A

Training Report
On
“JK CEEMENT LTD,NIMBAHRA”
Submitted in partial fulfillment for the award of degree of BTECH
IN
MECHANICAL ENGINEERING

A Report on

“Cement manufacturing process anduse of kiln in cement industry”

At J.K. CEMENT LTD.,NIMBAHERA
Duration – 1 May,2019 to 15th June,2019
st

Submitted To Submitted by

MR.SAMRITH SUTHAR NAME -SUNILSINGH SOLANKI

HEAD OF DEPARTMEENT BRANCH -MECHANICAL

ROLL NO-16ERIME005

I
 CANDIDATE DECLARATION

I declare that the dissertation for B.Tech. Entitled “JK CEMENT LIMITED” is my own work conducted
under the guidance of Mr. NK VAISHNAV. I further declare that to the best of my knowledge, the dissertation
for B.Tech. Does not contain any part of the work, which has been submitted for the award of any degree either
in this University.

SUNIL SINGH SOLANKI

BTECH 4th YEAR
Mechanical Engineering
R.I.E.T,Chittorgarh

CERTIFICATE

II
This is to certify that the dissertation entitled “JK CEMENT LIMITED” submitted by SUNIL SINGH
SOLANKI, to the Department of Mechanical Engineering, R.I.E.T., Chittorgarh, in partial fulfillment of the
requirements for the award of the degree “BTECH” in “Mechanical Engineering” is a record of the work carried
out by him under our supervision and guidance.

GUIDE NAME Head of Department

MR. NK VAISHNAV MR. SAMRITH SUTHAR

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

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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 Dr. MS SHEKHAWAT,Asst. Vice President –

HR, ER & RTC for giving me opportunity in thisfield.

I also wish to acknowledge my profound gratitude towards Mr. N K Vaishnav, Manager–RTC and Mr.
Faraz Mohammed, Sr. Officer - RTC for incessantly guiding me in-depth training on “Cement
Manufacturing Process and Use of Kiln in Cement Industry” they support me in every aspect of
my report and encouraging me at every step.

I would be a thankless child if I don’t mention the name of my continuous source of energy and
inspiration i.e. that is my Teacher’s & parents who always encourage and support me at every right
step in my life.

- SUNIL

ABSTRACT

This paper analyzes an existing working management system in a cement factory in the city of
cement Nimbahera, chittaurgarh using a modified questionnaire. The analysis shows that there are
strong areas such as predictive maintenance and maintenance automation. This analyzes shows that

IV
how a cement industry is execute their plans in field. It describes how J.k. plants are growing them
self in market and making most productive and recognize cement. Energy cost and environmental
standards encourage cement manufacturing.

The goal is to optimize process control and alternative fuel consumption while maintaining product
quality. Working with kiln and with safety is a big task but them doing exceptionally well.This paper is
an assessment initiative for maintenance and productivity continuous improvement and can be
integrated as a part of a decision support system for manufacturing management.

An Introduction to

V
 HR Department
JK Cement Works
Kailash Nagar, Nimbahera
District: Chittaurgarh-312617
(Rajasthan)

C O N T E N T S

ACKNOWLEDGEMENT ...................................................................................................I

ABSTRACT......................................................................................................................II

AN INTRODUCTION TO J.K.CEMENT LTD. ………………………………………………III

1. OVERVIEW OF J K CEMENT LTD...........................................................................1

1.1The Company..........................................................................................................1
VI
 1.2 About J K Cement...................................................................................................2

1.3Grey Cement Plants and Production Capacity........................................................4

1.4 Power Plants...........................................................................................................8

2. MANAGEMENT SET- UP ……………………………………………………………... 10

2.1 Corporate Level- Kanpur ..................................................................................... 10

2.2 Heads ..................................................................................................................10

3. ORGANISATIONAL CHART……………………………………………………………11

4. Regional Training Centre : Nimbahera................................................................ 12

5. CORPORATE SOCIAL RESPONSIBILITY............................................................ 13

5.1 Education Schools and University.........................................................................13

5.2 Educational services .......................................................................................... 14

5.3 Medical services....................................................................................................14

5.4 Religious services ............................................................................................... 15

5.5 Sports services..................................................................................................... 15

5.6Other social services............................................................................................ 15

6. MANUFATURING PROCESS – WHITE CEMENT................................................ 16

7. MANUFATURING PROCESS -GREY CEMENT....................................................18

7.1 Raw material used………………………………………………….……………..……19
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 7.2 Stages of manufacturing process……………………………………………………..19
7.2.1 Quarrying………………………………………………………………………….20

