INTERNSHIP REPORT AT RAJASHREE CEMENT WORKS,

MALKHED, KALABURAGI, KARNATAKA.

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INTERNSHIP REPORT ON PROCESSES INVOLVED IN

MANUFACTURING OF CEMENT AT RAJASHREE
CEMENT WORKS LIMITED ,MALKHED,
KALABURAGI, KARNATAKA.

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Chapter 1
INTRODUCTION
1.1 COMPANY PROFILE

Ultratech Cement Limited is the largest manufacturer of cement in India and ranks among the
world’s leading cement makers. Ultratech’s vision is to be ‘The Leader’ in Building
Solutions. The company has a consolidated capacity of 116.8 million tonnes per annum
(MTPA) of grey cement. Ultratech has a strong presence in international markets such as
UAE, Sri Lanka and Bahrain. Ultratech is a founding member of the Global Cement &
Concrete Association.
Ultratech has 22 integrated manufacturing units, 23 grinding units, one Clinkerisation unit
and 7 Bulk Packaging Terminals. In the white cement segment, Ultratech goes to market
under the brand name of Birla White. It has one White Cement unit and one Wall Care putty
unit, with a current capacity of 1.5 MTPA. Ultratech has over 130 ready mix concrete (RMC)
plants in 50 cities across India. Ultratech has a network of over one lakh channel partners
across the country and has a market reach of more than 80% across India.

1.1.1 Business

Ultratech is India’s largest manufacturer of grey cement, white cement and ready mix
concrete (RMC). It also has a slew of speciality concretes that meet specific needs of
discerning customers.

Ultratech Building Products business is an innovation hub that offers an array of scientifically
engineered products to cater to new-age constructions. Aerated autoclaved concrete (AAC)
blocks are economical, light-weight blocks ideal for high-rise buildings, while dry mix
products include waterproofing, grouting and plastering solutions designed for faster
completion of projects.

The retail format of Ultratech Building Solutions offers a wide range of construction products
to the end customers under one roof. Ultratech pioneered the Ultratech Building Solutions
(UBS) concept to provide individual home builders with a one-stop-shop solution for
building their homes. Today, UBS is the largest single brand retail chain with over 2500
stores across India.

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1. Aditya Cement Works Table 1.1.

Table 1.2.
2. Andhra pradesh Cement Works
3. Awarpur Cement Works
Grinding Units
4. Bagha Cement Works
1. Aligarh Cement Works
5. Baikunth Cement Works
2. Arakkonam Cement Works
6. Balaji Cement Works
3. Bagheri Cement Works
7. Bela Cement Works
4. Bara Cement Works
8. Dhar Cement Works
5. Bhatinda Cement Works
9. Dalla Cement Works
6. Dadri Cement Works
10. Gujarat Cement Works
7. Dankuni Cement Works
11. Hirmi Cement Works
8. Ginigera Cement Works
12. Jafrabad Cement Works
9. Hotgi Cement Works
13. Kotputli Cement Works
10. Jhajjar Cement Works
14. Maihar Cement Works
11. Jharsuguda Cement Works
15. Manikgarh Cement Works
12. Magdalla Cement Works
16. Nathdwara Cement Works
13. Nagpur Cement Works
17. Rajashree Cement Works
14. Neem ki thana Cement Works
18. Rawan Cement Works
15. Panipat Cement Works
19. Reddy Palayam Cement Works
16. Pataliputra Cement Works
20. Sewagram Cement Works
17. Ratnagiri Cement Works
21. Sidhi Cement Works
18. Roorkee Cement Works
22. Vikram Cement Works
19. Sikandrabad Cement Works
20. Sonar Bangla Cement Works
Table 1.1 and 1.2: Integrated and Grinding 21. Tanda Cement Works
Units of Adithya Birla ultratech Respectively. 22. Wanakbori Cement Works
23. West Bengal Cement Works

1.1.2 Products

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Ultratech provides a range of products that cater to the needs of various aspects of
construction, ranging from foundation to finish, fewer than five business verticals:
 Grey Cement
 White Cement
 Concrete
 Ultratech Building Solution
 Building Products

1.1.3 Sustainability

As the largest cement manufacturer in India, Ultratech Cement continually strives to play a
key role in finding effective and responsible ways to preserve the environment. As a
company, Ultratech is committed to its focus areas of climate change, health and safety,
energy conservation, water conservation, biodiversity and natural resource substitution.
Ultratech is the first company in India and the second company in Asia to issue dollar-based
sustainability linked bonds.
Ultratech Cement is fully aligned to the United Nations Sustainable Development Goals
(SDGs). It has been certified as 3.9 times 'water positive'. Ultratech Cement has a power
generation capacity of 125 MW through waste heat recovery systems which is expected to
reach 302 MW by FY2024. More than 80% of its power consumption is met through captive
power plants.

1.1.4 Corporate Social Responsibility

Ultratech believes in the Group’s CSR vision “To actively contribute to the social and
economic development of the communities in which we operate. In doing so build a better,
sustainable way of life for the weaker sections of society, to contribute effectively towards
inclusive growth and raise the country’s human development index”. It is carrying this legacy
forward by taking concrete steps to co-create value for business and the society. The focus
areas being healthcare, education, sustainable livelihood, infrastructure and social reform.
As part of its CSR, Ultratech reaches out to more than 2.1 million beneficiaries in over 500
villages across India covering areas of education, healthcare, sustainable livelihoods,
community infrastructure and social causes. The company has identified 100 villages to be
transformed into model villages.

1.1.5 Brands
 Birla White
 Ultratech

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1.2 ABOUT THE GROUP

A US $41 billion (Rs. 2,50,000 crore) corporation, the Aditya Birla Group is in the League of
Fortune 500. Anchored by extraordinary work force of over 120,000 employees, belonging to
42 nationalities. Over 50 per cent of its revenues flow from its overseas operations spanning
36 countries.

The Aditya Birla Group has been ranked fourth in the world and first in Asia Pacific in the
Top Companies for Leaders’ study 2011, conducted by Aon Hewitt, Fortune Magazine and
RBL (a strategic HR and leadership Advisory firm). The Group has topped the Nielsen’s
Corporate Image Monitor 2014-15 and emerged as the Number one corporate, the ‘Best in
Class’, for the third consecutive year.

1.2.1 Globally, the Aditya Birla Group is:

 A metals powerhouse, among the world’s most cost-efficient aluminium and copper
producers. Hindalco-Novelis is the largest aluminium rolling company. It is one of the
three biggest producers of primary aluminium in Asia, with the largest single location.
 Copper smelter No.1 in viscose staple .
 No.1 in carbon .
 The fourth-largest producer of insulators.
 The fifth-largest producer of acrylic fibre.
 Among the top 5 cement producers globally.
 Among the best energy-efficient fertiliser plants.
 The largest Indian MNC with manufacturing operations in the USA, wherein 95
percent Of the workforce comprises of Americans.
 1st in aluminium rolling.
 1st in viscose staple fibre.
 1st in carbon black.
 3rd in cement (excluding China).
 3rd largest producer of insulators.

