Presenths ud ation -Arjun ram prajapat.pptx
- 1. Title of the Training : Cement Plant Operation & Maintenance UltraTech Cement Limited Unit : Birla White Cement Works, Kharia Khangar, Jodhpur Rajasthan 342606 Training Period – From 18.05.2016 to 30.06.2016 From : Arjun Ram Prajapat Birla White Cement Works
- 3. 1984 1st plant set up by Indian Rayon with Production capacity of 1500 TPD, upgraded to 3100 TPD through modifications L-1 : 3100 TPD Total : 3100 TPD 1990 Commissioned 2nd Line with clinker production capacity of 3000 TPD, upgraded to 4150 TPD through modifications. 1995 Commissioned 3rd Line with clinker production capacity of 3500 TPD, upgraded to 5250 TPD through modifications. L-2 : 4150 TPD Total : 7250 TPD L-3 : 5250 TPD Total : 12500 TPD 2013 Commissioned 4th Line with Clinker Capacity of 10000 TPD. With potential for 12500 TPD. L-4 : 12500 TPD Total : 25000 TPD Consistent Capacity
- 4. UltraTech Plants : Spread across the country Rajashree Cement AndraPradesh Cement Works Pune BT Central Cluster Nagpur GU 5
- 5. Rajashree Cement Works …..the largest single location cement plant in India, with a production capacity of 25000 TPD and maintaining bag cost (Rs 53.00 ) lowest in UTCL cement business
- 7. 7 Material having adhesive and cohesive properties capable of bonding mineral fragments into a compact mass. OR Simply Binding material made out of Calcareous and Argillaceous material. What is Cement?
- 8. Types of Cement 33 Grade - IS : 269-2013 43Gr ade IS : 8112-2013 53 Gr ade IS :12269-2013 P.P.C - IS : 1489 -1991 P.S.C - IS : 455 -1989 MASONRY - IS : 3466 -1988 CEMENT ORDINARY PORTLAND CEMENTS BLENDED CEMENTS
- 9. Composition of Cement Ordinary Portland cement contains two basic ingredients, namely argillaceous and calcareous. In argillaceous materials, clay predominates and in calcareous, calcium carbonate predominates. A typical chemical analysis of a good Ordinary Portland Cement is as follows: Ingredient Percent Lime (CaO)………..63.00 Silica (SiO2)……….21.50 Alumina (Al2O3)………6.50 Iron Oxide (Fe2O3)……….4.50 Magnesia (MgO)…………1.00 Sulphur Trioxide (SO3)-------------2.00 Alkalies (Na2O+K2O)….0.50 Loss on Ignition (LOI)……..........1.00 Total…………………………………100.00
- 11. Major Equipment and Technology used Mining: LS Crushers are supplied from L & T Hazmag. Excavators of Tata Hitachi & high capacity Dumpers of both Caterpillar & BEML are used for mining activity. Raw Mills: Raw Mills are equipped with ball mill and energy efficient roller press which includes V-separator and in Line-IV Roller press finish grinding is equipped. Coal Mills: Unit-I Coal mill is of ball mill type supplied by KHD. Unit-II, III has energy efficient vertical coal mills are supplied by M/s. Loesche. Newly established Line-IV also has vertical coal mills supplied by Gebr – Pfeiffer Kiln: All 4 lines has grate coolers. Line I & II coolers are of KHD make and Line-III is recently changed to IKN cooler which is energy efficient, maintenance friendly & reliable.. Newly established line-IV is equipped with IKN cooler.
- 12. Cement Mill: Cement Mills are equipped with energy efficient ball mill with roller press obtained from M/s KHD Humboldt Wedag Ltd. Germany. CPP: Captive power plant I,II&III are equipped with AFBC boilers and newly established CPP IV & V are equipped with latest technology CFBC boilers. For all 5 Captive power plants, TG is supplied by BHEL, SKODA, ALSTOM & THERMAX. WHRS is obtained from NTK/Tech Pro for energy conservation. The plant operated through Fuzzy logic, X-Ray, XRD, On-line Ash & moisture Analyzers and Cem-scanner for optimum production. New Robotic laboratory is installed in Line-IV for online sample analysis and precision process control. Major Equipment and Technology used
- 13. Mines Department
- 14. LIMESTONE MININGS What is mining??? Any excavation for the purpose of extracting minerals is termed as mining process. ULTRATECH Unit Rajashree Cement Works, has a total mining area of 1800 acres. Out of which, only 354 acres has been utilized since 1981.
- 15. Flow chart of Geological Activity
- 16. Drilli ng •Purpose:- The drilling is done for the survey of the reserve limestone at the location and for the charging of explosive for blasting.
- 17. Blasti ng Why ? •Because the hardness of limestone is higher in the reserve found in our mines so surface mining method is not preferred. •PROCESS OF BLASTING The process of blasting comprises of certain steps. 1. MARKING 2. DRILLING 3. EXPLOSIVES
- 18. HEM M •HEMM stands for Heavy Earth Moving Machines. •HEMM are the heavy duty equipments used for performing drilling, excavation, dozing, loading, transportation etc. in mines. •Two types of HEMM:- 1. Track Type 2. Tyre Type
- 19. EXCAVATOR DRILL MACHINE ROCK BREAKER DOZER HEMM TRACK TYPE
- 21. Crusher
- 22. CRUSHE R •Crusher is used to reduce the size of the raw material limestone to an optimum feed size.
- 23. Major Components
- 25. STACKING AND RECLAIMING • After Crushing it is passed to the Stackers for stacking through the conveying belts. The Rajashree Cement has six limestone stockpiles, namely 1A, 1B, 2A, 2B, 3A & 3B. The material from 1A and 1B is fed to Unit-2, 2A & 2B to Unit-1 and 3A & 3B to Unit-3. The crushed material is stored in these stock piles with the help of automatic stackers where the limestone of High and Low grade is stored.
