Maple Leaf Cement Factory Limited

Internship Report

Training Organization:

Maple Leaf Cement Factory Limited

Iskanderabad Road، Iskandarabad, Mianwali, Punjab

Training Duration:

20 week (5 Months)

Presented to Department of Mechanical Engineering and Technology

Institute of Southern Punjab, Multan

Submitted By:

Tanveer Abbas
BSETM-021R18-3

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 ACKNOWLEDGEMENT

I offer my humblest thanks to ALMIGHTY ALLAH, The most Beneficent and the Most Considerate
and the entire source of all knowledge and wisdom. I thank ALMIGHTY, ALLAH, who gave me the
aptitude to do this project efficiently and successfully.

I faced a lot of difficulties during this phase of developing internship report. But Allah gave me a lot
of patience and due to the continuous encouragement of my teachers and other people concerned; I
was able to complete this project.

It’s not very easy for me to find the right words to express my gratefulness to our praiseworthy
advisor Mr. Shakeel Aslam, his enthusiastic interest, in time and useful suggestions, continuous
encouragement, vivacious supervision and kind behavior throughout my internship period.

Apart from my respectable advisor, there are many other people who have been very helpful to me
right from the beginning. I would whole heartedly acknowledge the entire management of Maple
Leaf Cement Factory Limited who provided me this opportunity to achieve this practical experience
under their valuable supervision and helping suggestions to complete this report.

I would like to thanks ENGR ATIF MEHMOOD guiding us in understanding the concepts of Cement
Plant Production. I would also like to thank all our teachers guiding us in solving our problems.

I would also like to thank my family and friends for their continuous encouragement and moral
support.

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 Executive Summary

This report is based on my 20 weeks EXPERIENCE at MAPLE LEAF CEMENT FACTORY

LIMITED as an internee from 10th March to 28th july. THE COMPANY Is a highly reputed
organization. Maple Leaf is one of the pioneers of the cement industry in Pakistan. It owns and
operates grey and white cement plants located at Daudkhel District Mianwali

The salient features of this report are: Maple Leaf’s background, its vision, corporate values and
goals. This report focuses its business operations including major areas as its overall marketing
strategies, its production and operations, and it’s Human Resource. The Financial Analysis of the firm
has been done in detail. The Ratio Analysis, Common Size Analysis and Index Analysis of the firm
are really a fascinating experience of mine.

This report accentuates the details of my learning and observation at Maple Leaf. It also includes the
actual forms that are used in this organization to carry out basic business processes. And I am sure
that this report will provide you a complete and clear image of organization.

Abstract

Maple leaf cement factory is the top ranking cement industry in Pakistan and in the world. I have
completed my internship at maple leaf cement factory in July 2021. During my stay at maple leaf I
learn about the working of the impact hammer crusher, double roller crusher, stacker, reclaimer, raw
mill, control flow silo, pre-heater, kiln and cooler, cement mill, packing plant, and different type of
methods used for cement transportation from one machine to another.

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 History and Background

Maple Leaf Cement Factory Limited:

Maple Leaf is one of the pioneers of the cement industry in Pakistan. It owns and operates grey and
white cement plants located at Daudkhel District Mianwali.

History:

Maple leaf Cement Factory Limited was established by the Pakistan Industrial Development
Corporation (PIDC) in 1956. It was later incorporated as “Maple Leaf Factory Limited” in April
1960. The company started as a producer of grey Portland cement, with a wet process plant of 400
tons per day (“tpd”) clinker capacity installed with the assistance of the Canadian Government, in
1960 a second wet process plant Portland cement was installed with a clinker capacity of 600 tpd.

In 1969, a company by the name of White Cement Industries Limited (WCIL) was formed with a 50
tpd white cement plant. In 1974, under the PIDC Transfer of Company & Project Ordinance, the
management of two companies, namely MLCFL and WCIL were transferred to the newly established
State Cement Corporation of Pakistan (SCCP), which controlled the entire cement industry in
Pakistan after nationalization.

In 1983 SCCP expanded WCIL’s white cement plant by adding another unit of the same capacity
parallel to the existing one. In 1986 SCCP also set up another production unit of grey cement with a
capacity of 600 tpd based on wet technology under the name of Pak Cement.

Company’s Policy

“Quality Policy”

MLCFL’s policy for quality is based upon the mission statement. MLCFL manufactures grey
ordinary Portland cement for industrial and domestic use. MLCFL shall achieve its policy through
the application of quality management system; by identifying, understanding, managing, and
maintaining a quality system of inter related quality processes which are structured to comply with
the requirements of ISO 9001: 2000 (E) and all applicable regulatory and statutory requirements.

MLCFL shall continually improve the effectiveness of Quality Management System for the
organizations over all performance and efficiency. All the employees of MLCFL believe in

“Continual improvement through team work”

MLCFL understands that the involvement of people at all levels is equally beneficial for both the
organization and its employees and the effective decision at all functions shall be based on the
analysis of data and information. MLCFL believes that the suppliers are important part of the
organization and play a key role in the smooth operation of plant. This policy is issued to clearly
indicate the attitude of the company with regard to quality and customer satisfaction for the long term
of MLCFL’s competitive position, reputation and employees’ satisfaction.

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 Table of Contents
Acknowledgement.............................................................................................................................3
Executive Summary..........................................................................................................................4
Abstract..............................................................................................................................................4
History and Background..................................................................................................................5
Company Policy................................................................................................................................5

Chapter 01........................................................................................................................................9
1.1 History of cement........................................................................................................................9
1.2 The Chemistry of cement.............................................................................................................9
1.3 Back ground of MPLCF..............................................................................................................9
1.4 Geographical Importance............................................................................................................10
1.5 Three Product.............................................................................................................................10

CHAPTER 02.................................................................................................................................11
THEORY RELATED TO INTERNSHIP........................................................................................11
2.1 Cement.......................................................................................................................................11
Raw Materials..................................................................................................................................11
Fig 2.1 Raw material........................................................................................................................11
2.2 Production Capacity....................................................................................................................12
2.3 Maple leaf Cement Plant.............................................................................................................12
2.3.1 Step 1 - Quarrying...................................................................................................................12
2.3.2 Step 2 - Raw material preparation............................................................................................12
2.3.3 Step 3 - Clinkering..................................................................................................................12
2.3.4 Step 4 - Cement milling..........................................................................................................13
2.4 TRANSPORTATION SYSTEM................................................................................................13
2.4.1 BELTS....................................................................................................................................14
2.5 BUCKET ELEVATOR...............................................................................................................14
2.6 AIR SLIDE.................................................................................................................................14
Fig 2.2 Air slide................................................................................................................................15
2.7 SCREW CONVEYOR................................................................................................................15
Fig 2.3 screw conveyor.....................................................................................................................15
2.8 Machinery used...........................................................................................................................16
Fig 2.4 production method................................................................................................................16
2.10 PRODUCTION PROCEDURE:................................................................................................17
2.10.2 Step-I......................................................................................................................................17
2.10.2 Step-II....................................................................................................................................17
2.10.3 Step-III...................................................................................................................................17
2.10.4 Step-IV...................................................................................................................................17
2.10.5 Step-V....................................................................................................................................17
2.10.6 Step-VI..................................................................................................................................18
2.10.7 Step-VII.................................................................................................................................18
2.10.8 Step-VIII...............................................................................................................................18
2.10.9 Step-IX..................................................................................................................................18
2.10.10 Step-X.................................................................................................................................18
2.10.11 Step-XI................................................................................................................................18

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CHAPTER 03..........................................................................................................................19
STRUCTURE OF INDUSTRY.................................................................................................19
3.1 C.C.R (COMPUTER CONTROLE ROOM)......................................................................19
3.2 CRUSHING AREA.............................................................................................................20
Two type of crushers are used to crush raw material................................................................20
3.2.1 ROTOR...........................................................................................................................20
3.2.2 HAMMER BARS............................................................................................................20
Fig 3.1 Hammer crusher............................................................................................................21
3.2.4 Roller Crusher..................................................................................................................21
3.2 STORAGE AREA..............................................................................................................21
3.4 RAW MILL........................................................................................................................22
Fig 3.2 parts of raw mill...........................................................................................................23
3.5 .C.F (CONTROLE FLOW) SILO......................................................................................24
3.6 KILN AND COLLAR........................................................................................................25
Three types of bricks is used in kiln.........................................................................................25
3.8 CEMENT MILL.................................................................................................................26
3.9 PACKING PLANT............................................................................................................27
3.10 UTILITY AREA..............................................................................................................27
3.10.1 AIR...............................................................................................................................28
Fig 3.3 Single stage compressor..............................................................................................28
Fig 3.4 Double stage compressor............................................................................................29
3.10.2 WATER.......................................................................................................................30
Type of pumps are used...........................................................................................................30
General Components of Centrifugal Pumps............................................................................32
Fig 3.5 parts of centrifugal pumps...........................................................................................32

CHAPTER 04.......................................................................................................................33
STRUCTURE RELATED TO MECHANICAL....................................................................33
TECHNOLOGY....................................................................................................................33
4.1 CRUSHER.......................................................................................................................33
4.1.1 Impact hammers crusher................................................................................................33
4.1.2 Roller crusher................................................................................................................34
Lime stone crusher;.................................................................................................................36
4.3 STACKER AND RECLAIMER......................................................................................37
4.4 RAW MIL:......................................................................................................................37
Fig 4.1 parts of raw mill.........................................................................................................38
Two parts of raw mill require lubrication..............................................................................39
4.5 .PRE HEAATER.............................................................................................................39
4.6. KILN.............................................................................................................................41
4.6.1 Kiln dimension:............................................................................................................41
TABLE 4.1 TENSILE STRENGTH OF STEEL..................................................................41
4.6.2 KILLEN LINE 1 SPECIFICATION............................................................................42
4.6.3 KILLEN LINE 2 SPECIFICATIONS..........................................................................42
4.6.4 DIFFERENCE B/W KILLEN LINE 1 AND Line 2....................................................43
4.8 CLINKER CRUSHER....................................................................................................43
4.9 CEMENT MILL..............................................................................................................43
4.10 BALL MILL.................................................................................................................44
Fig 4.2 Ball mill....................................................................................................................44

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4.10.1 CRITERIA FOR MEDIA SELECTION.............................................................................45
4.10.2 BALL MILL SPECIFICATION..........................................................................................45
Fig 4.3 Vertical Cement mill...........................................................................................................46
4.11.1 Product quality.....................................................................................................................46
4.11.2 Particle Size Distribution......................................................................................................47
4.11.3 Dehydration of the gypsum added to the cement.................................................................47
4.11.4 Pre hydration of the clinker minerals...................................................................................48
4.11.5 Water injection for temperature c control............................................................................48
4.11.6 Versatility............................................................................................................................49
4.11.7 Upgrading............................................................................................................................49
4.12 PACKING..............................................................................................................................50
Fig 4.4 packing plant......................................................................................................................50
4.12.3 Open-ended..........................................................................................................................51
4.12.4 Modularity and flexibility.....................................................................................................51
4.12.5 Main parts of packer.............................................................................................................52
4.13 EMISSIONS FROM CEMENT FACTORY...........................................................................53
4.13.1 Dust emissions.....................................................................................................................53
4.13.2 CO2......................................................................................................................................53
4.13.3 Liquid Effluents...................................................................................................................53
4.13.4 Ambient Noise.....................................................................................................................53
4.13.5 Quarry and plant water runoff..............................................................................................54
Future Recommendations about this industry:................................................................................55
References.......................................................................................................................................55

