FINAL INTERNSHIP REPORT ON

MAPLE LEAF CEMENT FACTORY

Supervisor

ENGR. TOUSEEF ASGHAR

SENIOR INSTRUCTOR MT

Submitted By

MUHAMMAD IRFAN 2012-UET-KIT-MECH-31

DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING TECHNOLOGY
DR A Q KHAN INSTITUTE OF TECHNOLOGY
MIANWALI

October 2016

I
INTERNSHIP AT MAPLE LEAF CEMENT FACTORY

Supervisor

ENGR. TOUSEEF ASGHAR

SENIOR INSTRUCTOR MT

Submitted By

MUHAMMAD IRFAN 2012-UET-KIT-MECH-31

A Project Report submitted in partial fulfillment of the

requirements for the award of Bachelor’s Degree in
Mechanical Engineering Technology

DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING TECHNOLOGY
DR A Q KHAN INSTITUTE OF TECHNOLOGY
MIANWALI
OCTOBER 2016

II
 Undertaking

I certify that internship report titled “INTERNSHIP AT MAPLE LEAF CEMENT

FACTORY” is my own work. No portion of the work presented in this report has been

submitted in support of another award or qualification either at this institution or

elsewhere. Where material has been used from other sources it has been properly

acknowledged.

MUHAMMAD IRFAN

2012-UET-KIT-MECH-31

2012-UET-KIT-MECH-21

Supervisor: __________________

Chairman: __________________

Principal: ___________________

III
 Acknowledgements

I would like to thanks ENGR ATIF MEHMOOD guiding us in understanding the

concepts of Cement Plant Production. I would also like to thank all our teachers

guiding us in solving our problems related to Plant Technology my project supervisor

Engr. TOUSEEF ASGHAR his cooperation and support to bring this project to

completion and I would like to thanks Mr. Asad Bashir, Shahid Mehmood,

Mumtaz-ul-haq and Hamad Hasan my class fellows and my best friends.

I would also like to thank my family and friends for their continuous encouragement

and moral support.

IV
 Abstract

Maple leaf cement factory is the top ranking cement industry in Pakistan and in the

world. I have completed my internship at maple leaf cement factory in October 2016.

During my stay at maple leaf I learn about the working of the impact hammer

crusher, double roller crusher, stacker, reclaimer, raw mill, control flow silo, pre-

heater, kiln and cooler, cement mill, packing plant, and different type of methods

used for cement transportation from one machine to another.

V
Table of Contents
Chapter 01 ............................................................................................................................... 1
Introduction.............................................................................................................................. 1
1.1 History of cement ............................................................................................................. 1
1.2 The Chemistry of cement ............................................................................................... 1
1.3 Back ground of MPLCF .................................................................................................. 2
1.4 Geographical Importance ............................................................................................... 3
CHAPTER 02 .......................................................................................................................... 4
THEORY RELATED TO INTERNSHIP .............................................................................. 4
2.1 Cement:....................................................................................................................................... 4
Raw Materials: ..............................................................................................................................................4
Fig 2.1Raw material ............................................................................................................... 4
2.2 Production Capacity: ....................................................................................................... 5
Maple leaf has installed capacity of;[9] ................................................................................................ 5
2.3.1 Step 1 - Quarrying..............................................................................................................................5
2.3.2 Step 2 - Raw material preparation ...................................................................................................5
2.3.3 Step 3 - Clinkering .............................................................................................................................6
2.3.4 Step 4 - Cement milling .....................................................................................................................7
2.4 TRANSPORTATION SYSTEM: .................................................................................... 8
2.4.1 .BELTS: ...............................................................................................................................................8
2.5 BUCKET ELEVATOR: .................................................................................................... 9
2.6 AIR SLIDE: ..................................................................................................................... 10
Fig 2.2 Air slide ............................................................................................................... 11
2.7 SCREW CONVEYOR: .................................................................................................. 12
Fig 2.3 screw conveyor ....................................................................................................... 12
2.8 Machinery used: ............................................................................................................ 13
Fig 2.4 production method .................................................................................................. 13
2.10 PRODUCTION PROCEDURE: ................................................................................. 13
2.10.2 Step-II: ............................................................................................................................................. 14
2.10.3 Step-III: ............................................................................................................................................ 14
2.10.4 Step-IV: ........................................................................................................................................... 15
2.10.5 Step-V: ............................................................................................................................................ 15
2.10.7 Step-VII: .......................................................................................................................................... 15
2.10.8 Step-VIII: ......................................................................................................................................... 16
2.10.10 Step-X: .......................................................................................................................................... 16
CHAPTER 03 ........................................................................................................................ 17
STRUCTURE OF INDUSTRY............................................................................................ 17
3.1 C.C.R (COMPUTER CONTROLE ROOM): .............................................................. 17

VI
3.2 CRUSHING AREA: ....................................................................................................... 19
Two type of crushers are used to crush raw material .................................................... 19
3.2.1 ROTOR: ............................................................................................................................................ 19
3.2.2 HAMMER BARS: ............................................................................................................................. 20
Fig 3.1 Hammer crusher ..................................................................................................... 20
3.2.4 Roller Crusher: ................................................................................................................................. 20
3.2 STORAGE AREA: ......................................................................................................... 22
3.4 RAW MILL: ..................................................................................................................... 23
Fig 3.2 parts of raw mill ....................................................................................................... 23
3.5 .C.F (CONTROLE FLOW) SILO ................................................................................. 25
3.6 KILN AND COLLAR: ..................................................................................................... 27
Three types of bricks is used in kiln ....................................................................................... 27
3.8 CEMENT MILL: .............................................................................................................. 28
3.9 PACKING PLANT: ......................................................................................................... 30
3.10 UTILITY AREA:............................................................................................................ 31
3.10.1 AIR: .................................................................................................................................................. 31
Fig 3.3 Single stage compressor ....................................................................................... 32
Fig 3.4 Double stage compressor...................................................................................... 33
3.10.2 WATER: .......................................................................................................................................... 34
Type of pumps are used ..................................................................................................... 34
General Components of Centrifugal Pumps .......................................................................................... 37
Fig 3.5 parts of centrifugal pumps ..................................................................................... 38
CHAPTER 04 ........................................................................................................................ 40
STRUCTURE RELATED TO MECHANICAL .................................................................. 40
TECHNOLOGY..................................................................................................................... 40
4.1 CRUSHER ...................................................................................................................... 40
4.1.1 Impact hammers crusher: ............................................................................................................... 40
4.1.2 Roller crusher: .................................................................................................................................. 41
Lime stone crusher; ............................................................................................................. 45
4.3 STACKER AND RECLAIMER: .................................................................................... 46
4.4 RAW MIL:........................................................................................................................ 47
................................................................................................................................................. 48
Fig 4.1 parts of raw mill ..................................................................................................... 48
Two parts of raw mill require lubrication. .............................................................................. 49
4.5 .PRE HEAATER............................................................................................................. 49
4.6. KILN: ............................................................................................................................... 52
4.6.1 Kiln dimension: ................................................................................................................................. 52

VII
TABLE 4.1 TENSILE STRENGTH OF STEEL ................................................................ 53
4.6.2 KILLEN LINE 1 SPECIFICATION: ................................................................................................ 54
4.6.3 KILLEN LINE 2 SPECIFICATIONS: .............................................................................................. 55
4.6.4 DIFFERENCE B/W KILLEN LINE 1 AND Line 2 ......................................................................... 55
4.8 CLINKER CRUSHER: .................................................................................................. 56
4.9 CEMENT MILL: .............................................................................................................. 56
4.10 BALL MILL: ................................................................................................................... 56
Fig 4.2 Ball mill ..................................................................................................................... 57
4.10.1 CRITERIA FOR MEDIA SELECTION ........................................................................................... 58
4.10.2 BALL MILL SPECIFICATION: ..................................................................................................... 59
Fig 4.3 Vertical Cement mill ............................................................................................. 60
4.11.1 Product quality ............................................................................................................................... 60
4.11.2 Particle Size Distribution ............................................................................................................... 61
4.11.3 Dehydration of the gypsum added to the cement ............................................... 62
4.11.4 Pre hydration of the clinker minerals .......................................................................................... 63
4.11.5 Water injection for temperature c control ................................................................................... 64
4.11.6 Versatility......................................................................................................................................... 64
4.11.7 Upgrading ....................................................................................................................................... 65
4.12 PACKING : ................................................................................................................... 67
Fig 4.4 packing plant............................................................................................................ 67
4.12.3 Open-ended .................................................................................................................................... 69
4.12.4 Modularity and flexibility ................................................................................................................ 69
4.12.5 Main parts of packer: ..................................................................................................................... 69
4.13 EMISSIONS FROM CEMENT FACTORY .............................................................. 72
4.13.1 Dust emissions ............................................................................................................................... 72
4.13.2 CO2.................................................................................................................................................. 72
4.13.3 Liquid Effluents ............................................................................................................................... 73
4.13.4 Ambient Noise ................................................................................................................................ 73
4.13.5 Quarry and plant water runoff ...................................................................................................... 73
Future Recommendations about this industry: ................................................................ 77
References ............................................................................................................................ 78

VIII
 LIST OF FIGURES
Fig 2.1Raw material ............................................................................................................... 4
Fig 2.2 Air slide ............................................................................................................... 11
Fig 2.3 screw conveyor ....................................................................................................... 12
Fig 2.4 production method .................................................................................................. 13
Fig 3.2 parts of raw mill ....................................................................................................... 23
Fig 3.1 Hammer crusher ..................................................................................................... 20
Fig 3.3 Single stage compressor ....................................................................................... 32
Fig 3.4 Double stage compressor...................................................................................... 33
Fig 3.5 parts of centrifugal pumps ..................................................................................... 38
Fig 4.1 parts of raw mill ..................................................................................................... 48
Fig 4.2 Ball mill ..................................................................................................................... 57
Fig 4.3 Vertical Cement mill ............................................................................................. 60
Fig 4.4 packing plant............................................................................................................ 67

IX
 LIST OF TABLES
TABLE 4.1 TENSILE STRENGTH OF STEEL ................................................................ 53

X
 Chapter 01

Introduction

1.1 History of cement

Cement is a fine powder which after few minutes when mixed with water. And then hardens

in to solid strong material. Cement is mainly used to bind fine sand and solid aggregates to

gather in concrete.

Joseph Aspadin, a leads builder invented the port land cement in 1824. In this process

Aspadin mixed and ground hard lime stone and finally divided clay in form of slurry and

calcined it in a furnace similar to kiln till carbon dioxide was expelled. The mixture so

calcined was than ground to a fine powder and was used as a port land cement. The name

Portland is given owing to its resemblance of this hardened cement paste to a natural stone

available at a place called port land in England.

Portland cement was first produced commercially in New Zealand in 1886 by James Wilson

and Co., and has been produced here ever since[7].

1.2 The Chemistry of cement

Concrete mix is a mixture of cement and aggregate – sand and gravel. When water is added

to this the cement undergoes a series of chemical reactions to form a "gel" (a coloidal2

system). The fine cement particles are broken down into even smaller particles (thus

increasing the reactive surface) by crystallizing out from the supersaturated solution formed.

A series of immensely strong Si-O-Si bonds form between the particles, making a network in

which the aggregates are trapped. In addition, bonds are formed to the aggregates, but these

1
are much weaker, especially for smooth, inert, hard aggregates: because they have a smaller

surface area than rough aggregates, a smaller area can be involved in bonding.

1.3 Back ground of MPLCF

Maple leaf cements industry is located in Daudkhel; district Mianwali, Punjab, Pakistan. It is

one of the leading cement industries of Pakistan in particular and world in general. Use of

latest plant and technology, dedicated and specialized team of staff, skilled labor and strict

vigilance on quality of the final product as per international standards, makes it unique and

un-match able in cement producing facilities in Pakistan.

