INPLANT TRAINING UNDERGONE in

THE INDIA CEMENTS LTD SANKAR NAGAR-WORKS TIRUNELVELI 627357

Reported by

ESSAKKI RAJ.M (01107153016) B.Tech 2nd year PetroChemical Technology ANNA UNIVERSITY THIRUCHIRAPPALLI-620024

DECLARATION

I am ESSAKKIRAJ.M hereby declare that the Training report entitled

“Mechanical

Operations
Dean &

in

cement
Head of and

manufacture” is done by us under the permission of
Mr.Santhanamuthu, PetroChemical Mr.Kumaraguru(class Mr.Saker, ANNA Department inchare)

UNIVERSITY,

THIRUCHIRAPPALLI-620024 to improve my technical knowledge in BACHELOR OF TECHNOLOGY.

DATE : PLACE: SIGNATURE OF THE CANDIDATE

(ESSAKKIRAJ.M)

Mr.Antony (L..C.R unit) Mr.Kasi (V.R.M unit) Mr.Varatharajan (Coal mill) Mr.Senthil (Cement mill) Mr.Kailasam (Workshop) Mr.Appadurai (Packing section)

CONTENTS
S.NO 1. 2. 3. 4. TOPICS INTRODUCTION COMPANY PROFILE POLICIES OF THE COMPANY MANUFACTURING PROCESS (i) (ii) (iii) (v) Crusher Vertical roller mill Kiln Cement mill

(iv) Coal mill (vi) Packaging 5. FUNCTIONAL AREAS OF MANAGEMENT a. Maintenance management system b. Information management system c. Marketing management system d. Quality analyzing system c. Finance and account’s management system d. Personnel management 6. CONCLUSION

ICL - INTRODUCTION:
The India Cements, which is located in Sankarnagar, manufactures cement, which fulfills the entire requirement of south Indian people. The company was incorporated in 21st February 1946. On the starting stage wet process technique was used which was converted to dry process in the year 1990.

COMPANY PROFILE:
The India Cements, which is located in Sankarnagar, manufactures cement, which fulfills the entire

requirement of south Indian people. The company was incorporated in 21st February 1946. The initial annual capacity of one lakh tones is increased gradually reaching 463000 tones by 1959. In August 1990, the wet process technique is converted to dry process and the existing wet process kilns were replaced with a modern single dry process kiln increasing the capacity of the plant to one million tone per annum. On 10th April, the Bureau of Indian Standards (BIS) granted ICL Sankarnagar the license for quality systems certification “ IS/ISO 9001:2000 “ in respect of the manufacture and supply of the cement.
CEMENT Cement may be defined as an adhesive substance capable of uniting fragments or masses of solid matters to a compact mass. Cement is the lifeline of construction industry and cement constitutes about 15% of the construction cost.

SUBSIDIARY

COMPANIES OF ICL :

ICL Foundary Ltd ICL Securites Ltd ICL International Ltd ICL Financial Services
Industrial

Chemicals

and

Monomers

Ltd

DIVISIONS :
• Shipping division • Wind form division

Real Estate , Property development

AWARDS WON:
1. Corporate excellence award from SEBI. 2 .Best presented accounts from institute of charted accounts. 3. CAP EXIL special award from Export from Port Trust. 4. Traffic promotion award from Port Trust.

GOLDEN JUBILEE:
ICL celebrated the Golden Jubilee on 21 st February 1996 for that all workers received some gift. And the experienced employees got special award by the chairman

COMPETITORS:
 MADRAS CEMENTS LTD  ACC GROUPS ULTRA TECH GUJARAT AMBUJA GRASIM INDUSTRIES

TYPES OF CEMENTS: The ICL is producing three types of cements, which suits the . customer requirement Ordinary Portland Cement (53 Grade) Ordinary Portland Cement (43 Grade) Portland Pozzalona Cement

POLICIES AIM:
This plant is maintaining many policy for * Environment * Quality * Safety

Environmental policy :
Protect the environment by the prevention of

pollution.
Compliance to relevant environmental regulations. Continual improvement of environmental performance energy conservation, waste minimization and wherever practicable waste utilization. Propagation of environmental policy to all employees