LIST OF FIGURES

Fig 2.1Raw material...............................................................................................................11

Fig 2.2 Air slide....................................................................................................................15
Fig 2.3 screw conveyor..........................................................................................................15
Fig 2.4 production method.....................................................................................................16
Fig 3.1 Hammer crusher........................................................................................................20
Fig 3.2 parts of raw mill.........................................................................................................22
Fig 3.3 Single stage compressor............................................................................................28
Fig 3.4 Double stage compressor..........................................................................................29
Fig 3.5 parts of centrifugal pumps........................................................................................32
Fig 4.1 parts of raw mill........................................................................................................38
Fig 4.2 Ball mill...................................................................................................................44
Fig 4.3 Vertical Cement mill................................................................................................46
Fig 4.4 packing plant............................................................................................................50

LIST OF TABLES

TABLE 4.1 TENSILE STRENGTH OF STEEL................................................................41

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Chapter 01

Introduction

1.1 History of cement

Cement is a fine powder which after few minutes when mixed with water. And then hardens in to
solid strong material. Cement is mainly used to bind fine sand and solid aggregates to gather in
concrete.
Joseph Aspadin, a leads builder invented the port land cement in 1824. In this process Aspadin mixed
and ground hard lime stone and finally divided clay in form of slurry and calcined it in a furnace
similar to kiln till carbon dioxide was expelled. The mixture so calcined was than ground to a fine
powder and was used as a port land cement. The name Portland is given owing to its resemblance of
this hardened cement paste to a natural stone available at a place called port land in England.
Portland cement was first produced commercially in New Zealand in 1886 by James Wilson and Co.,
and has been produced here ever since[7].

1.2 The Chemistry of cement

Concrete mix is a mixture of cement and aggregate – sand and gravel. When water is added to this
the cement undergoes a series of chemical reactions to form a "gel" (a coloidal2 system). The fine
cement particles are broken down into even smaller particles (thus increasing the reactive surface) by
crystallizing out from the supersaturated solution formed. A series of immensely strong Si-O-Si
bonds form between the particles, making a network in which the aggregates are trapped. In addition,
bonds are formed to the aggregates, but these are much weaker, especially for smooth, inert, hard
aggregates: because they have a smaller surface area than rough aggregates, a smaller area can be
involved in bonding.

1.3 Back ground of MPLCF

Maple leaf cements industry is located in Daudkhel; district Mianwali, Punjab, Pakistan. It is one of
the leading cement industries of Pakistan in particular and world in general. Use of latest plant and
technology, dedicated and specialized team of staff, skilled labor and strict vigilance on quality of the
final product as per international standards, makes it unique and un-match able in cement producing
facilities in Pakistan.

It has two phases; Phase-I and Phase-II. Phase-I plant is involved in production of white cement
while Phase-II plant is involved in production of gray cement. In 1992, maple leaf was privatized and
owned by Kohinoor group of industries and up till now it has been modified in terms of capacity. In
1996, line-I of 3300 TPD previously was then enhanced to the 4000 TPD and in 2006 another plant
of 6700 TPD was installed, both plants are supply of FLS, a Danish based cement plant manufacturer
group.

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 My Opinion about MAPLE LEAF CEMENT Ltd:

I am honored to join this prestige organization as an internee in Mechanical field, and being the
student of Mechanical Engineering Technology ISP Multan. It was a great opportunity for me to
expand my theoretical knowledge with practical knowledge.

During my short stay at Maple leaf, I was able to learn a lot in the most professional and conducive
environment for learning. Here is the short report about what I witnessed during my stay at Maple
Leaf.

1.4 Geographical Importance

Maple leaf is blessed in a sense that the raw material is available at the door as the factory is located
at front of the mountains which are blessed and enriched with gypsum, Iron ore, Clay and other
precious minerals, abundantly. Maple leaf has its own facility of mining and exploitation of required
raw material from these mountains.

1.5 Three Products

Maple leaf cements are capable of producing special and quality goods of the following types:

 Grey Cement
 White Cement
 Salphate Resistance (S-R) cement

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CHAPTER 02

THEORY RELATED TO INTERNSHIP

2.1 Cement:

Typical Portland cements are mixtures of tri calcium silicate, tri calcium Iluminate and di calcium
silicate, in varying proportions, together with small amounts of magnesium and Iron compounds.
Gypsum is also added.

Raw Materials:

Fig 2.1 Raw material

Raw materials for the manufacturing of cement in the maple leaf cement plant are as follows:

 Lime stone (76%)

 Clay (20%)
 Iron (4% -5%)

Gypsum is also mixed with the final product to increase the setting time of the cement. In maple leaf
cement factory lime stone is derived from local mountains while coal is imported from Indonesia and
south Africa and iron from Makarwal (Pakistan). Maple leaf is the only industry in Pakistan which
uses glycerin in cement to increase its softness, Glycerin is more costly chemical and not available at
local level.

2.2 Production Capacity:

1) Gray Cement 6700+4000= 11700 Ton/day

2) White Cement 550 Ton/day

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2.3 Cement Plant:

Maple leaf‟s cement plant technology is one of the best technologies in the world. It is using FLS‟
(German company) cement plant. Raw mill is made by F.L.S Germany. The cement manufacturing
process involves four distinct stages, and these are outlined below.

2.3.1 Step 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 of the cement,
while the iron reduces the reaction temperature and gives the cement its Characteristic grey color.

2.3.2 Step 2 - Raw material preparation

The steps involved here depend on the process used. There are two main cement manufacturing
processes currently used in New Zealand: the dry process (used by Golden Bay) and the wet process
(used by Milburn). The dry process uses more energy in grinding but less in the kiln, and the wet
process has lower overheads than the dry process. The two processes are discussed separately
below[2,3].

2.3.2.1 The dry process

The quarried clay and limestone are crushed separately until nothing bigger than a tennis ball
remains. Samples of both rocks are then sent off to the laboratory for mineral analysis. If necessary,
minerals are then added to either the clay or the limestone to ensure that the correct amounts of
Aluminum, iron etc. are present. The clay and limestone are then fed together into a mill where the
rock is ground until more than 85% of the material is less than 90μm in diameter.

2.3.2.2 The wet process

The clay is mixed to a paste in a wash mill - a tank in which the clay is pulverized in the presence of
water. Crushed lime is then added and the whole mixture further ground. Any material which is too
coarse is extracted and reground. The slurry is then tested to ensure that it contains the correct
balance of minerals, and any extra ingredients blended in as necessary.

2.3.3 Step 3 - Clinkering

This is the step which is characteristic of Portland cement. The finely ground material is dried, 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 mineral constituents of Portland cement. The
powder from the dry process doesn't contain much moisture, so can be dried in a pre heater tower. As
it falls through the tower (which takes 30 seconds) it is heated from 70 to 800oC. The moisture
evaporates, up to 20% of the de carbonation (loss of CO2) occurs and some intermediate phases such
as CaO•Al2O3 begin to appear. The mixture is then fed into the kiln.

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2.3.3.1 The kiln

The kiln shell is steel, 60m long and inclined at an angle of 1 in 30. The shell is supported on 3 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 high temperatures. Coal is injected with
air into the kiln at a rate of 9 - 12 T hr. The reaction processes occurring within the kiln are not easily
understood due to the wide variations in raw-mix chemistry, raw-mix physical properties and kiln
operating conditions, and the physical difficulties of extracting hot materials from the process for
investigation before they cool.

2.3.3.2 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.

2.3.4 Step 4 - 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 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 sieve 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.

2.4 TRANSPORTATION SYSTEM:

The transportation of raw material from query area to final place is performing by using different
methods. Some of these systems are given below:

1) Belts
2) Bucket elevator
3) Air slide
4) Screw conveyor

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2.4.1 BELTS:

Belts are used to transport raw material such as lime stone , clay , iron ore , gypsum from query area
to working area. Different rollers are used to support and run the belts. Motors are also used to rotate
the belts. Belts has a width of 1.5 foot and length is adjusted according to our needs. At the end of the
built motor is fitted which drive the belts.

2.4.1.1 Belts safety:

Following procedure is followed for the purpose of built safety to avoid any type of built breakage or
belts stop.

2.4.1.2 Speed monitor

Is used to monitor the speed of built and it can also help to control the speed of belts. Speed of built is
monitored and control by sensors that are control from control room.

2.4.1.3 Sway switches

Used to keep the built on track.

2.4.1.4 Pull card

Is actually a wire which is fitted over the built and its function is to stop the built in any emergency
case.

2.5 BUCKET ELEVATOR:

Bucket elevators are used to transfer material at the angel of 90 degree. Material is provided to bucket
elevator through built drive. Bucket elevator is mostly used where material is required to send to the
top of any building. Bucket elevator is derived with the help of a motor. Buckets are fitted at a belt
that‟s why it is called bucket elevator. Bucket elevator is fully covered by metal sheet to avoid
material losses. Bucket elevator is rotate at the speed of 25-30 rpm. Buckets are made up of mild
steel.

2.6 AIR SLIDE:

In air slide a cloth is used in which there is a cement and fans are used below it which provide air to
cloth and cloth transfer the material by moving up and down. air slides are used where material is
required to transfer more smoothly and quickly as compared to belt drive and bucket elevator. Air is
delivered to the cloth with the help of fans that are fitted on the both sides of air slides. Compressed
air cannot be used in air slides because it has high pressure which is not suitable for cloth used in air
slides. Air Gravity Conveying System uses the forces of gravity to do most of the work without any
moving parts. Material fluidized through a porous media with low pressure air. Material flow is
achieved by sloping the Air slide conveyor to match the fluidized angle of repose of the powdered
material. At the correct slope, fluidized materials flow with the consistency of a liquid.

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Typical Air slide Conveyor Applications:

 Distribution from bucket elevators to storage silos

 Gathering under bag houses / precipitators
 Feed to process
 Feed to other conveyors
 Load out from bulk silos to trucks, railcars or barges
 In-plant conveying
 Storage silo / bin withdrawal

Fig 2.2 Air slide

2.7 SCREW CONVEYOR:

Fig 2.3 screw conveyor

Screw conveyors move materials either horizontally, on an incline or vertically. They are used to
feed, distribute, collect or mix and can be equipped to either heat or cool while performing this
transfer with the proper cover and gas cutting, they are easily made dust or weather tight and rodent
proof. Their clean compact design saves valuable space since no return run is required. Screw
Conveyors fit in cramped quarters, are simple to support and easy to install . . . and they cost less than
most other types of conveyors. Screw Conveyor Corporation's performance-proved Screw Conveyors
are ruggedly built and accurately manufactured to assure complete dependability as well as the
versatility required to meet a wide range of job assignments.

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The screw conveyor is one of the most economical conveyor types available for moving bulk
materials. It is completely enclosed to contain the moving material and its atmosphere. The standard
unit, with variations in design, is suitable for solving a variety of bulk material handling problems.
Screw conveyor is looks like a screw which rotate and transfer material from one place to another.
Screw conveyor is another type of transportation system it works as rack and pinion.

