GUJRAT SIDDHI CEMENT LIMITED

INDEX
Sr 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 Subject Acknowledgement Introduction Production flow Diagram Mines Crusher Stacker & Declaimer Rawmill C.F Silo Preheater Kiln Cooler Clinker storage Cement mill ESP
1

Page 2 3 6 7 11 14 16 18 19 24 28 29 32 33

GUJRAT SIDDHI CEMENT LIMITED

4 15 1 6 1 7 1 8

Packing plant Instrumentation used in cement plant. Plant Interlocking diagram Heartily thanks to

34 36 48 51

GUJRAT SIDDHI CEMENT LIMITED

ACKNOWLEDGEMENT
This is the acknowledgement for those personalities who have helped me directly or indirectly to organize my training, helped me during my training period and to make my training report. I am also thankful to all staff members of automation division, who have helped me to clear my doubts & concepts.

GUJRAT SIDDHI CEMENT LIMITED

1 INTRODUCTION
####################################################
1.1

INTRODUCTION:
The SIDDHI Cement production process is here under: Mines Crusher Belt Conveyor Additives Rawmill hopper

Raw Mill C.F. Silo

GUJRAT SIDDHI CEMENT LIMITED

Preheater Kiln Cooler Clinker Storage

Cement Mill

Clinker yard

Cement Silo Packing Plant

GUJRAT SIDDHI CEMENT LIMITED

GUJRAT SIDDHI CEMENT LIMITED

GUJRAT SIDDHI CEMENT LIMITED

2 MINES
####################################################
2.1

INTRODUCTION:
The lime stone

2.2

MINING:

Here in the GSCL Lime Stone Mine mining is done in two methods: 1. Conventional Mining 2. Surface Mining
1.

CONVENTIONAL MINING

These explosives and detonators are stored is called the magazine. First of all the top soil is removed with the bulldozer. This soil is transported to the mines only when ordered, otherwise it is heaped at the mines. The drilling machine is used to make holes upto the depth of 10 m and 150 mm diameter. It also takes samples of soil at various levels for the assessment of the soil. According to the kind of earth i.e., soft or hard the placing of explosive is decided. If the soft earth is charge with an explosive, then the gases pass through the porous soil and hole is not blasted, hence explosive is wasted.
8

GUJRAT SIDDHI CEMENT LIMITED

It is very important to ram and compact the earth after piling explosive. Otherwise it might explode in the air. Even the rock develops the cracks, so if the drilling machine is used in the area it might get stuck up in crack. The blast explosive is of 125 mm and 83 mm Diameter. It is class 2 explosive weighting 6.25 kg. The 83 mm Diameter explosive is Aqua dyne, also manufactured by IDL Chemicals. It has weigh of 2.77 kg. The explosive have following compositions: Nitrate - 60 % Ag Powder - 10 % Water - 10 % Nitroglycerine - 20 % These explosive are Nitroglycerine based explosive and they are in a thick paste form and contains salver. The cost is Rs.18/kg. When we observed the blasting there were 19 holes of depth 10 m each, so 35x15x10x1.5 tons of limestone is acquired against the usage of 1500 kg of explosive used. Here the holes blasting affective area are 34 m long and 15 m wide. The power factor ranges from 3 to 5 which are considered less. A detonating chord is used to connect these holes to each other. These are made up to Penta Ethylene Tetra Nitrate coater with plastic. A one meter long chord contains 10 gm of PETN. This is used in a chord form so that the contact is not broken. It fires at the rate of 6000 m/sec.
9

GUJRAT SIDDHI CEMENT LIMITED

A detonator is used to connect these holes and complete the circuit. The wire is made of steel which is covered with plastic. This wire is ignited. An Ohms meter is used to check whether the circuit is completed or not. Then the dynamo is charged and the red light on it lights frequently and fire button is pressed, and blast occurs. The place where the stone and it is 60 cm thick stacking of explosives and detonators are done separately. In the case of accidents if explosives ignite, they just burn, but if detonators ignite, they explode. The explosives are stacked on a wooden platform, 6 inch above the ground, so that no harm is caused by rats also. Special care is taken not to use any iron material in the magazine, instead of iron, Cu is used. The stacking is done only upto 1.2 m. A red line is marked almost about 2.5 m above the ground which marks the maximum storage capacity. A passage is left between the stacks, so that if one starts burning the others might be removed. These magazines have special Z type ventilators for the purpose of security. These are also made from Cu. The vehicle used for carrying the explosives is made from Al. It has a partition between back part and front part and also a silencer in front, so there will not any chance of fire.
2.

SURFACE MINING:

10

GUJRAT SIDDHI CEMENT LIMITED

Mining lime stone with surface miner is of very recent origin in India and it has got definite advantages over conventional mining. First of all the mining with surface miner eliminates totally drilling and blasting. Surface miner performs in site crushing while mining, which cases out the problems encountered in transportation of limestone to crusher. The system needs no separate loading arrangement and the machine loads the material directly to he trucks or dumpers. The need for haul road maintenance is drastically reduced, since the mine surface with the surface miner is very gradual and uniform. The biggest advantage with surface miner is that it eliminates primary crushing, since the product size will be maximum 150 mm and 50 % will be less than 75 mm. Surface miner provides scope of selective mining and hence gives greater opportunity for exploiting the reserve where contamination is more and where conventional mining is not possible. The elimination of drilling and blasting provides environmental friendly mining operations with utmost safety for the mine operators.