Quality policy :
♦ Maintaining consistent quality ♦ Maintaining cost effectiveness ♦ Ensuring customer satisfaction ♦ Ensuring continual improvement

Safety policy:
Some safety aspects are given below:

♦ There

should

be

adequate

natural

ventilation through doors, Windows and ♦ ventilators. Local exhaust ventilation

should be provided. ♦ Hazardous Process should be in closed to prevent contamination of the air in the workroom. ♦ Good house keeping should be

maintained. ♦ Workers should be provided with

approved Protective equipments like masks (or) respirator goggles, aprons etc. ♦ Adequate Protective clothing should be given to workers where necessary like aprons, gloves, books, caps and hoods. ♦ If necessary Protective ointments for hands arms and face should be

provided.

FLOW CHART OF MANUFACTURE OF CEMENT
RAW MATERIALS (LIME STONE + IRON ORE + BAUXITE VRM(VERTICAL ROLLER MILL) - GRINDING - BLENDING SILO FIVE STAGE Pre heaters - CLINKER - COOLERS - CLINKER SILO CEMENT MILL GRINDING ( CLINKER+GYPSUM ) +FLYASH+GYPSUM 43,53 GRADE OPC CEMENT SILOS PACKING (House 3 &4) PPC CEMENT SILOS PACKING (House 1,2, 5&6) ( CLINKER )

STEPS INVOLVED: The following are the various steps involved in the manufacture of cement.

CRUSHER,STACKER&RECLAIMER

VRM
 KILN

COALMILL

CEMENT MILL PACKING

CRUSHER FLOW DIAGRAM
L.S Hopper

CRUSHER

Stackar

Reclaimer

Chute Chute Additive Hopper

Hoppers

CRUSHER: There are two crushers (New and Old crushers).

OLD CRUSHER (HAMMERTONE CRUSHER):

 Limestones are brought through laminated conveyor from the hopper.  Laminated conveyor has high load capacity. It can be used only for short distances.  There is a membarane shaft, which connects the crusher to the motor instead of belt.  In crusher, there are 10 hammers, which breaks the incoming LS.  The hammer arm which contains hammer is connected to the flywheel and then to the motor.  The broken LS comes out through grate bar to the belt conveyor.  The capacity of the crusher is 150 TPH (tonnes per hour).  The LS entering the crusher are limited to the size of 800 mm and the out going particles are of the size 75mm.  The power of the motor is 1000 hp.

NEW CRUSHER (IMPACT CRUSHER): SPECIFICATIONS: Crusher motor power Speed of the motor Approximate speed of crusher No. Of blades in the crusher Design capacity Motor power rating four apron conveyor : : : : : : 448kW 988rpm 400rpm 6 5020TPH 55kW

 Apron drives are used to transfer LS to the crusher from mining.

 The centre rotating area is called rotor.  There are 6 blow bars on the rotor, which rotates by a 3-phase induction motor.  These blow bar cuts the LS to 75 mm through no. Of stages from 300 mm.  There are fixed blades called stator blades in the crusher whose distance from the blow bar decides the diameter of the LS.  The temperature of the blow bar is measured by using scanner.  The LS from the crusher moves to the stacker through belt conveyor. TRANSFER OF LIMESTONE FROM CRUSHER TO STACKER: 1) 2) By apron feeding mechanism LS are brought into the crusher. There is a Grizzly filter in-between this, which separates LS less than 95 mm into belt conveyor (1020). 3) The grinding particles (dust) from the crusher are brought into 1020 belt conveyor. 4) From 1020 the dust particles along with hot gas are taken to bag filter system which absorbs the dust particles using bags. Bags are inserted into a case. Air of capacity 30000 cu.m/hr is passed inside and comes out through air vent. The timer is activated once in 15-20 seconds. The bag bulges and retards due to the entry of this air inside the bag the suspended dust particles fall down to the dust hopper. Beneath the dust hopper there is a sump and a rotary air lock. Rotary air lock is used to regulate the

