“Cement plant”

Traning report

Submitted

In a partial fulfillment

For the Award of the Degree of

Bachelor of Technology

In Department of Electrical Engineering

2019-2020

SUBMITTED TO : SUBMITTED BY :

Mr. MOHSIN ALI DEEPESH KUMAR SAIN

17ECAME005

Department of Mechanical Engineering

Chartered Institute of Technology, Abu road

Rajasthan Technical University, Kota

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Content

Certificate.......................................................................................................................................iv

Candidate declaration.....................................................................................................................vi

Acknowledgement………………………………………………………………………….… ...vii

Abstract………………………………………………………………………….…………….….2

Introduction………………………………………………………………………………….........3

Chapter 1: Wagon tippler……………………………………………………………………….4

1.1 Working description………………………………………………….…………...….…...4

1.2 Mail components………………………………………………………………………….5

1.3 Salient features……………………………………………………………………………5

1.4 Side arm charger…………………………………………………………………………..6

a. Operation …………………………………………………………………………………6
b. Main components…………………………………………………………………………7
c. Salient features……………………………………………………………………………7

Chapter 2: VRM (Vertical Roller Mill) ………………………………………………….…….8

2.1 Introduction……………………………………………………………………………….8

2.2 Working principle of VRM………………………………………………………………..9

2.3 Parts of VRM……………………………………………………………………………...9

Chapter 3: Ball mill…………………………………………………………………………….10

3.1 Introduction …………………………………………………………..…………………10

3.2 Process control method……………………………………………...……………….......11

3.3 Process variable and characteristic…………………………………………………….....11

3.4 Structure of ball mill………………………………………………………………….….12

Chapter 4: Roller Press………………….………………………………………………….….14

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4.1 Introduction……………………...…...…………………………………………………14

4.2 General Design and Working Principle….….………………………………………….14

4.3 Working Principle………………………………………………………………………15

4.4 Operational Aspects…………………………………………………………………….15

4.5 Mechanical Aspects…………………………………………………………………….17

Chapter 5: Stockpile……………………………………………………………………………19

Chapter 6: cement silo and fly ash silo………………………………………………………...20

6.1 working principle……………………………………………………………………….20

Chapter 7: Distributed Control System DCS…………………………………........................21

7.1 What is DCS System?......................................................................................................21

Reference…………………………...………………………………………….……….….…...23

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LIST OF FIGURES
Fig:1.0…………………………………………………………………………………………….4

Fig:1.4…………………………………………………………………………………………….6

Fig:2.0……………………………………………………………………………...……………..8

Fig:3.0…………………………………………………………………………………………...10

Fig:3.3…………………………………………………………………………………………...11

Fig:3.4. I.1……………………………………………………………………………………….13

Fig:3.4.II.1……………………………………………………………………………………….13

Fig: 3.4.III.1……………………………………………………………………………………...13

Fig:4.0…………………………………………………………………………………………...14

Fig:5.0…………………………………………………………………………………………...19

Fig:6.0…………………………………………………………………………………………...20

Fig:7.0…………………………………………………………………………………………...21

Fig:7.1.1…………………………………………………………………………………………22

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CERTIFICATE

This is to certify that Deepesh Kumar Sain of V Semester, B.Tech (Mechanical) 2019-20, has
presented a training report “cement plant” in partial fulfillment for the award of the degree of
Bachelor of Technology under Rajasthan Technical University, Kota.

Date: 20.06.19

Place: Heidelberg cement India limited, Jhansi

Mr. Mohsin Ali

ME Department

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CANDIDATE’S DECLARATION

This is to declare that this report has been written by. No part of the report is plagiarized from
other source. All information included from other sources has been duly acknowledged. We ever
that if any part of the report is found to be plagiarized, we shall take full responsibility for it.

Deepesh kumar sain

B.Tech mechanical (5th Sem.)

Chartered Institute Of Technology, Abu Road

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ACKNOWLEDGEMENT

I am very thankful to our Institution to provide us with an opportunity to accomplish my summer

training at Heidelberg Grinding Unit Jhansi.
It is my pleasure to be indebted to various people, who directly or indirectly contributed in the
development of this work and who influenced my thinking, behavior, and acts during the course
of study.
For This Great Learning Experience, we avail us at most gratitude to our head “Mr. Deepak
Kakkar”, Who Had been a great source of guidance.
I am thankful to Mr. Ankur Senjaliya, Mr. A.K. Srivastava, Mr. Rajesh Agarwal, Mr. Krishna for
their support, cooperation, and motivation provided to me during the training for constant
inspiration, presence and blessings.
I am also thankful to Mr. Mohsin Ali for providing useful information regarding the report.
Lastly, I would like to thank the almighty and my parents for their moral support and my friends
with whom I shared my day-to-day experience and received lots of suggestions that improved my
quality of work.