2.8 Machinery used:

1) CRUSHER
2) STACKER
3) RECLAIMER
4) RAW MILL
5) C.F SILO
6) KILLEN
7) COOLER
8) BIN
9) CEMENT MILL
10) PACKING PLANT

2.9 PRODUCTION METHOD:

Fig 2.4 production method

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2.10 PRODUCTION PROCEDURE:

Cement plant in the Mianwali has higher production of cement whether it is grey cement or white
cement while during internship I came to know that how the production process starts and how it
proceeds and takes it final shape and which type of equipment in the plant was used for the
production. Each and every person in the plant guided in the visit and I was able to understand the
concepts of production. Production methods in the plant adopted are discussed below:

2.10.1 Step-I:

First step is the selection of raw material. Each and every useful product is produced by raw material.
Raw material in production of cement is as follows:

 Lime stone
 Clay
 Iron ore
 Gypsum

2.10.2 Step-II:

Raw materials brought from the sources are larger in size and are not able to be used for the
production process. The process for this step is called crushing. Crushing is done through crushers
installed in the factory. These raw materials are then sending to crushers, which convert large stones
to the desired size particles. Then these crushed components are separately piled up in different piles.

2.10.3 Step-III:

Then there are reclaimers, which re-claim material from these piles and send the required material to
Stack (Hoppers) through conveyor belts. Hoppers are large storage tanks which have controlled
output from them. Lime stone, clay and Iron ore are separately stacked into their stackers. rushed
components are separately piled up in different piles.

2.10.4 Step-IV:

Then there is a combine belt on which these all three materials are taken at a time. Output from each
stacker is pre-decided and hence adjusted according to the need and the feed of the belt is adjusted
properly so the material which falls on the belt is now mixture of all these three raw materials and
according to their proportions required to make the cement.

2.10.5 Step-V:

Next process is the production of cement and it is done in the raw mill. The mixture obtained from
the above raw materials is send to the raw material for the start of cement production.

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2.10.6 Step-VI:

Raw meal is then fed to the C.F Silo (controlled flow silo). What a silo do? It gives us blending and
controlled continuous flow. Here the raw meal is stored. This raw meal is then fed to the L.O.W (loss
of weight) tank through 7 air slides. In L.O.W tank, we can have the weight of the raw meal.

2.10.7 Step-VII:

From loss of weight tank, raw meal is send to the cyclones through air slides and elevator. What a
cyclone do? It separates dust from air and collects it. Material comes in cyclone 2 first, then it is
sucked to the Cyclone 1 from where it is sucked in cyclone 3 and the dust is collected in cyclone 2.
From cyclone 2 the dust is send to the cyclone 4, from where it is sucked in cyclone 3. From cyclone
3, dust is sucked in cyclone 5 and then again into cyclone
4. I can represent it in this way.

2 1 3 2 4 3 5 4

From cyclone 4, 60% material is send to the calciner and 20% is send to the cyclone 5 and then to the
smoke chamber (inlet of the KILN) through dividing gate.

2.10.8 Step-VIII:

Than this material which is pre heated through the calciner is now send to the Kiln, the main and very
important part of cement.

2.10.9 Step-IX

Raw meal after heating at extreme temperatures now comes out as a major product called as
CLINKER. This red hot clinker is then cooled through special coolers and is then large particles are
crushed through clinker crusher to desired size of 20-25mm. Then this cooled clinker is transferred to
the clinker hopper/dome for storage through apron conveyor.

2.10.10 Step-X:

Clinker is actually a cement particle. It is just grinded to the powder form. Gypsum is an additive
which has no link with the strength but it only increases the setting time of the cement. So the clinker
is then taken to the cement mills called OK MILL for grinding and the gypsum is added.

2.10.11 Step-XI:

At the end, the cement is stored in cement silos from where it is send to packing plant and is packed
in bags.

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CHAPTER 03

STRUCTURE OF INDUSTRY

Maple leaf cement factory has following departments:

1) C.C.R (COMPUTER CONTROLE ROOM)

2) CRUSHING AREA
3) STORAGE AREA
4) RAW MILL
5) C.F (control flow silo)
6) KILLEN AND COOLER
7) BINS
8) CEMENT MILL
9) PACKING PLANT
10) UTILITY AREA
11) WHR (WASTE HEAT RECOVERY)

3.1 C.C.R (COMPUTER CONTROLE ROOM):

In computer control room drawings of machinery that is used inside the factory are kept. It also has
drawing of factory building. All the processes are monitored from computers control room by using
different sensors, for example if the temperature of kiln is increasing or decreasing sensors or sense
that and decision is sends to the supervisor which controls the temperature by on or off the cooling
fans. In computers room cell no of employs are also kept so that they can contact in any emergency
condition. Lay out of whole factory and information related to machinery can also be derived from
control room.

Widely used in our society. It has been manufactured in New Zealand for more than 100 Cement is
the substance which holds concrete together, which means that it is external years, and during this
century production has increased one hundred-fold. Portland cement (the only type of cement in
common use today) is manufactured in a four step process.

Step 1 - Quarrying

Limestone and a 'cement rock' such as clay or shale are quarried and brought to the cement works.
These rocks contain lime (CaCO3), silica (SiO2), alumina (Al2O3) and ferrous oxide (Fe2O3) - the
raw materials of cement manufacture.

Step 2 - Raw material preparation

To form a consistent product, it is essential that the same mixture of minerals is used every time. For
this reason the exact composition of the limestone and clay is determined at this point, and other
ingredients added if necessary. The rock is also ground into fine particles to increase the efficiency of
the reaction.

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Step 3 - Clinkering

The raw materials are then dried, heated and fed into a rotating kiln. Here the raw materials react at
very high temperatures to form 3CaO•SiO2 (tri calcium silicate), 2CaO•SiO2 (di calcium silicate)
3CaO•Al2O3 (tri calcium iluminate) and 4CaO•Al2O3 •Fe2O3 (tetra calcium alumina-ferrate).

Step 4 - Cement milling

The 'clinker' that has now been produced will behave just like cement, but it is in particles up to 3 cm
in diameter. These are ground down to a fine powder to turn the clinker into useful cement. Cement
production has several quite serious environmental hazards associated with it: dust and CO2
emissions and contaminated run-off water. Both cement works in New Zealand have measures in
place to minimize these hazards.

3.2 CRUSHING AREA:

Two type of crushers are used to crush raw material:

1) Impact hammer crusher

2) Roller crusher

3.2.1 ROTOR:

Rotor is made of high-carbon steel casting, and has wedge-shape hammer holding grooves extending
parallel to the shaft. Its peripheral part is hardened by high frequency induction heating for greater
wear resistance. The shaft is press fitted and the rotor shaft assembly is dynamically balanced to
assure vibration free operation.

3.2.2 HAMMER BARS:

The hammer bars extend over the full width of the rotor. The bars are so designed that these can be
reused by repositioning after one face wears out. The hammer bars are of Ms steel castings.

3.2.3 FRAME:

The frame is fabricated with heavy steel plates and is stress relieved. Inside surface of the frame is
provided with cast Mild steel liners.

Fig 3.1 Hammer crusher

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3.2.4 Roller Crusher:

Roller crusher is used to crush clay in powder form. Roller crusher has following types

 Single roller crusher

 Double roller crusher
 Triple roller crusher

In maple leaf cement factory Crushing area consist of a 3 crushers 2 crusher used for lime stone
crushing and one for clay. Lime stone crusher consist of 4 excels fitted on a shaft. 8 hammers fitted
on each excel having a weight of 85-90 kilo gram. lime stone crush the material in the size of 25-30
mm. clay crusher crush the clay in to powder form and consist of a rollers of 3 ft diameter,

Lime stone crusher

Consist of a 4 excels. 8 hammers are fitted on each excels and each excel has a weight of 85-90 kilo
gram. Raw material is drives from mountains and stored in a hopper from where it is send to crusher
area with the help of a belt which is called apron feeder. This belt is made up of mild steel and has v
type grooves on it. Crusher is rotated with the help of motor of 650 kilo watt power. Motor rotate the
excel at 90 rpm. When excels rotates it strike the lime stone and break it in to 25-30 mm size. Under
the hammers a grate type basket is fitted which function is to send back the raw material of more than
30 mm size to crusher with the help of belt drive. Lime stone crusher is a impact hammer type
crusher. Coupling which is used b/w crusher and motor is flexible fluid oil coupling, capacity of line
1 crusher is 900 ton/hour and line 2 is 700 ton/hour.

Clay Crusher

Clay Crusher is a roller type crusher which consist of 2 rollers of diameter 2 foot which match to
gather and clay is crushed by b/w them. 500 kilo watt motor is used to rotate the rollers at 65-70 rpm.
These rollers crush the clay in to powder form.

A bag filter is used with crusher to collect dust and store it in another place. Water sprayer is used to
minimize the dust by spraying water.

3.2 STORAGE AREA:

In storage area raw material like lime stone, clay, iron ore, and coal is stored. Stacker is used to make
a pile of lime stone and clay. Lime stone pile is of 30,000 ton, and one pile of clay is 25000 ton.
RECLAIMER is used to reclaim the material and put it on a belt. In storage area stacker is used to
make a pile of clay and lime stone. It consists of 2 gear boxes self-align and adders. Self-align gear
box is used to keep built straight, adders are a rollers on which belt moves and they are more in
numbers.

Fluidic coupling is used in stacker to minimize the load of motor and for built safety.

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RECLAIMER

Reclaimer is used to reclaim the lime stone and clay .RECLAIMER consists of blades that are called
sprockets. Sprockets are of three types drive sprockets, tail sprockets, guide sprockets. RECLAIMER
or of 2 types boom type, bridge type. Boom type is used to reclaim clay and bridge type is used to
reclaim lime stone. No of blades of bridge type reclaimer is 113. Buffer plate is used on reclaimer to
adjust the material in the center of the belts. A magnet separator is used to detect and eliminate metals
from raw materials.

The stacker deposits raw material longitudinally in the form of pile. The pile is normally 250-300 m
long and 8-10 m high, The reclaimer cuts the pile vertically, The proportioned raw material is
transferred by a conveyor belt to raw mill for grinding, After the grinding the raw material is stored in
control flow silo (control flow) where blending takes place. Blending is done by injecting compressed
air, This powdered material is fed to the kiln for burning.

3.4 RAW MILL:

Raw mills are a type of industrial equipment used to crush or grind material in to small particles. Raw
mill is widely used in concrete and mixing field and are also used to process gypsum. These units can
process both raw and recycled material, while helping to reduce and preserve virgin supplies of these
materials.

Raw mill is used to crush the mixture of lime stone clay and iron. Raw mill consist of a 3 rollers of
weight 60 ton. These rollers crush the material in to powder form with the help of rotating table
which is driven by a motor.

