KESHORAM CEMENT INDUSTRY

A
Training Report
Submitted in partial fulfilment for the award of the
Degree of
Bachelor of Technology (Mechanical Engineering)

Submitted by:

AMIT KUMAR MEENA

(16EBKME010)

Under the Supervision of:

N P SINGH
(GM Mechanical Department)
&
T. RAMESH
(Senior Manager of cement mill)

B K BIRLA INSTUTE OF ENGINEEERING AND TECHNOLOGY

PILANI, RAJASTHAN
 Index
S. No Title Page no.

1 Declaration Ⅲ
2 Acknowledgement Ⅳ
3 Abstract Ⅴ
4 Table of Contents Ⅵ
5 List of Figures Ⅷ
6 List of Tables Ⅷ
7 Introduction Ⅸ
8 Conclusion 26
 1. DECLARATION

I, the under-mentioned, solemnly declare that this internship report on

CEMENT MANUFACTURING is my original work. I further declare
that I have strictly observed reporting ethics and duly discharged copy-
right obligation and properly referred all outsourcing of materials used
in this report and nothing is confidential in this report in respect of the
company of my internship. I take the responsibility for all legal and
ethical requirements regarding this report.

Signature: __________________

Amit kumar meena (16EBKME010)

Deepak (16EBKME022)

Pankaj (16EBKME049)

Sunil (16EBKME077)
 3. ACKNOWLEDGEMENT

It gives me immense pleasure to express my deepest sense of gratitude

and sincere thanks to my guide N P SINGH (GM Mechanical
Department), KESORAM CEMENT, BASANTNAGAR, TELNGANA
for his valuable guidance, encouragement and help for completing this
work. I would like to express my sincere thanks to RAJESH GARG,
Plant Head for giving me this opportunity to undertake this project. I
would also like to thank R. Ramesh, DGM, & J. Praveen Kumar Senior
Manager, Kesoram Cement for whole hearted support. I am also grateful
to my teachers Mr. D C Sharma for their constant support and guidance.

At the end I would like to express my sincere thanks to all my friends

and others who helped me directly or indirectly during this project work.

Amit kumar meena (16EBKME010)

Deepak (16EBKME022)

Pankaj (16EBKME049)

Sunil (16EBKME077)

3 JULY 2019
 4. ABSTRACT

Cement is typically made from limestone and clay or shale. These raw materials are extracted
from the quarry crushed to a very fine powder and then blended in the correct proportions
This blended raw material is called the 'raw feed' or 'kiln feed' and is heated in a rotary kiln
where it reaches a temperature of about 1400 C to 1500 C. In its simplest form, the rotary kiln is
a tube up to 200 meters long and perhaps 3.85 meters in diameter, with a long flame at one end.
The raw feed enters the kiln at the cool end and gradually passes down to the hot end, then falls
out of the kiln and cools down.
The material formed in the kiln is described as 'clinker' and is typically composed of rounded
nodules between 1mm and 25mm across.
After cooling, the clinker may be stored temporarily in a clinker store, or it may pass directly to
the cement mill.
The cement mill grinds the clinker to a fine powder. A small amount of gypsum - a form of
calcium sulfate - is normally ground up with the clinker. The gypsum controls the setting
properties of the cement when water is added.
Block diagram showing the basic components of the cement production process

Figure 1: The basic components of the cement production process.

 5. TABLE OF CONTENTS

CHAPTER 1 – Cement mill……………………………………………………….…. 1- 7

1. Introduction of cement mill...................................................................................... 1
2. Description………………………………………………………………..……….. 1
3. Working principle……………………………………………………….….……... 2
CHAPTER 2 – Ball mill…………………………………………………………....… 8-16
1. Ball mill……………………………………………………………………..…...... 8
2. Ball mill internal…………………………………………………………..………. 8
3. Accessories of ball mill……………………………………………………...... 9- 12
I. Liner plates…………………………………………………………..……. 9
II. Chambers …………………………………………………………..…...… 9
III. Diaphragm………………………………………………………..……..... 10
IV. Grinding media………………………………………………………....… 11
4. Mill girth gear……………………………………………………………..…….... 12
5. Motor drive gearbox……………………………………………………………..…13
6. Inching drive…………………………………………………………………........ 15
7. Function of gypsum……………………………………………………………...... 16
8. Temperature control………………………………………………………………. 16
CHAPTER 3 – Cement mill accessories…………………………………………….. 17-20
1. Dust collector…………………………………………………………….…..… 17-18
I. Cyclone separator………………………………………………….……… 17
II. Bag filters………………………………………………………….……… 17
2. O-sepa..………………………………………………………………………….... 18
3. O-sepa cyclone………………………………………………………………….… 19
4. Air slide blower…………………………………………………………………... 19
5. Hoppers…………………………………………………………………………… 19
6. Bucket elevator…………………………………………………………………… 20
CHAPTER 4 – Lubrication system…………………………………………………. 21-22
1. Servo mesh SP-320……………………………………………………………….. 21
2. Servo mesh SP-460……………………………………………………………….. 21
 3. Servo system-320………………………………………………………………..... 21
4. Servo coat-140………………………………………………………………..…... 22
5. Servo gem-3…………………………………………………………………..…... 22
CHAPTER 5 – Maintenance………………………………………………………… 23-25
1. Objective of maintenance……………………………………………………..…... 23
2. Types of maintenance…………………………………………………………..23-25
I. Break down maintenance…………………………………………….…… 23
II. Planned preventive maintenance………………………………………..… 24
III. Condition based predictive maintenance………………………………..… 24

