A

Training Report
On
"Cement Manufacturing Process and Use of Crushers in
Cement Plant”

J.K.Cement LTD. Nimbahera.

Submitted to
RAJASTHAN TECHNICAL UNIVERSITY

in partial fulfilment of Requirement for Course of

Bachelor of Technology
in
Department of Mechanical Engineering

Submitted To: Submitted By:

Prof. Arun Arya Hitesh Lalwani
Head of Mchanical Engg. Deptt. Roll No.:17EARME041

Department of Automobile Engineering

Arya College of Engineering and I.T., Jaipur
Session 2018-19

1
 Candidate’s Declaration
I hereby declare that the work, which is being presented in the Practical Training Report
,entitled “Cement Manufacturing Process and Use of Crushers in Cement Plant" in partial
fulfilment for the requirement of course of “Bachelor of Technology” in Deptt. of
Mechanical Engineering and submitted to the Department for a record of my own studies
carried under the Guidance of Shri/ Dr.Prof. Arun Arya. Department of Mechanical
Engineering, Arya College of Engineering and I.T., Jaipur
I have not submitted the matter presented in this Report anywhere for the requirement of any
other course.

Name of Student:- Hitesh lalwani

2
 ACKNOWLEDGEMENT

I am extremely grateful towards Mr. S.K. RATHORE, Unit Head, and

the
entire management of J. K. Cement Works for giving me this opportunity
to undergo an Industrial Training at their reputed premises.
I also wish to acknowledge my profound gratitude towards Shri M S
Shekhawat,
Asst. Vice President – HR & ER for giving me opportunity in this field.
I pay my thanks to Mr. N K Vaishnav, Asst. Manager – RTC for incessantly
guiding me for my in-depth training on “Cement Manufacturing
Process and Use of Crushers in Cement plant”,they supported
me in every aspect of my report and encouraged me at every step.

Name of Student:- Hitesh Lalwni

3
 List of Figure
1. JK Cement factory
2. Regional Training Center
3. Drilling Machine
4. Excavator
5. Dumper
6. Dozer
7. Impact Crusher
8. Hammer Crusher
9. Limestone Mining, Crushing, Stacking
10. Belt Conveyor
11. Stacker Machine
12. Piles
13. Reclaimer
14. Raw mill grinding
15. VRM
16. Horizontal Mill
17. CF Silo
18. Preheating section
19. Rotary Kiln
20. Cement mill
21. Double toggle jaw crusher
22. Swing hummer crusher
23. Solid rotor impactor breaker
24. Gyratory Crusher

4
CONTENT
1. Introduction and Overview of J K Cement WORKS
1.1 History & Milestones
1.2 Production Capacity and Financial Performance
2. Management Set- up.
3. Organizational Chart.
4. Regional Training Centre - North
5. Corporate Social Responsibility
6. Introduction to Cement
6.1 History of Cement
6.2 Definition of Cement
6.3 Types and Uses of Cement
6.4 Types of Processes
6.5 Process Overview
6.5.1 Mining
6.5.2 Crushing of Limestone

6.5.3 Prehomogenisation

6.5.4 Grinding of Raw Material

6.5.5 Homogenisation

6.5 .6 Pyroprocessing

6.5.7 Cement Grinding

6.5.8 Packing Plant

6.6 Quality Characteristics of Cement

7. Crusher, Stacker & Reclaimer

7.1 crusher
7.2 Stacker & reclaimer
8.Conclusion
9. Reference

5
Introduction to

HR Department
JK Cement Works
Kailash Nagar, Nimbahera
District: Chittaurgarh-312617
(Rajasthan)

6
J.K. Cement is an affiliate of the J.K. Organization, which was founded by Lala Kamlapat Singhania. The J.K. Organization is an
association of industrial and commercial companies and has operations in a broad number of industries.

Our cement operations commenced commercial production in May 1975 at our first plant at Nimbahera in the state of Rajasthan. At
Nimbahera, we started with a single kiln with a production capacity of 0.3 million tons. We added a second kiln in 1979 with
production capacity of 0.42 million tons, and a third kiln in 1982 with a production capacity of 0.42 million tons. We added a
precalciner with a capacity of 0.4 million tons in 1988, which increased our capacity at Nimbahera to 1.54 million tons. During the
years 1998 through 2003, we continued to implement modifications to each of our kilns, which increased our aggregate capacity at
Nimbahera to 2.8 million tons as of September 30, 2005.

We commissioned a second grey cement plant at our Mangrol plant in 2001, with a production capacity of 0.75 million tons. As of
September 30, 2005, we had an aggregate production capacity of 3.55 million tons per annum of grey cement. Our white cement plant
was completed in 1984 with a capacity of 50,000 tons. Our continuing modifications to the plant have increased its production
capacity to 300,000 tons as of September 30, 2005.

Today, J. K. Cement Ltd. is one of the largest cement manufacturers in Northern India. We are also the second largest white cement
manufacturer in India by production capacity. While the grey cement is primarily sold in the northern India market, the white cement
enjoys demand in the export market including countries like South Africa, Nigeria, Singapore, Bahrain, Bangladesh, Sri Lanka,
Kenya, Tanzania, UAE and Nepal.

Our access to high quality limestone reserves that are suitable for production of white cement provides us with a competitive
advantage. Based on geological surveys conducted by independent agencies on our mines between 1996 and 2001, our limestone
reserves for both grey and white cement are expected to meet our existing and planned limestone requirements of 4.0 MnTPA of grey
cement and 0.4 MnTPA of white cement, for approximately 40 years.