dust along the horizontal direction. In rotary air lock there is an impeller and housing whose gap is very low (ie) 1-2 tou (1 tou = 1/1000 inches). Through these impeller vanes the dust particles passes to the other side (ie) 1030 belt. 5) From 1030 belt they are transferred to transit hopper which has 40 tonne capacity. 6) 7) Then it is move on to variable speed conveyor 1035 & 1035A. From there it is brought to 1180A which is a cross belt analyzer (CBA). Cross belt analyzer passes gamma rays beneath the source and the LS particles are exposed to these rays. These constituents are seen in Quality control lab and LSF (lime saturation factor) is tested. Due to variation in LSF high or low grade LS are mixed to compensate the variation. There is a load cell to determine weight per umit time according to the speed. Soad cell is commected to 1035 in a closed loop. 8) From CBA, it passes to the stacker.

STACKER: SPECIFICATIONS:

Motor used Travel drive Thyristor brake Hydraulic pumps motor

: : : :

bidirectional AC motor 11kW 0.2kW 4kW

 It is used for arranging LS into several layers called pile.  It has a boom. The LS from 1180 belt conveyor move on to the belt conveyor of the boom and the pile is formed as several layers (12 layers normally) of thickness 105 cm. The length of the pile is 100 m, the intermediate gap between two piles is 15-30 m.  Stacker is a moving part in-between two truck.  One end of the stacker has a boom and the other end is compensated by concrete to balance the boom.  The length of the pile is determined by the magnetic sensors (ie) there is a sensor on the wheel of the stacker and the magnet placed on the rails determines the length to which the pile

RECLAIMER:

SPECIFICATIONS: Travel drive Thyristor brake Scrapper chain Harrow drive : : : : 7.5kW 0.2kW 75kW 15kW

 It is used to transfer the LS from pile to the bucket conveyor.  There are two harrows on the either side of the reclaimer.

 The harrows are used to scrap the LS from the pile. After scrapping, the LS are dropped down, which are collected by bucket conveyer system.  Chains connect the buckets.  From reclaimer, the LS (low-grade) passes to the Raw mill through belt conveyor.

VRM: Limestone, high grade lime stone, iron ore, bauxite are mixed and brought to Vertical Raw Mill through belt conveyors. It is grinded finely by the roller mill. The roller mill contains four rollers. The powder is then sucked by the ESP fan through to Dynamic seperator. Here the fine

particles are separated and coarse particles are fed back again into the mill. The separated particles are feed to the blending silo.

Vertical Roller Mill Flow
          
Stack Bag Filter

E.S.P    
 

T o

BLIN DING SILO

P .

A

GC
Reject Hopper.

230
olle r

a rtic Ve l il M

lR

VERTICAL ROLLER MILL: SPECIFICATIONS: Capacity of VRM Power of VRM Size of VRM Speed of VRM : : : : 275TPH 1900kW 46/23 25.4rpm

T

CHEMICAL SUBSTANCE IN RAW MILL: LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, LSF, S.R., A.R.

DYNAMIC SEPERATOR:  In the top of VRM, there is a dynamic seperator. It is a rotating device. The dusts are sucked by air through dynamic seperator. The stator blades are fixed. The blade angles determine the fines of dust particles. A rotor rotates rotor blades. Fluid coupling is used in drive to rotate rotor blades. The dusts are vent through pipe to ESP and coarse particles get down to VRM.  The coarse particles are brought through bucket elevator to reject chute and they are feeded in seperator. The cone like structure in seperator feeds coarse particles to VRM. With this recycling process, there will be no wastage of LS.

ELECTROSTATIC PRECIPITATOR (ESP): • The dusts seperated by seperator are send to ESP, to separate hot gas and dust. • In ESP, 4 sets of electrode are used. They are connected with themselves.

Power supplied is 40000V. Dust coming inside ESP are charged and settled in positive electrode. Positive electrode is collecting

electrode and emitting electrode is negative. The emitting electrode supplied area is called carona. The rapping method is used to collect dust from ESP. The rapping rods hit electrodes and dust fall down. • The hot gases are sucked by ESP fan.