Fig 3.2 parts of raw mill

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Raw mill has following main parts:

1) Roller
2) Separator
3) Gear box
4) Suction duct
5) Main drive
6) Lubrication system
7) Table
8) York

Rollers: are used in raw mill and each roller has a weight of 60 ton .These rollers are fitted on a York
with the help of nut and bolts York consist of three holes which are used for lubrication system. Each
roller consist 12 segment .2 bearings are used on the both sides of rollers. On front side „spherical
double roller‟ bearing are used and on back side „NU‟ cylindrical bearings are used.
Separator: is grate type component which is used to separate raw material and fine material .raw
material is sending back on table to crush again.
MAAG: gears are used in raw mill. it is also called galaxy gears because a small rotate in the center
and 3 big gears moves around it like planets.
SUCTION DUCT: is used suck the fine material and sends it to c.f silo.
Table: rotates with the help of a motor and helps to grind the material. A 4300 kW motor is used to
rotate the table .Motor rpm is 995 and table rpm is 85-90. Weight of motor is 25000 kg and made by
V.E.M Germany. Coupling type is male female. Grinding pressure is 80 bars and this pressure is
controlled with the help of jack system. 6 pumps are used for lubrication system 3 pumps Are H.P
AND 3 are L.P.
Separator: is grate type component which is used to separate raw material and fine material .raw
material is sending back on table to crush again.
MAAG: gears are used in raw mill. it is also called galaxy gears because a small rotate in the center
and 3 big gears moves around it like planets.
SUCTION DUCT: is used suck the fine material and sends it to c.f silo.
Table: rotates with the help of a motor and helps to grind the material. A 4300 kW motor is used to
rotate the table .Motor rpm is 995 and table rpm is 85-90. Weight of motor is 25000 kg and made by
V.E.M Germany. Coupling type is male female. Grinding pressure is 80 bars and this pressure is
controlled with the help of jack system. 6 pumps are used for lubrication system 3 pumps Are H.P
AND 3 are L.P. Lubrication can takes on rollers and gears. Raw mill line 1 capacity is 300 ton/hour
and line 2 capacity is 550 ton /hour.

WORKING:

Feed material is directed on to the grinding table by feed chute .The rotation of the grinding table
accelerate the material toward grinding track and passing it under the rollers .Coarse material and
bigger lumps drop through the nozzle ring and is eventually re-circulated in to the feed material inlet
.Moisture evaporates almost immediately as the gas stream carries finer portion of material to the
separator. The separator allows the material that has reached required fineness to leave the grinding
mill.

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3.5 .C.F (CONTROLE FLOW) SILO

The CF (Controlled Flow) silo is a continuously operating system for blending and storage of cement
raw meal. Material is extracted simultaneously at different flow rates from a number of outlets in the
silo bottom. The CF system including suitable kiln feed equipment ensures stable kiln feed
composition at minimum power consumption and investment cost. Two criteria must be met to
achieve a high degree of homogeneity in a continuously operating, through-flow silo where blending
is not achieved simply by air agitation:

1) All the raw meal in the silo must be kept in constant movement towards the outlets.
2) The raw meal must pass through the silo in flow zones with different residence times

FIG 3.5 C.F SILO

The silo bottom is raised above the ground with the kiln feed or blending tank placed underneath. The
silo bottom has seven extraction points. The material is supplied continuously to the silo. The
standard features of the silo top include manholes, overpressure and under pressure valves, and level
indicators. The unique characteristic of the CF silo is the design of its bottom. As shown in figure the
silo bottom is divided into seven identical hexagonal sectors. At the center of each hexagonal sector
is an outlet with a large conical cover made of steel. These steel cones are designed to maintain an
optimal flow pattern during extraction of the raw meal, which influences blending efficiency.
Besides, the cones are designed to relieve the pressure above the outlets, and to ensure extraction
from the aerated part of the silo bottom,

Each of the seven sectors is divided into six triangular subsectors. So the bottom consists of a total of
42 subsectors, all of which are provided with aeration units. These 42 separate subsectors represent
42 individual areas from which the material is extracted in a preset sequence of shorter duration than
the retention time in the blending tank below the silo.

Each of the seven outlets is provided with a shut-off valve by which extraction from a given outlet
can be started and stopped together with the aeration of the appertaining subsectors. Slide gates are
provided to facilitate the maintenance of the shut-off valves from the silo outlets the material passes
via air slides to the kiln feed or blending tank mounted on load cells.

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3.6 KILN AND COLLAR:

The kiln shell is steel, 60m long and inclined at an angle of 1 in 30. The shell is supported on 3 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 high temperatures. Coal is injected with
air into the kiln at a rate of 9 - 12 T hr.

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

Killen is used to heat the material at the temperature of 1600 degree centigrade. Material is heated by
using coal as a fuel. kiln length is 67 m and height is 5.5 m and rotate at 3.5-5 rpm. After the raw
material is heated it is send to cooler. In cooler 8 cooling fans are used to provide air for cooling
purpose. After cooling raw material become clinker.

Three types of bricks is used in kiln

Magnesia bricks are used start of the kiln in the length of 45 m.

High alumina is used in the center of kiln in the length of 10 m.
Low alumina is used at the end of the kiln and in the length of 11
m.
Pneumatic jack is fitted on kiln inlet seal and is used to hold kiln inlet seal and control seal moment.
Thrust device is used to hold kiln to avoid axial fluctuation.
Live ring is used to support the kiln.
Shell cooling fans is used to cool the shell of kiln protect the shell from over heat age.

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.

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3.7. BINS:

Bins are used to store clinker, gypsum, and lime stone. Each bin has a capacity of 6000 ton. From
these bins material is send to the cement mill where it is grinded and converted in to powder form
and raw material is finally converted to cement form.

3.8 CEMENT MILL:

In modern plants clinker and gypsum is crushed in roller press and subsequently fed in to ball mill for
fine grinding. The installation of roller press technology is very beneficial in terms of both quality
and energy conservation. The cement produced from roller press is showing better particle size
distribution in cement and consumes less power.

Two types of cement mills is used in world Open mill and close mill vertical mill is the example of
close mill and horizontal mill is the example of open mill. In cement mill clinker, gypsum, and lime
stone comes on different belts and grinded here. Cement mill consist of 4 rollers of 36 ton weight
each. After crushing material become cement.

Cement mill has following types

Vertical mill & horizontal mill

Mainly due to lower specific energy consumption (measured in kWh/t of produced material) and
higher production (t/h) values, vertical cement mills are slowly, but steadily, outnumbering
“traditional”, horizontal ball mills. The immediate advantages of such mills can be easily summed up
in the following key points:

 Vertical cement mills are able to reach production values which are significantly higher than
the ones achievable with traditional ball mills. As the latter ones are able to reach an
indicative maximum of 180-200 t/h, vertical mills can provide up to 300 t/h.
 Lower energy consumption, resulting in a lower specific cost (€/kg).
 while traditional mills have to be first assembled by the manufacturer and then transported to
the industrial site with all the resulting costs as well as logistical problems, vertical mills are
usually build “on-site”. This aspects permits to reach mill sizes (and therefore production
values) which are not achievable in the case of traditional ball mills.
 Vertical mills offer a greater versatility than traditional ones: for example, intermediate
cleaning silos are not necessary, as the transition times between different cement
types/compositions are significantly shorter if not inexistent.
 Additionally, vertical mills are less sensitive to the eventual high-humidity content of raw
materials (given a sufficient energy source is present).

At Maple leaf cement factory booth the mills are used. Vertical cement mill consist of 4 rollers and
each roller has a weight 36 ton. Cement mill has the same functions as vertical raw mill. Gypsum,
clinker and lime stone comes on 3 different belts from bins.

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In vertical mill they are grinded in to powder form. Vertical mill consist of 4 rollers.

In horizontal mill balls are used as a grinding medium and also called ball mill. Ball mill has two
chamber grinding chamber and blending chamber. B/w these chambers a diaphragm is used .in
grinding chamber balls of 80 mm diameter is used and in blending chamber 40-45 mm balls are used
to grind material. Ball mill is drives with a motor of 4650k w .clutch coupling is used at ball mill.
Ball mill rotates at 14.7 rpm. And vertical mill rotates at 24.28 r.p.m.

3.9 PACKING PLANT:

Cement is packed in HDPE bags of 50 kg. Electronically control, high efficiency rotary packers are
used for packing. Packers are highly precise with tolerance of +/- 0.5 %, It displays the weight of
each bag before discharge. It ensures the weight of packed bag is 50 kg the packed bags are loaded
into trucks, wagons. In packing plant cement is packed in bags. 6 packers are used inside the factory.
At same time 8 bags can be filled at each packer.

Cement from cement silos is send to air slide through mechanical or electrical control valve by
opening it according to demand. From air slide material is send to bucket elevator which put the
material at separator which is located at the top function of separator is separate fine material and raw
material.
Raw material is send back to cement mill with the help of a belt drive after passing the separator
cement is send to hopper where it is partially stored. Under the hopper a butterfly valve is used which
looks like a round disk and is operated with the help of a computer command. When valve is open
cement comes in packer where it is packed in the bags.

When bag is full with cement (50k.g) it is send to Vento check belt where weight of bag is checked.
If weight is less or more than 50 kg bag is send to cutter. If weight is 50 kg bag is send to square
roller where it is balanced after this discharge belt discharge the bag and bags are loaded on vehicles.

3.10 UTILITY AREA:

Utility area covers the needs of water and air of cement factory.

Two types of air are used in maple leaf cement factory:

 Blower air
 Compressed air

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 3.10.1 AIR:

3.10.1.1 Compressed Air

Not as fast as electricity or as slow as hydraulics, compressed air finds a broad field of applications
for which its response and speed make it ideally suited. Where there is an overlap, the choice often
depends on cost and efficiency and air is likely to hold the advantage. It is a utility that is generated
in-house, so owners have more control over it than any other utility. In addition, air does not possess
the potential shock hazard of electricity or the potential fire hazard of oils. However, compressed air
is under pressure and can cause harm and bodily damage if not respected. Safety codes and
regulations should be followed when working with compressed air.

How Can Air Generate Power?

When air is compressed, it is under pressure greater than that of the normal atmospheric pressure and
it characteristically attempts to return to its normal state. Since energy is required to compress the air,
energy is released as the air expands and returns to atmospheric pressure. Air compressors were
designed to compress air to higher pressures and harness this potential energy source. Unlike other
sources of power, no conversion from another form of energy such as heat is involved at the point of
application. Compressed air or pneumatic devices are therefore characterized by a high power-to-
weight or power-to-volume ratio.

3.10.1.2 Types of Compressors

Air compressors in sizes 30 horsepower and below include both reciprocating and rotary
compressors, which compress air in different ways. Major types of reciprocating compressors include
reciprocating single acting, reciprocating diaphragm and reciprocating rocking piston type. Major
types of rotary air compressors include rotary sliding vane, rotary helical screw and Rotary scroll air
compressors.

3.10.1.2.1 Reciprocating Single Acting Compressors

Reciprocating single acting compressors are generally of one-stage or two-stage design. Compressors
can be of a lubricated, non-lubricated or oil-less design. In the single-stage compressor, air is drawn
in from the atmosphere and compressed to final pressure in a single stroke. The single-stage
reciprocating compressor is illustrated in (Single-stage compressors are generally used for pressures
of 70 psi (pounds per square inch) to 135 psi.

Fig 3.3 Single stage compressor

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In the two-stage compressor, air is drawn in from the atmosphere and compressed to an intermediate
pressure in the first stage. Most of the heat of compression is removed as the compressed air then
passes through the intercooler to the second stage, where it is compressed to final pressure. Two-
stage compressors can include two cylinder designs.

