Cement Manufacturing Process:

The process of cement manufacturing starts with blasting the mountains to get the
required raw material or mix limestone. This material is brought from mountains to
the cement industry through the help of trucks and then drop it into hopper of
crusher to crash the material. Here we also brought clay and literate for crushing
this material is brought from outside areas. After getting crushed, the material is
then brought to the stacker area by the conveyor belt. Now the piles of these
materials are made by the stacker. The material then loaded on to another conveyor
belt by the reclaimer. The material is then taken by the conveyor belt to the
hoppers. Underneath the hoppers, there are weigh feeders which send the required
proportions of each of the four types of materials to the raw press area. The
material is then fed into the V separator where the fine material is been sucked up
by the dynamic separator and the coarse material is been rejected then it goes to a
feeding bin through a bucket elevator. The feeding bin then feed the material to the
roller press where the material is been pressed. This material again goes to V
separator through bucket elevators. Again, the acceptance and rejection cycle take
place. After the material is accepted by the dynamic separator, it is then taken to
the multi cyclones. This material is then carried to the CF Silo. From the CF Silo
the material then comes down to a feeding bin through bucket elevator. The
material is then sent to the first stage of the pre heater after passing through a feed
fister which regulates the feed of the material. In pre heater the material comes
from top to bottom and the hot gases go from bottom to top. These hot gases come
from the PC of the pre heater. The material is heated so that the material may
undergo the process of calcinations. The material is heated up to 850 degrees
Celsius. It is then brought to kiln where further heating up to 1450 degree Celsius
takes place. This material goes through the clinker cooler where it is cooled down
by aeration. After the cooling of clinker, the material undergoes crushing in the
clinker crusher. Then this clinker is carried to the clinker silo by the pin conveyor.
From this clinker silo, the clinker is then shifted to the clinker hopper. Gypsum and
PI are also brought to their respective hoppers by bucket elevator. Gypsum is
crushed in the gypsum crusher before coming to the hopper, whereas the limestone
is also crashed in crusher before coming to the hopper. Underneath the hoppers,
there are weigh feeders which send the required proportions of each of the three
materials to a bucket elevator which drops it into a feeding bin. This feeding bin
drops material into a roller press where the material is pressed. After getting
pressed, this material goes to the V separator through bucket elevator. The fine
material is accepted by the dynamic separator, whereas the material rejected then
goes to the cement mill through an air slide. After the material is milled, the
material is put back into the dynamic separator by a series of air slides and bucket
elevator. From the dynamic separator the fine material is been sucked by the bag
filter. After the process of purging, the material is dropped into an air slide. This
air slide leads to a bucket elevator which drops the material into the cement silo.
The cement comes to the packing plant through the air slides. It is loaded in the
feeding bin first by a bucket elevator. It is then dropped to the packer. Before
coming to the packer, the cement passes through a vibrating screen which removes
any unwanted material from the cement like metal rods, coarse material etc. It also
passes a rotary valve which is there to control the flow of cement. The cement is
then packed into bags and sent for loading.
 Week No: 1
Crusher
Crusher:
Crusher is a kind of machinery that is widely used in the cement production
industry. It is mainly used in the material preparation process to crush the raw
materials into proper size particles.This is the first area where the raw material for
the manufacture of cement comes.

Hammer Crusher:(capacity:1200 t/h)

The hammer crusher machine completes the
crushing material operation by the impact energy.
During the operation of hammer crusher machine,
the motor drives the rotor to rotate at a high speed,
and the material enters the crusher cavity evenly.
The high-speed rotary hammer impacts, shears and
tear the material, all the materials are broken.

We have double rotor hammer crusher in line 3. It

has a 800-kW motor(asynchronous) for each of its
two rotors. On each rotor, there are six shafts and on
each shaft there are eight hammers. Each hammer
weighs 157 kg (normal). The hopper of the crusher
has a maximum capacity of 200 tons. Crushing of the
material is done by the rotating hammers on the
shafts.

Material input size: 1 to 1.5 m

Material output size: 50-70-80 mm
Each rotor have 48 hammers
Total hammer:96
Distance between two rotor hammers ;500 mm
Parts
Rotors
v-belts
pin coupling
Hammer discs
Side discs
Hammers
Hammer axles
Grides bar (60 mm slots and 300 mm length)
Shaft
Flywheel
Bearings(spirical double roller )
Bearing housing
Clamping ring
Sporocket beams

Anvil/breaking bars
It is located between the two rotor
On this anvil together with the two rotors the feeding material will be primarily
crushed
It cannot only prevent the large particle from getting into discharge area but also
induce the material to two discharge areas equally
Impact Crusher:
In line 1, the crusher is an impact crusher. The impact crusher consists of a rotor
that rotates and throws the material on the impact plates by which the material is
crushed. There are two kinds of impact plates. They are namely the primary impact
plate and the secondary impact plate. Primary plate is closer to the inlet point and
is placed above the secondary plate, so, crushing is done
first by the primary plate.

