An Internship Report

On

A STUDY OF CEMENT PLANT PRODUCTION AND

MAINTENANCE
Submitted to

MADANAPALLE INSTITUTE OF TECHNOLOGY AND SCIENCE

MADANAPALLE
In partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by

L. KARUNAKAR REDDY - 17695A0316

P. SAIPAVAN KUMAR - 17695A0335
Under the Guidance of
Dr.K. V. NAGESHA
Senior Assistant Professor
Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

MADANAPALLE INSTITUTE OF TECHNOLOGY & SCIENCE
(UGC - AUTONOMOUS)
(Affiliated to JNTUA, Ananthapuramu)
An ISO 9001:2008 Certified Institution, Accredited by NBA
ANGALLU, MADANAPALLE
2019 - 2020
 DECLARATION

by the B.Tech. Student

I/We hereby declare that the Project Work Report entitled “ A STUDY OF CEMENT PLANT
PRODUCTION AND MAINTENANCE ” which is being submitted to the Madanapalle
Institute of Technology and Science, Madanapalle for the award of the Degree of Bachelor of
Technology in “MECHANICAL ENGINEERING” is a Bonafide report of the work carried out
by me/us. The material contained in this Project Work Report has not been submitted to any
University or Institution for the award of any degree.

Register Number, Name & Signature of the Student(s):

(1) 17695A0316 - L. KARUNAKAR REDDY

(2)17695A0335 - P. SAIPAVAN KUMAR

Department of Mechanical Engineering

Place: MITS, Madanapalle

Date:
 Ph.08571-280255,280590 Fax: 08571-280433

MADANAPALLE INSTITUTE OF TECHNOLOGY & SCIENCE

(UGC – AUTONOMOUS)
An Engineering College Sponsored by
RATAKONDA RANGA REDDY EDUCATIONAL ACADEMY
Approved by AICTE, New Delhi and Affiliated to JNTUA, Anantapur
An ISO 9001:2008 Certified Institution
P.B.No-14, Angallu, Madanapalle -517325, Chittoor District, A.P.
www.mits.ac.in

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that this project report titled “A STUDY OF CEMENT PLANT

PRODUCTION AND MAINTENANCE” is the Bonafide work of ”L. KARUNAKAR
REDDY, P. SAIPAVAN KUMAR "bearing Hall Ticket Numbers 17695A0316,
17695A0335 who carried out the project under our supervision. Certified further, that to the
best of our knowledge the work reported herein does not form part of any other project report
or dissertation on the basis of which a degree or award was conferred on an earlier occasion on
this or any other candidate.

PROJECT GUIDE HEAD OF THE DEPARTMENT

Dr. K. V. NAGESHA Dr. T. N. Sreenivasa M.E, Ph.D.
Senior Assistant Professor Professor, Head & Dean
Dept. of Mechanical Engineering, Dept. of Mechanical Engineering,
MITS, MITS,
Madanapalle. Madanapalle.
Internal Examiner External Examiner
 Department of Mechanical Engineering

PLAGIARISM VERIFICATION CERTIFICATE

This is to certify that the B. Tech Project report titled, “A STUDY OF

CEMENT PLANT PRODUCTION AND MAINTENANCE” submitted by Mr.
L. KARUNAKAR REDDY (Regd. No: 1795A0316), Mr.P. SAIPAVAN
KUMAR (Regd. No: 17695A0335), has been evaluated using Anti-
Plagiarism Software, URKUND and based on the analysis report generated
by the software, the reports similarity index is found to be 9%.

The following is the URKUND report for the dissertation consisting of ……

Pages.

Plagiarism Incharge
 ACKNOWLEDGEMENT

We sincerely thank the MANAGEMENT of Madanapalle Institute of

Technology and Science for providing excellent infrastructure and lab
facilities that helped me to complete this internship.

We express our sincere thanks to Dr.K.V.Nagesha our guide for his extra
support, critical guidance, encouragement and constructive advice throughout
the internship that helped us to complete this internship.

We are thankful to our company guide K. Sisindra kumar reddy, Senior

Divisional Manager and M. Ravindra Kumar, Chief Manager Hr &
Admin for their guidance and suggestions in analyzing and testing thoroughly
the period of our work.
We sincerely thank Dr. C. Yuvaraj, Principal for guiding and providing
facilities for the successful completion of our project at Madanapalle Institute
of Technology and Science, Madanapalle.

We express our deep sense of gratitude to Dr. T. N. Sreenivasa, Professor,

HOD & Dean of Mechanical Engineering for his valuable guidance and
constant encouragement given to us during this work.

Last but not least we extend our gratitude to all the staff of Bharathi cement
plant, being so helpful during the internship.

ABSTRACT
Bharathi Cement is one of the India's largest cement manufacturing producer with a
manufacturing capacity of 5 million tons per Annum. Among the cement producing
plants of AP cements is at the premium brand. Bharathi cements ranks among the
most modern equipments in the manufacturing process.

The Bharathi Cement plant has the most advanced vertical roller mill of (type 63.3)
from LOESCHE the world's best mill, Germany. This mill has capacity of producing
360 tons per hour and is equipped with a 6700KW motor and drive system.
Bharathi Cements consists of 2 lines, line 1 producing a capacity of 5250 tons per day
and line 2 producing a capacity of 5500 tons.

The main aim of this project is Observing and study about the all processes which are
involving in the cement manufacturing. Those processes are crushing, storing and
reclaiming, raw mill grinding, Pre heating, Cooling, Cement mill grinding, Storing,
Packing and Dispatching.

Among the all process in raw mill grinding process there is one problem occurred.
Due to this the hoses are not in position to supply pressurized oil because of leakage.
If thin film is not formed the smooth motion of table does not takes place and remove
the thin coated material. To changing the thrust pads is more costly process.

To find out the solution for the problem by using the Fish bone diagram and make a
table for easy understanding.

