ALL PRAISES TO ALMIGHTY ALLAH

WHOSE UNIQUENESS ONENESS &

WHOLENESS IS UNCHANGEABLE.ALL
RESPECTS ARE FOR HIS LAST PROPHET

HAZRAT MUHAMMAD (PBUH)

WHO ENABLED US TO RECOGNIZE OUR
CREATOR

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Internship
Report

KHAIR PUR PLANT, KALAR KAHAR.

Prepared by
MUHAMMAD WAQAS
Roll# CE-M10-38

DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITY OF PUNJAB LAHORE.

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Table of CONTENTS
Preface
Acknowledgement
Executive Summary
IndustryProfile

04
05
06
07

Introduction .07
Company Overview
Environment...08
Environment Protection
Best quality Procedure....10

Brand

11

Product ....11

Mission Statement

13

Business Process
Flow Process of Production

14
17

Vision Statement..13
Quarry .....17
Lime stone Crusher..17
Bag Filter.....18
Magnetic Separator .....19
Storage yard.....19
Raw mill feed area....20
Raw mill. .21
Cyclone separator .22
Conditioning Tower .....23

Laboratories

24

Chemical Test ...25

Physics Test ....25
Coal yard ........25
Coal Mill ........26
Pre-heater cyclones...27
Kiln .28
Cement mill feed area .....32
Cement mill .....32
Storage Silo....33

Packing Plant
Conclcusion
Reference
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35
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PREFACE
Learning in practical side is somewhat that cannot be compared with books
knowledge. BSc CHEMICAL ENGINEERING program is designed in such a way that
students are required to do the projects and researches then give their recommendation
and conclusion.
It also provides student an opportunity to apply this knowledge in practical field.
Now to fulfill the practical requirement of this course, I successfully completed an
internship report on DGKCC (Pvt). Limited a unit of Nishat Group. It was great
opportunity for me to apply theoretical knowledge and get practical exposure. I have
visited almost all the departments and studied function of each department at factory.
The purpose of the report is to elaborate on my experience about DGKCC (Pvt.)
Limited. I have tried to present the overview of the company and its operations and the
task that are carried out during my stay at DGKCC (Pvt.) Limited. Although four weeks
is a small time to completely understand the processes and philosophy of a company, but
at least one gets a good overview about it, and I have tried to write all that grasped during
this short time, in this report. This report includes DGKCC working way outs,
information about their departments function and working.
I have analyzed their working and have given certain recommendations on the basis
of my observation. I have tried my level best to give real look about DGKCC while
writing this report. May ALLAH succeed me while evaluation of this report

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Acknowledgement
My greatest thanks to ALLAH Almighty who bestowed me with the ability and
potential to complete this Internship. Before I go into depth of the things, I would like to
add a few deepest words and also says thanks for the people who were part of this report
in numerous ways people who gave unending support right from the stage the
internship was assigned. Particularly I also wish to thank the managerial staff at DGKCC
especially SAFDAR KAMAL and his team who helped me to gain a lot of information
regarding the company and cement industry and also who provide me an opportunity
to learn and understand the working of organization as an internee CHEMICAL engineer.
I am also thankful to Dy. General manager who played a role of polar star for me
in the organization and whose experience taught me a lot about the industry and the
organization., CHEMICAL ENGINEERS helped me a lot and solve each and every one of
my problem at every step of my difficulties.
Most of all I am very much thankful to Mr. Safdar Kamal who selected me for
internship and to give me opportunity to improve my industrial skills that will help me in
my future. And finally deepest and warmest appreciation to the whole team of DG Khan
Cement Company.

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EXECUTIVE SUMMARY
Dera Ghazi Khan Cement Company Limited (KhairPur Plant) a unit of NISHAT group is a
strategic business unit of Nishat Group, which is the largest and most growing industrial group in
Pakistan. Apart from its competitors; its product is of good quality. Its plant is situated in P.O.
KhairPur, Tehsil, kallar kahar. Distt. Chakwal, Pakistan and head office is situated at Lahore.
Factory site Unit that is situated in very remote area of Punjab, yet it proved a blessing for the
company. Because it has all three basic raw materials i.e. Lime stone, Shale, and Gypsum at one
place.
The plant is made by F.L.Smidth Denmark.Khairpur plant has capacity of 6700 TPD(Tons
Per Day).Presently the company is also exporting the cement to export. Now a days D.G.Khan
cement (KhairPur) plant is stepping forward to clean the area from garbage, a new plant which is
in process called RDF (Refused Derived Fuel) which will use the garbage and after processing its
process which will be discuss later the garbage will be thrown into KILN which will be used as
fuel this will also decrease the use of coal which is expensive and also helps to clean the city and
economy of company will increase. The Power plant of D.G.KHAN cement (Khairpur) producing
32.3 MV of energy that are fulfilling the requirement of energy for company. D.G.Khan cement
(Khairpur) also have Paper Mill that is producing the cement bags not for DG cement but as well
as for many other companiesThe team of the D.G. Cement is story of success of D.G. Cement.
The whole team is self-motivated and had played a vital role in the success of the company.

