Overview of Cement Manufacturing 09.06.21

PLANT PRESENTATION
2021
MANIKGARH CEMENT WORKS
www.ultratechcement.com
Ultratech Values
Acting and making decisions in a manner that is fair and honest.
Doing all that is needed to deliver value to all stakeholders. In the process, being Thinking and working together across functional groups, hierarchies, businesses
accountable for our own actions and decisions. and geographies.
An energetic, intuitive zeal that arises from emotional engagement with the Responding to internal and external customers with a sense of urgency.
organization that makes work joyful and inspires each one to give his or her best.
Overview of a Cement Plant
Stages of Cement Plant Process
CEMENT MANUFACTURING PROCESS
PHASE 1: RAW MATERIAL EXTRACTION

Cement uses raw materials that cover calcium, silicon, iron and aluminum. Such raw materials are
limestone, clay and sand. Limestone is for calcium. It is combined with much smaller proportions of sand
and clay. Sand & clay fulfill the need of silicon, iron and aluminum.
Generally, cement plants are fixed where the quarry of limestone is near bye. This saves the extra fuel
cost and makes cement somehow economical. Raw materials are extracted from the quarry and by
means of conveyor belt material is transported to the cement plant.
There are also various other raw materials used for cement manufacturing. For example, shale, fly ash,
mill scale and bauxite. These raw materials are directly brought from other sources because of small
requirements.
Before transportation of raw materials to the cement plant, large size rocks are crushed into smaller size
rocks with the help of crusher at quarry. Crusher reduces the size of large rocks to the size of gravels.
PHASE II: RAW MATERIAL PREPARATION

The raw materials from quarry are now crushed
through limestone crusher to get the required size for
further fine grinding at mill. These crushed limestone
is then stored in stockpile through stacker and feed
through reclaimer to raw mill grinding storage bins.
There is cross belt analyser system for continuous
monitoring of quality of limestone under pile
preparation.
PHASE III: RAW MEAL PREPARATION
Now cement plant grind the raw mix with the help of heavy wheel type rollers and
rotating table. Rotating table rotates continuously under the roller and brought
the raw mix in contact with the roller. Roller crushes the material to a fine
powder and finishes the job. Raw mix is stored in a pre-homogenization silos after
grinding raw mix to fine powder.
Maratha Cement Works, India
Kiln Feed
1.653 kg-Feed/kg-Clk PHASE IV: CLINKERIZATION (PRE-HEATING
South String North String (ADM)
RAW MATERIAL, KILN PHASE & COOLING
0.886 Nm3/kg-clk
PHASE)
6A/B 6C/D Raw Mill/Baghouse
After final grinding, the material is ready to face the pre-
heating chamber. Pre-heater chamber consists of series of
5A 5B
vertical cyclone from where the raw material passes before
4A 4B
facing the kiln. Pre-heating chamber utilizes the emitting hot
gases from kiln. Pre-heating of the material saves the energy
3A 3B and make plant environmental friendly. Kiln is a huge
1.167 Nm3/kg-clk
0.027 kg-Dust/kg-Clk
rotating furnace also called as the heart of cement making
2A 2B
process. Here, raw material is heated up to 1450 ⁰C. This
ESP
temperature begins a chemical reaction so called de-
carbonation. In this reaction material (like limestone)
1A 1B releases the carbon dioxide. High temperature of kiln makes
Calciner
slurry of the material.
Calciner Firing Kiln Firing
0.048 kg-Coal/kg-Clk 0.027 kg-Coal/kg-Clk
0.011 Nm3/kg-clk 0.015 Nm 3/kg-clk
The series of chemical reactions between calcium and silicon
0.329 Nm3/kg-clk
T.A. Duct dioxide compounds form the primary constituents of cement
Primary Air
0.041 Nm 3/kg-clk i.e., calcium silicate compounds. Kiln is heating up from the
KILN
KILN #REF!
exit side by the use of natural gas and coal. When material
reaches the lower part of the kiln, it forms the shape of
0.221 Nm3/kg-clk Cooler clinker.
Clinker After passing out from the kiln, clinkers are cooled by mean
of forced air. Clinker released the absorb heat and cool down
to lower temperature. Released heat by clinker is reused by
recirculating it back to the kiln. This too saves energy.
PHASE V: CEMENT
GRINDING
Final process of 5th phase is the
final grinding. There is a
horizontal filled with steel balls.
Clinker reach in this rotating
drum after cooling. Here, steel
balls tumble and crush the
clinker into a very fine powder.
This fine powder is considered as
cement. During grinding gypsum
is also added to the mix in small
percentage that controls the
setting of cement.
PHASE VI: PACKING AND SHIPPING

