will separate it from any processing
or storage areas.

6.12 Warehouse
The engineer must decide whether warehouses should be at ground level or at dock
Level. The latter facilitates loading trains and trucks, but costs 15-20 percent more
Than one placed on the ground. It is usually difficult to justify the added expense of a
Dock-high warehouse.

6.13 Utilities
The work utilities is now generally used for the ancillary service needed in operation.
These services will normally be supplied form a central site facility. The utilities
required include:
1. Water
2. Electricity
3. Steam requirement for process heating
4. Storage & movement of raw materials/products
5. Fire protection
6. Maintenance facilities
7. Plant sewer system and waste disposal
6.14 Water
Water is vital for any plant following types of water used for the plant. Natural and
forced draft cooling towers are generally used to provide the cooling water required
on site. Some treatment is necessary for once through system to prevent scale of small
quantity of surface active agents is added to the water. So, it increases the solubility of
the salt in the water by preventing. Prevented by adding corrosion inhibitors such as,
chromate or surfaces acidic phosphates. Dematerialized water from which all the
minerals have been removed by ion exchange, is used when pure water is needed for
process use and as boiler feed water. Requirement for fire water are intermittent and
assumed that other services will be shunt if necessary, to provide sufficient water
capacity. The fire water lop system should be so designed that breakdown at a specific
hydrant does into put the entire system out of operation. Provision should be made for
emergency connection of the fire water system into the large reservoir of water. Sea
water and brackish water is often used if plant is located at the coastal area.

6.15 Sanitary Water

It must be free disease-causing bacteria and potable Treated water is chlorinated to
destroy bacteria. Sanitary water systems are operated at 20-30 psi. An elevated water
storage tank is installed to ensure uninterrupted flow of water.

6.16 Utility Water

Utility water is used for miscellaneous washing operations such as cleaning an
operating area. It should be free form sediments. Notices should be put to wan
personnel not to drive this.

6.17 Electricity
The power required for motor drivers, righting and general use, may be generated
onsite, but usual it is purchased form the local supply company. In our plant main air
blower is the high power consuming equipment. As in our plant large quantity of
excess is available, we produce power in plant itself by using steam turbine. Actually
electricity is one of the by-products of our company. The voltage at which the supply
is taken will depend on the demand. In this case three phases 415V is used for general
industrial purpose and 210V single phase for lighting and other low requirements.
 CONCLUSION
• The mining sector enters significantly in the cement industry, this sector is considered
the most important in terms of extraction, mining, and processing of raw materials.
• 99% approximately from the raw materials used are considered mining material.
• Mining methods used in the extraction equipment for a cement raw material
considered ways rather easy and inexpensive and most commonly used material
extracted from quarries.
• Considered one of Lime stone and clay the most important raw material for the
manufacture of cement different kinds.
• Mining and processing of raw materials include Setting curing and clinker.
• Cement process include wet, dry, wet dry process and finish process.
• Roasting cement Considered one of the most important processing steps where they
are roasting constituent components through the roasting oven.
• After use cement (concrete) greatly affect on the environment in general, Bust greatly
affect the soil and groundwater.
• Environmental and health effects of pollutants resulting from the cement industry
include environmental impact caused by emissions into the air liquid waste disposal
of solid waste.
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