POORNIMA COLLEGE OF ENGINEERING JAIPUR

1. POORNIMA COLLEGE OF ENGINEERINGJAIPUR Training Presentation on VIKRAM CEMENT(KHOR) NEEMUCH,M.P. Submitted by: Manish SinghECE 4th yr 7th sem. www.powerpointpresentationon.blogspot.com

2. CONTENTS • VIKRAM CEMENT PLANT • CEMENT • RAW MATERIALS • EXCAVATION • CRUSHING • STACKING • RAW MILL • COAL MILL • KILN • CEMENT FROM CLINKERS • SILOS • DESPATCH • CONCLUSION

3. Company Profile:Vikram Cement Limited has an annual capacity of 18.2 million tones. It manufactures and markets Ordinary Portland Cement, Portland Blast Furnace Slag Cement and Portland Pozzalana Cement. It also manufactures ready mix concrete (RMC).Vikram Cement Limited has five integrated plants, six grinding units and three terminals — two in India and one in Sri Lanka.Vikram Cement is the country’s largest exporter of cement clinker. The export markets span countries around the Indian Ocean, Africa, Europe and the Middle East.

4. ADITYA BIRLA GROUP

5. FEATURES • One of India’s mega national & multinational group. • Produces aluminum, copper, cement, viscose, staple fiber, carbon black, fertilizer, chemicals, iron,etc. • World leader in production of viscose and staple fiber. • 40 companies, 18 countries. • The group has 72,000 employees -7000,000 shareholders.

6. VIKRAM CEMENT PLANT

7. VIKRAM CEMENT • Established in 1985 at KHOR, district NEEMUCH, M.P. • 3 units and 2 mines. • Largest single location plant in the country.

8. RAW MATERIALS • Limestone • Gypsum • Laterite • Clay

9. Rotary Kiln Process Rotary kiln process is adoptable in large cement plant. The steps involved in the process are: • 1. Mixing • 2. Burning • 3. Grinding • 4. Packing.

10. 1. Mixing • Dry Process: The calcareous and argillaceous materials are crushed and powdered separately. The powdered materials are mixed in proper portions to get dry “raw mix”. It is kept ready and stored, in storage bins (silos) and then fed into rotary kiln for burning. • Wet Process: The calcareous materials are crushed, powdered and stored in silos. The argillaceous material is mixed with water in wash mills. The powdered lime stone and wet clay are led to grinding mills in proper proportion. Here they are mixed to form a paste called slurry’ containing nearly 4O% water. Its composition is adjusted and sent for burning process.

11. 2. Burning Process • (a) Drying Zone: it is upper part of rotary kiln, where temperature is around 100—400°C Water in the slurry gets evaporated here. • (b) Calcining Zone: It is at the central part of kiln. The lime stone of “dry mix” or “slurry” undergoes decomposition at a temperature of 1000°C. • (c) Burning Zone: It is the hottest zone. Temperature is about 1600°C. Here the mixture melts and forms clinkers (Small, round. grayish masses).

12. 3. Grinding • From the rotary kiln we get clinkers. These clinkers after cooling are carried to ball mills. It is mixed with 2—3% gypsum and grinded in ball mills. Gypsum increases the initial setting period of cement. 4. Packing • The ground fine power of cement is stored in silos and is then packed into 50 kg bags.

13. Cement production layout

14. EXCAVATION • MINES (khor mines & super mines) • Drilling • Blasting (explosive-ANC) • Shovels, dozers, dumpers-transportation

15. CRUSHER • Limestone excavated –not of appropriate size • Between rollers the limestone is dumped • The size is reduced required for raw mill

16. TYPES OF CRUSHER • JAW crusher • GYRATORY crusher • ROLL crusher • IMPACT crusher • HAMMER crusher

17. STACKING • Main job is to pile up the raw material. • Series of ridged roofs are formed. • Coarser material rolls down the pile. • Stacking device moves continuously to & fro over longitudinal center line of stock pile.

18. STACKING

19. Reclaiming • Removal of materials from stockpiles. • A raking down device sweeps across the cross sectional face. • Each cycle removes a thin slice also mixes the raw materials.

20. RAW MILL • VERTICAL raw mill • HORIZONTAL raw mill

21. VERTICAL RAW MILL

22. RAW MILL • rollers • circular plate • Tunnel for hot air • Material inlet • Plate rotates with rocker arm • Due to plate rotation, rollers rotate • material between both is grinded

23. HORIZONTAL RAW MILL

24. coal mill

25. COAL MILL • Not much different then raw mill. • Has to grind coal, lighter than limestone. • Rollers, plate, rocker arm assembly, coal inlet and outlet. • Working same as raw mill.

26. CLINKERING • Firing of raw material takes place in kiln. • Coal is used as a fuel. • At high temperature clinkers are formed. • Clinker= tri calcium silicate[C3S (alite)].

27. CLINKER STORAGE • Kiln does not always run simultaneously. • Direct grinding due to high temperature is not possible. • Storage capacity should be equal to one months production.

28. CEMENT FROM CLINKERS • Cement mill is used for clinker grinding. • Clinkers are fed in between rollers. • To create larger reactive surface.

29. GYPSUM • Gypsum - CaSO4.2H2O. • Speed of dehydration varies from one deposit to other. • The binding property of cement is due to gypsum.

30. CEMENT SILOS • Silos are buffer storage between production & despatch. • Tall cylinders made of concrete. • Some have partitions in them.

31. INTERNAL STRUCTURE OF SILO

32. DESPATCH • Cement is packed - jute bags. • By railways and roadways cement is transported to market.

33. DESPATCH OF CEMENT

35. CONCLUSION During my training of 30 days I saw machines working, studies being implemented, how to work in a group, above all I came to know what is the real job of an engineer.

36. ReferencesTraining Noteswww.wikipedia.com

37. THANK YOU

38. ANY QUERRY ?