7.2.2 Raw material preparation………………………………………….……….……21

7.2.3 Clinkering………………………………………………………………………….22

7.2.4 The kiln……………………………………………………………………………23

7.2.5 Cement milling……………………………………………………………………29

7.2.6 Packing and dispatch………………………………………………………...….30

7.3 Maintenance in cement industry……………………………………………………...31

8. THE ROLE OF THE LABORATORY…………………………………..………32

8.1 Product development………………………………………………………………..…32

9. ENVIRONMENTAL IMPLICATIONS……………………………………………...…….33

9.1 Dust emissions………………………………………………………………...………..33

9.2 CO2………………………………………………………………………………………34

9.3 Quarry and plant water runoff………………………………...……………………….35

9.4 Chrome bricks…………………………………………………………………………..35

10. A Passion for Quality – Characteristics of Cement……………………………….37

REFRENCE ……………………………………………………………………………………38

VIII
 List of figures

Figure 1.1: Kamla Tower, Kanpur ………………………………………………………….. 1

Figure 1.2:J.K. Cement, Nimbahera………………………………………………………..5

Figure 1.3: J.KCement Works plant,Fujairah……………………………………………….7

Figure 1.4: J.K. Cement plants in INDIA……………………………………………………..9

Figure 4.1: Regional Training Center,Nimbahera………………………………………....13

Figure 5.1: J.K, Cement Institute of Techonoligy & J.K.School of

Education,Nimbahera…………………………………………………………………….…14

Figure7.1:J.K.Cement, Mangrol……………………………………………………………18

Figure 7.2:Excavation of row materials from karoonda mines…………………………..21

Figure 7.3: Cement manufacturing process………………………………………………..25

Figure 7.4: Cyclone preheater using for preheating clinker before kiln process……….26

Figure 7.5:Cement milling machine for fine powder of clinker…………………………..30

Figure 7.6:Paking of cement bages in 50 kg each one in packing plant……………….31

Figure7.7: Shutdown time kiln maintenance work running………………………………31

Figure8.1: Product development knowledge at throw training program……………….33

Figure 9.1:shows the limestone stacker operation without and with water spraying…34

Figure 9.2:Typical Gypsum storage area and open stock pile of Clinkeran…………..36

Figure10.1: X-RAY Machine,Nimbahera…………………………………………………..37

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 List of tables

Table1.1: CLINKER PRODUCTION – Nimbahera and Mangrol Plant………………… .4

Table1.2: PRODUCTION ANALYSIS IN TONS – Nimbahera and Mangrol Plant……. 4

Table1.3: FINANCIAL ANALYSIS IN Million – J K Cement Ltd…………………………. 5

Table7.1: Major mineral constituents of Portland Cement……………………………... 20

Table 7.2: Alternative fuel options for the cement industry……………………………... 27

Table 7.3: Properties of fuels of interest to the cement industry……………………..… 28

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1. OVERVIEW OF J K CEMENT LTD.

1.1 The Company

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. Figure 1.1:Kamla Tower, Kanpur

1
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.

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.

2
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.

1,3Grey Cement Plants and Production Capacity

3
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

Table1.1:CLINKER PRODUCTION – Nimbahera and Mangrol Plant

Plant Capacity ( Tonnes / day)

J K Plant, Nimbahera
7550
I. Kiln 1200 II. Kiln 1650 III. Kiln 4700 TPD

Unit 1 at Mangrol 2100

Unit 2 at Mangrol 5000

Total Capacity 14650 TPD

Table1.2: PRODUCTION ANALYSIS IN TONS – Nimbahera and Mangrol Plant

Year Clinker Cement

2012 - 13 2955814 3567226

2013 – 14 3008736 3523527

2014 – 15 1961430 2378020

Table1.3: FINANCIAL ANALYSIS IN Million – J K Cement Ltd.

Year Turnover PBT

2012 - 13 3342.58 337.54

2013 – 14 3201.72 114.18

4
2014 – 15 3859.40 144.10
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 Figure1.2: J.K Cement Nimbahera

QMS and ISO-14001:2004 for EMS.

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.

5
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.

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 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.

6
J.K. Cement Works, Fujairah

Foundation Stone Laying Ceremony of 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.

Figure1.3: J.KCement Works plant,Fujairah

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.

