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A REPORT ON WINTER TRAINING On "CEMENT MANUFACTURING PROCESS" J.K. CEMENT LTD., NIMBAHERA Vellore Institute of Technology, Vellore DURING SESSION 2015-16 Guided By: Submitted to: Mr. N K Vaishnav Mr. Shailendra Sharma Sr. Officer RTC Manager HR & RTC Submitted By: Anshul Bhandari 13BCH0001 B. Tech (Chemical Process Engineering)

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Page 1: Project report_raw meal

A

REPORT ON WINTER TRAINING

On

"CEMENT MANUFACTURING PROCESS"

J.K. CEMENT LTD., NIMBAHERA

Vellore Institute of Technology, Vellore

DURING SESSION 2015-16

Guided By: Submitted to:

Mr. N K Vaishnav Mr. Shailendra Sharma Sr. Officer – RTC Manager – HR & RTC

Submitted By:

Anshul Bhandari

13BCH0001

B. Tech (Chemical Process Engineering)

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PREFACE

As per the requirement of engineering curriculum, J K Cement WORKS, Nimbahera has been

kind enough to permit me to complete my vocational training on “CEMENT

MANUFACTURING PROCESS”.

The internship report is a detailed submission on the cement making process starting from the

source to its final packing stage. It includes the unit operation, process equipments, control

systems, and the quality control analysis undergone by the JK Cement Works at Nimbahera

(Rajasthan).

(………………………………)

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ACKNOWLEDGEMENT

It gives to me tremendous pleasure in acknowledge the invaluable assistance to me by various

personalities. In successful completion of this report, I express my gratitude towards Mr. S K

Rathore, Unit Head, and the entire management of J. K. Cement Works for giving me a chance

to work as a vocational trainee in their esteemed organization.

I wish to acknowledge my profound gratitude towards Shri M S Shekhawat, Asst. Vice

President – HR & IR for giving me opportunity in this field.

I also wish to acknowledge my profound gratitude towards Mr. Shailendra Sharma, Manager –

HR & RTC and Mr. N K Vaishnav, Sr. Officer - RTC for incessantly guiding me in-depth

training on “Cement Manufacturing Process”

I also wish to acknowledge my parents and university faculties who always encourage and

support me at every right step in my life.

(………………………)

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An Introduction to

HR Department

JK Cement Works

Kailash Nagar, Nimbahera

District: Chittaurgarh-312617

(Rajasthan)

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CONTENTS

1. Overview of J K Cement Works

1.1 The Company

1.2 About J K Cement

1.3 Grey Cement Plants and Production Capacity

1.4 Power Plant

2. Management Set- up.

3. Organizational Chart.

4. Regional Training Centre - North

5. Corporate Social Responsibility

6. Manufacturing of White Cement

7. Manufacturing of Grey Cement

8. A Passion for Quality - Characteristics of Cement

9. Preparation of Raw Meal

9.1 Mined and crushed raw material

9.2 Prehomogenization

9.3 Grinding

9.4 Homogenization

9.5 Raw Meal

10. Conclusion

11. Bibliography

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1. OVERVIEW OF J K CEMENT LTD.

1.1 The Company

Kamla Tower, Kanpur

J.K. Cement Ltd is an affiliate of the multi-disciplinary industrial conglomerate J.K.

Organisation which was founded by Lala Kamlapat Singhania. For over four decades, J.K.

Cement has partnered India's multi-sectoral infrastructure needs on the strength of its product

excellence, customer orientation and technology leadership The Company has over four decades

of experience in cement manufacturing. Our operations commenced with commercial production

at our first grey cement plant at Nimbahera in the state of Rajasthan in May 1975. Subsequently

the Company also set up 2 more units in Rajasthan at Mangrol and Gotan. In the year 2009 the

Company extended its footprint by setting up a green-field unit in Muddapur, Karnataka giving it

access to the markets of south-west India. In the year 2014, the company further expanded its

capacity in the north with brownfield expansion of 1.5 MTPA integrated unit at Mangrol and

split grinding unit of 1.5 MTPA at Jhajjar. Today J.K. Cement has an installed grey cement

capacity of 10.5 MTPA making it one of the leading manufacturers in the country.