It has two phases; Phase-I and Phase-II. Phase-I plant is involved in production of white

cement while Phase-II plant is involved in production of gray cement.

In 1992, maple leaf was privatized and owned by Kohinoor group of industries and up till

now it has been modified in terms of capacity. In 1996, line-I of 3300 TPD previously was

then enhanced to the 4000 TPD and in 2006 another plant of 6700 TPD was installed, both

plants are supply of FLS, a Danish based cement plant manufacturer group.

I am honored to join this prestige organization as an internee in Mechanical field,

and being the student of Mechanical Engineering Technology it was a great

opportunity for me to expand my theoretical knowledge with practical knowledge.

During my short stay at Maple leaf, I was able to learn a lot in the most professional

and conducive environment for learning. Here is the short report about what I

witnessed during my stay at Maple Leaf[8].

2
1.4 Geographical Importance

Maple leaf is blessed in a sense that the raw material is available at the door as the factory is

located at front of the mountains which are blessed and enriched with gypsum, Iron ore, Clay

and other precious minerals, abundantly. Maple leaf has its own facility of mining and

exploitation of required raw material from these mountains.

1.5 Three Products

Maple leaf cements are capable of producing special and quality goods of the following

types:

 Grey Cement

 White Cement

 Salphate Resistance (S-R) cement

3
 CHAPTER 02

THEORY RELATED TO INTERNSHIP

2.1 Cement:

Typical Portland cements are mixtures of tri calcium silicate, tri calcium

Iluminate and di calcium silicate, in varying proportions, together with small amounts

of magnesium and Iron compounds. Gypsum is also added. [1]

Raw Materials:

Fig 2.1Raw material

Raw materials for the manufacturing of cement in the maple leaf cement plant are as follows:

 Lime stone (76%)

 Clay (20%)

 Iron (4% -5%)

 Gypsum is also mixed with the final product to increase the setting time of the

cement. In maple leaf cement factory lime stone is derived from local mountains

4
 while coal is imported from Indonesia and south Africa and iron from Makarwal

(Pakistan). Maple leaf is the only industry in Pakistan which uses glycerin in cement

to increase its softness, Glycerin is more costly chemical and not available at local

level.

2.2 Production Capacity:

Maple leaf has installed capacity of;[9]

1) Gray Cement 6700+4000= 11700 Ton/day

2) White Cement 550 Ton/day

2.3 Cement Plant:

Maple leaf‟s cement plant technology is one of the best technologies in the world. It is using

FLS‟ (German company) cement plant. Raw mill is made by F.L.S Germany. The cement

manufacturing process involves four distinct stages, and these are outlined below.

2.3.1 Step 1 - Quarrying

The raw material for cement manufacture is a rock mixture which is about 80%limestone

(which is rich in CaCO3) and 20% clay or shale (a source of silica, alumina and Fe2O3).

These are quarried and stored separately. The lime and silica provide the main strength of the

cement, while the iron reduces the reaction temperature and gives the cement its

Characteristic grey color.

2.3.2 Step 2 - Raw material preparation

The steps involved here depend on the process used. There are two main cement

manufacturing processes currently used in New Zealand: the dry process (used by Golden

5
Bay) and the wet process (used by Milburn). The dry process uses more energy in grinding

but less in the kiln, and the wet process has lower overheads than the dry process. The two

processes are discussed separately below[2,3].

2.3.2.1 The dry process

The quarried clay and limestone are crushed separately until nothing bigger than a tennis ball

remains. Samples of both rocks are then sent off to the laboratory for mineral analysis. If

necessary, minerals are then added to either the clay or the limestone to ensure that the

correct amounts of Aluminum, iron etc. are present. The clay and limestone are then fed

together into a mill where the rock is ground until more than 85% of the material is less than

90μm in diameter.

2.3.2.2 The wet process

The clay is mixed to a paste in a wash mill - a tank in which the clay is pulverized in the

presence of water. Crushed lime is then added and the whole mixture further ground. Any

material which is too coarse is extracted and reground. The slurry is then tested to ensure that

it contains the correct balance of minerals, and any extra ingredients blended in as necessary.

2.3.3 Step 3 - Clinkering

This is the step which is characteristic of Portland cement. The finely ground material is

dried, heated (to enable the sintering reactions to take place) and then cooled down again.

While it is being heated various chemical reactions take place to form the major mineral

constituents of Portland cement. The powder from the dry process doesn't contain much

moisture, so can be dried in a pre heater tower. As it falls through the tower (which takes 30

seconds) it is heated from 70 to 800oC. The moisture evaporates, up to 20% of the de

6
carbonation (loss of CO2) occurs and some intermediate phases such as CaO•Al2O3 begin to

appear. The mixture is then fed into the kiln.

2.3.3.1 The kiln

The kiln shell is steel, 60m long and inclined at an angle of 1 in 30. The shell is supported on

3 roller trunions and weighs in at over 1100 T. The kiln is heated by injecting pulverized coal

dust into the discharge end where it spontaneously ignites due to the very high temperatures.

Coal is injected with air into the kiln at a rate of 9 - 12 T hr. The reaction processes occurring

within the kiln are not easily understood due to the wide variations in raw-mix chemistry,

raw-mix physical properties and kiln operating conditions, and the physical difficulties of

extracting hot materials from the process for investigation before they cool.

2.3.3.2 The cooler

Immediately following the kiln is a large cooler designed to drop the temperature of the

clinker (as the fused material is now called) from 1000oC to 150oC. This is achieved by

forcing air through a bed of clinker via perforated plates in the base of the cooler. The plates

within the cooler slide back and forth, shuffling the clinker down the cooler to the discharge

point and transport to a storage area.

At this point in the process the materials have been formed into all the required minerals to

make cement. Like cement, the clinker will react with water and harden, but because it is

composed of 1-3 cm diameter fragments it is too coarse to be used.

2.3.4 Step 4 - Cement milling

To produce the final product the clinker is mixed with gypsum (CaSO4 •2H2O), which is

added as a set retarder, and ground for approximately 30 minutes in large tube mills. The

cement flows from the inlet to the outlet of the mill (a rotating chamber), being first ground

7
with 60 mm then 30 mm diameter steel balls. The first grinding breaks up the material and

the second grinds it to a fine powder. The amount of grinding is governed by the volume of

cement fed into the mill: the greater the volume the coarser the grind. This has practical

limits, with too much cement clogging up the mill and not enough actually increasing the

particle size. The particle size is measured by laser diffraction analysis, and the quantity of

material entering the mill adjusted accordingly. Over time the charge (steel grinding balls)

wear out, so when they reach a certain size they fall through a sieve and then are replaced.

The cement grinding process is highly energy intensive. The largest mill at Golden Bay

Cement is some 11 m in length, weighs over 230 T, is driven by a 2100 kW motor and can

produce over 60 T hr-1. The rotating mill generates significant quantities of energy and water

is added to both the inlet and outlet ends of the mill to cool the product and the mill itself.

2.4 TRANSPORTATION SYSTEM:

The transportation of raw material from query area to final place is performing by using

different methods. Some of these systems are given below.[4,5,6]

A. Belts

B. Bucket elevator

C. Air slide

D. Screw conveyor

2.4.1 .BELTS:

Belts are used to transport raw material such as lime stone , clay , iron ore ,

gypsum from query area to working area. Different rollers are used to support and run

the belts. Motors are also used to rotate the belts. Belts has a width of 1.5 foot and

8
 length is adjusted according to our needs. At the end of the built motor is fitted which

drive the belts.

2.4.1.1 Belts safety:

Following procedure is followed for the purpose of built safety to avoid any type of built

breakage or belts stop.

2.4.1.2 Speed monitor

Is used to monitor the speed of built and it can also help to control the speed of belts. Speed

of built is monitored and control by sensors that are control from control room.

2.4.1.3 Sway switches

Used to keep the built on track.

2.4.1.4 Pull card

Is actually a wire which is fitted over the built and its function is to stop the built in any

emergency case.

2.5 BUCKET ELEVATOR:

Bucket elevators are used to transfer material at the angel of 90 degree. Material is provided

to bucket elevator through built drive. Bucket elevator is mostly used where material is

required to send to the top of any building. Bucket elevator is derived with the help of a

motor. Buckets are fitted at a belt that‟s why it is called bucket elevator. Bucket elevator is

fully covered by metal sheet to avoid material losses. Bucket elevator is rotate at the speed of

25-30 rpm. Buckets are made up of mild steel.

9
2.6 AIR SLIDE:

In air slide a cloth is used in which there is a cement and fans are used

below it which provide air to cloth and cloth transfer the material by moving up and down.

air slides are used where material is required to transfer more smoothly and quickly as

compared to belt drive and bucket elevator. Air is delivered to the cloth with the help of fans

that are fitted on the both sides of air slides. Compressed air cannot be used in air slides

because it has high pressure which is not suitable for cloth used in air slides. Air Gravity

Conveying System uses the forces of gravity to do most of the work without any moving

parts. Material fluidized through a porous media with low pressure air. Material flow is

achieved by sloping the Air slide conveyor to match the fluidized angle of repose of the

powdered material. At the correct slope, fluidized materials flow with the consistency of a

liquid.

Air slide Air Gravity systems provide high capacity material handling while offering many

economical and environmental advantages. Energy requirements are minimal because only a

small volume of air at a low pressure is required to move material. Since the system is

installed overhead, valuable floor space and added headroom are Available for other

purposes. By eliminating the need for massive support members, it permits a flexibility of

plant design not available with straight-line conveyors.

The Air slide conveyor is dust tight. As a result, the system is extremely friendly to the

environment.

Noise level is extremely low in the area surrounding the Air slide conveyor as the system‟s

air supply is the only moving part to generate noise, and it is generally located in a remotely

insulated area to further reduce noise. Maintenance of the Air slide conveyor is very simple

10
because there are no moving parts other than the air supply equipment, which also

contributes to increased plant safety. Air slide conveyors require no lubrication.

Typical Air slide Conveyor Applications

• Distribution from bucket elevators to storage silos

• Gathering under bag houses / precipitators

• Feed to process

• Feed to other conveyors

• Load out from bulk silos to trucks, railcars or barges

• In-plant conveying

• Storage silo / bin withdrawal

Fig 2.2 Air slide

11
2.7 SCREW CONVEYOR:

Fig 2.3 screw conveyor

Screw conveyors move materials either horizontally, on an incline or vertically. They are

used to feed, distribute, collect or mix and can be equipped to either heat or cool while

performing this transfer. With the proper cover and gas cutting, they are easily made dust or

weather tight and rodent proof. Their clean compact design saves valuable space since no

return run is required. Screw Conveyors fit in cramped quarters, are simple to support and

easy to install . . . and they cost less than most other types of conveyors. Screw Conveyor

Corporation's performance-proved Screw Conveyors are ruggedly built and accurately

manufactured to assure complete dependability as well as the versatility required to meet a

wide range of job assignments.

The screw conveyor is one of the most economical conveyor types available for moving bulk

materials. It is completely enclosed to contain the moving material and its atmosphere. The

standard unit, with variations in design, is suitable for solving a variety of bulk material

handling problems.

Screw conveyor is looks like a screw which rotate and transfer material from one place to

another. Screw conveyor is another type of transportation system it works as rack and pinion.

12
2.8 Machinery used:

A. CRUSHER B. STACKER

C. RECLAIMER D. RAW MILL

E. C.F SILO F. KILLEN

G. COOLER H. BIN

I. CEMENT MILL J. PACKING PLANT

2.9 PRODUCTION METHOD:

Fig 2.4 production method

2.10 PRODUCTION PROCEDURE:

Cement plant in the Mianwali has higher production of cement whether it is grey cement or

white cement while during internship I came to know that how the production process starts

and how it proceeds and takes it final shape and which type of equipment in the plant was

used for the production. Each and every person in the plant guided in the visit and I was able

13
to understand the concepts of production. Production methods in the plant adopted are

discussed below:

2.10.1 Step-I:

First step is the selection of raw material. Each and every useful product is

produced by raw material. Raw material in production of cement is as follows:

 Lime stone

 Clay

 Iron ore

 Gypsum

Next thing after the selection of raw material is to bring the raw material to the factory. This

task is accomplished by the worker which performs the operation of mining and

transportation department brings the raw material to the factory area.

