INDUSTRIAL TRAINING REPORT

IN ORIENT CEMENT DEVAPUR

SUBMITTED BY :

NAME: DASARI.VENKAT ( 19090-M-029)

BRANCH: MECHANICAL DEPARTMENT

COLLAGE: V.M.R.POLYTECHNIC,WARANGAL.
 ORIENT CEMENT DEVAPUR
(PROP: ORIENT PAPER &INDUSTRIES LTD.)
TRAINING REPORT
BY
NAME: DASARI.VENKAT

PIN: 19090-M-029

VMR POLYTECHNIC, WARANGAL.

UNDER THE GUIDANCE OF:

MR.BALA GIRIDHAR (AVP)

MR.KRANTHI (ENGG)

MR.HARISH (ENGG)

Signature of Mr. BALA GIRIDHAR (AVP)

Signature of Mr. ANAND ANIL KULKARNI (GM HR)

Signature of Mr. B.PAVAN KUMAR (AGM)

ORIENT CEMENT CK BIRLA GROUPS
Company chairman: Mr. Chandra Kant Birla
Chandra Kant Birla is an Indian industrialist and philanthropist. He is chairman of
the CK Birla Group, a conglomerate operating across home and building products,
automotive and technology, and healthcare and education.
ORIENT CEMENT:
Orient Cement is one of the only two Indian cement companies to be awarded the
prestigious TPM (Total Plant Maintenance) excellence award by the Japan Institute of
Plant Maintenance. The company has also received numerous awards for green and
safety practices including ‘Green Pro Certification’ by CII – Green Products and Services
Council for its product Birla.A1 Premium Cement (PPC).

Orient Cement’s products are produced at the technologically advanced

manufacturing facilities. With the help of equipment sourced from only the world’s
best manufacturers like L&T, CIMMCO, FLSmidth and KHD, the entire cement
manufacturing process is monitored & controlled centrally from a state-of-the-art
central control room to fine tune and ensure quality output. Our NABL accredited
quality lab houses the latest equipment like the X-Ray Analysers from Bruker & Oxford,
Particle Size Analysers and Optical Microscope amongst many others.
The mother plant situated at Devapur (Telangana) was established in 1979. With
addition of a split-grinding unit in Jalgaon (Maharashtra) and an integrated unit in
Chittapur (Karnataka), the total capacity is now 8 MTPA.

Orient Cement stands for strength and trust, and has established a reputation for the
same with the use of only high-grade raw materials. The products are suitable for all
types of industrial, residential and commercial constructions.
HISTORY:

Established in 1979, Orient Cement was formerly, a part of Orient Paper & Industries.
It was demerged in the year 2012 and since then, it has emerged as one of the fastest
growing and leading cement manufacturers in India. Orient Cement began cement
production in the year 1982 at Devapur in mancherial District, Telangana. In 1997, a
split-grinding unit was added at Nashirabad in Jalgaon, Maharashtra. In 2015, Orient
Cement started commercial production at its integrated cement plant located at
Chittapur, Gulbarga, and Karnataka. With a total capacity of 8 MTPA(million tonnes
per annum), they serve Maharashtra, Telangana, Andhra Pradesh, Karnataka and
parts of Madhya Pradesh, Tamil Nadu, Kerala, Gujarat and Chhattisgarh.

HISTORY OF PLANT (DEVAPUR):

Devapur plant is Orient Cement’s first integrated cement unit project, the plant
situated at Devapur in mancherial District, Telangana. The Line- I construction
completed in 1982 and the first truck was dispatched in the same year. In 1990, Line-II
was commissioned. Line-I was upgraded to 1.18 MTPA in 1997 and Pre Calcinator
string was added in 1999. Cement Mills I and II were upgraded in 2010 and 2008
respectively. Line III was commissioned in July 2009. The cement production capacity
of the plant is 3.0 MTPA.
FINAL PRODUCTS:
The product mix includes
 Pozzolana Portland cement (PPC) TRADE, NON-TRADE.
 Ordinary Portland Cement (OPC) 43 trade and non-trade, 53 grade.
 Strong Crete
Marketed under the brand name of Birla.A1-Birla.A1 Premium Cement and Birla.A1
StrongCrete.