Backed by state-of-the-art technology and highly skilled manpower against the backdrop of India’s infrastructural growth in an
overdrive, we are upbeat about the future. We are confident of contributing heavily in India’s journey of development. We see a world
of concrete ideas on the horizon.

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1.Overview of J K Cement WORKS
1.1 HISTORY BEHIND J K CEMENT

The initial "J.K." stands for a father- son team, namely: Juggilal Kamlapath Singhania

 J .K. organization started in the year 1884 at Calcutta. J .K. started their business as a
Financier, Investor, Trading Supplier of cotton belts and manufacturer of small
machinery parts like ‘V' belts, etc. They established few small cotton textile
industries also.
 In the year 1914 they shifted their business from Calcutta to Kanpur where they
established many big industries like J.K. cotton Mills, Straw product Co, Lohia Mach,
J.K. Pulp and Raymond’s Woolen, etc.
 In the year 1934 J.K. organization started one more division, as J.K. Synthetics Ltd.
They established various big plants of Nylon, Acrylic fiber, etc. at Kota and Tyre
Cord, Chemical and Pesticides at Jhalawar.
 In the year 1974 under the same division one more unit was started for manufacturing
of Grey Cement at Nimbahera.
 The present cement factory was commissioned in the year 1974. The plant started its
production from 27th Dec 1974.
 Ist plant / kiln was commissioned in 1974 and the capacity of this plant was 900 tonne
per day and 3 lakh tonne per year. After modification in Preheater, its present
capacity is 1200 TPD.
 Expansion of this plant took place in the year 1979, when 2nd kiln was commissioned
with a capacity of 1200 tonne per day and 7 lakh tonne per year. After modification in
Preheater its present capacity is 1650 TPD.
 Again in the third phase, a kiln was erected in the year 1982 and production of this
kiln was 1350 tonne per day.
 In the year 1988 a new technology was introduced in this 3rd Kiln that consisted of
precalcination process, which raised the capacity of this plant to 3400 tonne per day,
which was earlier 1350 tonne per day. In Aug.-2003 after again some modification in
Preheater and Folex cooler its capacity is increased to 4700 TPD.
 Besides, J.K. cement plant is having its own diesel generator sets, producing power to
meet the power energy requirements.
 Main raw material for cement is LIMESTONE, for limestone we have our own open
cast mines adjoining to the plant. Besides we have developed few more mines at
Maliakhera, Karoonda and Tilakhera for producing 10,000 tonnes limestone per day
as needed.

8
  J .K. Cement erected one more plant from Jan. 2001 with the capacity of 1400 tonne
per day at village Mangrol. In Nov.-2003 after modification in Preheater and
installation of Mechanical elevator its capacity increased to 2200 TPD.
 Due to power shortage as imposed by Ajmer electricity supply board J.K. established
its own Thermal Power Plant at village Bamania, near Shambhupura, which is
generating 15 M.W. power every day, which is consumed by J.K. Cement Plant.
 J K Cement also has a plant of 400TPD installed capacity of White Cement at Gotan,
Nagour (Raj).
 Cement Plant at Karnataka of over 5500 TPD and Thermal Power Plant of capacity
30 MW.
 Thermal Power Plant at Nimbahera of 22 MW.
 Waste Heat Recovery Plant at Nimbahera of 13.2 MW capacity.
 J.K. cement is one of the most productive, cost efficient cement producing plant in
the country, a company, believing in corporate responsibility to society, integrity and
fairness. The company’s cement is sold under the J.K. Sarve Shaktiman brand name,
enjoys good brand image and a price premium.
 The following types of cements are produced by J K Cement Works.
(a) Ordinary Portland Cement (OPC)
(b) Portland Pozzolana Cement (PPC)
(c) Super Silicate Cement (SSC)
(d) Masonry Cement (MC)
(e) Portland Slag Cement (PSC)
(f) White Cement 7
J. K. Cement manufactures and markets cement and clinker for both domestic as well
as exports markets.

1.2 PRESENT CAPACITY AND PERFORMANCE

1.2.1 CLINKER PRODUCTION – Nimbahera and Mangrol Plant

Plant Capacity(tones/day)
1 Plant/kiln
st
1200
2 Plant/kiln
nd
1650
3rd Plant/kiln 4700
4rt plant at Mangrol 2100
Total Capacity 10200 TPD
PLA

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1.2.2 PRODUCTION ANALYSIS TABLE: IN TONS – Nimbahera and Mangrol Plant

Year Clinker Cement

2005-06 3170268 3511022
2006-07 2907196 3638786

2007-08 2917045 3690726

2008-09 3024091 3646220
2009-10 3096463 3594387
2010-11 2461905 3280016
2011-12 2907630 3465353
2012 - 13 2955814 3567226
2013 – 14 3008736 3523527

2014-15 3067368 3809902

1.2.3 FINANCIAL ANALYSIS: IN Million – J K Cement Ltd.

Year Turnover PBT

2005-06 11087 522

2006-07 15297 2720

2007-08 18128 3466

2008-09
18765 2340
2009-10 22481 3112

2010-11 26520 837

2011-12 28835 2858

2012 - 13 3342.58 337.54

2013 – 14 3201.72 114.18

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 2. MANAGEMENT SET- UP

2.1 Corporate Level- Kanpur

Chairman - Dr Gaur Hari Singhania
Managing Director - Shri Y P Singhania
Special Executives - Shri Raghavpat Singhania
Shri Madhavkrishna Singhania

2.2 Heads:

Project
Project Head Shri NK Mishra
BU
Unit Head J K Cement, Nimbahera and Mangrol,
Shri S K Rathore
Distt: Chittaurgarh, Rajasthan
President Shri B K Arora J K Cement- White and Grey Plants at
Gotan, Distt: Nagaur, Rajasthan
JK Cement Works, Muddapur,Distt:
Unit Head Shri R B M Tripathi
Bagalkot, Karnataka

3. ORGANISATIONAL CHART

J K Organization

J K Cement Ltd.