2.10.2 Step-II:

Raw materials brought from the sources are larger in size and are not able to be used for the

production process. The process for this step is called crushing. Crushing is done through

crushers installed in the factory. These raw materials are then sending to crushers, which

convert large stones to the desired size particles. Then these crushed components are

separately piled up in different piles.

2.10.3 Step-III:

Then there are reclaimers, which re-claim material from these piles and send the required

material to Stack (Hoppers) through conveyor belts. Hoppers are large storage tanks which

have controlled output from them.

14
Lime stone, clay and Iron ore are separately stacked into their stackers. rushed components

are separately piled up in different piles.

2.10.4 Step-IV:

Then there is a combine belt on which these all three materials are taken at a time. Output

from each stacker is pre-decided and hence adjusted according to the need and the feed of the

belt is adjusted properly so the material which falls on the belt is now mixture of all these

three raw materials and according to their proportions required to make the cement.

2.10.5 Step-V:

Next process is the production of cement and it is done in the raw mill. The mixture obtained

from the above raw materials is send to the raw material for the start of cement production.

2.10.6 Step-VI:

Raw meal is then fed to the C.F Silo (controlled flow silo). What a silo do? It gives us

blending and controlled continuous flow. Here the raw meal is stored. This raw meal is then

fed to the L.O.W (loss of weight) tank through 7 air slides. In L.O.W tank, we can have the

weight of the raw meal.

2.10.7 Step-VII:

From loss of weight tank, raw meal is send to the cyclones through air slides and elevator.

What a cyclone do? It separates dust from air and collects it. Material comes in cyclone 2

first, then it is sucked to the Cyclone 1 from where it is sucked in cyclone 3 and the dust is

collected in cyclone 2. From cyclone 2 the dust is send to the cyclone 4, from where it is

sucked in cyclone 3. From cyclone 3, dust is sucked in cyclone 5 and then again into cyclone

4. I can represent it in this way.

15
2 1 3 2 4 3 5 4

From cyclone 4, 60% material is send to the calciner and 20% is send to the cyclone 5 and

then to the smoke chamber (inlet of the KILN) through dividing gate.

2.10.8 Step-VIII:

Than this material which is pre heated through the calciner is now send to the Kiln, the main

and very important part of cement

2.10.9 Step-IX

Raw meal after heating at extreme temperatures now comes out as a major product called as

CLINKER. This red hot clinker is then cooled through special coolers and is then large

particles are crushed through clinker crusher to desired size of 20-25mm. Then this cooled

clinker is transferred to the clinker hopper/dome for storage through apron conveyor.

2.10.10 Step-X:

Clinker is actually a cement particle. It is just grinded to the powder form. Gypsum is an

additive which has no link with the strength but it only increases the setting time of the

cement. So the clinker is then taken to the cement mills called OK MILL for grinding and the

gypsum is added.

2.10.11 Step-XI:

At the end, the cement is stored in cement silos from where it is send to packing plant and is

packed in bags.

16
 CHAPTER 03

STRUCTURE OF INDUSTRY

Maple leaf cement factory has following departments.

A. C.C.R (COMPUTER CONTROLE ROOM)

B. CRUSHING AREA

C. STORAGE AREA

D. RAW MILL

E. C.F (control flow silo)

F. KILLEN AND COOLER

G. BINS

H. CEMENT MILL

I. PACKING PLANT

J. UTILITY AREA

K. WHR (WASTE HEAT RECOVERY)

3.1 C.C.R (COMPUTER CONTROLE ROOM):

In computer control room drawings of machinery that is used inside the factory are kept. It

also has drawing of factory building. All the processes are monitored from computers control

room by using different sensors, for example if the temperature of kiln is increasing or

decreasing sensors or sense that and decision is sends to the supervisor which controls the

temperature by on or off the cooling fans. In computers room cell no of employs are also kept

so that they can contact in any emergency condition. Lay out of whole factory and

information related to machinery can also be derived from control room.

17
 Widely used in our society. It has been manufactured in New Zealand for more than 100

Cement is the substance which holds concrete together, which means that it is external

years, and during this century production has increased one hundred-fold. Portland

cement (the only type of cement in common use today) is manufactured in a four step

process.

Step 1 - Quarrying
Limestone and a 'cement rock' such as clay or shale are quarried and brought to the cement

works. These rocks contain lime (CaCO3), silica (SiO2), alumina (Al2O3) and ferrous oxide

(Fe2O3) - the raw materials of cement manufacture.

Step 2 - Raw material preparation

To form a consistent product, it is essential that the same mixture of minerals is used every

time. For this reason the exact composition of the limestone and clay is determined at this

point, and other ingredients added if necessary. The rock is also ground into fine particles to

increase the efficiency of the reaction.

Step 3 - Clinkering
The raw materials are then dried, heated and fed into a rotating kiln. Here the raw materials

react at very high temperatures to form 3CaO•SiO2 (tri calcium silicate), 2CaO•SiO2 (di

calcium silicate) 3CaO•Al2O3 (tri calcium iluminate) and 4CaO•Al2O3 •Fe2O3 (tetra

calcium alumina-ferrate).

18
Step 4 - Cement milling
The 'clinker' that has now been produced will behave just like cement, but it is in particles up

to 3 cm in diameter. These are ground down to a fine powder to turn the clinker into useful

cement.

Cement production has several quite serious environmental hazards associated with it: dust

and CO2 emissions and contaminated run-off water. Both cement works in New Zealand

have measures in place to minimize these hazards.

3.2 CRUSHING AREA:

Two type of crushers are used to crush raw material

1. Impact hammer crusher

2. Roller crusher

Impact Crushers are suitable for crushing hard rock‟s such as limestone, dolomite, The

Granite and other similar materials under toughest operating conditions. Impact hammer

crusher has following parts.

3.2.1 ROTOR:

.rotor is made of high-carbon steel casting, and has wedge-shape hammer holding grooves

extending parallel to the shaft. Its peripheral part is hardened by high frequency induction

heating for greater wear resistance. The shaft is press fitted and the rotor shaft assembly is

dynamically balanced to assure vibration free operation

19
3.2.2 HAMMER BARS:

The hammer bars extend over the full width of the rotor. The bars are so designed

that these can be reused by repositioning after one face wears out. The hammer bars are of

Ms steel castings.

3.2.3 FRAME:

The frame is fabricated with heavy steel plates and is stress relieved. Inside surface of the

frame is provided with cast Mild steel liners.

Fig 3.1 Hammer crusher

Coupling and gears via V-belts. The crushing material is fed into them achieve by means of

conveyors or similar aggregates while it is spread over the whole width of the roll.

3.2.4 Roller Crusher:

Roller crusher is used to crush clay in powder form. Roller crusher has following types

 Single roller crusher

 Double roller crusher

 Triple roller crusher

20
In maple leaf cement factory Crushing area consist of a 3 crushers.2 crusher used for lime

stone crushing and one for clay. Lime stone crusher consist of 4 excels fitted on a shaft. 8

hammers fitted on each excel having a weight of 85-90 kilo gram. lime stone crush the

material in the size of 25-30 mm. clay crusher crush the clay in to powder form and consist

of a rollers of 3 ft diameter,

Lime stone crusher consist of a 4 excels. 8 hammers are fitted on each excels and each excel

has a weight of 85-90 kilo gram. Raw material is drives from mountains and stored in a

hopper from where it is send to crusher area with the help of a belt which is called apron

feeder. This belt is made up of mild steel and has v type grooves on it. Crusher is rotated with

the help of motor of 650 kilo watt power. Motor rotate the excel at 90 rpm. When excels

rotates it strike the lime stone and break it in to 25-30 mm size. Under the hammers a grate

type basket is fitted which function is to send back the raw material of more than 30 mm size

to crusher with the help of belt drive. Lime stone crusher is a impact hammer type crusher.

Coupling which is used b/w crusher and motor is flexible fluid oil coupling, capacity of line

1 crusher is 900 ton/hour and line 2 is 700 ton/hour.

Clay crusher is a roller type crusher which consist of 2 rollers of diameter 2 foot which

match to gather and clay is crushed by b/w them. 500 kilo watt motor is used to rotate the

rollers at 65-70 rpm. These rollers crush the clay in to powder form.

A bag filter is used with crusher to collect dust and store it in another place.

Water sprayer is used to minimize the dust by spraying water.

21
3.2 STORAGE AREA:

In storage area raw material like lime stone, clay, iron ore, and coal is stored. Stacker is used

to make a pile of lime stone and clay. Lime stone pile is of 30,000 ton, and one pile of clay is

25000 ton. RECLAIMER is used to reclaim the material and put it on a belt.

In storage area stacker is used to make a pile of clay and lime stone. It consists of 2 gear

boxes self-align and adders. Self-align gear box is used to keep built straight, adders are a

rollers on which belt moves and they are more in numbers.

Fluidic coupling is used in stacker to minimize the load of motor and for built safety.

RECLAIMER is used to reclaim the lime stone and clay .RECLAIMER consists of blades

that are called sprockets. Sprockets are of three types drive sprockets, tail sprockets, guide

sprockets. RECLAIMER or of 2 types boom type , bridge type .

Boom type is used to reclaim clay and bridge type is used to reclaim lime stone. No of blades

of bridge type reclaimer is 113.

Buffer plate is used on reclaimer to adjust the material in the center of the belts. A magnet

separator is used to detect and eliminate metals from raw materials.

The stacker deposits raw material longitudinally in the form of pile . The pile is normally

250-300 m long and 8-10 m high , The reclaimer cuts the pile vertically, The proportioned

raw material is transferred by a conveyor belt to raw mill for grinding, After the grinding the

raw material is stored in control flow silo ( control flow) where blending takes place.

Blending is done by injecting compressed air, This powdered material is fed to the kiln for

burning.

22
3.4 RAW MILL:

Raw mills are a type of industrial equipment used to crush or grind material

in to small particles. Raw mill is widely used in concrete and mixing field and are also used

to process gypsum. These units can process both raw and recycled material , while helping to

reduce and preserve virgin supplies of these materials.

Raw mill is used to crush the mixture of lime stone clay and iron. Raw mill consist of a 3

rollers of weight 60 ton. These rollers crush the material in to powder form with the help of

rotating table which is driven by a motor.

Fig 3.2 parts of raw mill

Raw mill has following main parts

1. Roller 2. Separator

23
 3. Gear box 4. Suction duct

5. Main drive 6. Lubrication system

7. Table 8. York

3 rollers are used in raw mill and each roller has a weight of 60 ton .These rollers are fitted

on a York with the help of nut and bolts York consist of three holes which are used for

lubrication system. Each roller consist 12 segment .2 bearings are used on the both sides of

rollers. On front side „spherical double roller‟ bearing are used and on back side „NU‟

cylindrical bearings are used. Separator is grate type component which is used to separate

raw material and fine material .raw material is sending back on table to crush again.

MAAG gears are used in raw mill. it is also called galaxy gears because a small rotate in

the center and 3 big gears moves around it like planets.

SUCTION DUCT is used suck the fine material and sends it to c.f silo.

Table rotates with the help of a motor and helps to grind the material.

A 4300 kW motor is used to rotate the table .Motor rpm is 995 and table rpm is 85-90.

Weight of motor is 25000 kg and made by V.E.M Germany. Coupling type is male female.

Grinding pressure is 80 bars and this pressure is controlled with the help of jack system.