1.2.2 Birla Group Profile:

 A global conglomerate Founded in 1857: Seth Shiv Narayan Birla commences cotton
trading operations at Pilani, Rajasthan, sets foundation of the Birla Group of
Companies
 Is in the League of Fortune 500
 An extraordinary force of over 140,000 employees, belonging to 100 nationalities
 Over 50 per cent of its revenues flow from its overseas operations spanning 36
countries

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 Named the AON best employer in India for 2018 - the third time over the last 7 years
 The Group topped the Nielsen's Corporate Image Monitor 2014-15 and emerged as
the
 'No.1 Corporate', the 'Best in Class', for the third consecutive year

1.2.3 Beyond business:

 Reaches out annually to 9 million people through the Aditya Birla Centre for
Community Initiatives and Rural .
 Works in 7,000 villages globally.
 Runs 56 schools which provide quality education to 46,500 children. Of these 18,000
students belong to the underprivileged segment.
 Merit scholarships are given to 24,000 children from the interiors.
 Its 20 hospitals tend to more than a million villagers.
 Ongoing education, healthcare and sustainable livelihood projects in Philippines,
Thailand, Indonesia, Egypt, Korea and Brazil lift thousands of people out of poverty.
 Providing mid-day meals to 74,000 children through Akshaya Patra.

1.3 HISTORY OF CEMENT

Discovery Of Cement:

The origin of hydraulic cements goes back to ancient Greece and Rome. The materials used
were lime and a volcanic ash that slowly reacted with it in the presence of water to form a
hard mass. This formed the cementing material of the Roman mortars and concretes of more
than 2,000 years ago and of subsequent construction work in western Europe. Volcanic ash
mined near what is now the city of Pozzuoli, Italy, was particularly rich in essential
aluminosilicate minerals, giving rise to the classic pozzolana cement of the Roman era. To
this day the term pozzolana, or pozzolan, refers either to the cement itself or to any finely
divided aluminosilicate that reacts with lime in water to form cement. (The
term cement, meanwhile, derives from the Latin word caementum, which meant stone
chippings such as were used in Roman mortar—not the binding material itself.)

Portland cement is a successor to a hydraulic lime that was first developed by John Smeaton
in 1756 when he was called in to erect the Eddystone Lighthouse off the coast of Plymouth,
Devon, England. The next development, taking place about 1800 in England and France, was
a material obtained by burning nodules of clayey limestone. Soon afterward in the United
States, a similar material was obtained by burning a naturally occurring substance called
“cement rock.” These materials belong to a class known as natural cement, allied to portland
cement but more lightly burned and not of controlled composition.

The invention of portland cement usually is attributed to Joseph Aspdin of Leeds, Yorkshire,
England, who in 1824 took out a patent for a material that was produced from a synthetic
mixture of limestone and clay. He called the product “portland cement” because of a fancied
resemblance of the material, when set, to portland stone, a limestone used for building in
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England. Aspdin’s product may well have been too lightly burned to be a true portland
cement, and the real prototype was perhaps that produced by Isaac Charles Johnson in
southeastern England about 1850. The manufacture of portland cement rapidly spread to
other European countries and North America. During the 20th century, cement manufacture
spread worldwide. By 2019 China and India had become the world leaders in cement
production, followed by Vietnam, the United States, and Egypt.

1.3.1 HISTORY OF CEMENT IN INDIA

India entered into the Cement Era in 1914, when the Indian Cement Company Ltd. Started
manufacturing Cement in Porbundar in Gujarat.

However, even before that a small cement factory was established in Madras in 1904 by a
company named South India Industrial Ltd.

Indian Cement Company Ltd produced only one type of cement which was designed by the
British standard committee as “Artificial Portland Cement”. This company marketed its
product in Mumbai, Karachi, Madras and other parts and became a financial success.

At that time India had to import cement from England. The price of the imported cement was
higher. Some other factors such as increase in domestic demand, reduction in supply from
abroad (due to war), availability of Indian Capital, ample raw material, Cheap labour, support
of the government etc. Made it a leading industry in India in a short period of time.

In January 1915, a cement unit was started at Katni in Madhya Pradesh

In December 1916, another unit at Lakheri in Rajasthan was started.
During the First World War period, cement production in these three important factories was
taken under control of the government and later the control was lifted once the war was over.
After the war, 6 more units were launched in India.

In 1924, India’s cement production was 267000 tons. However, initially this increased
production could not reduce the imports and the industry suffered a rate war. This led to
closure of many indigenous units. The Indian companies which were away from ports or
commercial centres faced the locational disadvantage.

The above incidents led to the industry stakeholder approach to the government for some
kind of protection. The British government constituted a Tariff board , which recommended
protection of the indigenous industry against the dumping of the imported cement. It
recommended raising of the customs duty to 41% which was around 15% at that time, but
this recommendation was not accepted by the government.

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1.3.2 Key Other Landmarks in History of Cement:

 1925, first association of the cement manufacturers was formed as “Cement

Manufacturers Association“.
 It was followed by “Concrete Association of India” in 1927.
 In 1930 “Cement Marketing Company of India” was started and this was followed by
a quota system on the basis of installed capacity of the factories.
 In 1936, all the cement companies except one i.e. Sone valley Portland Cement
Company agreed and formed Associated Cement Companies Ltd. (ACC).This was the
most important even in the history of cement industry in India. Many more companies
were established in the following years.
 Before partition India had 24 factories, out of which India retained 19 factories, which
annual production of 2.1 million tons. Pakistan faced a problem at the supply side as it
had problem of disposal of the cement produced and India faced a problem in demand
side as production fell to 2.1 million tons from 2.7 million tons.
 After Independence, the partition of the country had a bad impact on the cement
industry.

Cement Expansion Scheme:

In 1948, the government adopted the Cement Expansion Scheme which envisaged new

factories to increase the production. New factories were established at Bagalkot, Jaipur,
Orissa, Travancore etc. In 1950-51, there were 22 operating units with an installed capacity
of 3.3 million tons. Cement industry was given a great importance in all the initial five year
plans. The target of the first five year plan was to raise the installed capacity to 5.4 million
tons which was achieved. The industry has grown to manifold since then.

