Professional Documents
Culture Documents
Burning to clinkers
1 Raw material (Lime Stone-CaC03) which is the basic constituent of cement is obtained
from
2.Lime stones from mines are subjected to crusher. Lime stone of size 1M X 1M X 1M
are received / accepted at crusher(Maximum size acceptable is 1.2 x 1.2 x 1.2 meters),
which are crushed to size of 75mm. The crushing of lime stone is done in four stages
where the lime is passed through various stages and its size is reduced at each stage, and
the final size of lime stone received at crusher is less that or equal to 75mm.
I) 210 mm
II) 130 mm
III) 110 mm
IV) 60 mm
It is taken care of that +90 should be nil at the output of crusher.
Lime stone of RAS mines is directly taken to stacker by transportation.
The specification of crusher at Shree mines
MAKE : L&T.
MODEL : APPM 1822
MOTOR RATING : 950 KW.
CAPACITY : 800 TPH
2 The lime stone is received from various mines at STACKER UNIT, where PILE of lime
stone is made by the STACKER (Size of lime stone is below 75 mm.), to maintain
uniform quality of lime. There are TWO units of stacker's. Pile is tested at interval of 1
hour to get quality of lime stored in Pile.
3 Reclaimer is used to reclaim the lime stone from the pile. There are TWO units of
reclaimer units.
Capacity of Reclaimer is 400 & 600 TPH.
5 The material from reclaimer is stored at hoppers.
Laterite (Iron Ore) is stored in separate hopper.
6 CCR controls the feeding of High grade lime stone, Average grade lime stone, & Laterite
to the RAW MILL.
7 In raw mill grinding of material takes place and then stored in raw mill silos known as
C.F. SILOS.
8 From C F Silo’s, powdered lime stone goes to PRE-HEATER( PYRO STRING & KLIN
STRING -5-stage Cyclones) where the powder is heated ( The process is known as
calcination ) using the hot flue gases of Klin from 65 Deg. Centigrade to 1000 Deg.
Centigrade.
9 Now material enters in rotary kiln where it is heated up to 1400-1600 deg. C thus forming
clinkers. The hot gases of the kiln passed to Pre – Heater's for heat exchange.
10 Then clinker is passed to cement mill through coolers mid way where in Gypsum and
other materials are mixed with the clinkers and crushed collectively resulting Cement
(final product).
11 Gypsum is added to increase settling time of cement as per requirment of type of cement
being produced.
12 We manufacture two types of cement i.e.
➢ Ordinary Portland Cement (OPC) – 88% (Lime Stone) + 4% (Gypsum)+ Fillers.
➢ Portland Pozolona Cement (PPC) – 65% (Lime Stone) + 4% (Gypsum) + 25%
(Fly ash) + Fillers
Finally cement is stored in silos and from there it is sent to packing plant for packing and
transportation:
Process department coordinates with all the departments like Mechanical for maintenance
purpose, Instrumentation for automation, electrical and Shree power for power supply, mines
for raw material, physical & quality control lab for parameter study & control of production
quality.
MIS- STUDY:
INPUT/OUTPUT PROCESS:
Being final product, the cement is stored in cement silos. There are five silos in our company,
three for Unit-I and two for Unit-II.
Cement is carried forward to an elevator and is collected in cement bin .Bin is connected to
vibrating screen through which cement is passed down to cement tank. There is a valve
attached between vibrating screen and cement tank which regulates the flow of cement, level
sensor senses the level of hopper attached to cement tank. The gate valve is connected to
solenoid valve. The capacity of tank is 45 tons. To measure the temperature of cement, a
RTD is connected to cement tank. There is also a direct pathway (optional) from vibrating
screen bin to loader if there is no requirement for packing the cement.
Dust suppression system has been installed to collect the dust at various locations.Collected
dust through dust suppression system is sent back to elevator and and vibrating screen bin.
From cement tank, cement is fed to packers. The packer it self has in house tank of capacity
of 5 tons.
Packer plant consists of two types of packers based on their feature, capacity and working
style.
Packer are of mechanical as well as automatic type.
