Internship Report

DG Khan Cement
D. G. Khan Plant
(From 08-11-19 to 07-11-19)

Reported to:

Head of Quarry Department,

DG Cement Company D. G. Khan

Reported by:
Engr. Muhammad Athar
Email: athar001122@gmail.com
Contact: 03357804973

DEPARTMENT OF MINING ENGINEERING

UET PESHAWAR

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 Table of Contents
1. Introduction of DGKCC ............................................................................................................. 3
1.1 Vision .................................................................................................................................... 3
1.2 Mission .................................................................................................................................. 3
2. Introduction of Cement .............................................................................................................. 4
2.1 Raw Materials Used For Cement .......................................................................................... 4
2.11 LimeStone ....................................................................................................................... 4
2.12 Shale ................................................................................................................................ 5
2.13 Silica Sand....................................................................................................................... 5
2.14 Iron Ore ........................................................................................................................... 5
3. Cement Manufacturing Process .................................................................................................. 6
Process Flow Diagram (PFD): .................................................................................................... 6
Block Flow Diagram: .................................................................................................................. 7
3.1 Quarry ................................................................................................................................... 7
3.1.1 Surveying ....................................................................................................................... 8
3.1.2 Drilling ........................................................................................................................... 8
3.1.3 Blasting ........................................................................................................................ 11
3.1.4 Loading and Transportation ......................................................................................... 13
3.1.5 Crushing ....................................................................................................................... 14
3.2 Stockpiling and Reclaiming ................................................................................................ 15
3.3 Raw Mill ............................................................................................................................. 15
3.4 Burning ............................................................................................................................... 15
3.5 Cement Mill ........................................................................................................................ 16
3.6 Packing and Transportation of cement ............................................................................... 16
4 Summary .................................................................................................................................... 17

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1. Introduction of DGKCC
Dera Ghazi Khan Cement Company Limited, (DGKCC) is a strategic business of Nishat
Group, which is the largest industrial group in Pakistan. DGKCC is amongst largest the
cement manufacturers of Pakistan with a production capacity of 22,400 tons per day (6.72
million tons/annum) and it is a producer and seller of Ordinary Portland and Sulphate
Resistant Cement. DGKCC has four cement plants, two plants located at Dera Ghazi Khan,
one at Khairpur Distt. Chakwal and one at Hub Lasbela District (Balochistan). All the plants
are based on latest Dry Process Technology.
The company operates through a countrywide distribution network managed by different
Regional Sales Offices. The company’s products are preferred on projects of national repute
both locally and internationally due to the un-paralleled and consistent quality. The
Company is listed on Pakistan Stock Exchanges.
D. G. Khan Cement Company is market leader with respect to international market share of
about 11.4% and exporting to more than 10 countries including Afghanistan, Iraq, UAE and
Russia. DGKCC has 13% market share of country. Apart from its competitors; its product is
high priced yet it has highest market share because of good quality.
DGKCC D.G. Khan Plant is working with clinker production of 6700 tons per day.

1.1 Vision
To transform the company into a modern and dynamic cement manufacturing company with
qualified professionals and fully equipped to play a meaningful role on a sustainable basis in
the economy of Pakistan.

1.2 Mission
To provide quality products to customers and explore new markets to promote/expand sales
of the company through good governance and foster a sound and dynamic team, so as to
achieve optimum prices of the products of the company for sustainable and equitable growth
and prosperity of the company.