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SI. NO. State Number of Annual Production

Plants (Million tonnes/annum)
1. Madhya Pradesh 18 19.60
2. Andhra Pradesh 20 11.22
3. Rajasthan 13 09.32
4. Gujarat 12 06.32
5. Karnataka 12 05.57
6. Tamilnadu 08 04.99
7. Maharashtra 05 04.81
8. Bihar 07 0.438
9. Uttar Pradesh 06 03.08
10. Himachal Pradesh 03 02.02
11. Orissa 03 02.06
12. West Bengal 02 00.87
13. Haryana 02 00.57
14. Kerala 01 00.42
15. Assam 01 00.20
16. Meghalaya 01 00.20
17. Jammu and Kashmir 01 00.20

Table 1.3: NUMBER OF STATES WITH CEMENT FACTORIES IN INDIA.

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Table 1.4: NUMBER OF CEMENT FACTORIES IN KARNATAKA

SI.NO. Place Brand Name Annual

Production
(million
tonnes/annum)
1. Wadi ACC 5.2
2. Malkhed Ultratech 4.3
3. Ammasandra Diamond(MCL 5.75.
4. Sedam Vasudatta 4.1
5. Bagalkot JK 3.0
6. Bagalkot Konaria 1.1
7. Ballari ACC 1.1
8. Badravati VISL 0.3
9. Thondebhavi ACC 1.60
10. Shahbad HMP 0.48
11. Belgaum Keshav 0.4
12. Hubli Penna 0.35

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1.4 TYPES AND PHASES OF CEMENT

1.4.1 Different types of cement

 Ordinary Portland Cement.

 Rapid Hardening Cement (or) High Early Strength cement.
 Extra rapid hardening cement.
 Sulphate Resisting Cement.
 Quick Setting Cement.
 Low Heat Cement.
 Portland Pozzolana Cement.
 Portland Slag Cement.
 High Alumina Cement.
 Entraining Cement.
 Supersulphated Cement.
 Masonry Cement.
 Expansive Cement.
 Colored
Cement.
CCN Actual formula Name Mineral phase
 White Cement.
Etc
C3S 3 CaO · SiO2 Tricalcium silicate Alite

C2S 2 CaO · SiO2 Dicalcium silicate Belite 1.4.2 Different

Phases Of Cement
Aluminate or
C3A 3 CaO · Al2O3 Tricalcium aluminate
Celite

4 CaO · Al2O3 · Tetracalcium alumino

C4AF Ferrite
Fe2O3 ferrite

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Table 1.5 : Important phases of cement.

1.5 ABOUT THE PLANT

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Figure 1.1: Rajashree Cement Works limited Gate way Malkhed, Gulbarga,
Karnataka.

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MCC constructed the first 1,500 TPD plant of Rajashree Cement, Plants were also constructed
for Cement Corporation of India at Kurkunta in Gulbarga District as well as Phase-II of Mysore
Cements Limited at Ammasandra, Karnataka.

Rajashree Cement in Malkhed Road, Gulbarga is known to satisfactorily cater to the demands of its
customer base. The business came into existence in 2013 and has, since then, been a known name in
its field. It stands located at Adityanagar, Malkhed Road-585292. The business strives to make for a
positive experience through its offerings.

Customer centricity is at the core of Rajashree Cement in Malkhed Road, Gulbarga and it is this
belief that has led the business to build long-term relationships. Ensuring a positive customer
experience, making available goods and/or services that are of top-notch quality is given prime
importance. It is one of the players in Precast Concrete, Gray Cement, OPC Cement, Slag Cement,
White Cement to name a few.

India’s leading B2B market place, Jd Mart ensures engaging in business activities is a seamless
process for small and medium enterprises as well as large businesses. In a wake to enable these
businesses to reach their audience, this portal lets them showcase their offerings in terms of the
products and/or services through a digital catalogue. This business has a wide range of product
offerings and the product/catalogue list includes Grey Cement, Portland Slag Cement, Porous
Concrete, Ordinary Portland Cement(OPC), Waterproofing Coat etc. Kindly scroll up for the address
and contact details of Rajashree Cement in Gulbarga

Rajashree Cement Works (RCW) is one of the largest cement manufacturing units in Karnataka with
a Clinker production capacity of 12300 tonne per day (TPD) Rajshree currently comprises three
manufacturing lines. Line I was commissioned in 1984 with a capacity of 1500 TPD. As the industry
witnessed an increase in demand, Line 11 was commissioned in 1990 with a capacity of 2700 TPD
Line Ill was commissioned in 1995 with a capacity of 3500 TPD. Subsequently all three lines were
upgraded for increasing its capacity to Unit-1-3150 TPD, Unit-11-4150 TPD and Unit-III-5200 TPD.
In line with the business vision of expanding production capacities for future demand drivers,
Rajashree Cement Works commissioned and started its commercial production on 12th March 2014
and commissioned TPP-4 on 22nd March 2014. The proposal to start the brown Geld expansion
project came up in March 2010, to achieve the Business Vision of 120 MTPA cement production by
2020.

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Apart From All One Thing I Liked In this Plant is They Gave First Prefence to the Safety and
Heading of the every Board in the Plant Written in Regional language(Kannada) Which helps
Visitors and local Workers.

Figure 1.2: Inside view of Rajashree cement works limited.

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Chapter 2

ABOUT THE INTERNSHIP

The internship training programme was carried out at Rajashree Cements Works, Malkhed,
Karnataka. The study on major processes cement manufacturing process was done in process
department during this programme. The Rajashree Cements has a total of 4 Units namely, RC-1, RC-
2, RC-3 and RC-4 in that 3 units are at same place and RC-4 is away from remaining 3units. The
focus of this training programme was mainly on major processes Raw mill, Clinker processing and
Cement processing. Our Internship Co-ordinator Mr. Umesh paniwal was the Guide at of RC-3 unit,
and he provided us a work schedule for the internship between dd/mm/yyyy dd/mm/yyyy, as follows.

Week Work On/Study On

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Table 2.1: Work Schedule

Chapter 3
PROCESSES IN CEMENT MANUFACTURING
3.1 GENERAL PROCEDURE
Lime stone
(lime stone is mined by blasting)

Crusher
(big lumps of lime stone is crushed to 40-50mm size)

Raw Mill
(In a ball mill mixture of lime stone(87-92%) , Bauxite and Laterite/Hematite are powered and stored
in Raw Mill Silo.)

Pre-heater
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(6 Stage Pre-heater 450-900°C)

Rotary Kiln
(1200-1300°C Clinkers produced are have temperature about 1000-1200 °C)

Clinker Cooler
(Clinkers from the Kiln are cooled to 100°C and those Clinkers are stored in Clinker stock pile)

Cement Mill
( Clinkers From the stock pile are mixed with Gypsum Before Ball Mill)

Packing and Dispatch

Figure 3.1: Flow Diagram of Processes Involved in Cement Manufacturing.

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Figure 3.2: Schematic Diagram of Cement Manufacturing process

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3.2 RAW MATERIALS

The major raw materials used in the manufacture of cement are Calcium, Silicon, Iron and
Aluminum. These minerals are used in different form as per the availability of the minerals.

