INDUSTRIAL TRAINING REPORT

AMRIT CEMENT LIMITED ,UMLAPER

(MEGHALAYA)

TRAINING
PRODUCTION OF CEMENT

SUBMITTED TO SUBMITTED BY
DEPT ,CEMENT TECHNOLOGY MANISH MOHAN UPADHYAY
DIPLOMA 20129C01008
ACTS, SATNA BRANCH -CT
EMESTER -5TH
 ACKNOWLEDGEMENT

I sincerely express indebtedness to esteemed and revered guide of Process

Department; ‘HRD Department; of Meghalaya for their invaluable guidance support
throughout the Industrial training.
I take the opportunity to express deep sense of gratitude to Mrs. Shrija Chandak ; AVP
of HR, Mr. Gagan Kashyap; HOD of HRD, Mr. Arup Kumar Das ; GM of process
Department, And Mr. MD Sir of Amrit cement Limited for guidance and support
during training, and providing the best available facilities.
I Own thanks to all the engineers in Process Department, for their advice, and support
me time to time. Thanks for all of you to support me.

Date:- 2 august 2022 Manish mohan upadhyay

Place:- Meghalaya 20129CO1008
 ABSTRACT

This report covers the experience, which I got in ‘ INDUSTRIAL TRAINING, at

Amrit Crop . Ltd ( Meghalaya ) Firstly I was Introduced in the Cement Mill and Packing
plant section .
In operation of Cement mill the clinker first come from the clinker storage pile of the
clinker hopper through the deep bucket conveyor. where it crushes and the fed to cement
mill for further grinding and mixing . There is also a recirculation system , which again feed
the coarse material. The very fine material from cement mill is then stored in the cement silo
. from the cement silo the cement is fed to the packers , where it filled in the bags of 50 kg.
Then I was introduced in the process section , Impact crushers and then Raw Mill
and Coal Mill section . In Raw Mill and coal mill Section I got The Knowledge of
various instruments like Pressure transmitted , temperature transmitters ,pressure gauge ,
proximity switches , flow switches, level switches, Temperature sensors like RTD and
thermocouples weigh feeders, metal detector and small separators etc. then I was Introduced
to kiln and preheaters section WHRS and all other section one by one and learnt the process
and working ofVarious machines and their significance

28
 INDEX
SECTION SECTION NAME
COMPANY PROFILE 1-4
PROCESS FLOW 5-7
1 INTRODUCTION ON THE TOPICS
A) WEIGH FEEDER 8-9
B) BELT WEIGHER 10
C) TEMPERATURE MEASURING INSTRUMENTS 11
D) PRESSURE MEASURING INSTRUMENTS 12
E) LEVEL MEASURING INSTRUMENTS
2 CEMENT MANUFACTURE PROCESS
A) QUARRYING 13-14
B) RAW MATERIAL PREPARATION 16 -19
C) PREHEATER TO KILN 20
D) CLINKER BURNING AND STROAGE 21-28
E) CEMENT GRINDING 29
F) MINERALS ADDITION PREPARATION 30
G) CEMENT DISPATCH 31
H) CENTERAL CONTROL ROOM 32
3 SAFETY 33
COMPANY PROFILE
 AMRIT CEMENT LIMITED
FOUNDER MD Mr. PRADEEP BAGLA

INTRODUCTION OF THE COMPANY

AMRIT CEMENT LIMITED

Amrit cement Limited is a private company , incorporated On 24 JANUARY
2008 it ,s public unlisted company and is classified As ; company limited by shares
Company ,s authorized capital stands at Rs 1500.0 Lakhs and Has 91.96375 %
paid -up capital which Rs 1379.46 lakhs . Amrit Cement Limited Last annual
general meet (AGM) Happened on 26 september, 2017 .The Company last updated
Its financials on 31 Mar ,2017 as per Ministry of corporation
Affairs ( MCA)
 Amrit cement limited is majorly in. Manufacturing (metal and Chemicals, and
product thereof) business from last 14 years And currently , company
operations .are active . current Board members and Director are Mr. BHALANG
SINGH PHANBUH ,Mr. BHARAT KUMAR SETA, Mr. PRADEEP KUMAR BAGLA, Mr.
SUNIL KUMAR KHEMKA and Mr. PURUSHOTTAM JANKILAL MEHESHWAR.
Company is registered in Shillong ( Meghalaya ) Registar office . Amrit cement
limited registered address is opposite horse Shoe Building Lower Lachumiere
Shillong Meghalaya 793001
Amrit cement LTD.