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2. Introduction of Cement
A cement is a binder, a substance used for construction that sets, hardens, and adheres to
other materials to bind them together. The most common raw materials used in cement
production are: Limestone (supplies the bulk of the lime) Clay, marl or shale (supplies the
bulk of the silica, alumina and ferric oxide) other supplementary materials such as sand, fly
ash/pulverized fuel ash (PFA), or ironstone to achieve the desired bulk composition. There
amount required for cement manufacturing is as follows:
Raw Material Oxide Abbreviation Approximate %
Lime CaO C 60-66
Silica SiO2 S 19-25
Alumina Al2O3 A 3-8
Iron Oxide Fe2O3 F 1-5
Magnesia MgO M 0-5
Alkalis-Soda Na2O N 0.5-1
Polassa K2O K 0.5-1
Sulfur Try-Oxide SO3 P 1-3

2.1 Raw Materials Used For Cement

2.11 LimeStone
Limestone is a sedimentary rock composed primarily of Calcium Carbonate (CaCO3) in the form
of the mineral calcite. This limestone which is extracted from nearby quarry is pure and highest
composition used in Cement.

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 2.12 Shale
Shale is a fine-grained sedimentary rock that forms from the compaction of silt and Clay-size
mineral particles that we commonly call "mud". This composition places Shale in a category of
sedimentary rocks known as "mudstones". Bulk Shale is 2nd highest composition in cement.

2.13 Silica Sand

Sand is a naturally occurring granular material composed of finely divided rock and mineral
particles. The composition of sand is highly variable, depending on the local rock sources and
conditions, but the most common constituent of sand in inland continental settings and non-
tropical coastal settings is silica (silicon dioxide, or SiO2).

2.14 Iron Ore

Earth's most important iron ore deposits are found in sedimentary rocks. They
formed from chemical reactions that combined iron and oxygen in marine and
fresh waters. The two most important minerals in these deposits are Iron
oxides: hematite (Fe2O3) and magnetite (Fe3O4).

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3. Cement Manufacturing Process
The both calcareous and argillaceous raw materials are firstly crushed in the gyratory
crushers to get 30-40 mm size pieces separately. The crushed materials are again grinded to
get fine particles into ball mill.
Each finely grinded material is stored in hopper after screening. Now these powdered
minerals are mixed in required proportion to get dry raw mixture which is then stored in silos
and kept ready to be sent into rotary kiln. Now the raw materials are mixed in specific
proportions so that the average composition of the final product is maintained properly.
Process Flow Diagram (PFD):

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 Block Flow Diagram:

Following is the list of steps involved for manufacturing of cement

 Quarry
 Stockpiling and Reclaiming
 Raw Mill
 Burning
 Cement Mill
 Packing and Transportation

3.1 Quarry
Quarry is the place from where raw materials are extracted for manufacturing the cement and
quarry is defined as: A surface excavation which is up to sky and above the sea-level is called
as quarry.
Quarry is designed according to production of clinker in plant. On these basis crusher with
production in TPH is installed and bench height is specified. Quarry is started from the peak
of deposit while little blasting is done for access road from bottom level to peak level.
At quarry following operations are carried out:
 Surveying
 Drilling
 Blasting
 Loading and Transportation
 Crushing

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 3.1.1 Surveying
Surveying or land surveying is the technique, profession, art and science of determining the
terrestrial or three-dimensional positions of points and the distances and angles between them.
A land surveying professional is called a land surveyor. Surveying is of vital importance in
any engineering project. During execution of the project of any magnitude is constructed along
the lines and points established by surveying. The measurement of land and the fixation of its
boundaries cannot be done without surveying. The main aspects of surface mining regarding
to surveying are
• Deposit calculation
• Direction (Dip and Strike)
• Access Roads
• Bench Design
Regarding to this limestone deposit surveying tells that our deposit is anticline Dungan
Limestone deposit which was exposed due to geological fault of deposit and it is dipping West-
East with strike of North-South direction.
3.1.2 Drilling
Drilling is a cutting process perform with drill machine that uses a drill bit to cut a hole of
circular cross-section in solid materials. The drill bit is usually a rotary cutting tool, often
multi-point. Drill machines can be classified on the basis of their power source i.e.
• Electric
• Pneumatic
• Hydraulic
There are two basic types of drill machines
• DTH A down-the-hole drill, usually called DTH by most professionals, is basically a
mini jackhammer screwed on the bottom of a drill string. The fast hammer action
breaks hard rock into small flakes and dust which is blown clear by the air exhaust
from the DTH hammer.