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INTRODUCTION
D . G. Khan C ement Comp any L i mited (D GKCC ), a u nit of Nis hat grou p
is the s econd la r gest ceme nt - manu facturi ng u nit in Pakista n with a
production capacit y of 13,400 tons clinker per day. It has a countrywide distribution
network and its products are preferred on projects of national repute both locally and
internationally due to the un-parallel and consistent quality. It is list on all the Stock
Exchanges of Pakistan. D GKCC was es tablished u nde r the m anageme nt control
of State Cement C orporation of Pakis tan Limited (SCCP) in 1978. DGKCC started
its commercial production in April 1986 with 2000 tons per day (TPD) clinker based on
dry process technology. Plant & Machinery was supplied by UBE Industries of Japan.

D.G. Khan Cement Company Limited, (DGKCC) is amongst largest cement manufacturers of
Pakistan with a production capacity of 14,000 tons per day (4.200 million tons/annum). DGKCC
has three cement plants, two plants located at Dera Ghazi Khan and one at Khairpur Distt.
Chakwal. All the plants are based on latest Dry Process Technology.
The Company operates through a countrywide distribution network managed by different Regional
Sales offices. The Company's products are preferred on projects of national repute both locally and
internationally due to the un-parallel and consistent quality. The Company is listed on all the Stock
Exchanges of Pakistan
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Environmental Management
DG Khan Cement Co. Ltd., production processes are environment friendly and comply
with the W orld Ba nk s envi ronm ent al st and ar ds. It h as b ee n c erti fi ed f or Envi ro nmen t
Man a geme nt System ISO 14001 by Quality Assurance Services, Australia. The company was
also certified f or IS O - 9002 (Qu alit y M an a geme nt S yst em) in 19 98. B y ac hievi n g this
landm ar k, DG Kha n Cement became the first and only cement factory in Pakistan certified for
both ISO 9002 & ISO 14001.

Environmental Protection
DGKCC is fully aware of its responsibility for permanent reduction of environmental
impact of its production activities. DG Khan Cement Co. Ltd. is an ISO 9001-2008 and
ISO14001:2004 certified company for its manufacturing, storing, marketing and distribution of
cement. The state-of-the-art technology at both of its plants guarantees that emissions from both
the plants are well below the limits specified in National Environmental Quality Standards
(NEQS).
The company has devoted considerable amount of investment funds on environmentalfriendly projects and has adopted a comprehensive approach toward environmental protection
which is based on the principals of sustainable development. The environmental friendly projects
completed at our plants include:
1: Waste Heat Recovery Plant a Clean Development Mechanism (CDM) Project :
Through this project company has been able to replace 10.4 MW of carbon intensive grid
electricity with zero carbon electricity by utilizing exhaust gases emitted to the atmosphere through
the stacks of clinker cooler and kiln pre-heater of kilns. The emissions are significantly reduced
and herewith it relieves the atmosphere radically.
2. Alternative Fuels Projects:
At both of its cement plants, D G Khan Cement Company has embraced environmentally
acceptable technology for replacing coal fuel with alternative fuels. The technology is acquired
from world renowned Veco-plan of Germany at its cement kilns. The projects involve huge capital
investment. The Alternative Fuels considered for burning at kilns are agricultural wastes, RDF,
rubber tires, and other industrial wastes. The projects will contribute towards the solution of
energy problems that are being faced presently by the country. The project activity shall partially
displace coal with renewable or less carbon intensive fuels and reduce GHG emissions.
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3. Social Responsibility Initiative:

The company has a powerful socio-economic impact in region regions where it
operates. It supplies rural water supply to the people living in the adjoining community areas The
company provides medical treatment under emergency to the populace living in the vicinity of
factory Has launched program to help improve literacy level of adjoining communities Has
supported local govt. funds and other necessary assistance for beautification of D G Khan City by
developing main Chok Churatta which is used as main gate pass for entry and exit of city.
Last but not the least, company pay attention to further improvement of the exterior
and cleanliness of plants, thus creating a better working environment for both our employees and
our business partners and visitors coming to our plants. In adherence to the company policy
wherein environmental protection is given due consideration, the company has been awarded the
Annual Environmental Excellence Award 2011 by National Forum for Environment and Health
Pakistan.

BEST QUALITY PROCEDURE

DGKCC is part of the solution and it has the track record to prove it. A leader in the fight
against p o l l u t i o n , D G K C C h a s b e e n a p i o n e e r i n d e v e l o p i n g i n n o v a t i v e
m e t h o d s f o r r e c y c l i n g . I t s pate nte d c em ent - maki n g p ro c ess - Ce mS ta r signifi c antl y r edu ce s ca rb on diox id e (C O 2) and nitro ge n ox id e ( NOx ) emissi ons i n
the cem ent -m akin g ki ln pr oc ess.

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Tod a y, c em ent p rodu c ers t h r o u g h o u t t h e P A K I S T A N u s e t h a t p r o c e s s

, resulting in a cleaner environment nationally the company constantly seeks news ways to utilize
innovative technologies in its environmental protection program. The commitment made by
D.G.KC.C to the e nv ironm ent is p ar amou nt, the Comp an y s kilns use th e most
adv an ce d ai r pollutio n co ntro l systems ever utilized by a cement plant in PAKISTAN.