6 pumps are used for lubrication system 3 pumps Are H.P AND 3 are L.P.

Lubrication can takes on rollers and gears. Raw mill line 1 capacity is 300 ton/hour and line

2 capacity is 550 ton /hour.

WORKING:
Feed material is directed on to the grinding table by feed chute .The rotation of

the grinding table accelerate the material toward grinding track and passing it under the

rollers .Coarse material and bigger lumps drop through the nozzle ring and is eventually re-

circulated in to the feed material inlet .Moisture evaporates almost immediately as the gas

24
 stream carries finer portion of material to the separator. The separator allows the material

that has reached required fineness to leave the grinding mill.

3.5 .C.F (CONTROLE FLOW) SILO

The CF (Controlled Flow) silo is a continuously operating system for blending and storage of

cement raw meal. Material is extracted simultaneously at different flow rates from a number

of outlets in the silo bottom. The CF system including suitable kiln feed equipment ensures

stable kiln feed composition at minimum power consumption and investment cost. Two

criteria must be met to achieve a high degree of homogeneity in a continuously operating,

through-flow silo where blending is not achieved simply by air agitation:

1. All the raw meal in the silo must be kept in constant movement towards the outlets.

2. The raw meal must pass through the silo in flow zones with different residence times

FIG 3.5 C.F SILO

25
The silo bottom is raised above the ground with the kiln feed or blending tank placed

underneath. The silo bottom has seven extraction points. The material is supplied

continuously to the silo. The standard features of the silo top include manholes, overpressure

and under pressure valves, and level indicators. The unique characteristic of the CF silo is the

design of its bottom. As shown in figure the silo bottom is divided into seven identical

hexagonal sectors. At the center of each hexagonal sector is an outlet with a large conical

cover made of steel. These steel cones are designed to maintain an optimal flow pattern

during extraction of the raw meal, which influences blending efficiency. Besides, the cones

are designed to relieve the pressure above the outlets, and to ensure extraction from the

aerated part of the silo bottom,

Each of the seven sectors is divided into six triangular subsectors. So the bottom consists of a

total of 42 subsectors, all of which are provided with aeration units. These 42 separate

subsectors represent 42 individual areas from which the material is extracted in a preset

sequence of shorter duration than the retention time in the blending tank below the silo.

Layers of raw meal of varying chemical composition are fed to the silo. The variations in

extraction rate/retention time mean that these layers are broken up as they proceed down

through the silo. The resulting raw meal product, extracted from the silo during any stage of

the extraction sequence, will therefore be a mixture of raw meal components of different

chemical composition.

Each of the seven outlets is provided with a shut-off valve by which extraction from a given

outlet can be started and stopped together with the aeration of the appertaining subsectors.

Slide gates are provided to facilitate the maintenance of the shut-off valves.

26
From the silo outlets the material passes via air slides to the kiln feed or blending tank

mounted on load cells.

3.6 KILN AND COLLAR:

The kiln shell is steel, 60m long and inclined at an angle of 1 in 30. The shell is

supported on 3 roller trunions and weighs in at over 1100 T. The kiln is heated by injecting

pulverized coal dust into the discharge end where it spontaneously ignites due to the very

high temperatures. Coal is injected with air into the kiln at a rate of 9 - 12 T hr.

The reaction processes occurring within the kiln are not easily understood due to the wide

variations in raw-mix chemistry, raw-mix physical properties and kiln operating conditions,

and the physical difficulties of extracting hot materials from the process for investigation

before they cool.

Killen is used to heat the material at the temperature of 1600 degree centigrade. Material is

heated by using coal as a fuel .kiln length is 67 m and height is 5.5 m and rotate at 3.5-5 rpm.

After the raw material is heated it is send to cooler. In cooler 8 cooling fans are used to

provide air for cooling purpose. After cooling raw material become clinker.

Three types of bricks is used in kiln

Magnesia bricks are used start of the kiln in the length of 45 m.

High alumina is used in the center of kiln in the length of 10 m.

Low alumina is used at the end of the kiln and in the length of 11 m.

Pneumatic jack is fitted on kiln inlet seal and is used to hold kiln inlet seal and control seal

moment.

Thrust device is used to hold kiln to avoid axial fluctuation.

Live ring is used to support the kiln.

27
Shell cooling fans is used to cool the shell of kiln protect the shell from over heat age.

.Immediately following the kiln is a large cooler designed to drop the temperature of the

clinker (as the fused material is now called) from 1000oC to 150oC. This is achieved by

forcing air through a bed of clinker via perforated plates in the base of the cooler. The plates

within the cooler slide back and forth, shuffling the clinker down the cooler to the discharge

point and transport to a storage area.

At this point in the process the materials have been formed into all the required minerals to

make cement. Like cement, the clinker will react with water and harden, but because it is

composed of 1-3 cm diameter fragments it is too coarse to be used.

3.7. BINS:

Bins are used to store clinker, gypsum, and lime stone. Each bin has a capacity of 6000 ton.

From these bins material is send to the cement mill where it is grinded and converted in to

powder form and raw material is finally converted to cement form.

3.8 CEMENT MILL:

In modern plants clinker and gypsum is crushed in roller press and

subsequently fed in to ball mill for fine grinding. The installation of roller press technology is

very beneficial in terms of both quality and energy conservation. The cement produced from

roller press is showing better particle size distribution in cement and consumes less power.

Two types of cement mills is used in world Open mill and close mill vertical mill is the

example of close mill and horizontal mill is the example of open mill.

In cement mill clinker, gypsum, and lime stone comes on different belts and grinded here.

Cement mill consist of 4 rollers of 36 ton weight each. After crushing material become

cement.

28
Cement mill has following types

Vertical mill & horizontal mill

Mainly due to lower specific energy consumption (measured in kWh/t of produced material)

and higher production (t/h) values, vertical cement mills are slowly, but steadily,

outnumbering “traditional”, horizontal ball mills. The immediate advantages of such mills

can be easily summed up in the following key points:

• Vertical cement mills are able to reach production values which are significantly higher

than the ones achievable with traditional ball mills. As the latter ones are able to reach an

indicative maximum of 180-200 t/h, vertical mills can provide up to 300 t/h.

• Lower energy consumption, resulting in a lower specific cost (€/kg).

• while traditional mills have to be first assembled by the manufacturer and then transported

to the industrial site with all the resulting costs as well as logistical problems, vertical mills

are usually build “on-site”. This aspects permits to reach mill sizes (and therefore production

values) which are not achievable in the case of traditional ball mills.

• Vertical mills offer a greater versatility than traditional ones: for example, intermediate

cleaning silos are not necessary, as the transition times between different cement

types/compositions are significantly shorter if not inexistent.

• Additionally, vertical mills are less sensitive to the eventual high-humidity content of raw

materials (given a sufficient energy source is present).

At Maple leaf cement factory booth the mills are used. Vertical cement mill consist of 4

rollers and each roller has a weight 36 ton. Cement mill has the same functions as vertical

raw mill. Gypsum, clinker and lime stone comes on 3 different belts from bins.

In vertical mill they are grinded in to powder form. Vertical mill consist of 4 rollers.

29
In horizontal mill balls are used as a grinding medium and also called ball mill. Ball mill has

two chamber grinding chamber and blending chamber. B/w these chambers a diaphragm is

used .in grinding chamber balls of 80 mm diameter is used and in blending chamber 40-45

mm balls are used to grind material. Ball mill is drives with a motor of 4650k w .clutch

coupling is used at ball mill. Ball mill rotates at 14.7 rpm. And vertical mill rotates at 24.28

r.p.m

3.9 PACKING PLANT:

Cement is packed in HDPE bags of 50 kg. Electronically control,

high efficiency rotary packers are used for packing. Packers are highly precise with tolerance

of +/- 0.5 %, It displays the weight of each bag before discharge. It ensures the weight of

packed bag is 50 kg .the packed bags are loaded into trucks, wagons.

In packing plant cement is packed in bags. 6 packers are used inside the factory. At same

time 8 bags can be filled at each packer.

Cement from cement silos is send to air slide through mechanical or electrical control valve

by opening it according to demand. From air slide material is send to bucket elevator which

put the material at separator which is located at the top .function of separator is separate fine

material and raw material. Raw material is send back to cement mill with the help of a belt

drive .after passing the separator cement is send to hopper where it is partially stored .

Under the hopper a butterfly valve is used which looks like a round disk and is operated with

the help of a computer command. When valve is open cement comes in packer where it is

packed in the bags.

When bag is full with cement (50k.g) it is send to Vento check belt where weight of bag is

checked. If weight is less or more than 50 kg bag is send to cutter. If weight is 50 kg bag is

30
send to square roller where it is balanced .after this discharge belt discharge the bag and bags

are loaded on vehicles.

3.10 UTILITY AREA:

Utility area covers the needs of water and air of cement factory.

Two types of air is used in maple leaf cement factory

A. Blower air

B. Compressed air

3.10.1 AIR:

3.10.1.1 Compressed Air

Not as fast as electricity or as slow as hydraulics, compressed air finds a broad field of

applications for which its response and speed make it ideally suited. Where there is an

overlap, the choice often depends on cost and efficiency and air is likely to hold the

advantage.

It is a utility that is generated in-house, so owners have more control over it than any other

utility. In addition, air does not possess the potential shock hazard of electricity or the

potential fire hazard of oils. However, compressed air is under pressure and can cause harm

and bodily damage if not respected. Safety codes and regulations should be followed when

working with compressed air.

How Can Air Generate Power?

When air is compressed, it is under pressure greater than that of the normal atmospheric

pressure and it characteristically attempts to return to its normal state. Since energy is

required to compress the air, energy is released as the air expands and returns to atmospheric

pressure. Air compressors were designed to compress air to higher pressures and harness this

31
potential energy source. Unlike other sources of power, no conversion from another form of

energy such as heat is involved at the point of application. Compressed air or pneumatic

devices are therefore characterized by a high power-to-weight or power-to-volume ratio.

3.10.1.2 Types of Compressors

Air compressors in sizes 30 horsepower and below include both reciprocating and rotary

compressors, which compress air in different ways. Major types of reciprocating compressors

include reciprocating single acting, reciprocating diaphragm and reciprocating rocking piston

type. Major types of rotary air compressors include rotary sliding vane, rotary helical screw

and Rotary scroll air compressors.

3.10.1.2.1 Reciprocating Single Acting Compressors

Reciprocating single acting compressors are generally of one-stage or two-stage design.

Compressors can be of a lubricated, non-lubricated or oil-less design. In the single-stage

compressor, air is drawn in from the atmosphere and compressed to final pressure in a single

stroke. The single-stage reciprocating compressor is illustrated in (Single-stage compressors

are generally used for pressures of 70 psi (pounds per square inch) to 135 psi.

Fig 3.3 Single stage compressor

32
In the two-stage compressor, air is drawn in from the atmosphere and compressed to an

intermediate pressure in the first stage. Most of the heat of compression is removed as the

compressed air then passes through the intercooler to the second stage, where it is

compressed to final pressure. Two-stage compressors can include two cylinder designs.

Fig 3.4 Double stage compressor

For blower air blowers are used. Blower is used in cement silos, c.f silo, and coal mills etc.

compressed air cannot be used because it has moisture in it.

Compressed air is used for instrumentation such as in air slides, bag filters e.t.c

Blowers can achieve much higher pressures than fans, as high as 1.20 kg/cm2. They are also

used to produce negative pressures for industrial vacuum systems. Major types are:

centrifugal blower and positive-displacement blower.

Centrifugal blowers look more like centrifugal pumps than fans. The impeller is typically

gear-driven and rotates as fast as 15,000 rpm. In multi-stage blowers, air is accelerated as it

passes through each impeller. In single-stage blower, air does not take many turns, and hence

it is more efficient.