II

TABLE OF CONTENTS
CHAPTER NO CONTENTS PAGE
NO

CHAPTER – 1 INTRODUCTION 1-5

1.1 Company Profile

1.2 Introduction to BCCPL
1.2.1 Types of cement
1.2.2 Composition of Cement
1.2.3 Plant location

CHAPTER – 2 LITERATURE SURVEY 6-8

2.1 Literature survey-1

2.2 Literature survey-4
2.3 Literature survey-3
2.4 Literature survey-2

CHAPTER – 3 OBJECTIVES 9-12

3.1 The main objective of this project

CHAPTER – 4 CASE STUDY OF PROCESSES IN BCCPL 13-22

4.1 Crushing
4.2 Storing and Reclaiming
4.3 Raw mill grinding
4.4 Pre-heater
4.5 Cooling
4.6 Cement mill grinding
4.7 Cement storage
4.8 Packing and dispatching
4.9 Details of processes and their parameters

CHAPTER - 5 CONCLUSION AND FUTURE SCOPE

5.1 Conclusion 21
5.2 Future scope
CHAPTER – 6 BIBLIOGRAPHY 23-24
III

CHAPTER – 7 REFERENCES

LIST OF FIGURES
FIGURE NO FIGURE NAME PAGE NO

1.2.1 Bharathi cement industry

1.2.2 OPC Cement
1.2.3 PPC Cement
4.1.0 Working process in industry
4.1.1 Fish bone diagram about crushing process
4.2.1 Fish bone diagram about storing and reclaiming
4.3.1 Vertical roller mill
4.3.2 Fish bone diagram about vertical roller mill
4.3.3 Damaged hoses
4.3.4 Removal of damaged hoses
4.3.5 Single and Double hose pipe holders
4.3.6 Welding of clamps
4.3.7 Clamp fixed to lubrication pipes
4.3.8 Fixing of clamps
4.3.9 Clamps using to hold 3 pipes
4.3.10 Top view of clamps arrangement
4.3.11 External view of metallic pipes
4.3.12 Metallic pipes passing into gear box
4.3.13 Reduced the length of hoses
4.3.14 Hole drilled away from thrust pads
4.3.15 Hoses comes aside from thrust pads
4.3.16 Total view of thrust pads before replacement
4.3.17 Total view of thrust pads after replacement

IV
CHAPTER 1

INTRODUCTION

1.1 Company Profile:

Cement, in the most general sense of the word cement is a binder, a substance
that sets and hardens independently and can bind other materials together. In 1817
Louis Vicat discovered artificial cement. Cement industry is the 2nd highest revenue
contributor in terms of excise duty, Rs.4000 crore per annum. India is the rd largest
producer of cement in the world with state-of-art technology, comparable to the best
in the world and with most efficient parameters. Also cement industry has invested Rs
35000 crore of capital by the way of share holders stake and debt from public
financial institutions. This industry employs over 1.5 lakh workers directly and 13
lakh workers indirectly. Cement in this way strengthens the nation core. Top 5
companies which control more than 50% of the market in the country are —Bharathi
Cement Corporation Limited, Ultra Tech Cement Limited — Adithya Birla Group,
Gujarat Ambuja, Grasim (ABG) and India Cements.

The latest of the plants commissioned by Bharathi cements Corporation

Limited has setup most modern cement plant with the state of art technology in
kadapa district with superior quality cement setting new standards in construction.
The plant has been certified as ISO 9001(2007), ISO 14001 and OHSAS 18001
company by TUV Rhineland.

The location of the plant is known for its superior quality Narzi limestone
deposits, processing high lime content that gives high early strength and ultimate long
term strength. Another characteristic feature of this limestone is low alkali and
magnesia and low chloride contents which are highly desirable parameters for
concrete durability.

1
This cement unit has advanced instrumentation systems, Robotic Quality
Control with online quality control by XRD and XRF. This plant is Eco-friendly with
elaborate pollution control facilities like electro-static precipitators, reverse Air Bags
houses, dust filters and vast areas of green belt. BCCL manufactures all types of
blended cements which are distributed through a wide network, authorized stockiest.

1.2 Introduction to Bharathi cement corporation private limited [BCCPL]:

Bharathi Cement is one of the India's largest cement manufacturing producer

with a manufacturing capacity of 5 million tons per Annum. Among the cement
producing plants of AP cements is at the premium brand.

Bharathi cements ranks among the most modern equipments in the

manufacturing process .The state of art technology adopted at the plant consists of
vertical roller mills of LOESCHE ,Germany for grinding of cements to achieve
optimum fineness , and controlled particle size distribution of cement particles.

The Bharathi Cement plant has the most advanced vertical roller mill of (type
63.3) from LOESCHE the world's best mill, Germany. This mill has capacity of
producing 360 tons per hour and is equipped with a 6700KW motor and drive system.

Bharathi Cements consists of 2 lines, line 1 producing a capacity of 5250 tons

per day and line 2 producing a capacity of 5500 tons.

Among all other cement plants, this plant consists of largest cement mill
producing 360tons capacity per hour. In case, if the cement mill is not in proper
working condition it consists of two other cement mills of capacity 230 tons capacity
each.

This cement unit is dry process plant incorporating pre- claimer technology,
advanced instrumentation systems, computerized process control along with robotic
quality control by XRF and XRD ensuring consistently high quality. The process
parameters are monitored and controlled by computer based systems.

2
Bharathi cements are eco-friendly with elaborate pollution control facilities
like ESP, Bag houses and dust filters. The captive mines adjacent to factories supply
high-grade limestone. The cement plant strictly follows the EMS and OHS standards.
  Homogenized mining
 Online process control
 Exclusive R&D facility for continuous product improvement

VRM Cement mill-The Largest in the world. Loesche vertical roller mills are the
most efficient mills in the world and achieve very high throughputs. They are
extremely maintenance friendly. Service tasks can be carried out quickly .Downtimes
are reduced to a minimum.