CONCLUSION…………………………………………………………….. 26
 6. LIST OF FIGURES
Name of the figure Page no.
Figure 1: The basic components of the cement production process
Figure 2: Flow diagram of cement mill-3 2
Figure 3: Ball mill 8
Figure 4: Internal of ball mill 8
Figure 5: Classifying liner 9
Figure 6: Step and wave liner 9
Figure 7: Internal of chamber 1 10
Figure 8: Scope diaphragm 11
Figure 9: Mesh diaphragm 11
Figure 10: Grinding media 11
Figure 11: Girth and pinion gear 13
Figure 12: Motor drive 13
Figure 13: Inching drive 15
Figure 14: Cyclone separator 17
Figure 15: Bag filter 17
Figure 16: O-sepa 18
Figure 17: Air slide blower 19
Figure 18: Bucket elevator 20

7. LIST OF TABLES
Name of table Page no.
Table 1: List of equipment’s 2
Table 2: Specification of cement mill-3 3
Table 3: Types of gearboxes 14
8. INTRODUCTION

Kesoram Industries Limited is one of the pioneer companies in India. It is under the flagship 'B
K Birla Group of Companies'. Its production ranges from tires to cement to rayon. According to
ET500, it’s all India ranking was 121 for the year 2010 with a net income of Rs. 502063 Crore
and a net profit of Rs. 648.29 Crore. In 2011, Kesoram Industries installed a small stationary
packing unit. Kesoram Industries entered into a joint venture with Maharashtra Seamless Limited
and Dhariwal Infrastructure Private Limited in 2012 for working a coal block allocated to it by
the Central Government in the State of Maharashtra. The company reported a net profit of Rs.
339.67 crore during the quarter of 2014-15 by selling a tyre plant to JK Tyres.

Founded in 1969, Birla Shakti is one of the global leaders in cement technology. Besides being a
leading supplier of cement and aggregates, we also offer consulting, research, trading,
engineering and other services to complement our customers’ business needs. Our headquarters
is in India and we have production sites in several parts of the country.

Under the cement division of Kesoram Industries Limited, Birla Shakti manufactures and sells
cement. We are widely recognized for our quality, strength and technology, which has enabled
us to build strong working relationships and gain the trust of our customers and builders. As a
mark of our quality management best practices, we have been certified an ISO 9001 company.

Birla Shakti has two cement manufacturing plants located at Sedam, Karnataka (the
"Vasavadatta Cement Plant") and Basantnagar, Andhra Pradesh (the "Kesoram Cement Plant").
Our cement business has been in operation for over 40 years, catering to the regional demands
predominantly in Karnataka, Andhra Pradesh and Maharashtra. Our plants are strategically
located near our leased limestone deposits in the states of Karnataka and Andhra Pradesh.
Presently, we have a combined total installed capacity of 7.25 million MT.
Each of our milestones reflected in the timeline is a reflection of our passion, dedication and
persistence in Total Productivity Maintenance (TPM). And in this short period of time, we at
Kesoram Cement and Vasavadatta Cement have grown from strength to strength – emerging as
leaders of the cement industry.
 CHAPTER 1. Cement Mill

 Introduction of Cement Mill:

A cement mill is the equipment used to grind the hard, nodular clinker from the cement kiln
into the fine grey powder that is cement. Most cement is currently ground in ball mills and
also vertical roller mills which are more effective than the ball mills.

A ball mill is a type of grinder used to grind and blend materials for use in mineral dressing
processes, paints, pyrotechnics, ceramics and selective laser sintering. It works on principle
of impact and attrition; size reduction is done by impact has the ball drop from near the top of
the shell.