Production & Location

J K Cement J K Cement J K Thermal J K Cement J K Cement ABROAD

Works, Works, Power Mudhol, Gotan (Raj.)
Nimbahera Mangrol (raj) Bamania Karnataka White Cement JK Cement
(Raj.) (Raj.) –1000 TPD Fujairah,
Grey Grey Cement – UAE
cement
8000 TPD Grey Cement– CPP – 15 9000 TPD 1200 TPD
C P P- 22MW 3000 TPD MW CPP-50MW CPP – 7.5MW
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4 . Regional Training Centre - North
The Regional Training Centre - North is a premier training centre of North India
promoted with assistance from World Bank, DANIDA and Govt. of India as a unique
HRD project in Cement Industry. It is equipped with modern training aids and caters to
the skill enhancement and competency developmental needs of more than 20 cement and
other plants. It has trained over 8000 technical and managerial personnel during the last
14 years. The centre has conducted many tailor-made in-house programs for cement and
other industries:

Abroad:

 Oman Cement, Oman

 Star Cement, Dubai
 Hama Cement, Syria / EHDASSE Sanat Corp. Iran.
India
 J & K Cement, Srinagar
 Thermax Ltd., Pune
 Jindal Steel & Power Ltd., Raigarh, etc.

RTC has specialized packages / modules in Mining, Process,Maintenance disciplines

like Operation & Maintenance of HEMM / Gear-boxes / Pumps / Compressors /
Electrical & Electronics Equipments / Energy Conservation / Environment Management
and Machinery Alignment, etc. designed and developed by renowned International /
National agencies like FLS Denmark, NCCBM, TATA Interactive Systems, VEC,
NITTTR, etc. More than 100 senior line mangers from ten plants have been trained at
Denmark, NITTTR, Bhopal and Chennai, who act as resource persons for these
programs. Besides, OEM’s and management experts of national repute are invited for
various technical and management programs to make them effective and gainful
experience for the participants.

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5. CORPORATE SOCIAL RESPONSIBILITY

J K Cement has contributed significantly to the development of various services in and

around its offices and plants. Some of such activities can be enumerated as under :

 Education Schools and University

 Educational services
 Medical services
 Religious services
 Sports services
 Other social services

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6. INTRODUCTION TO CEMENT
6.1 HISTORY OF CEMENT

The history of cement is the story of civilization from primitive caves of pre-
historic times to the skyscrapers of the modern age. It is said that the use of cement is
form the period of use of fire. Egyptians utilized gypsum plaster as cementing material as
early as 3000 BC building their monuments.

However, It was in 1824, sixty-eighty years after the discovery of hydraulic properties of
lime Joseph Aspdin patented his product, which was called "Portland Cement" The plants
manufacturing portland cement outside England were commissioned in Belgium and
Germany in 1855. The interest that is evoked in the technology of cement resulted in the
development of Rotary kilns in 1886.

Modern cement is the outcome of the combined research and development efforts of
chemists, technologists and architects. The cement technology is an offshoot of the
overall development in other industries, technology, constructional activities and
knowledge and the availability of raw material.

6.2 DEFINITION OF CEMENT

Cement can be defined as any substance, which can join two or more pieces of some
other substance together to form a unit mass. Cement, as used in construction industries,
is a fine powder which when mixed with water and allowed to set and harden can join
different components or members together to give a mechanically strong structure. Thus
cement can be used as bonding material for bricks or for bonding solid particles of
different sizes (rubber masonry) to form a monolith.

Ordinary Portland Cement (OPC)

The most common type of cement used by concrete manufacturers is Portland cement,
which is prepared by igniting a mixture of raw materials mainly composed of calcium
carbonate or aluminum silicates. According to ASTM standard specification C 150,
Portland cement is defined as “a hydraulic cement produced by pulverizing clinker
consisting essentially of hydraulic calcium silicates, usually containing one or more of
the forms of calcium sulfate as an interground addition” . The phase compositions in
Portland Cement are shown below and they are denoted as tricalcium silicate (C3S),
dicalcium silicate (C2S), tricalcium aluminate (C3A), and tetracalcium aluminoferrite
(C4AF).

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Components of Portland Cement

Description Formula %Composition

Tricalcium Silicate(C3S) 3CaOSiO2 49
Dicalcium Silicate(C2S) 2Ca0SiO2 25
Tricalcium Aluminate(C3A) 3CaOAl2O3 12
Tetracalcium 4CaOAl2O3Fe2O3 8
Alumminoterrite(C4AF)

Composition of Ordinary Portland Cement:

Ordinary Portland Cement is the basic cement and it has three grades namely 33, 43 and 53
respectively. Limestone is the principal raw material for the manufacturing of cement. Our
country has enough reserve of raw material needed in the cement industry. Cement
consumption growth is highly correlated to the GDP growth and serves as a
leading
indicator. More industrial activity and greater purchasing power means more asset formation
and construction and thus more consumption of cement.

Ingredient Percentage Range

Lime 64 63-66
Silica 22 17-25
Alumina 5 3-6

Calcium sulphate 4 3-5

Iron Oxide 3 3-4
Magnesia 2 0.1-3.0

Sulphur 1 1-3

Alkalise 1 0.2-1.0

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 Advantages of OPC Cement

Develops early strength at 3 and 7 days with exceptionally high 28 days strength. Form
work of slabs and beams can be removed much earlier which results in increased speed
of construction.
 Unbeatable consistency in quality gives better accountability for mix design
 The higher characteristics strength of concrete leads to higher bond strength
minimizing the possibility of slippage of reinforcements.
 The dense and least permeable concrete prevents leakage / seepage problems.
 Its high fineness offers better workability for a given water cement ratio ensuring very
dense, compact and durable concrete.
Being the low alkali cement it provides insurance against alkali-
aggregate reaction,
this results in durable structures.