11

GUJRAT SIDDHI CEMENT LIMITED

3 CRUSHER
##########################################

Apron Feeder
It comprises of specially fabricated frame on which two heavy duty endless link assemblies are wounded. The apron flights are of rolled steels and are bolted on the chains and are used for conveying the material. The drive arrangement is a D.C. motor and a gear ox connected to the drive shaft of the apron feeder. The link assembly and the flight are supported and guided on the top of the frame by deck rollers. The drive shaft has two sprocket hub assemblies which mesh with the link assemblies and drive the apron feeder. On the return end of the apron conveyor is the tail wheel assembly for guiding the link assembly.
1.

Scraper Chain Conveyor

The scraper conveyor consists of a trough assembly within with a scraper chain assembly travels. The round link chain and fabricated scraper flight runs on scraper trough while conveying the spillage load on trough support assemble while returning. Actual conveying of spillage is done by the bottom strand by scraping material alone the trough bottom plate. The drive arrangement consists of an A.C. electric motor and shaft mounted

12

GUJRAT SIDDHI CEMENT LIMITED

reduction gear box which directly rotates the drive shaft. At the rear end, the scraper tail wheel assembly guides the round ling chain assembly.
2.

Impactor

The crusher is Impactor Cursher. Crushing is done by impact and it is a dynamic operation. The main size reduction is carried out by striking i.e., by impact of the impeller bars to the crusher feed. The purpose of the breaker plates arranged inside crusher is to function as deflecting plated. The material thrown against them is reflected back into crushing compartment, where it is again hit by the impeller bars, until it leaves the crusher through slot between rotor and lower edge of breaker plate. By the impact of material against roller plates and material gets crushed and then material is supposed to crush by chunking against each other. The material is ground to the size of 50-60 mm in first phase. There are three types of impact plates 1: front impact 2: rear impact 3: grinding lower

13

GUJRAT SIDDHI CEMENT LIMITED

CONVEYOR BELT:

The crushed material from is convening through many numbers of belt conveyor. The material is feeded to stacker through conveyor BC 4A and BC 4B.

14

GUJRAT SIDDHI CEMENT LIMITED

3 STACKER & RECLAIMER

####################################################
3.1

STACKER:

The stacker type SU is used to stack raw material at the yard. The stacker runs on the rails fixed at the right hand side of the pile in longitudinal direction. The material are stacked with a certain homogenizing effect normally according to Chevron method or longitudinal stack piling method, with help of Boom stacker. Chevron method is a roof like stock piling method. The stacker consists of two main parts: 1. Tripper 2. Jib
1.

TRIPPER:

Tripper and jibs are linked together and are provided with RBCs. For the traveling of stacker four drive motors are provided which are attached with jibs rollers through gear boxes. The tripper is fitted with four wheels which are mounted in wheel casing.

15

GUJRAT SIDDHI CEMENT LIMITED 1.

JIB:

The stacker consists of a mobile rotable frame and a stacker capable of lifting in the vertical plane. The hydraulic equipment serves to move the stacker jib in step from the lower to the upper working position. While the stacker lift the stacker jib according to the height of the pile.
3.2

RECLAIMER:

The bridge scraper is used for homogenization of particular materials at longitudinal store and for conveyance of material from piles to outgoing conveyor belt. Reclaimer has a long scrapper chain through which homogenized material is transported to outgoing conveyor. Harrow carriage has cross conveyors on it and cross conveyors have horrows on it. Horrows move horizontally by horrow carriage. The horrows cut the stack horizontally and material falls down and from the stacker chain material gets collected. The scrapper chain moves ahead and material comes on conveyor belt and further goes to additive silos. Thus, reclaimer has an important role for homogenization of material. And it helps to achieve good quality of final product.

16

GUJRAT SIDDHI CEMENT LIMITED

4 RAW MILL
#################################################### 4.1

INTRODUCTION:

Lime stone, clay, Iron ore fed into mill. The chemical composition of raw materials is controlled by computer calculations based on analyses of raw materials, as well as actual amount of compositions of meal in the homogenizing silo. During transport to mill inlet, magnetic objects are removed by a magnetic separator, which is mounted over belt conveyor. Metal detectors are also built in as further protection. If a metal is detected, a pneumatically operated gate is activated for discharge of a portion of materials containing metal piece. Another metal detector is placed near box feeder, where belt stops for manual removal if a metal is detected. The box feeder at mill inlet operates as a buffer and as an air sluice to reduce false air intake. After box feeder, raw material drops on rotary grinding table. Here, they are thrown under rollers by rotary movement of table, and ground. The grinding table is driven by mill main motor. The material might contains some moisture upto 4%. This is dried by hot kiln exit gases supplied through nozzle ring surrounding grinding table. The reflected material from mill is returned to mill inlet. The ground and dried materials i.e., raw meal are carried by air flow to
17