Meghalaya

 The Amrit cement industrial plant is situated in

a Umlaper, Elka-Rymbai, Meghalaya 793200
 These plant manufacture two types of cement.

1. Ordinary Portland cement(OPC)

2. Portland pozzolana cement(PPC)
AMRIT CEMENT LIMITED SENIOR MANAGEMENT TEAM

1. Mr . Pradeep bagla - Managing Director (Chairman)

2. Mrs. Dipa Bagla – Director (Finance)
3. Mr. Umang Bagla-Director(Sales and Marketing)
4. Mr . Savan kumar Jayantilal jasoliya - vise president
5. Mrs. Shrija Chandak - vice president ( HR & ADMIN)
6. Mr . Manoj Lohia – ( general manager – finance )
7. Mr . Rajesh Bagri DGM – ( Finance and account)
 PROCESS FLOW

Quarry Crusher Pre blending Raw mill

yard stacker

reclaimer
QUARRY

Coal supply Coal

crusher Coal
Raw mill
mill
KLIN

Cooler

Cement
gypsum
Mill

hopper
Fly ash

Cement mill
market packing Cement silo
CEMENT MANUFACTURING PROCESS
 AMRIT CEMENT LIMITED

FLOW
DIAGRAM
PLANT
PROCESS

BALL MILL RAW MILL

ROTARY KLIN CEMENT PLANT

 INTRODUCTION
TOPIC

WEIGH FEEDER

Weigh feeder is a machine it feeds material to the next process while weighing in
proper quantity .It is like conveyor Belt but the belt speed is varied by weighing the
material so as The feed to the next process remains constant. The material on the belt is
weighed by local cell under the belt and the speed is varied by the speed control of dc
motor . the signal from the load cell and speed ( measured by tachometer) and the
capacity of weigh feeder is a 20000 thousand TPH . The resultant shows the feed in TPH .
Further this TPH is compared by a set point given externally .the microprocessor controller
Generates the error which is amplified and given to the thyristor controlled , which control
the power the fed to the Dc motor . which is accordance varies the speed of the belt with
The gear box and hence control feed

INPUT ,OUTPUT AND MARKER

These are one bit variable that can have LOW or HIGH status. Inputs are signal from
outside to the control program and output are signal from the control program to the
external System. Markers and internal variable and serve as memory.

limestone

Clinker Cement
blending Kiln
stone mill

clay

Within the control system they are available outside the control system when they
have been copied into outputs . the diagram depicts the basic process of cement blending
and stages.
 BELT WEIGHER
A.
It is a system used to measure the feed of material to any m/c through belt
conveyor . we are using it in many location In raw mill it is being used

 Principle of operation
Mass of material flowing in BC is sensed by load cell are located under the belt
In such a way that the force acting on the load cell is equal on the load cell is
equal to amount of material on the ½ meter on the belt it represent in k/gm
 TEMPERATURE MEASURING INSTRUMENTS

1.THERMOCOUPLE
The thermocouple are sensors that Measure temperature , their application
range from industrial Manufacturing and experiment setting to the meat
Thermometer .they are often used any where it Is important to be able to reliably
monitor or record Temperature data.
Types of thermocouple
 The alloy combustion is of platinum ( 6 % Rhodium )
And platinum ( 30% Rhodium)
 Chromel and constant are the alloy that from an
E – type thermocouple
 J type of thermocouple is formed with iron and constantan
 Chromel and Alumel from a k – type thermocouple

2. RESISTANCE TEMPERATURE DETECTOR (RTD)

A Resistance temperature detector ( also knowns as a Resistance
Thermometer or RTD ) In electronic device used to Determine the temperature by
measuring the resistance of an Electrical wire This wire is referred to as a
temperature sensor . if we want To measure temperature with high accuracy , an
RTD is the Ideal solution , as it has good linear characteristics over a wide range of
temperatures. Other common electronics devices used to measure temperature
 3. KILN SHELL TEMPERATURE SCANNER