Hyd ration

In this experiment, the hydration rate for each type of tricalcium silicate component is measured.
Hydration is the reaction that takes place between cement and water that leads to setting and
hardening. All compounds present in Portland cement clinker are anhydrous, but when brought
into contact with water, they are all attacked or decomposed, forming hydrated compounds. When
the tri- or di- calcium silicates react with water a calcium-silicate-hydrate gel is formed.
This
calcium-silicatehydrate (C-S-H) is the principal hydration product and primary binding phase in
Portland cement.

The chemical reactions that take place during hydration are summarized below:-

Tricalcium Silicate (C3S)

2(3CaO-SiO2) + 6H2O→3CaO - 2SiO2–3H2O + 3Ca (OH)2

Dicalcium Silicate (C2S)

2(2CaO-SiO2) + 4H2O→ 3CaO - 2SiO2–3H2O + Ca (OH)2
Tricalcium Aluminate (C3A)
3CaO-A12O3 + 6H2O→ 3CaO – A12O3–6H2O
Tetracalcium Aluminoferrite (C4AF)
4CaO-A12O3 – Fe2O3+ 2Ca(OH)2 + 10H2O →3CaO – A12O3–6H2O+3CaO-Fe2O3-6H2O

16
Pozzolana Portland Cement (PPC)

It is cheaply manufactured because it uses flyash /burntclay/ coal waste as the main
ingredient. PPC has a lower heat of hydration which is of advantage in preventing cracks
where large volumes are being cast. PPC accounts for 18.3% of the production. Suitable
for most of the applications as stated in OPC ideally suited for domestic consumption like
plastering, brickwork, mass concreting works like dams, large foundation. This cement
enchances the impermeability and cohesiveness of concrete. As a result durability is
enhanced. It also generates low heat of hydration.

Portland Pozzolana Cement is manufactured by intergrinding well-burnt OPC Clinker

with 15 to 35 % Pozzolana and required percentage of Gypsum to the fineness of not
less than 300 m2 /Kg.

Portland Pozzolana Cement is new generation cement. It contains high reactive Silica
(HRS) to enhance ultimate performance of concrete. Pozzolana is essentially a siliceous
material in finely divided form with the presence of water, that react with Calcium
hydroxide at ordinary temperature liberated during the hydration of Portland Cement to
produce stable, cementitious compounds. These compounds contribute to strength and
water tightness of Cement and are specially suitable for Dams and mass construction
like foundation.

Advantages of PPC Cement

 Higher durability of concrete structure due to less permeability of water.

 More resistance towards the attack of alkalies, sulphates, chlorides, chemicals.
 Better workability.
 Low heat of hydration.
 Less Cracks.
 More resistance towards leakages.
 Due to more fineness, PPC have better cohesion with aggregates and make
more dense concreteness.
 Comparative lower Water-Cement ratio provides an added advantage for the
further increase of compressive strength of the concrete.
 Portland Pozzolona Cement has a lower specific gravity and therefore weight
for weight produce a higher yield of concrete.

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 6.3 TYPES AND USES OF CEMENT:
(a) Type of Cement:
 Grey Cement

 White Cement

(b) Uses of Cement:

Types of Cement Application

Ordinary Portland Cement (OPC) General construction

Portland Slag Cement General construction and marine works.

Portland Pozzolona Cement (PPC) General construction, hydraulic construction & marine.

White Portland Cement Architectural purposes, decorative work and in manufacturing

of titles.

Oil Well Cement Connecting the steel casing to the walls of gas oil wells at high
temperature and to seal porous formations in petroleum
industry.

Low Heat Portland Cement Where low heat on hydration is required as in mass concrete for
dams.

Super Sulphated Cement In a varity of aggressive conditions like marine works, concrete
sewers carrying industrial effluents.

High Alumina Cement Mainly as refractory cement and as structural material giving
high early strength development in cold regions.

6.4 TYPES OF PROCESSES

Basically there are two types of process for cement manufacturing that is

 Hydro Processing (Wet Process)

 Pyro Processing (Dry Process)

At JK Cement works we are using Pyroprocessing (Dry Process) for manufacturing

cement.

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6.5 PROCESS O VERVIEW
6.5.1 MINING OF LIMESTONE

In cement industry mining is one of the major aspect. Raw material (limestone) required
for the manufacturing of cement is extracted from captive mines. JK Cement have four
mines:
1. Ahirpura Mines
2. Malikhera Mines
3. Tilakhera Mines
4. Karoonda Mines

MINING METHOD
Limestone mining operation traditionally is carried out generally as Opencast mining in
India. However, newly developed Eco-friendly Surface Miners are also used in limestone
mines today in various cement plants. Mining methods includes the following activities:

 Obtaining approval from the government (regarding lease, environmental clearance

and license for explosives).
 Planning and executing a systematic exploration program.
 Draw scope of drilling campaign. How to carry out survey and perform drilling
activities for exploration purpose.
 Establish system for computerized mine-planning in order to ensure supply of
limestone with consistent quality.
 Planning and executing drilling and blasting programme in normal course at site to
take optimum output from blasting as well as achieving economy in explosive
consumption.
 Loading and transportation of lime stone boulders to crusher site.
 Implementing statutory requirement for safety and environment