The Company is the second largest manufacturer of white cement in India, with an annual

capacity of 600,000 tonnes in India. We are also the second largest producer of Wall putty in the

country with an annual installed capacity of 5,00,000 tonnes.

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J.K. Cement was the first Company to install a captive power plant in the year 1987 at Bamania,

Rajasthan. J.K Cement is also the first cement Company to install a waste heat recovery power

plant to take care of the need of green power. Today at its different locations, the Company has

captive power generation capacity of over 140.MWs which include 23 MW of waste heat

recovery power plants.

The Company has made its first international foray with the setting up of a green-field dual

process white cement-cum-grey cement plant in the free trade zone at Fujairah, U.A.E to cater to

the GCC and African markets. The plant at Fujairah has a capacity of 0.6 million tonnes per

annum for White Cement with a flexibility to change over its operation to produce upto 1 million

tonnes per annum of Grey Cement.The commercial production from Fujairah Plant started from

Sep'2014.With this, J.K Cement Ltd has become the second largest White Cement Producer in

the World.

As a part of its new initiatives, the Company plans to increase the production capacity of Wall

Putty to keep pace with the rising demand .In this direction, the company plans to put up 6 lac

tonnes capacity at Katni in M.P.The first phase of 2 lacs tonnes will be taken up by the end of

Fiscal 16.

Backed by state-of-the-art technology, access to the best quality raw materials and highly skilled

manpower against the backdrop of India's infrastructural growth in an overdrive, we are upbeat

about the future. Superior products and a strong Brand name, an extensive marketing and

distribution network and the technical know-how represent the Company's abiding strengths.

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1.2 About J K Cement

J.K Cement has three decades of experience in cement manufacturing. From modest beginning in

the year 1974 with a capacity of 0.3 million tonnes at Nimbahera in Rajasthan, today J.K Cement

has 6 kilns of different capacities with a combined annual capacity of 7.5 million tonnes. The

three cement units having aggregate capacity of 4.5 million tonnes are located in Rajasthan at

Nimbahera (capacity 3.25 million TPA), Mangrol (capacity 0.75 million TPA) and Gotan

(capacity 0.47 million TPA) and one unit in Karnataka at Muddapur with capacity of 3 million

TPA. The Company is the second largest manufacturer of White Cement in India, with an annual

capacity of 400,000 tonnes and value-added building products such as Wall Putty.

The Company also has a fully automated plant of White Cement based Wall Putty having a

production capacity of 3 lac tonnes per annum. J.K. White Cement's plants are accredited with

ISO - 9001 and 14001 Certified Company by LRQA. Further, the plant is also OHSAS 18001

(For safety and environmental upkeep) accredited.

1.3 Grey Cement Plants and Production Capacity

We manufacture grey cement in two facilities located at Nimbahera and Mangrol in the state of

Rajasthan in Northern India. Our plants have obtained many accolades and recognition, the most

noteworthy being IMS Comprising of : ISO-9001:2008 for QMS and ISO-14001:2004 for EMS

for the grey cement facility at Nimbahera and Mangrol.

The following tables shows: PRESENT CAPACITY AND PERFORMANCE

CLINKER PRODUCTION – Nimbahera and Mangrol Plant

Plant Capacity ( Tonnes / day)

J K Plant, Nimbahera

I. Kiln 1200 II. Kiln 1650 III. Kiln 4700

TPD

7550

Unit 1 at Mangrol 2100

Unit 2 at Mangrol 5000

Total Capacity 14650 TPD

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PRODUCTION ANALYSIS TABLE: IN TONS – Nimbahera and Mangrol Plant

Year Clinker Cement

2012 - 13 2955814 3567226

2013 – 14 3008736 3523527

2014 – 15 1961430 2378020

FINANCIAL ANALYSIS: IN Million – J K Cement Ltd.