Deepesh Kumar Sain

5th sem 3th year
ME

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ABSTRACT

This report covers the experience, which I got in “summer training “. Firstly, I was introduced
in the Cement mill & packing plant section. In operation of cement mill the clinker first come
from the clinker storage pile to the clinker hopper through the deep bucket conveyor. Then
transferred to the hopper of the cement mill then fed to the mill for grinding and mixing. There
is also a recirculation system, which again feed the coarse material to the polycom. The very
fine material from cement mill is then stored in then cement silo. From the cement silo the
cement is fed to the packer, where it filled in the bags of 50kg. I got the knowledge of various
machines like VRM (vertical roller mill), ball mill, wagon tippler, truck tippler, weigh feeder,
metal detector & metal separator etc. The brief description of various field instruments.

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INTRODUCTION

Heidelberg cement India Limited (HCIL/ Company) is a subsidiary of Heidelberg Cement

Group, Geramany. The Company has It’s Operation In Central India at Damoh (Madha
Pradesh),
Jhansi (Uttar Pradesh) and in Southern India at Ammasandra (Karnataka). The company
increased its capacity to 5.4 million tones p.a. through brown field expansion of its facility in
central India in 2013. With the help of the committed sales effort supported by a quantity by a
quality products the company has carved a niche for its brand “ Mycem” in the new market and
has further improved its brand positioning in the existing one. The company has also
introduced its premium cement “mycem power” last year which has been receive well in the
market. Capacity of Jhansi plant is 2.85MTPA and the cement made is Portland Pozolona
cement. The raw material used to make is gypsum (4.5%), clinker (57.5%) and flyash
(38%).The maximum production of cement per day is 2400 tones. The maximum demand of
plant is 20 MVA. The capacity of cement silo 28000 tones. Height of silo is 65 meter. There
are 4 weigh feeders for gypsum, clinker, wet flyash and dry flyash. The capacity of clinker
weigh feeder is 250 TPH. The capacity of gypsum weigh feeder is 25 TPH. The capacity of
wet flyash weigh feeder is 150 TPH. The capacity of dryflyash weigh feeder is 125 TPH. .In
operation of cement mill the clinker first come from the clinker storage pile to the clinker
storage pile to the clinker hopper through the deep bucket conveyor. Then transferred to the
hopper of the cement mill then feed to the mill for grinding and mixing. There is also a
recirculation system, which again feed the coarse material to the polycom. The very fine
material from cement mill is then stored in then cement silo. From the cement silo the cement
is fed to the packer, where it filled in the bags of 50kg and departure to different place.

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Chapter 1 : Wagon Tippler

Fig: 1.0

1.1 Working Description:

The loaded wagon to be discharged is placed to the central position on the tippler cradle and is
weighed with Weigh Bridge (If installed). At rest position of the Wagon Tippler the Movable
side support moves forwards and touches the side wall of the wagon gently and gets locked. At
the start of rotation of the end rings the rail platform with loaded wagon lifts from its supports
and as a result of the offset pivot, the wagon adjusted slightly and rests against the longitudinal
movable side beam. The rotation continues and the wagon is swung towards the top copings of
wagon.The tippler is driven by a Hydraulic motor and the top-clamping device is actuated by
four hydraulic cylinders mounted on the End Ring. Cylinders are operated by a hydraulic power
pack, which gives necessary fluid flow, and pressure to operate the cylinders. During the
tippling operation, Top clamping device starts moving to clamp the wagon from top. At 40
(approx) of the wagon rotation, top clamp comes in contact with the wagon's top coping. At
this condition cylinders get locked, in turn wagon is securely held between cradle platform and
top clamp pads.
Rotation continues up to 160and material starts to discharge at 40 (approx) and continues up to
160. In the process of discharge, the cylinder force is so adjusted hydraulically that no extra
force is applied on the wagon walls. After a pause of 3 sec., return cycle starts. The release of
the top clamp device takes place at 40 (approx) from the rest position. The cradle platform with
empty wagon comes to rest position. The empty wagon is pushed out and the platform becomes
ready to receive next loaded wagon. The weight of the empty wagon (if weigh bridge is
installed) is recorded. The empty wagon is then pushed away from the cradle table and next

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loaded wagon of the rake is placed on the table for tipping operation. The tippler is interlocked
electrically with Side Arm Charger and succeeding equipment (feeders below hopper) with
respect to operational & safety requirement.