The Loesche grinding principle combines a horizontal grinding table with a large
tapered roller under hydro-pneumatic loading-the best possible compromise between
output and wear. The product quality can be enhanced by altering the classifier speed.
All Loesche mills can be started with grinding rollers raised. Metal to metal contact
between grinding parts does not occur. Their quiet smooth operation is appreciated.

Fig.1.2.1 Bharathi cement industry

1.2.1 Types of cement:

The different products of Bharathi cements include

1. Ordinary Portland Cement (OPC)
2. Portland Pozzolana Cement (PPC)
3. Portland Slag Cement (PSC)
3
Ordinary Portland Cement:

OPC is the most commonly used cement for a wide range of applications.
These applications cover dry- lean mixer, general purpose ready mixer and even
high strength pre cost and pre stressed concrete.

Fig 1.2.2 OPC Cement

Portland Pozzolana Cement:

Portland pozzolana cement is ordinary Portland cement blended with

pozzolana materials (PowerStation fly, burn clays, ash from burnt plant material or
siliceous earths), with together are separately. Portland clinker is ground with gypsum
and pozzolana materials which, through they do not have cementing properties in
themselves, combined chemically with Portland cement in the presence of water from
extra strong cementing material which resist wet cracking, thermal cracking and has a
high degree of cohesion and workability in concrete and mortar.

Fig 1.2.3 PPC Cement

1.2.2 Composition of cement:
4

Type of Silica (%) Alumina (%) Ferric oxide Calcium Oxide

cement (%) (%)
OPC 20-21 4.5-5.5 3.5-4.5 62.5-63
PPC 25-26 4-4.5 3-3.5 59-60
PSC 23-24 4-4.5 3-3.5 55-57

1.2.3. Plant Location:

This the plant location of the BCCL

 Plant is located at the kamalapuram mandal.

 Located at the border line between anantapur and Kadapa districts.
 43 kms from Kadapa city.
 16 kms from the nearest town yerraguntla.

 Railway siding served by the railway station between yerraguntla and

kamalapuram on the guntakal – Chennai line.

CHAPTER 2
LITERATURE SURVEY
.
2.1 Literature Survey-1
Pradosh Nath and P.R. Bose (2002) have attempted to study about Indian
Cement industry in the context of globalization and liberalization and have argued
that there is a limit to leveraging liberalization. In their article ‘Leveraging
liberalization - The case study of Indian cement industry’, have argued that both
the developed, developing alike globalization/liberalization continued to be the most
debated economic and political issue of the past couple of decades.
Both theoretical and empirical articulations of globalization in recent
decades have dampened the enthusiasts a bit and strengthen the voice of dissent. They
argued that both capacity and production in cement industry in India were doubled by
1990’s.This achievement can be attributed to the technology up gradation drive taken
up from 1984. They also prove that Indian cement industry could not capitalize on its
early advantage over late entrance like Thailand, Indonesia and China. [1]

2.2 Literature Survey-2

Susmita Das Gupta (2002) in his discussion paper,
'Globalization and cement industry’, argue that threat of MNC’s is not a sufficient
cause to assign to the decline f cement industry. But it is because of weakening of
rupee via the dollar. According to the author the fact that Indian companies are unable
to sell across to the developed countries is because they lack the right networking and
trading arrangements. Globalization is more a matter of adequate networking as it is a
matter of technology and pricing. Thus, the role of globalization is highlighted in
achieving a good performance in cement industry in India. Finally the author
suggested keeping liberalization alive without globalization . [2]

2.3 Literature survey-3

Cement industry before and after de-control. The objective of his
study includes,
6
1. To estimate the level and growth of capital stocks, input and value
added during different phases of growth of cement industry between the year (1943-
94). 2. To estimate the change in capital output ratio overtime and make an
attempt to locate the factors responsible to change in it.
3. To highlight the impact of changing pattern environment on the level
and growth of productivity and efficiency in the industry during 1943- 94. 4 To
examine the change in input-outputs relationship to policy change in the industry.

2.4 Literature Survey-4

Sharma, P.V, Y.V Apparao (1990) in their article titled 'Indian
Cement industry - Regional Analysis’, explained about the determination of location
of cement factories, growth of cement industry and efficiency of cement industry in
India with reference to different regions. According to them location of cement
factories depend on factors such as,
a) Proximity to limestone deposits,
b) Nearness of steel plants, thermal power plants, etc., procuring of
supplementary raw materials like granulated blast furnace, slag and fly ash,
c) Proximity to sources of coal and gypsum, availability of uninterrupted
power at lower costs,
d) Connection to the railway transport and nearness to the cement
consuming centers Rakesh Kumar (2003) has made an attempt to find the performance of
.

CHAPTER 3
OBJECTIVES:
3.1 The main objective of this project:

 To analysis the technological changes in the cement manufacturing industry.

Studies were completed about the technology what is in the cement industry.
process to process how the technology involve in the systems were studied.
Then studies were completed about this technology helps to increase the
production or not.

 To observe the manufacturing process one by one. studies were completed on

how the material is converted from raw material to finished product. Processes
were observed and discussed.

 Maintenance of different processes in the plant. There is lot of processes in the

plant. In every process there is a lot of systems are installed. Every system is
maintained must should. It helps to increase the performance of the system.

 To inspect various machinery and if the machine is not working properly then
fixing the problem or replacing the damaged part should be done. When the
problem is not identified the damage occur in the machine. It is more
dangerous to the machine.

 To give the new solutions if there is any problem is occur in the plant or give
the new ideas for the plant implementation.

 Observing the steps involved in the manufacture of cement are as follows.

1. Crushing
2. Storing and reclaiming
3. Raw mill Grinding
4. Pre heating
5. Clinker formation
6. Cooling
7. Cement mill Grinding
8. Packing and dispatch
8
These processes were studied completely. The problems were
identified and given the solutions for the problems with references. Each problem
which is occurred in the different process were studied and modified.