1.3.1 J.K. Cement Works, Nimbahera

Commenced commercial production in 1975 with an

initial capacity of 0.3 MnTPA. In the year 1979, a

second production line was added to enhance the

production capacity to 0.72 MnTPA. 1982 witnessed the

incorporation of another production line taking the

production capacity to 1.14 MnTPA. In 1988 a pre-

calciner was installed and the production capacity

touched 1.54 MnTPA. Constant modernization and up-

gradation was instrumental in bringing the plant to its

present capacity of 3.25 MnTPA. Major modification to

reduce the electrical energy cost & to utilize the waste

heat at maximum, Waste Heat Recovery System of 13.2

MW was installed in the year 2007-2008.Recognition:

IMS comprising of ISO-9001:2008 for QMS and ISO-

14001:2004 for EMS.

Nimbahera

Year Turnover PBT

2012 - 13 3342.58 337.54

2013 – 14 3201.72 114.18

2014 – 15 3859.40 144.10

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1.3.2 J.K. Cement Works, Mangrol

Commenced commercial production in Dec'2001 with a capacity of 0.75 MnTPA. It is situated

close to Nimbahera plant (10kms away) - offers it significant synergy benefits like assistance

from technical & commercial staff of Nimbahera Complex. The current capacity is 1.0

MnTPA. We are also starting work on a brown field expansion at Mangrol having a capacity of

3 MnTPA, integrated plant with 1.5 Mn. TPA cement grinding capacity, 25 MW Captive

power plant and 10 MW Waste Heat Recovery plant.

1.3.3 J.K. Cement Works, Muddapur

It is situated near Muddapur village of taluka - Mudhol, District - Bagalkot (Karnataka) and has

the latest state of art technology to manufacture 3.0 Million tonnes of cement per annum. The

commercial production at Muddapur started in September, 2009 and the despatch commenced in

October, 2009. The plant has the latest and the most modern dry process pre-calcination

technology with sophisticated state of the art technology and control system from Internationally

renowned firms like FL Smidth, Tahio Engineering Corporation, Japan and others for

manufacturing cement with robotic technology and to ensure top quality cement consistently.

The best equipments available in the global market have found their way into the plant making it

the most modern plant. The plant has a 6500 TPD kiln. The cement production capacity of the

plant is upto 3.0 Milliontons per annum based on the quantum of OPC, PPC and Slag Cement.

1.3.4 J.K. White Cement Works, Gotan

Our pioneering foray into white cement 25 years ago created a new chapter in the history of J.K.

Cement and the J.K. White Cement Plant is an integral part of the same.

We were the first White Cement facility in India, which was limestone based, and manufactured

Cement through the dry process. The White Cement plant was commissioned in 1984 at Gotan,

Rajasthan, with an initial production capacity of 50,000 tons. The White Cement plant uses

technical expertise from F.L. Smidth & Co. from Denmark and state of the art technology with

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continuous on-line quality control by micro processors and X-rays ensure that only the purest

White Cement is produced. Over the years, continuous process improvements & modifications

have increased the plant's production capacity to 400,000 tons per annum.

1.3.5 J.K. Cement Works, Fujairah

The Foundation Stone being laid by H.H. Sheikh Mohammed Bin Hamad Al Sharqi - Crown

Prince of Fujairah along with Shri Yadupati Singhania - MD & CEO, J.K. Cement Ltd. and Shri

Raghavpat Singhania - Special Executive.

J.K. Cement Ltd. has added yet another feather to its cap with the announcement of its maiden

overseas plant at Fujairah, UAE which has a capital outlay of US $ 150 million. The plant's

foundation stone laying ceremony was held on November 14th, 2011in the presence of His

Highness H.H. Sheikh Mohammed Bin Hamad Al Sharqi - Crown Prince of Fujairah. Also

gracing the occasion were Shri Yadupati Singhania – MD & CEO, J.K. Cement Ltd., Shri

Raghavpat Singhania – Special Executive, Mr. A.K. Saraogi – CFO & President (CA), Mr. N.

Gowrishankar – Unit Head (J.K. Cement Works, Fujairah) and Mr. D. Ravisankar – President,

J.K. Cement Works, Nimbahera.

The capacity of the Grey cum White cement plant is slated to be at 1,750 tonnes per day (tpd) for

White Cement clinker and 2,800 tonnes per day (TPD) Grey cement clinker.