1.2 Main Components:

1. Tippler drive Unit (Hydraulic Drive with Power Pack)
2. End Ring with Sector Gear
3. Movable Side Support
4. Top clamping arrangement
5. Tippler platform
6. Brakes
7. Counterweights
8. Hydraulic Clamping
9. Main bearing and main shaft

1.3 Salient features:

1 Type Hydraulic
2 Capacity of wagons that can be handled at 90-110 tones gross weight of each
a time wagon (Max)
3 Angle of rotation(Approx.)-degree 160 Max.
4 Height of wagon handled 2761mm to 2735mm
5 Width of wagon handled 2955mm to 3250mm
6 Length of wagon handled
7 Max. speed 8 km/hr.
8 Type of lubrication arrangement provided Manual
9 No of clamps provided (Hydraulic) Six

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1.4 Side Arm Charger:

Fig:1.4
Side Arm Charger is a marshalling device to position the loaded wagon centrally on tippler
platform one by one for unloading operation by wagon tippler. Side Arm Charger is a rail
mounted machine used to pull the loaded wagons along with the rake & push out the empty
wagon from the tippler platform after tippling.

1.4.a Operation:

The full rake of 58 wagons shall be brought in by locomotive and stopped with the first wagon
within range of the Side Arm Charger. The locomotive is then taken away. The charger shall
be driven towards the first wagon, its arm is lowered and it is coupled to the first wagon of the
rake. The charger then hauls the rake forward by one wagon length and stopped. Here the first
wagon is decoupled from the rake manually. The charger then propels the first wagon on to the
tippler table centrally and then automatically decouples and clears off the tippler. Now the
wagon tippler is ready for operation. In the meanwhile, the side arm charger is moves back to
initial position for next cycle. In next cycle, the rake is drawn up by the one wagon length, and
the previously tippled wagon is ejected simultaneously. After tippling of the last wagon, the
charger is used under manual control to eject the last wagon from the tippler, if the next wagon
is not already in position. The Side Arm Charger is run on a separate pair of rails which runs
parallel to wagon tippler rail. Approximate travel length of the charger is 33M. Side Arm
Charger movement on rail is actuated by the rack & pinion arrangement. Three numbers of
driving pinions are mounted on output shaft of planetary gear box coupled with hydraulic motor
or directly coupled with hydraulic motor. The hydraulic motor is driven from hydraulic
pressure and flow generated from a power pack positioned at operator cabin.

Side Arm Charger is connected to the rake of wagon by a swing arm. The swing arm is raised
and lowered by a hydraulic cylinder which is powered by the same power pack. Electric power
to the machine is fed through the festoon cable mounted along the SAC machine track. The

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SAC is of robust construction and designed for continuous duty. The SAC arrangement has
convenient access for inspection and maintenance of all parts. Adequate platforms are provided
for ease of maintenance. Ladders and safety hand railings are provided wherever required.

1.4.b Main Components:

1. Hydraulic power pack

2. Electric supply system
3. Supports
4. Rack and pinion
5. Buffer stop etc.

1.4.c Salient Features:

1 Type Hydraulic
2 Operating speed:
Rack 0.45 m/sec
Single 0.60 m/sec
Return 0.60 m/sec
3 Tracie effort for pushing & pulling 35 T to 52 T
4 Travel Length 33 m

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Chapter -2 Vertical roller mill