33
Centrifugal blowers typically operate against pressures of 0.35 to 0.70 kg/cm2, but can

achieve higher pressures. One characteristic is that airflow tends to drop drastically as system

pressure increases, which can be a disadvantage in material conveying systems that depend

on a steady air volume. Because of this, they are most often used in applications that are not

prone to clogging. Positive-displacement blowers have rotors, which "trap" air and push it

through housing.

Positive-displacement blowers provide a constant volume of air even if the system pressure

varies. They are especially suitable for applications prone to clogging, since they can produce

enough pressure- typically up to 1.25 kg/cm2 - to blow clogged materials free. They turn

much slower than centrifugal blowers (e.g. 3,600 rpm), and are often belt driven to facilitate

speed changes.

7 compressors are used for line 1 and 6 compressors are used for line 2 . two stage

compressors are used at maple leaf cement factory.

Compressors are used to compress the atmospheric air at 8 bar. Input power is 114kw.

Air is sucked with the help of suction filter than it is send to intake regulator which controls

the air pressure at 7.2 bars. After that air is send to compressors element where oil and air is

compressed. After the compression oil and air is send to separator where oil is separated,

after the separation oil is send to oil cooler and air is send to air cooler. After the filtration oil

is circulated in the system. Air is send Air dryer, in air dryer silica gel is used to absorb

moisture from air

3.10.2 WATER:

Type of pumps are used

Two types of pumps are used in maple leaf cement factory

34
 Centrifugal pumps and Submersible pumps

3.10.2.1 Centrifugal pumps:

In 1689 the physicist Denis papin invented the centrifugal pumps and today these kinds of

pumps are most used around the world. The centrifugal pumps built on a simple principal:

“Liquid is led to the impeller hub and by means of the centrifugal force it is flanged toward

the periphery of the impellers.”

The construction is fairly in expensive, robust and its high speed makes it possible to connect

the directly to a synchronous motor. The centrifugal pump provide a steady liquid flow, and

it can easily be throttled without causing the any damage to the pump.

If a pressure difference occurs in the system while the centrifugal pump is not running liquid

can still pass through it due to its open design.

3.10.2.2 Characteristics of centrifugal pumps

The centrifugal pump has several characteristics and in this we will present most

important ones.

The number of stages

Depending on the number of impeller in the pump, a centrifugal pump can be either a

single stage or multistage pump.

The position of the pump shaft

Single stage and multistage pumps comes with horizontal or vertical pump shaft. These

pumps are normally designated horizontal or vertical pumps.

3.10.2.3 Single suction or double suction Impeller:

Depending upon the construction of the impeller, a pump can be fitted with either a

single suction impeller or double suction impeller.

35
Coupling stages:
The pump stages can be arranged in two different ways: in series and in parallel.

Construction of the pump casing:

We distinguish b/w two types of pump casing: volute casing and return channel casing

with guide vanes.

A centrifugal pump generate pressure that exerts forces on both stationary and moving

parts of pumps, Pumps parts are made to with stand these forces.

310.2 SUBMERSIBLE PUMPS:

These pumps are also called waste water pumps. The submersible pumps Is an enclosed

unit with a pump and a motor. In submersible installation with auto coupling system

double rails are normally used. The auto coupling system facilitates, repair and

replacement of the pump. Because of the construction of the pump it is not necessary to

enter the pit to carry out service. In fact it is possible to connect and disconnect the pump

automatically from outside of the pit.

Normally waste water pumps have to be able to handle large particle. Therefore they are

fitted special impellers that make it possible to avoid blockage and clogging. Different

type of impeller exists; single channel impellers, double channel impellers and triple

channel impellers and vortex impeller.

Waste water pumps usually come with a dry motor. Motor and pump have a common

extended shaft with a double mechanical shaft seal system in a intermediate oil chamber,

Waste water pumps are able to operate either intermittently or continuously depending

on the installation in question.

36
Working Mechanism of a Centrifugal Pump

A centrifugal pump is one of the simplest pieces of equipment in any process plant. Its

purpose is to convert energy of a prime mover (a electric motor or turbine) first into velocity

or kinetic energy and then into pressure energy of a fluid that is being pumped. The energy

changes occur by virtue of two main parts of the pump, the impeller and the volute or

diffuser. The impeller is the rotating part that converts driver energy into the kinetic energy.

The volute or diffuser is the stationary part that converts the kinetic energy into pressure

energy.

Note: All of the forms of energy involved in a liquid flow system are expressed in terms of

feet of liquid i.e. head.

General Components of Centrifugal Pumps

A centrifugal pump has two main components:

I. A rotating component comprised of an impeller and a shaft

II. A stationary component comprised of a casing, casing cover, and bearings.

The general components, both stationary and rotary, are depicted in Figure

The main components are discussed in brief below.

37
Fig 3.5 parts of centrifugal pumps

38
Submersible pumps used on wells. 3 centrifugal pumps are used on line 1 3 used for line 2

Water after usage send to well from where it is send to water treatment plant. 2 water tanks

are also used

1. Industrial water tank

2. Fresh water tank

Industrial water tank is used for the purpose of cooling water while fresh water tank is

used for daily use.

39
 CHAPTER 04

STRUCTURE RELATED TO MECHANICAL

TECHNOLOGY

Mechanical is the mother of all technologies and has a huge range of machinery in used. In

this chapter we try to cover the machinery that is used at maple leaf cement factory.

A. CRUSHER B. STACKER AND RECLAIMER

C. RAW MILL D. PRE HEATER

E. KILLEN AND COOLER F. CEMENT MILL

G. PACKING PLANT

4.1 CRUSHER

Crushing is a process of dividing big stones in to smaller one. In maple leaf

cement factory 3 crusher are used 2 for crushing lime stone and 1 for clay.

Two types of crusher are used for crushing purpose.

1. Impact hammer crusher

2. Roller crusher

4.1.1 Impact hammers crusher:

Impact hammer crushers are of a progressive design that combines the advantages of impact

crushers with those of hammer crushers. Crushers are predominantly used for single-stage

crushing of extracted limestone, dolomite, gypsum, limestone marl as well as other medium

hard materials and materials that contain sticking clays and loams. As a rule, crushers are

used in the cement industry where ball mills are part of the grinding plant.

40
The exceptional operating properties of impact hammer crushers are:

฀ High operating reliability

฀ Low cost for operating and maintenance

฀ Long service life of main crushing elements

฀ High specific throughput

฀ Excellent degree of communication

฀ Favorable specific electric power consumption

฀ Favorable grain size distribution of the product

฀ Capability to crush even materials containing sticky components

฀ Insensitivity towards non-crushable matters Staggered hammers that cover the entire

working width of the crusher. This design together with the structural arrangement of the

crushing chamber provides a high crushing ratio and has the capacity to process materials

that could not be processed in the past.

The grate is the second essential component of the crushing space and limits the use of the

crusher with regard to the material stickiness. The grate is designed so that the functional

plates act as a safety device when non-crushable matter is trapped into the crushing chamber.

Catastrophic failures are minimized when the grate plate breaks. The plate pieces do not

come into contact with the rotating hammers, instead, they fall freely into the discharging

hopper positioned under the crusher.

4.1.2 Roller crusher:

Roll Crushers use a combination of compression and shear force with up to four crushing

rolls to reduce a variety of friable materials, such as coal, salt, coke, gypsum, potash, lignite,

lime, limestone, glass, phosphate (and many others with similar characteristics) to a desired

41
sized-cubical product with minimum fines. Roll Crushers are not intended to crush hard rock

such as granite or basalt where Jaw Crushers, Cones and Imp actors are applied. Horizontal

crushing rolls are supported through the steel roll shafting by roller bearings. A Single Roll

Crusher crushes against a curved plate; a Double Roll Crusher is designed to crush against

two opposing rolls; a Triple Roll Crusher uses a single roll mounted over a double roll and

the Quad Roll Crusher is designed with a double roll mounted over another double roll. Both

the Triple and Quad Roll Crushers provide two-stage reduction.

Roll Crushers are designed for safe operation with exposed moving components guarded in

accordance with MSHA and OSHA. In case of jamming or plugging of the rolls, under speed

detection de-energizes the electric motor.

Features Include:

• Heavy-Duty, Fabricated Steel Frames

• Abrasion-Resistant Steel Plate Liners

• Alloy-Carbon Steel Shafting

• Spherical Roller Bearings

• Cast Iron or Steel Crushing Rolls And Segments

• Automatic Spring And Toggle Tramp Relief

• Product Size Adjustability

• Zoned Lubrication – Manual or Automatic

4.1.2.1 SINGLE ROLL CRUSHERS

UP TO 6:1 FEED-TO-PRODUCT REDUCTION RATIO

A single drive utilizes a gear and pinion transfer to apply the appropriate speed to the

crushing roll.

42
Cobra Used in the primary reduction of clean coal, frozen coal, sand cores, resin, lime, coke,

salt and other similar material. Ideal for wet, sticky feeds.

Black Diamond Used in the primary reduction of coal, salt, soft shale, cinders, brick, coke,

phosphate and other similar material. Ideal for scabby or wet, sticky feeds.

Super Black Diamond Used in the primary reduction of shale, slate, gypsum, bauxite, coal

with friable refuse and other medium-hard feeds. Ideal for scabby or wet, sticky feeds.

Rock master Used in the primary reduction of rock, ore, mine refuse and ROM coal. Ideal

for scabby, or wet, sticky feeds.

Shale King

Used in the primary reduction of harder rock. Ideal for oil shale and material of similar

hardness.

4.1.2.2 DOUBLE ROLL CRUSHERS

UP TO 4:1 FEED-TO-PRODUCT REDUCTION RATIO

Available in either a single or dual drive motor, depending on the application. Single drive

units transfer power to the opposing roll via an inter stage belt drive.

Black Diamond

Used for the secondary and tertiary reduction of clean coal, coke, salt, trine, quicklime,

pebble lime, burnt lime, glass and other similar materials.

Heavy Duty

Used for the secondary, tertiary and fourth-stage reduction of harder materials such as ROM

coal with refuse, limestone, gypsum, bauxite, oil shale, various ores and other materials of

similar hardness.

43
4.1.2.3 TRIPLE ROLL CRUSHERS
Available in single, dual or three motor drive depending on crusher model and application

.Utilizes gear and pinion, chain and sprocket or interstate belts to transfer roll rotation.

Standard Duty

Used in the two-stage reduction of clean coal, salt, coke, glass and other similar material.

Medium Duty

Used in the two-stage reduction of harder coal and feeds containing medium-hard shale and

other similar material.

Super Duty

Used in the two-stage reduction of harder coal and ROM feeds containing up to 10% hard

rock and other similar material.

4.1.2.4 QUAD ROLL CRUSHERS

Available in single, dual or four motor drive depending on crusher model and Application.

Utilizes gear and pinion, chain and sprocket or interstate belts to transfer roll rotation.

Standard Duty

Used in the two-stage reduction of clean coal, salt, coke, glass and other similar materials.

Medium Duty

Used in the two-stage reduction of harder coal and feeds containing medium hard

shale and other similar material.

Abrasive Duty

Used in the two-stage reduction of hot, abrasive feeds, such as sinter, iron ore, coke and other

similar materials.

44
Super Duty

Used in the two-stage reduction of ROM coal and other similar material containing moderate

percentages of medium to hard refuse.

In maple leaf cement factory crusher are used for following purpose

Lime stone crusher;

Lime stone crusher is used to crush lime stone. It is used to

crush the lime stone of size 3*3 foot in to 25-30 mm size. This crusher is made by a German

company F.L.S. This crusher consist of 4 excels fitted on a shaft. Each excel has 8 hammers

of weight 85-90 kg. a 1100kw motor is used to rotate the crusher. Lime stone crusher is a

impact hammer type crusher. It is impact hammer type crusher.