The Commercial production from the plant started from Sep'14.

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The plant at Fujairah has a capacity of 0.6 million tonnes per annum for White Cement with a

flexibility to change over its operation to produce upto 1 million tonnes per annum of Grey

Cement. The plant shall have the flexibility to have 100% white cement, a mix both of white

cement and grey cement or 100% grey cement, depending upon the market demand. Thus, the

Company plans to cater to the demand in the region as well as to the neighbouring countries

through this manufacturing facility.

As has been a ritual with J.K. Cement Ltd., in this venture as well, we will continually strive to

uphold the quality consciousness, customer experience and best ethical practices that J.K.

Cement Ltd. is known for.

1.4 Power Plants

All our plants have captive power facilities except grinding unit at Jhajjar. Infact, J.K. Cement

was the first Company to install captive power plant in the year 1987. J.K Cement is also the first

cement Company to install a waste heat recovery power plant to take care of the need of green

power. Today at its different locations, the Company has captive power generation facilities of

over 140.7 MWs including Waste Heat Recovery of 23.2 M.W.

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2. MANAGEMENT SET- UP

2.1 Corporate Level- Kanpur

Chairman & Managing Director - Shri Y P Singhania

Special Executives - Shri Raghavpat Singhania

Shri Madhavkrishna Singhania

Business Head - Shri Rajnish Kapur

2.2 Heads:

Project

President Project Shri D Ravishankar

Units

Unit Head Shri S K Rathore J K Cement, Nimbahera and Mangrol,

Distt: Chittaurgarh, Rajasthan

Unit Head Shri A K Jain JK Cement Works, Muddapur,Distt:

Bagalkot, Karnataka

President - Works Shri B K Arora J K Cement- White and Grey Plants at

Gotan, Distt: Nagaur, Rajasthan

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3. ORGANISATIONAL CHART

J K Cement Ltd.

Production & Location

J K Cement

Works,

Mangrol

(Raj.)

Unit 1 & 2

Grey

Cement–

7100 TPD

J K

Thermal

Power,

Bamania

(Raj.)

CPP – 15

MW

J K

Cement,

Mudhol,

Karnataka

Grey

Cement –

9000 TPD

CPP– 50

MW

J K Cement,

Gotan (Raj.)

White Cement

–1000 TPD

Grey Cement

– 1200 TPD

CPP – 7.5MW

J K Cement

Works,

Nimbahera

(Raj.)

Grey Cement–

7550 TPD

CPP – 22MW

WHR–13.2 MW

ABROAD:

JK Cement

Fuzairah,

UAE

White and

Grey Cement

2800TPD

J K Organization

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4. Regional Training Centre: Nimbahera

The Regional Training Centre - North is a premier training centre of India promoted with

assistance from World Bank, DANIDA and Govt. of India as a unique HRD project in Cement

Industry. It is equipped with modern training aids and caters to the skill enhancement and

competency developmental needs of more than 20 cement and other plants. It has trained over

13000 technical and managerial personnel during the last 21 years.

The centre has conducted many tailor-made in-house programs for cement and other industries in

India and abroad including for Oman Cement, Oman and Star Cement, Dubai and Hama Cement,

Syria / EHDASSE Sanat Corp.Iran and NCC Yemen.RTC has specialized packages / modules in

Mining, Process, Maintenance disciplines like Operation & Maintenance of HEMM / Gear-boxes

/ Pumps / Compressors / Electrical & Electronics Equipments / Energy Conservation

/Environment Management and Machinery Alignment, etc. designed and developed by renowned

International / National agencies like FLS Denmark, NCCBM, TATA Interactive Systems, VEC,

NITTTR, etc. More than 100 senior line mangers from ten plants have been trained at Denmark,

NITTTR, Bhopal and Chennai, who act as resource persons. Besides OEM's and management

experts of national repute are invited to make these programs effective and gainful experience for

the participants.

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RTC VISION Be a premier centre of excellence in competency development of

human resources in cement,mining and other industries for meeting

the techno-economic challenges under globalized environment.

RTC MISSION RTC seeks to develop ordinary manpower to produce extra ordinary

results by providing the best inputs of learning to help industry

generate surpluses with sensitivity towards environment, quality and

cost.