Resources:

(a) Explosives

Kelvex 600

Ammonium Nitrate

(b)Equipment:

Drilling Machines- for making the deep holes for explosives. (Fig.1)

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 Excavators / Shovels- for loading the material in dumper. (Fig.2)

Dumpers- for transportation of raw material fro

m mines to crusher plant. (Fig.3)

Dozers-to remove the raw material and to clear the passage. (Fig.4)

(C) Operations:

Drilling and Blasting

Loading and transportation

Limestone from mines is explored by using drilling and blasting techniques. Drilling is done with
the help of DRILLING MACHINE and then explosive is inserted in hole and blasting is done.
Sequential Timer Blasting Machines are used for blasting operations. This timer machine reduces
the problem of noise, ground vibrations and improves fragmentation by introducing inter
row
delays. Noise, dust and illumination surveys are conducted at regular intervals in our mines to
keep the same under control. Instruments used for noise and surveys include Noise Dosimeter and
Gravimetric Dust Sampler respectively. Equipments used in this method of Open cast Mining
includes HM-25 dumpers, POCLAIN & DEMAGE shovels, Hindustan and BEML loaders,
BEMLl dozers etc. The limestone produced by this method are in the form of big boulders having
their physical dimensions may be from 1.5 meter to small fragment size up to few millimeters.
Therefore before taking the limestone to grinding machines, boulder crushing in one or two
stages is required for reducing the size of limestone for preparing suitable feed size to grinding
mills.

20
Fig.1 Drilling Machine Fig.2 Excavator

Fig.3 Dumper Fig.4 Dozer

21
MINING WITH SURFACE MINER

Surface miners were firstly developed for road making and are now used for limestone mining
operation also. Being eco friendly machine, Surface Miners eliminate the problems associated
with drilling, blasting, crushing & loading and the complaints associated with their activities.

The surface miner is a track-mounted machine with a powerful diesel engine and hydraulic
pumps for delivering the power to the cutting drum. The cutting drum is made up of a special
alloy steel with replaceable Tungsten Carbide cutting tools (spikes), which can be quickly
detached or fixed. The drum can be lowered or lifted by hydraulic system with powerful
hydraulic motors thereby varying the depth of cut. Dust is suppressed at the source itself by water
spraying on to the milling drum thereby making it an environment friendly machine. As the cut
materials are of uniform size and the impact on the crusher while crushing is reduced. Whenever,
there is an interstitial reject band encountered, the same is eliminated by loading and dumping it
separately in the specified dump thereby facilitating Selective Mining with this machine.

6.5.2 CRUSHING OF LIMESTONE

Crushing is the process of reducing the size of BOULDERS through crushers. The big
boulders produced during drilling and blasting methods of limestone mining are crushed
in suitable type of crushers. Crushers are of three types:

1. Double Toggle Jaw Crusher (Capacity : 400 TPH): Used as primary crusher.
2. Swing Hammer Crusher (Capacity : 200 TPH) used as secondary crusher.
3. Compound Impactor (Capacity : 800 TPH) combined unit of primary and
secondary crusher.
The crushing is carried out either in single or double stages by using Primary crusher and
Secondary crusher, or in a single stage crushing machine depending upon the size of the
boulder produced while mining. This also depends on the type of grinding mills used for
grinding of raw materials for preparation of finally pulverized raw meal. In our plant, we
have two types of crushers:

22
1. PRIMARY CRUSHER (ONE IMPACT CRUSHER)- Capacity 800 tonnes / hr.
(Fig.5)

2. SECONDARY CUSHERS (TWO HAMMER CRUSHERS)- 200 tonnes / hr.

(Fig.6)

Fig.5 Impact Crusher

23
 Fig.6 Hammer Crusher

These crushers are used for reduction of size of limestone boulders to a suitable feed size
acceptable to the different types of grinding machines installed in plants. The crushers are mainly
installed at the plant site. The limestone produced in the mine is transported to crusher site with
the help of dumpers and tippers of different capacities. In some mines the crushers are installed at
mine site and crushed limestone is transported to plant stockpile with the help of Belt conveyor/
Ropeway. Fig.7 below illustrates the raw limestone mining and crushing at a limestone mine of a
cement plant.

24
6.5.3 PREHOMOGENISATION

The crushed limestone is then transported to stacker reclaimer site with the help of BELT
CONVEYOR (Fig.8) installed at different plant site. Finally the crushed limestone is
pre-
blended with the help of stacker and reclaimer systems. The crushed limestone travelling on the
belt conveyors is stacked in layers through STACKER MACHINE (Fig.9) and PILES (Fig.10)
are formed. (Pile is the arrangement of one layer of raw material over the another in a
longitudinal form).The stacked materials is then cut in slices with the help of a RECLAIMING
MACHINE (Fig.11) which mixes the layers of stacked limestone which reduces the variation in
quality of limestone as compared to the large variations obtained in the limestone obtained from
mines. The full fledge stack pile ready for reclaiming and feeding to raw mill hoppers can be seen
in the above figure. In our plant at Nimbahera, we have the following type of stacker and
reclaimer:

Stacker:
 Type of Pile: Longitudinal.

 Details of Piles: 20000 – 30000 tonnes per pile. Height of pile up to 11.00 meters.
 Rated capacity: 1000 tonnes per hour. It varies from plant to plant depending upon the
production requirement.
 The stacker moves on longitudinal rails.
Reclaimer
 Type: Bridge Scrapper Type.
25
  Rated Capacity : 600 tonnes per hour It will vary from plant to plant depending on
the production requirement (in TPD).
 Working Principle: Cuts Stack Pile in slice from parallel to face of pile. Shifting
material
(limestone) to belt with the help of scrapper.