Capacity Addition
To me et th e inc r eas in g de mand a nd t o ca pitali z e on its ge o gr ap hic
loc ation, th e ma na ge ment further expanded the capacity by adding another production line
with a capacity of 3,300 tons per d a y i n y e a r 1 9 9 8 . D e s i g n o f t h e n e w p l a n t i s
b a s e d o n l a t e s t d r y p r o c e s s t e c h n o l o g y , e n e r g y e ffi ci en t and e nvi ronm ent al
prot ecti on fr om p a rti cul ate poll ution a cc o rdin g to the int er nati onal sta nd ard s. Th e
plant and ma chi ne r y was sup plie d b y M /s F. L. S mit hs of D enm ark . As a res ult,
DGKCC em e r ge d as the la r gest c ement prod ucti on pl ant in P akist an with ann ual
prod ucti on ca pa cit y of 1 ,650 ,0 00 M ton s of clin ke r (1,7 3 2, 000 M. Tons C em ent )
constit utin g about 1 0 % s h a r e o f t h e t o t a l c e m e n t p r o d u c t i o n c a p a c i t y o f t h e
c o u n t r y . T h e o p t i m i z a t i o n p l a n i s s t i l l unde rw a y to in cr ea se the total c ap a cit y of
the t wo u nits to 67 00 TP D b y mid of 2005 f rom 5 500 TPD at present.
Expansion -Khairpur Project
Fu rth ermo r e, th e Gr oup s et up a n e w cem ent p rod ucti on
line o f 6,7 00 TP D cli nke r ne a r K ala r K a h a r , D i s t t . C h a k w a l , t h e s i n g l e l a r g e s t
p r o d u c t i o n l i n e i n t h e c o u n t r y . F i r s t o f i t s k i n d i n cement industry of Pakistan, the
new plant have two strings of pre-heater towers, the advantage of twin strings lies in the
operational flexibility whereby production may be adjusted according t o m a r k e t c o n d i t i o n s .
T h e p r o j e c t i s e q u i p p e d w i t h t w o v e r t i c a l c e m e n t g r i n d i n g m i l l s . T h e cement
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grinding mills are first vertical Mills in Pakistan. The new plant would not only increase th e
ca pa cit y but would al so pro vide p rox imit y to the unt app ed m ar k et of N ort he rn P unj ab
and NWFP besides making it more convenient to export to Afghanistan from northern borders.

Power Generation
F or conti nuou s a nd sm o oth op er atio ns o f th e pl ant u nint er rupt ed
pow er s uppl y is v er y cru ci al. The com pa n y has it s ow n po we r gen er ation pla nt al on g
with W AP DA s uppl y. The inst all ed generation capacity is 23.84 MW.

Products
ORDINARY PORTLAND CEMENT
Exceptional Strength
To ensure that cement dispatched to customers is with Zero defect
quality and have exceptionally high strength superseding national and international
standards, automatic quality control is done through online X-ray analyzer and computer
controlled systems. Our focus is not only on the quality of cement dispatched but on the
consistency of the high quality cement dispatched. We may further add that the Quality
Control department carries out regular checks and analysis of various raw materials,
intermediate products and final products in order to have additional quality checks. At
DGKCC the chemical composition and grinding fineness are closely monitored to ensure that
both Pakistani and British standards are surpassed and our customers get cement of
exceptional strength.
Ideal Setting Time
In order to allow sufficient time for application, cement must have a quick
initial settings time. However once in place, the final settings should not take too long. At
DGKCC ideal initial and final setting times are maintained.

SULPHATE RESISTANT CEMENT

Low C3A Content
Sulphate salts present in these soil combine with moisture and tri-calcium
aluminate (C3A) , one of the constituents of cement to form a compound known as Sulpho
Aluminate off Hydrated Calcium. This compound is highly expansive and gradually results
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in the destruction of concrete. However, if a C3A content is very low, it is rendered inert and
there is thus no reaction at all. British and Pakistani standards specify that in a Sulphate
Resistant Cement, the C3A content must not exceed 3.5%. D.G Sulphate Resistant Cement
has a much lower C3A content, making the cement highly effective against Sulphate attacks
High Strength
As with any type of cement, strength is the fundamental property of Sulphate
Resistant Cement D.G. Sulphate Resistant Cement achieves high strength through finer
grinding and better particle distribution. In term of strength,, it not only exceeds by far the
standards specified for Sulphate Resistant Cement, but also exceeds those of Ordinary
Portland cement

Low Alkali Content

Certain aggregates contain alkali sensitive ingredients, which under
unfavorable conditions, can result in expansion leading to cracking of concrete. The presence
of alkali also causes staining and other undesirable effects on concrete. American Standards
specify that cement can be termed low-alkali if its alkali content does not exceed 0.6%. D.G.
Sulphate Resistant Cement has alkali content below 0.6 and a unique distinction of being a
Sulphate Resistance Cement that can also be classified as low - alkali cement

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Mission statement
To provide quality products to customers and explore new markets to
promote/expand sales of the Company
through good governance and
foster a sound and dynamic team, so as to achieve optimum prices of
products of the Company for sustainable and equitable growth and
prosperity of the company.

Vision Statement
To transform the Company into a modern and dynamic cement
manufacturing company with qualified professionals and fully
equipped to play a meaningful role on sustainable basis in the
economy of Pakistan.
.

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BUSINESS PROCESS
Cement acts as a binding agent, holding particles of aggregate together form concrete
Cement production is highly energy-intensive process and involves the chemical
combination of calcium carbonate (limestone), silica, alumina and small amounts of other
materials
Burning limestone to make clinker produces cement, and the clinker is blended with
additives and then finely ground to produce different cement types.

BLOCK DIAGRAM
Block diagram of cement manufacturing in DG khan cement is given below the
description of each and every part is given below the diagram

D. G. Khan Cement factory adopt true dry production process for the manufacturing of cement.
This process consists of following steps.