A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell
maybe either horizontal or at a small angle to the horizontal. It is partially filled with the
balls. The grinding media is the balls, which may be made up of steel (chromium steel),
stainless steel, ceramic or rubber. The inner surface of the cylindrical she’ll is usually lined
with an abrasion-resistant material such as manganese steel or rubber. Less wear take place
in rubber lined mills.

 Description:

Final processing step in the manufacture of the cement is cement grinding. It is the grinding
of mixture of clinker and additives into a finished product. Object is to create a particular
fineness of the product to achieve some pre-determined physical characteristics in the
cement. Main ingredient used in cement is the clinker. Clinker is ground with gypsum to
produce Portland cement. Grinding mill is the main component used in finish grinding
system. A ball mill is horizontal cylindrical drum with two compartments having steel balls
of the different diameter as grinding media. The critical speed (rpm) is given by: NC =
42.29/√d, where d is the internal diameter in meters. Ball mills are normally operated at
around 75% of critical speed, so a mill with diameter 3.4 meters will turn at around I7 rpm.
Clinker is ground by a closed circuit grinding system where mill product is routed through
the dynamic air separator and the material ores than the required grain size is returned to the
mill. Thus, separator removes the ores and the fine particles, which are feedback to the mill.
Cement clinker is usually ground using a ball mill. This is essentially a large rotating drum
containing grinding media - normally steel balls. As the drum rotates, the motion of the balls
crushes the clinker. The drum rotates approximately with 17 RPM. The drum is generally
divided into two or three chambers, with different size grinding media.
As the clinker particles are ground down, smaller media are more efficient at reducing the
particle size still further. Grinding systems are either 'open circuit' or 'closed circuit.' In an

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 open circuit system, the feed rate of incoming clinker is adjusted to achieve the desired
fineness of the product. In a closed circuit system, ores particles are separated from the finer
product and returned for further grinding.

 Working Principle:

In case of continuously operated ball mill, the material to be ground is fed from the left
through a 60° cone and the product is discharged through a 30° cone to the right. As the shell
rotates, the balls are lifted up on the rising side of the shell and then they cascade down (or
drop down on to the feed), from near the top of the shell. In doing so, the solid particles in
between the balls and ground are reduced in size by impact. The ball mill is a key piece of
equipment for grinding crushed materials, and it is widely used in production lines for
powders such as cement, silicates, refractory material, fertilizer, glass ceramics, etc. as well
as for are dressing of both ferrous and non-ferrous metals.

 Layout of cement mill:

Figure 2: Flow diagram of cement mill 3

 Table No.1 : List of equipment’s

S.N Equipment name S.N Equipment name

O O
1 Clinker hopper 15 O-sepa
2 Gypsum hopper 16 O-sepa return air slide
3 Clinker weigh feeder 17 O-sepa cyclone with
hopper
4 Gypsum weigh feeder 18 O-sepa fan
5 Feed belt conveyor 19 Junction duct

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 6 Cement mill 20 O-sepa dust collector
cyclone
7 Mill vent dust collector 21 O-sepa dust collector
8 Dust collector fan & 22 O-sepa vent fan
chimney
9 Fly ash hopper 23 Cement silo feed belt
conveyor
10 Fly ash bin hopper 24 Silos feeding air slide
11 Fly ash roto scale 25 Cement storage silos
12 Fly ash feed air slide 26 D/C for belt Tran point
13 Mill discharge air slide 27 D/C fan & chimney
trans point
14 Bucket elevator 28 1&2 Cement mill cross
belt

 Table No. 2: Specifications of cement mill 3

S.N Name of Description Quantity

O equipment
1 Clinker hopper Capacity: 400 MT 1
2 Gypsum Capacity: 200 MT 1
hopper
3 Fly ash system Main hopper capacity: 140 MT 1
Bin hopper capacity: 40 MT
Air slide blower: ST. PR: 500
MMWG
Capacity: 17.5 M3/MIN.
Speed: 1440 RPM
Roto scale:
Capacity : 60 TPH
TEMP: 120 deg. Centigrade
Bulk density: 0.8 T/M3
4 Feed belt Belt length: 31 M, Width: 800 1
MM
Gear box:
Type: SUMB,7" Ratio: 30:1,
1500 RPM
5 Clinker weigh Width:1200 mm, length : 5.1 1
feeder m
Capacity: 200 TPH
Gear box: Ratio: 78.07
Power: 2.2 KW
6 Gypsum weigh Width:800 mm, length : 5.1 m 1
feeder Capacity: 20 TPH
Gear box: Ratio: 70.1

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 Power: 2.2 KW
7 Weigh feeder No. of bags: 64 , fan capacity: 1
pocket dust 12000 M3/HR
collector Static pressure: 250 MMWG