Apron feeder:
Apron is a mode of transportation for the raw material from
the hopper of the crusher to the crusher itself. This apron
chain has 55 kW motor(invertor duty motor/yxvf250m-4)
that runs at 1482 rpm. It also has a planetry gear box which acts as a reducer. The
apron conveyor can operate from 80 to 800 t/h.

Maintenance ;
Apron dect/buckets(repair or replace)
Roller changes
Bearing wear
Bearing lubrication
Nut and bolt change
Hammer change (loss 25% weight then by neumatic jags we change it)
Grides bar wear
Hammer ceramics slots wear
Liner plates change

Bag Filter:
It is a filter that is used for the dust control in
various areas of the factory. One of its functions is
also to avoid any wastage of material. It is also
important for the environment. It helps the
environment to be pollution free. This equipment
is present in every area of the factory where there
is dust.

A bag filter consists of a fan that sucks the air and

dust from the material. The dust particles get
stuck to bags(7.6 m length) in the bag filter, whereas, the cleaned air goes out to
the environment. In the bags, the dust particles combine to form larger particles.
Then in order to put these particles back into the cycle, there are three different
kinds of mechanisms:

 Mechanical Shakes: In this method, the top side of bags is connected to

a beam which is connected to a motor that vibrates the beams in order to
shake the material off the bags.
 Reverse Air Pressure: In this method, fresh air is both ejected as well as
injected. The injected air helps clean the off the bags.
 Jet Impulse
The mechanism used here is Jet Impulse. A jet of air in reverse direction is passed
through these bags in reverse direction after every 10 to 15 seconds. This process is
also known as purging.

Parts;
Bag filter
Neumatic jags
Screw conveyor
Bush bearing
Pipe
Intruments jags
maintenance
Bags change
Gearbox lubrication (320 oil)
Bearing change

Stacker
The raw material comes from the crusher to the
stacker via the belt conveyer. The stacker is a machine
that makes piles of the material in the stacker area
before it is sent to the raw press area. Stacker has a
limit switch. The stacker will stop itself when a
particular height of the pile is achieved.

Reclaimer:
It is a large machine that loads the material onto the belt conveyor. From there, the
material goes to the hoppers in the raw press area.

There are two kinds of reclaimers in line 2. One of them is called a mount
reclaimer and the other is called side reclaimer. The difference between the two is
this that, mount reclaimer has teeth on
both sides, whereas side reclaimer has
teeth on only one side.

The reclaimer has three different motors.

One of the motor is for the buckets of the
reclaimer. This motor has a power of 75 kW and it runs at 1490 rpm. There is a
gear box as well which acts as a reducer. The buckets of the reclaimer help in
pushing the material onto the belt conveyor. One of the motors is for the linear
movement of the reclaimer and the last motor is for the movement of the teeth. The
teeth of the reclaimer help in making the material fall from the pile so that the
buckets can push it. The second and third motors have a clutch between them.

In line 2, the stacker and reclaimer assembly is linear, whereas, in line 3, it is

circular. In circular assembly, the stacker and reclaimer work together at the same
time. They move around in circles stacking and discharging at the same time. This
circular assembly takes lesser space than the linear assembly.

Maintenance;
Sprockets
Chain
Gearbox
Buckets (bolt ,shaft)
Motor
Coupling spirical bearings

Week No: 2

Raw Press(480 t/h)

The raw material reaches the raw press area from the stacker area through belt
conveyor.

Hoppers:
In the raw press area, there are 4 hoppers. Each hopper is specified for one type of
material. Following are the 4 different types of materials in these hoppers:

1. Mixed Limestone
2. Laterite
 3. Clay/Slate
4. Pure Limestone

The hopper that contains mixed limestone has a greater capacity than others. It can
hold a maximum of 790 tons. The capacity of clay hopper is 200 tons and that of
laterite and pure limestone is 230 tons.

Each of these hoppers has a bag filter at the top of them except for the hopper that
contains pure limestone. This bag filter is there to reduce the amount of dust in the
hoppers and also to avoid any sort of material wastage.

There are specific percentages of all these materials. These specific percentages are
sent forward with the help of weigh feeder. Each hopper has a weigh feed under it
which controls the feed rate of material from the hopper.

Weigh feeder:
It is a material feed controlling device. It is placed mostly under the hoppers in this
plant. It controls the amount of each material dropping from the hopper. The feed
of material is changed by changing the speed of the belt
on the weigh feeder.

V Separator:
V Separator is a type of separator that separates coarse
and fine particles. It does not have any moving part.
That is why, it is also called static separator. A V
separator does not have any running cost. Along with
separating fine and coarse material, a V separator also
performs the function of removing the moisture from
the material because hot gases from the conditioning
tower are passed through the v separator.