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Step 1:
Quarry is the place from where raw material in extracted. Drilling and blasting is done to
extract the material. A hole of about 10-15 m is drilled and ammonium nitrate in filled as an
explosive in these holes. When this explosive is ignited the rocks are broken into pieces of
different sizes. These pieces are then loaded on the dumper trucks and using conveyor belt to the
crusher. It is located about 3-4 Km from the plant. The motors that are used for moving the
conveyor belt are induction motors of 6 Kw of power
Drilling
Drilling is done in the quarry with the help of drilling machine. They create a space for
the powder explosive
Blasting
The powder explosive is blasted under a controlled process to get different small
segments of limestone. The large segments are also converted into small segments which is called
crushing process.
Transportation
The small fragments are loaded on the 7-Km long 3 belts conveyor system
running over rough terrain. This conveyor takes the new material from quarry to the factory site.
The limestone and shale to stored in the open space.
Extraction of raw material
The raw material are extracted from quarry by digging the holes
through machines in mountains containing limestone and other resources needed to be used in
process than they do blasting.
Step 2 :
Storage and blending of raw materials
After storage, the stored limestone and shale are fed to
the raw mill with the help of two hoppers according to predetermined mixed proportion. The
roughly crushed material passed through 3 rollers. The mixture is dehydrated, sized, and fine
particulars are separated.
The cyclone extracts different gasses, which are emitted in this process. The collected
separated mixture is called raw meal. It is stored in a silo of 15000 ton. During the process water is
also used with the purpose:
To lower the gas volume
To control the variation
To maintain the temperature
Then all these raw materials are to be stored for the further process. Those raw materials are then
crushed and then blend with each other. Th en t hes e ar e t r anspo rt ed t o th e pl ant wh e re the y
ar e st or ed fo rmin g pil es th rou gh m ac hin es a nd hom o ge niz ed .
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Step 3:
Raw grinding and burning
Aft er th at th er e will be gri ndin g in a c a re ful mix tur e whi ch
prod uc es a very fine powder in a 2000 horse power roller mill, so this fine powder is known as
Raw Meal
Next, the fine powder is heated as it passes through the Pre H e a t e r Tower into a lar ge kiln, wh ich is ove r h alf th e l en gth of a footb all fi eld and
4.2 meters in diameter. In the kiln, the powder is heated to 1500 degrees Celsius. And being
suddenly and dramatically cooled by bursts of air. Now this creates a new
p r o d u c t , c a l l e d Clinker. And is just like small black soft stones. It is the basic requirement for
the production of all cements.

Step 4:
Cement grinding and storage.
A sm all amo unt of g yps um (3 -5% ) i s ad ded to t he c link er to
re gulat e how the c em ent will s et. The mixture is then very finely ground in a finishing mill.
The mill is a large revolving cylinder containing 250 tons of steel balls that is driven by 4000 horse
power motor. Then " pure cement " is obtained and is so fine th at it c an pass th rou gh a si ev e
that will h old w at er. Duri n g this ph as e, di ff er ent min e ral m ate r ials, cal l ed " cement
additives", ma y b e ad ded al on gsi de th e g ypsum. Us ed in va r yi n g prop ortio ns, th ese
additi ves , give s the c eme nt spe ci fic p rop er ties su ch as red uc ed perm e abilit y, gr eat e r
resi stan c e to sulfates and aggressive environments, improved workability, or higher-quality
finishes. Finally, the cement is stored in silos before being packing and delivers to the sites.
Step 5:
Packing and delivering.
After being stored in silos there is a last phase of packing that cement and
loading and delivering that very fine cement to the sites where it requires. Th e c em en t
manu fa ctu rin g pro c e ss con sists o f man y simultan eou s an d c ontinuo us op er atio ns
using some of the largest moving machinery in manufacturing. Over 5000
s e n s o r s a n d 5 0 computer s all ow th e e ntir e ope rati on to b e c ontr olled b y a coupl e o f
operators from a central control room. Each t one o f cem ent re quir es a bout 1 .7 ton e o f
limeston e, g yp s um a n d silic a, et c. B y v olu me limestone accounts for about 80% and clay
19% of the intermediate product

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Flow Process of Production

The following raw material is required in the production process

QUARRY
1. Li me s ton e
T his ra w mat er ial i s c ompa n y o wn ed an d is ex tra cte d f rom th e n e a r b y
quarry Unit. Limestone has the highest composition in the cement
product.76% of the cement constitutes of limestone.
2. Cl ay
Clay is another natural resource. This raw material is also company
owned. 24% of cement composition comprises of clay
3. Iron Ore, Bauxites and silica sand
Iron Ore is the only resource
t h a t i s b o u g h t f r o m contr a cto rs. Ir on Or e, Ba ux ites an d si lica s an d a re add ed i n
small q ua ntitie s le ss t hen on e p er c ent and it helps to strengthen the cement.
4. Gyp su m
G yp sum acts as a retarding agen t. It slows d o wn the h ard ening
process which in turn gives the constructor enough time to use it.
Proportions of different Raw Materials
There are basically three main raw materials that are used for the production of cement .In
addition to that, a small proportion of other additives such as silica and Bauxites are also added
.1. Limestone 76%
2. Clay 24%
3. Iron ore (less than 1%)
4. Silica sand (less than 1%)
5. Bauxites (less than 1%)Lime stone and clay are extracted from the same place.
Iron ore is bought from a contractor.