A bag filter is used in crusher to collect dust and store it at separate palace. Water sprayer is

also used to minimize the dust by spraying water,

MOTOR POWER ------------------------------------------ 1100 K.W

MOTOR R.PM ------------------------------------------ 1400

COUPLING TYPE ------------------------- FLEXCIBLE FLUID OIL COUPLING

BEARING TYPE ---------------------------------------------- JOURNAL BEARINGS

MADE B ------------------------------------------------------F.L.S (GERMANY)

CRUSHER TYPE ------------------------------------------ HAMMER CRUSHER

4.2. CLAY CRUSHER:

Clay crusher is double roller type crusher and is used to crush

clay in powder form.

MOTOR POWER ------------------------------------------------------ 800K.W

MOTOR R.PM ------------------------------------------ 1100

45
COUPLING TYPE -------------------------FLEXCIBLE FLUID OIL COUPLING

BEARING TYPE ---------------------------------------------- JOURNAL BEARINGS

MADE BY ------------------------------------------------------ F.L.S (GERMANY)

CRUSHER TYPE ------------------------------------------ ROLLAR CRUSHER

ROLLAR DIA ------------------------------------------------ 3.5 FOOT

4.3 STACKER AND RECLAIMER:

Stacker is used to make a pile of lime stone and clay.

Stacker has two gear boxes

a. Self-align

b. Adders

Self-align are used to keep belt on track. Addles are more in number and used to fed

lime stone and clay.

RECLAIMER is of two types and are also called bridge scraper.

A. Bridge type

B. Boom type

Bridge type is used to reclaim lime stone while boom type is used to reclaim clay.

Sprockets:
These are like belts and of 3 types

a. Drive sprocket (to drive reclaimer)

b. Tail sprocket (to put clay or lime stone on belts)

c. Guide sprocket (to put the material down on tail sprocket)

46
4.4 RAW MIL:

Mainly due to lower specific energy consumption (measured in kWh/t of

produced material) and higher production (t/h) values, vertical raw mills are slowly, but

steadily,

vertical cement mills are able to reach production values which are significantly higher than

the ones achievable with traditional ball mills. As the latter ones are able to reach an

indicative maximum of 180-200 t/h, vertical mills can provide up to 300 t/h

• Lower energy consumption, resulting in a lower specific cost (€/kg).

• while traditional mills have to be first assembled by the manufacturer and then transported

to the industrial site with all the resulting costs as well as logistical problems, vertical mills

are usually build “on-site”. This aspect permits to reach mill sizes (and therefore production

values) which are not achievable in the case of traditional ball mills.

• Vertical mills offer a greater versatility than traditional ones: for example, intermediate

cleaning silos are not necessary, as the transition times between different cement

types/compositions are significantly shorter if not inexistent. Advantages of such mills can be

easily summed

• Additionally, vertical mills are less sensitive to the eventual high-humidity content of raw

materials (given a sufficient energy source is present). Nevertheless, vertical mills also

present certain disadvantages, if compared to traditional grinding systems. These aspects can

be summed up in the following key-points:

• High pressures of the roller presses are required in case high Blaine values are desired.

• Vertical mills are more sensitive to materials which present a very high fineness (the

threshold is set around a maximum of 50% material < 4 mm).

47
• a significant amount of water has to be added in the grinding process in order to keep the

vibration level of the whole grinding system low at any time. This aspect has major

repercussions on the cement temperature; therefore an external heat supply is needed to

guarantee a certain exit temperature, thus increasing the specific production costs. In maple

leaf cement factory raw mill is an area where lime stone, clay, and iron have been crushed.

Raw mill has 3 rollers of 60 ton each. Layer thickness b/w roller and table is 4-6 mm during

working condition. And in stop condition layer thickness is 100-120 mm. Rollers are made

up of magnet steel. Bearing are used on both sides of rollers. On front side “spherical double

roller bearings is fitted and on back side “NU cylindrical “bearing is used. Cylindrical and

spherical are the balls used in bearings

Fig 4.1 parts of raw mill

SPECIFICATION OF RAW MILL:

Capacity of raw mill line 1 ----------------------------------------- 550 ton/h

Capacity of raw mill line 2 ----------------------------------------- 300 ton/h

Motor power ---------------------------------------- 4300k.w

48
Motor r.p.m ----------------------------------------- 995r.p.m

Motor weight ----------------------------------------- 25000k Kg

Made by ------------------------------------------V.E.M (GERMANY)

MOTOR VOLT ------------------------------------------ 6300 VOLTS

COUPLING TYPE ------------------------------------------ MALE – FEMALE

RAW MILL TEMP ------------------------------------------ 120 DEGREE

GRINDING PRESSURE ------------------------------------------- 110 BAR

LIFTING PRESSURE --------------------------------------------- 80 BAR

RAW MILL LUBRICATION:

Two parts of raw mill require lubrication.

1. Gear lubrication

2. Roller lubrication

Gear lubrication:

Mage gear is used in raw mill. It consist of 4 gears .

One gear which is in smaller size and in the center is called sun gear 3 gears rotate about it is

called galaxy gears. Mage gears are bevel type gears.

Roller lubrication:

In rollers NU bearing and double roller spherical bearings are lubricated. Bearings are
lubricated York on which rollers are fitted.

4.5 .PRE HEAATER

Pre heater is used to heat the raw material before going to kiln. An i.d (induced draft) fan is

used in pre heater, its function is to collect the heat from kiln and provide it to cyclone which

is on the top of pre heater. This fan is also called pre heating fan.

5 cyclones in pre heater is 5 . No. of cyclone does not matter last cyclone has a dividing head

which function is to divide the material

49
NUMBER OF STAGES:
For many years, the pressure drop across one pre heater stage was up to 1.5 kpa. The reason

for the 4 stages pre heater being so widely used is, that is represented an optimum b/w

investment cost (structure height and foundation) pressure drop and heat consumption.

The pressure drop occurs mainly in the cyclones shape, design and the size which is

determining factor for cost.

New cyclone design is now in the market with only 0.5 to 1 kpa pressure drop per stage.

Considering increasing energy cost it is justified to install 5 or 6 pre heater stages for new or

modified kiln system.

The following table indicates the estimated effect of 5 or 6 cyclone stages.

Pre heater operation:

The performance of pre heater is assessed based on the criteria

 Temperature profile

 Pressure profile

 Oxygen profile

Some reasons for poor pre heater performance is frequently experienced.

 Worn out or non existing immersion tubes (often in bottom stage)

 Open inspection doors leaky gas kits or holes in pre heater

50
  Blocked or non existing meal flaps

 No splash boxes (specially older pre heater) combined with not optimum position of

meal feed point

 Excessive dust circulation due to poor separation efficiency of cyclones

As already mentioned, several time serious operating problems occurs with suspension pre

heaters with 4 or more stages caused by circulation phenomena. These occurs due t0

 Excessive input via feed or fuel

 Chemical unbalance

 Unfavorable kiln / burner operation

 Unfavorable design geometry of bottom stage and kiln gas riser duct area

Countermeasures known‟s today allow to solve the problems are

 Change feed composition or fuel quality

 Improve burning condition

 Install automatic cleanings (air cannons , bag filters ) at critical location

 Change temperature profile by installing a small secondary burner

 Install a bypass system

Raw meal is send to the cyclones through air slides and elevator. What a cyclone do? It

separates dust from air and collects it. Material comes in cyclone 2 first, then it is sucked to

the Cyclone 1 from where it is sucked in cyclone 3 and the dust is collected in cyclone 2.

From cyclone 2 the dust is send to the cyclone 4, from where it is sucked in cyclone 3. From

cyclone 3, dust is sucked in cyclone 5 and then again into cyclone 4. I can represent it in this

way.

2 1 3 2 4 3 5 4

51
From cyclone 4, 60% material is send to the calcined and 20% is send to the cyclone 5 and

then to the smoke chamber (inlet of the KILN) through dividing gate.

4.6. KILN:

Like many other great ideas rotary kiln was invented at the end 0f 19th century. The first

successfully working unit was developed in USA by Hurry and Seaman in 1897. Being used

for a clinker burning process for more than a century the rotary kiln is still more suitable

machine for the calinkrization of process.

4.6.1 Kiln dimension:

Kiln dimension are defined with diameter D (for kiln with different diameters burning zone

D and length L).

A limiting factor for the diameter is mechanical stability of the” arch “of the brick lining.

Maximum diameter that can be safely realized with standard size of bricks is about 6.5 m.

The L/D ratio ranging from 40 for long wet kiln to 11 for modern short kiln with calciner. It

has to be mentioned that the diameter D is the inside diameter f the kiln shell.

The maximum recommended kiln shell temperature varies by plant, by country and by kiln

manufacturer, despite the fact that most kiln shells are made of low alloy carbon steel. Age of

the kiln shell, distance between the tires, and structure of the shell are some important points

should be considered before deciding what the maximum allowable temperature for a kiln is.

Let us explain these points briefly:

1. Age and condition of the kiln shell: Old kilns shells have been exposed to creep for a long

time and are more prone to develop fatigue cracks than newer shells.

52
2. Distance between tires: The longer the shell span, the less it will resist high temperatures

without sagging. Therefore, longer spans have more tendencies to develop permanent

deformation than shorter spans.

3. Kiln shell structure: Kiln shells are made with structural rolled steel plate, such as

A.S.T.M. A36. The tensile strength of this type of steel at room temperature is 50,000 to

80,000 psi. As stated before shell strength is measured at a room temperature.

TABLE 4.1 TENSILE STRENGTH OF STEEL

there is an oxygen injection system connects to kiln burner or pre calciner burner to enhance

the combustion of the fuel. In general, the use of oxygen enriched combustion air in the

clinker burning process allows an increase of the energy efficiency, production capacity or

substitution of fossil fuels by low calorific value or (secondary) fuels and that way the

specific CO2 emissions can be reduced.

Three types of calciner used in kiln

1. In-Line calciner is installed in the kiln exhaust gas flow which means that the combustion

takes place in an air/kiln gas mix. This pre calciner can be considered an enlarged kiln riser

duct.

53
2. Off-Line calciner is installed off the kiln exhaust gas flow. The combustion takes place in

pure (tertiary) air which is also responsible for lifting up the meal.

1. Separate-Line calciner is off-Line calciner with a separate pre heater string.

2. In Maple leaf cement factory Kiln is used to heat the raw material at 1600 degree

centigrade .when Killen starts for 24 hours furnace oil is used to run the Killen. After

that fine coal is used as a fuel in Killen. . its shell is Inclined at 2 to 3 degree. 3 types

of bricks are used in Killen.

1. Magnesia

2. High Alumina

3. Low alumina

Magnesia bricks are used in the start of kiln and in the length of 45 m and also used in the

burning zone.

High alumina is used in the center of the Kiln and in the length of 10 m. Low alumina is used

in the end of the Killen and in the length of 11 m.

Killen line 1 drives with the help of girth gear while line 2 drives with the help of rollers

4.6.2 KILLEN LINE 1 SPECIFICATION:

Killen line 1 length --------------------------------------- 67 m

Diameter --------------------------------------- 4.5 m

r.p.m ---------------------------------------- 3.5-5

Feed ----------------------------------------- 252 ton/hour

Outside temperature ------------------------------------- 300-350 degree

Temperature --------------------------------------- 1600 degree centigrade

54
4.6.3 KILLEN LINE 2 SPECIFICATIONS:

Killen length ----------------------------------------------- 66 m

Diameter ------------------------------------------------ 5.5 m

Capacity ------------------------------------------------- 300 ton/hour

Temperature ------------------------------------------------- 1600 degree centigrade

4.6.4 DIFFERENCE B/W KILLEN LINE 1 AND Line 2

Killen line 1 has a length is 67 m and line 2 has length of 66 m. line 1 diameter is 4.5 m and

line 2 diameter is 5.5 m. kiln line 1 capacity is 252 ton /hour line 2 capacity is 300 ton /hour.