Fig 3.4 Double stage compressor

For blower air blowers are used. Blower is used in cement silos, c.f silo, and coal mills etc.
compressed air cannot be used because it has moisture in it.

Compressed air: is used for instrumentation such as in air slides, bag filters e.t.c
Blowers can achieve much higher pressures than fans, as high as 1.20 kg/cm2. They are also used to
produce negative pressures for industrial vacuum systems. Major types are: centrifugal blower and
positive-displacement blower.
Centrifugal blowers: look more like centrifugal pumps than fans. The impeller is typically gear-
driven and rotates as fast as 15,000 rpm. In multi-stage blowers, air is accelerated as it passes through
each impeller. In single-stage blower, air does not take many turns, and hence it is more efficient.

Centrifugal blowers typically operate against pressures of 0.35 to 0.70 kg/cm2, but can achieve
higher pressures. One characteristic is that airflow tends to drop drastically as system pressure
increases, which can be a disadvantage in material conveying systems that depend on a steady air
volume. Because of this, they are most often used in applications that are not prone to clogging.
Positive- displacement blowers have rotors, which "trap" air and push it through housing.

Positive-displacement blowers: provide a constant volume of air even if the system pressure varies.
They are especially suitable for applications prone to clogging, since they can produce enough
pressure- typically up to 1.25 kg/cm2 - to blow clogged materials free. They turn much slower than
centrifugal blowers (e.g. 3,600 rpm), and are often belt driven to facilitate speed changes.
7 compressors are used for line 1 and 6 compressors are used for line 2 . two stage compressors are
used at maple leaf cement factory.

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Compressors are used to compress the atmospheric air at 8 bar. Input power is 114kw.

Air is sucked with the help of suction filter than it is send to intake regulator which controls the air
pressure at 7.2 bars. After that air is send to compressors element where oil and air is compressed.
After the compression oil and air is send to separator where oil is separated, after the separation oil is
send to oil cooler and air is send to air cooler. After the filtration oil is circulated in the system. Air is
send Air dryer, in air dryer silica gel is used to absorb moisture from air

3.10.2 WATER:

Type of pumps are used

Two types of pumps are used in maple leaf cement factory.

 Centrifugal pumps and Submersible pumps

3.10.2.1 Centrifugal pumps:

In 1689 the physicist Denis papin invented the centrifugal pumps and today these kinds of pumps are
most used around the world. The centrifugal pumps built on a simple principal: “Liquid is led to the
impeller hub and by means of the centrifugal force it is flanged toward the periphery of the
impellers.” The construction is fairly in expensive, robust and its high speed makes it possible to
connect the directly to a synchronous motor. The centrifugal pump provide a steady liquid flow, and
it can easily be throttled without causing the any damage to the pump.
If a pressure difference occurs in the system while the centrifugal pump is not running liquid can still
pass through it due to its open design.

3.10.2.2 Characteristics of centrifugal pumps

The centrifugal pump has several characteristics and in this we will present most important ones.

The number of stages

Depending on the number of impeller in the pump, a centrifugal pump can be either a single stage or
multistage pump.

The position of the pump shaft

Single stage and multistage pumps comes with horizontal or vertical pump shaft. These pumps are
normally designated horizontal or vertical pumps.

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3.10.2.3 Single suction or double suction Impeller:

Depending upon the construction of the impeller, a pump can be fitted with either a single suction
impeller or double suction impeller.

Coupling stages:

The pump stages can be arranged in two different ways: in series and in parallel.

Construction of the pump casing:

We distinguish b/w two types of pump casing: volute casing and return channel casing with guide
vanes. A centrifugal pump generate pressure that exerts forces on both stationary and moving parts of
pumps, Pumps parts are made to with stand these forces.

310.2 SUBMERSIBLE PUMPS:

These pumps are also called waste water pumps. The submersible pumps Is an enclosed unit with a
pump and a motor. In submersible installation with auto coupling system double rails are normally
used. The auto coupling system facilitates, repair and replacement of the pump. Because of the
construction of the pump it is not necessary to enter the pit to carry out service. In fact it is possible to
connect and disconnect the pump automatically from outside of the pit.

Normally waste water pumps have to be able to handle large particle. Therefore they are fitted special
impellers that make it possible to avoid blockage and clogging. Different type of impeller exists;
single channel impellers, double channel impellers and triple channel impellers and vortex impeller.
Waste water pumps usually come with a dry motor. Motor and pump have a common extended shaft
with a double mechanical shaft seal system in a intermediate oil chamber, Waste water pumps are
able to operate either intermittently or continuously depending on the installation in question.

Working Mechanism of a Centrifugal Pump

A centrifugal pump is one of the simplest pieces of equipment in any process plant. Its purpose is to
convert energy of a prime mover (a electric motor or turbine) first into velocity or kinetic energy and
then into pressure energy of a fluid that is being pumped. The energy changes occur by virtue of two
main parts of the pump, the impeller and the volute or diffuser. The impeller is the rotating part that
converts driver energy into the kinetic energy. The volute or diffuser is the stationary part that
converts the kinetic energy into pressure energy.

Note: All of the forms of energy involved in a liquid flow system are expressed in terms of feet of
liquid i.e. head.

Page | 31
General Components of Centrifugal Pumps

A centrifugal pump has two main components:

 A rotating component comprised of an impeller and a shaft

 A stationary component comprised of a casing, casing cover, and bearings.

The main components are discussed in brief below:

Fig 3.5 parts of centrifugal pumps

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CHAPTER 04

STRUCTURE RELATED TO
MECHANICAL
TECHNOLOGY

Mechanical is the mother of all technologies and has a huge range of machinery in used. In this
chapter we try to cover the machinery that is used at maple leaf cement factory.

 CRUSHER
 STACKER AND RECLAIMER
 RAW MILL
 PRE HEATER
 KILLEN AND COOLER
 CEMENT MILL
 PACKING PLANT

4.1 CRUSHER

Crushing is a process of dividing big stones in to smaller one. In maple leaf cement factory 3 crusher
are used 2 for crushing lime stone and 1 for clay.

Two types of crusher are used for crushing purpose.

1) Impact hammer crusher

2) Roller crusher

4.1.1 Impact hammers crusher:

Impact hammer crushers are of a progressive design that combines the advantages of impact crushers
with those of hammer crushers. Crushers are predominantly used for single-stage crushing of
extracted limestone, dolomite, gypsum, limestone marl as well as other medium hard materials and
materials that contain sticking clays and loams. As a rule, crushers are used in the cement industry
where ball mills are part of the grinding plant.

The exceptional operating properties of impact hammer crushers are:

 High operating reliability

 Low cost for operating and maintenance
 Long service life of main crushing elements
 High specific throughput
 Excellent degree of communication
 Favorable specific electric power consumption
 Favorable grain size distribution of the product
 Capability to crush even materials containing sticky components
Page | 33
Insensitivity towards non-crushable matters Staggered hammers that cover the entire working width
of the crusher. This design together with the structural arrangement of the crushing chamber provides
a high crushing ratio and has the capacity to process materials that could not be processed in the past.

The grate is the second essential component of the crushing space and limits the use of the crusher
with regard to the material stickiness. The grate is designed so that the functional plates act as a safety
device when non-crushable matter is trapped into the crushing chamber. Catastrophic failures are
minimized when the grate plate breaks. The plate pieces do not come into contact with the rotating
hammers, instead, they fall freely into the discharging hopper positioned under the crusher.

4.1.2 Roller crusher:

Roll Crushers use a combination of compression and shear force with up to four crushing rolls to
reduce a variety of friable materials, such as coal, salt, coke, gypsum, potash, lignite, lime, limestone,
glass, phosphate (and many others with similar characteristics) to a desired sized-cubical product with
minimum fines. Roll Crushers are not intended to crush hard rock such as granite or basalt where Jaw
Crushers, Cones and Imp actors are applied. Horizontal crushing rolls are supported through the steel
roll shafting by roller bearings. A Single Roll Crusher crushes against a curved plate; a Double Roll
Crusher is designed to crush against two opposing rolls; a Triple Roll Crusher uses a single roll
mounted over a double roll and the Quad Roll Crusher is designed with a double roll mounted over
another double roll. Both the Triple and Quad Roll Crushers provide two-stage reduction.

Roll Crushers are designed for safe operation with exposed moving components guarded in
accordance with MSHA and OSHA. In case of jamming or plugging of the rolls, under speed
detection de-energizes the electric motor.

Features Include:

 Heavy-Duty, Fabricated Steel Frames

 Abrasion-Resistant Steel Plate Liners
 Alloy-Carbon Steel Shafting
 Spherical Roller Bearings
 Cast Iron or Steel Crushing Rolls And Segments
 Automatic Spring And Toggle Tramp Relief
 Product Size Adjustability
 Zoned Lubrication – Manual or Automatic

Page | 34
4.1.2.1 SINGLE ROLL CRUSHERS

UP TO 6:1 FEED-TO-PRODUCT REDUCTION RATIO

A single drive utilizes a gear and pinion transfer to apply the appropriate speed to the crushing roll.

Cobra: Used in the primary reduction of clean coal, frozen coal, sand cores, resin, lime, coke, salt
and other similar material. Ideal for wet, sticky feeds.
Black Diamond: Used in the primary reduction of coal, salt, soft shale, cinders, brick, coke,
phosphate and other similar material. Ideal for scabby or wet, sticky feeds.
Super Black Diamond Used: in the primary reduction of shale, slate, gypsum, bauxite, coal with
friable refuse and other medium-hard feeds. Ideal for scabby or wet, sticky feeds.
Rock master: Used in the primary reduction of rock, ore, mine refuse and ROM coal. Ideal for
scabby, or wet, sticky feeds.

Shale King: Used in the primary reduction of harder rock. Ideal for oil shale and material of similar
hardness.

4.1.2.2 DOUBLE ROLL CRUSHERS

UP TO 4:1 FEED-TO-PRODUCT REDUCTION RATIO

Available in either a single or dual drive motor, depending on the application. Single drive units
transfer power to the opposing roll via an inter stage belt drive.

Black Diamond: Used for the secondary and tertiary reduction of clean coal, coke, salt, trine,
quicklime, pebble lime, burnt lime, glass and other similar materials.
Heavy Duty: Used for the secondary, tertiary and fourth-stage reduction of harder materials such as
ROM coal with refuse, limestone, gypsum, bauxite, oil shale, various ores and other materials of
similar hardness.

4.1.2.3 TRIPLE ROLL CRUSHERS

Available in single, dual or three motor drive depending on crusher model and application .Utilizes
gear and pinion, chain and sprocket or interstate belts to transfer roll rotation.

Standard Duty: Used in the two-stage reduction of clean coal, salt, coke, glass and other similar
material.
Medium Duty: Used in the two-stage reduction of harder coal and feeds containing medium-hard
shale and other similar material.
Super Duty: Used in the two-stage reduction of harder coal and ROM feeds containing up to 10%
hard rock and other similar material.

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4.1.2.4 QUAD ROLL CRUSHERS

Available in single, dual or four motor drive depending on crusher model and Application. Utilizes
gear and pinion, chain and sprocket or interstate belts to transfer roll rotation.