Limestone Crusher (EV 200*300)

Capacity : 1500 tons/hr
Supplier : FL Smidth
Description
R aw mat e ria l suc h as lim esto ne , cl a y, ma rl and sh a le ar e d ump ed i nto
hopp ers b y dump t ru c ks a nd ent er ed i nto a hamm er c rush er th rou gh a n apr on fe ed er .
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In sid e h a m m e r c r u s h e r t h e r e a r e h a m m e r s e a c h h a v i n g a wei ght o f 100 102 k g. Th e y r otat e a t a spe ed of 120 0 - 13 00 rpm an d is ca pabl e of c rushi n g f ee d of
ver y l ar ge sizes.

Bag Filter
The dust produced by crushing process can cause damage to the
e q u i p m e n t a n d m a y p r o d u c e d u s t , t o o v e r c o m e t h i s probl em a ba g
filte r is empl o ye d. A fan blo ws air an d all the d ust goes to th e ba g filt er. In sid e th e
ba g filt er a sp e cial t ype of c anv as clot h i s used . W h en air p ass es through this filter cloth,
the dust particles s t i c k t o t h e c l o t h a n d c l e a n a i r p a s s e s t h r o u g h . T h e
d u s t p a r t i c l e s a r e t h e n col le cte d and s ent to the c onv e yo r. A ft er som etim e
whe n th e filt er is c ho ked with p a r t i c l e s , P u r g i n g s y s t e m i s u s e d i n w h i c h h i g h
p r e s s u r e a i r i s u s e d , t h i s a i r removes all particles from the filter cloth.

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Composition analyzer
A comp ositio n an al yz er is inst all ed up on th e f ee d con ve yo r b elt.
This an al yz e r d e t e c t s t h e c o m p o s i t i o n o f t h e f e e d b e f o r e i t g o e s t o t h e
s t o r a g e p i l e . T h e radio a ctive mat eri al used i d Cli fo rnium . It s h alf li fe i s 2.5
ye a rs an d its pri c e is 84,00000. This element emits rays which pass through the feed and are
deflected back to the analyzer, which then checks the composition. The composition of eacs
material is specific.
Magnetic separator :
A ma gn etic s ep ar ato r is install ed on th e f e ed b elt. It a t t r a c t s
a n d r e m o v e s m e t a l o b j e c t s f r o m t h e f e e d which are collected in the bin.

Storage Yard:
Th e cr us hed m at eri al i s sto re d in th e fo rm o f pil e s in th e st or a ge ya r d.
The re a re 6 pil es in t he sto r a ge ya rd . Mix ed pil es ar e use d in larger quantity where as
high grade and additive piles are used in small quantity.

2 Mixed piles (limestone & clay)

2 High grade (pure limestone)
1 Iron ore (additive)
1 Bauxite (additive)
Stacker :
A s t a c k e r i s a d e v i c e w h i c h f o r m c o n i c a l p i l e s o f t h e crushe d
mate ri al. F ee d is co n ve ye d t o th e sta ck er t hrou gh conveyor belts. This stacker then moves
too an fro to make a pile. The stacker belt is called Jib in engineering terms. N o w , f o r
c o n v e y i n g t h i s m a t e r i a l f r o m p i l e s t o t h e conveyor following equipment
are used :
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1. Side scrapper
2. Reclaimer

Side scrapper :
S i d e s c r a p p e r i s a d e v i c e w h i c h p i c k s t h e c r u s h e d f e e d from the
piles through its feed belt called Hoist. This belt has a number of small buckets of low capacity.
When this belt moves , the bu ck ets pi cks f ee d fr om the p ile an d put it on the belt
conv e yo r. S id e s cr ap per i n us ed f or t hos e piles whic h a r e r equ ired i n low qu antit y
like b aux ite an d i ron ore.

Reclaimer :
Reclaimer is an equipment which is used to throw feed down from the pile. It has tw o
arms cal led H ar ro w s Th es e ha rr ows ar e ins ert ed into th e p ile, wh en th e y mo ve
side wa rd, th e f e ed d r ops do wn th e pile . T his f eed i n the n coll e cte d b y hi gh c ap acit y
buck ets inst all ed in t he bottom o f the re cl aime r. Th es e bu ck ets pick th e f eed and put
it on the be lt con ve yor. It is a la r ge ca p a cit y e quipm ent a nd f or those piles which are
required in high quantity like Mixed Pile

Raw mill Feed area

The raw mill feed area consists of 4 feed hoppers:
1.
2.
3.
4.

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Mixed feed hopper

Pure limestone hopper
Bauxite hopper
Iron ore hopper

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The capacity of first two hoppers is 800 tons while the other two hoppers have a capacity of
600 tons. The feed from each pile is conveyed to the hoppers through conveyor belts in
relevant hoppers. Each hopper has 4 load cells.
Load Cells :
These are sensing devices which tells the load being put on the hopper by the feed.
From these hoppers, the feed in required proportions is transferred by the belt conveyor to the Raw
Mill. A lot of dust is produced during the conveying of material, to avoid this problem Bag Filters
are installed. A Magnetic separator is also installed to remove metal impurities.

Raw Mill
Capacity: 500 tons/hr
Motor power : 4300 kw
Supplier : FL Smidth

Sections Of Raw Mill

There are 3 sections of a raw mill.
1. Table with 3 rollers
2. Bottom scrapper
3. Separator
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Table
The raw feed from the belt conveyor directly falls on the rotating table of the raw mill. The
table contains 3crushing rollers. The raw fed is crushed to fine powder with these rollers. The
coarse particles are collected at the bottom of raw mill and are sent to the vibrator from where they
are sent to the raw feed belt conveyor and again recycled to the ram mill for recrushing. The
vibrator is use to handle the quantity of the material being put on the belt.