A V separator consists of a casing and dispersion plates. Dispersion plates are there
for the protection of the casing as the material coming from the hopper will fall
directly on these dispersion plates, hence avoiding any damage to the casing.

The suction of the fine material from the v separator is done by the fan of dynamic
separator. The fine material is sucked up to the dynamic separator and the coarse
material is rejected to the bucket elevator which then goes to the bin and roller
press.

Dynamic Separator:
Dynamic separator also performs the same function of separating the fine and
coarse materials but with a different mechanism.

A dynamic separator consists of static guide

vanes, dynamic vanes and a fan for suction.
The fan is there for the suction of material.
When the material enters the dynamic
separator, the dynamic vanes provide the
rotation to the material. So, now the material is
under equal centripetal and centrifugal force.
The fine particles having a lesser mass will be
sucked up by the fan, whereas, the coarse
particles having a greater mass will keep circling until they go through the gap
between the vanes. Then, they will collide with the static guide vanes and fall
down towards the static separator.

Parts
Drive part
Rotor part
Shell part
Baffle cone
Cooling air sleeve
Weight valve
Lubricating grease
Multi Cyclones:
After the dynamic separator, the
material comes towards the
cyclones. In these cyclones the
separation of the fine material and
air takes place. The material
coming from the dynamic
separator enters the cyclones in
such a way that it adopts the path
of a cyclone. This is because of the centrifugal force of the particles. The air on the
other hand stays in the middle and is been extracted out by the fan through the dip
pipe present in the center of the cyclone. There are four cyclones where the
material is been stored before it is taken to the CF Silo.

Roller Press:
Roller press consists of two rollers.
One of them is stationary and the other
is moveable. There is a 25 to 30 mm
gap between the two. It is for the
material to go through the rollers.
When a large rock having a size greater
than 25 mm passes through the rollers,
it causes the moveable roller to move
back. It is pushed forward by the
hydraulic jags. Two hydraulic jags are
there on the drive and two on the non drive side. Hydraulic jags maintain a
pressure of 80 to 120 bars.

For each roller, there is a drive of 1600 kW that runs at 992 rpm. These drives have
a planetary gear box as reducer. The drive and the gear box are connected by a
universal coupling. The reducers of these drives have a ration of 48.7:1.

The gear box has a lubrication unit as well. The lubrication is done by 320 oil. For
the cooling of this oil, the lubrication unit also has a water supply.

Conditioning Tower:(line 2)
Conditioning tower is also called GCT (Gas
Conditioning Tower). The function of this tower
is to cool down the hot gases coming from the
pre heater. This conditioning tower also has
connections with other equipments through a
duct. It is connected to the V Separator to which
it supplies the hot gases as per the requirement.
In V Separator, the hot gases are required to
remove any sort of moisture from the material.
The conditioning tower also provides hot gases to the coal mill for the grinding of
coal.

The cooling process inside the conditioning tower takes place by water sprays.
These sprays are sprayed at the hot gases after a specific interval. After cooling
down, these gases can be released into the atmosphere.

Parts
Motors
Rollers
Roller support
Planetary gear box
Frame
Torque support
Hydraulic unit
Lubricating set
Feeding device
Roller shield
Control unit
Roller name; trp(r)220-160
Dia of roller ;2200 mm
Width of roller ;1600 mm
Weight ;412 ton
Roller speed ;18.4 r/m
Maintenance;
Teplon pad
Air slide fiber change
Fluid coupling in belt conveyer
Pinion gear box greaseing change
Guid roller
Plate change in v seprator
Week No: 3

Kiln and Coal Mill

The material from the multi cyclones comes to the CF Silo via the air slides and
bucket elevator.

CF Silo:
CF Silo stands for Controlled Flow Silo. It is a
storage equipment to store the powdered
material from the raw press. CF Silo has 7
extraction points. 6 of these points work in
pairs. Only one pair works at a time. The last
extraction point in middle works at all time.
Each point has a pressure relief cone which has
blowers on all its side. They help release the
material. CF Silo also has a bag filter at the top of it for dust management.

Coal mill:
Coal is used as the main fuel in kiln
and pre heater. Coal comes from the
coal reclaimer area towards the coal
mill. Here the coal is collected in a
feeding bin. From that feeding bin it
is fed to the coal mill for milling
purpose.

Coal is mill is a vertical type mill. It

has a grinding plate and 3 vertical
rollers. For each roller there are 2
hydraulic jags which lift the rollers
up. During the process, the pressure
of the jags is released and the rollers
come down on the material for grinding. The grinding plate is connected to a
motor, whereas the rollers are free. The rollers move due to the contact with coal or
the grinding plate. When the material is grinded into powder, it is been sucked up
by the bag filters. In the bag filters, purging takes place to knock the material off
the bags and into the storage bins. There are two storage bins. One of them is for
the main burner of kiln and the other is for the calciner. The material is sent to the
burners after passing through a feed fister. The requirement of PC is greater than
the main burner. The feed fister of PC send 20 to 25 tons per day and the feed fister
of kiln main burner send 10 to 15 tons per day towards their respective burners.