Killen line 1 drives with the help of girth gears and line 2 is drives with the help of rollers. A

motor is used to drive the rollers. Rollers cannot be run at kiln power because of high

temperature. Internal temperature of both the kilns is 1600 degree centigrade.

4.7COLLER:

Cooler function is to cool the raw material and convert it to clinker. 8 cooling

fans are used in cooler. 2 types of plates are used in cooler.

1. C.F.G (control flow grate)

2. R.F.T (Reduced flow plates)

These are also called rotator and stationary plates. Hydraulic jack is used for forward and

backward moment. M.F.R (mechanical flow regulator) is used to control the flow of air.

Air passed through M.F.R to cool clinker.

Line 1 cooler name ------------------------------------------ Grate bar cooler

Line 2 cooler names ------------------------------------------ cross bar cooler

55
4.8 CLINKER CRUSHER:

Clinker crusher is used to crush clinker in the size of 25-30 mm.3 excels are fitted on a

shaft on each excel 23 hammers are fitted. Total hammers are 69 and each hammer has a

weight of 60-65 kg.

4.9 CEMENT MILL:

Two types of cement mills are used in the world.

1. Open mill (ball mill)

2. Close mill (vertical mill)

In maple leaf cement factory one ball mill is used and two vertical mills are used.

4.10 BALL MILL:

Grinding in ball mills is an important technological process applied to reduce the size of

particles which may have different nature and a wide diversity of physical, mechanical and

chemical characteristics. Typical examples are the various ores, minerals, limestone, etc. The

applications of ball mills are ubiquitous in mineral processing and mining industry,

metallurgy, cement production, chemical industry, pharmaceutics and cosmetics, ceramics,

different kinds of laboratory studies and tests.

56
 Fig 4.2 Ball mill

Ball mill is in horizontal shape. In this iron balls are used to crush clinker, lime stone and

gypsum. Iron balls are also called grinding media. Ss plates are used inside ball mill to

control temperature

There are three types of grinding media that are commonly used in ball mills:

• Steel and other metal balls;

• Metal cylindrical bodies called clypeus;

• Ceramic balls with regular or high density..

Steel and other metal balls are the most frequently used grinding media with sizes of the balls

ranging from 10 to 150 mm in diameter. Clypeus are slightly tapered cylindrical grinding

media with rounded edges and equal length and diameter with sizes varying from 8×8 to

45×45 mm. Their shape is developed to maximize the grinding efficiency due to their high

density and specific surface area. Ceramic balls with regular density are usually porcelain

balls and the high density balls are made with a high alumina oxide content and they are

more abrasion resistant. The basic properties of the milling bodies are their mass and size,

57
ware rate, influence on the particle breakage rate and energy efficiency of the grinding

process.

4.10.1 CRITERIA FOR MEDIA SELECTION

Selection of grinding media depends upon several factors, some of which are interrelated.

• Specific gravity. In general, high density media give better results. The media should be denser

than the material to be ground. When grinding some slurry, media with higher density may be

required to prevent floating.

• Initial feed size. Smaller media cannot easily break up large particles.

• Final particle size. Smaller media are more efficient when ultrafine particles are desired.

• Hardness The harder the media the better the grinding efficiency and consequently, the longer

the wear.

• PHS Some strong acid or basic material may react with certain metallic media. • Discoloration.

For instance, white material should remain white.

• Contamination. The material resulting from the wear of the media does not affect the product

or can be removed by a magnetic separator, chemically, or in a sintering process.

• Cost. Media that may be 2-3 times more expensive may wear better, sometimes 5-6 times

longer, therefore, well worth their extra cost in the long run.

Ball mill has 2 chambers.

1. Grinding chamber

2. Blending chamber

B/w this chamber there is diaphragm which have holes in it.

58
 In grinding chamber 80 mm size grinding media is used and in blending chamber 40-45 mm

media is used.

4.10.2 BALL MILL SPECIFICATION:

Ball mill motor ------------------------------------------------- 4650k.w

Volt -------------------------------------------------- 6300

Ampere -------------------------------------------------- 539

Temperature ------------------------------------------------- 50 degree centigrade

Motor weight ------------------------------------------------- 850k.g

Ball mill gear ------------------------------------------------- F.L.S SYMETRO

Coupling -------------------------------------------------- clutch coupling

Ball mill r.p.m -------------------------------------------------- 14.7

4.11VERTICAL MILL:

Vertical mill is just like a raw mill. It has 4 rollers and each roller has

weight of 36 ton.

59
 Fig 4.3 Vertical Cement mill

In the cement industry, the necessity of continuous improvements in the grinding process and

the related cost reduction has promoted the diffusion of vertical cement mills worldwide.

These particular mills present a vast series of advantages with respect to traditional,

horizontal ball mills. Raw mills are a type of industrial equipment used to crush or grind

material in to small particles. Raw mill is widely used in concrete and mixing field and are

also used to process gypsum. These units can process both raw and recycled material, while

helping to reduce and preserve virgin supplies of these materials.

However, despite a generally good performance of vertical roller mills used for grinding of

cement and related products the vertical roller mill is still inferior to the ball mill in terms of

sensitivity to variations of mill feed quality (fineness) and mill feed rate.

4.11.1 Product quality

The purpose of the mill system is to provide a fineness to the product that will result in the

required reactivity and consequently the strength producing potential of the product the

cement. The fineness of cement is usually monitored by measuring the specific surface area

(Blaine) or a sieve residue of the product. However, the effects of the mill system on the

60
quality of the product are more complex than what is reflected by a Blaine value or a sieve

residue. It includes the following factors associated with the product:

· The particle size distribution

· The degree of dehydration of the gypsum added to the cement

· The pre hydration and carbonation of the clinker minerals

4.11.2 Particle Size Distribution

It is characteristic of grinding in vertical roller mills that the energy input to the material per

pass between roller and table is small, for which reason a large number

of passes are required to obtain the necessary specific energy input to the material.

This leads to a very high internal material circulation factor.

.High circulation factors invariably lead to steep particle size distribution curves, if the

separation process is efficient. It has therefore been necessary to adapt special measures to

reduce the inclination of the particle size distribution curve, in order to

get a cement quality that is similar to the quality of cement ground in a ball mill.

There are a number of ways to adjust the inclination of the particle size distribution curve for

cement ground in an OK mill.

In order to reduce the circulation factor, the grinding track on the grinding table has

an upward curved shape that helps to retain a certain minimum amount of material under the

rollers. The grinding table is further – at the periphery – equipped with an adjustable dam

ring. A higher dam ring will result in a thicker grinding bed corresponding to a longer

retention time of the material on the grinding table. The material will thus receive a higher

energy input before leaving the grinding table, resulting in a lower circulation factor via the

separator and thus a particle size distribution curve with a lower inclination.

61
4.11.3 Dehydration of the gypsum added to the cement

In the grinding process heat will be generated and the cement will be heated up. The

temperature of the cement leaving the mill will be dependent on the temperature of the

materials (especially the clinker) fed to the mill and to features of the mill and the grinding

process. It wills typically in the range from 90 to 120 deg. C. At this temperature- level the

water of crystallization of the gypsum added to the mill will partially be lost, i.e. the gypsum

will be partly dehydrated.

This dehydration will increase the solubility of the gypsum and make it more effective

as retarder for the iluminate reaction in the cement and thus more effective in setting control.

Another consequence is a general increase of the strength during the hardening of the

cement. However, too high content of dehydrated gypsum can lead to early precipitation of

gypsum crystals between the cement grains in the paste and cause early stiffening (false set).

Although some dehydrating of gypsum usually is advantageous, too high a degree of

dehydration (or too much dehydrated gypsum) can lead to problems.

62
As less grinding energy is used in producing a cement of a required fineness in an

OK mill and the retention time in the mill is shorter, the product will not be heated up as

much as in a ball mill. This means that a lower degree of dehydration of the gypsum must

be anticipated. This may not be a problem if the gypsum is sufficiently reactive to control the

setting reactions, which is normally the case. If in special cases this is not so, different

measures may be applied to cope with the problem:

· Addition of more gypsum (if it is possible within the SO3-limit)

· Increase dehydration of gypsum by adding more heat to the mill system

· Addition of a more reactive form of gypsum.

4.11.4 Pre hydration of the clinker minerals

Another chemical aspect to be considered in connection with cement grinding is the Pre

hydration of cement particles that may take place during the grinding. The

Moisture for pre hydration can come from moisture in the feed materials, from internal

cooling systems, and/or from dehydrating gypsum. The latter is mainly a problem in

connection with storage of hot cement in a silo.

Pre hydration of cement can, when exceeding a certain level, lead to reduced reactivity of the

cement and thus longer setting times and reduced strengths, particularly early strengths.

Pre hydration can also enhance the tendency of false set in cement with a high content of

dehydrated gypsum.

Pre hydration is normally not as problematic in an OK mill as in ball mill systems where

internal water-cooling systems are often required. However, if cement is Produced at a

relative high temperature and still has a lot of gypsum that is not de hydrated, one should be

aware of the problem of possible gypsum dehydration coupled with clinker pre hydration

63
which can take place during storage in the cement Silos . If a problem of this kind is present,

it can be remedied by one (or more) of the following options:

· Ensure that the cement is cooled to a lower temperature before entering the silo.

·Provoke a higher dehydration level to the gypsum in the mill (see above).

·Replace part of the gypsum by natural anhydrite.

4.11.5 Water injection for temperature c control

For a vertical roller mill, water injection for temperature control is usually not required.

The heat generated by the grinding process is low due to the high grinding efficiency, all air

to the mill air inlet may be ambient air, and the air flow through a vertical roller mill is much

higher than through a ball mill.

For a ball mill the situation is quite the opposite. The heat generated by the grinding process

is high and the air flow through the mill is relatively low. Therefore most ball mills grinding

OPC operate with internal water cooling. The amount of water required is not only dependent

on the clinker temperature, but also on the operation of the separator. The separator circuit

may be arranged for air cooling using from 0% to 100% of ambient air for the process.

4.11.6 Versatility

A vertical roller mill is a very versatile mill capable of grinding a wide range of products.

The OK mill has proved suitable for grinding not only pure slag and

Ordinary Portland Cement but also blended cements with a wide range of additives such as

slag, pozzolana, limestone and fly ash. Several OK mills grind two or more products in

alternate grinding. Shifting from one product type to another is easy and with only a very

short transition period. A decided advantage of the vertical roller mill compared to a ball mill

is its ability to dry feed materials with high water content, like for instance slag. Further, the

64
operational parameters of a vertical roller mill are easily adapted to suit alternative products.

Even adjustment of the dam ring, should that be required, is an easy task compared to

moving the diaphragm of a ball mill. With respect to versatility the vertical roller mill can

thus be considered to be superior to the ball mill.

4.11.7 Upgrading

Over the last two decades quite a large number of ball mill installations for cement grinding

have been upgraded by installation of pre-grinders, mostly roller presses.

Dependent on the complexity of the upgrade the system capacity may be increased

By, say from some 30% up to around 100%.

This option may not only be interesting as regards existing ball mill installations, but may

even be taken into consideration in relation to new installations that are included in a two-

phase investment program, i.e. a low capacity first phase engineered with a view to the

second phase – a later upgrade.

Raw mill is used to crush the mixture of lime stone , clay and iron. Raw mill consist of a 3

rollers of weight 60 ton. These rollers crush the material in to powder form with the help of

rotating table which is driven by a motor. Raw mill has following main parts

1. Roller 2. Separator

2. 3. Gear box 4. Suction duct

5. Main drive 6. Lubrication system

7. Table 8. York

3 rollers are used in raw mill and each roller has a weight of 60 ton . These rollers are

fitted on a York with the help of nut and bolts. York consist of three holes which are used

for lubrication system. Each roller consist 12 segment .2 bearings are used on the both sides

65
 of rollers. On front side „spherical double roller‟ bearing are used and on back side „NU‟

cylindrical bearings are used. Separator is grate type component which is used to separate

raw material and fine material. Raw material is send back on table to crush again.