GUJRAT SIDDHI CEMENT LIMITED

dynamic separator. Here, coarse particles are returned to grinding table while finer particles pass for separator in dedusting cyclones. There are a number of oil pumps for Lubrication and cooling of gr unit and bearing of grinding table. Grinding pressure between three rollers and grinding table. A constant and correct lubrication of bearing in three rollers. There are nozzles installed in front of rollers and on grinding table, for use when temperature or grinding process makes it necessary. Here, in raw mill hot gas blow is taken from kiln string. It helps material to dry and thus to less moisture content. Yet moisture content remains 0.5%, which is necessary for easy operation. The mill is automatically stopped when very strong vibrations occur. The air flow to mill is supplied by fan. A gas recirculation duct with damper is also installed to ensure sufficient constant air flow. The air from mill fan is drawn through ESP. The raw meal produced is carried by fluxosides and elevators to C.F. silo for storage. The dust precipitated in ESP and transported to C.F. silo. The most important feature of raw mill is that instead of balls, it has rollers. There are three rollers of 50 tons each around centre shaft. The production of a ball mill cant exceed more than 150 tons, where as the kiln needs 450 tons of raw meal. The production of raw mill is 500 tons/hours.

18

GUJRAT SIDDHI CEMENT LIMITED

CONTROLLED FLOW SILO :

FLS have developed a new, continuously operated silo for blending and storage of cement raw mix, called C.F. silo. It extracts material simultaneously at different rates from a number of outlets in silo bottom. The C.F. silo bottom is divided into seven identical hexagonal sectors. Each of these sectors is divided into six triangular sub sectors. Thus, the bottom consists of a total of 42 sub sectors. These sub sectors represent 42 individual areas from which are provided with aerating units. These 42 separate sub sectors represent 42 individual areas from which material can be extracted accurately to a predetermined program. In actual operation, homogenization is performed by using three of seven discharge outlets simultaneously, each blower aerating only one sub sector at a time. The raw meal flow stream from extraction points of part silos is then blended in a tank placed after silo.

19

GUJRAT SIDDHI CEMENT LIMITED

5 PRE-HEATER
####################################################

5.1 PREHEATER AND CALCINER:

A decisive factor in heat economy of cement dry production process was development of preheater. With this, it was possible to obtain very low exit gas temperature of about 250oC which were not attainable before.

ADVANTAGES OF PREHEATER:
The kiln dimensions can be considerably reduced. The calciner can be supplied with combustion air from clinker cooler at a temperature of approximately 900oC. Since control devices are located in gas stream behind preheater. The process control allows for a suitable margin of safety against overheating, even at a calciner stage of 90-95%. The high degree of calcinations and regular feeding of kiln ensure stable kiln operation without kiln upset conditions. The characteristic feature of calciner is through blending of raw mix and fuel prior to introduction of combustion air and subsequent initiating of combustion process. The combustion air is drawn from clinker cooler at a temperature of about 900oC. The air flows from inlet to outlet of calciner, with only a low pressure drop. The heat generated in calciner is utilized partly to raise raw mixture temperature to calcining level and to implement actual calcining process. The preheater here has a double string-kiln string

20

GUJRAT SIDDHI CEMENT LIMITED

and calciner string 6-stage preheater with low pressure type cyclones. Kiln string: 3x6 m + 3x6.3 m cyclone. Calcining string: 1x2x5.4 m + 1x7.5 m + 2x7.8 m + 2x8 m By using separate strings for kiln and calciner important operational advantage of independent and accurate draught control is obtained. The raw meal feed is extracted from the C.F. silo into feed bin. The feed control is based on schenck impact weigher concept. The feed bin is placed on load cells. After the feeding system, raw meal is transported to the preheater inlet by means of elevators and air slides. At preheater inlet, feed is split into two preheater strings in such a way that outlet temperatures are equalized. The preheater is operating as a counter current heat exchanger with raw meal passing downwards by gravity and air going upwards by the INDUCED DRAUGHT (ID) fans. After fifth stage of the calciner string and sixth stage of kiln string, combined raw meal enters calciner vessel. Here, about 55% of fuel is fired. The combustion for the calciner is hot atmosphere air drawn from coolax cooler through a separate tertiary air duct mixed with combustion has from kiln. The calciner is designed for a gas retention time of more than 3 seconds. In calciner, raw meal will be calcined to about 90-95%.
21

GUJRAT SIDDHI CEMENT LIMITED

The material from calciner is routed onwards to four cyclone stage of calciner string from where it slides into kiln. Part of gases leaving top stage of preheater cyclones is taken to raw mill for drying and transporting raw material before it is taken to bag house.