RTC OBJECTIVE To prepare the employees of Cement and other industries by

developing desired competencies for meeting the requirements of

present and future roles.

To develop and maintain a pool of competent technocrats and

managers to meet the emerging challenges of competition &

growth.

To help people strive for innovative solutions and create a passion

for quality, energy, Environment conservation and optimization

of resources.

5. CORPORATE SOCIAL RESPONSIBILITY

J K Cement has contributed significantly to the development of various services in and around its

offices and plants. Some of such activities can be enumerated as under :

Education Schools and University:

Dr Gaur Hari Singhania Institute of Management & Research, Kanpur

Sir Padampat Singhania Technical University at Bhatewar, Udaipur.

J K Institute of Technology – JKIT at Nimbahera

Padam Vidya Vihar – Primary School at Nimbahera

Kailash Vidya Vihar – Sr Secondary School at Nimbahera

Sr Secondary School, Gotan

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Educational services:

Construction of rooms in Govt. College at Nimbahera.

Running JK Institute of Technology, ITI in five trades affiliated to NCVT.

Running 10+2 CBSE affiliated school

Running Regional Training Centre for Cement technocrat’s aided by WorldBank &

DANIDA.

Various constructions in nearby Govt. Schools of Chittorgarh district.

We are involved in girls school (under construction) and committed reasonable financial

contribution for above

Medical services

Rs. 36 lacks contribution for the construction of govt. Hospital at Nimbahera.

Ambulance to govt. Hospital.

Free facility of pathological laboratory for the persons of surrounding area.

Financial contribution to various NGOS for medical camps in the district.

Financial contribution for construction of dispensary & health centre in nearby villages.

Free Homeopathic consultancy/medicines for the patients of nearby area.

Religious services

Radhakrishna temple at colony premises.

prayer hall in hanuman temple in Nimbahera.

Bheemkeshwar temple in staff colony.

Dharmashala at Bhanwarmata (tourist/ religious place).

8 rooms for Dharamshala at Pashupati Nath temple in Mandsaur (M.P.).

Various temples in number of nearby villages.

Sports services

Sports infrastructure like wooden badminton court, table tennis court, billiard room, and

cricket ground, volleyball ground in colony campus.

Sponsoring all India youth football, volley ball and badminton tournaments.

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Sponsoring inter-district tournaments.

Arranging summer camps for various sports.

Other social services

Construction of approach roads in and around villages of mining area.

Digging of tube wells.

Supply of tube well pumps.

Construction of water tanks.

Supply of drinking water in tankers in nearby needy places during summer.

Regular plantation in plant, colony and nearby villages.

Direct and indirect employment to thousands of persons of surrounding area.

Financial helps to NGOS.

Financial aid to organize religious festivals by municipal board.

6. Manufacturing Process - White Cement

At J.K. White Cement Works, Gotan we use technical expertise from F.L. Smidth & Co. from

Denmark and state of the art technology with continuous on-line quality control by micro

processors and X-rays to ensure that only the purest White Cement is produced. We manufacture

White Portland Cement through these 5 significant stages - Crushing, raw meal grinding,

clinkerisation, cement grinding and packing for dispatch.

At raw mill, crushed limestone, clays and feldspar of desired chemical compositions are fed

through electronic weigh feeders.

Clinkerisation is the heart of cement manufacturing process, where the raw material is fed to

pre-heater at controlled rate through electronic weigh feeder. The feed enters the kiln through

cyclones and fuel is fired at the kiln outlet end.

Clinker and gypsum are fed to the cement mills through electronic weigh feeders at controlled

rate and ground in ball mills. The classifier (high efficiency separator) controls the fineness of

white cement. The finished product of desired chemical composition and physical properties

is transported to Cement Silos for storage.

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White cement is drawn from cement silos, for packing in bags by electronic rotary packer and

in small pouches by Fill, Form and Seal machines..