Apart from this, there is a duct coming towards the coal mill from the conditioning
tower. This is for the heating up of the coal so that the grinding is easier.

Feed Fester:
It is also a material feed controlling device. It is used in
the coal mill and also in the pre heater. Feed Fester has
two bucket plates. One of the plates rotates. This plate
has a hole in it. So, the only way for the material to
come out is this hole. The material is extracted out of
feed Fister either through suction or through gravity.

There are two ceiling plates as well. Higher ceiling

plate is between the two bucket plates. And the lower
ceiling plate is below the lower bucket plate.

The feed of material is changed by changing the rotational speed.

Preheater:
There are two processes of cement
manufacture. One of them is dry
process and the other is wet
process. Pre heater is used in the
dry process. Pre heater is the core
element of the dry process. It
preheat the material before it goes
into the kiln, hence, reduces the
size of kiln. Heating in pre heater
takes place in the calciner. It is called calciner because the process of calcination
takes place in here. Calcination is the process of thermal decomposition of
limestone. The calcinations of limestone begin at a temperature of 800 to 850
degree Celsius.

The chemical reaction is given below:

CaCO3  CaO + CO2

The pre heater in this factory is single string 5 stage in line calciner pre heater in
the pre heater, the material is dropped from the top and the hot gases come from
the bottom as the calciner is at the bottom. On each stage of the pre heater, there
are cyclones. In these cyclones, the material enters in such a way that it adopts the
path of a cyclone. In the center of each cyclone, there is a dip pipe. It is for
transport of hot gases.

Parts;
Cyclones
Air pipe
Balancing pipe
Decomposing furnace
Distributing box
Feeding chamber
Pushing device
Hydraulic system
Air blockage valve
Expansion joint
Electric distribute valve
Gate valve
inner cylinder

Kiln:
It is a core equipment of clinker
production. Inside the kiln, the calcination
process is completed and clinker is made.
Kiln in line 3 has a diameter of 6.5 m and a length of 62 m. A maximum of 6700
tons/day of clinker can be taken out of the kiln.

Kiln has two drives. One of them is the main drive and one is an auxiliary drive.
Each drive has a reducer. The drive rotates the pinion which in turn rotates the
girth gear on which the kiln is mounted. There is a jaw coupling that connects the
two reducers on drives. Whenever we want to use the main drive, we will decouple
the coupling. The main drive has a power of 1000 kW and it operates at 1499 rpm.
The speed of kiln on the main drive is 4 to 4.5 rpm. Then whenever we want the
kiln speed to be slower, we will run it on the auxiliary drive. It runs the kiln at less
than 1 rpm. On the auxiliary drive, the speed of kiln gets this slow because the
transmission passes through 2 reducers.

Apart from this kiln also has roller supports. These roller supports have general
bearings on both sides. In these general bearings oil is been used. Kiln also has a
thrust roller. This thrust roller has an axial thrust device as well. This assembly
compensates for the axial force that the kiln applies because of its 3 to 4 percent
degree. This axial thrust device uses hydraulic oil 46 to apply pressure through a
hydraulic jag to put the kiln back on its position. This push back occurs every 8 to
14 hours or depending upon the load in kiln.

Parts;
Hydraulic unit
Lubrication unit
Inlet seal
Outlet seal
Blaster
Cooling fans
Panel box
Bearing
Rollers
Tire
Girth gear
Pinion
Thrust device
Kiln nozing plate
Chair plates
Kiln zones;
Inlet zone
Calcining zone
Safty zone
Upper transition zone
Burning zone
Lower transition zone
Cooling zone
Clinker Cooler and Crusher:
After coming out of Kiln, the clinker is red
hot at a temperature of almost 1400 degree
Celsius. It has to be cooled down. This is
done by the clinker cooler.

The cooler in line 3 is a i-cam cooler. This

cooler has 7 chambers. Each of these
chambers is for the aeration purpose. Each of
them has a fan connected in them. The pumps of the fans have a power of 160 kW
and they run at 1485 rpm. Chamber 3 and 6 have connection of 9 rows of 2-way
hydraulic jacks. They are for the movement of the cross bars which in turn moves
the material forward. The sequence of movement is such that the forward
movement of all the bars is the same and the reverse movement is in groups of
three. First the row 1,4 and 7 move back and so on. The hydraulic jags maintain a
pressure of 140 to 180 bars normally. There are three axial pumps for these
hydraulic jacks. In these hydraulic jacks hydraulic oil 46 is used.

After the cooler, the clinker falls into a crusher. This crusher has 4 rotors. Each
rotor has a motor of power 11 kW running at 1460 rpm. In crusher, the motor and
the gear box are connected by a flange coupling.