Fig:2.0
2.1 Introduction
In cement production, vertical grinding mill shows its remarkable advantages and features,
which is why vertical grinding mill draw more and more attentions of investors in the world.
Vertical mill integrates crushing, grinding, drying, classifying, elevator into one set, not only
space saving but also reduce the investment cost. Here, we mainly introduce development
history of vertical grinding mill. Vertical roller mill is also called vertical grinding mill, roller
mill and vertical roller mill. The first vertical mill was invented in the 1920s in Germany while
the first vertical mill used for cement production appeared in 1935 in Germany. After many
years' application in the European cement factory, vertical mill started to get adopted in the
USA and Canada. At that time, vertical mill got popular in Europe, USA and Canada was
because the fuel cost and electricity expense was relatively high. It was exactly because of its
high electricity expense, the US paid more attention to vertical mill. The first vertical mill put
into operation in the USA was in the year 1973. Later, Japan, Egypt, Mexico, New Zealand,
Argentina, Congo and some other countries all adopted vertical mill. At the end of last century,
the economy of Southeast Asia developed rapidly, which also brought the remarkable growth
of cement market. Many international companies started to invest in Southeast Asia leading to
the appearance of many large scaled cement production plants. At the same time, vertical mill
got wide application in Southeast Asia area. The technology breakthrough of vertical mill
started from the 1960s. From then, vertical mill got optimized and upsizing. After being used
for grinding raw material in cement industry in Europe, America and Asia, vertical mill got
rapid development in the 1970s. Large scale vertical mill with capacity 500t/h even appeared
at that time. Entering the 1990s, new breakthrough appeared for the international vertical
milling technology. It optimized the structure and producing process, ensuring the application
of extra-large scaled vertical mill. The application of vertical mill in China first started at the
end of 1940s, using for raw material grinding in while cement factory. Since 1950s, some small
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cement factories started to adopt small scaled vertical mill to grind raw material, some even
use vertical mill to grind coal in wet cement factory. Later, manufacturers kept on researching
and optimizing vertical mill. Throughout the application and development of vertical mill in
China and abroad, vertical mill is developing into large and extra-large scale, in order to meet
the requirements of dry and wet cement production line.

2.2 Working principle of VRM

The motor dives the grinding table to turn through the speed reducer. At the same time, hot air
comes into the roller mill from the air inlet. The materials fall down the center of grinding table
from the feeder. Because of the centrifugal force, the materials move to the edge of grinding
table from the center The materials are crushed by the grinding roller when by-pass of the
groove on the grinding table. The crusher materials continue to move to the edge of the grinding
table until taken away by the airstream Then the bigger materials fall down the grinding table
and the process of crushing continues. When the materials in the airstream pass the separator
on the top of the mill, the materials fall down the grinding table from the taper filler under the
force of guide leaf blade. The fine powder comes out with the airstream, and is gathered by the
dust catcher of the system. The powder gathered is the final product of roller mill in the process
of the contact of airstream, the materials are dried to meet the clients need at the proper
moisture. Through the adjustment of the angle between the separator and the leaf of wind's
direction (not suitable to the small type of vertical mill), and also the speed of the separator
rotor, it can reach the proper fineness of the materials.

2.3 Parts of VRM

1. Hot gas generator: To start VRM we need to give an initial heat to it, that heating is
provided by hot gas generator. 2 to 3 hours constant heating is required in which 300-
400 liters diesel is used.
2. Bag house: bag house is consisting of bag filter and bag house fan. Bag house fan
works in two ways, for suction and blowing air.
3. Gear box: gear box is used to rotate the grinding table.
4. Pedestal: pedestal holds the rollers rolling inside the mill.
5. Nitrogen cylinder: nitrogen cylinder used as a shock absorber. On pedestal due to
movement of rollers the too much force is applied on it, to avoid this force on pedestal
nitrogen cylinders are fixed to the pedestal which is works as a shock absorber.
6. Table: table is bed on which the mixture falls. Gearbox will rotate the table and as the
table starts rotating it will rotate the rollers on it. The table and rollers will have same
rpm.

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Chapter 3 Ball Mill

Fig:3.0
Two chamber mills are used for grinding cement, slag and similar materials. They are typically
arranged in a circuit with high efficiency VTP separators. They grind materials up to 6500
cm2/g according to Blaine. The mill itself is equipped with a lifting armoring in the first
chamber with larger balls with a high comminuting effect. The second chamber is equipped
with classifying armoring using smaller balls for finish grinding.
The partition diaphragm is equipped with a controllable material flow so that both chambers
maintain an optimum filling ratio.
Material from the second chamber is supplied to a separation circuit via an outlet wall. In case
warmer materials are ground, water is sprayed into the second chamber or both chambers. In
case the grinding circuit includes a roller press, single chamber mills with classifying armoring
without a partition diaphragm are used.