Ingredients Percentage
Lime (CaO) 62
Silica (SiO2) 22
Alumina (Al2O3) 5
Calcium sulphate (CaSO4) 4
Iron Oxide (Fe2O3) 3
Magnesia (MgO) 2
Sulphur (S) 1
Alcalies 1
Total 100

Table 3.1 : Basic Material Required in Manufacturing of Cement

Raw materials used in RCW are:

1. Lime stone 87-92%.

2. Bauxite 5-6%.
3. Laterite 4-5%.
4. Clay 2-3%.
5. Hematite 4-5% (Inbetween Laterite and Hematite one Material is used it is depend on
stock of the material available)
6. Fly ash 0.4% in OPC, 30-35% in PPC, 20-25% in PPCS.
7. Zypsum 5% During Cement Milling.

3.2.1 Mines
The unique aspect about Rajashree Limestone Mine is the systematic and scientific
development of the limestone deposit. The thickness of the limestone deposit is 57 meters
The deposits near Rajashree are one of the best in India, and sufficient for catering to the
needs of all four production lines in the years to come. The total mining lease area is about
733.82 hectares, out of which about 120 hectares has been excavated so far. There are total 7
benches of minimum height of 10 meters.
The present requirement of limestone is about 40,000 TPD of limestone to cater all the four
lines. The total limestone reserves are estimated at about 700 million tonne, of which only
15% has been excavated so far. The reserves are expected to suffice needs for about 45 years.

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Figure 3.3: Mines of the Rajashree Cement Works Malkhed.

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Figure 3.4: Limestone Benches

3.2.3 BLASTING AND CRUSHING

Limestone is obtained from the mines by blasting, in the form of large boulden Raw material
such as limestone High Grade & Low Grade material dumped into hoppers by dump trucks
and entered into a hammer crusher through an apron feeder, product size of limestone is
-50mm. The raw material Lime stone is transported to the stock pile by Belt conveyor.

 Blasting
The explosive used in blasting is SME-Site Mixed Emersion. The blasting process is
done on weekly basis. It is carried out by drilling holes on the needed bench. The
total depth of drill is 10 meters out of which 6.5 meter is filled with explosive
material and rest 3.5 meters is vacant. Then an electrical cable is used to explode.

 Crushing

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RC has Two crushers i.e., Crusher 3 and 4 with each having capacity of 1200TPH
and Crusher-5 has 1600 TPH.

CRUSHING EQUIPMENT : IMPACT CRUSHER

Table 3.2: Specification of Crusher-3

1. Manufacturer L&T HAZEMAG

2. Type of Impactor Compound Impactor

3. Model APCM 2022

4. Size of feed opening 1770mm × 2270mm

5. Capacity 1200TPH

6. Bulk density of feed material 1.6t/m²

7. Compressive strength 1200kgf/cm²

8. Feed size 0-1400 mm corner to corner with max.Lump

Size 1400×1100×1100
1000 to 1500 mm:1%
450 to 1000mm : 9%
300 to 450mm : 20%
50 to 300mm : 60%
0 to 50 mm : 10%
9. Product size 95% (-)25mm sq.Mesh
Max. 50mm
Typical sieve analysis:
90%(-) 20mm, 95%(-)25mm
10. Rotar Dia. 20000mm

11. Rotar width 2250mm

12. No. Of rotars Two

13. Drive motor Pri. : Slip ring

1100KW, 1000 rpm

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Sec. : Slip ring

1450KW, 1000

Crushing Process:

Dump trucks Hoppers Apron Feeder Wobbler Feeder

Bag Filter Crusher

Fines Limestone
(40-50mm)

Figure 3.4 : Flowchart of Crushing Process

3.3 STACKING AND RECLAIMING

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The stacker and reclaimer is a kind of pre-homogenization equipment, mainly used for
stacking and reclaiming bulk materials, such as limestone, coal, chemicals, etc. It is not only
suitable for the raw material pre-homogenization of large cement plants but also suitable for
the storage or homogenization of bulk materials in the coal mine, power plant, port,
metallurgy, and other industries.

This is the primary step of the whole process. It is one of the most important steps since the
right composition of the required minerals such as calcium percentage, aluminium content is
adjusted and maintained.

1. Limestone: Contains pre-dominantly calcium carbonate (CaCO,) and to use in cement

manufacture. It should have 42-43% lime (CaO) minimum. In cement manufacture it is prime
raw material and its usage would be 90-93%.
2. Clay: It contains more of silica (SiO₂)and its usage should be 2-3% manufacture in cement
3. Bauxite: It contains alumina (Al₂O3) and its usage should be 2-3% in cement manufacture.
4. Laterite: It contains Iron (Fe₂O) and its usage should be 2-3% in cement manufacture.

3.3.1 STACKING
The materials are made into large prism shaped heaps using stackers For additives, the raw
material is obtained from the supplier itself and is stored in yards. The additive is dumped by
dump trucks into grids which is then conveyed to the raw mill section directly through belt
conveyors.

1. General
a. Stacking capacity 1450 MTPH
b. Stock pile dimension 33m(B)*12.4m(H)*126m(L)
c. Stacking method Triangular Chevron
d. Number of layers 290(approx.)
e. Stacking methods Conveyor method
2. Angel of repose 37°
3. Travel speed 22m/min
4. Boom conveyor
a. Belt speed 2.2m/sec
b. Troughing angle of idlers 35 degree
5. Tripper
a. Belt speed 2.0m/sec
b. Troughing angle of idlers 35°
c. Slew speed 20m/min @ boom tip

Table 3.3: Specifications of Stacker-3

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Figure 3.5 : Limestone saturated Pile (Stacker).

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3.3.2 RECLAIMING
These are equipments which have teeth all over its body. The reclaimer move perpendicularly
until it reaches the front face of the heap and it then moves parallel perpendicular
simultaneously, thereby mixing the particles at the top are thrown down and vice versa.

The reclaimer is usually equipped with constant speed motors. The reclaimed material is
carried by belt conveyers driven by constant speed motors and discharged into a feed bin of a
relatively large volume. Reclaiming capacity is higher than the mill requirement and the
reclaimer therefore operates in an ON/Off mode controlled by maximum /minithum level
indicators in the feed bin. On leaving the bin,the material is proportioned and feed to the mill
by weigh feeders.

1. General
a. Capacity 500 tph
b. Lump size 0-15mm
c. Angel of repose 37°
2. Travel drive
a. Rail centres 36m
b. Travel speed(operational) 0.33-3.3m/hr
3. Gear box Bevel helical, ratio 90:1, 3.5rpm
4. Clutch Rotor Type clutch

Table 3.4 : specifications of LS Reclaimer.