Standard Duty: Used in the two-stage reduction of clean coal, salt, coke, glass and other similar
materials.
Medium Duty: Used in the two-stage reduction of harder coal and feeds containing medium hard
shale and other similar material.
Abrasive Duty: Used in the two-stage reduction of hot, abrasive feeds, such as sinter, iron ore, coke
and other similar materials.
Super Duty: Used in the two-stage reduction of ROM coal and other similar material containing
moderate percentages of medium to hard refuse.

In maple leaf cement factory crusher are used for following purpose

Lime stone crusher;

Lime stone crusher is used to crush lime stone. It is used to crush the lime stone of size 3*3 foot in to
25-30 mm size. This crusher is made by a German company F.L.S. This crusher consist of 4 excels
fitted on a shaft. Each excel has 8 hammers of weight 85-90 kg. a 1100kw motor is used to rotate the
crusher. Lime stone crusher is a impact hammer type crusher. It is impact hammer type crusher.

A bag filter is used in crusher to collect dust and store it at separate palace. Water sprayer is also used
to minimize the dust by spraying water,

MOTOR POWER 1100 K.W

MOTOR R.PM 1400
COUPLING TYPE--------------------------FLEXCIBLE FLUID OIL COUPLING
BEARING TYPE-----------------------------------------------JOURNAL BEARINGS
MADE B F.L.S (GERMANY)
CRUSHER TYPE-------------------------------------------HAMMER CRUSHER

4.2. CLAY CRUSHER:

Clay crusher is double roller type crusher and is used to crush clay in powder form.

MOTOR POWER 800K.W

MOTOR R.PM 1100
COUPLING TYPE-------------------------FLEXCIBLE FLUID OIL COUPLING
BEARING TYPE-----------------------------------------------JOURNAL BEARINGS
MADE BY F.L.S (GERMANY)
CRUSHER TYPE-------------------------------------------ROLLAR CRUSHER
ROLLAR DIA..................................................................3.5 FOOT

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4.3 STACKER AND RECLAIMER:

Stacker is used to make a pile of lime stone and clay. Stacker has two gear boxes

 Self-align
 Adders

Self-align are used to keep belt on track. Addles are more in number and used to fed lime stone and
clay.

RECLAIMER is of two types and are also called bridge scraper.

1) Bridge type
2) Boom type

Bridge type is used to reclaim lime stone while boom type is used to reclaim clay.

Sprockets:

These are like belts and of 3 types

1) Drive sprocket (to drive reclaimer)

2) Tail sprocket (to put clay or lime stone on belts)
3) Guide sprocket (to put the material down on tail sprocket)

4.4 RAW MIL:

Mainly due to lower specific energy consumption (measured in kWh/t of produced material) and
higher production (t/h) values, vertical raw mills are slowly, but steadily,

vertical cement mills are able to reach production values which are significantly higher than the ones
achievable with traditional ball mills. As the latter ones are able to reach an indicative maximum of
180-200 t/h, vertical mills can provide up to 300 t/h

 Lower energy consumption, resulting in a lower specific cost (€/kg).

 while traditional mills have to be first assembled by the manufacturer and then transported to
the industrial site with all the resulting costs as well as logistical problems, vertical mills are
usually build “on-site”. This aspect permits to reach mill sizes (and therefore production
values) which are not achievable in the case of traditional ball mills.
 Vertical mills offer a greater versatility than traditional ones: for example, intermediate
cleaning silos are not necessary, as the transition times between different cement
types/compositions are significantly shorter if not inexistent. Advantages of such mills can be
easily summed

Page | 37
  Additionally, vertical mills are less sensitive to the eventual high-humidity content of raw
materials (given a sufficient energy source is present). Nevertheless, vertical mills also
present certain disadvantages, if compared to traditional grinding systems. These aspects can
be summed up in the following key-points:
 High pressures of the roller presses are required in case high Blaine values are desired.
 Vertical mills are more sensitive to materials which present a very high fineness (the
threshold is set around a maximum of 50% material < 4 mm).
 a significant amount of water has to be added in the grinding process in order to keep the
vibration level of the whole grinding system low at any time. This aspect has major
repercussions on the cement temperature;

Therefore an external heat supply is needed to guarantee a certain exit temperature, thus increasing
the specific production costs. In maple leaf cement factory raw mill is an area where lime stone, clay,
and iron have been crushed. Raw mill has 3 rollers of 60 ton each. Layer thickness b/w roller and
table is 4-6 mm during working condition. And in stop condition layer thickness is 100-120 mm.
Rollers are made up of magnet steel. Bearing are used on both sides of rollers. On front side
“spherical double roller bearings is fitted and on back side “NU cylindrical “bearing is used.
Cylindrical and spherical are the balls used in bearings.

Fig 4.1 parts of raw mill

SPECIFICATION OF RAW MILL:

Capacity of raw mill line 1------------------------------------------550 ton/h

Capacity of raw mill line 2------------------------------------------300 ton/h
Motor power 4300k.w
Motor r.p.m 995r.p.m
Motor weight 25000k Kg
Made by V.E.M (GERMANY)
MOTOR VOLT 6300 VOLTS
COUPLING TYPE-------------------------------------------MALE –
FEMALE
RAW MILL TEMP-------------------------------------------120 DEGREE
GRINDING PRESSURE--------------------------------------------110 BAR
LIFTING PRESSURE 80 BAR
Page | 38
RAW MILL LUBRICATION:

Two parts of raw mill require lubrication.

1) Gear lubrication
2) Roller lubrication

Gear lubrication:
Mage gear is used in raw mill. It consist of 4 gears. One gear which is in smaller size and in the
center is called sun gear 3 gears rotate about it is called galaxy gears. Mage gears are bevel type
gears.

Roller lubrication:
In rollers NU bearing and double roller spherical bearings are lubricated. Bearings are lubricated
York on which rollers are fitted.

4.5 .PRE HEAATER

Pre heater is used to heat the raw material before going to kiln. An i.d (induced draft) fan is used in
pre heater, its function is to collect the heat from kiln and provide it to cyclone which is on the top of
pre heater. This fan is also called pre heating fan. 5 cyclones in pre heater is 5 . No. of cyclone does
not matter last cyclone has a dividing head which function is to divide the material.

NUMBER OF STAGES:

For many years, the pressure drop across one pre heater stage was up to 1.5 kpa. The reason for the 4
stages pre heater being so widely used is, that is represented an optimum b/w investment cost
(structure height and foundation) pressure drop and heat consumption. The pressure drop occurs
mainly in the cyclones shape, design and the size which is determining factor for cost. New cyclone
design is now in the market with only 0.5 to 1 kpa pressure drop per stage. Considering increasing
energy cost it is justified to install 5 or 6 pre heater stages for new or modified kiln system.

The following table indicates the estimated effect of 5 or 6 cyclone stages.

- ---

4to5st 5 to6st

Heat consumption Exhaustgas kJ/kg cli -80 -50

temperature Exhaust gas quantity oC - 40 - 20
DryingcapacityinRM Nm3/kg cli -0,03 -0,015
% H20 from8 -6,5 from6,5-5,5

Page | 39
Pre heater operation:

The performance of pre heater is assessed based on the criteria

 Temperature profile
 Pressure profile
 Oxygen profile

Some reasons for poor pre heater performance is frequently experienced.

 Worn out or non existing immersion tubes (often in bottom stage)

 Open inspection doors leaky gas kits or holes in pre heater
 Blocked or non existing meal flaps
 No splash boxes (specially older pre heater) combined with not optimum position of meal
feed point
 Excessive dust circulation due to poor separation efficiency of cyclones

As already mentioned, several time serious operating problems occurs with suspension pre heaters
with 4 or more stages caused by circulation phenomena. These occurs due t0

 Excessive input via feed or fuel

 Chemical unbalance
 Unfavorable kiln / burner operation
 Unfavorable design geometry of bottom stage and kiln gas riser duct

area Countermeasures known‟s today allow to solve the problems are

 Change feed composition or fuel quality

 Improve burning condition
 Install automatic cleanings (air cannons , bag filters ) at critical location
 Change temperature profile by installing a small secondary burner
 Install a bypass system

Raw meal is send to the cyclones through air slides and elevator. What a cyclone do? It separates dust
from air and collects it. Material comes in cyclone 2 first, then it is sucked to the Cyclone 1 from
where it is sucked in cyclone 3 and the dust is collected in cyclone 2. From cyclone 2 the dust is send
to the cyclone 4, from where it is sucked in cyclone 3. From cyclone 3, dust is sucked in cyclone 5
and then again into cyclone 4. I can represent it in this way.

2 1 3 2 4 3 5 4

From cyclone 4, 60% material is send to the calcined and 20% is send to the cyclone 5 and then to
the smoke chamber (inlet of the KILN) through dividing gate.

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4.6. KILN:

Like many other great ideas rotary kiln was invented at the end 0f 19th century. The first successfully
working unit was developed in USA by Hurry and Seaman in 1897. Being used for a clinker burning
process for more than a century the rotary kiln is still more suitable machine for the calinkrization of
process.

4.6.1 Kiln dimension:

Kiln dimension are defined with diameter D (for kiln with different diameters burning zone D and
length L). A limiting factor for the diameter is mechanical stability of the” arch “of the brick lining.
Maximum diameter that can be safely realized with standard size of bricks is about 6.5 m. The L/D
ratio ranging from 40 for long wet kiln to 11 for modern short kiln with calciner. It has to be
mentioned that the diameter D is the inside diameter f the kiln shell.

The maximum recommended kiln shell temperature varies by plant, by country and by kiln
manufacturer, despite the fact that most kiln shells are made of low alloy carbon steel. Age of the kiln
shell, distance between the tires, and structure of the shell are some important points should be
considered before deciding what the maximum allowable temperature for a kiln is. Let us explain
these points briefly:

1) Age and condition of the kiln shell: Old kilns shells have been exposed to creep for a long
time and are more prone to develop fatigue cracks than newer shells.
2) Distance between tires: The longer the shell span, the less it will resist high temperatures
without sagging. Therefore, longer spans have more tendencies to develop permanent
deformation than shorter spans.
3) Kiln shell structure: Kiln shells are made with structural rolled steel plate, such as A.S.T.M.
A36. The tensile strength of this type of steel at room temperature is 50,000 to 80,000 psi. As
stated before shell strength is measured at a room temperature.

TABLE 4.1 TENSILE STRENGTH OF STEEL

Page | 41
There is an oxygen injection system connects to kiln burner or pre calciner burner to enhance the
combustion of the fuel. In general, the use of oxygen enriched combustion air in the clinker burning
process allows an increase of the energy efficiency, production capacity or substitution of fossil fuels
by low calorific value or (secondary) fuels and that way the specific CO2 emissions can be reduced.

Three types of calciner used in kiln

In-Line calciner: is installed in the kiln exhaust gas flow which means that the combustion takes
place in an air/kiln gas mix. This pre calciner can be considered an enlarged kiln riser duct.
Off-Line calciner: is installed off the kiln exhaust gas flow. The combustion takes place in pure
(tertiary) air which is also responsible for lifting up the meal.
Separate-Line calciner: is off-Line calciner with a separate pre heater string.