5.2

BAG HOUSE:

Reversible air bag house has an important role to deal with environmental pollution problems. As the whole pre heater system works on the negative draft system by ID Fans, the air goes upward direction. These gases contains material or particle form material and if they are directly send or vented out on the air, then pollution problems will occur and even lot of material loss will be there in the manufacturing process, so it is very necessary to do something with this. The system consists of a sixteen compartments bag houses with associated safety device. Support structures By using separate strings for kiln and calciner important operational advantage of independent and accurate draught control is obtained. The raw meal feed is extracted from the C.F. silo into feed bin. The feed control is based on schenck impact weigher concept. The feed bin is placed on load cells.
22

GUJRAT SIDDHI CEMENT LIMITED

After the feeding system, raw meal is transported to the preheater inlet by means of elevators and air slides. At preheater inlet, feed is split into two preheater strings in such a way that outlet temperatures are equalized. The pre heater is operating as a counter current heat exchanger with raw meal passing downwards by gravity and air going upwards by the INDUCED DRAUGHT (ID) fans. After fifth stage of the calciner string and sixth stage of kiln string, combined raw meal enters calciner vessel. Here, about 55% of fuel is fired. The combustion for the calciner is hot atmosphere air drawn from coolax cooler through a separate tertiary air duct mixed with combustion has from kiln. The calciner is designed for a gas retention time of more than 3 seconds. In calciner, raw meal will be calcined to about 90-95%. The material from calciner is routed onwards to sixth cyclone stage of calciner string from where it slides into kiln. Part of gases leaving top stage of preheater cyclones is taken to raw mill for drying and transporting raw material before it is taken to bag house. These gases contains material or particle form material and if they are directly send or vented out on the air, then pollution problems will occur and even lot of material loss will be there in the manufacturing process, so it is very necessary to do something with this. Reversible air bag house has an important role to deal with environmental pollution problems. As the whole preheater system
23

GUJRAT SIDDHI CEMENT LIMITED

works on the negative draft system by ID Fans, the air goes upward direction.

24

GUJRAT SIDDHI CEMENT LIMITED

6 KILN
#################################################### 6

.1 INTRODUCTION:

The kiln is 75 m long and it have 4.75 m diameter. The kiln is supported on three types of 2 rollers each. It rotates at a speed of 3 to 4 rpm. The burning zone temperature in kiln is around 14001500oC. Pulverized coal is used as fuel in kiln and calciner. The fuel supply rate to kiln installation is determined on basis of an evaluation of clinker quality and current status of kiln. The exit gas analysis is done for evaluation of combustion process. The smoke gases must not contain any unburnt substances i.e., C or Co. They may cause fire and also waste latent heat of unburnt part of gases. A certain surplus air is supplied during the combustion process, because of inadequate air is supplied, smoke may contain unburnt gases. There are alarm limits set up to monitor CO and O2 levels in exist gases. If due to any reason there is a blockage in cyclones, kiln is shut down. The lubrication between supporting rollers and kiln type must be provided by means of dry graphite lubrication. Providing an oil bath can prove fatal as kiln is almost floating in air. Usually refractory lining of kiln is replaced if the thickness of bricks is reduces to half of its original size due to wear. Hence, kiln shell must not be overheated. If kiln shell temperature rises above
25

GUJRAT SIDDHI CEMENT LIMITED

400-500oC, affected area must be cooled by means of fans. There are 14 fans for this purpose. In event of a further rise in temperature kiln must be shut down for a repair of lining. A radiation pyrometer (scanner) has been installed for purpose of checking condition of kiln lining during operation. If there are any hot spots observed, kiln motor is run at lowest speed until temperature of hot spot has been reduced. In burning zone, the temperature reaches upto 1400oC and clinkerization occurs.

BURNING PROCESS IN KILN:

For burning purpose firing is done in kiln. The firing is done through nozzle, coal is fired, reaching temperature of flame upto 1800oC and maintaining temperature in kiln upto 1400-1500oC of material. KILN SPEED: Slowing kiln will heat kiln up through out its length. It will also increase draft, which will tend to reduce rate of heating in burning zone and increase temperature at feed end. Speeding kiln up will have opposite effect. When a kiln is slowed down for longer period of time, increase in draft should be controlled by regulating damper, to avoid overheating of feed end, fuel rate is decreased.

26

GUJRAT SIDDHI CEMENT LIMITED

The kiln should be controlled by change in fuel rate, as sight increase in fuel which is not enough to overheat burning zone will, if left on long enough, heat up feed end and correct slowly dropping back end temperature.

CHEMICAL PROCEDURE:
During burning and decarbonation of carbonates of Mg and Ca and removal constitutional water, there are schematically three consecutive stage of clinker mineral formation. During burning of first stage upto 990oC all aluminium oxide reacts with lime, generating monocalcium alluminate silica also starts to combine with lime generating dicalcium silicate. At this phase of clinker compounds dicalcium silicate concentration is low. At second stage of formation, when the material is heated to a range from 1190oC to 1400oC, monocalcium alluminate formed during first stage is further saturated with lime reacts with iron oxide creating dicalcium alluminoferrit which is also called browmmillerite. Formation of dicalcium silicate which started first stage is now being completed. At third stage, material reaches temperature above 1285oC, at this stage of clinker formation, known exothermal effect occurs, which produces generally 120-150 kcal/kg clinker. The rapid heating of material by this effect causes clinker to behave in this kiln section similar to fluidized material, thus increasing the transport velocity of material which can disturb the regular kiln operation. The partially fused condition of material permits one part of dicalcium silicate to be saturated with remainder of the

27

GUJRAT SIDDHI CEMENT LIMITED

uncombined lime, and thus be converted to tricalcium silicate. The formation of clinker is completed with third stage.