Fig.8 BELT CONVEYOR Fig.9 STACKER MACHINE

Fig.10 PILES Fig.11 RECLAIMER

6.5.4 GRINDING OF RAW MATERIALS

The pre-blended limestone from stack pile is transported to raw mill hoppers. More than
one hoppers are used for proportioning of raw mix in case the limestone is obtained from
more than one sources or purchased sweetener or additive materials are required to be
26
 mixed with captive mines limestone. Presently Raw mill hoppers are provided with
continuous weighing machines known as weigh feeders in order to produce a suitable raw
meal proportioned appropriately for production of desired good quality of cement clinker.
Vertical Roller Mill and Tube Mill Grinding machines are used for production of
pulverized raw meal in cements plants. Figure 12 presented below is a typical
representation of raw mill grinding section in a cement plant where raw mill hoppers,
vertical roller mill along with dust collecting arrangement can be seen.
At JK Cement Works, raw grinding is done with the help of two types of MILLS:

Fig 12: Raw Mill Grinding Section

1. VERTICAL MILL (ATOX MILL) (fig.13)

2. HORIZONTAL MILL (BALL MILL) (fig.14)

The feed size of the vertical mill is 40 mm and it saves 20% energy as compared to Ball
mill. The rotating size of Atox mill is 25-27 rpm. For ball mill the feed size is 25 mm. In
ball mill the material is grinded through the impact of balls inside the mill. The rotating
speed of ball mill is 16-17 rpm.

In our plant we have four mills codified as RM1, RM2, RM3, and RM4. The grinding
capacity of each mill is as follows:
 RM1-90 tonnes / hour.

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  RM2-110 tonnes / hour.
 RM3-110 tonnes / hour.
 RM4-200-210 tonnes / hour.

In case of raw grinding the fineness of output 20-24 % residue on 90 µ and 3.5 – 4.5 %
residue on 212 µ.

Fig.12 VRM (Atox Mill)

Fig.13 Horizontal Mill

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 6.5.5 HOMOGENISATION

The raw material grounded in the raw mill is thoroughly blended in C.F Silos of capacity
10000 tonnes or more. The blending is performed by introducing the compressed air and

sliding of bed of fine raw meal due to operation of different chutes for a certain interval
from C.F Silo to discharge bin. The characteristics of blending raw meal should satisfy
the requirement of standard deviation in the range of (+/-) 0.8 to 1.0 in LSF of raw meal.
The moisture content of raw meal powder is less than 0.7 %. The properly blended raw
meal is now ready for burning the same to produce cement clinker in cement rotary kiln.
The grounded raw material is sent to CF SILO (CONTINOUS FLOW SILO) (fig.14),
where the raw material is blended properly.

Fig.14 CF Silo

6.5.6 PYROPROCESSING

The modern pyroprocessing system comprises the following important three sections:
1. Preheating and precalcining.
2. Clinkerisation and
3. Cooling.
The PREHEATING section (fig.15) is 90-100 meters tall and comprises of battery of
cyclones arranged one over the other in series. The modern preheaters are comprising of
5-6 stage of low pressure cyclone as compared to conventional 4 stages of cyclone
preheaters. The riser ducts of top stage cyclones are connected with powerful induced
29
draft fan also known as preheater fan, smoke gas fan etc. Precalcining of raw meal is
carried out in separate vessel vertically held and placed in between preheating and
clinkerisation section known as Pre-Calciner.
The CLINKERISATION reaction is carried out in a ROTARY KILN (fig.16 & 16.a).
The rotary kiln is a long cylindrical shell provided with refractory bricks from inside
which prevents the heat loss from the kiln and protects the steel shell from any damage
due to exposure to high temperature maintained inside the kiln. The kiln is inclined at an
angle of about 3-4° from horizontal from preheating to the cooling end. The kilns are
mounted on tyres and rotated at a speed of 1.5-4.5 rpm depending upon type of kiln. The
dry and properly blended raw meal is lifted either by Air lift or mechanically by Bucket
Elevator from the bottom of raw meal blending / storage silo to the top of the preheater,
and fed at the top stage of cyclone inlet duct with the help of screw conveyor and rotary
air lock. Raw meal weigh-feeders are installed for continuous weigh of raw meal for
feeding the same to pre-heater at a constant rate.

Fig.15 Preheating Section Fig.16 Rotary Kiln

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CHEMICAL TRANSFORMATIONS
During heating of the raw meal to the burning temperature 1350oC to 1450oC (clinkerization or
sintering) certain physio-chemical processes take place. These include Dehydration of the
argillaceous minerals; decomposition of the carbonates (decarbonisation or expulsion of CO 2
commonly known as calcination); reactions in solid phase and reactions with the participation of one
liquid phase and crystallizations at the temperature range of 850 C -900 C.
o o

These processes are influenced by chemical factors in the raw meal (such as its chemical
composition), by mineralogical factors (its mineralogical composition), by physical factors (fineness
or particle size in the raw meal), homogeneity and other factors. The complete course of these
endothermic reactions plays a decisive role in quality of the resulting cement.

In pre-heater kiln, the first five transformations shows in figure 17 will take place in pre-heater
tower. The decomposition of limestone and other carbonates will primarily take place in the
calciner vessel where the calcination temperature is maintained by injection of fuel. The last two
transformations will take place in the rotary kiln.