With focus on resilience and durability, the company has created benchmarks in the
industry with the quality of its products. It is certified for QMS ISO 9001:2015, EMS
ISO 14001:2015, OHSMS 45001:2015, ISO 19011:2018, ISO 50001:2011, ISO
27001:2013. Orient Cement is one of the only two Indian cement companies to be
awarded the prestigious TPM (Total Plant Maintenance) excellence award by the
Japan Institute of Plant Maintenance. The company has also received numerous
awards for green and safety practices including ‘Green Pro Certification’ by CII –
Green Products and Services Council for its product Birla.A1 Premium Cement (PPC).
CEMENT:
A Cement is a binder, a substance used for construction that sets, hardens, and
adheres to other materials to bind them together. Cement is seldom used on its own,
but rather to bind sand and gravel together. Cement mixed with fine aggregate
produces mortar for masonry, or with sand and gravel, produces concrete.

Cement as we know it was first developed by Joseph Aspdin, an enterprising 19th-

century British stonemason, who heated a mix of ground limestone and clay in his
kitchen stove, then pulverized the concoction into a fine powder. The result was the
world's first hydraulic cement: one that hardens when water is added.

TYPES OF CEMENT:

 Ordinary Portland Cement (OPC) ...

 Portland Pozzolana Cement (PPC) ...
 Rapid Hardening Cement. ...
 Extra Rapid Hardening Cement. ...
 Low Heat Cement. ...
 Sulfates Resisting Cement. ...
 Quick Setting Cement. ...
 Blast Furnace Slag Cement.

USES OF CEMENT:

1. It is used in mortar for plastering, masonry work, pointing, etc.

2. It is used for making joints for drains and pipes.
3. It is used for water tightness of structure.
4. It is used in concrete for laying floors, roofs and constructing lintels, beams,
stairs, pillars etc.
5. It is used where a hard surface is required for the protection of exposed
surfaces of structures against the destructive agents of the weather and certain
organic or inorganic chemicals.
6. It is used for precast pipes manufacturing, piles, fencing posts etc.
7. It is used in the construction of important engineering structures such as
bridges, culverts, dams, tunnels, lighthouses etc.
8. It is used in the preparation of foundations, watertight floors, footpaths etc.
 9. It is employed for the construction of wells, water tanks, tennis courts, lamp
posts, telephone cabins, roads etc.

Manufacturing of cement:

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 set of the
cement).

The three processes of manufacture are known as the wet, dry, and semidry
processes and are so termed when the raw materials are ground wet and fed to the
kiln as a slurry, ground dry and fed as a dry powder, or ground dry and then
moistened to form nodules that are fed to the kiln.
SHORT FORMS:
BC-BELT CONVEYOR
BE- BUCKET ELEVATOR
SC-SCREW CONVEYOR
AS-AIR SLIDE
DC-DUST COLLECTOR
WF-WEIGH FEEDER
D.D.P.C-DEEP DRAWN PAN CONVEYOR
C.S.P-CLINKER STORAGE PILE
VRM-VERTICAL ROLLER MILL
PH-PRE HEATER
P.B.S.R-PRE BLENDING STACKER & RECLAIMER
FLOW SHEETS:
LINE-1
LINE 2
LINE 3
 PROCRESS:
MINES:

The area where limestone is available abundantly is mines. Limestone is

available in the mines in various qualities. All the limestone we are taking is
of not the same quality . The limestone is available i n mines i n the form of a
hard rock material, so therefore to make it into the same pieces first of all
they drill. The deep holes in the mines with the driller. After that they place
the high explosives in that holes and therefore the blasting takes place in
the mines. The hard rock materials, the limestone hill is now made to the
bolder. That bolder are loaded into the dumpers by using the shawl
(poclin). From there the dumpers carry the material and dump into the
crusher. Mines is also called as the kwaris. Blasting time in mines l.30pm
to 2.30pm and 6.00pm to 7.00pm.

Damper:* To transport limestone material from mines to limestone hopper

DUMPER CAPACITY 35T

DUMPER VOLUME 24m 3

DUMPER ENGINE H.P 400

LIME STONE CRUSHER:

To reduce the size of lime stone form 1200m m to + 25mm (max5%) &+40 Mm

(MAX1 %) with minimum power and zero break down.