Nos. TYPE MAKE SPOUT DISCHARGE
04 MECHANICAL L & T 12 SINGLE
03 AUTOMATIC ELECTRONIC 12 DOUBLE
ERIWXCO
In each packer there are 12 nozzles. The packer rotates on it’s axis. When an office in-charge
inserts a bag in nozzle, the latter auto-matically hold the bag until the bag weighs 50 kg. Load
cell is mounted and attached with rotors for weighing the quantity of cement in bag . As soon
as the load cell sense 50 kg, the nozzle releases the bag and bag moves on the belt conveyor
towards to loading point to be loaded in trucks / wagons.
Since the packer makes rotation so a person has got to keep inserting bags one by one in each
nozzle. After one complete revolution, the nozzle releases the bag. The whole process goes
on this way.
The average capacity of packing plant is around 9000 tons/day.
Finally packed cement is made to reached on loaders through conveyor belts. There is
interlocking system also in between.
There are 18 loaders, 12 for trucks and 6 for trains (wagons).
ROTO PACKERS CEMENT
(7 Nos.) SILOSMech
(5) , 3-Electronic
CEMENT TANK 4- (18 Nos.)
LOADING POINTS (18 Nos.)
FLOW DIAGRAM:
Gate Valve
Level Sensor
RTD
Load Cell
1 Sales and Logistics: These are the departments kept in touch regularly with packing
plant. The sales department directs packing plant to load the required quantity and
Logistic department specifies the mode of transportation.
2 Instrumentation: For controlling and maintenance of field instruments like load cell,
packers and PLC.
MIS STUDY:
SAFETY MEASURES:
1 The labour should wear hand gloves while loading bags in to trucks / wagons.
2 The use of dust mask must be in practice with in the premises.
MECHANICAL:
ORGANISATION STUDY:
KILN I :
MAKE - L&T
SIZE - 3.98 X 56 M2
CAPACITY - 3000 TPD
INCLN - 4% 82’ 28”
KILN RPM - 3.8
MOTOR - DC 226 KW, 1000 rpm
PRE HEATER I
MAKE - L&T/FLS
CAPACITY - 3000 TPD
TWIN CY. I - 5.6 X 8.9 M2
II - 6.9 X 6 M2
III - 6.9 X 6 M2
IV - 6.9 X 6 M2
CALCINER - 6.3 X 17.9 M2
RAW MILL II
MAKE - L&T/FLS
TYPE - 280/ 307
PR. - 100 MMWG
TEMP - 350 degC MAX
CAPACITY - 6000 m3
MOTOR - 1600 KW, 991 rpm
IMPELLOR - 3070 mm
To get hired suitable man power department coordinates with P & A Department.
For any maintenance work there is a format of SAFETY PERMIT. In that safety officer
review the situation and write the safety instruction on permit. Those instructions should be
followed by responsible engineers and workers.
MIS- STUDY:
MAINTENANCE PRACTICES:
1. Preventive maintenance
2. Shut down maintenance (1 Major -20 days , 2 Minor-10 days)
3. Routine check list for equipments
Responsible maintenance person takes round of their areas and make observation according
to their check list Preventive maintenance schedule is followed up and any abnormality found
in between is rectified in coordination with process department.
ELECTRICAL:
SHREE POWER generates power of 11 KV which is further stepped down to 6.6 KV. All
HT motors, fans, coolers are connected to 6.6 KV. Again it is stepped down to 415 V for LT
small field drives.
SCL is having 45 MW TG Power (2x18 MW, 1x6MW, 1x3 MW) capacity and DG sets
which is used in case of power failure or as an auxiliary supply to power plant.
The power distribution is done as below:
Electrical department coordinates with all the departments like Process, Mechanical,
Instrumentation, Shree Power, Store, Purchase, IT and Rajasthan Electricity Board (Power
Grid) to get power for RAS etc.
MIS- STUDY:
Unit-2
UNIT-2 :
LC (Load Center)-1
1. Mines
2. High Grade Feeder
3. Crusher
4. Truck Unloader
5. Conveyer Belts
6. Stacker
LC-2
1. Reclaimer
2. Raw Mill Fan
3. Spare
4. RM Feed and Grinding
5. RM Transport
6. Raw Mill Hopper
LC-3
1. Spare
2. PCC Kiln & Cooler
3. ESP Fan
4. Coal Mill Fan
5. PH Fan
6. Cooler Vent
7. MCC-9
LC-4
1. Cement Mill
2. Roller Press
3. PCC Cement Mill
4. SEPAX
UNIT-1
Instrumentation department plays a vital role in any process industry. The whole plant is run
and controlled by field instruments and Programmable electronic controllers.