CHAPTER 4
CASE STUDY OF PROCESSES IN BCCPL:

4.1.0 Working process in industry

Process description:
The steps involved in the manufacture of cement are as follows.
 Crushing
 Storing and reclaiming
 Raw mill Grinding
 Pre heating
 Clinker formation
 Cooling
 Cement mill Grinding
 Packing and dispatch

4.1 Crushing:

The lime stone which is obtained from the mines is crushed by means of
impact crusher. The crusher10here used is BCCPL made APPM 2022 impact crusher.
Its capacity is 1000 tones per hour. The maximum size it could in take is 1 cubic
meter. The feed is maintained up to a level of 1 .5m in the apron feeder to minimize
the impact on the conveyor belt. The maximum size of the limestone at this output is
 100 mm. the main advantage of this type of crusher is that the blow bar could be used
at the either of the face sides. The crushed lime stone is taken to stacker and reclaimer
with the help of belt conveyors.
The belt conveyors used here has a ply rate of 6 and with a speed of 2.65
m/sec. the largest conveyor used in this plant has a total length of 400m.No remarks
in the crushing section.

MATERIAL MEN

Shifts
Lime stone Training
Operators
CRUSHI
NG
LIME
Humidity Crusher feed-1000t/h Jaw crusher APPM STONE
Crusher output-100mm Cone crusher
Temperature Conveyor speed-2.65m/s Belt conveyor

ENVIRONME MEASUREMENT MACHINE

4.1.1 Fish bone diagram about crushing process

4.2 Lime stone storing and reclaimer:

It is a place where the raw limestone from the crusher is stored. Here
circular homogenization operation takes place. The stacker has a capacity of 60, 000
tons.

11
 MATERIAL MACHINE

Iron Ore Stacker

Lime stone
STACKIN
Bauxite Reclaimer
G AND
RECLAIM
Humidity Stacker cc-60,000tons ING
Weather Conveyors ply rate-4
Temperature Conveyor speed-2.65m/s No man power is used

ENVIRONMENT MEASUREMENTS MEN

4.2.1 Fish bone diagram about Storing and Reclaiming

Reclaiming operation of lime stone is conducted by means of a scraper bridge

and reclaiming system conveyor. The raw materials iron ore, limestone, bauxite are
taken to feeding hoppers through belt conveyors which has a ply rate of 4 and a speed
of 2.65 m/sec. No remarks in the storing and reclaiming section.

Feeding hoppers:

There are 4 feeding hoppers, two for each raw mill. The two hoppers are
meant for lime stone one for iron ore and bauxite and another for low grade lime
stone. It is fed to the raw mill with the help of weigh feeders. The feeder provides a
control over the feeding. The feed goes to the raw mill through belt conveyors. If
there is any material, it is detected by metal detector and is taken off by a magnetic
separator. No remarks in the feeding hoppers.

4.3 Raw mill grinding:

A raw mill is the equipment used to grind raw materials into "raw mix" during
12
the manufacture the cement. Raw mix is then fed to a cement kiln, which transforms it
into clinker, which is then ground to make cement the cement mill.
 The raw milling stage of the process effectively define the chemistry (and
therefore physical properties) of finished cement, and then it has a large effect upon
the efficiency of the whole manufacturing process.

Material is fed to the mill through an inlet chute from here the material drops
down on the grinding table and flows onward to the grinding truck where material is
ground as a result of the contact pressure and size between grinding rollers and
grinding track and ultimately due to the centrifugal force.

Ejected outer edge of the grinding table the hot air stream from the inclined
ducts is the nozzle ring and carries the ground material up to mill housing the tailings
are re-circulated to the grinding track for additional grinding where as the fines are
routed up to the separator.

The grinding material is routed through the guide vanes of the separator and
into the rotor of the separator the function of the guide vanes is to ensure an even
distribution of the material across the entire height of the rotor and at the same time
effective perspiration of grinding material by bringing the material mixture of air and
grinding material into rotation.

While the fine fraction passes through the rotor with subsequent discharge
through the outlet, coarse particles on impact with the rotor blades in the direction of
guide vanes and discharged in to the cone under the rotor from here they are returned
through the cone valve to the grinding table for additional grinding.

13
 4.3.1 Vertical roller mill

The fineness of the finished product can be adjusted by changing the rotor
speed the fine which is obtained from the top of the raw mill goes to cyclone where
the powdered material comes down and it taken to Blending Silo through bucket
elevator. The dust is taken to reverse air bag house (RABH).

While grinding the temperature in the raw mill increases due to hot air from
pre-heater fan gases, water is sprayed into the raw mill to an optimum level to control
the material bed thickness.

Problem in vertical roller mill:

Due to this the hoses are not in position to supply pressurized

oil because of leakage. To avoiding the damage of thin film on the thrust pads. If thin
film is not formed the smooth motion of table does not takes place and remove the
thin coated material. To changing the thrust pads is more costlier process.
14
 MATERIAL MEASUREMENTS

Thrust pads Vertical mill feed-210t/h

Hose pipes Gears-6 OIL
Clamps Hose pipes-12 LEAKAGE
Rubbing action of pipes Damaged pipes-5, 6 &7 IN
VERTICAL
Hose pipe length-15m&20m
ROLLER
MILL
Inspection Vertical roller mill
Humidity
Replace parts Gear box Temperature
Weather conditions

MEN MACHINES ENVIRONMENT

4.3.2 Fish bone diagram about Vertical roller mill

Solution for the problem:

Steps involved to preventing the oil leakage problem in the vertical roller mill.
1. Modification of thrust pad hoses due to frequent damage of hose
pipes.
2. Arrangements of clamps to the gear box
3. Replacement of hoses with metallic pipes to reduce the leakage of
oil.

1. Modification of thrust pad hoses due to frequent damage of hose pipes:

In previous hose piping is arranged inside the gear box system. Each
thrust pad consists of a hose pipe these are 12 in number which are connected
individually. Due to the vibrations occurred in the gear box wear and tear occurs
on the pipes as they are 15
placed or contacted with the surface.