Step 1 (Mining) Step 2 (Crushing) Step 3 (Grinding) Step 4 (Fuel Preparation)

Step 5 (Kiln Operations) Step 6 (Cement Grinding) Step 7 (Packing Process) Step 8 (Loading Process)

7. Manufacturing Process - Grey Cement

The production process for cement consists of drying, grinding and mixing limestone and

additives like bauxite and iron ore into a powder known as "raw meal". The raw meal is then

heated and burned in a pre-heater and kiln and then cooled in an air cooling system to form a

semi-finished product, known as a clinker. Clinker (95%) is cooled by air and subsequently

ground with gypsum (5%) to form Ordinary Portland Cement ("OPC"). Other forms of cement

require increased blending with other raw materials. Blending of clinker with other materials

helps impart key characteristics to cement, which eventually govern its end use.

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All J.K. Cement plants are dry process plants. Limestone is crushed to a uniform and usable size,

blended with certain additives (such as iron ore and bauxite) and discharged to a vertical roller

mill/Ball Mill, where the raw materials are ground to fine powder. An electrostatic precipitator

dedusts the raw mill gases and collects the raw meal for a series of further stages of blending.

The homogenized raw meal thus extracted is pumped to the top of a preheater by mechanical

transport /FK pumps. In the preheaters the material is heated to 750ºC. Subsequently, the raw

meal undergoes a process of calcination in a precalcinator (in which the carbonates present are

reduced to oxides) and is then fed to the kiln. The remaining calcination and clinkerization

reactions are completed in the kiln where the temperature is raised to between 1,450ºC and

1,500ºC. The clinker formed is cooled and conveyed to the clinker silo from where it is extracted

and transported to the cement mills for producing cement. For producing OPC, clinker and

gypsum are used , for producing Portland [Pozzolana] Cement ("PPC"), clinker, gypsum and fly

ash are used and for producing Portland Slag Cement (PSC), cement uses clinker , gypsum and

slag.

The JK Cement has adopted the latest technology of manufacture of cement by dry process with

suspension pre heater and pre calcination. The unit has selected the dry process for the

manufacturing of cement because the fuel consumption in dry process of cement manufacture is

less; compared to wet process, The coal consumption ratio of wet and dry process is about 1.3: 1.

However, in the case of dry process power consumption is higher. The present worldwide trend

in cement industry is to put up all plants with dry process mainly because of the overall economy

and lesser need of water resources.

RAW MATERIALS USED

1) Lime Stone

2) Gypsum

3) Laterite

4) Alumina

5) Coal

6) Fly Ash

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STAGES OF MANUFACTURING PROCESS

STAGE I - MINING

Maliakhera, Karoonda and Tilakhera are the mines feeding the plants. Open cast mining

technique is used. The limestone is transported to the crusher hopper through conveyor belts and

dumpers.

STAGE II - CRUSHER

The limestone is crushed to the standard size for feeding the Raw Mill.

STAGE III - STACKER RECLAIMER

The stacker is used to make huge stockpiles of crushed raw material while the reclaimer picks up

the required quantity of raw material from the stockpiles and feed them into the Raw Mill

through a belt conveyor.

STAGE IV - RAW MEAL HOPPER

There are different hoppers for storing crushed Limestone, Alumina, Laterite & Gypsum, before

being fed into the Raw Mill.

STAGE V - RAW MILL

All these components of raw mix are put through grinding mills and then properly homogenized

and stored in silos.

STAGE VI - KILN

The materials from the silos are fed to the kiln through automatic weigh feeders. The hot flue

gases from the kiln passes through pre heater where raw meal gets partly calcinied and converted

into clinker at a temperature of about 1400 degree centigrade in the main burning zone of the

kiln.

STAGE VII - COAL SECTION

Bituminous and Lignite varieties of coal are used here. The coal from the stock yard is fed into

the coal crusher from where the crushed coal is stored in the coal hopper. This coal to be used as

fuel for the kiln is crushed, pulverized and fed into the kiln along with primary air.

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STAGE VIII - CLINKER STORAGE

After the coal is fired into the kiln and the raw meal undergoes chemical reactions, the product,

which emerges, is called the clinker. The clinker obtained from the kiln is cooled and transported

to the clinker storage yard through pan - conveyors.