3.3.3 CONVEYORS
Three types of conveyers are used in transmitting the material from one place to another
place and they are

1. Belt conveyor
2. Deep pan conveyor
3. Bucket conveyor

1. Belt conveyor : A belt conveyor is rubber or textile structure with belt shape closed ring
with a vulcanized or metallic joint, used for material transportation. The belt conveyors
are capable of transporting materials generally lump size upto 600mm. Belt conveyors are
most used for transport of solid objects and bulk material at a great speed, covering great
distance (up to 30km).

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Table 3.5 : Specifications of Belt Conveyor

Belt size 1400mm
Belt length 656m
Speed of belt 2m/sec
Capacity 1450 tph
No. of carrying idlers 786
No. of return idlers 105

2. Deep pan conveyor : Suitable for handling hot material like clinker in horizontal and
inclined profile upto 45degree. Pans are pressed in high capacity presses using special
dies which imparts high strength and ensures very less spillage of handledmaterial.
Special alloy steel chain links are provided which have high absorption independent
rollers are fixed at regular intervals to the pan.
Table 3.6 : Specifications of Deep pan conveyor
Capacity 350 tph
Ctc distance 113.68 m
Angel of inclination 38°
Conveying speed 0.3m/sec
Bucket capacity 342m³/hr

3. elevator : If material needs to be moved vertically, chances are a bucket elevator is a ideal
solution for the job. In facts, the versatility and configurability Of this equipment make
bucket elevator a common material handling system in a number of different industries.
Table 3.7 : Specifications of Bucket elevator
Location Roller press to seperator
Shaft C/C distance (mm) 37100
Speed (m/sec) 0.71
Bucket size (mm) 1250×745
Chain 175×100/130×20
No. Of buckets 112
Power (KW) 2×110

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3.4 RAW MILL AND COAL MILL

3.4.1 RAW MILL
RC has three raw mills for respective lines. It has ball mill with roller press, V-separator,
Dynamic separator. A raw mill is the equipment used to grind raw materials into "raw mix"
during the manufacture of cement.
The four major components of the Raw Mill are:
1. Weigh feeder and hopper.
2. Roller press
3. Ball Mill
4. V-separator
5. Dynamic separator The raw materials ie, Limestone, Bauxite and Laterite are weighed and feeded
to the belt conveyor with the help of weigh feeder. Then the raw materials are mixed to form the raw
mix.

1. Weigh Feeder and hopper.

A weigh belt feeder enables a continuous, controlled product flow. The bulk material is transported
over a weighing section, placed in the feeder frame. The feed rate is calculated and the speed of the
belt adjusted to maintain a constant feed rate. A hopper is a temporary storage bin, filled from the top
and emptied from the bottom, often funnel-shaped.

Figure 3.6 : Hopper And Weigh Feeder Respectively

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Table 3.8 : Specification of LS Hopper

Grain size 50mm
Bulk density 1.35-1.5 t/m³
Moisture content (max) 8%
Material characteristics Free flowing

Table 3.9 : Specifications of Bauxite Hopper

Grain size 50mm
Bulk density 1.1-1.3 t/m³
Moisture content (max) 8%
Material characteristics Sluggish

Table 3.10 : Specifications of Laterite Hopper

Grain size 50mm
Bulk density 1.4 t/m³
Moisture content ( Max) 8%
Material characteristics Free flowing

Table 3.11 : Specifications of Weigh Feeder

A) Limestone
Max. Feed rate 350 tph
Belt width 1600mm
Pulley 3300mm
Pulley dia. 340mm
Weight/pc 3150kgs
Drive Power KW 3.7, DC
Feed rate change 1:10
B) Bauxite
Max. Feed rate 12 tph
Belt width 800mm
Pulley 3300mm
Pulley dia. 340mm
Weight/pc 2000kgs
Drive Power KW 1.5, DC
Feed rate change 1:10
C) Laterite
Max. Feed rate 10tph
Belt width 800mm
Pulley 3300mm
Pulley dia. 340mm
Weight/pc 2000kgs
Drive Power KW 1.5, DC

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Feed rate change 1:10

2. Roller press
The roller presses are designed for the comminution of medium hard to hard materials in the fines
range. They are used for clinker, ore, quartzite, limestone etc. The machine described is a horizontal
roller pres designed for gravity feeding which means that the rollers are arranged horizontally and
next to each other in the frame with the feed being admitted to the gap by gravity i.e., vertically from
above.
Mode of operation
The feed is vertically admitted to the roller gap by means of the feeding device. The feed is nipped
into the gap as a result of the opposite rotation of the rollers, comminuted, compacted and shaped to
the flakes. Two processes are taking place at the same time:
a) Expelling most of the air contained in the feed.
b) Destroying the feed microstructure.

Figure 3.7 : Roller Press

Table 3.12 : Specifications of Roller Press
1. Max. Feed 750tph
2. Feed particles size ›37mm
3. Max. Feed temperature 30°C
4. Flake thickness 37(approx.)
5. Roller dia. 1400mm
6. Speed 24.54mm
7. Circumferential speed 1-8m/sec
8. Max. Specific pressing force 7.6N/mm²
3. Ball Mill

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A ball mill is a horizontal cylinder partially filled with steel balls (or occasionally other shapes)
that rotates on its axis, imparting a tumbling and cascading action to the balls. Material fed through
the mill is crushed by impact and ground by attrition between the balls.
The smaller grades are occasionally cylindrical (“pebs) rather than spherical There exists a speed of
rotation (the “critical speed”) at which the contents of the mill would simply ride over the roof of the
mill due to centrifugal action

.Figure 3.8 : Ball Mill

Table 3.13 : specifications of Ball mill-(3).

Capacity 300 tph

Absorbed power at shaft 9.87 KWh/T
Tube diameter 4.8m
Grinding path length 9.0m
Tube plate thickness 45mm
Trunion bearing diameter 2000mm
Mill speed 14.6rpm (approx.)
Power requirement 2960KW

4. V-Seperator

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The V-separator is highlighted by two characteristics in particular. The cascade that has
feed material drops downward step by step and separation at transverse flow as well as in
the following upward current by means of a guide vane s/m Principle of functioning: The
feed falls over the cascade due to the gravity. The smaller particles are entrained by the
transverse air flow and directed to the guide vane sim where the finer fraction is
discharged from separator top with the air. The courser particles slide back, fall over the
cascade with the very coarse particle and leave the separator at the bottom. Either fresh
air, circulated air or hot gas is used as Separating air.
Table 3.14 : Specifications of V-Seperator
Feed rate 1000tph
Air quantity 175000 Nm³/hr
Inlet channel 8000×2148×2500 mm
Outlet channel 7500×3250×2000 mm
Housing 8000×2266×2000 mm
Weight 29.5 tonnes

5. Dynamic seperator

In the dynamic separator, the material is fed by air gravity conveyors into a housing
located over a distribution disc which at the same time, serves as the top cover of the
rotor. This central feed arrangement assures even material distribution. The material is
dispersed through ducts. The fineness and particle size distribution of the product are
controlled primarily by varying the rotor rpm as well as continuous control of the
separating air Quantity.