Separator
At the top of the raw mill, there is separator section. Hot gases from the kiln comes
from the bottom of the raw mill and lift very fine particles with it. A suction fan with motor power
of 4500 kw produces suction and sends dusty air into the cyclones at the top. Here the dusty air
rotates and particles are separated from the air. These particles are collected at the bottom of the
cyclone and sent to the CF silo with the help of air slides. The air which still contains dust particles
are separated in Conditioning tower and Electrostatic precipitator.

Bottom separator
Some fine particles from raw feed fall on the table, these particles are collected
by means of a bottom scrapper and sent to the CF silo.
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Conditioning tower
The air from the cyclones still contains the dust particles which must be separated before
the air is exhausted to the atmosphere. Air from the separator is passed through conditioning tower.
In conditioning tower, water is sprinkled through very fine nozzles. The particles in the air get wet
and settle down. These particles are then conveyed to the CF silo via screw conveyor.

Electrostatic precipitator
The clean air from the conditioning tower still contains some particles
which have to be removed. These particles are separated from air by passing it through the
Electrostatic precipitator. In Electrostatic precipitator there are 2 corona wires which are mesh like.
These wires are negatively charged. There is a positively charged electrode in the Centre which is
equidistant from both corona wires. Dusty air passes through these corona wires and the particles
get negatively charged. The negatively charged particles in air are then attracted by the positively
charged electrode and the particles stick with it and clean air is exhausted from the chimney.

Cleaning of the electrostatic precipitator:

In order to remove particles from the electrode . A
Wrapping device is used. This device hits the electrode as a hammer and particles fall down
from it. These particles are collected and conveyed to the CF silo via screw conveyor.

REFUSED DERIVED FUEL (RDF)

Refused Derived Fuel (RDF) is the under construction project at DG Cement Plant. I
would like to briefly explain its features, RDF indirectly will clean the city from garbage all the
garbage from nearby cities will bring to RDF and a CRUSHER which using a SQUIRRL CAGE
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(INDUCTION MOTOR) low starting torque producer will cut-off the garbage into small pieces that
will be conveyed by conveyor belts to storage yard and from there it will be cleaned from stones
and metallic materials using same technology as discussed before in cement mills. From
preheaters this garbage will be thrown into KILN for burning purposes. RDF have 6 motors that I
have seen during my stay in DG Cement these all are SQUIRRLCAGE motors that will move the
conveyor belts and each motor have 4300KW of power.

Laboratories
There are different laboratories for the determination of quality and strength of the
cement. Different types of tests are conducted to determine different properties of the product.
Also different types of fuels are tested for their inherent properties: for example:
Fineness of coal
Humidity level of coal
Calorific value of coal
Composition of feed material and product
Settling time of cement
Residual material Following are the different labs available
Sample preparation lab:
In sample preparation lab, different samples of cement are prepared and
tested. Raw material in put in an equipment called Swing mill. A swing mill is a grinding mill.
This grinding mill has a special type of vessel in which material is ground to very fine powder.
Press mill :
The ground material is put into a circular dye and placed into a press mill. The mill
exerts pressure on it and a rigid dye is produced which a metallic circular outer layer The press
mill exerts a pressure of 150 KN on the dye to produce a sample.
X-ray analysis :
Now, the sample dye is put into an x-ray analysis machine to determine its
composition. The sample is place for 2 min in the machine. The x-ray machine is controlled by a
computer software. This software restricts the machine to determine up-to a limit of 6 to 8
elements. After 2 mins , the percentage of each element in a particular sample is shown on the
computer screen. The x-ra machine is very fast in producing accurate results.

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Chemical Testing lab

Chemical testing of a cement sample is done to determined its
composition. It was a slow and time consuming process, but now days x-ray analysis is used due to
its speed and accuracy. In chemical testing lab in spite of x-ray analysis, samples are also tested by
manual experimentation.
For this purpose a distillation unit with a capacity of 25 litrers is used to get distilled water
for experimentation. If normal tap water is used, it may be hard, it can alter the sample
composition and may produce error full results. Two muffle furnaces at 1200 C and 1600 C are
used to determine the residual matter, volatile matter and moisture content.

Physical Testing lab

In physical testing lab, physical tests of different cement samples are done
to check its properties. Following are the equipment available is physical testing lab:
Weigh balance
Turbula mixer
Tensile strength machine
Water bath and curing tank
Compression testing machine
Motor mixer

Coal yard
Coal yard is the area where coal is stored which is used for burning purposes. There are
different piles for the storage of local and imported coal. The coal is imported from South Arica,
and Indonesia. The coal is handled by a loader, the loader picks up the coal and throws on a sieved
net which separates bigger pieces of coal and stones form it, before it goes to the tunnel.
From the tunnels the coal is placed on the belt conveyor which takes it to the coal mill feed area.
Pet coke which is hard is also used in the coal feed.
Coal mill feed area :
After the impurities are removed from the coal, it is chuted on the belt
conveyor .A bag filter is employed which sucks the coal dust and thus prevents the coal from being
wasted. The coal is then shifted to the coal storage hoppers.
Coal storage hoppers :
There are 3 hoppers for the storage of coal. Two hoppers are for the storage
of local coal and the other is for the imported coal. All the three hoppers have a capacity of 250
tons. The coal required in different proportions are chuted on the belt conveyor from the hoppers.
A bag filter is employed to remove coal dust. A magnetic separator is employed to remove metal
impurities. This belt conveys the raw coal to the raw coal mill.
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Coal mill ATOX 25