Electrostatic Precipitator:
It is a device used for dust control in such places
where the temperature is very high as the bag
filters cannot operate at very high temperatures.

EP works on the working principle of the

attraction of a charged particle by the oppositely
charged plate. Then after the particles are stuck to the plate, they are removed and
put back into the process by hammering.

WHR:
WHR stands for Waste Heat Recovery. There are two WHR units. One is
connected with the kiln main burner and the other is connected to the PC. These
WHR units are actually steam boilers that use the excess heat of the burners to
form steam that is used to run the turbines to produce electricity.

Excess Heat:
The whole kiln area works on the heat produced in the burners. The temperature in
the PC is about 850 to 900 degree Celsius and in the main burner the temperature
is up to 1450 degree Celsius. If the heat in the main burner exceeds this optimum
value, then the heat is transferred to PC via the Treachery Air Duct.

The excess heat is also used in WHR to produce steam which is in turn used to
produce electricity.

If still excess heat is left, then the hot gases are sent to the conditioning tower from
where they are sent to the V separator and the coal mill as per the requirement. The
remaining hot gases are cooled down by the periodic water sprays in the
conditioning tower.

Week No: 4

Cement Mill(365 t/h)MVR-6300 C-6

Clinker Silo:
The material after going through the clinker
crusher comes to the clinker silo via the pin
conveyor. Here the clinker is stored. There are
three groups of shoots in the clinker silo. At a
time, material is extracted of only one of them.
Below each group there is a separate belt
conveyor. These belt conveyors unite into one
after some distance. That belt conveyor then
goes towards the clinker hopper.
Hoppers:
There are three hoppers in this area.

Clinker Hopper:
It is the largest hopper out of the three. Its maximum capacity is 660 tons. Material
comes to this hopper from the clinker silo.

Gypsum Hopper:
Gypsum hopper has a capacity of 180 tons. Gypsum, before coming to the hopper
undergoes the crushing process in the gypsum crusher. The gypsum crusher has a
single rotor that runs on a drive that has a power of 250 kW and a speed of 990
rpm. The material after going through the crushing process comes to the hopper by
the bucket elevator.

PI Hopper:
PI stands for Performance Improver. Its hopper has a maximum capacity of 190
tons. The material comes to the hopper via the same bucket elevator which carries
gypsum to its hopper as well.

Then a calculated amount of each material is sent forward. This is done by weigh
feeders. More than 90 percent, clinker is sent forward. 5 percent gypsum and 4
percent PI is added.

Cement Mill:
There are two different kinds of cement mills in this cement industry:
Ball Mill:
In line 1 and 2, there is a
ball mill. In a ball mill, the
grinding of material occurs
by both pressing (friction)
and impact. In a ball mill,
there are balls which are
called media. When the
material is dropped to a
ball mill, first of all the
grinding is done by
pressing. This happens
when the material comes
between these media. The
second type of crushing occurs when the mill rotates. The media rotate with it up to
a certain height. Then the media falls down and the material is grinded further due
to the impact of these media with the material.

The ball mill has 2 chambers in it. The chambers are distinguished by the size of
media in them. Apart from this, the ball mill has two drives. One of them is a main
drive and the other is auxiliary drive. The main drive has a power of 3550 kW and
runs at 1480 rpm. The main drive is connected to the main reducer through a gear
coupling. The reduction ratio of the main reducer is 1:46.97. So, on the main drive
the mill operates at 15.6 rpm. Mill also has a auxiliary drive that has a power of 45
kW and runs at 744 rpm. The auxiliary drive and auxiliary reducer are connected
by a pin bush coupling.

Ball mill has four general bearings as well, two on each side. The working of these
bearings depends upon the pressure developed by the pumps. For each side there
are 2 high pressure pumps and a low pressure pump. The high pressure pump is
used at the start to lift the ball mill. It does this by maintaining a pressure of 70 to
100 bars. After the ball mill is lifted
0.2 mm, the low pressure pump
starts working. Its job is to maintain
this level of oil.
Vertical Mill
In line 3, the cement mill is a vertical mill. Its working is the same as the coal mill.
But it is bigger than the coal mill. It has 6 vertical rollers in it and a single grinding
table.

Maintenance;
Oil lubrication
Oil seal changes
Bag house
Fan vibration increase
Clinker feeder
Bucket change
Coupling damage
Oil replacement reduce gear change

Week No: 5

Packing Plant
The cement comes to the packing plant via the air slides. This cement is thrown
into the bucket elevator. This cement is then thrown into a feeding bin.

Vibrating screen:
Before going to the packer, cement
goes through a vibrating screen. This
vibrating screen removes any sort of
unwanted solid material from the
cement such as any sort of metal
scrap which was accidentally dropped
in the cement.