7
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.

8
 Figure1.4: J.K. Cement plants in INDIA

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

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2.2 Heads:

Project
President Project Shri D Ravishankar
Units
J K Cement, Nimbahera and
Unit Head Shri S K Rathore Mangrol, Distt: Chittaurgarh,
Rajasthan
JK Cement Works, Muddapur,Distt:
Unit Head Shri A K Jain
Bagalkot, Karnataka
J K Cement- White and Grey Plants
President - Works Shri B K Arora
at Gotan, Distt: Nagaur, Rajasthan

3. ORGANISATIONAL CHART

J K Organization

J K Cement Ltd.

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 Production &
Location

J K Cement J K Cement J K Thermal J K Cement, J K Cement, ABROAD: JK

Works, Works, Power, Mudhol, Gotan (Raj.) Cement
Nimbahera Mangrol (Raj.) Bamania Karnataka White Cement Fuzairah,
(Raj.) Unit 1 (Raj.) –1000 TPD UAE White
&2GreyCement Grey Cement – Grey Cement and Grey
Grey Cement– –7100 TPD CPP – 15 9000 TPD – Cement
7550 TPD MW
1200 TPD

11
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.

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.

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 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.

Figure 4.1: Regional Training Center,Nimbahera

5. CORPORATE SOCIAL RESPONSIBILITY

5.1 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

13
Figure 5.1:J.K, Cement Institute of Techonoligy & J.K.School of Education ,Nimbahera.

5.2 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

5.3 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.

14
  Financial contribution for construction of dispensary & health centre in nearby
villages.
 Free Homeopathic consultancy/medicines for the patients of nearby area.

5.4 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.

5.5 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.
 Sponsoring inter-district tournaments.
 Arranging summer camps for various sports.

5.6 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.

15
  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.
 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.

16
Step 1 (Mining) Step 2 (Crushing) Step 3 (Grinding) Step 4 (Fuel

Preparation)

Step 5 (Kiln Operations) Step 6 (Cement Step 7 (Packing Step 8

Grinding) (Loading
Process)
Process)

KILN

ADDITIES GRINDER CLINKER

CEMENT

7. Manufacturing Process - Grey Cement

LIMESTON CRUSHER GRINDER ROW MILL

17
 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
requireincreased blending with other raw
materials. Blending of clinker with other materials
helps impart key characteristics to cement, which
eventually govern its end use.
Figure7.1: J.K.Cement, Mangrol

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.

18
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.

7.1 Raw material used

a) Lime Stone
b) Gypsum
c) Laterite
d) Alumina
e) Coal
f) Fly Ash

7.2 Stages of manufacturing process

Concrete is an extremely versatile material, being used in the production of anything

from nuclear radiation shields to playground structures and from bridges to yachts. It is
able to be used in such a wide variety of applications because it can be poured into any
shape, reinforced with steel or glass fibres, precast, coloured, has a variety of finishes
and can even set under water. Modern concrete is made by mixing aggregate (sand,
stones and shingle) with Portland cement and water and allowing it to set. Of these
ingredients, the most important is Portland cement.

Cement is a fine grey powder which when reacted with water hardens to form a rigid
chemical mineral structure which gives concrete its high strengths. Cement is in effect
the glue that holds concrete together. The credit for its discovery is given to the

19
Romans, who mixed lime (CaCO3) with volcanic ash, producing a cement mortar which
was used during IX-Materials-B-Cement-2 construction of such impressive structures as
the Colosseum. When the Roman empire fell, the information on how to make cement
was lost and was not rediscovered until the 16 th century.

Table7.1:Major mineral constituents of Portland Cement.

Compound Abbreviation Chemical Typical

* formula concentration/
%
Tricalcium C3S 3CaO•SiO2 60-70%
silicate
Dicalcium C2S 2CaO•SiO2 10-20%
silicate
Tricalcium C3A 3CaO•Al2O3 5-10%
aluminate
Tetracalciu C4AF 4CaO•Al2O3 3-8%
m •Fe2O3
alumino-
ferrate

The cement manufacturing process involves four distinct stages, and these are
outlinedbelow.

7.2.1 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 ofthe cement, while the iron reduces the reaction
temperature and gives the cement itscharacteristic grey colour.

20
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.

Figure 7.2:Excavation of row materials from karoonda mines.