Lime stones materials of 1200 mm are taken from blasting hills through dampers
and are dumped into hopper. The large particles of material from hopper are sent
to compound impacted through apron feeder, and very small particles are drop on
scraper feeder. the compound impacted contain primary rotors and secondary
rotor , due to the impact the material is crushed between the rotors and the
resultant material is transported through belt conveyer-1,belt conveyer-2, belt
conveyer-3 to stacker , the product obtained is of the range 25 mm to 40mm.
Specifications (in orient cement):
 It is impact type horizontal \ shaft crusher
 Crusher is L&T make mode\ APCM022
 P r im a r y rotor-S type section
 Secondary roto-K type section
 Feed is dumped from truckers in to crusher hopper
 Hopper depth 5m
 Then it is fed through apron feeder in to crusher

APCM CRUSHER SPECIFICATION:

 Model:APCM-2022
 Capacity:1100 TPH
 Power Requirements:2x1150 KW
 Inlet size:1770x2270
 Maximum feed size:60(1500 mm)
 Rotor size:2000x2250
 Weight:143600 kg
 Specific power consumption: 1.4 kw-Hr/Metric ton.
 Crushes 6500-7000 ton/shift.
3
 Maximum input size is 1 m
 HORIZONTAL SHAFT CRUSHER:
Hardness: soft to medium hard materials

 Abrasion: slightly abrasive

 Moisture content: dry or wet, not sticky
 Reduction rate:10/1 to 25/1
 Purpose: Quarried materials, sand and gravel recycling.
 Crush has 3 rotors:
1. Primary rotor (1400 RPM; less voltage)
2. Secondary rotor(≥1400 RPM; high voltage)

 Impactors are still. As blow ba rs rotate, material between t he n gets

crus hed d u e to im p a c t .
 After series of i m pa ct between primary a n d secon da ry rotors it fa lls on
Grinding path assembly (GPA)
 Reduces material
 Material crushed here is sent to PBSR th rough Be lt conveyor.
3
 Crusher has a dust collector with capacity 60000 cm .
 Crusher has Average lifeof8-10 lakhs MetricTons.

*PROS:
o Less expensive.
o Higher reduction rate. (Approximately 2 times compression crusher.)
o More production.
o Product benefaction through particle shape and improved material
soundness.

*CONS:
1. Excess fines production in soft materials and more amount of dust is
generated. More wear rate.

Belt conveyer
The material from crusher is conveyed to stacker through 3 belt conveyers.
P.B.S.R:

* To get homogeneous mixture

 BLINDING RATIO: 5:1(approx)

 Criteria: CaCo3SiO2

PBSR (Pre Blending Stacker and Reclaimer) consists of two piles. Out of
which one is a stacker where the lime stone brought from crusher through belt
conveyer-3 is piled up, and the other one i s reclaimer from where the crushed
limestone is conveyed to the raw mill, stacker moves on the rail tack, it consists of
a boom conveyer through which the crushed lime stone is discharged lime stone
from a pile of different layers, for the to and fro motion of stacker on the rail
track .This pile contains different CaCo3% at different layers. High or low

CaCo3 i s not useful for manufacturing cement.

Generally for manufacturing cement CaCo3%to of 78-86% is required. Reclaimer

contains harrows. The to and fro motion of the harrows reclaiming the pile
horizontally so as to collect all the layers of limestone simultaneously. So the
material comes from to bottom which resulting homogeneous mixture is
collected a scrapper conveyer and charged on belt conveyer-4 and 5 send to
limestone hopper of raw mill.
  Stacker to stack different grade material with boom conveyor.
 Reclaimer to consume the materialthrough scraper conveyor.
 Arrow so that blending of different grades takes place 2 piles with ca pacity
of 5OOOO Tons a long 130-140m length.
 It ta kes about 3 days to consume a heap.
 The angle of boom conveyor is 15° up and 8°down.
 Boom conveyor load 45 kw.
 The arrow angle is 45°.