28

GUJRAT SIDDHI CEMENT LIMITED

7 COOLER
####################################################

7.1 COOLER:
The cooler receives approximately 145oC. Hot clinker from rotary kiln, cooling clinker down to a temperature which is approximately 80oC at a production of 6500 t/day. Some of thermal energy contained in clinker is simultaneously recuperated. The thermal energy is transmitted to cooling air which is subsequently utilized in kiln and calciner. Grate-1 is designed as CFG system while grate 2 and 3 are designed as RFT system. From kiln outlet, clinker drops down onto the inclined grate plates, latter being alternately stationary and moveable.

CONTROLLED FLOW GRATE:

The airstreams to first grates is very powerful so that clinker is well distributed across the entire width of the grates. This will prevent clinker from being backed together at very high temperature. The air flow is adjusted so that clinker is kept bubbling on surface of layer. Hence, heat recuperation will be optimized. A controlled flow means that air is fed to grates, individually controlled to smaller units of grate. This is accomplished by means
29

GUJRAT SIDDHI CEMENT LIMITED

of ducts, with damper of adjusting flow and hence air pressure, to single zones. All cooling air is forced upward through narrow gaps in grates to clinker bed. High air velocity will prevent dust and small clinker particles from dropping into gaps of grate while cooler is operating. As mentioned, air ducts are connected to supporting beams which are also configured as air ducts.

REDUCED FALL ZONE:

In RFT zone, the clinker is cooled further down to the desired temperature. In RFT zone, entire airflow is injected under grates, penetrating up into clinker bed at gap between grates and via openings at bottom of hollow girders. A pressure loss, corresponding to one-third of pressure in the components, is allowed for in design of RFT grates and the hollow girders so as to ensure favorable distribution of air. The grates carry clinker down to outlet where clinker is pushed onto and outlet grate, where clinker less than 25 mm, drops through grate and down into clinker conveying system, whereas remaining others are pushed off grates and they pass under hammers of crusher and down to clinker conveying system.

7.2

CLINKER STORAGE:

The reason for storing clinker is, because kiln operation does not always run simultaneously with finish mill operation. Also, in
30

GUJRAT SIDDHI CEMENT LIMITED

many cases, high temperature of clinker leaving cooler does not allow direct grinding, because hot clinker causes high grinding temperatures, which impair not only mill operation but also cement quality so, far cooling and as a production buffer clinker is stored in various storage facilities. The storage time of a good quality clinker, stored in protected facilities does not influence grinding process nor the quality of cement. Even clinker stored for many years in dead space of clinker holes did not show a drop in quality. Here, for purpose of clinker storage, they have a clinker yard erected with aluminium sheets and a clinker silo of R.C.C. The bottom diameter of silo is 80mts and capacity is 400,000 tons. From the clinker yard, it is taken to cement mill with help of trucks, whereas from silo, it is taken via conveyor belt, clinker is also stored in open space. Size of clinker is 2 to 25mm.

31

GUJRAT SIDDHI CEMENT LIMITED

32

GUJRAT SIDDHI CEMENT LIMITED

8 CMENT MILL
####################################################

8.1 INTRODUCTION:
Cement clinker and 2-5% raw gypsum is ground together to form cement. The purpose of grinding mills: Creation of larger reactive surface, so that clinker minerals can react with water. Controlling of setting properties of cement by adding gypsum. At L&T, there are four cement mills of capacity 133 t/hr. It consists of two chambers divided by double wall. This wall allows particles of 4 mm size to pass through. About 27 % of volume consists of grinding media. The first chambers has high chrome ball of 60 to 90 mm diameter whereas second chamber has 15-20 mm diameter high chrome balls In first chamber grinding takes place due to impact and in second due to attrition. The product is taken to air separator where coarse particle are recirculated to mill. The mill converts majority of energy input into heat. Gypsum is dehydrated at 130oC at high temperature. Gypsum loses its property as cement setting retarded and becomes false set cement. Hence temperature inside mill is 70-80oC. For this water is injected into hottest part of mill where it evaporates instantly. Water is carried into mill by compressed air through a simple nozzle which breaks up water into very small drops; from where material goes to air separator.

33

GUJRAT SIDDHI CEMENT LIMITED

8.2

ELECTOSTATIC PREICIPITATOR:

In plate type electric precipitator, only electrical precipitation is employed. This ESP is used after and Cement Mill. In addition to precipitation by action of the electrical dust collection also precipitation of a certain quantity of dust particle by action of gravity as well as direction and by impact. During the elimination of every supply, the electrical precipitator works as the dust settling chamber with collection of 30 to 70 %. The size and velocity with which the dust is attracted by the collecting electrodes is of importance for the collection efficiency. High resistivity and is difficult to remove from the collecting electrodes and often it may cause a detrimental operating condition known as return throw of sparks or as back ionization. ESP is less efficient than bag house, as it fails to work at high temperature.

34

GUJRAT SIDDHI CEMENT LIMITED

9 PACKING PLANT
####################################################

9.1

INTRODUCTION:

A rotary packing machine is used here having 6 filling spouts. This machine completes 2.5 rotates per minute. Hence filling 30 bags/minutes or 1800 kg/hour. The spouts are mounted at the bottom of cylindrical container. The manual work comprises of placing the empty bags on the spouts as they pass it. Fluidized cement flows into the rotating container. At the bottom of the container. Certain amount of fluidized air is added to the cement to increasing flowability through the filling spouts into the bags. Each spout has its own weighing device. By the time the spout finished one rotation 50 kg of cement is filled into the bag. It is dropped off on the conveyor belt. All the extra cement falls in the hopper from where it is transported to the cement silo. In case of transportation by ship, they are carried to the jetty they are slide down and loaded in to the trucks standing underneath.