7.2.2 Raw material preparation

The steps involved here depend on the process used. There are two main
cementmanufacturing processes currently used in New Zealand: the dry process
(used by GoldenBay) and the wet process (used by Milburn). The dry process uses
more energy in grindingbut less in the kiln, and the wet process has lower
overheads than the dry process. The twoprocesses are discussed separately
below.

The dry process

21
The quarried clay and limestone are crushed separately until nothing bigger than a
tennis ballremains. Samples of both rocks are then sent off to the laboratory for
mineral analysis. Ifnecessary, minerals are then added to either the clay or the
limestone to ensure that thecorrect amounts of aluminium, iron etc. are present.
The clay and limestone are then fedtogether into a mill where the rock is ground
until more than 85% of the material is less than90μm in diameter.

The wet process

The clay is mixed to a paste in a washmill - a tank in which the clay is pulverised in
thepresence of water. Crushed lime is then added and the whole mixture further
ground. Anymaterial which is too coarse is extracted and reground. The slurry is
then tested to ensurethat it contains the correct balance of minerals, and any extra
ingredients blended in asnecessary.

7.2.3 Clinkering

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

The powder from the dry process doesn't contain much moisture, so can be dried
in a preheatertower. As it falls through the tower (which takes 30 seconds) it is
heated from 70 to800oC. The moisture evaporates, up to 20% of the
decarbonation (loss of CO2) occurs andsome intermediate phases such as
CaO•Al2O3 begin to appear. The mixture is then fed intothe kiln.

The slurry from the wet process contains too much moisture to be successfully
dried in apreheater tower. Instead, the slurry is fed directly into the kiln where it is
formed into dryballs by the heat and rotation of the kiln. Because of this extra role

22
of the kiln, wet processkilns are generally longer than dry process kilns: e.g.
Milburn's kiln is more than 100 m inlength, whereas that used by Golden Bay is
only 60 m long. The kilns used in both processesare inclined on a shallow angle
and lined with heat-resistant bricks.

7.2.4 The kiln

The kiln shell is steel, 60m long and inclined at an angle of 1 in 30. The shell is
supported on3 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 hightemperatures. Coal is injected with air into the kiln at a rate of 9
- 12 T hr-1.

The reaction processes occuring within the kiln are not easily understood due to
the widevariations in raw-mix chemistry, raw-mix physical properties and kiln
operating conditions,and the physical difficulties of extracting hot materials from
the process for investigationbefore they cool.

Breaking the reaction processes into a number of simple zones means we can
make someapproximations about the cement formation process.

Zone 1: 0 - 35 min, 800 - 1100oC

Decarbonation. Formation of 3CaO•Al2O3 above 900oC. Melting of fluxing

compounds

Al2O3 and Fe2O3.

heat

CaCO3 → CaO + CO2

23
Zone 2: 35 - 40 min, 1100 - 1300oC

Exothermic reactions and the formation of secondary silicate phases as follows:

heat

2CaO + SiO2 → 2CaO•SiO2

Zone 3: 40 - 50 min, 1300 - 1450 - 1300 oC

Sintering and reaction within the melt to form ternary silicates and tetracalcium
aluminoferrates:

heat + time

2CaO•SiO2 + CaO → 3CaO•SiO2

heat + time

3CaO•Al2O3 + CaO + Fe2O3 → 4CaO•Al2O3

•Fe2O3

Zone 4: 50 - 60 min, 1300 - 1000oC

Cooling and crystallisation of the various mineral phases formed in the kiln.

Kiln System Chemistry

24
The chemical reactions that occur in the kiln are described in detail in
(3). The temperature isincreased when going from the meal feed to the
rotary kiln. The most important oxides thatparticipate in the reactions
are CaCO3, SiO2, Al2O3 and Fe2O3. Up to about 700C water isremoved
from the meal. In the preheating section (700-900C) calcination as well
as an initialcombination of alumina, ferric oxide and silica with lime
takes place. Between 900C and1200C belite, C2S (= 2CaO*SiO2),
forms. Above 1250C a liquid phase appears and thispromotes the
reaction between belite and free lime to form alite, C3S (= 3CaO*SiO2).
During thecooling stage the molten phase forms C3A, tri calcium
aluminate, (= 3CaO* Al2O3) and if thecooling is slow alite may dissolve
back into the liquid phase and appear as secondary belite.
Usually the production of clinker is done so that one type of clinker
allows the plant tomanufacture several well-defined types of cement
that comply with the physical demands asspecified by cement
standards.