In Maple leaf cement factory Kiln is used to heat the raw material at 1600 degree centigrade. when
Killen starts for 24 hours furnace oil is used to run the Killen. After that fine coal is used as a fuel in
Killen. . its shell is Inclined at 2 to 3 degree. 3 types of bricks are used in Killen.

1) Magnesia
2) High Alumina
3) Low alumina

Magnesia bricks are used in the start of kiln and in the length of 45 m and also used in the burning
zone. High alumina is used in the center of the Kiln and in the length of 10 m. Low alumina is used
in the end of the Killen and in the length of 11 m.

Killen line 1 drives with the help of girth gear while line 2 drives with the help of rollers

4.6.2 KILLEN LINE 1 SPECIFICATION:

Killen line 1 length 67 m

Diameter 4.5 m
r.p.m 3.5-5
Feed 252 ton/hour
Outside temperature--------------------------------------300-350 degree
Temperature----------------------------------------1600 degree centigrade

4.6.3 KILLEN LINE 2 SPECIFICATIONS:

Killen length 66 m
Diameter.................................................................5.5 m
Capacity 300 ton/hour
Temperature 1600 degree centigrade

Page | 42
4.6.4 DIFFERENCE B/W KILLEN LINE 1 AND Line 2

Killen line 1 has a length is 67 m and line 2 has length of 66 m. line 1 diameter is 4.5 m and line 2
diameter is 5.5 m. kiln line 1 capacity is 252 ton /hour line 2 capacity is 300 ton /hour. Killen line 1
drives with the help of girth gears and line 2 is drives with the help of rollers. A motor is used to
drive the rollers. Rollers cannot be run at kiln power because of high temperature. Internal
temperature of both the kilns is 1600 degree centigrade.

4.7 COLLER:

Cooler function is to cool the raw material and convert it to clinker. 8 cooling fans are used in cooler.
2 types of plates are used in cooler.

1) C.F.G (control flow grate)

2) R.F.T (Reduced flow plates)

These are also called rotator and stationary plates. Hydraulic jack is used for forward and backward
moment. M.F.R (mechanical flow regulator) is used to control the flow of air.

Air passed through M.F.R to cool clinker.

Line 1 cooler name-------------------------------------------Grate bar cooler

Line 2 cooler name-------------------------------------------Cross bar cooler

4.8 CLINKER CRUSHER:

Clinker crusher is used to crush clinker in the size of 25-30 mm.3 excels are fitted on a shaft on each
excel 23 hammers are fitted. Total hammers are 69 and each hammer has a weight of 60-65 kg.

4.9 CEMENT MILL:

Two types of cement mills are used in the world.

1) Open mill (ball mill)

2) Close mill (vertical mill)

In maple leaf cement factory one ball mill is used and two vertical mills are used.

Page | 43
4.10 BALL MILL:

Grinding in ball mills is an important technological process applied to reduce the size of particles
which may have different nature and a wide diversity of physical, mechanical and chemical
characteristics. Typical examples are the various ores, minerals, limestone, etc. The applications of
ball mills are ubiquitous in mineral processing and mining industry, metallurgy, cement production,
chemical industry, pharmaceutics and cosmetics, ceramics, different kinds of laboratory studies and
tests.

Fig 4.2 Ball mill

Ball mill is in horizontal shape. In this iron balls are used to crush clinker, lime stone and gypsum.
Iron balls are also called grinding media. Ss plates are used inside ball mill to control temperature.

There are three types of grinding media that are commonly used in ball mills:

1) Steel and other metal balls;

2) Metal cylindrical bodies called clypeus;
3) Ceramic balls with regular or high density.

Steel and other metal balls are the most frequently used grinding media with sizes of the balls ranging
from 10 to 150 mm in diameter. Clypeus are slightly tapered cylindrical grinding media with rounded
edges and equal length and diameter with sizes varying from 8×8 to 45×45 mm. Their shape is
developed to maximize the grinding efficiency due to their high density and specific surface area.

Ceramic balls with regular density are usually porcelain balls and the high density balls are made
with a high alumina oxide content and they are more abrasion resistant. The basic properties of the
milling bodies are their mass and size, ware rate, influence on the particle breakage rate and energy
efficiency of the grinding process.

Page | 44
4.10.1 CRITERIA FOR MEDIA SELECTION

Selection of grinding media depends upon several factors, some of which are interrelated.

Specific gravity: In general, high density media give better results. The media should be denser than
the material to be ground. When grinding some slurry, media with higher density may be required to
prevent floating.
Initial feed size: Smaller media cannot easily break up large particles.
Final particle size: Smaller media are more efficient when ultrafine particles are desired.
Hardness: The harder the media the better the grinding efficiency and consequently, the longer the
wear.
PHS: Some strong acid or basic material may react with certain metallic media.
Discoloration. For instance, white material should remain white.
Contamination: The material resulting from the wear of the media does not affect the product or can
be removed by a magnetic separator, chemically, or in a sintering process.
Cost: Media that may be 2-3 times more expensive may wear better, sometimes 5-6 times longer,
therefore, well worth their extra cost in the long run.

Ball mill has 2 chambers.

1) Grinding chamber
2) Blending chamber

B/w this chamber there is diaphragm which have holes in it. In grinding chamber 80 mm size
grinding media is used and in blending chamber 40-45 mm media is used.

4.10.2 BALL MILL SPECIFICATION:

Ball mill motor 4650k.w

Volt 6300
Ampere 539
Temperature 50 degree
centigrade Motor weight 850k.g
Ball mill gear F.L.S SYMETRO
Coupling clutch coupling
Ball mill r.p.m 14.7

Page | 45
4.11VERTICAL MILL:

Vertical mill is just like a raw mill. It has 4 rollers and each roller has weight of 36 ton.

Fig 4.3 Vertical Cement mill

In the cement industry, the necessity of continuous improvements in the grinding process and the
related cost reduction has promoted the diffusion of vertical cement mills worldwide. These
particular mills present a vast series of advantages with respect to traditional, horizontal ball mills.
Raw mills are a type of industrial equipment used to crush or grind material in to small particles. Raw
mill is widely used in concrete and mixing field and are also used to process gypsum. These units can
process both raw and recycled material, while helping to reduce and preserve virgin supplies of these
materials.

However, despite a generally good performance of vertical roller mills used for grinding of cement
and related products the vertical roller mill is still inferior to the ball mill in terms of sensitivity to
variations of mill feed quality (fineness) and mill feed rate.

4.11.1 Product quality

The purpose of the mill system is to provide a fineness to the product that will result in the required
reactivity and consequently the strength producing potential of the product the cement. The fineness
of cement is usually monitored by measuring the specific surface area (Blaine) or a sieve residue of
the product. However, the effects of the mill system on the quality of the product are more complex
than what is reflected by a Blaine value or a sieve residue. It includes the following factors associated
with the product:

 The particle size distribution

 The degree of dehydration of the gypsum added to the cement
 The pre hydration and carbonation of the clinker minerals

Page | 46
4.11.2 Particle Size Distribution

It is characteristic of grinding in vertical roller mills that the energy input to the material per pass
between roller and table is small, for which reason a large number of passes are required to obtain the
necessary specific energy input to the material.

This leads to a very high internal material circulation factor. High circulation factors invariably lead
to steep particle size distribution curves, if the separation process is efficient. It has therefore been
necessary to adapt special measures to reduce the inclination of the particle size distribution curve, in
order to get a cement quality that is similar to the quality of cement ground in a ball mill. There are a
number of ways to adjust the inclination of the particle size distribution curve for cement ground in
an OK mill. In order to reduce the circulation factor, the grinding track on the grinding table has an
upward curved shape that helps to retain a certain minimum amount of material under the rollers. The
grinding table is further – at the periphery – equipped with an adjustable dam ring. A higher dam ring
will result in a thicker grinding bed corresponding to a longer retention time of the material on the
grinding table. The material will thus receive a higher energy input before leaving the grinding table,
resulting in a lower circulation factor via the separator and thus a particle size distribution curve with
a lower inclination.

4.11.3 Dehydration of the gypsum added to the cement

In the grinding process heat will be generated and the cement will be heated up. The temperature of
the cement leaving the mill will be dependent on the temperature of the materials (especially the
clinker) fed to the mill and to features of the mill and the grinding process. It wills typically in the
range from 90 to 120 deg. C. At this temperature- level the water of crystallization of the gypsum
added to the mill will partially be lost, i.e. the gypsum will be partly dehydrated.

This dehydration will increase the solubility of the gypsum and make it more effective as retarder for
the iluminate reaction in the cement and thus more effective in setting control. Another consequence
is a general increase of the strength during the hardening of the cement. However, too high content of
dehydrated gypsum can lead to early precipitation of gypsum crystals between the cement grains in
the paste and cause early stiffening (false set). Although some dehydrating of gypsum usually is
advantageous, too high a degree of dehydration (or too much dehydrated gypsum) can lead to
problems.

Page | 47
As less grinding energy is used in producing a cement of a required fineness in an OK mill and the
retention time in the mill is shorter, the product will not be heated up as much as in a ball mill. This
means that a lower degree of dehydration of the gypsum must be anticipated. This may not be a
problem if the gypsum is sufficiently reactive to control the setting reactions, which is normally the
case. If in special cases this is not so, different measures may be applied to cope with the problem:

 Addition of more gypsum (if it is possible within the SO3-limit)

 Increase dehydration of gypsum by adding more heat to the mill system
 Addition of a more reactive form of gypsum.

4.11.4 Pre hydration of the clinker minerals

Another chemical aspect to be considered in connection with cement grinding is the Pre hydration of
cement particles that may take place during the grinding. The Moisture for pre hydration can come
from moisture in the feed materials, from internal cooling systems, and/or from dehydrating gypsum.
The latter is mainly a problem in connection with storage of hot cement in a silo. Pre hydration of
cement can, when exceeding a certain level, lead to reduced reactivity of the cement and thus longer
setting times and reduced strengths, particularly early strengths. Pre hydration can also enhance the
tendency of false set in cement with a high content of dehydrated gypsum.

Pre hydration: is normally not as problematic in an OK mill as in ball mill systems where internal
water-cooling systems are often required. However, if cement is Produced at a relative high
temperature and still has a lot of gypsum that is not de hydrated, one should be aware of the problem
of possible gypsum dehydration coupled with clinker pre hydration which can take place during
storage in the cement Silos . If a problem of this kind is present, it can be remedied by one (or more)
of the following options:

 Ensure that the cement is cooled to a lower temperature before entering the silo.
 Provoke a higher dehydration level to the gypsum in the mill (see above).
 Replace part of the gypsum by natural anhydrite.

4.11.5 Water injection for temperature c control

For a vertical roller mill, water injection for temperature control is usually not required. The heat
generated by the grinding process is low due to the high grinding efficiency, all air to the mill air inlet
may be ambient air, and the air flow through a vertical roller mill is much higher than through a ball
mill. For a ball mill the situation is quite the opposite. The heat generated by the grinding process is
high and the air flow through the mill is relatively low. Therefore most ball mills grinding OPC
operate with internal water cooling. The amount of water required is not only dependent on the
clinker temperature, but also on the operation of the separator. The separator circuit may be arranged
for air cooling using from 0% to 100% of ambient air for the process.