Rotary kiln shell temperature monitoring Kiln scan is a high performance

thermal scanner dedicated to the real time , 24/7 temperature monitoring of the
kiln Shell . it displays the full temperature profile of the kiln and gives early warning
of hot spots indicative of refractory failure

4. RADIATION PYROMETER
t is also detects the heat radiation emitted from the object these radiation are finally
I

converted into temperature using the necessary optics and electronic circuit

PRESSURE MEASURING INSTRUMENTS

 PRESSURE TRASMITTER . A pressure transmitter is a mechanical device that measure

the expansive force of a liquid or gaseous sample . also know as a pressure
Transducer , this type of sensor is typically composed of a pressure sensitive surface
are made of steel, silicon or other.

LEVEL MEASURING , INSTRUMENTS

1 NUCLEONIC LEVEL SENSORS

The phenomenon of reducing the intensity of gamma radiation when passing
through liquid s or soild is used in Nucleonic devices for measurement of level of
liquid and soild fig. present radiation – type level detector A small quantity of
radioactive substance ( cobalt 60, radium 226 etc,) is placed is source unit 1. This
unit is attached to the wall of a tank 2 filled with substance 3 which level is to be
measured . A radition detector 4 . usually geiger -mueller tubes ,is fixed to the wall
of the tank on the opposite side of the tank
 CEMENT MANUFACTURING PROCESS

There are four stages in the manufacture of portland cement: (1) crushing and
grinding the raw materials, (2) blending the materials in the correct
proportions, (3) burning the prepared mix in a kiln, and (4) grinding the burned
product, known as “clinker,” together with some 5 percent of gypsum (to
control the time of ...

QUARRING

Mining is the process of extracting buried material below of the earth surface .
Quarring refers to extracting material directly from the surface . in mining and
quarring , water Is used and gets polluted in a range of activites , including minerals
processing , dust suppression and slurry transport
 Mining
 Lime stone - the lime stone blasted from the mountain
Is fed uniformly by the vibration feeder through the silo and transported to the jaw
crusher for coarse crushing .
The coarsely crushed materials are screened by vibrating screen and then conveyed
by belt conveyor to cone crusher for medium and fine crushing

 IMPACT CRUSHER- the mechanical structure of an impact crusher is defined by its

rotor , the primary instruments for breaking apart material . the rotor is set among
mounted
Plates , anvils, and aprons , inside a heavy housing ; the apron or anvils serve to
bears the impact of the material being processed and further break them apart

IMPACT CRUSHER
 Primary crusher – the primary crusher reduced the large run -of – mine material such
as rocks and ore lumps , into smaller sizes furthering processing down stream ,
whether that transport be transported to additional crusher or to a wet processing
plant . the size of out put in primary crusher less< 40 mm to 10 %

 Secondary crusher -The secondary crushers are designated as standard cone crushers
having stepped cone crushers having stepped liners and tertiary short head cone
crusher . which have smoother crushing face and stepper cone
Angle of the breaking head, the secondary crusher output size below < 16 mm to 10%

STOCK PILE
A stock pile is a pile or storage location or bulk material forming part of the bulk
material handling process
A stock pile made upto 10000 to 13000 stock pile in 3 to 4 days

A lime stone stock pile ( closed stock pile) has been proposed at the plant size with
stackers re- claimer . will help in feeding a homogenized lime stone by mixing rich
quality LS with low grade minerals. By installing a re- claimer in the plant , the plant
can achieve not only quality raw material input but also the conversation of the
natural resources by utilizing low – grade raw material
 RAW MILL HOPPERS
 RAW MILL FEEDING
Cement manufacturing the raw mill feeding is an intermediate activity between pre-
homogenization After monitoring and controlling the quality of incoming raw
material , the area of high activity of incoming raw material , the area of high activity
for quality department to ensure quality mix cement ‘’ mill feeding system ‘’ the
system consists of material hoppers/ bins weighing , conveying , venting and mill
feeding gate
 MILL FEEDING HOPPER
Hoppers for limestone / clay / iron ore serve the purpose of providing a buffer
storage for mill feed and a convenient Arrangement for feeding to weigh feeders for
proportioning purposes . hopper used to be designed to hold the requirement of one
shift . raw mill capacity reaching 250-700 tph reclaimer belts of stacker reclaimer
system running round the clock it is as well no longer practical necessary to do so .
thus hopper masy be designed to hold only 4 hours requirement . clay /
silcastone ,iron ore are very low that hopper to hold 8 hours need are too small