Figure 1 DTH

• TH in Top Hammer Drilling the hammer produces a percussive force on the drill rods
or tubes, which is transmitted to the drill bit. The feed device is usually attached with
a hinged boom to a mobile unit. The percussive system strikes the drill rod, for example

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 2,000-5,000 strikes per minute, and the rotation speed can be, for example, 60-200
rounds per minute. Together these elements make it possible to drill holes in the hard
rock. The excess material (cuttings) is flushed up from the bottom of the hole by means
of pressurized air or water. Top hammer drills are primarily used in mining,
construction and quarrying of rock material. Top hammer drilling, combined with the
“drill and blast” method, makes the whole excavation process extremely efficient.

Figure 2 Top Hammer

3.1.2a Drilling Patterns

Following figure shows the different types of pattern for drilling

For the best fragmentation result we use staggered pattern.

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 3.1.2b Data Collected From Field
B S B.H Drilling Angle Sp. G Hole Dai No. of Pattern
depth holes

4m 4m 15 m 15m 82º-83º 1.7g/cc 115mm 17 Double

line

Calculation for Powder Factor (P.F) or Yield:

Total width to be removed = B*Pattern
W = 4* 2
W=8m
Total Length to be removed = spacing* No. of Holes
L = 4*17
L = 68 m
Area to be blast = L*W
A = 544 m2
Volume to be blast = A*B.H
V = 8160 m3
Total Tonnage to be blast = V*specific gravity of limestone
Tonnage = 13872 ton
Yield = Powder Factor = Total Tonnage / Total Explosive used
OR
P.F = Total Explosive Used / Total Tonnage
P.F = 13872 / 1700 or (1700/13872)
P.F = 8.12 T/Kg or (0.12 kg/T) Ans

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 3.1.2c Specification of Drill Machines and Compressors
Drill machine and the compressors used at quarry are listed below with their specifications:
S.No. Name of Machine Model Quantity Capacity Horse
of Power
Machine
1 Air Compressor Airman PCR-250 1 250 CFM 140 HP
2 Air Compressor Sullair 750HH 2 750 CFM 250 HP
3 Air Compressor Atlas XAHS-830 2 830 CFM 300 HP
Copco
4 Air Compressor Atlas XA-230 1 650 CFM -
Copco
5 Air Compressor Atlas XRS396 1
Copco
6 Crawler Drill Furukawa PCR-200 2 For 75mm Hole -
Dia
7 Crawler Drill Atlas Copco PC-460 2 For 110mm Hole -
Dia
8 Hydraulic Drilling Rig L-6-44 1 For 110mm Hole 315 HP
Dia
9 Hydraulic Drilling Rig D-50 1 For 110mm Hole 315 HP
Dia
10 Pneumatic Hand Held BBD12T 1
Rock Drill

3.1.3 Blasting
Blasting is basically use of explosives to break the rock for the mining purpose, the blasted
material then transported to the crush plant by means of dumpers.
Data gathered from the field is given below:
• Yield = 7-9kg/ton
• Powder factor = 0.21m3/kg or 0.12 kg/ ton
• Explosive ratio = High explosive (Emulite)15%
=Low explosive (ANFO) 85%
• Detonator = #8 (plain)
• Delay = 25ms
• Safety fuse burning rate 120 sec/m
• Detonating cord with VOD 7000 m/s
• Wabox (Nitroglycerine based) with VOD 5500+ m/s

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• Emulite (Emulsion type) with VOD 5000-6000 /s
• Ammonium Nitrate NH4NO3 (ANFO) with VOD 4000- 4500 m/s
• Blaster (Water gel) with VOD 4500+ m/s
• Stemming of moist-clay/ mud