Specifications of coal mill :
Capacity : 52 ton/hr (coal mix)
26 ton/hr (pet coke)
Supplier : FL Smidth
Motor : 600 KW

Sections of a coal mill :

There are 3 sections of a coal mill similar to the raw mill.
1. Table
2. Rollers
3. Bottom scrappers
The coal on the belt conveyor falls on the table of the mill where rollers grind it to a fine powder.
A blower of very high power pushes very fine particles towards the two fine storage bins. From the
1st storage bin the coal is sent to the kiln for its use in the burner and from 2nd storage bin it is sent
to the precalciner for calcinations.
CF Silo (continuous flow)
The fine particles from the conditioning tower and electrostatic
precipitator and the powdered feed from the raw mill are conveyed to the bucket elevator.

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The bucket elevator picks this feed and take it to the top of the CF silo and then throws it in.
Specifications of a CF silo :
Length = 54 m
Dia = 22.4 m
Capacity = 25,500 tons
Air circulations :
After the feed is stored in the silo bin. Now for the movement of feed in the bin,
air is blown from the bottom through different points in CF silo. These points are located at the
base of the CF silo. Due to air circulations, fine particles are sent to air slides from where they are
transferred to Low bin (Loss of weight bin). The capacity of low bin is 118 tons. The feed from the
low bin is sent to a bucket elevator which lifts it to the preheater.

Pre-heaters:
The bucket elevator puts the material on the top of 2nd cyclone. The hot gases from
the kiln flow with very high velocity in countercurrent direction. The hot gasses lift the particles
from the particles from the top of 2nd cyclone and put it on the top of the 1sr cyclone. From there
the material falls on the top of the 3rd cyclone and sends it into the 2nd cyclone. Then the material
falls on the top of 4th cyclone and hot gases take it into the 3rd cyclone.. then the material falls on
the top of the 5th cyclone and hot gases take it into the 4th cyclone and finally into the 5th cyclone
preheater.
During this complete cycle, the hot gases foe in the countercurrent direction. These cyclones serve
the purpose of preheating the feed material with hot gases of kiln.

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There are total 10 cyclone preheaters . 5 are on the right side of the precalciner and 5 on the left of
the precalciner. The temperature of feed increases as the feed flows downwards the preheaters.

Pre-calciner:
The feed from the 5th cyclone preheater falls into the precalciner which has burner
with a supply of coal and furnace oil. Here the calcinations of feed material takes place due to
burning. Exchange of heat also takes place in the pre-calciner. CO2 is evolved and exhausted in
the atmosphere and the feed is entered into the kiln riser at high temperature. Some of the feed
directly goes to the kiln without going to the pre-calciner through separate pipes.

Kiln :
The preheated feed from the kin and the preheaters enter into the kiln riser. From the kiln
riser the feed enters into the kiln.

Specifications of the rotary kiln :

The rotary kiln has a length of 66 m and dia of 5.5 m. its
inclination is 4 %.Its r otatin g sp e ed va ri es ac co rdin g to th e qua ntit y o f f ee d ent er ed.
Aro und t he inner dia of the kiln there is refractory lining to prevent the shell from damage and to
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cont rol th e e nvi ronm ent t empe r atu re. Out side th e kiln t he r e a re in du ced dr aft fans
which turn on automatically when the shell temperature increase more then a certain limit.
Kiln Motors:
There are two kiln bases on which motors are installed which impart rotary motion to
the kiln.
Kiln burner :
On the other end of the kiln , there is huge burner having a supply of coal, furnace
oil and air. The burner emits a flame which is prolonged with high pressure air. The flame burn the
material and the product is formed.

Zones of a rotary kiln :

There are different zones in the rotary kiln namely :
1. Alex
2. Victor
3. Magkor.
Alex :
In this zone, feed from the precalciner and preheaters enter into the kiln.
Victor :
It is the main reaction zone where the conversion takes place by burning.
Magkor
: In this section clinker formation takes place of the burned material

Alex

victor
magkor
Sections of a rotary kiln
The ash due to the burning of coal also goes with the product which causes LSF(limestone factor)
to reduce from the required limit. Thats why the material which enters the kiln has a higher %age
of limestone because it is balanced with the ash of coal. The hot gases from the kiln are not wasted
but used in different equipment

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Clinker
In this kiln shell following reactions take place.
CaCO3

CaO + O2 (Calcium Oxide)

CaCO + SIO2

CaOSiO2 (Calcium Silicate)

CaOSiO2 + CaO
2 CaOSiO2 (Dicalcium Silicate)
2CaOSiO2 + CaO
3CaOSiO2 (Tricalcium Silicate)
CaO + Al2 O2

CaO Al2 O3
CaO Al2O3 + CaO
2CaO Al O3 + CaO

2 CaO Al2 O3
3 CaO Al2 O3

C4AlF*
(Tetra Calcium Aluminum Fersite)
The kiln shell can be divided into four portions.
Firstly, the incoming raw meal is heated with the help of preheated air which comes from the
cooler at the terminal end of the kiln. Heat is provided by the combustion of the furnace oil. The
raw meal is moved on the sloped shell which have four zones of temperature.
Calcination zone 1200 OC
Transition zone 1250 OC
Sintering zone 1300 OC
Burning zone 1400 - 1500 OC
After the position of burning zone the mixture is cooled down with the help of air fans of graze
cooler. The heated is omitted which reduce the temperature of mixture. This heated air is used to
raise the temperature of raw meal entering into the kiln. The finished product is called clinker,
which is stored in an open yard having capacity of 30000 tons.
3CaOAl2O3 +