- 26. Raw Mill
- 27. Raw Mill Principle:- Its major working is based on crushing of material between grinding rollers and the table or grinding bowl. The crusher product is further reduced by grinding in ball mills/vertical roller mills/ ball mill – roller press to a fineness below 0.2mm size (raw meal) and is ready for feeding to the kiln after homogenization. Types of Raw Mill:- ▪ Roller mill ▪ Ball mill
- 29. WORKING OF VRM
- 30. Raw Grinding Process / Raw Mill Process
- 31. ROLLER PRESS • High pressure roller grinding of cement & clinker and hard brittle material. It is a modern & very energy-efficient process. • Significant development from a pre-grinding process to a range of applications • Including semi-finish grinding and finish grinding. The roller press is a flexible solution, highly suitable both for upgrades and for new installations. Upgrading may increase capacity by up to 100 percent, while the total specific energy consumption of new installations may be reduced by 20-30 percent compared with conventional grinding systems.
- 32. Ball Mill • Ball mill is a key grinding mill for regrinding, usually when materials after 2 or 3 stage • of crushing and grinding. Ball mill is efficiency to grinding many stones and rocks into • powder, like quartz, feldspar, coke coal, gold, copper, and so on • Ball milling application Our ball mill’s output size is range from 0.075mm to 0.4mm; it is widely used for Gold mining, coal grinding, cement, powder making, glass industry and export to Philippines, Pakistan, India, Iran, South Africa, Indonesia, Malaysia, Australia etc. Our ball mill can grind ore, stone, and rock, mineral or other materials that can be Grinded either by wet process or by dry dress.
- 33. Ball mill features and benefits 1. Highly reliable 2. Easy operation, easy maintenance 3. Wear-resistant parts – durable shell lining 4. Open or closed circuit operation 5. Grinds to any level of fineness 6. Energy efficient; large through-flow area ensures low pressure drop Adapts to capacity, plant layout and end product
- 34. Coal Mill
- 35. Process Flow for Coal handling
- 37. Kiln
- 38. The kiln system is most essential part of a cement plant and has to be operated continuously for as long as possible. The major components of the kiln system are. Pre-heater Pre calciners Kiln Tube Clinker grate cooler Kil n
- 39. S.no Temp. range Process 1 70 to 110 °C Free water is evaporated. 2 400 to 600 °C clay-like minerals are decomposed into their constituent oxides 3 650 to 900 °C Calcium carbonate reacts with SiO2to form belite (Ca2SiO4). 4 900 to1050 °C The remaining calcium carbonate decomposes to calcium oxide and CO2. 5 1300 to 1450 ° Partial melting occur and belite reacts with calcium oxide to form alite(Ca3O·SiO4). Process at Various Temperature
- 40. The different Zone in Rotary Kiln
- 42. CHARACTERSTICK OF CEMENT COMPONENTS C3S: High early strength Its range is 50-55% in cement If % is higher , it’s difficult to burn C2S: If C2S is higher, then C3S will be under burning. At higher temperature and quenching, C2S get transferred in C3S It contains 20-22% of the total clinker.
- 43. C3A: It is responsible for giving plasticity Its range is 6-8%, more plastic cement. High C3A, means low resistant against sulphate attack Low C3A means higher resistant against sulphate attack. C4AF: It imparts colour to the cement. Greater the range, higher will be the darkness to the cement
- 44. Clink er Clinker Chemistry Tri-calcium silicate (3CaO.SiO2) , (50-55%) Dicalcium silicate (2CaO.SiO2), (15-20%) Tricalcium aluminate (3CaO.Al2O3), (5-10%) Tetracalcium aluminoferrite(4CaO.Al2O3.Fe2O3), (5-15%)
- 45. CLINKER COOLERS –Types Of Cooler •Reciprocating Grate Cooler •IKN Cooler
- 46. Perforated Grates moving one over other creating forward motion for clinker. Air with high velocity flows vertically up 90 degree to Clinker flow. Reciprocating Grate Cooler
- 47. Grates doesn’t move. Forward motion for clinker is created by Horizontal Air Jet with very high velocity. Air with very high velocity flows parallel to Clinker flow & then moves vertically up. IKN Cooler
- 48. Cement Mill
- 49. • Clinker is ground with gypsum (calcium sulfate) to produce Portland cement • Fine grinding is necessary for high early strength • 85-95% -325 mesh (45 microns) • ~ 7 trillion particles per pound • Gypsum absorbs water and prevents setting of C3A during shipment CLINKER GRINDING
- 50. TYPES OF GRINDING MILLS – Ball mills – Vertical roller mills – Combination of Roller press & Ball mill
- 51. BALL MILL Ball or tube mills are horizontally rotating steel cylinders where size reduction of a given material is performed by motion of the grinding media. Rotation of the mill cylinder raises the pile of mill feed and grinding media to an optimum height, necessary for grinding operation. Grinding is performed by impact and friction between the grinding balls which hit one against another, as well as between the grinding media and the mill lining itself
- 52. VERTICAL ROLLER MILL Vertical roller mills are having rollers which travel in a horizontal circular path on a bed of feed material with which they are pressed in contact by vertical forces applied externally to them and the material being committed by the combination of compressive and shear action
- 54. Packing Plant
- 55. PACKING PLANT
- 56. SCHEMATIC VIEW OF TYPES OF PACKERS
- 58. FLOW OF CEMENT IN PACKING PLANT
- 60. Final Product of Cement Plant