STAGE IX - CEMENT MILL

The material from the clinker storage is fed into the clinker hopper and gypsum into the gypsum

hopper. The proportionate mixture of gypsum and clinker in the crushed form is sent to the

cement mill, which grinds it into fine powder called cement.

STAGE X - PACKING AND DISPATCH

The cement from the cement mill is pneumatically fed into cement storage silos from where it is

packed in HDPE bags by rotary packing machine and then directly loaded into wagons or trucks.

The complete process is controlled by a most modern process control instrumentation system.

There is a well-equipped laboratory for controlling the quality of the product at various stages in

its manufacturing process.

8. A Passion for Quality – Characteristics of Cement

At J.K. Cement, quality is not just a product centric vision but an Omni-organisational vision.

With a firm belief that quality begins and ends with people, the management has inculcated a

quality culture in the very thought process of the organisation.

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J.K. Cement Works - Nimbahera & Mangrol

J.K. Cement has effectively pledged its reputation as the market leader in quality of cement

manufactured. At Nimbahera and Mangrol, our labs are equipped with State-of-the-art Process

control instrumentation and quality control system. The testing laboratory is manned by qualified

personnel to ensure quality of product comparable to the best available in the market at all times.

The quality management system at J.K. Cement Works is certified by the Prestigeous Lloyds

Register for quality assurance since the year 1995.

Our plants are also ISO 9001:2008 & ISO 14001:2004 certified and are in the process of getting

our laboratory accredited with the NABL-National Accreditation Board for Testing and

Calibration Laboratories.

Locate our Plants

Grey and White Cement Works

NIMBAHERA

Nimbahera Dist - Chittorgarh,

Kailash Nagar - 1,

Rajasthan – 312617

Phone - 01477 - 220087

MANGROL

Mangrol, Tehsil Nimbahera

Dist - Chittorgarh, Rajasthan

Phone - 01477 - 246324

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MUDHOL Muddapur

Taluk Mudhol - 587122

Dist - Bagalkot, Karnataka

Phone - 08350-289000

Fax - 08350 - 280710

JHARLI (GRINDING UNIT)

P.O - Jharli

Dist – Jhajjar

Haryana – 124106

GOTAN

P.O.Gotan - 342902,

Dist - Nagaur, Rajasthan

Phone - 01591 – 230201

Fax - 01591 – 230206

(Both white and grey cement works)

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9. Preparation of Raw Meal

Raw Meal is prepared from the mined raw materials in the following way:-

Mined and Crushed Raw Material

Prehomogenization

Grinding

Homogenization

RAW MEAL

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9.1 Mined and Crushed Raw Material

Drill Compound Impact Crusher

The raw material is mined by blasting the mining sites using ammonia and fuel. An

approximately 8 meters of bench height is maintained for mining in JK Cements, Nimbahera

(Rajasthan). Also there are some other specifications like there should be a minimum of 4 meters

of distance between 2 successive holes and also there should be a minimum difference of 23

milliseconds between 2 successive blasts. Also a minimum of 300 meters of distance is to be

maintained from the blasting site for safety purposes.

The dumpers carry mined limestone from quarry to crushing plant where crushers are used for

coarse size reduction of limestone. Mainly three types of crushers are used:

1) Double Toggle Jaw Crusher

2) Double Swing Hammer Crusher

3) Single Rotor Impact Crusher

The mined limestone is first fed to the unloading hopper that has a maximum size allowance of

1m X 1.5m and has a capacity of 300 MT. This feed is then send to the main crusher

(Compound Impact type) having a rated capacity of 800TPH which gives an output size of less

than 40mm which is further send for prehomogenization process via Rubber Belt Conveyers

(RBCs)

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9.2 Prehomogenization

Linear Stacker (Chevron Formation) Scraper Reclaimer

Prehomogenization process involves stacking of crushed run of mined limestone onto a stock

pile and subsequently reclaimed in such a way that the inherent fluctuations in the Calcium

Carbonate (CaCO3) content are evened out.

The mined and crushed raw material is then transported from crusher to the stock piling site

using Rubber Belt Conveyors (RBCs) where the material is stacked either in chevron type

(longitudinal direction) or in windrow type (Linear direction). For this purpose, two types of

stackers can be used; either linear stacker that gives a longitudinal stock pile or circular stacker

that gives a circular stock pile with an arc formed by circular rotation of boom delivery point.