Figure 7.3:Cement manufacturing process.

25
Cyclone preheater

The raw materials are preheated or calcined in preheater or series of

cyclones before entering to the rotary kiln. A preheater, also called as
suspension
preheater is a heat exchanger in which the moving crushed powder is
dispersed in a
stream of hot gas coming from the rotary kiln. Common arrangement of
series of
cyclones is shown in figure.

Figure 7.4: Cyclone preheater using for preating of clinkers before KILN
PROCESS.

26
Alternative fuels

The range of fuels is extremely wide. Traditional kiln fuels are gas, oil or
coal. Materials likewaste oils, plastics, auto shredded residues, waste
tyres and sewage sludge are often
proposed as alternative fuels for the cement industry. Also all kinds of
slaughterhouse residuesare offered as fuel nowadays.

Table7.2: Alternative fuel options for the cement industry

Liquid waste fuels Tar, chemical wastes, distillation
residues, waste solvents, used oils,
wax
suspensions, petrochemical waste,
asphalt slurry, paint waste, oil sludge
Solid waste fuels Petroleum coke (“petcoke”), paper
waste, rubber residues, pulp sludge,
used tires, battery cases, plastics
residues, wood waste, domestic
refuse,
rice chaff, refuse derived fuel, nut
shells, oil-bearing soils, sewage
sludge
Gaseous waste Landfill gas, pyrolysis gas

To be able to use any of these fuels in a cement factory it is necessary to know the
composition of the fuel. The choice is normally based on price and availability. The
energy and ash contents are also important, as are the moisture and volatiles
contents. All kinds of varieties from liquid to solids, powdered or as big lumps can
be encountered when dealing with alternative fuels, requiring a flexible fuel feeding
system. Somehow they should all be fed into the burning chamber of the process.
It may be fed directly into the burning zone in the kiln itself or into the pre-heating
system for dissociating part of the carbonates from the meal before it enters the
kiln for clinker formation. In Table we can see examples of different alternative
fuels. They are separated into three groups (1).

27
 In Table several fuels of interest to the cement industry and their properties are
listed. Some of these were used in model calculations reported here. The
calculations were made to test the influence of a fuel change on the kiln process,
specially the demand of combustion air in the burning zone

Table 7.3:Properties of fuels of interest to the cement industry

BITUMI PET MEAT SEWAG CAR COALPE

NOUS COKE AND E TYRE TCOKE
COAL BONE SLUDG RUBBER MIX
MEAL E

C (%-wt, 66,6 89,5 42,1 42,9 87,0 75,1

dry)
H (%-wt, 3,99 3,08 5,83 9,00 7,82 4,20
dry)
N (%-wt, 1,07 1,71 7,52 1,4 0,33 1,70
dry)
S (%-wt, 1,22 4,00 0,38 0,12 0,80 3,00
dry)
O (%-wt, 8,85 1,11 15,3 27,2 1,81 4,90
dry)
Ash(%- 18,4 0,50 28,3 17,9 2,20 11,1
wt, dry)
Volatiles 28,3 10,0 64,5 85,0 6,66 20,0
(%-wt)
Volatiles 47,9 89,5 7,20 5,00 31,1 69,21
(%-wt)
H2O(%- 2,35 1,50 8,09 5,20 0,73 1,23
wt)
LHV(MJ/k 25,3 33,7 16,2 15,8 35,6 29,71
g)
HHV(MJ/ 26,2 37,3 28,97

28
 kg)

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.

7.2.5 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 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

29
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 seive 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.

Figure 7.5:Cement milling machinefor fine powder of clinker.

7.2.6 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.

30
 Figure 7.6: Paking of cement bages in 50 kg each one in packing plant.

7.3 Maintenance in cement industry

High productivity at the modern cement plant is highly dependent on regular,

scheduled maintenance. This requires planning, to ensure that company staff
always have the knowledge, manpower and parts on hand to give equipment the
attention it needs when it’s due for scheduled maintenance. The primary
maintenance approach is to do what necessary to keep the equipment running with
maximum production. Maintenance include elements such as motor and bearing
lubrication, motor belt replacement, fan blade cleaning, fan wheel balancing, and
compressed air system maintenance.

Figure7.7: shutdown time kiln maintenance work running.

