Internship Presentation

DG KHAN CEMENT COMPANY –KHAIRPUR PLANT

Limestone Minning And Processing
Operations
1. Drilling
2. Blasting (Primary and Secondary)
3. Loading/Transporting
4. Crushing (Hammer Crusher)
Limestone Crusher (1500 t/h)

 Parts
1. Hopper
2. Apron Feeder
3. Inlet Roller
4. Main Rotor
a. Rotor Disks:
b. Hammer
5. Grit Bar
6. Anvil Plate
7. Chain curtain
8. Chain Scrapper
9. Motor
10. Gearbox
Storage Yard

1. Stacker
2. Side Scraper
3. Reclaimer
Limestone Flow Diagram
Raw Mill Section

 Raw Mill Feed Area

1. Mixed hopper
2. Pure hopper
3. Bauxite hopper Iron 
4. Ore hopper
Ø Sections of Raw Mill
1. Three Rollers
2. Bottom Scrapper
3. Separator 
Raw Mill Area

 Coal Mill
 Coal Pfister
 Cyclone
 CF Silo
 Storage Bins
Pre-Heater

The most important activity in cement manufacturing is clinkering (burning) of raw

material. Clinkering takes place in the kiln and the Pre-heater system. Pre-heater
systems supply heat from the hot kiln gas. Now Material is fed to Pre-heater which
Increase the temperature of grinded material up to 900 ˚C. Pre-heating is necessary
because in kiln temperature is 1200 ˚C to 1600˚C. So, if material is fed directly to
this temperature it will burn out. It consists of number of cyclones and material is fed
to top-most cyclone and get out from bottom most.
Rotary Kiln

The rotary kiln is a long cylindrical vessel, inclined slightly to the horizontal, which is
rotated slowly about its axis. The material to be processed is fed into the upper end of the
cylinder. As the kiln rotates, material gradually moves down towards the lower end, and
may undergo a certain amount of stirring and mixing. Hot gases pass along the kiln,
sometimes in the same direction as the process material (co- current), but usually in the
opposite direction (counter-current). The hot gases may be generated in an external furnace,
or may be generated by a flame inside the kiln. The fuel for this may be gas, oil or
pulverized coal. It is the most important part of the cement manufacturing process, also
called heart of process, as materials are baked here to produce clinker. A Rotary Kiln is a
pyro processing device used to rise temperature of material into a continuous process. It has
a length of 66m and diameter of 5.5m. It is inclined at 5˚ to 7˚, so that no material is stuck
inside the kiln. Its rotating speed varies according to the quantity of feed entered. Normally,
it is kept at 4rpm. Revolution is proportional to the amount of material transferred. The kiln
is rotated by two motors installed outside the kiln having power of 4700kW each.
Clinker Cooler

The clinker cooler is used to lower the clinker temperature. There are seven induced
draught fans which take fresh (ambient air) air from the atmosphere and send it to the
cooler. At the bottom of the cooler there are reciprocating rails or bars which move to
and fro with the help of hydraulic motors. These bars are inclined at some angle.
These bars are actually perforated metal plates through which air moves. These rails
convey the clinker forward to the clinker storage. At outlet of clinker cooler, the
temperature is 200˚C. There are three types of air, primary air is used for burning
purpose inside the kiln, secondary air moves inside the kiln while tertiary air
bypasses kiln and directly enters into the preheater. The clinker cooler code is 4x7F
where 4 is number of drives, 7F is number of ID Fans. The area of clinker 2 cooler is
160m . The pressure maintained inside the cooling chamber is 55.5mbar. 
Clinker Crusher & Storage

 Clinker Crusher
 Clinker Storage
Cement Feed Mill Area

There are two cement mills and three hoppers in the cement mill feed area. Both
cement mills have specifications:
OK 36.4
Power of motor 3600kW
Capacity of 175TPH 

 Gypsum Addition
 Mixing of Additive
 Metal detector
 Storage Silos
Packing Plant

The packing plant comprises of 6 packers and 12 terminals. Each packer has a
capacity of 100 tons/hr. The cement bags are attached automatically (2 -packers) and
manually (4- packers) to the rotating packer which fills the cement bag. The amount
of cement to be filled in bag can be varied from CCR. When the bag is filled up to the
required weight (50kg), it automatically falls on the conveyor belt which takes the
bags to the roller conveyor. From these rollers the bags slide to different channels and
finally cement bags are loaded on the trucks for dispatching.