Mode of operation:
The separating air is generated by an externally mounted fan and supplied through 3
fabricated inlet ducts forming a logarithmic spiral. The material is separated in the
separation zone by mass and flow forces into the fine and coarser products. The guide
vanes at the discharge end of the spiral serve to maintain the swirling of the air flow.
Rotor blades prevent he penetration of coarser particles into the interior of the rotor. The
coarser product drops into the collection cone and is re-circulated into the grinding
circuit. The fines along with the separating air flow in the interior of the rotor separator
and are pulled downwards and into the cyclones.
Table 3.15 : Specifications of Dynamic Separator
1. Feed rate 600 tph
2. Air flow 390000
3. Motor speed 375-1500rpm
4. Max. Cage wheel speed 166 rpm
5. Drive
a) Ratio 3.867:7
b) Power 250 KW

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6. Cyclone (4) 3600mm

3.4.2 RAW MILL SILO

After Raw Mill and Roller Pressing Raw Mix is stored in a big container called
Silo (Raw mill silo).
Table 3.16 : Specifications of Raw Mill Silo
Silo Capacity (MT)
Raw Mill Silo 2×5000
2×20000
1×28000

Figure 3.9 : Raw Mill Silo

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3.4.3 COAL MILL

RC has three coal mills for each of the lines. RC-1 has Ball mill for Coal Grinding
Remaining Unit have Vertical Coal Mill. Coal mill consists of coal stacker, coal reclaimer
and coal vertical mill Coal vertical mill is a machine that crushes and grinds the coal
briquette into pulverized coal.

There are various grades of coals. RC uses indigenous coal, imported coal, pet coke.
Among these pet coke has higher CV with low cost.

Table 3.16 : Specifications of Vertical Coal Mill-(3).

1. Type of Mill Loesche-Vertical mill

2. Capacity 40tph
3. Feed Size 90mm(max.)
4. Motor power 600KW
5. Table diameter 2600mm
Figure 3.9 6. Absorbed powder at shaft 15.00KWh/T :

Vertical Coal Mill

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3.5 PYRO-SECTION
Pyro- section is the part of the process where heat treatment is given to the raw mix and
various other raw materials to manufacture clinker. Clinker is the product formed after
cooling the treated product of raw mix fly ash (if any). The clinker is then mixed with
gypsum in cement mills to get cement of various grades and qualities as prescribed by the
Bureau of Indian Standards (BIS).

The Pyro-section consists of:

 Pre-heater (600-800 °C)

 Kiln (1200-1300 °C)
 Cooler (around 100°C)

RC has three pre-heater, kiln and cooler units for each line respectively.

3.5.1 PREHEATER
The function of preheater in a cement manufacturing plant is to preheat the raw mill
temperature of about 750°C before feeding into kiln.

Major components

1. Cyclones.
2. Immersion pipes.
3. Double separator.
4. Gas ducts.
5. Pyro clone calciner.

1. Cyclones:

The cement manufacturing industries uses cyclones for the seperation of raw mill from gas
flow depending on the cyclone arrangement and the design, if the preheater in which
cyclones have been incorporated, the inflow of material may be either from above or from
below. Cyclone consists of top section, bottom section and funnel shaped part. The section in
turn compresses the ceiling, the inlet spiral, the cylindric force and the immersion pipe.
For absorbing thermal expansion, the cyclone ceilings are pre-stressed when mounted. The
bottoms of the inlet spirals are inclined towards the cyclindric portion thus preclouding mill
deposits and/or accumulations.
The bottom sections are of tapered configuration and provided with 2 circular reinforcing
rings which includes 3 supports the funnel shaped part have at their end smaller dia been
provided with flange for connection to the raw mill duct. Because of the high temperature
prevailing at the inside of the cyclones they have been given refractory lining.

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2. Immersion pipes:

Immersion pipes are used in cyclones separator for improving latter’s efficiency. Apart from
that they influence the pressure loss in cycline separator. Immersión pipes are composed of
several segments to from a circular inner pipe For this, the immersion pipes have been
repeatedly divided over their circumference. Immersion pipes are made of alloy materials to
ensure the proper absorption of thermal loads placed on them.

3. Double Separator:

For improving the separating efficiency, the cyclones of the top most preheater stage have
been designed as double separator. The double separators comprised of the ceiling, inlet
spirals, immersion pipes, cyclindric section and bonom part To improve the separating
efficiency the cyclone bottom parts incorporate so-called "starts" as obstructing plants.

4. Gas ducts:

The ducts join the individual cyclones stage to each other. The raw mill line coming from the
next higher stage ends in the gas duct underneath. The raw mill particles are entrained by the
upward flowing gas stream and taken to the cyclone above, which means that the heat
exchange is achieved in concurrent flow. The gas duct between stages 1 and 2 consists of the
cylindroids section, with supports of carrying the preheater platform, the elbow and the
adaptor for collection to the double cyclone. The gas ducts of the remaining prehcater stages
also consist of the same parts but without supports in the cylindric section.

5. Pyroclon-calciner

The pyro clone calciner is the extended gasline between TAD and the cyclones of the
bottommost Pre-heater stage.

Starting from the bottom, the major components are:

 The gas duct, ascending from the TAD.
 The adaptor element.
 The cylindrical gas duct with 180° elbow.
 The 90% elbow with connection to the cyclone inlet spiral

The raw mill discharged from the last cyclone but one is feed into the pyroclon-calciner over
the raw mill line and over the feed chute. Upon entering into the pyroclon-calciner, the raw
mill is entrained by the ascending gas current and taken to the next cyclone. During the
transport heat is transferred from the hot gas on to the raw mill.
The burner of the second firing has been installed at the level of Feed Chute.