31
8. THE ROLE OF THE LABORATORY

The laboratory forms an integral part of the control systems on site with testing from raw
materials to finished product. The laboratory operates a 24 hour facility in line with a
continuous manufacturing facility responsible for the following aspects:

 Testing raw materials prior to blasting in the quarry and assisting with
development of quarrying strategies forms the first step in the process.
 Analysing rock samples from the raw mill at regular intervals during the day and
night and fine tuning the process to ensure chemical control is maintained.
 Analysing clinker at the end of the cooler (before grinding) to ensure that the
manufactured process meets specification.
 Checking that cement mills are undertaking grinding correctly and that customers
receive the right product.
 Checkings despatched materials for quality and compliance with NZ Standards
requirements. Certificates of conformance are issued to customers based on
these analyses.

8.1 Product development

Testing work within the laboratory ranges from simple air permeability measurements to
hightechnology X-ray fluoresence analysis (see air pollution article). Qualifications
within thelaboratory relect this wide range of testing and skills requirement with
university qualifiedstaff working alongside others with minimal formal qualifications.

32
 Figure 8.1 : Product development knowledge at throw training program.

9. ENVIRONMENTAL IMPLICATIONS

Many of the aspects of the cement making process are potentially environmentally
damaging, although these risks can be minimised. The areas of potential concern are
listed below.

9.1 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

33
earthed collection plate. The electrostatic discharge between the electrode and the plate
forces the dust onto the plates, from which it is removed.

The current emission limit from the main stack at Nimbahera is 250 mg m-3 and at
Mangrol is 150 mg m-3, while in Indian emission limits of down to 50 mg m-3 are
becoming common.

This poses a significant challenge to the manufacturing operation both in capital cost to
reduce emissions and monitoring of emissions to ensure compliance with existing
resource consents.

Figure 9.1 :shows the limestone stacker operation without and with water spraying.

9.2 CO2

Cement manufacture is an energy intensive process. One of the most significant

challengesfacing the industry into the 21st century is a requirement to reduce CO2
emissions. CO2 isproduced during the calcination phase of the manufacturing process
and also as a result ofburning fossil fuels. Opportunity to reduce emissions through
increased energy efficiency isonly possible on the latter of the CO2 emissions.

34
9.3 Quarry and plant water runoff

Runoff of storm water and treatment of waste water from quarries is a problem for
almost allquarry operations. Usually this is trapped in wetland areas where the water is
treated in acontrolled manner. Within the factory runoff can be contaminated by oils and
lubricants, butthe runoff is monitored and training programmes are reguarly undertaken
to ensure this doesnot happen.

9.4 Chrome bricks

Kiln bricks used to be made of hexavalent chrome, which is a carcinogen and

causesdermititus in some people. Since the problems associated with its use were
identified bothalong with almost all cement manufacturers internationally. Replaced
these bricks with environmentally-sound magnesium-spinal bricks.

35
Figure 9.2 :Typical Gypsum storage area and open stock pile of Clinkeran.

36
10. 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.

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.

FIGURE 10.1: X-RAY MACHINE,NIMBAHERA

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.

37
 REFRENCE

 Indian Portland Cement Industry Plant Information Summary.

 Compliance report of environment clearance is reference letter from
MOEF,New Delhi -J-11011/1273/2007-1A (II).
 Official website of JK Cement
www.jkcement.com /www.jkcement.com/above
Nimbahera Dist - Chittorgarh, Kailash Nagar - 1,
Rajasthan – 312617 Phone - 01477 – 220087
 Reference from Wikipedia
En.wikipedia.org/../.j.k.Orgnisation

38
Locate The Plants

Grey Cement Works

NIMBAHERA MANGROL

Nimbahera Dist - Mangrol, Tehsil

Chittorgarh, Nimbahera

Kailash Nagar - 1, Dist - Chittorgarh,

Rajasthan
Rajasthan - 312617
Phone - 01477 –
Phone - 01477 - 246324
220087

MUDHOL GOTAN
Muddapur
P.O.Gotan -
Taluk Mudhol - 342902,
587122
Dist - Nagaur,
Dist - Bagalkot, Rajasthan
Karnataka
Phone - 01591 -
Phone - 08350- 230201
289000
Fax - 01591 –
Fax - 08350 - 230206
280710
JHARLI
(GRINDING UNIT)

P.O - Jharli

Dist - Jhajjar

Haryana – 124106
     

39
 White Cement Works

GOTAN

Gotan - 342902,
Dist - Nagaur,
(Rajasthan)

Phone - 01591 -
230201

Fax - 01591 -
230206

40