The carbonate Ca CO decomposes between 800 C – 900 C to form CaO. Quartz and clay will
3
O O

have started decomposing slightly before that to liberate free reactive Al2O3and SiO 2

The CaO being formed at this stage, now reacts with SiO2to form C S and later with more CaO to
2

form C S. Some CaO will also react with Al O

3 2 3 and Fe O to form various intermediate
2 3

components such as CA, C A and others, which will decompose at higher temperature at later
12 7

stage.

C S content is seen to grow steadily during the heating and reach maximum content at approx.
2

1300 C which is a point where liquid phase appears. The major part of C S is then transformed to
O
2

C S in the liquid phase on further increase in temperature and the final content of C S in the
3 2

clinker is less than the content of C3S.

Combustible fuels eg., coal, liquid fuel oil, or natural gas are used for providing heat
for
converting raw meal into clinker.

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Our plant uses a mixture of petro coke (75-85%) and remaining coal obtained from
Indian / South African coal mines. The coal obtained in the form of lump containing upto
10% moisture is ground to suitable fineness in vertical roller mills or closed circuit tube
mills at different cement manufacturing facilities. The cooler exhaust/ part of preheater
gases are used for drying away the moisture from coal while grinding the same in the
airswept VRM or tube mills. The figure16 represents a typical pyroprocessing kiln with

planetary coolers in a dry process 4-stage suspension preheater kiln equipped with folax
cooler.

Conversion of raw meal into cement clinker is accomplished in steps in various zones of
kiln circuit. The pulverized fuel (about 35-40% of total fuel to be fed to kiln system) is
pushed into the burning zone of rotary kiln through a specially designed burner pipe
along with the primary air known as Primary air. The high temperature persisting in
burning zone makes the fine coal to burn near the tip of burner pipe and helps in flame
shape formation.
The combustion gases generated from burning of purlverized coal in clinkerisation zone
of the kiln flow towards the inlet of PH fan under the influence of the induced draft
created in the kiln circuit. While flowing from burning zone towards the inlet of fan after
passing through Kiln Precalciner–Preheater circuit, the high temperature combustion gas

transfer its heat to the finally derived raw meal which is fed to the inlet duct of 1st stage

twin cyclone and falls towards the bottom end of preheater after passing through all

stages of cyclones under the influence of hot gases flowing in the circuit. The moisture

and other volatile contents present are completely driven away and thus raw meal attains

a precalcination of about 35-40% before reaching the precalcining vessel installed in

between preheater and kiln. The precalciner is fired with 55-60 % of total pulverized fuel

for increasing the precalcination degree of raw meal upto 90-95% before the same is fed
to kiln for accomplishing the clinkerisation reaction. The remaining 5-10% degree of
calcination of raw meal is performed in the kiln before the meal enters in to the burning
zone. Thus burning zone in rotary kiln receives complete decarbonated material, the part
of which is transformed into liquid after achieving appropriate melting temperature of
some of the raw meal components and powdery form of raw meal gets converted into
nodulized clinker form. The final clinkerisation of raw meal is achieved between the

temperature range of 1350-1450oC depending upon the raw meal characteristics. The
high temperature clinker nodules varying in size then fall out of the kiln and enter the
32
 cooler and then COOLING of hot clinker is done. In our plant there are three kiln, out of
which 2 kiln are provided with planetary coolers and one kiln is equipped with Folax
grate cooler .The modern Folax grate coolers are provided with fixed and moving grate plates.
Below the grate are provided number of air chambers which receive atmospheric cold air with
the help of number of high pressure discharge fans in different compartments. The
pressurized air flows through the holes provided in the grate plates cools the clinker
which is travelling in the form of granules on the grate plates. The clinker is cooled down
to a temperature of 100-150oC while leaving the outlet end of the cooler. The cold
clinker is crushed continuously in a suitable clinker crusher provided at the outlet end of
the cooler before the same is discharged on the clinker transportation system for
transporting the same to clinker storage Silo stock/ Pile.

6.5.7 CEMENT GRINDING

In a modern cement plant, the total power consumption is about 70-100 Kwh / tonne
whereas cement grinding process accounts about 40%. The quality of final cement
product depends on operational mode and parameters of cement grinding plant.
Cement has to be ground fine enough to meet the requirements for strength properties
specified in current standards. As it takes quite long time to determine especially the late
strength, the hour –to-hour and day –to-day control of cement grinding has to be based on
cement fineness.
Strength development of concrete is the result of hydration of the particles. Smaller the
particles, larger the specific surface and faster the hydration. Particles coarser than 30–50
microns hydrate very slowly and will only affect late strengths. On the other hand,
superfine particle with 2-3 micron size may hydrate before the concrete has been cast and
will have limited influence on strength development.
Clinker from storage yard /CSP is ground in cement grinding mills along with
appropriate quantity of gypsum and other additive materials for production of finely
pulverized cement with desired fineness.

Fig.18: Cement Mill

33
 The Ball / Tube mills (in open circuit or closed circuit mode) are used for clinker
grinding in cement plant worldwide. However, the energy requirement of Ball Mills
being compartively higher for cement grinding, new types of energy efficient equipments
like Vertical Roller Mills, Roll Presses / Roller Presses in combination with Ball Mill /
Closed Circuit Ball Mills, Horro Mills etc., are now being used for grinding cement
clinker. Our plant is using ball mill grinding machines for cement grinding. We have 6
ball mills codified as CM1, CM2, CM3, CM4, CM5, CM6. The capacity of these
cement mills are as follows:

CM1 - 60 tonnes / hour.

CM2 - 70 tonnes / hour
CM3 & CM6 - 90 tonnes / hour in OPC and 95 tonnes / hour in PPC.
CM4 & CM 5 - 160 tonnes / hour in OPC and 165 tonnes / hour.

The cement grinding unit along with dust collector, cement storage silo and the despatch
section are illustrated in the figure 19.