I/P
(24 V (24 V
DC) Commn. Bus DC) O/P
On-Off DI DO 24VDC
(Switch)
CPU
(Microprocessor)
(4-20 (4-20
Variable ma) ma)
(Flow,Pr AI Memory (EEPROM) AO 4-20 ma
Temp, % etc.)
Instrumentation department coordinates with all the departments like Process, mechanical,
electrical, shree power, store, purchase, IT etc.
MIS- STUDY:
PLC
Location Processor
1. Mines & crusher - MODICON 984-480E
2. RM-1 - MODICON 984-785E
3. RM-2 - MODICON 984-785E
4. KILN & PH-2 - MODICON 984-785E
5. Cooler & Coal mill - MODICON 984-785E
6. Cement mill-2 - MODICON 984-785E
7. Kiln-1 - SCNEDZER CPU 43412A
8. Cement mill-1 - SCNEDZER CPU 43412A
9. Packing Plant - MODICON 984-785E
10. Stacker - ALLEN BREDLY SLC 5/03
11. Reclaimer - ALLEN BREDLY SLC 5/03
DRIVES
1. Kiln main drive - D.C. drive
2. Cooler grates 1,2,3 - D.C. drive (LHTOR make)
3. Raw mill - D.C. drive (SIEMENS)
4. Reclaimer 1 - A.C. drive
5. Reclaimer 2 - D.C. drive
6. Cooler fans-7, 8, 9, 10 - V.F.D.
7. Mills classifiers - V.F.D.
8. Coal feeding screw - V.F.D.
9. Luffing Drive (Reclaimer) - A.C. drive
10. Slew drive (Reclaimer) - A.C. drive
OVERVIEW:
P & A department plays a major role in an organization. It deals in manpower planning and
recruitment, security, training, system management and rectification. It coordinates with
every department in a company in order to facilitate by giving them manpower, transport,
cultural events and maintaining the record of attendance, leaves of their employees.
It also takes care of the human welfare activities like arranging cultural events, national
festivals and excursion.
P&A department also manage the staff colony and to provide them the basic amenities like
healthy air, potable water, security and clean environment.
1. This department coordinates with every department in the company for providing
and meet the plant requirement for smooth functioning of organization.
2. Besides it has also got stint to make relations with other departments out side to
the company.
1. Mines safety : Blasts should be done properly , use of dust masks ,etc.
2. Electrical safety : Checking competency certificates , earting of equipments , etc .
3. General safety : Road safety , lighting & air ventilation arrangements , etc
4. Shutdown & Safety permits : Height permits, silo cleaning permits, electrical
shutdown, etc.
5. Fire safety : To look after fire extinguishers , hydrant pumps ,etc
RMH - RAW MATERIAL HANDLING:
INPUT/OUTPUT PROCESS:
Raw material is that material which gets processed upon and gives final (desired) product.
It is considered as an input to any industry to get some planned output such as product and
energy. There fore every industry is dependent upon the supply of raw material.
In Shree Cement and Shree Power, we have a separate department which takes care of all
types of raw material, required for the plants to produce the desired output.
It has different application depending their contents, calorific values and cost.
In our industry we use lime stone and petroleum coke.
There is only one RMH section which caters to both Shree cement and Shree Power.
Lime Stone, Pet coke, Gypsum, Laterite, Mill scale, Fly ash, Bituminous, Coal are the types
of raw materials used in our company.
1. PROCESS FLOW:
Buyers
Order/ demand
Packing Plant
INPUT/OUTPUT PROCESS:
As marketing department get an order from a buyer, they inform our logistics deptt and make
sure that dispatch along with required quantity has to be carried out in the stipulated time.