Material is directly conveyed to the silos (silos are the large
storage tanks of cement) from the grinding mills. Further, it
is packed to 50 kg bags. Only a small percent of cement is
packed in the bags only for those customers whom need is
very small. The remaining cement is shipped in bulk
quantities by mean of trucks, rails or ships.
INTRODUCTION OF MANIKGARH CEMENT WORKS
M/s Manikgarh Cement Works was established in the year 1987 at village Gadchandur, Dist
Chandrapur, Maharashtra. Presently, there are two units in MCW as Unit-I & Unit-II
www.ultratechcement.com 2
INTRODUCTION
1] Manikgarh Cement Unit – I :
Manikgarh Cement Unit-I was established in the year 1987 at Gadchandur,
Chandrapur, in the state of Maharashtra. This high-tech cement plant had an
initial capacity of 1 MTPA which was later expanded to its present capacity of
2.0 MTPA.
2] Manikgarh Cement Unit – II :
Manikgarh Cement Unit-II was established in the year 2014 close to Manikgarh
Cement Unit-I plant with a capacity of 4.0 MTPA
SAFETY
Safety Vision
• Zero Fatality, LTI (Lost Time Injury) Reduction 20% & MTI (Medical Treatment Injury) Reduction 20%
Safety Practices
• Involvement of senior leadership in Tool Box Talk before start of Jobs.
• SO rounds & Near Miss Reporting System implemented in manual format.
• All lifting tools and tackles of company and contractors are tested and colour coded. Centralized tool room is provided at workshop .
• Inspection and Testing of all electrical equipments completed– master list of all electrical equipment is made and tagging procedure is
under progress.
• Eye testing of all staff done and safety goggles (power lens) are distributed.
• Implementation of UTCL standard started (Work at height, electrical safety, PPE’s, scaffolding, confined space, machine guarding, permit
to work initiated)
• Platform prepared for tarpaulin tying, coal sampling, fly ash bulker, laterite trucks, wagon loading installed at respective locations.
• UTCL theme of the month started.
• Area owner developed for various locations to implement and maintain safety initiatives and house keeping.
Vehicle/pedestrian safety
• Safety Instructions announcement system at Truck and Bulker yards.
• Crush helmet for two wheeler rider as well as pillion riders and seat belt for four wheeler are implemented, Speed limit 30 kmph.
• Zebra crossing, pathway marking initiated.
• Inspection of vehicles initiated.
PLANT FACILITIES
Equipment's Unit-II Unit-I

Limestone Crusher
Capacity 1200 TPH 1000 TPH
Type Double Rotor Impactor Single Rotor Impactor
Limestone Transportation Long Pipe Conveyor Rope-way
Length 7.5 KMS 7.5 KMS
Stacker Reclaimer
Feed conveyor & stacker 1300 TPH 750 TPH
capacity
Reclaimer & reclaim 990 TPH 450 TPH
conveyor capacity
Storage capacity 2 x 40000 2 x 40000
Raw Mill Pfiffer Loesche (2 No's)
Capacity 600 155
Type MPS 6000 LM32.4
PLANT FACILITIES

Pre-Heater
Type 6 stage(twin string)/ILC 4 stage(Single string)/ILC
No. of string 2 1
Kiln FLS Fuller
Kiln design capacity 8000 TPD 4500 TPD
Length / Diameter 86 meter / 5.5 meter 67.05 meter / 4.57 meter
Coal Mill Pfiffer Loesche
Type MPS 3350BK LM 21.2 VRM 2 ROLLERS
Cooler & ESP FLSmidth (ABC cooler inlet under FULLER
project)
Design Capacity 8000 4500 (after modification)
Type Cross Bar SF 5*7F 1 Comp- Fons, 2&3-GRATE COOLER
Clinker Silo
Capacity 50000 Silo 40000 Dome
PLANT FACILITIES
Equipment's Unit – II Unit – I

Cement Mill
Type Ball Mill (CM 1, 2 & 3) Ball mill (CM 1&2)
Ball Mill+Roller Press (CM3 )
Capacity 160 - OPC, 210 - PPC OPC/PPC-100/120 CM 1&2
PCC-135 CM3
Installed Power 5000 2000 x2(twin Drive)-CM 1&2
1250 x 2 (twin Drive)-CM3
Cement Silos 4 Nos 5 nos
Capacity 2 x 10000 – OPC53 2 X 5000 - PCC & PPC
1 x 10000 - OPC43 2 X 5000 - OPC & PPC
1 x 10000 - PPC 2 x 500 - SRC
Clinker Wagon Loading System
Buffer Hopper Capacity Hopper – 2 x 500 Ton and -
2 x 4000 Ton Concrete Silos
Loading Spout 2x3 -
Loading Capacity 2 x 1200 TPH -
PLANT FACILITIES