6.5.8 CEMENT STORAGE PACKING & DESPATCH

The pulverized different types of cements are stored in different silos installed with
different capacities. Depending upon the market requirements the cement is loaded in
bulk or packed in 50KG bags with the help of conventional rotary packers or electronic
packers, loaded on to trucks / wagons and finally despatched to the required destinations.

Purpose:
To pack cement in appropriate packages suitable for consumption at site.

Common packs available:

Grey Cement:

 50 Kg bags
 Bulk handling of cement has started at selected places .Bulk cement loading in
close container is available at our Mangrol Plant
 White Cement:
 50 Kg and small size packs as per market demand

34
 Packers:
 Mechanical Packers
 Electronic Packers

In JK Cement, we have 6 mechanical packing stations with 12 spout each. The

four stations are used for PPC packing and two stations are used for OPC packing. The

cement is loaded in trucks and railway wagons and finally sent to destinations.

6.6 QUALITY CHARACTERISTICS OF CEMENT

The survival and well being of the cement plants / companies in the market depends upon
the quality of product and its cost. Quality and cost together define the value of the

product (i.e. cement in this case). The concept of quality has undergone a sea change
from mere quality control of the product to total quality management (T.Q.M.) with
emphasis on quality defined as “totality of features and characteristics of product /
services that bears on its ability to satisfy the stated and implied needs”

The quality of the product depends on variety of factors such as technology, quality of
raw materials and fuels, operation and quality control procedures to produced consistent
product.

The broad quality parameters of cement relate to chemical and physical properties as per
IS Code are as mentioned below:
CHEMICAL PROPERTIES:
 Loss on ignition [LOI]
 Insoluble residue [IR]
 Sulphur trioxide [SO3]
 Magnesium oxide [MgO]
 Total chloride [Cl]
 Lime saturation factor [LSF]
 Alumina modulus [AM]
.

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PHYSICAL PROPERTIES
 Fineness
 Consistency
 Setting time – initial and final
 Soundness
 Compressive strengths (3 days, 7 days and 28 days)
 Heat of hydration
 Drying shrinkage [for PPC]

7.0 CRUSHER, STACKER AND RECLAIMER

7.1 : CRUSHER

 Purpose:
Size reduction from 1.0M * 1.4M * 1.1M boulder to 25mm size limestone pieces.
 Daily requirement of crushed material:
1.6 to 1.7 times the production capacity of clinker (approx. 5600 tonnes per day
for 1.0 million tonnes plant).
 Common type of Crushers:
 Double Toggle Jaw Crusher (Capacity : 400 TPH): Used as primary crusher.
 Swing Hammer Crusher (Capacity : 200 TPH) used as secondary crusher.
 Compound Impactor (Capacity : 800 TPH) combined unit of primary and
secondary
crusher.

7.2 : STACKER & RECLAIMER

 Purpose:
 Homogenization of crushed lime stone.
 The stacker moves on longitudinal rails.

 Reclaimer Stacker:
 Type of Pile: Longitudinal.
 Details of Piles: 20000 – 30000 tonnes per pile. Height of pile upto 11.00 meters.
 Rated capacity: 1000 tonnes per hour. It varies from plant to plant depending upon the
production requirement

 Type: Bridge Scrapper Type.

 Rated Capacity :  600 tonnes per hour It will vary from plant to plant depending on
the production
requirement (in TPD
36
 Working Principle:
 Cuts Stack Pile in slice from parallel to face of pile.
 Shifting material (limestone) to belt with the help of scrapper.

7.1.A: DOUBLE TOGGLE JAW CRUSHER

37
7.1B : Swing – Hammer Crushers

Operating Principles:

As for the solid rotor impactor, this crusher type contains one or sometimes
two heavy rotors horizontally mounted inside a rigid frame, which is lines
throughout with replaceable liner plates.

7.1

7.2

38
Contrary to the solid rotor impactor, the rotor of the swing-hammer crusher is made
of a series of discs, between which the hammers are freely suspended. When the rotor
revolves at high speed, the hammers are flung outwards due to the centrifugal force.

The material is either fed to the crusher via a feed ramp, similar to the solid-rotor
impactor, via feed rollers – or entered directly on top of the rotor. The latter feed
arrangement is normally only applicable for low capacity, double –rotor machines
where the material is crushed against a centrally mounted anvil between the rotors.

When the feed material enters the crusher, it is initially struck by the hammer and
then projected against the breaker plates at the opposite side of the feed opening.

Advantages and Disadvantages:

The disc construction of the rotor allows undersize feed material to penetrate the
rotor, thus reducing the amount of material being hit by the hammers. Contrary to the
solid–rotor impactor, where the breaker plates normally are suspended from the roof
of the crusher, the breaker plates of a swing – hammer crusher are usually placed
directly on the crusher frame walls.

As for the solid–rotor impactor, a large material expansion chamber has to be

incorporated in the crusher design.

39
7.1C : Solid-Rotor Impactor Breakers

7.3

40
7.1D : GYRATORY CRUSHER:

41
42
8.CONCLUSION
The summer internship in JK CEMENT plant in Nimbaher was a great opportunity
to understand how manufacturing process of cement is done . On a personal front it
was an invaluable opportunity for me to have a practical experience of a cement
manufacturing plant.

9.REFERENCE
Books and Authors
 R G Blezard, The Hostory of Calcareous Cement in P C Hewlett
 A C Davis, Hundred Years of Portland Cement

WEB SITE

 www.jkcement.com
 www.rtcnorthindia.org
 www.crushermill.com
 www.mineral-grinder.com
 www.unique-machinery.com

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