Raw mill:

Bauxite
Al2O3
Limestone Laterite
CaCO3 Fe2O3
WEIGH
FEEDERS

Raw mill
ROLLER PRESS:
 It is used to crush the materials like limestone, clinker in cement plants.
 For crushing we use high-pressure hydraulic rollers.
 It consists of fixed and movable roller. Rollers have profiling on it for better
grinding. Check plates to avoid spillage of material.
 The shaft of the roller is hollow for heat exchange purpose.
 The shaft of roller is hollow for heat exchange purpose. Roller press crushes the
material between its rollers with a gap of 18 mm in running condition. Output
of roller press falls into hopper then through belt conveyor it is sent into ball
mill.
 Planetary gear box is used.
 Cylindrical roller bearings are present.
 Fluid coupling used along with carden shaft.
 Nitrogen actuator is present.
 Vibration sensors are present on the mill to know the health of machine.
BALL MILL:
 It is a type of grinder used to grind/blend the materials.
 It works on the principle of impact and attrition.
 The impact depends upon critical speed of a ball mill i.e. ,when
gravitational force equals to centrifugal force the balls in mill raise
to certain height and drops causing impact on material and size is
reduced

 SPECIFICATIONS:

SI NGLE CHAMBER:
1.Media should be denser then material.
2. Grinding media is made of h igh chrome steel a nd the liners are
made of high chrome steel or stainless-steel.

3. The diameter of grinding media ranges from 20-90mm

4. The ball should not exceed critical speed of18 rpm.
5. Hardness of balls should be high and tough so that it doesn't wears out.
*SINGLE CHAMBER:
 It has 1inlet and outlet.
 Step liners and classified l iners.
 Less efficiency.
 Diaphragm slot 8-lOmm.

*DOUBLE CHAMBER:

 It Has 2 Inlets and 1outlet classified liners

 Classified efficiency
 Diaphragm slot 12-14

Balls used in ball mill.

 The ba ll mill is rotated with the help of girth gear
 The either ends of mill is attached to bearings for thrust loads and to rotate
the assembly
 Here, trunion and slide-shoe bearings are used.
 High pressure lubricati ng pump is used to lift the ba ll mill and later i t
works on low pressure pump.
SPERATOR:
We have two types of separators:
1 .Static sepa rator:

 It is a lso ca lled as V-separator which sepa rates fines f rom raw m ill circuit.

Materials fed from above where the coarse materials fallsdown over step
grate, then d ischarges at bottom of h ou sing.
 Where as, the fi n es are carried with th e a i r through separati ng channels.

Since no movi ng parts are present energy i s saved.

2. Dynamic separator :

 it is a device separatescoarseandfine materials as rejected product.

 I t co n si sts of blades, c asing and reject box.
 Separation occurs at the periphery of roto cage i n a vortex by air deflectors
and the rotation of cage.
 The air stream which feed horizontal will drag the fines against
ce ntrifugal forcetoinsidecageand fromthere to fine discharge
 Thecoarse is pushed away f rom separator by ce ntrifugal force and drops to coarse
materialdischarge.
  DUST COLLECTOR:

Oust is collected on the bag and purging takes place inside the bag.

Solenoid valve is used for this.

 REVERSE AIR BAG:

Dust is collected inside the bag. And the filtered air is used for purging
ELECTRO STATIC PRECIPITATOR:
Suspended pa rticles a re removed by a pplying high vo ltage electrostatic charge
a nd collecting the particles on cha rged plates.
(PRE HEATER)CYCLONES:
 The a ction of cyc lone is essentially Centrifugal:
 It consists of a dip tube which decreases the Velocity of the particle.

 The dust-gas i s drawn in to vessels

 Tangentially at highvelocity causing it to revolve rapidly so that relatively

dense particles

 Concentrate towards the outside edge.

CYCLONE CYCLONE ORDER IN PREHEATER

KILN:
 It is a Pyro-processing device which is used to raise materials to high
temperature in Continuous process.
 Slightly inclined to horizontal and rotated parallel to its longitudinal.
BASIC kiln COMPONENTS:
1. Shell:
 It is mad e from rolled mild steel plate which are fabricated by welding.
 Shell thickness ranges from 15-30mm.