Page | 48
4.11.6 Versatility

A vertical roller mill is a very versatile mill capable of grinding a wide range of products. The OK
mill has proved suitable for grinding not only pure slag and Ordinary Portland Cement but also
blended cements with a wide range of additives such as slag, pozzolana, limestone and fly ash.
Several OK mills grind two or more products in alternate grinding. Shifting from one product type to
another is easy and with only a very short transition period. A decided advantage of the vertical roller
mill compared to a ball mill is its ability to dry feed materials with high water content, like for
instance slag. Further, the operational parameters of a vertical roller mill are easily adapted to suit
alternative products. Even adjustment of the dam ring, should that be required, is an easy task
compared to moving the diaphragm of a ball mill. With respect to versatility the vertical roller mill
can thus be considered to be superior to the ball mill.

4.11.7 Upgrading

Over the last two decades quite a large number of ball mill installations for cement grinding have
been upgraded by installation of pre-grinders, mostly roller presses. Dependent on the complexity of
the upgrade the system capacity may be increased By, say from some 30% up to around 100%. This
option may not only be interesting as regards existing ball mill installations, but may even be taken
into consideration in relation to new installations that are included in a two-phase investment
program, i.e. a low capacity first phase engineered with a view to the second phase – a later upgrade.
Raw mill is used to crush the mixture of lime stone, clay and iron. Raw mill consist of a 3 rollers of
weight 60 ton.

These rollers crush the material in to powder form with the help of rotating table which is driven by a
motor. Raw mill has following main parts:

 Roller
 Separator
 Gear box
 Suction duct
 Main drive
 Lubrication system
 Table
 York

3 rollers are used in raw mill and each roller has a weight of 60 ton . These rollers are fitted on a York
with the help of nut and bolts. York consist of three holes which are used for lubrication system. Each
roller consist 12 segment .2 bearings are used on the both sides of rollers. On front side „spherical
double roller‟ bearing are used and on back side „NU‟ cylindrical bearings are used. Separator is
grate type component which is used to separate raw material and fine material. Raw material is send
back on table to crush again.

Page | 49
MAAG: gears are used in raw mill. it is also called galaxy gears because a small rotate in the center
and 3 big gears moves around it like planets.

SUCTION DUCT: is used suck the fine material and send it to c.f silo.

Table: rotates with the help of a motor and helps to grind the material. A 4300 kw motor is used to
rotate the table .Motor rpm is 995 and table rpm is 85-90. Weight of motor is 25000 kg and made by
V.E.M Germany. Coupling type is male female. Grinding pressure is 80 bar and this pressure is
controlled with the help of jack system. 6 pumps are used for lubrication system 3 pumps Are H.P
AND 3 are L.P. Lubrication can takes on rollers and gears. Raw mill line 1 capacity is 300 ton/hour
and line 2 capacity is 550 ton /hour.

WORKING: Feed material is directed on to the grinding table by feed chute .The rotation of the
grinding table; accelerate the material toward grinding track and passing it under the rollers. Coarse
material and bigger lumps drop through the nozzle ring and is eventually re-circulated in to the feed
material inlet. Moisture evaporates almost immediately as the gas stream carries finer portion of
material to the separator. The separator allows the material that has reached required fineness to leave
the grinding mill.

VERTICAL MILL SPECIFICATION:

Mill fan 2200kw

Motor 3400kw
Motor r.p.m 990
Table r.p.m 24.28

4.12 PACKING:

In cement silos blowers are used due to which cement does not damage and no stones are formed.
Compressed cannot be used in cement silos only blower air is used.

Fig 4.4 packing plant

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Flsmidth Ventomatic Spa was the first manufacturer to develop a microprocessor based controller for
filling and weighing units on packers and the first to introduce the electronic rotary packer in an
industry that up until than had only known packers with mechanical weighing system.

The latest and most successful step in the continuous path of innovation is represented by the new
GIROMAT EVO rotary packer generation that distinguishes itself in the market for the very compact
and modular design with very high flexibility and expandability, thanks to the modular integration
between mechanical parts and electronic control. GIROMAT EVO rotary packers are specially
designed and developed for handling many types of building materials, with a wide range of
configurations such as:

 Various impeller designs;

 Bag clamping device for glued and stitched bags and suitable for various bag construction
material;
 Quick discharge system;
 Bag sealing system on board (ultrasonic technology).

Flsmidth Ventomatic supply and control complete packing

Lines including:

 Cement feeding such as bucket elevator, vibrating screen and vane feeder;
 Filled bag transport system comprising bag cleaning, electronic check weighed, bag trap, belt
conveyor, curves, bag diverters;
 Bag loading comprising automatic and manual truck loaders, pelletizes;
 Dust recovery system comprising screw conveyors, bag filters, hoppers.

4.12.1 Main features:

4.12.1.1 Electronic
The packer is equipped with the last generation of electronic weighing units, EWU (OIML approved),
encoder and optical connection.
4.12.1.2 Versatile
Available for wide-range of bag types, sizes and for manual or automatic adjustment.
4.12.3 Open-ended
Suitable either for cement material or dry mix, gypsum and other powdery products
and expandable in capacity.

4.12.4 Modularity and flexibility

A Flsmidth Ventomatic packer is composed of a number of preassembled modules, which are
prepared and tested before delivering. These modules are quickly and easily mounted on the central
tank of the packer during the erection. The numbered pneumatic connector plugs and electric rapid
connectors avoid the possibility of mistakes. If required and in order to minimize the initial
investment, it is possible to put the packer in service with a reduced number of bag filling units. In
case of future growth in production demand, additional filling units can be easily added on.

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4.12.5 Main parts of packer:

4.12.5.1 Optical connection

Infrared data transmission device for connecting the filling units (mounted on the rotating part), the
operator panel and the control system
4.12.5.2 Encoder
To track the angular position of the filling units and control the bag filling sequences
(Filling cycle)
4.12.5.3 Electronic weighing unit
Multiprocessor electronic weighing unit specifically designed for bagging application
4.12.5.4 Impeller
Vertical configuration for optimal filling
4.12.5.5 Filling Unit
Designed for high weight accuracy, high output and low dust emission

CAPACITIES OF LINE-II EQUIPMENTS:

Production EQUIPMENT CAPACITY RUNNING HOURS

capacities of major
equipment are
given below; Serial
No.
1 Lime stone crusher 1000~1500 t/h 16 hours/day
2 Lime stone(2 piles) 35000 ton each -
3 Clay(2 piles) 13000 ton each -
4 Lime stone bin 250 t -
5 Clay bin 250 t -
6 Additive bin 350 t -
7 Raw mill 560 t/h 310 days/year
8 Coal mill 54 t/h -
9 Coal mill silos(2) 150 ton each -
10 C.F Silo 25000 t -
11 Kiln 280 t/h 330 days/year
12 Clinker dome 40000 ton
13 Cement mill OK-36- 175 t/h 310 days/year
1
14 Cement mill OK-36- 175 t/h 310 days/year
2
15 Cement Silo (2) 10000 ton each -

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 ENVIRONMENTAL IMPLICATIONS OF CEMENT INDUSTRY:

4.13 EMISSIONS FROM CEMENT FACTORY

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

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

4.13.2 CO2

Cement manufacture is an energy intensive process. One of the most significant challenges facing the
industry into the 21st century is a requirement to reduce CO2 emissions.

CO2 is produced during the calcinations phase of the manufacturing process and also as a result of
burning fossil fuels. Opportunity to reduce emissions through increased energy efficiency is only
possible on the latter of the CO2 emissions.

4.13.3 Liquid Effluents

Normally, effluents requiring treatment originate from cooling operations or as storm water. Treated
effluent discharges should have a pH in the range of 6–9. Cooling water should preferably be
recycled. If this is not economical, the effluent should not increase the temperature of the receiving
waters at the edge of the mixing zone (or 100 meters, where the mixing zone is not defined) by more
than 3° Celsius. If quantities of suspended solids in the effluent are high in relation to receiving
waters, treatment may be required to reduce levels in the effluent to a maximum of 50 milligrams per
liter (mg/l). Note that the effluent requirements are for direct discharge to surface waters.

4.13.4 Ambient Noise

Noise abatement measures should achieve either the levels given below or a maximum increase in
background levels of 3 decibels (measured on the A scale) [dB(A)]. Measurements are to be taken at
noise receptors located outside the project property boundary.

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4.13.5 Quarry and plant water runoff

Runoff of storm water and treatment of waste water from quarries is a problem for almost all quarry
operations. Usually this is trapped in wetland areas where the water is treated in a controlled manner.
Within the factory runoff can be contaminated by oils and lubricants, but the runoff is monitored and
training programmers are regularly undertaken to ensure this does not happen.

4.13.6 Chrome bricks

Kiln bricks used to be made of hexa valent chrome, which is a carcinogen and causes dermatitis in
some people. Since the problems associated with its use were identified both Milburn and Golden
Bay (along with almost all cement manufacturers internationally) replaced these bricks with
environmentally-sound magnesium-spinal bricks.

4.14 Characteristics of energy consumption in cement production:

The cement industry is said to be an energy-intensive industry together with steel, paper and
petrochemical industries. The percentage of energy cost in port land cement production cost is 20 to
30%. If the energy cost is reduced, the manufacturing cost is lowered, resulting in increasing the
company’s profits. Ninety percent or more of fuel is consumed for clinker burning. About 40% of
electric power is consumed for finish grinding, and a little under 30% each is consumed by the raw
material process and the clinker burning process. The finish grinding process mainly consumes
electric power for the mill, and the clinker burning process mainly for the fan.

The raw material grinding process consumes a large volume of power for the mill and fan The
Japanese cement production process is mostly occupied by SP and NSP kilns and coal is used as fuel,
so that the ratio of electric power consumption by the clinker burning process is high. In a plant
mainly using a wet process kiln, the finish grinding process consumes power in a larger quantity than
the aforementioned example. In such a case, energy conservation measures shall be taken by focusing
on the clinker burning process for the fuel consumption and on the finish grinding process for the
electric power.

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 Future Recommendations about this industry:

Maple leaf cement factory is one of the top ranking industries in Pakistan. This industry is counted in
those industries in Pakistan which using latest techniques and technology for the production of cement.

After completing my internship my recommendations about this industry is

 Prefer maple leaf cement factory for internship because excellent environment is provided
here to learn and inhance your knowledge.
 After completing your internship at maple leaf cement factory you should be able to join any
cement industry in the world because latest technologies are adopted here for cement
production.
 If you get a chance don’t waste your time and take keen entrust in your job.
 Prefer cement industry for your job inside Pakistan because this industry has a very huge
scope in future and has a potential to play a very vital role in the economy of Pakistan.

CONCLUSION

Maple leaf cement factory is the best place to learn specially for the students of mechanical technology
because almost every type of machines are used here for production purpose.

 High accuracy and latest technology plants are fitted at maple leaf with high production rate.
 German and French technology plants are used.
 Latest techniques for cement manufacturing are used at maple leaf cement factory.
 High qualified and hard working staff is employed in this factory.
 Excellent working environment is provided to internee engineers. They can provide a chance
to trainee’s inhance their skills and knowledge about their study.

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