8 Mill Diameter: 3.4 m, length: 16.05 1

m
Make: AVB
9 Mill inlet White metal journal bearing 1
bearing and oil Oil pump: 1.5 inch * 1.5 inch
pump Pressure : 5 KG/CM2
10 Mill outlet White metal journal bearing 1
bearing and oil Oil pump: 1.5 inch * 1.5 inch
pump Pressure : 5 KG/CM2
11 Counter shaft White metal bearing size: 365 2
bearing and oil mm
pump Vicker oil pump: 0.5 inch * 0.5
inch
12 Motor 1 White metal bearing size: 7" 2
bearing and oil Vicker oil pump: 0.5 inch * 0.5
pump inch
13 Main drive Power : 2000 HP Speed: 2
gear box 1 and 750/124
oil pump Ratio: 6.05:1
Oil pump: 1.5"*1.5"
Geared oil pump: 5 kg/cm2
14 Main drive Power : 2000 HP Speed: 2
gear box 2 and 750/124
oil pump Ratio: 6.05:1
Oil pump: 1.5"*1.5"
Geared oil pump: 5 kg/cm2
15 Inching drive Power : 40 HP , speed:1500/10 1
gear box 1 RPM: 1500
16 Inching drive Power : 40 HP , speed:1500/10 1
gear box 2 RPM: 1500
17 Mill outlet air ST. PR: 500 MMWG , 2
slide blower capacity:17.5 M3/MIN. RPM:
1or 2 1440
18 Mill discharge Capacity:300TPH, 1
bucket elevator Gear box:
Ratio : 55:1, RPM:1500
19 O-sepa Gear box: 1
Power: 55 KW, ratio : 4:1
20 O-sepa oil AUROTO geared oil pump: 2
pump gear box Size : 0.5"*0.5"
and rotor

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 bearing
21 O-sepa HT fan Capacity: 125000 M3/HR. 1
ST. PR: 550 MMWG, Speed:
975 RPM
22 O-sepa rotary Rotary lock 1
air lock Size: 600*600,Capacity: 160
TPH
Gear box:
Ratio: 50:1, Speed: 1500 RPM
23 O-sepa vent No. of bags 252 , fan 1
dust collector capacity:38000 M3/HR.
24 Mill vent dust No. of bags 360 fan capacity: 1
collector and 50000 M3/HR
fan ST. PR: 350 MMWG
25 O-sepa return ST. PR: 500 MMWG , 2
air slide capacity:17.5 M3/MIN. RPM:
blower 1 & 2 1440
26 Silo belt Belt length: 250 m, width:1000 1
conveyor 1 mm
Gear box:
Type: C-100 , speed:1440/36
27 Silo top air ST.PR: 500 MMWG 2
slide blower 1 Capacity: 17.5 M3/MIN.,
or 2 RPM: 1440
28 Internal water Capacity: 10 M3/HR. 1
spray system Speed: 2900 RPM
Pressure : 5-10 KG/CM2

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 CHAPTER 2. Ball mill

 Ball Mill:

Cooled clinker is ground with gypsum in a ball mill. The grinding of clinker to cement is
essentially a dry grinding process and 3-6% gypsum is added to clinker during the process of
grinding. Fly ash is also added during grinding only, in case Pozzolannic Portland Cement
(PPC) is being produced. But in Ordinary Portland Cement (OPC) is produced. Each unit of
the plant has three Tube mills as a closed circuit grinding mills. As power requirement is
highest in the finishing grinding therefore, cement mill must be operated under best
efficiency conditions which can be obtained by:

Figure 3: Ball mill

1. Uniform feed size and uniform feed rate.

2. Keeping the loading of the individual chamber of the mill trim sidewise and weight wise.
3. Using efficient dust collecting system like Cyclone separators and Bag houses.

 Ball Mill Internal:

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 Figure 4: Internal of ball mill
 Accessories of Cement Mill:

 Liner plates:

The design of a liner is driven by the material of construction and the application, and
limited by casting, molding, and handling constraints. For large mills with wide inlet
trunnions, in excess of l.5m, liner handling machines are now in common use, and
this has allowed the evolution of large integral liner blocks, weighing up to 1.5 t a
piece.

Figure 5: Classifying liner Figure 6: Step and wave liner

The selection of the material of construction is a function of the application,

abrasivity of ore, size of mill, corrosion environment, size of balls, mill speed, etc.
liner design and material of construction are integral and cannot be chosen in
isolation. There are two types of liners we are using in cement ball mill. In the first
chamber we use step and wave liner and in the second chamber classifying liner.