MAAG gears are used in raw mill. it is also called galaxy gears because a small rotate in

the center and 3 big gears moves around it like planets.

SUCTION DUCT is used suck the fine material and send it to c.f silo.

Table rotates with the help of a motor and helps to grind the material.

A 4300 kw motor is used to rotate the table .Motor rpm is 995 and table rpm is 85-90.

Weight of motor is 25000 kg and made by V.E.M Germany. Coupling type is male female.

Grinding pressure is 80 bar and this pressure is controlled with the help of jack system.

6 pumps are used for lubrication system 3 pumps Are H.P AND 3 are L.P.

Lubrication can takes on rollers and gears. Raw mill line 1 capacity is 300 ton/hour and line

2 capacity is 550 ton /hour.

WORKING:

Feed material is directed on to the grinding table by feed chute .The rotation of the

grinding table; accelerate the material toward grinding track and passing it under the

rollers. Coarse material and bigger lumps drop through the nozzle ring and is eventually re-

circulated in to the feed material inlet. Moisture evaporates almost immediately as the gas

stream carries finer portion of material to the separator. The separator allows the material

that has reached required fineness to leave the grinding mill.

VERTICAL MILL SPECIFICATION:

Mill fan ------------------------------------------------------------- 2200kw

Motor -------------------------------------------------------------- 3400kw

Motor r.p.m -------------------------------------------------------- 990

66
Table r.p.m -------------------------------------------------------- 24.28

4.12 PACKING :

In cement silos blowers are used due to which cement does not damage and no

stones are formed. Compressed cannot be used in cement silos only blower air is

used.

Fig 4.4 packing plant

Flsmidth Ventomatic Spa was the first manufacturer to develop a microprocessor based

controller for filling and weighing units on packers and the first to introduce the electronic

rotary packer in an industry that up until than had only known packers with mechanical

weighing system.

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The latest and most successful step in the continuous path of innovation is represented by the

new GIROMAT EVO rotary packer generation that distinguishes itself in the market for the

very compact and modular design with very high flexibility and expandability, thanks to the

modular integration between mechanical parts and electronic control.

GIROMAT EVO rotary packers are specially designed and developed for handling many

types of building materials, with a wide range of configurations such as:

- Various impeller designs;

- Bag clamping device for glued and stitched bags and suitable for various bag construction

material;

- Quick discharge system;

- Bag sealing system on board (ultrasonic technology).

Flsmidth Ventomatic supply and control complete packing

Lines including:

- Cement feeding such as bucket elevator, vibrating screen and vane feeder;

- Filled bag transport system comprising bag cleaning, electronic check weighed, bag trap,

belt conveyor, curves, bag diverters;

- Bag loading comprising automatic and manual truck loaders, pelletizes;

- Dust recovery system comprising screw conveyors, bag filters, hoppers.

4.12.1 Main features:

4.12.1.1 Electronic
The packer is equipped with the last generation of electronic weighing units, EWU (OIML

approved), encoder and optical connection.

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4.12.1.2 Versatile
Available for wide-range of bag types, sizes and for manual or automatic adjustment.

4.12.3 Open-ended

Suitable either for cement material or dry mix, gypsum and other powdery products

and expandable in capacity.

4.12.4 Modularity and flexibility

A Flsmidth Ventomatic packer is composed of a number of preassembled modules, which are

prepared and tested before delivering. These modules are quickly and easily mounted on the

central tank of the packer during the erection. The numbered pneumatic connector plugs and

electric rapid connectors avoid the possibility of mistakes. If required and in order to

minimize the initial investment, it is possible to put the packer in service with a reduced

number of bag filling units. In case of future growth in production demand, additional filling

units can be easily added on.

4.12.5 Main parts of packer:

4.12.5.1 Optical connection

Infrared data transmission device for connecting the filling units (mounted on the rotating

part), the operator panel and the control system

4.12.5.2 Encoder
To track the angular position of the filling units and control the bag filling sequences

(Filling cycle)

4.12.5.3 Electronic weighing unit

Multiprocessor electronic weighing unit specifically designed for bagging application

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4.12.5.4 Impeller
Vertical configuration for optimal filling

4.12.5.5 Filling Unit

Designed for high weight accuracy, high output and low dust emission

WORKING:

Cement from cement silo is send to air slide through mechanical or electrical

control valve. From air slide material goes to bucket elevator and than to hopper. Over the

hopper a separator is used to separate fine material and raw material. Raw material is send

back to the cement mill through conveyor.

Material is send to packer after passing the butter fly valve which is control by a computer.

6 packers are used in maple leaf cement factory. 3 packers are fitted with each silo. Each

packers has 8 nozzles on which bags are fitted for cement filling When bags are filled with

cement than send to Vento check belt where weight of bag is checked. Bag above are below

50 kg are rejected and send to cutter. Ok bags are send to the discharge belt from where bags

are loaded on vehicles.

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CAPACITIES OF LINE-II EQUIPMENTS:

Production capacities of major equipment are given below;

Serial No. EQUIPMENT CAPACITY RUNNING HOURS

1 Lime stone crusher 1000~1500 t/h 16 hours/day

2 Lime stone(2 piles) 35000 ton each -

3 Clay(2 piles) 13000 ton each -

4 Lime stone bin 250 t -

5 Clay bin 250 t -

6 Additive bin 350 t -

7 Raw mill 560 t/h 310 days/year

8 Coal mill 54 t/h -

9 Coal mill silos(2) 150 ton each -

10 C.F Silo 25000 t -

11 Kiln 280 t/h 330 days/year

12 Clinker dome 40000 ton

13 Cement mill OK-36- 175 t/h 310 days/year

14 Cement mill OK-36- 175 t/h 310 days/year

15 Cement Silo (2) 10000 ton each -

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4.13 ENVIRONMENTAL IMPLICATIONS OF CEMENT INDUSTRY:

4.13 EMISSIONS FROM CEMENT FACTORY

Many of the aspects of the cement making process are potentially environmentally damaging,

although these risks can be minimized. The areas of potential concern are listed below.

4.13.1 Dust emissions

The manufacture of cement generates large quantities of dust. These must be prevented (both

on environmental and economic grounds) from escaping to the atmosphere. The two areas

where dust has the potential to escape are via air streams that have been used to carry cement

(e.g. the mills or kiln) and directly from equipment used to transport cement (e.g. the various

conveyor belts).

Thus to prevent dust emissions all transport equipment is enclosed, and the air both from

these enclosures and from the kiln and mills is treated in an electrostatic precipitator to

remove its load of dust. Here dust-laden air passes between an electrode carrying 50 000

volts and an earthed collection plate. The electrostatic discharge between the electrode and

the plate forces the dust onto the plates, from which it is removed.

4.13.2 CO2

Cement manufacture is an energy intensive process. One of the most significant challenges

facing the industry into the 21st century is a requirement to reduce CO2 emissions.

CO2 is produced during the calcinations phase of the manufacturing process and also as a

result of burning fossil fuels. Opportunity to reduce emissions through increased energy

efficiency is only possible on the latter of the CO2 emissions.

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4.13.3 Liquid Effluents

Normally, effluents requiring treatment originate from cooling operations or as storm water.

Treated effluent discharges should have a pH in the range of 6–9. Cooling water should

preferably be recycled. If this is not economical, the effluent should not increase the

temperature of the receiving waters at the edge of the mixing zone (or 100 meters, where the

mixing zone is not defined) by more than 3° Celsius. If quantities of suspended solids in the

effluent are high in relation to receiving waters, treatment may be required to reduce levels in

the effluent to a maximum of 50 milligrams per liter (mg/l). Note that the effluent

requirements are for direct discharge to surface waters.

4.13.4 Ambient Noise

Noise abatement measures should achieve either the levels given below or a maximum

increase in background levels of 3 decibels (measured on the A scale) [dB(A)].

Measurements are to be taken at noise receptors located outside the project property

boundary.

4.13.5 Quarry and plant water runoff

Runoff of storm water and treatment of waste water from quarries is a problem for almost all

quarry operations. Usually this is trapped in wetland areas where the water is treated in a

controlled manner. Within the factory runoff can be contaminated by oils and lubricants, but

the runoff is monitored and training programmers are regularly undertaken to ensure this

does not happen.

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4.13.6 Chrome bricks

Kiln bricks used to be made of hexa valent chrome, which is a carcinogen and causes

dermatitis in some people. Since the problems associated with its use were identified both

Milburn and Golden Bay (along with almost all cement manufacturers internationally)

replaced these bricks with environmentally-sound magnesium-spinal bricks.

4.14 Characteristics of energy consumption in cement production:

The cement industry is said to be an energy-intensive industry together with steel, paper and

petrochemical industries. The percentage of energy cost in port land cement production cost

is 20 to 30%. If the energy cost is reduced, the manufacturing cost is lowered, resulting in

increasing the company‟s profits.

Ninety percent or more of fuel is consumed for clinker burning. About 40% of electric power

is consumed for finish grinding, and a little under 30% each is consumed by the raw material

process and the clinker burning process. The finish grinding process mainly consumes

electric power for the mill, and the clinker burning process mainly for the fan.

The raw material grinding process consumes a large volume of power for the mill and fan

The Japanese cement production process is mostly occupied by SP and NSP kilns and coal is

used as fuel, so that the ratio of electric power consumption by the clinker burning process is

high. In a plant mainly using a wet process kiln, the finish grinding process consumes power

in a larger quantity than the aforementioned example.

In such a case, energy conservation measures shall be taken by focusing on the clinker

burning process for the fuel consumption and on the finish grinding process for the electric

power.

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 CONCLUSION

 Maple leaf cement factory is the best place to learn specially for the students of

mechanical technology because almost every type of machines are used here for

production purpose.

 High accuracy and latest technology plants are fitted at maple leaf with high

production rate.

 German and French technology plants are used.

 Latest techniques for cement manufacturing are used at maple leaf cement factory.

 High qualified and hard working staff is employed in this factory.

 Excellent working environment is provided to internee engineers. They can provide a

chance to trainee‟s inhance their skills and knowledge about their study.

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76
Future Recommendations about this industry:

Maple leaf cement factory is one of the top ranking industries in Pakistan. This

industry is counted in those industries in Pakistan which using latest techniques

and technology for the production of cement. After completing my internship my

recommendations about this industry is

 Prefer maple leaf cement factory for internship because excellent

environment is provided here to learn and inhance your knowledge.

 After completing your internship at maple leaf cement factory you should

be able to join any cement industry in the world because latest

technologies are adopted here for cement production.

 If you get a chance don’t waste your time and take keen entrust in your

job.

 Prefer cement industry for your job inside Pakistan because this industry

has a very huge scope in future and has a potential to play a very vital

role in the economy of Pakistan.

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 References

[1]Brabant, Malcolm ( 2011). Cement definition (research paper)

[2] Hill, Donald (1984).Process of cement (research paper)

[3] Ridi, Francesca (April 2010).process of cement (research paper)

[4] Pucher, John & Lewis Dijkstra (February 2000). "Making Walking and Cycling Safer:
Lessons from Europe" (PDF).Transportation Quarterly. Transportation Alternatives.
Retrieved 2007-08-15.

[5]Herman, Marc (October 2013). "Commuting by Bike Was Way Up Last Year". Pacific
Standard. Retrieved

[6] Vient, Ben (February 28, 2016). "Speeding to reverse in Alicante, Spain". Florida Today.

Melbourne, Florida. pp. 6E

Web Link

[7] History of cement available in web at http//www.maple leaf cement.pk

[8] Back ground of cement industry available in web at http//www.maple leaf cement.pks

[9]Production of cement industry is available at http//www.maple leaf cement.pk

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