The marketing dept. gives all the relevant details to the logistics. as soon as payment against
order is received the logistics deptt. Studies the suitable and shortest route, then decides the
mode of transportation keeping various constraint such as time, money and convenience in
their mind. the delivery is made to buyer all the taxes and freight already paid.. In addition to
it we have to pay excise duty on cement @400/ton and education cess @ 2%.
Generally around 150 trucks/ trailers are transported daily.
MIS REPORT:
Logistics deptt. has to make a MIS report against each dispatch and it has to specify in detail
how and why a certain dispatch has been carried out. It has to furnish all the details about the
dispatch such as freight rate, mode of transportation, route along with the causes for selection
of such parameters.
CENTRAL STORE:
INPUT/ OUTPUT PROCESS:
The central store is the place where all the need full items relating to technical, consumer
electronics and general things are kept and managed to their respective locations, all the
location are addressed according to their specifications . There is a fix pattern to manage and
access the various things. Spare parts, stationary, fuel ( petrol, diesel, oil) , general items
( rain coat, safety helmet e.t.c)., vehicle, consumables , electronic items are kept and
managed.
In our stores all the items are placed systematically and managed by in-house s/w
Sumridhi.Items could be located by their item code.
Any requirement of material is processed through stores. Department prepares indent through
ERP with proper specification and code and is then is then forwarded to stores. Stores verifies
the availability of materials and when it is not in stock then forwards to purchase department
for further process of purchasing.
One should have a primary know how process through ERP to make an indent.
The Purchase department will search the various vendors dealing in that item taking care of
quality and cost. Once it get thru, will ask for quotations from various vendors. After
receiving the quotations, it will study and find the one with good quality and less cost or as
per the requirement and generate the order only after the approval of Executive Director who
heads this purchase department.
After the delivery the required items are first kept in store, the store person will then inform
to it’s indentor to approve the item on MRN (Material receipt note). Once the indenter
approve, the store then permits him to get issued otherwise the store will again inform to
purchase department about the incorrect delivery of material . The purchase department will
then inform to his vendor and arrange to supply the required one. Once the vendor supplies
the required item and at the same time the user approves, the purchase deptt issues a bill and
forwards the same to account department. After verified for it’s correctness the payment is
made to vendor.Inventory items are identified , listed and minimum inventory is maintained.
Inventory management is carried out in store regularly to make sure the things are placed at
the right locations.
FLOW DIAGRAM:
CRUSHER
Indent
ERP(SumRiddhi)
Requisition Yes
STORE
No
Supply Indent
PURCHASE
Order
VENDOR
IT (INFORMATION TECHNOLOGY):
INPUT/OUTPUT PROCESS:
The section deals with all the departments, connecting al-together to data transfer and
communication. It takes care of maintenance work for all the systems, kept on desks. It
maintains all the data base of each employee up to date. IT section has designed our web site
names www.shreecementltd.com. Every employee has got the facility of having his own e-
mail account where by he can send and receive mails.
One of the major tasks of this section to have implemented an in house ERP called
SUMriddhi.
A robust IT platform with SUMriddhi, Shree ERP enables a seamless integration of
management practices with business process at Shree resulting in the achievement of
optimum speed , efficiency, transparency, internal controls and overall profitability. Through
this system every department has now become transparent to each other. We can have details
of store contents instantly by logging in ERP.
MIS STUDY:
IT department furnishes and submits daily reports to higher management covering the
various points as below.
4. Descriptions of all the calls received from various departments.
5. Daily routine work of server, networking and power supply.
As per requirement / order of individual department, purchase department carries out the
activity for purchasing the indented material
Indented material is checked against the existing stock at stores, if material is not found at
stores then indent process is initiated by raising an indent for the same following the consent
of Executive Director. Quotations from some concerned leading vendors are invited. After
consulting the vender for negotiating of price and genuine material. After the delivery of
required material, the indentor is called to check and approve the material received.
MIS STUDY:
1. Store
2. Account
ACCOUNT:
1. Inputs are payment, billing, quantity data, sales figure, salary details and any kind
of accounts related documents come from all other departments.
Accounts dptt coordinates to all the departments of SCL, RAS, DEPOTS and other branches.
Some of them are:
LAB: daily report of production & dispatch (excise purchase) comes from lab.