 WEIGH FEEDER
The simplest from of bulk material transportation is to convey them over a moving
belt and it is necessary to weigh a moving bulk material accurately to control the
process as per requirement weigh feeder is a closed – loop control system , which
controla the flow of material very accurately using controller and different
instruments This system accepts an external command from process computer like
SCADA , HMI , DSC.

WEIGH FEEDER RAW MILL

 RAW MILL

 RAW MILL TYPE OF BALL MILL

A Ball mill is a type of grinder used to grind or blend material for use in mineral
dressing processes, It works on the principal of impact and attrition ; size reduction is
done by impact as the balls drop from near the top of the shell
A ball mill consists of a hollow cylindrical shell rotating about its axis the axis of the
shell may be either horizontal Or at a small angle to the horizontal . it is partically
filled with balls , which may be made of steel ( chrome steel) Stainless steel, ceramic ,
or rubber . the inner surface of the cylindrical shell is usually lined with an abrasion -
resistant material such as manganese steel or rubbing lining . less wear takes place in
rubber lined mill
 Working of rall mill type of ball mill

In case of continuously operated ball mill, the material to be ground is fed from the
left through a 60 degree cone and the product is discharged through a 30 degree
cone to The right . as the shell rotates the balls the lifted up on the rising side of the
shell and then they cascade down ( or dowp down on to the feed) from near the top
of the shell .in a doing so, the solid particles in between the balls and ground are
reduced in size by impact

RAW MILL SILO

Before being burned in the rotary kiln , the material from the material from the
blending bed and the aggregates are ground to a fine raw mill in large mill . the
powdery material is the transported to the silo by pneumatic conveyor system .
reliable monitoring of the level is essential for optimal raw material storage
Silo storage in 4000 ton

PREHEATER
PREHEATER

Working principle of preheater

Pre heater tower ‘’ is place to use for preheating the raw material . the material
which comes from c. f silo pre heater is a device in which heat transfer takes place
from hot gases which comes from kiln due to counter current flow of material and
hot gases . the raw mill is heated about 850 ℃
KILN
KILN
Kiln is cylindrical rotary equipment rotating on supporting rollers at about 3.5
RPM .discharge in its completing calcination Reaction firing is done from kiln outlet with
help of burner pipe
 Construction : kiln can be divided into
 Kiln inlet ( consist seal , gear pump , lines , cylinders )
 Girth gear ( gear, pinion, spray, system)
 Thrust roller( hydraulic cylinder, oil line)
 Supporting roller and type ( consist of bearing , chair plate ,bolts etc)
 Kiln outlet seal( S.S shims, crown shell , seal)
 Burner pipe ( consist of air pipe, diesel pipe)
 Kiln inlet : kiln inlet is seated by sealing arrangement . greasing Is done by
pneumatic pump seal . it consist of 10-14 so, it can be mounted and disassembled
from kiln inside . A conical section forms an extension of the inlet ring . a brick
Retaining ring has been mounted at the end of conical section Girth gear : kiln is
rotating by gear _ pinion arrangement . girth Gear is mounted on kiln with the help
of spring plates Thrust roller : the function of thrust roller is to control axial Moment
of kiln in both upward and

Downward Supporting roller nd tyre : supporting roller are for support of kiln . they
are in contact with tyre which fitted in kiln shell kiln outlet : there is sealing
arrangement in kiln outlet, Burner pipe : it is for firing of fine coal into the kiln .air is
Controlled by damper and fine coal by solid flow meter