 Chambers:

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Two chamber mills are used for grinding cement, slag and similar materials. They are
typically arranged in a circuit with high efficiency VTP separators. They grind
materials up to 6500 cm2 /g according to Blaine.

The mill itself is equipped with a step and wave armoring in the first chamber with
larger balls with a high crushing effect. The second chamber is equipped with
classifying armoring using smaller balls for finish grinding. The partition diaphragm
is equipped with a controllable material flow so that both chambers maintain an
optimum filling ratio. Material from the second chamber is supplied to a separation
circuit via an outlet wall. In case warmer materials are ground, water is sprayed into
the second chamber.

Figure 7: Internal of chamber 1

First chamber is also known as the crushing chamber. The liner used in the crushing
chamber is step and wave liner (Semi blotless). The effective diameter of the
chamber is 3.28 m and the effective grinding path is 5.4 m long. The empty height of
the crushing chamber is 2.24 m and the maximum possible grinding media tonnage
is 57 MT which is 28.46% of the total volume. For the better efficiency we use 54
MT grinding media which is 27.13% of the total volume.

Second chamber is also known as the grinding chamber. The liner used in the
grinding chamber is classifying liner. The effective diameter of the chamber is 3.3 m
and the effective grinding path is 8.9 m long. The empty height of the crushing
chamber is 2.29 m and the maximum possible grinding media tonnage is 109 MT
which is 30.87% of the total volume. For the better efficiency we use 92 MT
grinding media which is about 25.94% of the total volume.

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 Diaphragm:

In a conventional closed circuit ball mill, to prevent the clinker nibs entering to
second chamber of the ball mill, first chamber slot size has been kept 6-8 mm by
different manufacture. Second chamber diaphragm slot size has been kept 8-10mm.
AIA mill designer also follows the same industrial design norms that we are using.

Figure 8: Scope diaphragm Figure 9: Mesh diaphragm

 Grinding media:

Grinding media, the objects used to refine material and reduce particle size, are
available in a wide range of shapes, sizes and materials to meet an equally wide
range of grinding and milling needs.

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 Figure 10: Grinding media

Composition – metallic grinding media like carbon steel, forged steel, stainless steel
or chrome steel grinding balls are best for some applications, while others require
non-metallic media made of alumina, ceramics, glass, silicon carbide, zirconium
oxide or other specialized materials.

 Chrome steel balls type 52100

Chrome Balls (steel type 52100) are through-hardened and tempered steel balls
designed to achieve maximum strength and quality. Ball hardness is in the 60–67
HRC range. They wear better than 440C stainless steel and through-hardened
carbon steel. They are also recommended for applications where a through-
hardened steel ball is needed in larger sizes (½" and larger). The wear rate of the
chrome steel balls is 65 gm/mt.
The size of the grinding media depends upon the material which is to be grind. In
the first chamber of the cement mill we use the balls of the diameter 90, 80, 70 &
60 mm and in the second chamber we use the balls OD diameter of 50,
40,30,25,20 & 17 mm.

 Mill Girth Gears:

Mill Girth Gears comprise high integrity girth gears that find application in driving
horizontal grinding mills. With these gears developed for achieving superior finish
strength and process reliability, these can be designed for different kW applications

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 as well as in diameter and weight choices. For ensuring in them flawless finish
support, we use them in temperature controlled environment.

 Features:

 Available in different hardness range

 Can be developed using material choices including Cast steel, Ductile iron,
Fabricated forged steel plates and others
 Girth gear drive provide optimum performance as mechanical systems for
reducing motor speed to working speed of mill

Figure 11: Girth and pinion gear

 As an important component in gear drive assembly, these can be offered in

multiple segments including 2, 4 or 8 equal sizes
 Easy installation and low operational costs.

 Motor drive gear box:

In the cement mill 3 VCN-630 motor drive gear box is used. In the VCN-630
gearbox the drive speed is reduced by the factor of gear ratio. In cement mill the
application of gear ratio is to slow down the speed of mill.
A three stage gearbox can be achieved by simply increasing the length of the ring
gear and with serial arrangement of several individual planets stages.

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 Figure 12: Motor drive

Advantages:

1. Wide range of ratios.

2. Compact design with high transmission ratios.
3. Combination of different gearbox types possible.
4. Wide range of use.