TRANSFER OF DUST FROM ESP TO BLENDING SILO
1) The dusts are passed through a hopper to rotary air lock. It is used to remove any false air or gas going with dust. 2) Through aeropol conveyor using a blower, dusts are sent to blending silo. 3) Blending silo temperature is nearly 100 degree. Raw meal is present here. It is constructed in a way to set uniform mixture to preheater. It is 80-m height, but only 48 m is effective. Nearly, 16000 ton of raw meal is stored here.

HOT GAS SUPPLY TO VRM
1) 2) 3) VRM is effective only operating at nearly 350 degree. The hot gas from kiln is generally utilised by sending it to VRM. Gas conditioning tower is used. In gas conditioning tower, watercooling is done to reduce the high temperature to nearly low as needed by VRM.

PREHEATER:  From blending silo, dust is fed to preheater. There are 5 stages in preheater.  The flow of feed and gases are clearly shown in figure. The gas escapes by cyclone seperators. At each stage, feed comes down to next stage and hot gases goes up to next stage and escapes from cyclone seperators.  The hot gases are fed to VRM (ie) by use of gas conditioning tower.  60% of coal from fine coal hopper goes to preheater by pfister.  This process of preheating is called pyro process.  Preheater fan provides suction.

PREHEATER FAN: Capacity Power : : 170cu.m/sec 2360kW

 Calcination occurs in precalcinator (i.e) dust is preheated to 900 degrees.  In this stage, Caco3 ---------> Cao + Co2, reaction occurs moisture is also removed.  From here, feed goes to kiln. The entry temperature to kiln is nearly 900 degrees.  Autoloop system with PID (proportional integral derivative) is used for temperature control in preheating.

KILN: Kiln is the place where the limestone powder is changed into clinker. The materials are fed into the Preheater through the top while the hot gas is passed through the bottom. As the material passes down it absorbs heat from the gas and reaches the bottom with a high temperature. Then it passes through the Kiln which is at 1400 degree Celsius. Celsius. Thus the heated material is cooled to nearly 100 degree Then clinker is obtained. The hot Clinker from the Kiln is

discharged onto perforated in the Grate cooler. The cold Air penetrates the perforation of the plate and pas through the clinker, thus cooling it. Thus the obtained clinker is stored in silo. The Air

that gains heat from the clinker is taken through tertiary Air duct to the Pre-haeter, VRM & Coal dryer.

DEEP BUCKET CONVEYOR: Materials conveyed Capacity Conveying speed Inclination of conveyor Width of bucket Pitch of bucket Shaft centres No. Of buckets/rollers : : : : : : : : clinker 140TPH 220TPH 40 degrees 1000mm 630mm 110.5m 3 each

Kiln Flow Diagram
From P.H.Fan. GCT Bucket Elevator W.Bin To Coal Mill

Bag House

Vent Fan

Grate Cooler

A B P.H.Fan.

C Clinker Silo

Booster Fan.

CHEMICAL SUBSTANCES IN CLINKER: LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, SO3, CaCO3, C3S, C2S, C3A, C4AF, I.R., LSF, S.R., A.R.

GRATE COOLER: The hot Clinker from the Kiln is discharged onto perforated in the Grate cooler and is present as a bed of uniform height. The whole cooler is

mounted at a slope of 3 deg. The grate cooler has three chambers into which Air is blown through fans. The cold Air penetrates the perforation of the plate and pas through the clinker, thus cooling it. The Air that gains heat from the clinker is taken through tertiary Air duct to the Pre-haeter, VRM & Coal dryer. Variable speed control (AC drives) are used to control the speed of the fans. Airflow transmitter controls the flow of air.

Pressure transmitters and thermocouples are also present to measure pressure and temperature respectively.

 Air from exit of kiln goes by PA duct to preheater. It is supplying oxygen required for burning in precalcinator.  Also, remaining air and air from cooler are sent to heat exchanger. Heat exchanger reduces temperature to 100 degrees and sent to bag house.  From bag house gases escape to atmosphere through chimney by vent fan.  Bag house contains bags, where dust in air is removed. Polyurethane and Acriclic bags are used.