Packing Plant Enexco EEL & Enexco
No of packers 5 Nos Double Discharge 1 Double Discharge,
4 Single Discharge
Capacity 240 TPH 120 TPH Single,
180 TPH Double
Wagon Loader Nos 20 12
Wagon Loader Capacity 120 TPH 90 TPH & 100 TPH
Truck Loader Nos 8 7
Truck Loader Capacity 120 TPH 90TPH, 120TPH
CPP BHEL BHEL
Capacity 60 MW 10 MW + (5 MW obsolete)
Boiler Type CFBC AFBC
Boiler Capacity 230 TPH 2 x 37 TPH
Cooling Condenser Air Cooled Condenser Air Cooled Condenser + Water
Cooled Condenser
ENVIRONMENT ASPECT
Present environment
Capacity of Cement production 6.0 MTPA
clearance
ISO Certifications
Certified under IS/ISO 9001:2015
Certified under IS/ISO 14001:2015
Certification under IS 45001:2018
CEMENT PRODUCTS
At Manikgarh Cement Works we have facilities to manufacture the

following grades of Cement
Ordinary Portland Cement ( IRST 40 )
Portland Slag Cement
Portland Composite Cement
Sulphate Resisting Cement
Oil Well Cement (API Certified)
Ordinary Portland Cement ( 43 and 53 )
Portland Pozzolana Cement ( Fly Ash Based )
MCW PLANT OVERVIEW
Limestone Mines Mines Crusher
MCW PLANT OVERVIEW
Long Pipe Conveyor And Rope-way (7.5 KM)
MCW PLANT OVERVIEW
Stacker & Reclaimer Raw Mill

MCW PLANT OVERVIEW
Double String Six Stage Pre-heater Kiln

MCW PLANT OVERVIEW
AFR Utilisation & its Feeding System

MCW PLANT OVERVIEW
Cement Mill
MCW PLANT OVERVIEW
Quality
Control Lab
MCW PLANT OVERVIEW
Quality Control Lab for OWC Cement

MCW PLANT OVERVIEW
Packing Plant
MCW PLANT OVERVIEW
Truck Loader Wagon Loader
MCW PLANT OVERVIEW
Clinker Wagon
Loading System
MCW PLANT OVERVIEW
60 MW Captive Power Plant
www.ultratechcement.com 44
MCW PLANT OVERVIEW
60 MW Captive Power Plant Turbine

MCW PLANT OVERVIEW
10+5 MW Captive Power Plant Turbine

MCW PLANT OVERVIEW
Occupational Health Centre

MCW PLANT OVERVIEW
Manikgarh Staff Club Manikgarh Cement School
REWARD
Five Star Rating Mines Award for exemplary performance in implementation of Sustainable
Development Framework during 2016-17 assessed under the Star Rating System
MCW CSR ACTIVITIES
Beautification & dedication of Shahid Installation of two Bus Shelter

Bhagat Singh chowk to the citizen of at village Gadchandur
Chandrapur City.
Thank You

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PLANT PRESENTATION

MANIKGARH CEMENT WORKS

Acting and making decisions in a manner that is fair and honest.

PHASE 1: RAW MATERIAL EXTRACTION

PHASE II: RAW MATERIAL PREPARATION

PHASE VI: PACKING AND SHIPPING

1] Manikgarh Cement Unit – I :

Manikgarh Cement Unit-I was established in the year 1987 at Gadchandur,

Chandrapur, in the state of Maharashtra. This high-tech cement plant had an

2] Manikgarh Cement Unit – II :

Equipment's Unit-II Unit-I

Equipment's Unit-II Unit-I

Equipment's Unit – II Unit – I

Equipment's Unit-II Unit-I

At Manikgarh Cement Works we have facilities to manufacture the

Ordinary Portland Cement ( IRST 40 )

Portland Slag Cement

Portland Composite Cement

Sulphate Resisting Cement

Oil Well Cement (API Certified)

Ordinary Portland Cement ( 43 and 53 )

Portland Pozzolana Cement ( Fly Ash Based )

Limestone Mines Mines Crusher

Long Pipe Conveyor And Rope-way (7.5 KM)

Stacker & Reclaimer Raw Mill

Double String Six Stage Pre-heater Kiln

AFR Utilisation & its Feeding System

Quality Control Lab for OWC Cement

Truck Loader Wagon Loader

60 MW Captive Power Plant

60 MW Captive Power Plant Turbine

10+5 MW Captive Power Plant Turbine

Occupational Health Centre

Manikgarh Staff Club Manikgarh Cement School

Beautification & dedication of Shahid Installation of two Bus Shelter

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