Disadvantages:

1. More complex design.

2. Lower degree of efficiency.

• Given table shows the different type of gearboxes in cement mill:

Reduction Size Ratio Rating (kW)

Single
080 – 560 1.25:1 - 06:10 3.8 - 10600
(VAN/VAH)
Double
112 – 800 6.30:1 - 22.4:1 5.4 - 10500
(VBN/VBH)
Triple
160 – 800 20.0:1 - 125:1 3.0 - 02950
(VCN/VCH)
Quadruple
225 – 800 112.00 - 630 1.7 - 01190
(VDN/VDH)

Table No. 3: Types of gearboxes

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 Drive Gear of Cement Mills:

Requirements of mill drives are:

 High starting torque. The starting current must be limited to a maximum
Of two times the full load value to minimize voltage dips.
 An overload capacity of 50% for 1 min occurring for 4 times an hour.
 Three starts from cold conditions and two consecutive starts from hot conditions
per hour against full load.
The drive system used keeping in mind the above requirements are:
1. 3 phase slip-ring induction motors of 6.6 kV; though salient pole synchronous
motor can also be employed.
2. Liquid resistance starters are employed to start the motor and bring it up to full
speed.
3. Gear boxes are also attached in order to get the desired mill speed of about 15
rpm.
4. In order to improve the power factor of the line current drawn, high voltage
capacitors of adequate reliability and automatic capacitor control switchgear and
circuit breakers are used.

 Inching drive:
An inching drive is used as an auxiliary system to the main drive for a large machine
such as a ball mill, industrial kiln, conveyor, or elevator. Its purpose is to turn the
equipment at a speed slower than the normal operating speed typically 1 to 2 rpm,
although fractional rpms are also common and to do so at high torque typically 120
percent of the normal drive torque.

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 Figure 13: Inching drive
Three main components make up the inching drive an electric motor or internal
combustion engine, a gear reducer, and a connecting element to automatically or
manually engage with the equipment being driven. The use of either an electric
motor or an internal combustion engine depends both on the type of equipment being
driven and the conditions under which the inching drive will be used. For example, a
cement mill needs to be rotated constantly. If the main power supply fails, an inching
drive with an internal combustion engine can rotate the cement mill in the absence of
power. But for most other types of equipment, the inching drive is used primarily
during maintenance and repair operations. In these cases, electric motors are the
more common choice because they can provide positioning accuracy and good
holding capabilities.
 Function of Gypsum in cement:

Before discussing the effect of gypsum, certain terms need to be specified. The thick slurry
formed by mixing a hydraulic cement with aggregate and water in such the proportions that
settling will occur is called the paste. Settling is the initial stiffening, which usually occurs
within a few hours. Hardening is the development of strength, which slower process.

The reactions that cause settling and hardening are collectively described as hydration
reactions.

Addition of gypsum mainly is to control the initial reaction so as to prevent fast settling.

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 So, gypsum plays the role of a set retarded. Its serves as a pace maker for the hydration of
different lime compounds of the cement paste by forming calcium. The gypsum content
besides the controlling the settling. Sulpho aluminates plays a significant part in its strength
and in the volume stability up to a certain point, gypsum content promotes the strength of the
cement and avoid shrinking but if its content beyond a certain limit, it can give to
considerable expansion in the concrete, it also acts as grinding and in the process.

 Temperature control:

Heat generated in the grinding process causes gypsum to lose water, forming basanite. The
latter minerals are rapidly soluble and about 2% of these in cement is needed to control
tri-calcium aluminate hydration. If more than this amount forms, crystallization of gypsum
on their rehydration causes “false set” a sudden thickening of the cement mix a few minutes
after mixing which thins out on remixing.
High milling Temperature causes this. On the other hand if milling Temperature is too low,
insufficient rapidly soluble sulfate is available and this causes “false set” an irreversible
stiffening of the mix. Obtaining the optimum amount of rapidly soluble sulfate requires
milling with a mill exit Temperature within a few degree of 120 degree centigrade. Where
the milling system is hot, sum manufacturers uses 2.5% gypsum and the remaining calcium
sulfate.

CHAPTER 3: CEMENT MILL 3 ACCESSORIES

 Dust Collectors:

 Cyclone separator:

Cyclone separator is a method of removing Figure 14: Cyclone

particulates from an air, gas or water steam,
without the use of lifters, through vortex
separators. Rotational effect and gravity is used
to separate mixtures of the solid and fluids. A
high speed rotating flow is stablished with a
cylinder or conical container called a cyclone.
Air flow in a spiral pattern, beginning at the top
of the cyclone and ending at the bottom end

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 before exiting the cyclone in a straight steam through the center of the cyclone and out
the top. Larger particles in the rotating stream have too much inertia to follow the tight
curve of the steam and strike the outside wall, falling then to the bottom of

The cyclone where they can be removed. In a conical system, as the rotating flow
moves towards the narrow end of the cyclone the rotational radius of the steam is
reduced, separating smaller and smaller particles.