35

GUJRAT SIDDHI CEMENT LIMITED

36

GUJRAT SIDDHI CEMENT LIMITED

10

INTRUMENTATION USED IN

CMENT MANUFACTURING PROCESS

####################################################

1) Lime Stone Crusher and stacker :

As the control material is required to feed the crusher. Apron feeder is used and the speed of apron feeder is controlled by VFD (Variable Frequency Drive) and discharge of the crushed material flow to the belt is measured by belt wave. The material is taken to the lime stone stacker through number of belts proximity type speed monitors are provided in each belt. There are three micro logic 1000 mini PLCs has been used for controlling the stacker for making the limestone pile.

2) Limestone Reclaimer & raw mill grindings :

Limestone stacker is used to reclaim the material for pile for feeding to raw mill for fine grinding. Reclaiming speed is controlled by 2 dc motor which is controlled by thyristor control panel and skewing of Reclaimer is controlled by varying the correction speed by field weakening system of dc motor and required reclaimed material can be controlled by varying the speed of these dc motors which can be vary from 0-3m/hr. for cutting the material the hydraulic harrow having to & fro motion is
37

GUJRAT SIDDHI CEMENT LIMITED

there which is controlled by hydraulic system and the cylinder having four meter stroke length for string and on the moment the proximity switches are used harrow speed can also be varied with the hydraulic proportional valve which is controlled system. There are three mini PLCs used for logic control for lime stone reclaiming and as there two harrow are used, one each side which is controlled by min PLCs. There is online redundant PLCs are supervised in case operational PLCs fails. The materials are cuts by harrow slides down which is dragged by chain drive. It leaves discharging material on the belt proximity type speed monitoring is provided for monitoring the speed of bucket chain drive. The chain drive discharge the materials on the belt & to the third. Finally the material discharges into raw mill box feeder hopper. All the three belts which is carrying the material from reclaimer to raw mill to raw mill hopper and provided by proximity type speed motors. The function of these motors is to stop the system in case the belt jamming and belt is getting shared of to avoid further damages of the system. Box feeder hopper is having capacity of 70 tones which is weigher by three load cells having the capacity of 47 tones each and they are 120 degree apart in the periphery of the hopper. In order to have equal load distribution on all three load cells. As shielding cables is connected across three load cells. To protect three load cells shielding cable is connected by across each load
cell against the welding current. Care is also taken during welding jobs on such places by giving earthen point directly to the place where welding is done. The required quantity of the material on volumetric basis is fed to the vertical raw mill by controlling the box feeder speed. Box feeder speed is

38

GUJRAT SIDDHI CEMENT LIMITED

controlled by 11 kw VFD. The grinding capacity of vertical raw3 mill is 325 tones/hr. As the raw mill is vertical beam. Raw mill consists of a gear box, a grinding rollers and 2000kw dry motor(ac induction motor). Motor: motor rating is 2000 kw induction sleeping motor. 6.65 Kv H.T motor which is during the grinding table through gearbox. Gear box: Gear box is very heavy duty gear box hence sufficient lubrication is required. In case of failure of this oil lubrication system the gear and bearing can get damage hence bearing temperature are measured by pt100rtd which trips the system. If oil flow to the gear box becomes less than the desired value. Grinding table: Grinding table is rotating on six static show bearings and these bearings oil supplied by two high hydraulic pressure pumps in

order to maintain the continuous oil film between static show bearing and grinding table go down surface in order to avoid metal to metal contact to ensure the required pressure and flow to these static show bearing six thermal type oil. Oil flow transmitter and six pressure switches. On oil flow monitor and one pressure switch for each vein. This system ensures the continuous oil flow and pressure to the static show bearing in case of abnormality in the oil flow and pressure & the system trips in order to protect the static show bearing. The oil show discharged temperature is also monitored in order to maintain the required viscosity. There are three grinding rollers placed 120 degree apart connected by yolk at the centre and outer end of each roller is connected to hydraulic

39

GUJRAT SIDDHI CEMENT LIMITED

cylinders. The complete hydraulic system is provided to control the moment of the roller against grinding table. Pumping starts up in the roller which is in varied condition. The materials before rollers are brought down. Sufficient quantity of material is fed which is judged by differential pressure across the mill. For grinding the material the rollers are brought down to the table and as the table are rotating rollers are also free to rotate so whatever comes in between roller and the table gets crushed down. The crushed material flies up also with the hot gases connected to the inlet and going inside the mill at the periphery of grinding mill through mill. The crushed material is lifted along with hot gases which possess through static separator where the converse material is separated out and travel further and coarse material comes down for further grinding. The outlet temperature is measured by pt100rtd.

