INTRODUCTION TO

DEFINTION OFCEMENT
CEMENT-

cement is a binder, a substance which sets and hardens

independently, and can bind other materials together.

"cement" goes back to the Romans who used the term "opus
caementitium" to describe masonry.

Cements used in construction are characterized as hydraulic

or non-hydraulic.
 GUJARAT AMBUJA
Ambuja Cements CEMENT
Limited, formerly known as Gujarat
Ambuja Limited is a major Cement producing company in
India.

Principal activity is to manufacture and market cement and

clinker for both domestic and export markets.

Operates a hotel through its subsidiary GGL Hotel and Resort

Company.

Shown innovation in utilizing measures like sea transport,

captive power plants.
WHY PLANT LOCATED
THERE?
Availability of Raw materials.

Own limestone mines.

Sand available in nearby areas.

Muldwarka port located there.

PRODUCTION PROCESS
 RAW MATERIALS
Limestone Flyash

Sand slag

Different quality of cements can be made using

different proportions of raw materials.
 RAW GRINDING
Raw materials are dried.

Intermediate product, called ‘Raw Meal’ is

formed.

Provides an increased surface area to enhance

the heat exchange.
 HOMO SILOS
“Raw Meal” is stored in a homogenizing silo.

Process important to stabilize the downstream

sintering process .

Transferred to the PreheateD Tower.

 PREHEATER
‘Raw Meal’ undergoes a series of concurrent heat exchanges.
Gas and material stream are separated by cyclones.

Temperature increases from 80oC to 1000oC within 40 seconds.

Chemical reaction takes place in the Precalciner of the Preheater,

where limestone is decomposed.
 CONDITIONING
TOWER
The flue gas exiting the preheater is directed to
the raw mill for drying.

Its temperature and humidity is regulated in a

conditioning tower.

Process is essential as it affects the dust collecting

efficiency.
 ELECTROSTATIC
PRECIPITATORS
Used as the final dust removal device for flue
gases.

Contains a series of collection plates and an

overhead framework of suspended rigid high-
voltage electrodes.

Particles in gas stream are charged by a high-

voltage.
Highly active and visible glow in the electrode known as the
"corona“.

Particles are attracted to the grounded collector plates.

Particulate matter and high voltage electrodes is removed by

the impact of "rapper" mechanisms.

INDUCED
DRAFT FAN
I D Fan are installed in the process to drive the gas
stream movements.
 KILN
Calcinated material undergoes a long heating process.

Temperature rises from 1000oC to 1450oC .

Cement minerals formed at the sintering temperatures.

Semi-product called “clinker” is formed.

Ash from fuels is absorbed into the clinker matrix.

 GRATE COOLER
The residual heat from the clinker is recovered.

Cooling air is injected from the bottom and is

forced into the Clinker.

Heated air is then recycled as secondary air.

 FINISH GRINDING
Final process of cement making.

Clinker dosed with controlled amount of gypsum is fed .

A horizontal steel tube filled with steel balls.

Tumble and crush the clinker into a super-fine powder.

Particle size controlled by high efficiency air separator.

 SOME INTERESTING
FACTS
Gujarat Ambuja Cement Group, has its flagship cement factory
located at Kodinar in the state of Gujarat in India.

It has a manufacturing capacity of 4.5 Million tons per year.

The factory has been operating at 100% capacity.

GACL decided to hand over responsibility for the plant's operation

and maintenance to Wärtsilä India Ltd.
WARTSILA SOLUTION
The power plant consists of Wärtsilä DG sets along with a MMBL DG.

Wärtsilä India Ltd took over O&M responsibility for the power plant from 1
January 1998.

Wärtsilä have consistently exceeded the O&M benchmarks set out in the contract.
PLANT MAINTAINANCE
Maintained by various companies like, TCS , Vashila from Finland. And ground
is maintained by local people of kodinar.

Its various machinery parts are maintained by various other companies.

KIND OF PRODUCTION-
THE PRODUCTION PROCESS IS CONTINOUS .
 FORECASTING
MERGER WITH HOLCIM IN PROgress.

SINCE, MINES OF GACLTD. KODINAR ARE ALMOST

COMING TO AN END, AN ALTERNATIVE HAS BEEN
FOUND NEAR THE PLANT IN KODINAR WHERE THE
COMPANY WILL USE MINES WHICH HAVE BEEN
FOUND OUT BY A TEAM OF GACL.

current bse sensex rates of ACL is RS 130. EXPECTED TO

DOUBLE IN FUTURE.
 OUR
EXPERIENCE
 OPINION AS A
MANAGEMENT
harmful chemicalsSTUDENT
emitted out during production process

poor accommodation to mines, packing department workers.

admirable work done by adm.

facilities provided by ambuja to its employees.

PRESENTED BY