CaO + Fe2 O3

Kiln hood:
The hot material form the kiln falls into the kiln hood at the end which has an angular
sieve. When material passes through it attains the shape of clinker. Now this clinker is sent to the
cooler.
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Clinker cooler :
The clinker cooler is used to lower the clinker temperature. There are ID fans
which take fresh air from the atmosphere and send it to the cooler. At the bottom of the cooler
there are reciprocating rails which move with the help of hydraulic motors. These rails convey the
clinker forward to the clinker crusher.
Dust collection :
A suction fan is installed which sucks the product dust from the cooler and send
it to the electrostatic precipitator. In EP dust is removed and clean air is exhausted to the
atmosphere through a chimney. The dust particles are to the deep pan conveyor by a screw
conveyor.

Clinker crusher
When the clinker cools and hardens then it is sent to the clinker crusher installed
after the cooler. Big stones of clinker are crushed to small pieces. The crushed clinker is dropped
on the deep pan conveyor at the bottom of the conveyor which conveys it to the clinker storage.
Clinker storage :
The clinker from the deep pan conveyor is stored in the clinker storage. Its
capacity is 110,000 tons. Its length is60 m and its width is 46 m. There are 3 gates at the bottom of
the clinker storage from where the clinker is sent to cement mill through belt conveyor. Besides the
main clinker storage bin, there is a temporary clinker storage hopper with a capacity of 1400 tons.

If the temporary hopper is also full then the clinker is removed from the hopper and dumped into
clinker storage yard.

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Cement mill feed area

There are 2 cement mills and 6 hoppers (3 for each mill) in the cement mill feed area.
The 1 hopper contains the clinker which is major constituent of the cement. The cement contains
95 % clinker which is conveyed through weigh feeder to the main belt conveyor which takes it to
the cement mill.
st

Gypsum addition :
The crushed gypsum from a separate crusher is conveyed by belt conveyor to
the cement mill. It is mixed in the clinker while crushing. Gypsum is added to about 4 5 %. Its
purpose is to increase the settling time of the cement.
Mixing of additive :
The additive which is pure limestone is also added in the cement mill. Its
added to about 2 %. Its function is to increase strength of cement. A bag filter collects dust from
the main belt and a magnetic separator remove metallic impurities from entering into the cement
mill.
Metal detector ;
To protect the cement mills from damage, a metal detector is installed which
analyzes the feed and if a metal object is found it opens the dividend gate automatically and sends
the feed containing metal objects to the rejected bin, which is again recycled to the main belt and
magnetic separator removes it

Cement Mills
Cement mills specifications OK 36-4
Capacity : 175 ton/hr
Motor power : 3400 kw
Supplier : FL Smidth
Now the clinker enters into Cement Mill. In this mill clinker is ground with gypsum.
Almost 5% of gypsum is added. The main purpose of addition of gypsum is to increase the setting
time. The final product cement is prepared. It is stored in the silo having capacity of 10,000 ton
each.

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The feed which is free from impurities falls on the table of cement mill which
contains three rollers. Each roller has weight of 35 tons and the clearance between table and rollers
is 0.5 mm. These rollers move hydraulically using nitrogen gas as hydraulic fluid. The rollers
crush the feed to a very fine powder. The air slides conveys the ground product to the bucket
elevator which lifts it to enter into the 1st storage silo.

Storage silos
Specifications of storage silos :
Capacity : 21,000 tons
Length : 45 m
Dia : 22.4 m
There are 3 cement storage silos in which crushed cement is stored up-till packing..
To convey the cement to the other 2 silos air slides are used. From these silos the cement enters air
slides by air circulations through blowers. Now these air slides take the cement to the packing
plant.

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Packing Plant
In the packing unit, there are 4 rotary packers and each packer has 8 nozzles. The
whole packing process is automatic. Cement bags are loaded on the trucks and heavy rollers
automatically.

Each cement bag has 50 Kg weight. Sometimes heavy users ask for bulk quantity
of cement without packing. It is loaded into the truck.
The packing plant comprises of 6 packers and 12 terminals. Each packer has a
capacity of 100 tons/hr. The cement bags are attached manually to the rotating packer which fills
the cement bag. When the bag is filled up-to the required weight , it automatically falls on the
conveyor belt which takes the bags to the roller conveyor. From these rollers the bags slide to
different channels and finally cement bags are loaded on the trucks for dispatch.

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CONCLUSION:
Now at the end I would like to conclude my experience in industry. That was my ever
industrial tour and this was such a great experience I gain lot of knowledge about industries that
will be helpful for me in future. Being an engineer I simply got a direction for my future by this
internship. Finally I would like to thanks all staff of DG Cement (Khairpur) plant for such a
kindness, each and every person at factory site help me in every possible way without any kind of
hesitation

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Refrences :

www.dgcement.com
www.sick.com/.../cement/Pages/cement.aspx
www.siamrefractory.com/cement_cyclone.php
www.freepatentsonline.com
www.freepatentsonline.com
www.lwbref.de/en/markets/cement-lime-industry

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