 Bag Filter
Commonly known as baghouses, fabric
collectors use filtration to separate dust
particulates from dusty gases. They are one
of the most efficient and cost effective types
of dust collectors available and can achieve
a collection efficiency of more than 99% for
very fine particulates.

Dust-laden gases enter the baghouse and

pass through fabric bags that act as filters.
The bags can be of woven or felted cotton,
synthetic or glass-fiber material in either a
tube or envelope shape.
The high efficiency of these collectors is due
to the dust cake formed on the surfaces of Figure 15: Bag filter
the bags. The fabric primarily provides a
surface on which dust particles collect through the
following four mechanisms

Inertial collection – Dust particles strike the fibers placed perpendicular to the gas-
flow direction instead of changing direction with the gas steam.
Interception – Particles that do not cross the fluid streamlines come in contact with
fibers because of the fiber size.

 “O” SEPA (Separator)

O-sepa separator is a kind of air eddy separator. The application of this separator got well
effects. O-sepa separator was improved with combination of practical experiences, and
introduce K type o-sepa separator, it is main separating equipment of close cycle grinding
system in cement production.

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 Figure 16: O-sepa

In an O-sepa an air suction fan is connected which use to separate the fine material and
course
Comes down ward for the recycling purpose in a O-sepa first material goes in it after that the
fan create a high suction pressure due to this suction pressure fine particles are separated by
the suction and rest material feeded to the raw material and fine particles goes into the O-
sepa cyclone and the main dust collector from here the required size material directly goes
into the silos.

 O-sepa cyclone:

O-sepa cyclone is the output of the cement mills in this first material come from the cement
mills by suction fan or m fan and the material goes into the silos by the help of belts and
elevators.

 Air slide blower:

Air slide blower is to slide material in the pipes fitted at a slope. In this in the material
carrying pipe a layer is made making some space for the air in the pipe and material flows
over this layer when blowers flow the air in the pipe this air fill the empty air space in the

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 pipe due to this the layer go upward and again comes into its original position this repeat
again and again with the help of this action material in the pipe keep flowing we use this for
the flowing material in the silos.

Figure 17: Air slide blower

 Hoppers

A hopper is a large, pyramidal shaped container used in industrial processes to hold

particulate matter. Hoppers are usually installed in groups to allow for a greater collection
quantity. They are employed in industrial processes that use air pollution control devices
such as dust collectors, electrostatic precipitators, and baghouses/fabric filters. Most hoppers
are made of steel.

 Process

Dust enters the hopper from the collection device. For example, baghouses are shaken
or blown with compressed air to release caked-on dust from the bag. Precipitators use a
rapping system to release the dirt. The crumbling dust falls into the hopper. Once the
dust in the hopper reaches capacity, it is released through an opening in the bottom with
a diameter of about 8–12 inches (20–30 cm). Hoppers are rectangular in cross section
but have sides that slope at about a 60° angle. Slanted sides make it easier to remove
the ash. Conveyors are sometimes used to carry away the particulate matter
 Bucket elevator:

Bucket Elevators One of the most efficient ways to elevate bulk materials vertically is with
a bucket elevator. A Bucket Elevator consists of a series of buckets attached to a belt or chain
with pulleys or sprockets located at the top and bottom of the unit.

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 Figure 18: Bucket elevator

A bucket elevator contains the buckets in a series for carry the material. In this a motor is
connected to the pulley shaft for driving the elevator. There are two pulleys are using one is
head pulley connected with motor drive and second is boot pulley.

CHAPTER 4: Lubrication system

 Lubrication system:

1. Servo mesh SP-320

SERVO MESH SP 320 oils are extreme pressure type industrial gear lubricants. These
oils demonstrate improved thermal stability and oxidation resistance over conventional

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 lead-naphthenate oils. They have good demulsibility characteristics, low foaming
tendency and provide rust and corrosion protection to metal surfaces.

Applications:
1. Cement mill 1, 2 & 3 inlet and outlet bearings.
2. Cement mill 1, 2 & 3 belt elevator gear box.
3. Cement mill 1, 2 & 3 inching gear box.

2. Servo mesh SP-460

SERVO MESH SP 460 oils are extreme pressure type industrial gear lubricants. These
oils demonstrate improved thermal stability and oxidation resistance over conventional
lead-naphthenate oils. They have good demulsibility characteristics, low foaming
tendency and provide rust and corrosion protection to metal surfaces.

Applications:
1. Cement mill 1, 2 & 3 2000HP main gear box.
2. Cement mill 1, 2 & 3 silo belt conveyor gear box.
3. Cement mill 1 & 2 gypsum feed table gear box.
4. Cement mill 1 & 2 cross belt conveyor gear box.