PACKING: sales quantity report
MINES: limestone production quantity
CIVIL: Contractor’s bills
RMH: quantity data
SHREE POWER: Unit cost collected by cost department & then it comes here.
P & A: salary or package related data, leave record of individuals.
SALES A/C: sales figures, realization
LOGISTIC: Transport (rail, road) information, dispatch info.
IT: Here Mr. K.K.Soni from IT department is permanently sitting at A/C office.
MARKETING: TA, DA, DEPOTS bills
STORE: Here separate section for store accounting located at stores itself.
MIS- STUDY:
Account department submits the report, monthly balance sheet to higher management.
Covering following points:
Power Plant Operation can be broadly divided into four major parts.
1. DM Plant
2. Boiler
3. Turbine
4. Coal Handling Plant
DM plant:
It consists of following sub-divisions
Raw water reservoir
Pump House
RO plant
DM plant
Effluent Water Treatment Plant
Raw water is stored in raw water reservoir from different sources and then it comes
to RO Plant through pump house where RO water is generated and is stored in a
tank from where it is used in Cooling Tower and DM Plant for generation of DM
water. DM water stream is having a capacity of 5.0 M3/Hr. This DM water is used in
Boiler for Steam generation. The reject of RO plant and DM plant is fed to Effluent
water treatment plant which generates RO water which is used in cooling tower as
make up. The reject water of Effluent water treatment plant is sent to Mines directly
for road spray purpose and thus no water is disposed off which creates any pollution.
Boiler :
Shree power is having 2 Nos. coal fired AFBC boiler
Make TBW
Capacity 2x80 TPH
Pressure at SH Outlet 64 Kg/Cm2
Steam Temp. 485 Deg C
The Bed temperature is maintained around 9300C from where the fuel (normally Pet
coke) takes heat to get burnt and after burning liberates heat energy. The air
required for fuel combustion is supplied at certain pressure to the Boiler through the
FD fan. The PA fan is used to transport the fuel into boiler from the feeders The
specification of FD fan and PA fan is as follows
The ID fan is required to escape the flue gases out from the Boiler and maintain the
desired pressure in furnace and flue gas path. The specification of ID fan is given
below
Specification of ID fan
Make ABB
Type Centrifugal
Capacity 38.17 Kg/sec
I/L St. pr. 200 mmWC
Fan speed 890 RPM
Air/Gas Density 0.748 kg/m3
Motor Rating 180 kW
Motor speed 890 RPM
Coal is crushed to desired size in coal crusher. Coal crushers have been supplied by
McNally Bharat Engineering Co. Lime stone crushers have been installed for
crushing the limestone. Crushed coal and limestone are fed in their respective
bunkers through belt conveyors.
TG SET :
It includes low CV fuel Handling System, Bed ash Handling System and Coal
Handling/Lime handling system
Low CV Fuel Handling System
The flue gases coming out from the Boiler contains a huge quantity of Fuel and
therefore it is called as low CV fuel.
The heaviest particles in the flue gases are collected in a hopper called as Air
Pre Heater/Boiler Bank hopper due to gravity. Ahead, the low CV fuel is collected in
three Electro static Precipitator hoppers by charging them with the help of high
voltage.
By Dense phase system, this low CV fuel from all hoppers is collected in a silo from
where it is dumped into Tractor Trolleys or Trucks and is transported to Cement
Plant where it is again used in firing within the Kiln.
Bed ash handling system
Fuel contains some ash within it and limestone, which is used as a sorbent in the
boiler also, contains ash. These two increase thickness of the bed (heat reservoir) of
the boiler and therefore it is needed to reduce by draining it. This drained ash is
called as bed ash.
Again this is collected in a silo through dense phase system and is dumped into
trolleys and is transported to Cement Plant.
Coal Handling/Lime Handling System
The Fuel either coal or pet coke is initially collected into a hopper from where it
comes to Bunker within a definite size span through various belt conveyors, screens
and crusher. This fuel is fed to the boiler through Drag chain or rotary feeders.
Similarly the Bed material or Limestone is fed up to respective bunkers through belt
conveyors, screens and crusher within a definite size span. The bed material is fed
to the boiler directly but Lime stone is fed through the screw feeder and drag chain
feeders.