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 3.1.4 Loading and Transportation
For the purpose of transportation and load excavators and dumpers are used their details are
given below:
S.No. Name of Machines Model Quantity of Capacity Horse
Machine Power
1 Komatsu Dump HD605 2 32 Ton 320 HP
Truck
2 Volvo Dump Truck FM400 2 18 Ton 400 HP
3 Cat Dump Truck Cat 773B 3 52.3 Ton 650 HP
4 Cat Dump Truck Cat 773E 3 52.3 Ton 650 HP
5 Cat Dump Truck Cat 775F 2 63.5 Ton 798 HP
6 Komatsu Wheel WA-700-3 1 8.7 m3 bucket 672 HP
Loader capacity
7 Cat Wheel Loader WA-500 1
8 Cat Wheel Loader Cat-988F 2 6.1 m3 bucket 400 HP
capacity
9 Cat Wheel Loader Cat-980G 2 4.2 m3 bucket 300 HP
capacity
10 Cat Wheel Loader Cat-966H 1 4.0 m3 bucket 286 HP
capacity
11 Cat Wheel Loader Cat-988H 1 6.4 m3 bucket 530 HP
capacity
12 Komatsu Dozer D155A-6R 1 14 m3 blade capacity 320 HP
13 Komatsu Dozer D275A-5R 1
14 Komatsu Dozer D-155A-2 1
15 Cat Dozer Cat D9R 5 10.4 m3 blade 405 HP
capacity
16 Airman Excavator HM355 1 0.12 m3 bucket
capacity
17 Cat Excavator 509D-B 1 5.7 m3 bucket 513 HP
capacity
18 Cat Wheel Excavator M315C 2 0.75 m3 bucket 122 HP
capacity
19 Diesel Tanker NR 118 JR 1 10000 Liters
Mitsubishi
20 Mobile Workshop, TSD-55 1 3 Ton 150 HP
Isuzu TSD-55
21 Komatsu Motor GD-705A-4 1 Blade 4320×700 200 HP
Grader

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Observed cycle time for Loading and Transportation of Limestone from bench 7S face to
crusher II
Dumper Dumper Capacity Bench Cycle time
(avg. after total shift
observations)
DT No.1 55 ton 7S 8 min

Cycle time depends upon distance between crusher and working bench face. At the bench
7S loading and dumping operation was carried out with two dumpers and one loader.

Number of dumpers =2

Capacity of dumper = 55 ton

Round per shift of dumper = 38

Total shifts =2

Material transported to Crusher = 2*55*38*2

= 8360 tons/day

3.1.5 Crushing
The blasted Limestone is transported to Hammer Crusher and Shale is transported to Roll
Crusher to reduce their size so that they could easily conveyed through conveyor belts to piling
area at plant.
Limestone Crusher:
Crusher I & II Capacity: 450 & 800 ton/hour
Hoppers I & II Capacity: 200 & 300 Ton
Hoppers Feed Size: less than 1.7 m
Crushers Product Size: 50 mm
Type: hammer crusher (double rotter)
Hammers: 48
Hammer weight: 90 Kg/hammer

Clay Crusher:

Crusher Capacity: 350 TPH with 30 mm product size

Hopper Capacity: 130 Ton

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 3.2 Stockpiling and Reclaiming
After crushing limestone and shale are transported with long conveyor belt to stockyard, the
crushed limestone and shale/clay are piled longitudinally by an equipment called stacker. The
stacker deposits limestone and shale longitudinally in the form of a pile. The pile is normally
250 to 300 m long and 8-10 m high. The reclaimer cuts the limestone pile vertically from top
to bottom and scraper cuts the shale pile transversely to ensure homogenization of limestone
and clay.
3.3 Raw Mill
The crushed limestone and clay from pile is transported through belt conveyor to hopper.
Similarly, other raw materials like silica sand, bauxite, iron ore etc. are also transported by belt
conveyor from storage yard to respective hoppers. Hopper used to store the limited quantity
of raw material near raw mill. If there exist any problem to deliver from storage yard to raw
mill feed area hopper has some quantity to run the process. At the exit of hopper there is a
dosimeter which control the amount of material fall on conveyer belt. All raw materials fall
on one conveyer belt and fed to raw mill. A lot of dust is produced during conveying of
material, to avoid this problem bag filter are installed. A magnetic separator is also installed
to remove iron pieces.
Hoppers capacity installed in raw mill:
Limestone 300 tons