3. Servo system-320

These oils are high quality circulating oils designed for continuous use in circulation
Lubrication systems for gears and bearings. They provide outstanding performance at
the elevated temperature generally found in paper mills, plastic film calendars, coal
pulverizes etc., These grades are also recommended for use in compressors, machine
tools, hydraulic and circulation systems and enclosed gearboxes, which do not require
EP type lubricants.

Applications:
1. Cement mill 1, 2 & 3 counter shaft bearing.
2. Cement mill 3 o-sepa bearing.

4. Servo coat-140:

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 Servo coat compounds are heavy bodied, adhesive type black lubricants for open
gears, wire rope and chain lubrication. These gear compounds are formulated using
highly refined steam cylinder oils having excellent thermal and chemical stability.
They contain specially selected bituminous component, which provides excellent
adhesiveness. High load carrying characteristics are imparted to the product by a mild
EP additive.

Applications:
1. Cement mill 1, 2 & 3 girth gear.

5. Servo gem-3:

Servo gem greases are premium quality, lithium soap, and multipurpose industrial
greases. These greases possess excellent water resistance properties, high oxidation
stability, and maximum structure stability, high level of anti-rust and anticorrosion
properties. They give outstanding performance under varying operating conditions.
These grades are suitable for lubrication under sub-zero (-25°C) to reasonably high
(140°C) temperature conditions. Servo gem 2 has excellent pump ability characteristic.

Applications:
1. All belt drum bearings.
2. All blowers and fan bearings.

CHAPTER 5: MAINTENANCE

Maintenance is an action or combination of actions carried out on a machinery/ equipment/

system to restore the condition to which is considered as acceptable.

 Objectives of maintenance:

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 1. To extend the useful life of assets.
2. To ensure the optimum availability of installed equipment for production (or service)
and obtain the maximum possible return on investment.
3. To ensure the operational readiness of all equipment’s required for emergency use,
such as stand by units, firefighting and rescue equipment etc.
4. To ensure the safety of personnel using facilities.

 Types of maintenance:

1. Breakdown maintenance.
2. Planned preventative maintenance (PPM).
3. Condition based predictive maintenance (CBPM).

 Breakdown maintenance:

•No maintenance (run to failure mode).

•Results in lost production and/or poor quality production.
•Causes untimely failure.
•Catastrophic failure may lead to extensive damage (complete machine replacement).
•Safety related concerns.
•No lead time.

 Planned preventative maintenance (PPM):

 Advantages:-

• Improve reliability and availability by eliminating the risk of breakdown.

• Increases operational availability.
• Reduces failures and damage to equipment.

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 • More lead time.
• Greater control over parts and cost.

 Disadvantages:

• Periodic dis-assembly of every critical machine (and non-critical) is expensive

and time consuming.
• Period or interval is difficult to determine.
• A machine which is operating satisfactorily may actually be degraded by frequent
dis-assembly.
• There are still ‘unscheduled’ breakdowns.

 Condition based predictive maintenance (cbpm):

 Involves the trending and analysis of machinery performance parameters:

• Machinery vibration
• Lube oil analysis
• Ultrasonic thickness testing
• Motor current analysis
• Infrared thermography
• Bearing temperature

•The assessment on a continuous or periodic basis, of the mechanical condition of

machinery, equipment and systems from the observations and/or recordings of selected
measurement parameters.

 Advantages:

• Minimizes machine damage and allows scheduling of downtime, labor, and

materials.

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 • Helps eliminate costly trial and error approaches to solving problems.
• Allows machines in good operating condition to continue to run.
• Eliminates unnecessary overhauls.
• Improves safety and quality performance.
• Extensive damage to the machine resulting from forced failure can be avoided.

 Disadvantages:

• Benefits must be larger than the cost of instrumentation, measuring routines, and
analysis and follow up.

9. CONCLUSION

To do my internship in such an esteemed organization KESORAM CEMENTS was a

phenomenal learning experience for me. These 45 days are a joy ride for me in the mechanical
field and now on completion of my internship I can say that I have gained very sound knowledge
in mechanical field especially in the cement mill.
The mechanical department in the industry is not well equipped with latest technologies but still
in good condition. All the working of various department is semi-automatic. The company is

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following a firm base to adopt new technologies that are coming these days this ensures a healthy
and prosperous future.
I am highly thankful to T. Ramesh ( senior manager of cement mill ) under whose expert
guidance I did my internship and came to learn about the various minor and major aspects of
cement mill equipment’s and all various processing units which are available here.

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