3.1 Introduction
Grinding in ball mills is an important technological process applied to reduce the size of
particles which may have different nature and a wide diversity of physical, mechanical and
chemical characteristics. Typical examples are the various ores, minerals, limestone, etc. The
applications of ball mills are ubiquitous in mineral processing and mining industry, metallurgy,
cement production, chemical industry, pharmaceutics and cosmetics, ceramics, different kinds
of laboratory studies and tests. Besides particle size reduction, ball mills are also widely used
for mixing, blending and dispersing, amorphisation of materials and mechanical alloying.
As a construction, a ball milling device usually consists of a cylindrical vessel mounted on an
appropriate basis at both ends which allows rotation of the vessel around the center axis. The
mill is driven by a girth gear bolted to the shell of the vessel and a pinion shaft moved by a
prime mover. The prime movers are usually synchronous motors equipped with an air clutch
or gear transmission. After the mill is charged with the starting material (ore, rock, etc.) and
the grinding media (balls), the milling process takes place during rotation as a result of the
transfer of kinetic energy of the moving grinding media into the grinding product.

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The design of a ball mill can vary significantly depending on the size, the equipment used to
load the starting material (feeders), and the system for discharging the output product. The size
of a mill is usually characterized by the ratio “length to diameter” and this ratio most frequently
varies from 0.5 to 3.5. The starting material can be loaded either through a spout feeder or by
means of a single or double helical scoop feeder. Several types of ball mills are distinguished
depending on the discharge system and these types are commonly known as overflow discharge
mill, diaphragm or grate discharge mill and centre-periphery discharge mill. In industrial
applications, the inner surface of the mill is lined with mill liners protecting the steel body of
the mill and incorporating mill lifters which help to raise the content of the mill to greater
heights before it drops and cascades down.
There are three types of grinding media that are commonly used in ball mills:
• Steel and other metal balls;
• Metal cylindrical bodies called cylpebs;
• Ceramic balls with regular or high density.
Steel and other metal balls are the most frequently used grinding media with sizes of the balls
ranging from 10 to 150 mm in diameter. Cylpebs are slightly tapered cylindrical grinding media
with rounded edges and equal length and diameter with sizes varying from 8×8 to 45×45 mm.
Their shape is developed to maximize the grinding efficiency due to their high density and
specific surface area. Ceramic balls with regular density are usually porcelain balls and the
high density balls are made with high alumina oxide content and they are more abrasion
resistant. The basic properties of the milling bodies are their mass and size, ware rate, influence
on the particle breakage rate and energy efficiency of the grinding process.

3.2 Process control methods

The control of a grinding circuit is a difficult task due to many factors such as nonlinear and
undetermined character of the process, inaccuracies in the mathematical model, the presence
of interacting process variables with substantially different dynamics, the influence of
unmeasured disturbances and large time delays, rough operating conditions and inability to use
precise and reliable sensors. On the other hand, an efficient control of the process is of great
importance for increasing the throughput of the circuit and quality of the final product as well
as for a significant reduction of the production costs.

3.3 Process variable and characteristics

Fig:3.3

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The process input variables in the figure are: u1 − mill feed water flow rate, u2 − fresh ore feed
rate, u3 − mill critical speed fraction, u4 − sump dilution water flow rate and u5 − sump
discharge flow rate. The values of these variables can be manipulated in order to control the
output variables: y1 − product mass fraction with size of particles less than a given value, y2 −
product solids concentration, y3 − product flow rate, y4 − slurry level in the sump, y5 − sump
solids concentration. The most important disturbances to the process are ore hardness changes
and feed size variations.
The process control in a ball mill grinding circuit faces severe difficulties due to the following
well known characteristics:
• The process is nonlinear with immeasurable disturbances and unmodelled dynamics;
• There are strong interconnections among variables so that each input variable interacts with
multiple output variables;
• The time constants of the process have values in a wide range and there are significant time
delays in some input-output pairs;
• The system model contains a number of integrators;
• The process parameters vary in time as the circuit ages;
• There are technological constraints on the manipulated and controlled variables;
• The measurements are unreliable and noisy.
The main control objectives are as follows. At the first place, it is necessary to maintain a stable
operation at fixed set-points of the output variables. Within this objective, it is most important
to maintain a stable product size distribution measured as a percentage of the output material
with size of particles less than a given value. Alternatively, the control objective can be
formulated as an optimization problem including a performance criterion which is to be
optimized subject to certain constraints. It can be either the maximization of the grinding circuit
throughput or minimization of the production costs. Various constraints in the optimization
problem are the minimal or maximal values of the input, output and internal process variables
which represent equipment limits, safe operation requirements or environmental regulations.
Due to the inherent process characteristics and constraints, the control design for a grinding
circuit appears to be a challenging problem for most of the control methods applied in practice.
In the rest of this section, two of the most frequently used control approaches are briefly
described and an analysis of their main advantages and drawbacks is presented.