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Table 3.19 : Preheater-3 specifications

1. Capacity 350tpd

2. Preheater kiln stirring 4000mm 2cyclones l

a. Stage 1 dia. 6400mm

b. Stage 2 dia. 6400mm

c. Stage 3 dia. 6400mm

d. Stage 4 dia. 6400mm

e. Stage 5 dia. 6400mm

f. Stage 6 dia. 6400mm

3. Pyroclone stirring

a. 1st stage dia. 4400mm 2 cyclones

b. 2nd stage dia. 7000mm

c. 3rd stage dia. 7000mm

d. 4th stage dia. 7000m

e. 5th stage dia. 7000m

f. 6th stage dia. 7000m

4. Pyroclone calciner dia. 3700mm

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Figure 3.10 : 6 Stage Pre-heater unit-3 (RC-3)

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3.5.2 PRE-CALCINER
 The calciner is installed in the kiln line between the kiln inlet and the lowest cyclone
stage at the preheater. It is equipped with inside refractory lining.
 The raw meal is fed in the transition piece; the fuel and the tertiary air are conveyed
together with exhaust gas through the calciner to the cyclone of the lowest stage.
Exhaust gas, tertiary air and raw mill are flowing in co-current flow.
 In the calciner, the raw mill is heated by heat exchange.
 Air-separate" precalciner, in which the hot combustion air for the calciner arrives in a
TA-duct directly from the cooler, bypassing the kiln. Typically, 60-75% of the fuel is
burned in the precalciner. In this system, the feed entering the rotary kiln is about 90
95% calcined. The kiln has only to raise the feed to sintering temperature. In theory
the maximum efficiency would be achieved if all the fuels were burned in the
preheater, but the sintering operation involves partial melting and nebulization to
make clinker.

3.5.3 ROTARY KILN

Kiln is commonly known as heart of cement plant. The function of kiln in a cement plant is to
heat the raw material. In the kiln, the remaining 5% of the un-reacted raw mix reacts together
to form the product. Coal is fired from the opposite end of the kiln, so the process with the
kiln is counter current The kiln reaches a temperature of around 1400 °C. The kiln is 60
meters long with 4.4m dia and is inclined to the horizontal by an angle of 15 deg. The figure
shown below is of kiln.
The kiln has fans around it to cool the surface of the kiln by around 30 °C. This helps in
preventing damage caused to the surface of the kiln (made of alloy steel or mild steel) due to
high temperatures. The product from the kiln is sent into coolers where it is air cooled to
around 100 °C using cooler fans. The cooled product is called Clinker. The clinker is then
transferred to silos using bucket elevators. The cooler is connected to an Electrostatic
precipitator in which fines are recovered and air is vented out from the stack.
Table 3.20 : Specifications of Rotary kiln-(3)
1. Kiln dimensions
a. Diameter 4.4m
b. Length 60m
c. Kiln inclination 3.5%
d. Plate thickness of the tube section 25mm
28mm
35mm
e. Plate thickness of the tyre section 65mm
65mm
65mm
2. Capacity 3500tpd
3. Circumferential speed 0.806m/sec
4. Kiln speed 3.5rpm
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5. Tyre assemblies
a. Tyre material Normalised cast steel GS24MNS
b. Tyres Dia. 5260
4581*775 width
c. Supporting rollers Dia. 1600
285 width

Figure 3.11 : Rotary kiln line-3

Figure 3.12 : Rotary kiln line-2

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Figure 3.13 : Rotary kiln line-1

3.5.4 CLINKER COOLER

RC uses IKN pendulum cooler for each of their respective kilns. IKN cooler is a type of grate
cooler.

 Function of the IKN Pendulum .

The IKN Pendulum Coolers differs from conventional reciprocating grate coolers by the fact
that the movable components of the grate are suspended by a wear-free pendulum. The tasks
of each grate cooler are:

 Heat recovery.
 Cooling of the clinker.
 Transport of the clinker
In the Pendulum grate Cooler, here in after briefly cooler, the clinker is conveyed through
the cooler. By this transport a so called clinker bed is established on the grate surface. The
height of this bed is called clinker bed height. For cooling, the cooling air is induced
through the grate plates into the clinker bed. The cooling air is applied in the cross-flow
principle.
The conditions for efficient cooling of the clinker are:

 A sufficient amount of cooling air ✓ An even surface of the clinker bed

 An uniform flow of cooling air through the clinker bed

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 A sufficient cooling time

 The preservation of the clinker bed as a fixed bed (avoiding a fluidized bed).
To achieve the desired clinker outlet temperature normally more cooling air is used then
the kiln demand (recuperation air). The cooler is therefore divided into two zones, the
recuperation zone and the cooling zone.

Figure 3.15 : schematic diagram of Clinker cooler (IKN cooler).

Figure 3.15 : Overview of an Clinker cooler

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Table 3.21 : Specifications of Clinker cooler

Number of compartments 10
Number of fans 12
Number of rows 90
Grate Area 4200×29828 m

Main components of the IKN Pendulum Cooler

The main components of the IKN Pendulum Cooler are as follow:
 Cooler housing with kiln hood
 LPS-Linear Pendulum Suspension
 KIDS and Pendulum grate area
 Hydraulic power pack for grate movement and heat shield (optional)
 Cooling fans
 Roller Crusher.
 TDE-tube dust extractor
 Heat shield (optional)
 Water spray system
 CGS - Main CGS and local panel (LCB)

Figure 3.16 : Clinker cooler unit-3

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Clinker stock pile : After Clinker cooler Clinker of temperature 100-150°C are stored in stock pile
by bucket chain Elevator.
Table 3.22 : specifications of Clinker stock pile
Silo Capacity (MT)
Clinker 1×15000
1×35000
1×55000
1×150000

Figure 3.16 : Clinker stock pile

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3.6 CEMENT MILL

RC has three cement mills for each of its's respective units.

Clinker and the Gypsum is added to the Sepol separator from their hoppers via a system of
transporting system (Belt conveyors + bucket elevators).

Figure 3.17 : Cement Ball Mill Unit-3

Table 3.23: Specifications of Clinker hopper

Grain size 30mm
Bulk density 1.2-1.4 t/m³
Moisture content (max.) 2%
Material characteristics Free flowing

Table 3.24 : Specifications of Gypsum hopper

Grain size 30mm
Bulk density 1.1-1.3 t/m³
Moisture content 15%
Material characteristics Sluggish
Table 3.25 : Specifications of Weigh Feeder

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1. Clinker
a. Max. feed rate 275 tph
b. Belt width 1600mm
c. Pulley centres 3300mm
d. Pulley dia. 340mm
e. Weight/pc 3150kgs
f. Drive Power KW 3.7, DC
g. Feed rate range 1:10
2. Gypsum
a. Max. Feed rate 15 tph
b. Belt width 800mm
c. Pulley centres 3300mm
d. Pulley dia. 340mm
e. Weight/pc 2000kgs
f. Drive Power KW 1.5, DC
g. Feed rate range 1:10

Table 3.26 : Specifications of Ball Mill slide shoe (Cement mill)

1. Capacity 225 tph
2. Type of mill Ball mill with slide shoe
3. Cylinder dia. 4.6m
4. Cylinder length 14.5m
5. No. Of grinding chamber One
6. Mill speed 151rpm
7. Shaft power 285KW
8. Feed lump size 1800-2200 Blaine

 Polycom
The polycom high pressure grinding roll is used for the comminution of brittle grinding
material of all kinds. Comminution of the material to be ground is effected under extremely
high pressure in the gap between two contra-rotating rolls Having passed through the roll
gap, the feed material is completely fractioned and generally leaves the pair of rolls as a
tightly packed and compacted cake. The bearing blocks of the fixed roll are bolted to the
frame of the high pressure grinding roll. The pressure required for the comminution process
is transmitted via the floating roll to the material to be ground. During operation, this roll
continuously changes its position to adapt itself to the alternating properties of the material.
The necessary grinding forces are generated by a hydraulic s/m and transmitted via. cylinders
to the floating roll unit. Power transmission from the motor to the gear unit is effected
through a cardan shaft with a safety coupling on the gear side.