2. Refractory lining:
 Thickness of lining is from 80-300mm.
 The shell temperature s hould be around 3500 .
 it is checked with the help of pyrometer at regular intervals to give early
warnings of hotspots .
 Pulverized coa l is sent from VRM to kiln.
 Kiln is a Pyro sect ion/Heat treatment.
 Firing area h a s 1200 0 - 14000C .
 Around ·90% of calcination is done in preheaters.

3. TIRES AND ROLLERS:

 Tires are also called as riding rings.
 These tires rides on pair of smooth machine steel cylindrical rollers they are
called as supporting rollers.
 They withstand static and live loads.
 In addition to it we have retaining (thrust rollers) present against side of tire’s
which prevents kiln from slipping off.
 There are mechanical and hydraulic thrust rollers in plant.
DRIVE GEAR:
 Kiln is rotated with the help of girth gear and pinion.
 It is present on the cooler part of kiln tube called as nip point.
 Gear is connected through gear train to a variable speed electric motor. It
should have high starting torque to start kiln.
 It is dangerous to allow a kiln stand still, so for that auxiliary motor is used.
 Internal heat exchanger: Heat is exchanged by conduction, convection and
radiation.
 There is a series of chains hanging across the gas streams acts like heat exchanger
BURNER:

Consists of different channels for coal discharge, diesel discharge,

Swirl air and jet air, this air is used as a prima ry air.

Ai r from t h e cooler is treated as secondary air for burning. where as some amount
of air is flo wn into the tertiary above kiln hood.
COOLER:
 The clinker is passed into cooler from kiln hood.
 Two types of coolers are present:

1. Grate Plate Cooler

 It consists of alternative rows of perforated and overlapping stationary and
moving grates.
 Speed of grate is 3-30 strokes /min in normal operations 10-15 strokes/min.
 The under grate area is divided into compartments each provide with fan and
good sealing between compartment is maintained so that air only passes
upwards.

2. Cross bar cooler:

 It has stationary grate line with no under grate spillage or conveying system.
 It has air distribution plates with mechanical flow regulator.
 Separation of conveying and cooling system.
 Bars that are movable and reciprocates so as to optimize transport efficiency.

BENEFITS:
 Low and easy maintenance.
 Low power consumption.
 Fast, simple installation.
 Highly flexible.
CRUSHER:
 At discharge and cooler is fitted with clinker crusher to break down over sized

Particles of clinker.

 Hammer type breaker.

 It consists of hammers made of cast manganese steel, hubs (discs), pins and
shafts.
 Ahead of breaker is grizzly bar assembly which permits the small size clinker.
VERTICLE ROLLING MACHINE {VRM):

It consists of 3 sections
 Drive(It Has Motor With Planetary Gear Box)
 Grinding(It Has 3 Rollers)
 Separation (The Classifier Separates Fine And Coarse Which Depends On Rotor
Speed.
 And Coarse Drops Down For Further Grinding).

WORKING PRINCIPLE:

 Grinding force = roller weight + pressure.

 It consists of rotating table and rollers in static position.
 Angle between roller and table is15° and gap of 6mm.
 Hydraulic pressure is applied and to compensate any sudden loads
accumulator (oil + nitrogen) is arranged.

 Year wear rate = gm/ton.

c.s.p:
Clinker from the cooler is stored here by DDPC, and to silo using belt conveyer.

Weigh feed:
Weigh belt feeders operate by continuously weighing a moving bed of material on its
short conveyor, and controlling belt speed to result in the desired flow rate at
discharge. Therefore, weigh belt feeders can achieve high rates while remaining
compact. Open frame models are typically used in food applications.

2 clinker weigh feeders. 1 gypsum weigh feeder.

CEMENT MILL:

 Clinker i s sent into hopper or CSP from DDPC.

 Gypsumfrom Gypsumyard isalsosentto hopper.

 Both Clinker &Gypsum are feed into common belt conveyor by

weigh feeders.
 By bucket elevator feed is sent into static separator.
 Coarse material from it sent to roller press,while the fine is sent to
dynamic separator.
 Roller press output is sent to common belt conveyor for
recirculation.
 While the coarse material from dynamic separator sent to ball mill.
 Fly ash is also inlet to ball mill.
 Ball mill outlet is sent to dynamic separator. The super fine material
from dynamic separator collected in cement silo.