3.4 Structure of ball mill

I. Mill Shell: - Segmented plates are bent and welded together. After welding the
segments are annealed in order to relieve internal stress. The entire mill body is
inspected by non-destructive testing. It is machined and bearing rings are ground with
high accuracy

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.
Fig:3.4. I.1
II. Mill Seating: - Shoe-type bearings with tilting segments seated on swinging balance
beams are designed with hydraulic-dynamic lubrication. They perfectly fi t the shape
of the bearing rings.
Except for mills seated on shoe-type bearings PSP Engineering supplies also mills of a
classic design seated on trunnion bearings.

Fig:3.4.II.1
III. Mill Drive: - Mills are driven by a circumferential drive with a gearbox DMG 2 with
two integrated pinions via a girth gear or with a gearbox, countershaft and one pinion
for mills with a smaller diameter. An auxiliary drive is used for turning of the mill drum
during maintenance.

Fig: 3.4.III.1

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Chapter 4 Roller Press

Fig: 4.0
4.1 Introduction
The roller press is a relatively new development in the cement manufacturing process. This
efficient comminution machine is applied mainly for clinker but is also used for raw material
and slag. The size reduction of the material takes place under high pressure between two
rotating rollers. The press can be installed in combination with a tube mill (new installation or
expansion of an existing mil) or as a finish grinding system.

4.2 General Design And Working Principle

General Design

The design of the roller press is dependent on the supplier, however, the basic construction is
very similar for all makes.

The main elements are:

Press frame:

Pair of rollers:

 One fixed roller

 One movable roller

Each complete roller consists of the roller body with wear protection, two rolling bearings and
two sliding blocks (bearing housings). The lubrication can either be by oil or grease. The rollers
can be with/without water cooling.

Roller drive

 Planetary gear with torque arm

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 Drive shaft (fixed or movable)

 Electric motor (fixed or variable speed)

Hydraulic system

 Cylinders (two or four)

 Nitrogen accumulators (two or several)
 Power pack consisting of oil tank, pump, motor and valves

Feed arrangement

 Feed bin with level indicator or load cells (not part of the press)
 Adjustable feed gate

The area around the rollers is covered in order to prevent dust emission.

4.3 Working Principle

Bulk material is fed to the gap between two rollers which are driven in counter-rotation. The
necessary press force is created by a hydraulic-pneumatic system which works like a spring.

Feed

It is distinguished between choke feed and starved feed.

1. Choke feed: A column of material lays over the rollers. In this case, in order to assure
smooth operation, it is very important that the material is deaerated before it enters the
gap. The choke feed is the common solution.
2. Starved feed: The feed is dosed into the gap (no material column). The advantage is
that the air can easily escape, however, this solution requires a very accurate dosing
equipment

Pressing process (size reduction)

The compaction of the material with the density po starts at the nip angle a. The maximum is
achieved at the so called attack angle B (center of pressure) where the material reaches the slab
density PG Between a and B an inter particle comminution takes place where each particle
transmits the force imposed on it to another particle. Best results are achieved with materials
of wide particle size distribution with a maximum filling of the voids. In the pressing process
a simple size reduction takes place but also flaws and fissures within the particles are produced
reaching into the micro range.

Product
The material leaves the press in form of slabs which normally have the gap thickness. For
further processing these slabs must often be deagglomerated.

4.4 OPERATIONAL ASPECTS

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Installation of roller press

The roller press can be installed in various configurations.

1. In combination with tube mill

 Roller press as pre grinding unit
 Roller press as pre grinding unit with slab recirculation
 Two stage grinding system (semi-finish)
2. Finish grinding system
 The roller press is in closed circuit with a desk agglomerator and a separator

The detailed description with advantages and disadvantages is given in the paper VA
93/4014/E, Cement grinding systems.