Packer:
Packer is the device that
packs the cement into bags.
The bag is held by the bag
holder and the bag is placed in the bag chair. When the bag is filled as per the
programmed value of weight, the bag is then closed and sent forward. In the packer
the material comes out of nozzles. There is continuous flow of air through them to
avoid any choking of nozzles.

fter the cement is packed in the bags, the bags go through a series of belts.

Cleaning Belt:
In this belt the bags of cement are been cleaned of any sort of dust or cement on
them.

Weighing Belt:
In this belt the bags are been weighed. They should be 50 kg each.\

Rejection Belt:
The bags that do not weigh 50 kg are been rejected by the rejection belt.

Long Belt:
After passing the rejection belt, the bags are carried by the long belt. On this belt,
there are two diversions. These diversions are used depending upon where the
truck is standing for loading.

Parts:
Shutter plate
Base plate
Rubber spout
Ring
Impeller load cell jags
Butterfly valve
Rotary feeder
Bag chairs
Maintenance
Draft belt
Cleaning belt
Weighting belt
Reject belt
Bearing
Nozzle chocke
Impeller
Roller
Gearbox
Bucket elivator

Week No: 6

Workshop
Lathe Machine:
A lathe machine is a machine that removes undesirable material from a rotating
work piece in the form of chips in order to achieve the desired shape. It is one of
the oldest production machines known to man. This machine is also called the
mother of all machines.

Some of the main parts of the lathe machine are given below:

 Bed: It is the base of the whole machine on which the other parts are
mounted.
  Headstock: The main function of this part is to transmit power to other parts.
 Chuck: It is the part where the work piece is held. It may have 3 or 4 jaws.
The 3-jaw chuck is used for regular shaped work piece and the 4 jaw for the
irregular shaped work piece. 3-jaw chuck is called a universal chuck and 4-
jaw chuck is called an independent chuck.
 Tailstock: This part can be moved back and forth. It is used mainly for
drilling, boring or to hold large work piece tightly alongside the jaws.
 Tool Post: This is the part used to hold the tool.
 Cutting Tool: Different types of tools are used for different operations. The
tool used for most of these operations has a carbide tip as its cutting edge.

Some important operations that are done on the lathe are given below:

 Turning: In this
operation the
diameter of the
work piece is
reduced. The tool
used for this is
the turning tool. It
is the most used
operation. In
order to get a
better finishing on
the work piece,
cutting oil is
used. It gives a
well-polished finishing. For finishing on silver kerosene oil is used and for
copper and steel oil is used.
 Tapered turning: In this operation the diameter of the work piece is reduced
as well but in a slope. For this the tool post is set up on a degree.
 Facing: In this operation the face of the work piece is polished by removing
a very thin layer of material from it.
  Threading: For the required thread on the work piece, setting is done on the
head stock and then the feed is started. By doing so, we get the required
thread on the work piece.
 Parting: In this operation a deep groove is made on the material to remove a
specific part.
 Chamfering: In this operation, the ends of the work piece are beveled in
order to avoid cuts due to sharp edges.
 Knurling: In this operation the surface is made rough by imparting a regular
pattern onto it. This is done for a better grip. For this process knurling tool is
used.
 Drilling: In this operation, holes are made in the work piece. For this a drill
is used. This drill is fitted in the tail stock.
 Boring: Boring is also called internal turning. This operation helps increase
the diameter of an already existing hole.

Some of the materials that are used as work piece are:

 MS (Mild Steel)
 SS (Standard Steel/ Stainless Steel)
 Teflon
 Brass
 Cast Iron etc.

Shaper:
Shaper is a machine used for
producing horizontal, vertical
or flat surfaces. The shaper
holds a single point cutting
tool in a ram and holds the
work piece on the table of the
machine. The tool then
reciprocates back and forth in
order to remove the unwanted
material from the work piece.
Shaper is used in the work shop for the production different types of parts. It can
be used to make nuts. It can also be used to make grooves that are required in
different parts.

Power Hacksaw:
It is a machine used to
cut huge shafts into
sizes that are required.
First of all, the shaft is
fitted on to the
machine. Then, the
blade of the machine
starts to move back and forth
to produce the cut
required. There is a supply of
water given to the place where the cut is
been made for cooling purpose.

Drill Machine:
A drill machine is used to form holes in a
work piece. Let’s say we have a flange as
our work piece and we want to make 4
holes in it that have equal angular distance
between them. For that first we will have
to make markings of the holes. That is
done by a divider. After that we will place
our work piece on the drill machine. If the
holes to be made are small, then we can
simply use the drill of the required
diameter. But, if the holes are large, then
we should first make a small hole and then
enlarge that hole by using the drill of required diameter. If this is not done, then
there is possibility that hole will be not be accurately drilled on the marking.
Measurement Instruments:
Vernier Caliper:
It is an instrument used for linear measurement. It is the
most used instrument for measurements in the workshop.
It can measure linear lengths, internal and external
diameters, and even depths. The least count of this
instrument is 1 point (0.1 mm).