TRANSFER OF COAL: 1) Coal used is Indonesia coal, which has high calorific value. They are brought to plant by transportation. 2) Then they are fed to stacker area by belt conveyors.

COAL STACKER: ♦ Coal pile is formed using the stacker. ♦ Coal piles formed has 10000 X 3 T capacity. ♦ The stacker can be rotated to any angle along the fixed axis. There are 3 piles. The boom, which drops the coal from stacker to pile, can be moved upto 10th position. Each position has a certain height. There are 10 different speeds available. ♦ Magnetic sensors and limit switches are available to maintain length of pile and to drop coal exactly over the pile. ♦ The stacker is rotated by a motor drive using pinion and gear mechanism. The bull gear rotates entire stacker. Angle of rotation is determined by length of pile. Grease lubrication system is available.
♦ Manual and automatic operations are also possible. In case of automatic operation, they are controlled by CCR. The coal mill is a Ball mill

containing steel balls of different sizes. The coal mill is a twocompartment mill one for drying and the other for grinding. The coal gets pulverized in the air swept mill. The pulverized

COAL MILL: coal passes through a coarse separator where coarse particles are separated and fed back into the mill through a Screw conveyor. The pulverized coal is collected in the twin cyclones and is stored in the fine coal bin after it passes through an ESP, where the coal in the air stream is collected and sent to the fine coal bin. From here appropriate amounts of coal are fed to both ends of the Kiln by pfisters, three in number for the Kiln precalcinator and a standby and the coal gets fired in the already hot Kiln. The proximity

inductance sensor measures the speed of the drive. The low temperatures are measured using RTD.

COAL STACKER: ♦ Coal pile is formed using the stacker. ♦ Coal piles formed has 10000 X 3 T capacity. ♦ The stacker can be rotated to any angle along the fixed axis. There are 3 piles. The boom, which drops the coal from stacker to pile, can be moved upto 10th position. ♦ Magnetic sensors and limit switches are available to maintain length of pile and to drop coal exactly over the pile. ♦ The stacker is rotated by a motor drive using pinion and gear mechanism. The bull gear rotates entire stacker. Angle of rotation is determined by length of pile. Grease lubrication system is available. ♦ Manual and automatic operations are also possible. In case of automatic operation, they are controlled by CCR.

COAL MILL Diagram

FD Fan Mill Fan ESP Fan

E.S.P

Separator

Fine Coal Bin.

From P.H.

Pfisters

COAL MILL
To P.C To Kiln Main

EMERGENCY FEEDING: 1) In case of emergency, coal is feeded manually in a hopper available above apron conveyor. From lorries, coal is feeded in a steel structure above hopper, size of coal is controlled by this steel structure. 2) Then, from apron conveyor they are sent to raw coal hopper.

COAL RECLAIMER: ♦ The coal from pile is transferred into 5170 belt conveyor by means of a reclaimer. ♦ Harrow in reclaimer is used to scrap the material in pile to belt conveyor. ♦ The belt conveyor drains the coal into a hopper, located at centre of stacker. ♦ From this hopper, the coal is transferred to raw coal hopper through apron conveyor. ♦ Chain drive is available for harrow movement and sensors are available to determine the length to which it should move. Harrow is supported by means of a rope and can be moved to any angle. ♦ The reclaimer can reach pile by a mechanism available, which moves over circular fails. The speed mechanism can be controlled in control mill. There are 10 speeds available. Depending on step, speed is maintained. This determines the load supplied.

POLYSIUS CIRCULAR BLENDING BED: SPECIFICATIONS: Stacking rate Reclaiming rate : : 100T/hr 100T/hr

Material handled Bulk density, coal/lignite

: :

Coal/Lignite/Coal+Lignite mix 0.8T/cu.m 1.1 T/cu.m

Size of material Live storage capacity

: :

50mm 10000T

RAW COAL HOPPER:  From apron conveyor, feed is given to raw coal hopper.  Capacity of raw coal hopper is 200tonnes.  Coal of size upto 35mm is fed into the inlet of coal mill.  Through draconic belt conveyor and apron feeder, they are then fed into coal mill.