This rubbing action takes place continuously finally leads to the

damage of hose pipes.
 Fig 4.3.3 Damage of Hoses
Due to the damage of hose pipes the pressure gets leaked and sufficient
amount of pressure doesn't leads to the thrust pads. So film will not be formed
between the thrust pads and table and friction takes place between thrust pad and
table. If this action takes place continuously thrust pads got damaged. To replace this,
it is costliest affair and to get the new thrust pads with same specifications it takes
longer time.

These thrust pads are imported and the lead time to get them from Germany is
12 months. When damage takes place these requires the stoppage of the mill for
longer time. This problem can only be solved by pulling out the gear box and change
the hose pipes. The removal of the gear box is costly affair and involves an amount of
Rs30 lakhs and also stoppage of 15 days production.

4.3 STEPS INVOLVED IN THE REMOVAL OF GEAR BOX

In order to remove gear box from the raw mill it
includes various steps 16
 This is the initial external view of gear box which is
equipped with motor.
  The motor is directly coupled with input shaft
 This input shaft is connected with planetary gear
box
 This motor supplies the required power to run the
gear box.

To open top flange:

 These are the super bolts through which top flange
is attached to grinding table.
 Generally super bolts are 16 in number.
 In order to remove top flange these bolts should be
removed.
 These bolts are internally connected, by removing
these bolts only we can remove top flange.

jacks arrangement:
 After removal of super bolts jacks are fitted and
pressed this creates space between grinding table
and gear box.
 If this jacks are not used the gap between grinding
table and gear box cannot be created.

17
View of gear box with grinding table:
 From this figure it is seen that there is gap between
gear box and grinding table by fitting jacks.
 As there is gap between the two, it is easier to pull
the gear box out of the raw mill section.

Hole on the grinding table

 There exists a hole on this table which is used for
placing the supporting pillars.
 Initially the holes are closed after creating the space
only these holes are opened.
 Throughout the gear box 3 holes are present each at
120 degrees.

Supporting pillars arrangement

 These are supporting pillars which are placed in the
holes of the grinding table.
 The supporting pillars must be fitted correctly
inside the hole.
 The grinding table stands on the pillars placed
 As the grinding table is on the gear box, if it is
taken out it is difficult to withstand so it is mounted
on 3 pillars.
Pulling out the gear box
 After placing the supporting pillars the gear box can
be removed easily.
 Pulling out the gear box is difficult as it weighs
about 100 tons.
 So it is pulled by 18
using chain drives and using
cranes attached to drives.
Dummy plate removal:
 After removing gear box outside, at the top of gear
box one dummy plate is attached.
 In order to take out the dummy plate out of the gear
box 3 eye bolts are fitted on the plate.
 To this eye bolts chains are attached and dummy
plate is lifted up by using cranes.

Lubrication arrangement to the gear system:

 This is the view of lubricating pipes to the planetary
gear system.
From these pipes low pressure oil is supplied to the gear
system for lubrication purpose.

Removal of lubricating pipes

 The lubricating pipe connections are removed from
the gear box.
 The connections are taken out in order to view the
thrust pads which can be seen only after pulling out.

Planetary gear system:

 There are totally 6 planetary gears which are
arranged on top flange of gear box. This gearing
system is fitted inside the sun gear, with the input
shaft the power is transmitted to the grinding table.

19
Arrangement of sun gear:
 The smaller is called as the sun pinion which
transmits the motion to the planetary gear meshed
to it. The larger one called as sun gear which acts as
the housing between thrust pads and planetary gear.

Thrust pads arrangement:

 This is the arrangement of thrust pads inside the
gear box.
 12 thrust pads are arranged as shown.
 The planetary gearing system also is as shown.

Central distributor entry:

 All the 12 hose pipes enter into the gear box
through this entry.
 These hose pipes are intern connected to the thrust
pads.
 Each thrust pad is connected to an individual hose
pipe.

After opening of the gear box, the damaged hose pipes are identified actually
major damage occurs in 5, 6&7 thrust pad hoses as these travel longer distance from
central distributor entry. The damaged hose pipe connection is removed from central
distributor entry and thrust pads.

20
 Fig 4.3.4 Removal Of Damage Hoses
In place of damaged hose pipes new hoses are replaced and the gear box is
rearranged as per initial arrangement.

The steps for fitting the gear box in its original position are vice versa as that
of opening of gear box.

Precautions to be carried while placing the gear box in its initial position:
 Any existing dirt must be removed when it is exposed to the atmosphere dust
particles on the thrust pads must be removed while closing the gear box unit
after modification.
 After completion of work with the turning attachment the chain must be
removed again. All safety precautions have to be repeated in order to ensure
perfectly safe normal operation of the drive unit.
 All work must be carried out with great care and with due regard to safety.

The gear box is placed in its original position, by removing pillars which acts
as support to the grinding table
21 in place of gear box. The motor is connected as per
initial arrangement.

The whole operation is costlier and also difficult as it requires extra machinery
like crane 'chain pulleys, hydraulic jacks and other tools to remove gear box as it is
huge equipment. To perform this operation it is not only difficult but also it requires
stoppage of mill at least 15 days, if continuous work is carried out with additional
workers and technicians.

Stoppage mill is great loss to company, additional salary has to be paid by the
company to technicians and it is also unsafe to workers in lifting gear box by cranes.
The company has to bare the loss of nearly 30, 00,000/- and also have to pay the
additional amount to the service engineering from LOESCHE Company, who have
solved the problem. The same problem has risen frequently for every six months or 1
year.

2. Arrangements of clamps to gear box:

To rectify this problem LOESCHE Company has suggested a proposal .The

reason for the damage of hoses is direct contact between pipes and gear box. During
the operation due to vibration occurring in the gear box the hose pipes inside the gear
box wear and tear occurs.

The problem can be solved only by avoiding the contact between hose pipes &
gear box. Now the proposal by LOESCHE Company is that , instead of leaving hose
pipes on the surface of gear box they are lifted up and holded by the clamps which are
arranged at certain distance from the surface away from the gear box.