Micrometer:
It is a gauge used to measure small distances or thickness
of a body. This instrument is used when a greater accuracy is required as it is more
accurate than the vernier caliper. The least count of micrometer is 1 hundred (0.01
mm).

Mercer Gauge:
It is an instrument used for finding the internal diameter of
bores. It is used in areas where vernier caliper cannot be
used. It is a very precise instrument having an accuracy of
0.01 mm.

Internal Caliper:
This is a tool used to find internal diameters. It does not have a calibration on it.
So, after fitting it in a bore, we have to use a vernier caliper to get the reading of
the diameter.

Bevel Protractor:
It is an instrument that we use to measure the angle between the surfaces of an
object. The bevel protractor is opened and the surfaces are set up in it and then the
screw is tightened again. There is a calibration of degrees on this instrument which
gives us the angle between the surfaces.

Depth Gauge:
This instrument is just like a vernier caliper in terms of design and reading method.
But it is only specified for measuring depths.
Thread Gauge:
It is an instrument used to measure the pitch of threads on a work piece. It has
calibrations of both threads/mm and threads/inch.

Fabrication Workshop:
Welding:
Welding is a fabrication process whereby two or
more parts are fused together by means of heat,
pressure or both.

In the workshop, the machine used for welding

is a 3-phase welding machine. It is a 500A
machine. A 3-phase welding machine has 3
sources of AC power supply.

For welding purpose, different kinds of

materials are used. Some of those materials are
listed below:

 Cast Iron: Cast Iron is a brittle material. It is used for high temperature
application.
 MS (Mild Steel): Mild steel is the most used welding rod in the workshop. It
is a ductile material having a high tensile strength, hence making it a good
welding material. A single weld of MS 7018 can bear a mass of 1 ton.
 Nicro HLS: This material is used for applications like gear welding and kiln
tire welding.
Gouging Machine:
It is a machine used to cut off metal from a
material using Carbon electrode electric arc
welding. Compressed air is used to thoroughly
remove the metal from the surface. The machine
that this process uses is a 1000A machine.

Fire Cutter:
It is cutting equipment used to cut materials with
fire in the workshop as well as in other areas of the
factory. It uses two gases. These gases are stored in two different cylinders. One of
these gases is Oxygen and the other is
DA. This equipment is also used to
pre-heat some jobs before welding.
For some steel alloys’ jobs or jobs
having a thickness of more than 1
inch, preheating of the job is
important. This is done so that the
welded material is able to bond with
the material of the job. This is done
using the fire cutter.

Chain Lock:
This is an equipment which is used to lift very heavy stuff with comparably very
less effort. This equipment consists of pulley arrangements. One of the pulleys is
used for the input that is the pulling by the rigger and the other is for the output
that is the lifting of the object. The speed with which the object is lifted is much
slower than the speed with which the other pulley is pulled. But this slow speed is
compensated by the fact that the force required
to pull the input pulley is much less than the
actual weight of the object.

Grinding Machine:
It is a machine that is used to give a finishing to
the welding been done of the job.
Different kind of metal sheets used in workshop:

 MS (1 mm – 60 mm)
 Hard X (6 mm – 50 mm)
 Watted (This is actually MS coated with Hard X)
 SS
 GI Sheet

Transportation of material:
For the transportation of material, various types of equipments are used. These
equipments are discussed below:

Bucket Elevators:
Bucket elevator is the equipment that is used to convey the material vertically up
or down. Depending on the type of material been conveyed, different types of
bucket elevators are used. The two different types of bucket elevators are used:

Chain Bucket Elevator:

Chain bucket elevator is used when coarse
material is to be moved. In chain bucket
elevator, the buckets are connected by a chain
on both the sides. A chain bucket elevator can
also carry material at a higher temperature.
Chain bucket elevator can only carry the
material 60 to 70 m. This is because of the
tensile strength of the material with which the
chain is made. The material can only bear a
weight equivalent to this much height, otherwise, there is a huge risk of an
accident. This kind of bucket elevator is used in the raw press area and also in the
cement mill area where the material is coarse.

Belt Bucket Elevator:

Belt Bucket Elevator is used when the fine and a
low temperature material is to be moved. In this
type the buckets are attached together by a belt. Coarse material cannot be moved
in belt bucket elevator as it may cause damage to the belt on which all the buckets
are attached. High temperature may also cause damage to the belt. One of the
advantages of this type of bucket elevator is its increased range in terms of height.
It can carry the material to higher height than the chain bucket elevator. This is
used in the pre heater to take the material from the feed fister to the first stage
cyclone which is at the top of the pre heater. It is also used to take the cement to
the cement silo.