 Working of kiln
A Rotary kilns work by processing material in a rotating drum at high temperature
for a specified retention time to cause a physical change or chemical reaction in the
material being processed . the kiln is set at a slight slope to assist in moving material
through the drum Direct - fired kilns can be of the co- current or counter current
configuration ,referring to the direction the combustion gases flow in relation to
the material Rotary kiln system typically included secondary combustion chambers
of afterburners to ensure completDestruction of the hazardous waste . operating
kiln temperature range from 800 ℃ to 1300 ℃ In the secondary combustion
chamber or afterburner depending on the type of wastes During the operation of the
rotary kiln , flames can Reach temperature as high as 1900℃ ( 3452 ℉ )
In order to heat raw material s to roughly 1500℃ ( 2732℉ )

Rotary kiln (a) elevation view showing the different zones in which the kiln is
divided; zone 1 ( admission ) , zone 2 (subdivision of the material ) , zone 3 (calcinig)

Rotary kiln – when material is getting hot it is get the chemical reaction and it is
change of the clinker . due to the inclined position of kiln the gravity is shifting the
material in to lower portion of the kiln ( output ) . it also used to get maximum
temperature in the input ( top) position

 Clinker griding – clinker is ground as finished cement . in a vertical roller mill

for cement or in a ball mill those normally used for grinding hard raw material in
dry and semi – dry processes the clinker I smore difficult to grind than a raw material
and must also be finer ground The reduction of the clinker to cement ratio means
lower emission and lower energy use . ordinary po cement can contain up to 95 %
clinker ( the other 5% being gypsum). The current average clinker to cement ratio
over all cement 73.7%

COOLER

The clinker coming out of the kiln is hot . it is cooled in a set up called a cooler . in
the cooler cold air is blown to effect heat exchange between hot clinker and cold air

Deep pan conveyor

The deep bucket conveyor is essentially an equipment to lift material vertically it
working to heat material s come in belt belt was carried their heat in their heat in
the belt structures

ESP – ELECTROSTATIC PRECIPITATOR

ESP removes particles from a gas stream by using electrical energy to change
particles either positively or negatively

CLINKER STORAGE

CLINKER STORAGE
Clinker storage . after lime stone is reduced in size by processing the stored
limestone is then mixed with some mineral aggregates ( siliceous , aluminous , and
ferrous Material ) and water is high temperature kiln to form cl
 CEMENT BALL MILL

OUT SIDE BALL MILL INSIDE IN BALL MILL

 BALL MILL
A material fed through the mill is crushed by impact and ground by attrition
between the ball s . the grinding media are usually made of high – chromium steel .
the smaller grades are occasionally cylindrical There exists a speed of rotation ( the
‘’ critical speed ‘’) At which the contents of the mill would simply ride over
The proof of the mill due to centrifugal action . the critical speed ( rpm) is given by;
n c = 42. 29/√ d , where Is the internal diameter in meters . ball mills are normally
Operated at around 75 % of critical speed , so a mill with diameter 5 meter wil turn
at around 14 rpm . the mil is usually divided into at least two chamber ( although this
depend upon feed input size – mills including a roller press Are mostly single –
chambered), allowing the use of different sizes of grinding media . large balls are
used at the inlet , to crush clinker nodules ( which can be over 25 mm in . diameter ) .
. ball diameter here in the range 60-80mm . in a two – chamber mill , the media in
the second
Chamber are typically in the range 15-40 mm , although media down to 5 mm are
sometimes .as general rule , the size of media has to match size of material being
ground :
Large media can’t produce the ultra – fine particles required in the finished cement
but small media can’t break large clinker particles : mill with as many as four
chamber s, allowing a tight segregation of media sizes, were once used , but this is
now becoming are alternatives to multi chamber mill are:
 Pairs of mills, run in tandem charged with different – sized media
 Use of alternative technology ( see roll- press below ) to crush the clinker
piror to fine – grinding in a ball mil
 A current of air is passed through the mill . this help keep the mill cool, and
sweep out evaporated moisture which would other wise causes hydration and
disrupt material flow . the dust exhaust air is cleaned usually with bag filter
BALL MILL CIRCUIT BEFORE GRADARTION
 The coarse clinker is ground in the first chamber of the ball mill which large size ball
( 90 mm, 80 mm, 60mm, 50mm, are used
 Here the incoming particles are crushed from 25mm, to less than 2.5 mm
 The feed material is subjected to compression and shear and is pulverized mainly by
impact and precussion in this chamber .
 Fine grinding is done is the second chamber with classifying liners where size
reduction take place mostly by attrition
 The smaller size balls are used ( below 30 mm)
 VRPM