Roller press:

Dynamic separator
SILO:
A silo is a structure for storing bulk materials.

Silos in plant are,

Varys from 4200 – 25000 tons

 Raw mill(blending silo).

 Clinker silo.
 Cement silo.
 Fly ash silo.
PACKING PLANT:

 FROM SILOS TO PACKING HOPPER MATERIAL IS conveyed by air slides and

screw conveyors
 Old packing plant has 5 packers.
 New packing plant has 1 packer.
 4 single discharge (8 bags/roataion)
 1 double discharge (12 bags/rotation).
 5 silos for cement storage.
 4 silos(2 flat box; 2 inverted v-shape type)
 1 steel silo(inverted v-shaped )

 Silo 1-ppc-5500 tons

 Silo2-opc 53-5000 tons
 Silo3-opc43-5000 tons
 Silo4-ppc-5500 tons
 Silo5-ppc-5500 tons
 Steel silo-hsppc-500 tons
WAGON LOADING M/C:

To load bas into wagon.

TRUCK LOADING M/C:

To load bags into truck.

Final products:

Ppc:

Trade. Non-Trade.

Opc:

53 trade. 53 non trade. 43 grade.

Strongcrete:
Types of conveying system:

Belt conveyor:

 Most common means of coveying material in any production industry.

 The torque produced by pulley is transmited to the belt through friction.

Air slide:
It is designed to convey bulk powders mainly fine particles

It consists of a rectangular chamber separated by a permeable cloth.

The inclination of a chamber is about 1.5°.

Product fluidizes and flows down the length when compressed air is injected into it.
Screw conveyor:
It is a mechanism that uses a rotating helical screw blade called as blighting usually within a tube to move
liquid or g r a n u l a r material.

Bucket elevator:

It is to elevate bulk material vertically,there are two-are two types.

Chainbucket elevator:
 Designed for transporting hot bulk and coarse-grained material.

Belt bucket elevator

Desinged for transporting floury and small-sized bulk materials.ex:raw
mill,cement,sand etc.

DEEP DRAWN PAN CONVEYOR(DDPC):

It is used for conveying hot or abrasive bulk material.

Flow conveyor:
To convey material for medium and shorter distance by dragging the material with
help of chain link assembly.

For free flowing bulk materials Capacities over 800 tons per hour.

COUPLINGS:
Used to connect two shafts for purpose of transmitting power

TYPES OF COUPLING

PIN BUSH:
It is used to connect shaft which have small parallel/angular/axial misalignment.
Applications involving safety such as elevator drives, small motors.

CARDAN SHAFT COUPLING:

 Shaft with universal joint at one or two ends.

 Used where there is large mis-alignment.
Fluid coupling:

Used to transmit rotating mechanical power.

used under high loads & safety purpose, flexible.
Used in elevators

Gear coupling:

It is used at heavy load areas.

Torsion shaft

It used at heavy torque load.

Magnetic coupling:

It is used at slight load and low rpm.

 BEARINGS:

There are two types of bearings

1. Frictional bearings.

2. Anti-frictional bearings.

Most common used bearings in industries are “anti-frictional”.

 Spherical bearings.
 Deep grove ball bearings.
 Ball bearings.
 Angular Contact Ball Bearings.
 Self-Aligning Ball Bearings.
 Thrust Ball Bearings.
 Spherical Roller Bearings.
 Cylindrical Roller Bearings.
 Tapered Roller Bearings.

Gear box:
The gearbox is a mechanical device used to increase the output torque or to change
the speed (RPM) of a motor. The shaft of the motor is connected to one end of the
gearbox and through the internal configuration of gears of a gearbox, provides a given
output torque and speed determined by the gear ratio.

Types of gear boxes:

 Coaxial helical inline.
 Bevel helical gearbox.
 Skew bevel helical gearbox.
 Worm reduction gearboxes.
Mini load at elevator.
 Planetary gearbox
Used for roller press.
 Helical gearbox
Used at kiln 2 stage reduction.

Helical gear box plantary gearbox

CONCULSION:

I have succusfuly learnt about cement manufacturing and machinary

involed in it.and safty medium followed at industry.