Belt Conveyor:
Belt Conveyor is also used to carry material
from one place to another. It is also used for
inter area transportation of material. It is
mostly used for the movement of coarse
material as it is open from the top so it
cannot carry powdered material. It is present
in almost all the areas of the factory. It
consists of belt which moves on rollers to
transport the material.

Pin Conveyor:
Pin conveyor transports material by means of pins that are mounted on roller
chains. Pin conveyor is used in carrying the clinker from the clinker crusher to
clinker silo.

Air Slide:
An air slide is used to carry material that is in
powdered form from one place to the other. In an
air slide the material is fluidized by low pressure
air. Then due to the slight angle of the air slide, the
material comes forward under the action of gravity.
Air slide is used in many parts if the factory, for
example, it is used to transfer the cement from the
cement mill area to the bucket elevator of cement
silo.
Couplings:
A coupling is a machine component that is used to connect two shafts together.

Various types of couplings are been used in the whole plant. The selection of
coupling is been done on the basis of the needs. Some of these couplings are
discussed below:

Fluid Coupling:
It is the type of coupling in which the transmission of
torque is done by a fluid. This coupling consists of a
casing, an impeller and a turbine. The impeller is
connected to the drive side and the turbine to the
driven side. When the impeller rotates, it pushes the
fluid forward towards the turbine. Pressure is
developed slowly and when sufficient pressure is
developed, the turbine will start to rotate. In the plant,
fluid coupling is used to connect the motor and the reducer in many places such as
the bucket elevators or the dynamic separator. Some advantages of fluid coupling
are as follows:

 It allows transmission without any mechanical contact, so it can absorb any

sort of mechanical shocks.
 It allows the motor to start at zero load, hence, reducing any chance of
damage to the motor.
 It can easily be decoupled by draining the oil out of it.
  It has a temperature switch which melts at the extreme temperature. This
causes the oil to drain out, hence, decoupling the shafts.

Universal Coupling:
It is the type of coupling that allows relative
rotation in two axes. In the plant, this type of
coupling can be seen connecting the drive and
reducer of the roller press. Some of the advantages
of this coupling are:

 It transmits torque between such shafts that

have angular misalignment.
 It also transmits torque between such shafts whose angular misalignment is
continuously changing.
 It can absorb shocks very effectively due to its flexibility.

Gear Coupling:
Gear coupling is a coupling that is used to couple two
shafts that are not collinear. In this type of coupling both
input and output shafts have a gear at their ends. These
are connected by a sleeve with internal gears. In the
plant, gear coupling is used to connect the main drive
and main reducer of the ball mill. Some advantages of
this type of coupling are:

 It can transmit huge torques.

 It can deal with slight linear misalignments.

Pin Bush Coupling:

It is the type of coupling in which there are two flanges
mounted on both the input and the output shaft. They are
connected by pins over which rubber bushes are used. In
the plant, this type of coupling is used to connect the
auxiliary drive and auxiliary reducer of the ball mill.
Some of the advantages of this coupling include:
  It is having a simple design.
 It can be assembled and dismantled easily.
 It can transmit high torques.
 It can work with slight shocks and vibrations.

Jaw Coupling:
It is the type of coupling in which there are two
jaws mounted on both the drive and the driven
shaft. These jaws are connected by a rubber
spider in order to avoid any sort of metal
contact that may cause wear. In the plant jaw
coupling is used to connect the fluid coupling
to the reducer of the motor of bucket elevator.
It is also used to connect the main and auxiliary reducer of kiln. Some advantages
are given below:

 This coupling can bear slight misalignments.

 It also has the ability to damp the shocks and vibrations, hence, protecting
the other components.

Bearings:
Bearing is a machine element that constrains undesired motion and allows desired
motion.

Various types of bearings are used in the plant. Some of them are discussed below:

Ball Bearings:
It is the type of bearing in which there is a ring of metal
balls. It is designed such that machine parts roll over each
other rather than sliding. This type of bearing is used in
places where the rotational speed is high.

Roller Bearings:
In this type of bearing, there is a ring of cylindrical rollers. This type of bearing is
used in places where the load is high.
Spherical Roller Bearings:
In this type of bearing, there are two rows of cylindrical rollers.
They are placed at such a degree that the whole shape seems like
part of a sphere. This type of bearing can bear angular
misalignments. That is why it is also called self aligning bearing.
This type of bearing can bear more load than ball bearing and
can be operated at a higher speed than roller bearing.

Tapered Bore Bearings:

This is the type of bearing, in which the bore of the bearing is
tapered. This type of bearing can be mounted on a tapered shaft
directly. In the case when we need to mount this bearing on a
cylindrical shaft, we use an adapter sleeve or a with drawl
sleeve.

Journal Bearings:
This is the type of bearing which does not use any balls or
rollers. Instead it uses oil as a media for rolling. This type of
bearing is used with the roller supports of the kiln and also in the
ball mill.

The End

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