These clamps are placed at various places from central distributor entry to the
every thrust pad without touching the sides and surfaces.

The clamps must be fitted correctly in such a way that during operation it
should avoid contact between side and surfaces. The clamps used in this operation
should not have any mechanical deviation.

22
 Fig 4.3.5 Single & Double Hose Pipe Holders

These are the clamps that are used for holding hose pipes away from the gear box.

8.3 Types of clamps:

These are of two types:

1. Single Hose Pipe Holder
2. Double Hose Pipe Holder

23
 Fig 4.3.6 Welding Of Clamps

These are the metallic pipes attached to the gearing system and thrust pads. To
this metallic pipes clamps are fixed without touching the surfaces.

24

Fig 4.3.7 Clamps Fixed To lubrication pipes

 This is the arrangement of metallic pipes which are attached to the gearing
system and thrust pads.

Fig 4.3.8 Fixing Of Clamps

From the central distributor entry total 12 hoses divided into two directions, 6
for one side and other 6 for the opposite side. Here 6 hoses must be hold by using 3
clamps each holding 2 hose pipe without touching sides.

25
Fig 4.3.9 Clamps Using to Hold 3 Pipes

This is the internal arrangement of central distributor of hoses from which 6

are connected to one side of thrust pads and remaining for the other thrust pads.

The clamps are arranged in different positions so that they prevent the hoses
touching the gear box.

Fig 4.3.10 Top View of Clamps Arrangement

 This is one type of modification by which we can increase life of hoses, but
the problem cannot prevented permanently there is a chance of repeating the
problem.
 If at all the clamps are not arranged properly (or) the clamps do not having the
withstanding capacity due to the large vibrations occurred during operation.
Due to these reasons the problem may repeat again.
 Additional problem also occurs if the nuts& bolts used in the clamps to hold
the hoses may fall into the gearing system of gear box.
 If this happens the total gearing system will get damaged and gearing system
must be changed.
 The change of gearing system costs about 10 crores which create a great loss
and time taking as it is to be supplied from LOESCHE Company in Germany.
 If the damage of hoses occurs again the only solution to solve the problem is
26
to drag out the gear box and change of hoses must be carried out. This create
the problem again even after modification I.
 So, in order to solve the problem permanently, modification 2 is proposed.
3. Replacement of hoses with metallic pipes:

If the hoses are arranged outside the gearbox system, the main
problems which occur are:
1. Due to the continuous expose to sunlight and facing different environmental
conditions the hoses get damaged frequently, so in place of hoses metallic
pipes are arranged which serve the same function as that of the hoses. This is
one problem for changing the hoses to metallic pipes.
2. The life span of hoses will be less when compared to metallic pipes. And
hoses composition is not known as they are supplied from Loesche Company.
3. To have these hoses we must again order to the German company it takes time
and also costlier of about 2 lacs. Metallic pipes are lower in cost than hoses.
Generally the material used for metallic pipes are seamless stainless steel.
4. If the hoses are placed outside the gear box to hold the hoses more number of
clamps are to be arranged. But for metallic pipes these more number of clamps
is not necessary as that of hoses.

There is a chance of cutting the hoses easily. Compare to hoses the metallic pipes
are stronger and are difficult to cut. The length of flexible hose pipes is between 500
to 600mm.

 Metallic pipes should have resistance capacity.

 They should resist severe atmospheric conditions.
 Cost should be reasonable.
 The pressurized oil coming from the motor should be supplied to each thrust
pads at the same levels.

Process of arranging metallic pipes outside the gearbox

27
Previously central distributor entry is placed inside and outside of gearbox.
But now the inside central distributor entry is completely closed. Only from the
outside central distributor the metallic pipes connected to the individual thrust pads.
In such a way six from one side and remaining six from other side.

Fig 4.3.11 External View of Metallic Pipes at CDE

The seamless metallic pipes should be in such a way that it should pass the
circular shape of the gear box. To hold these metallic pipes in between the gear box
suitable holders are placed, which holds the pipes in position. At every place of thrust
pad a hole must be drilled to the gear box to send the metallic pipes inside the
gearbox.

The hole is drilled with the help of magnetic drilling machine. The magnetic
driller sticks to the gear box due to its magnetic properties. So this must be placed in
position where exactly the hole must be drilled for connection of pipes from outside to
inside thrust pads.

The metallic pipes used in this process are generally of12 mm diameter and
maximum length of 2m.inorder to supply the pressurized oil to the 6th thrust pad from
28 at least 2m length. To the gear box an 18 mm hole is
the initial position it requires
drilled at every place of connection to the thrust pads.
 To this 18 mm holes fasteners with washers are provided at both inside and
outside of gear box. During operation the thrust pads always tilts so these thrust pads
are also called as tilting pads.

As these are in always tilting position the pressure supplying pipes to the
thrust pads needs high flexibility which can be obtained from hoses not by metallic
pipes.

The pressurized oil is supplied to the thrust pads with the help of metallic
pipes from outside central distributor entry and by hoses which are arranged from the
drilled holes, reducing the length of the hoses, avoiding the contact with the gear box
surface with higher flexibility satisfying the function.

Fig 4.3.12 Metallic Pipes Passing Into the Gear Box

Metallic pipes supplying pressurized oil from outside gear box

29
 Fig 4.3.13 Reduced Length of Hoses
Hoses are supplying oil from inside of the gear box. From the above two
figures it can clearly understand the supply of pressurized oil from outside to inside
gear box section of thrust pads.

These pipes supply pressurized oil to the thrust pads which comes out of the
groove which is provided on it and forms thin film on the thrust pad which runs the
grinding table. The size of the hole drilled to the gearbox must be greater than 5mm to
that of metallic pipes then only it correctly fits into the gearbox. Because of these
proper care must be taken and carefully done.

After drilling 12 numbers of holes on the gear box, from the central distributor
entry each pipe will be connected to the thrust pad passing through the holes. For
every metallic pipe one pressure transmitter is attached.