 Single Compartment Tube mill

 The single compartment tube mill is a ball mill. The material to be ground is passed through
the grinding compartment and is mechanically discharged through a discharge filter
diaphragm. The material to be ground is fed through the inlet device directly into the grinding

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compartment of the single compartment tube mill. The grinding is effected by a special mill
lining and the grinding media. The balls are larger in size at the feed inlet and the size of the
balls gradually decreases towards the outlet. The ball mill helps in reduction of intermediates
(1-2 mm) to fines. The balls are either made of alloy steel or special materials such as
NICHROME (Ni, Cr, mild steel) to resist wear and tear and to provide good size reduction by
impact.

 Dynamic separator

In the dynamic separator, the material is fed by air gravity conveyors into a housing located
over a distribution disc which at the same time, serves as the top cover of the rotor. This
central feed arrangement assures even material distribution. The material is dispersed through
ducts. The fineness and particle size distribution of the product are controlled primarily by
varying the rotor rpm as well as continuous control of the separating air quantity.

Figure 3.18 : Cement Milling Unit

Table 3.27: Specifications of Cement Silo
Cement silo Capacity (MT)
(Multi compartment silo) 1×2000
Unit 2: 6×2500
Unit 3: 6×2500
Unit 4: 2×3×5000

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Figure 3.19 : Cement Mill Silo

3.7 PACKING AND DISPATCH SECTION

3.7.1 PACKING

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RC has packing dispatch sections. packing dispatch section is about line 3.

Packing cement involves modern technology. Cement which transported packing units where
they are filled packed in bags made of HDPE machines. machines designed in such a way that
as soon as cement bags weigh 50 kg (with+ or -0.5 kg), nozzle which cement discharged into
the bags withdrawn and cement bags itself automatically. Packers are precise tolerance +/-
0.5%.

 12-Spout Roto-Packer
The 12-spout roto-packer is rotating valve filling machine packing flowing powdery
granular bulk materials valve bags simultaneous weighing of the material from 10-50kg

Figure 3.20 : Roto Packer

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Table 3.27 : Specifications of Roto-Packer

1. Capacity 3000bags/hr for cement upto
3600 Blaine
2. No.of filling spouts 12
3. Bag weight 50kg
4. Direction of rotation Anti-clockwise
5. Power consumption 30KW(approx.)
6. Control air required 72Nm³/hr with 5 bar

3.7.2 DISPATCH
The cement bags are transported to the dealers via wagons (railway system). After the
printing of date and manufacture number on the cement bags, they are conveyed on belts to
the wagons. The filled wagons are then sent to the dealer or the customer.

Figure 3.21 : Transportation through Trucks

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Figure 3.22 : Transportation through Railway

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3.8 ABOUT UNIT 4

The work on Line IV started on 8th June 2011 and RC-IV engineering being done by a reputed
engineering consultant M/s.BAPL and also the equipment's have been selected from reputed
companies like M/s KHD, M/s.ABB, M/s.Siemens, M/s.Thermax and M/s Tecpro etc. The
total land for RC-IV is about 1000 acres for Plant as well as Railway Siding.

Some of the prominent highlights of the new line include use of robotics, automated sampling
of cement and clinker, ready-to-operate processes to eliminate accidents in commissioning,
process hazard analysis, among others. It has a capacity of 10000TPD and it also has waste
heat recovery system by which power is generated of 50 MW.

RC-IV has implemented the WCM system at the Project phase for first time in Ultratech. This
helps in eliminating the pathogen/ design defects and abnormalities at the erection &
commissioning stage, in turn helping achieve a vertical startup of the plant. While strategizing,
each step has been taken carefully keeping in mind ABG's values and its commitments towards
CSR. The policy firmly sticks to the ethics of climate protection, energy efficiency,
environment, human rights, codes of governance, health and safety, labour practices, social
initiatives, quality of products and processes, relations with customers and suppliers, and
research & innovation. Considering that around 6 mega projects by world's best groups are
currently running in Karnataka at the same time, it is a milestone for Rajashree to be labelled
as the "Best in State" in the construction category.

Figure 3.23 : Unit 4 (RC-4).

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Chapter 4
FILTERS
In Rajashree Cement Works ESP Bag filters are use to control pollution and to collect dust/fine
matter. Unit 3 have three pairs of Bag filters.
Bag filters are Present at three major processes
1. At Raw Mill section
2. At Clinker Cooler section
3. At Cement Mill section
These bag filters are get charged negatively when Power supplied and attract fine . when power
supply stops the fine material is collected from bag filters and reuse it.

Figure 4.1 : ESP Bag filters

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Chapter 5
LEARNINGS AND OUTCOMES
1. Studied about cement manufacturing process.
2. Studied how Different process works starting from Raw material to Cement final product.
3. Studied about testing of cement quality based on different parameters.
4. Studied about the various grade of cements manufacture by Rajashree Cement and Their
usage in different sectors.
5. Learnt about the waste heat recovery system (WHRS) in line IV.
6. Learnt about the idea of using various alternative fuels to overcome the consumption Of coal.

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Chapter 5

CONCLUSION

Cement manufacture involves complex mechanism and highly developed technologies. Starting from
raw material processing to the final stage of cement packing, technology used in Rajashree Cement is
impeccable.
Cement manufacture thus involves procurement of raw materials, crushing of the raw materials to
optimum size, production of raw mix, manufacture of clinker through a complex pyro-section that
involves pre-heater, kiln and cooler, and finally the production of cement using clinker-gypsum and
packing and transportation to customers and dealers.
Cement manufacture is the 2nd largest cement industry, after steel industry being the first. With
rising demands of cement and need for cleaner environment and lower worker health hazards and
risk.
Rajashree Cement takes full concern and care in reducing pollution problems and in lowering health
hazards and simultaneously produce good quality cement for the rising construction demands.
Rajashree Cements has three lines with capacity Unit- 1 3150 TPD, Unit-2 4150 TPD and Unit-3
5200 TPD. The new Unit-4 has 1000 TPD.

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REFERENCES
1. WWW.adithyabirla.com
2. RC Technical reports-CCR-3 Library
3. Annual reports Ultratech Cement Limited.

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