3)C.F silo
As consistent quality of material is required for stable operation C.F silo is used for homogizing the material in the top layers are getting discharged from 7 extraction points. As quantity of materials from 10-20% this discharging phenomenon converts its different quality of horizontal layers into vertical layers hence we are getting different quality of layers into vertical layers from
40

GUJRAT SIDDHI CEMENT LIMITED

different extraction points. These extracted material goes to wave bin where again it is getting mixed with the help of compressed air supplied from the bottom of wave bin. Therefore we are getting consistent quality from the bin. OPRATION: For the homogenizing the C.F silo there are 7 air slides connected to each discharged points getting air in sequence which is programming. Controlled by PLC there are 7 pneumatic gates at the discharge point which are also operated in sequence and are being controlled by PLC for level measurement of C.F silo on eco type radar has been put. There is one more pedal type level switch which is provided for monitoring high level of C.F silo.

4) KILN FEEDING SYSTAEM :

There are 2 outlets at the bin from where controlled desired material flow is fed to kiln pre heater one for P.C stream and one for P.H stream to sank impact flow meter are used for the system. The capacity of P.C feeder is 130 tones/hr where as the capacity of P.C feeder is 240 tones/hr. Dozing valves are provided as final element to control the flow.. Before the dozing valve to pneumatic gates are provided for total material

41

GUJRAT SIDDHI CEMENT LIMITED

cut off the material discharge from these feeders fed to the P.C & P.H stream by conveying through air slides and elevators at the discharge of the elevator there is one y-shoot diverter which can feed the material towards the C.F silo back to the system when it is in operation or to the system hence the total material from P.H & P.C feeder is carried by elevator there is one splitter gate is provided by which the material again splits to P.H & P.C streams in the same ratio from deferens. t feeder

4) PRE HEATING SYSTEM :

In the P.H stream ,flame is second the gases light from cooler through the kiln and P.H & P.C duct cyclones. The material flow is from top to bottom and hot gases flow in the P.H system is from bottom to top hence the heat exchange takes place and the material is separated out from the cyclone and goes to the P.C stream & P.C stream goes to P.C where again the burn coal fixed to maintain the temperature around 900 degree Celsius. The total material from P.C goes to the Cyclone of P.C stream and to the kiln inlet during this process 80-90% of calcinations takes place before it reaches to the kiln and if material comes into. The extreme temperature of 1400degree Celsius is maintained for burning process. So after the burning process in the kiln the material from powder to nodules. Finally it drops to the cooler. There are number of instruments used in the process. Each stage material temperature ad gas temperature are measured with the k-type thermocouple
42

GUJRAT SIDDHI CEMENT LIMITED

down to the transmitter. From here mV generated by the transmitter is converter to 420 million. After each transmitter repovided to PLC analog input cords. Each stage is also provided ,2 pressure points ,2 draft points, One at the cyclone outlet number order to know stable flow of material if any restriction forms into the coating formation into the system can be deducted by pressure defense at outlet of each strings. CO & O2 analyzers have been provided know the proper combustion of the gases in the P.C for getting the sample from the stream to gas analyzers probes are provided to have the continuous sampling to the analyzer and cleaning panel, O2 analyzer is based on the principle of infrared observation. The entire kiln rotated from 0-4.5rpm with the help of 670kw D.C motor which is being controlled by thyristor based 6 pulse D.C drive. The kiln is driven by the mechanism of gear box, pinion and pair of this continuous lubrication girth system where it is controlled by mini PLC mounted in the local plc mounted in the local panel there is one kiln thruster driven by hydraulic power system to control the float of kiln. In normal operation the float of kiln is controlled + - 5mm in abnormal condition if float of kiln is rises to + - 10mm as alert alarm is generated to system and when it is reached to + - 15mm system is given the rippling command to the kiln to know the float of the kiln. Assembly is provided which is attached to one of the leveling of the kiln through roller. Emergency limit switch is also provided to quit the kiln operation in switch assembly there are 3 supporting
43

GUJRAT SIDDHI CEMENT LIMITED

roller is moving through bearing which has the controller oil lubrication temperature of each bearing is also measured with pt 100rtds Abnormal rising temperature rising on any of its roller bearing trip the kiln operation for safety of the roller bearing there is one kiln same scanner is provided which scans the entire kiln 8 times a second. Hence the temperature of each point of its kiln surface, each recorded or stored into the computer. For the system coating thickness as the condition of kiln linings is monitored on continuous basis. Kiln lining migration is measured on continuous basis with the help of proximity switch at each lining which gives 1 pulse in the complete rotation is continuous indication. In case of hot zone forms just below the lining which can not be deducted by kiln. Shell temperature scanner red spot forms just below the lining which cannot be deducted by kiln shell temperature scanner which will result very local k lining migration which can damage or crack the kiln lining if in condition continuous for longer period.