Feed granulometry and roller speed

The maximum feed size depends on the roller diameter, the roller surface and the supplier. Up
to 50 [mm] is a normal given maximum size.

A commonly used value is also

max feed size 2 x gap opening

A strong relation exists between the granulometry of total feed and the circumferential speed
of the rollers. If the feed contains a high amount of very fine material and the speed of the
rollers is high ( 1.8 m/s) the press tends to vibrate and a smooth operation is not possible.

1. Pre Grinding without slab recirculation Coarse feed to the press, vibration normally not
a problem.
2. Pre Grinding with slab recirculation

This is the critical case since the slabs contain a high amount of fine material. Figure 6 shows
the relation between circumferential speed and circulating load. At a circulating load of 2 (total
feed product) the roller speed should not exceed 1.5 - 1.55 (m/s].

1. Two-stage and finish grinding system Not critical since the return from the separator
does not contain very fine material. The speed range of the "Holderbank" roller presses
is 1 1.55 (m/s)
2. Adjustable feed gate (Figure 7 and 8) An important influence on the press operation
(material intake, gap opening) has the feed gate. All press manufacturers supply their
presses with adjustable feed gates. A very sophisticated gate is Functioning.
 Lower gate 1: The two tongues have only an open or closed position. With this feature
the feed to the press can be interrupted and the press be stopped with a full feed bin.
(hydraulically or pneumatically activated).
 Upper gate 2: This is the real adjustable feed gate which allows:
 Flow regulation to the press (changing chute opening)
 Eccentrically distribution of the material.

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This part of the gate can also be motorized or kept manually, e.g.

 fixed roller side manually.

 movable roller side motorized.

shows a typical example how the gap opening can be influenced by the position and the opening
of the gate. Very often best results are achieved if the opening is moved towards the fixed roller
and with this position also equal power draw of the rollers is achieved. The best position must
be found by trials.

4.5 MECHANICAL ASPECTS

Wear
Wear on a roller press mainly occurs in the feed chute on the roller surface and on the cheek
plates. The wear rate depends on the feed material (abrasiveness, moisture etc.) and on the
operating parameters of the press.

1. Rollers:

The wear rate itself on the rollers is low (for clinker 1-2 g/t) and does not present a problem,
however, the entering of foreign matters (grinding balls, metal pieces etc.) can lead to the
destruction of the roller surface. The improvement of the resistance of the roller surface is still
an ongoing process and no final solution is found.

 Welded protection (common solution)

The welding consists of buffer layers and hard facing. The so called "peeling off" takes often
place if metal pieces enter the press (large pieces of welding are falling off). Smaller repair
work can be done in the press. Reconditioning should be made in a workshop.

 Stud lining

KHD introduced this type of protection. Wear resistant studs are welded onto the rollers. The
roller body is protected by the feed material which is pressed into the voids between the studs.
The reliability of this solution must still be proven.

 Clamped or bolted on segments

This solution reduces mainly the down time of the press if a damage occurs. This is a fairly
new approach and not enough experience is available. However, a trend can be seen towards
this solution.

2. Cheek plates:
The function of the plates is to avoid the escape of material sideward from the rollers. They are
made from wear resistant material and are easily exchangeable.

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Press protection
In order to keep the risk of roller surface damages as low as possible all foreign matters must
be removed from the press feed (fresh feed and recirculating material). The feed material must
pass below an electromagnet and a metal detector. The detector is linked to a by-pass gate.
Metals which are not removed by the magnet will be detected by the metal detector and will
by-pass the roller press. Some presses have in addition a screen between clinker storage and
press feed bin for a first separation of large foreign matters and oversized feed.

Movable feed bin

In order to simplify the disassembly of the rollers and to do major repair work on the press the
installation of a movable feed bin is advantageous.

Inspections

A continuous operation of a roller press can only be achieved if the critical areas or parts of the
press are regularly inspected and serviced.