Vertical roller pre- grinding mill

 It is evident that grinding efficiency of ball mill circuit can be increased by removing
coarse grinding from the first chamber of the ball mill which can be efficiently carried
out in vrpm
 Rotation of the table generates centrifugal force which causes material to spread
over the table in uniform layer
 Rollers are subjected to high compressive force generated
Through a hydraulic system
 Clinker particles are caught between rotating table and roller and efficiency ground
by a combination of compressive force from roller and shear force generated by
Difference in circumferential speed of table and roller.
 VRPM system is generally used in semi – finished mode where in the feed size to
the ball mill, is reduced to (-)
1 mm before entering the ball mill
 VRPM system in combustion of ball mill with common separator
system

 The circuit is ideal for cement plant

 Up – grading from open circuit to close circuit
 Setting up a spilt grinding unit
 Integrated plants using ball mill for mill for cement and raw material grinding
 CEMENT GRINDING

 Portland cement
It is produced by inter grinding cement clinker with a few percent of natural
Or industrial gypsum ( or any hydrite ) in a cement mill. And also Portland
cement is obtained by heating limestone and clay or other silicate mixture at
high temperature (> 1500℃ ) in a rotating kiln . the resulting clinker ,when
cooled is mixed with gypsum ( calcium sulfate) and ground to a high uniform
fine powder

 Ordinary port land cement

Ordinary port land cement refers to the hydraulic binding material ground by
mixing port land cement clinker 6% -15% blended material and appropriate
amount gypsum

The term bag house is applied to large filters containing a number of tubular
bags mounted in a usually rectangular casing the dust laden air is drawn
through them by suction

Cement mill bag house

 MINERALS ADDITION PREPARATION

Mineral addition from natural or industrial sources intended to be used in blended cement
may need to dried , crushed or ground in separate installation site. Separate ‘ grinding
plants’ where minerals addition and blended cement only produced may also be located
remote from the clinker production facility.

CEMENT SILO

The cement storage silo is used for storing the finished product – cement
 CEMENT DISPATCH

Cement may be slipped as a bulk cement or - usually to a leaser extent – packed into
bags and loaded into truck , automatically or by plant dispatch transport methods
( I e , road, railway, waterways ) depend on load condition and requirement

Packing and dispatch

The cement is packed with the help of a rotary packer and finally H ) dispatch to the
cement
 CENTERAL CONTROL ROOM

It is the nerve center of the cement plant since all equipment is controlled from this place .
it is the place from where all the process parameter controlled
The C C R operator is responsible for the operation of different plant sections from the
central control room
. plant operation and optimizing the process parameters
. co ordination with field side people from C C R for smooth operation of the plant
 SAFETY

Safety is most requirement for any plant because by taking proper measure against
Accident we can increase the profit of company and can save manpower from injury .
safety is totally an engineering system , according to telephone into ‘’ no job or service
Is so urgent that we cannot take time to perform our work safety’’ safety an attitude , a
State of mind that must be sustained in work environment

 ACCIDENT
Unwanted undesirable events which has potential to hit injury to a person or a
loss of property

 C AUSE OF ACCIDENT
Unsafe act – 85- 90 % unsafe condition 10 – 15%

 UNSAFE ACTS : UNSAFE CONDITION

Lack of knowledge no provision of safety attachment
Inattention leakage of oil ,water , stream
Hurry dust fumes and temperature
Violating safety condition of ladder / scrapped / stair
Over confidence
Worry and hypertension
Lack of experience

 HOW TO PREVENT ACCIDENTS

Use of proper safety devices

Toxic and inflammable material store process to be isolated

Preventive and periodically maintenance of equipment

By training of employees through video , audio , lecture to motive the people to

make part for creating awareness in the plant

Use of personal protective equipment