5) GRATE COOLER :

The entire cooler is divided into three moving grates. Each grete is having the number of fix end moving plates which can
44

GUJRAT SIDDHI CEMENT LIMITED

stand very high perforated temperature around 12-1400 degree Celsius. The moving plates are moving over the fixed plates in to&fro motion. This pattern of moving advances the material from one plate to another plate and so on. First grate is driven by 30kw D.C drive and second and third are drive by 37kw D.C motor. The speed of these gretes are controlled by thyristor variable speed control panal. The bottom of the grete is divided in number of compartments. These are total 16 compartments. Each compartment is connected with high prssure fan. The hot material then drops to static the first grete where the quenching takes place. Then it slides of the first plate, then it advances to the second plate and third. This clinker is getting cool high pressure fan through perforated grate plates which cools the clinker and the heat exchange takes place during this cooling process and heat again used by the system as secondary to the kiln and tertiary to the P.C stream. At the discharge of the third drive there is one hammer crasher is provided to break the big lumps of clinker and discharge to the bucket conveyor and to the kiln storage silo which is having storage capacity of 40000 tones. Each compartment under the grete cooler is having fine material collecting hoppers. The material discharge of this hopper is being controlled by level switches in order to maintain minimum level in the hopper to have air ceiling. One drag chain is also provided which collects the material discharge from the collecting hopper and put it to the bucket

45

GUJRAT SIDDHI CEMENT LIMITED

conveyor. The speed of gratecooler is controlled by under grate pressure in order to have proper bed of material over the grate. In order to have proper distribution of cooling air to grates. Each fan flow is controlled by damper and VFD. The excess air to the cooler is a part of hot gas from cooler is taken to the vertical coal mill for raw cool grinding.Excess air to the cooler is taken out through cooler ESP. This is done by maintaining killer hood draught at the desired level by controlling cooler vent fan. Speed which is controlled by thyristor control panel to know or to monitor the burning zone temperature on continuous basis pyrometer is used. Condition inside the kiln and the momentum of kiln by CCTV camera burning flame is also being monitored. The secondary air to kiln temperature and the tertiary air to P.C vessel temperature is also measured and the third drive water spray. Steam is also provided which controls the excess air exit temperature and that clinker temperature at the discharge of the cooling.

6) CEMENT GRINDING AND PACKING :

There are two ball mill type cement mill. Each mill is having three hoppers. One for clinker, second for gypsum and third for fly ash. Feeding of cement mill is controlled by belt wave feeder and for PPC grinding with clinker 2-5% gypsums fed with clinker . The quantity of gypsum is maintained in order to have setting time of cement. For manufacture PPC 20-

46

GUJRAT SIDDHI CEMENT LIMITED

30% fly ash is also added. There are two chambers in the cement mill. In first chamber mix of 80mm, 60mm,70mm manganese balls are used as grinding media for coarse of grinding and in the second chamber 10-15mm diameter slippers are grinding media or finer grinding. Flow of air through mill is created by cement mill ESP fan. Cement mill discharges the material for the cement in the screw conveyor carrid through belt conveyor through lift. From the air lift is carried to the cement silos. Cement temprature in the mill is controlled by internal water spray in the cement mill. Jamming of cement mill is controlled by phosphate which detects the jamming by sound level which is created by grinding process. For both the cement mill tuning bearing temprature measurement is provided. In case abnormal high temprature of tuning bearing it trips the system continuous oil lubrication for cement mill tuning bearing is also provided and to ensure continuous sufficient oil flow to the bearing being monitored with the help of capacitance type proximity switches which ensure the oil level on oil flow tray over the bearing the mill is driven by 3600kw ac induction motor through symmetric gear box and the rotation of cement mill is around 22rp.in the gear box oil lubrication is also ensured by oil switches. Bearing temperature of oil box is also measured on continuous basis. There is continuous vibration monitors at the input shaft of symmetric gear box. The grinded cement by cement mill stored in four silos having capacity of 5000tonnes. Each and every fine cement goes to the air collected in ESP is also fed
47

GUJRAT SIDDHI CEMENT LIMITED

back to belt and to the cement silos. For packing there are five fourteen spouts mechanical type of packing machines are there. These machines are packing the cement in 50kg bags which are loaded on the trucks through the belt conveyor. The speed of packer (rotary packer) is controlled by D.C drive.,

48

GUJRAT SIDDHI CEMENT LIMITED

11 BLOCK DIAGRAM OF PLANT INTERLOCK

##################################### ######

49

GUJRAT SIDDHI CEMENT LIMITED

Crusher. 2. BC 4A, BC 4B. 3. Stacker. 4. Reclaimer. 5. BC 8. 6. Raw mill. 7. ESP. 8. Drag chain. 9. Air Slider. 10. PC & PH. 11. Kiln. 12. Air slider. 13. LO 2 & LO 5 (Coal Silos). 14. Coal mill. 15. Cooler. 16. Clinker Silo. 17. Clinker storage yard. 18. Cement mill 1. 19. Cement mill 2. 20. LO-1& Lo-2(Cement Silos). 21. LO-3& LO-4(Cement Silos). 22. Packing plant. 23. Gypsum feeding. 24. Fly ash feeding. 25. Bucket elevator.
1.

50

GUJRAT SIDDHI CEMENT LIMITED

DESCRIPTIONSame color indicates same group of interlocking. If any One unit in the same group will shut of, Then all the unit from The same group will be shut of .

GRUPS 1. Crusher, BC 4A, BC 4B, Stacker 2. Reclaimer, BC 5, BC 8, Raw mill, ESP, Raw mill hydraulic plant. 3. PC, PH, Cooler, Bucket elevator. 4. Coal mill, Air slider. 5. Cement mill-1. 6. Cement mill-2 7. Packing plant.

51

GUJRAT SIDDHI CEMENT LIMITED

52