Finally a scraper reclaimer is used that evens out the fluctuations in CaCO3 content of raw

material. It uses a narrow rake covering the whole surface of pile. Its motion causes the particles

to roll down the slope. They are further reclaimed by the scraper chain moving in lateral

direction at the pile’s base.

The JK Cement Works uses a Swing Boom Luffing type stacker which forms a Chevron type

stock pile of capacity 30,000MT and is further reclaimed by Bridge type Scraper Reclaimer.

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9.3 Grinding

The prehomogenized raw material is then stored in supply hopper for fine size reduction.

Additional hoppers are used either for storing additives such as sandstone, Iron Oxide, etc or for

storage of corrective materials such as Laterite. The mixture is then ground in the raw mills and

the hot gases escaping from the pre heater exit are used for drying. For grinding purpose either

vertical raw mills or ball mills are used. Parallel to grinding, dust collectors either Bag Filters or

Electrostatic Precipitators (ESPs) are used for dust removal.

The JK Cement Works uses two Hammer Mills (200TPH) as secondary crusher which reduces

the prehomogenized raw material to 25 mm size from 40 mm input size and further sends it to

Ball Mills (RM1, RM2 and RM3) which further reduces size to 170 mesh. Apart from the

secondary crusher, the prehomogenized raw material, 40 mm in size, is directly send to the

Vertical Roller Mill (VRM 4) which gives an output size of 170 mesh. This grinded raw meal is

then stored in silos for further homogenization.

Prehomogenized Raw Material

(40mm)

Secondary Crusher (Hammer Mill)

(25mm)

Ball Mill (RM 1)

(170 mesh)

Ball Mill (RM 2)

(170 mesh)

Ball Mill (RM 3)

(170 mesh)

Vertical Roller Mill (VRM4)

(170 mesh)

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9.4 Homogenization

The grinded raw material from the raw mills either the Ball mills or the Vertical raw mill is

stored in silos. In the silos homogenization process take place in which additives and corrective

materials are added and blended uniformly by passing compressed air to form required raw meal.

The compressed air can be passed either mechanically or pneumatically that involves porous

ceramic plates/fabric covered boxes permeable to air that passes to porous plates to fluidize the

raw meal stored in silos.

9.5 Raw Meal

Pyroprocessing (Rotary Kiln)

Finally raw meal is prepared which is further used for formation of clinker and cement at later

stages. This raw meal is then sent to kiln via pre heaters and pre calciner to form clinker which is

further cooled and is stored in silos. This clinker as per demand and requirement is taken from

the silos, grinded and then mixed with appropriate amount of Gypsum to form cement. Finally

the processed cement is send to packaging plant.

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The JK Cement Works, Nimbahera uses Suspension Pre heater kiln type Pyroprocessing

technique to form clinker that consists of Pre heaters, pre calciner and rotary kiln. The clinker so

formed is then cooled and grinded by the ball mills. Gypsum is added to the crushed clinker to

alter the settling time of cement in the cement mill. In the plant there are 6 cement mills in which

the first and second one works individually while third and sixth; and fourth and fifth are coupled

to give processed cement.

Finally this cement is send to packaging plant where either mechanically or pneumatically

packing machines are used to fill cements in 50Kg bags which are finally forwarded to the

Loading Station.

Packing Station Loading Station

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10. CONCLUSION

The report focuses on the initial stages of Cement manufacturing process i.e. preparation of raw

meal from the mined and crushed raw material which is further used for making clinker and then

cement.

The limestone mined from the site has different grades and thus it is then prehomogenized so as

to obtain evened CaCO3 content which is further grinded and additives and corrective materials

are added to it in homogenization process which makes it suitable for Pyroprocessing and further

processes.

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11. BIBLIOGRAPHY

Books and Authors

Portland Cement 2nd Ed., Thomas Telford

Natural Cement Comes Back", October 1941, Popular Science

WEB SITE

www.jkcement.com

www.rtcnorthindia.org