COAL MILL: GENERAL SPECIFICATION: Type Size Material to be used Feed size Mill capacity : : : : : Air swept mill 4m diameter & 9m long Coal/Lignite/Coal+Lignite mix 0-50mm 40T/hr

DESCRIPTION: 1) 2) Coal mill is driven by caution shaft. Hot air from ESP and from kiln is fed to coal mill to maintain a temperature of 200 degree. 3) 4) 5) There are 2 chambers in coal mill. First chamber consists of plates used to dry the coal. There are 2 slideshoe bearings at one end. There is a high and low speed pump utilised in lubrication of slideshoe. Slideshoe bearing is a white metal bearing. There is a cylindrical drum for which lubrication is done, when rotating. High-speed pump first produces a gap of 0.4mm. Then slow speed pump lubricates. Oil and water are used for lubrication. Oil used is SERVO 320.
6)

Steel balls of diameter 15mm to 50mm are present in 2nd chamber. It fills 1/3rd area capacity is 40T/hr.

7)

There is a diaphragm blade in between 2 chambers. This serves for purpose of flow of coal in one direction only.

8) 9)

At the right, there is a pinion with girth gear. Girth gear lubrication is carried out with grease. Grease used is MOLUBALLOY 8031/6000. Multi service lubricant. It can withstand very high temperatures.

10)

After Girth gear, there is a trunnion bearing. It is made of Tungsten steel. It has less load carrying capacity.

11)

The balls revolve in a speed, so that coal particles are grinded and required fineness is achieved.

4) COAL MILL TO KILN: 1) Coal from coal mill pass into static seperator. There, the coal, which is not ground to required fineness, are again sent to coal mill. Return coal feed to mill occurs. 2) From there, it passes to a cyclone seperator at top. The blade angle is such that to get fine coal. 3) 4) Fine coal is again passed to cyclone seperators. The feed goes through two more cyclone seperators for extra cooling. From there, it goes to ESP. ESP removes fine coal and hot gas, then the fine coal moves to fine coal hopper by screw worm conveyor. 5) From the cyclone seperators, feed directly goes to screw worm conveyor. 6) Through screw worm conveyor fine coal is fed to fine coal silo. It has 200T capacity. 7) From fine coal silo, it goes to kiln or precalcinator accordingly. There are three pfisters available for this purpose. Kiln main, stand by, and precalcination pfister. Pfister serves for measuring and conveying of coal accordingly. 8) Air is also passed in and gets out in pfister. Load cell connected sets speed according to load needed. Stand by is used when problem occurs in others. The valve is opened and it operates either for kiln or precalcinator.

CEMENT MILL: The Clinker is brought to the Cement mill and feed into the chamber along with gypsum. Here it is grinded using balls. Then it is transferred to air slider, after which it is brought to Seperator through Bucket elevator. Here fine cement is separated and stored in silo. The coarse particles are fed back into Cement mill. Sound level transducers are used to sense

grinding level inside the mill. Weigh feeder are used to weigh the substance and tachometers are used to measure the speed. produce Tonnes /Hour of the substance passing out. CHEMICAL SUBSTANCES IN OPC53, PPC: LOI, CaO, MgO, SO3, I.R. Thus when combined

Cement Mill Flow Diagram

E.S.P

CEMENTMILL

To Cement Silo

CEMENT MILL: • The clinker silo stores clinker. From there. Through 6461 belt conveyor. It is taken to a hopper with deflector. • There are two deep pan conveyors at bottom. In one belt the gypsum and clinker for old cement mill are added. Where as in case of new mill one belt carries gypsum and the other carries the clinker. There is a weigh feeder which senses the quantity added according to the speed. Deflector serves for feed in two conveyors accordingly. • Gypsum 5% is added to 95% clinker. Gypsum increases the setting time of cement, hence high strength. • With the help of two belt conveyors feed is given to cement mill. • In new cement mill, there are two chambers. It is a ball mill type. Here balls move upward due to centrifugal force. At critical speed, they roll inside without falling down and hence no crushing occurs. Hence to grind efficiently, cement mill rotates at 6570% of critical speed. • First chamber contains 90-60mm balls. Balls are made of high chromium steel. • Second chamber contains 50-15mm balls. The grinded particle in first chamber enters second chamber through diaphragm blade. • The coarse grinding occurs in first chamber and fine grinding occurs in second chamber.