1. During operation
 Vibrations of press and press drive
 Bearing and oil temperatures (if oil lubricated)
 Lubrication system
2. During stop
 Wear parts (rollers, cheek plates, inside feed chute)
 Bearings and bearing sealings
 Lubrication system, water cooling system
 Hydraulic system, pressure setting accumulators
 Drive including gear boxes, shafts, clutches, electrical motors

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Chapter 5: Stockpile

Fig:5.0

A stockpile is a pile or storage location for bulk materials, forming part of the bulk material
handling process. Stockpiles are used in many different areas, such as in a port, refinery or
manufacturing facility. The stockpile is normally created by a stacker. A reclaimer is used to
recover the material. Stockpiles are normally stacked in stockyards in refineries, ports and mine
sites. A simple stockpile is formed by machinery dumping coal into a pile, either from dump
trucks, pushed into heaps with bulldozers or from conveyor booms. More controlled stockpiles
are formed using stackers to form piles along the length of a conveyor, and reclaimers to
retrieve the coal when required for product loading, etc.

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Chapter 6: Cement silo and Fly ash silo

Fig:6.0
Cement silo is suitable for storing various bulk materials such as grain, cement and fly ash. The
tank is equipped with a material level system to show the position of the material. Cement silo
is mainly used to store cement, fly ash and other raw materials for concrete production in
concrete batching plant.

6.1 Working principle of cement silo

1. To install the cement silo, it shall use a truck crane to lift it up, and then it will be placed on
the prefabricated concrete foundation. Check and ensure the silo is vertical and then the bottom
of the cement silo must be welded firmly with the embedded parts of the foundation

2. After the storage silo is fixed, the cement is transported to the site by bulk cement truck, and
then the conveying pipeline of bulk cement truck is connected with the feeding pipe of cement
silo, later the cement in the tank is conveyed into the cement silo by the help of the gas pressure
of bulk cement truck.

3. During the conveying, the operator shall press the button of the vibration motor of the dust
collector uninterruptedly to shake off the cement attached to the filtering bag of the dust
collector to prevent cement from blocking the cloth bag and avoid blasting.

4. Full and lack of material can be observed from high and low material level.

5. When discharging, firstly open the manual discharge valve at the bottom of the cone, and
then transfer the cement through the cement conveying device---screw conveyor. During the
discharging, if the phenomenon of "arcing" occurs, press the button of electromagnetic valve
of the broken arch device in time. It will blow the air to eliminate the "arching" and ensure the
smooth delivery of cement.

6.of there is any failure of the cement delivery device, close the manual discharge valve quickly
at the bottom of the cone to prevent the cement from overflowing and avoid wasting.

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Chapter 7: Distributed Control System DCS

In recent years, the use of smart devices and field buses makes distributed control system
(DCS) to be prominent in large and complex industrial processes as compared to the former
centralized control system. This distribution of control system architecture around the plant has
led to produce more efficient ways to improve reliability of control, process quality and plant
efficiency.
Nowadays, distributed control system has been found in many industrial fields such as
chemical plants, oil and gas industries, food processing units, nuclear power plants, water
management systems, automobile industries, etc.

Fig:7.0

7.1 What is DCS System?

A distributed control system (DCS) is a specially designed automated control system that
consists of geographically distributed control elements over the plant or control area.

It differs from the centralized control system wherein a single controller at central location
handles the control function, but in DCS each process element or machine or group of machines
is controlled by a dedicated controller. DCS consists of a large number of local controllers in
various sections of plant control area and are connected via a high speed communication
network.

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Fig: 7.1.1

In DCS control system, data acquisition and control functions are carried through a number of
DCS controllers which are microprocessor based units distributed functionally and
geographically over the plant and are situated near area where control or data gathering
functions being performed as shown in the figure above. These controllers able to communicate
among themselves and also with other controllers like supervisory terminals, operator
terminals, historians, etc.

Distributed individual automatic controllers are connected to field devices such as sensors and
actuators. These controllers ensure the sharing of gathered data to other hierarchal controllers
via different field buses. Different field buses or standard communication protocols are used
for establishing the communication between the controllers. Some of these include Profibus,
HART, arc net, Modbus, etc.

DCS is most suited for large-scale processing or manufacturing plants wherein a large number
of continuous control loops are to be monitored and controlled. The main advantage of dividing
control tasks for distributed controllers is that if any part of DCS fails, the plant can continue
to operate irrespective of failed section.

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REFERENCE:
 www.wikipedia.com/cement-plant
 www.wikipedia.com/cement-machines
 www.mycemco.com/VRM
 Quality Management of Cement Concrete Construction (Gahlot Edition)
 Concrete Technology (By Laxmi Production)

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