This pressure transmitter measures the incoming pressure to the thrust pads.
So that easily identifies the pressure at every individual thrust pads. If any deviation
occurs in pressure range that will be indicated in the CCR through pressure
30 be easily found.
transmitter, so that problem can

From this setup we can supply pressure to each thrust pad at sufficient level to
form thin film which comes from the groove of the thrust pad. Due to this, it will
rotate top flange which in turn rotates the grinding table.

As these metallic pipes are arranged outside the gear box, they should be
protected from the surrounding the main effect of environment on metallic pipes is
corrosion this can be avoided by painting the pipes and clamps with corrosion
resistant pipes available in the market.

The changes occurred after placing metallic pipes outside the gear box:
 The line pressure is increased to about 60 bars. Initially it is about 55-58 bar.
 At one place to drill a hole exactly at location of thrust pad became a problem
due to higher diameter casing. So the hole is drilled a side from exact position
and is connected to thrust pad with flexible hoses.

Fig 4.3.14 Hole Drilled Away From Thrust Pads

31
Interior view of arrangements:
 Fig 4.3.15 Hoses Coming Aside From Thrust Pads
Advantages after replacement of pipes outside:

 After identifying the problem the damaged metallic pipes can be changed
easily without the removal of gear box.
 It not only reduces the cost but also decreases the time span for changing.
 The metallic pipes placed at outside the gear box have the resistant properties
and serves the oil it is taken by hoses inside the gear box which are fitted from
the drilled holes.
 Due to this arrangement flexibility will be there for thrust pads inside as they
are continuous tilting and problem of frequent damage of pipes can be avoided
as they are taken from outside.
 The arrangement will be simple than earlier.

Comparison:

Comparison of hoses arrangement inside the gear box before and after
32
replacement:
 Fig 4.3.16 Total View of Thrust Pads Before Replacement

This picture clearly shows the hoses before modification which are dumped in the
gear box itself.

Fig 4.3.17 Arrangement after Replacement

This is the view of hoses which are taken from outside the drilled holes
reducing the length of hoses without touching the surface of the gear box after
replacement.
33
After studies were completed on the problems the results we got
 The damage of hose pipes can be avoided.
  Smooth running of mail can be achieved.
 The pressure of oil can be easily checked.
 If any damage occurs there can be easy replacement of hose pipes.

4.4 Pre-heater:

This plant is provided with two strings of 6stages pre heater system called
kilns stream and claimer stream. With the kiln stream about the 35% of the clinker
capacity can be produced. When the claimer stream is brought into the production
circuit; the production rate can go to 100%. The claimer string includes one stationary
vessel called claimer where about 60% of the total coal requirement will be fired
when the claimer is in circuit. The raw mix from both the strings is fed into the
claimer where 95% of the calcinations are achieved before the material enters in the
rotary kiln.

The raw mix is fed into the pre-heater ahead of the upper cyclone stage;
from here it passes all consecutive cyclone stages down to the kiln. On its way to the
kiln, the raw mixture comes in contact with the hot kiln exit gases. After passing the
lowest stage the raw mixture is heated to about 900 deg c. In the claimer string hot
tertiary air from the cooler are used for pm-heating the raw mixture.

Part of the gases leaving the top stage of the pre-heater cyclones is taken to
raw mill for drying and transporting the raw material before it is taken to bag house.
When the raw mill is not in operation the gases are cooled to a temperature of around
700deg.c and passes into RABH for dust collection. No remarks in the preheating
section.

4.5 Cooling:

The clinker which is entering at a temperature of 1000 degrees C. is cooled to

about ambient +70 degree.34Celsius. The job has been achieved by blowing the
atmospheric air through a series of fans. The fans are designed for a pressure of 500-
1000mm the pre-heated air is taken used for the kiln and claimer.
 The excess air is taken to an ESP and thus a negative draft is maintained in the
cooler and at the same time all fine clinker dust is collected in the ESP. the clinker is
discharged into a pan conveyor and transported to the storage silo of capacity 30,000
tons.

The clinker cooler of this plant is most modem and is known as SF Cross Bar
cooler and has three hydraulically driven grate drives. The first grate is known as
controlled flow grate and the second third grates are known as reduced fall through
gates.

This cooler system allows for maximum heat recuperation at cooler inlet
resulting in higher secondary and tertiary air temperature. The improved cooler
efficiency reduces total air needed for clinker quenching cooling air is distributed in
each grate resulting in the elimination of red river. This cooler gate system reduces
the spillage of fine clinker and leakage. These cooler clinkers are stored in storage
silos. No remarks in the cooling section.

Clinker storage silos:

There is one storage silo. The clinker from clinker storage silo is transferred to
cement mill for grinding through bottom gates and belt conveyors.

4.6 Cement mill:

There are three cement mills, which are vertical roller mills. It process starts
from clinker silo where clinker is in size around 75 mm. In order to obtain fine
powder, it is sent to cement mill. During this process, clinker is sent to concrete
hoppers by means Belt conveyors and weighed using weigh feeders.

The cement additives

35like gypsum, slag and fly ash are weighed and added
with clinkers proportionally sent to mill for grinding.. The fines from the internal
dynamic separator is collected in the dust collector and sent to cement silo by means
of bucket elevator and flux sides. No remarks in the cement mill.
Cement grinding:

By grinding is understood the combination of materials to a powder. Cement

manufacture by the dry process, it constitute the final stage in the production of raw
meal (raw grinding). The clinker discharged from the kiln has to be grounded to a fine
powder which, with the admixture of some gypsum, is the finished product of the
whole process-cement.

This final clinker grinding operation is often referred to as finished grinding.

The terms "pulverizing and milling" are basically synonymous with grinding but are
mostly confined to the combination of coal or lignite for use as pulverized fuel.

In cement industry about 75% of the total electric energy consumption is

consumed in grinding the raw materials, the clinker and where applicable the fuel. No
remarks in the cement grinding.