• There are two slideshoe bearings one at each end. High speed and low speed pump lubricate them. • Cement mill capacity is 130T, for one shift of load. • Drive is from DC motor. Girth gear driven by pinion is used. Grease lubrication is done for girth gear. • The output from cement mill passes by elevator to dynamic seperator. Seperator is present at centre and four cyclone seperators are surrounding it. Seperator seperates cement and passes it to a belt conveyor. The gas particles are sucked by cyclone seperators and sent out through chimney. The ESP fan connected provides suction. Coarse particles are again feed to mill, by seperator. • The clinker passing through deep pan conveyor is inspected by quality control lab, and accordingly grades are divided. • In old cement mill, there are four mills. Each has 40T capacity. Two of them have belt conveyors. Two have fluxo system, using compressor and pneumatic setup. This consumes high power than new cement mill. • No slideshoes are present here. They are ground and sent to packing through conveyors. • Output from new cement mill is sent through belt conveyors to cement silo.

PACKING:

Packing Section utilizes the mechanical counterpart for the packing of Powder Cement. Manual labors are used to connect the

plastic/paper pack with the Cement Valve and the mechanical lock is provided to fill the pack with fine cement powder. A counterbalance

of 50Kg connected in the top compares the pack weight with 50 kilograms and closes the cement outcome valve only when the pack is filled with 50kg. The pack is designed such that fine cement powder has only one way to enter into the pack and cannot escape. The packed 50kg Cement Pack is passed through Belt Conveyors and transported by Roadways and Railways.

THE CENTRAL CONTROL ROOM (CCR): The CCR is situated near the kiln area. From here the hopper weigh feeders, VRM, blending silo, kiln, grate cooler, coal mill and cement mill can be controlled. The CCR is the main control room for the entire plant. Depending upon the requirements, of the feed rate, volumetric flow rate for the gases and the water etc. The CCR operators control the dampers and the other equipment provided for the control of the control of these variables. The CCR control has been provided for the new cement mill which is driven by two drives.

PERSONNAL DEPARTMENT
MAIN FUNCTIONS OF THE PERSONNEL : It is responsible for maintaining cordial relationship between the employees and management. It trains and develops the employees to that they work effectively. It motivate the workers and keeps in them good morale. It looks after workers. Employees bonus compensation leave availed etc.

shift timings : There are 3 shifts in a day 6.30 am – 2.30 pm 2.30 pm – 10.30 pm 10.30 pm -6.30 am general shift timings : 07.30 am – 04.00 pm

Subsidized canteen : Free tea and coffee was given to all the staff members during the shift timings . The lunch can be provided at a confessional rate .

conclusion
The main aim of institutional training system in INDIA CEMENTS LTD is to improve the skill and knowledge of

students about the product of the industry and to improve the efficiency of institution. I thank all the staff in the ICL for their kind co-operation this training was helpful for us to carry further study in future. And we learnt many thing through the training. This training is a golden opportunity given for us. Through this training we gain knowledge about they hope with this situation.

Sankarnagar 24/01/2009 From ESSAKKI RAJ.M (01107153016), B.Tech 2nd year PetroChemical Technology, ANNA UNIVERSITY, THIRUCHIRAPPALLI-620024. To The Sr. Manager ( Personnel), India Cements Ltd, Sankarnagar. Through: Chief Manager Mech.) India Cements Ltd, Sankarnagar.

Respected Sir, As I have completed my “INPLANT TRAINING” from 19.01.2008 to 24/01/2009, I kindly request you to issue me the certificate for Inplant Training in Mechanical department. Thanking you, Yours Sincerely, ESSAKKI RAJ.M

(ESSAKKI RAJ.M)

Master your semester with Scribd & The New York Times

Special offer for students: Only $4.99/month.

Master your semester with Scribd & The New York Times

Cancel anytime.