Shale 225 tons

Silica sand 200 tons

Iron ore 150 tons

All raw materials are proportioned in requisite quantity through weigh feeders. The
proportioned raw materials are transported by belt conveyor to Raw Mill for grinding into
powder form. After grinding, the powdered raw mix, is stored in a raw meal-silo where
blending takes place. Blending is done by injecting compressed air. This powdered material
(Raw mix) is fed to the kiln for burning and Coal also requires homogenization as it contains
different ash.
3.4 Burning
The powdered raw mix is fed into 4 to 6 stage preheater from top by air pressure. The hot gases
from kiln enters preheater from bottom. The powdered raw mix slides down through cyclones
and comes in contact with hot air which travels from top to bottom. In preheater the 0oC
temperature of raw mix rises to 900oC to 1000oC and nearly 90% Calcination (removal of CO2
from CaCO3) takes place before entering the kiln.

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Powdered raw mix enters the kiln at one end and the burner is situated at the opposite end. The
rotary kiln rotates at the speed of 1 to 3 revolution per minute (RPM). The raw mix in the kiln
melts first into liquid form and then transforms into nodules due to the effect of the rotation of
the kiln.
There are two zones inside the kiln, namely calcining zone and burning zone. The zone where
raw mix enters into the kiln is called calcining zone where temperature would be 950-1000oC.
Burning zone starts after this zone where temperature would be 1350-1450oC.
The hot clinker from kiln discharge is cooled very quickly/ quenched in air with the help of
efficient coolers. The temperature of clinker is brought to 80-90oC from 1350oC. Fast cooling
is very essential to get good quality clinker. If cooling is not quick, the compound stability in
clinker will be adversely affected resulting in lower strength of cement after grinding. Clinker
is stored in clinker yard after cooling.

3.5 Cement Mill

Clinker from clinker yard and gypsum from gypsum silo is transported to cement mill by belt
conveyor. Similarly fly ash or any other additive are transported to cement mill by belt
conveyors.
In this cement mill clinker, gypsum and other additives are grinded with proper proportion to
get o fine powder which is our actual cement product with 5% gypsum that regulate setting
time of cement.
All operations of feeding of raw meal, coal, burning, temperature control and cooling are
automatic through fuzzy logic / computer control. These operations are controlled from
Central Control Room (CCR) which is the nerve center for any cement plant. The
proportioning of clinker, gypsum and fly ash is done by electronic weigh feeders. In modern
plants, clinker and gypsum are pre-crushed in a Roller press and subsequently fed into ball
mill for fine grinding. The installation of roller press technology is very beneficial in terms of
both quality and energy conservation. The cement produced from roller press is showing better
particle size distribution in cement (and hence good strength development) and consumes less
power. The resultant product is called cement and stored in a Multi compartment silo. This
avoids intermixing of products.
3.6 Packing and Transportation of cement
The cement from silos transferred to the cement bin with the help of air lifts. There installed a
mechanically vibrating screen (10mm) mesh size to avoid any metal piece or anything else
below each cyclone. The cement is packed into bags having capacity of 50kg per bag. Rotary
packers are used for packing. The packing system is fully computerized and works on the
programmable login control (PLC) system. After packing bags are transferred to vehicles by
the help of belt conveyor. Packing bags are made up of paper-polypropylene. Cement is
transferred to various locations as per the market requirement and stored in barns or the
distribution points, this is distributed through trucks and by rail or by cement Bulkers from the
plant.

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4 Summary
During the one month internship I have learned major steps involved in cement manufacturing
and the mining operations including drilling, blasting, quarry maintenance, crushing and safe
working operations.

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