4.7 Cement storage:

BCCPL is having 8 cement storage silos of capacities 6000 tones each but it is
loaded till 5000 tones only they are 30m height and 14m diameter the cement from
the cement mill is distributed by means of distribution box provided at the top of the
cement silos to various silos as per the requirement. No remarks in the cement storing
section.

4.8 Packing and dispatching:

The cement from the storage silos are taken to vibrating screen by means of
screw conveyor and bucket elevator. Lumps of cement are taken out from the
vibrating screw and it can be separated and powdered cement is taken to packers.

36
There are six Vento automatic packers (rotary) of capacity 90TPH each. The
packed bags are sent to dispatch section where it is dispatched there are 8 wagon
loaders and4 truck loaders respectively. Each bag is having a capacity of 50 kg.
 There are two varieties of bags namely paper bags and HDPE bags in which
the cement is packed but sold in market in different names such as OPC, PPC and
SLAG (B53) the wagon has the capacity to load 1125 bags of cements while in trucks
it depends upon its tonnage. Cement is extracted from the silos and packed in bags
and is dispatched to various spots of the countries by means of transport namely road,
rail etc,

BCCPL packing has 5 sets of packers as follows

 VIBRO SCREENER
 FEED BIN
 ELECTRONIC ROTARY PACKER
 BELT CONVEYOR
 WAGON LOADING MACHINE

37
4.9 DETAILS OF PROCESSES AND THEIR PARAMETERS:

S.NO PROCESSES PARAMETERS REMARKS

Crusher capacity-1000t/h
1 Feeding-1 cubic meter
Output-100mm max No remarks
Crushing Conveyor speed-2.65m/s
Conveyor ply rate-6
Conveyor length-400m
Stacker capacity-60000tns
Conveyor ply rate-4 No remarks
2 Storing and Reclaiming
Conveyor speed-2.65m/s
Vertical mill feed-210t/h Oil leakage due to
Raw mill grinding Gear box weight-100tons not position of
3
Gears-6 hose pipes.
Hose pipes-12 Solution
Damaged pipes-5,6&7 Change pipe with
Hose pipe length-13to15m metallic pipe.
Decrease rubbing
action.
Arrangement of
clamps.

6-Stages of preheat
Coal require-60% No remarks
4 Preheating
Raw mixed heat at-
1400deg.c
Clinker enters-1400deg.c
Cooling Cooling to below-70deg.c No remarks
5
Cooler range-40to80%
Rotary cooler dia-5m
38 Length-15m
Clinker size-75mm
Cement mill grinding Added additives-Slag, Fly No remarks
6
 75% electric consumption
in grinding process
8 Cement storages
6000 tons storage capacity No remarks
7 Storage
But loaded 5000 tons
Room height 30m dia 14m
6-Vento automatic packers
Capacity-90TPH No remarks
8 Packing and Dispatching
Each bag capacity-50kg

39
CHAPTER 5
CONCLUSION AND FUTURE SCOPE
5.1 Conclusion:

At Bharathi Cement Plant, we have studied about the whole of cement

manufacturing process and we recognized the importance of gear box that is used in
vertical roller mills.

The major problem facing by the BCCPL plant with the gear box is damaging
of hoses during operation. So we have studied the entire working and operation of
gear box.

Focused on the problem and had a detailed study about it by comparing

present gear box of FLENDER type with other gear box supplying companies like
MAAG, SEISA.

In that gear boxes the hoses supplying the oil to the thrust pads are taken from
outside by drilling the holes at exactly thrust pad position in the gear box. So, we
implemented this idea on this gear box.

Now the problem of damaging hoses can be eradicated and we replaced the
hoses with metallic pipes only at outside the gear box. At inside to supply the
pressurized oil we used hoses only as they have higher flexibility because the thrust
pads are always tilting. The contact surfaces of hoses with surface of gear box is
completely avoided by reducing its length as it is not placed inside the gear box.

The solution was found out by using Fish bone diagram. This diagram helped
a lot to found the solution for the given problem. The table was helped to to
understanding the problem easily. Finally Studies were completed on the processes
and successfully completed the project.

40

5.2 Future Scope:

 Hope the loesche company understands the problem of the hoses when they
arc inside the gearbox section and change their design model.

For solution they bring the hoses out so that easy maintenance and correct
level of pressurized oil can be supplied to the thrust pads for effective and efficient
functioning of the mill without any problem while running, and also for smooth flow
of operation. The project of ours may be the future design of loesche raw mill.

41

CHAPTER 6
BIBLIOGRAPHY

1. Cement and Concrete Science & Technology

a. – S.N. GHOSH
2. Cement data book
a. Walter H. Duda.
3. Design data book
-- P.S.G. College Faculty
a. COIMBATORE
4. Bureau of Indian Standards
a. –Data book
 Conveying system manual
a. ULTRATECH Co. Library
5. Bharathi Cements group website

6. Flender Gearbox manual.

42

CHAPTER 7
REFERENCES:

1. https://s.docworkspace.com/d/ALAlCcSyiMw3weTR1M6dFA
2. https://s.docworkspace.com/d/AAIjoaiyiMw3ofDs6s6dFA
3.  "Bharathi Cement to start two new plants". The Economic Times. 2018-07-
14. Retrieved 2019-07-26.

4.  "French co Vicat picks up 51% in Bharathi Cement". The Economic Times.

2010-04-20. Retrieved 2019-07-26.

5. "Hyderabad's Bharathi Cement bags Asia's most promising Brand Award for
2015-16". @business line. Retrieved 2019-07-26.

6. "Bharathi Cement | Latest & Breaking News on Bharathi Cement | Photos,

Videos, Breaking Stories and Articles on Bharathi Cement". Money control.
Retrieved 2019-07-26.

7. www.livemint.comhttps://www.livemint.com/2010/04/19212920/france8217s-
vicat-buys-51.html. Retrieved 2019-07-30. Missing or empty.
 
8. Urs, Anil. "Bharathi Cement launches 'BharathiUltraFast' in Karnataka
market". @business line. Retrieved 2019-08-12.

43