Satna Cement Works Six Weeks Training Report

Birla Corp. Ltd.

By:-
Deepesh Kumar Mishra
11202732
Satna Cement Plant
Counted amongst the larger plants of the Cement Division, Satna Cement Works
and Birla Vikas Cement at Satna (MP) along with Raebareli Cement Works (UP)
have an installed capacity of 2.36 million tones at present, which is projected to rise
to 2.84 million tones after the present expansion/modification.

Birla Cement Samrat and Birla Cement Khajuraho are already leading Brands and
frontrunners of company’s activities. Riding on the glory of very high standards of
quality, the company products are premierly priced in all the markets where it is
available.
Plant Layout
00. Limestone Quarry and Crushing plant
01. Limestone Stockpile
02. Additives Hopper
03. Additives Storage
04. Raw Mill Building
05. Blending and Storage Silo
06. Preheater
07. Gas Conditioning Tower and ESP
08. Kiln
09. Cooler
10. Deep Bucket Conveyor
11/12. Clinker/Gypsum Storage
13. Coal Mill Building
14. Cement Mill and Bag House
15. Cement Storage Silo
16. Packing & Dispatch
17. Central Control Room
Process Flow Chart
00. Limestone Quarry and Crushing plant

The major raw material for cement production is

limestone.

The limestone most suitable for cement production

must have some ingredients in specified quantities
i.e., calcium carbonates, silica, alumina, iron,etc
Belt Conveyors
The quarried raw material is transported to the
cement plant, using mechanical conveying
equipment such as ropeways or belt conveyors, or
by vehicles like wagons and trucks.

There are mainly two types of crushers available

- compression type or impact type crushers.

Imapct Crusher
01 Limestone Stock Pile

Circular or longitudinal stock piles are used to store

the material.

A number of layers are stacked in circular or

longitudinal piles and are reclaimed in transverse,
cross-sectional slices.

02 & 03 Additives Storage Hopper

In order to get the required composition of raw
material, certain additives such as iron ore, bauxite,
laterite, quartzite and flourspar are added in required
quantities.

These additives are stored at the plant in separate

hoppers and are extracted using belt conveyors in
conjunction with belt-weighing equipment.
04 Raw Mill Building

The raw material is finish-ground before being fed

into the kiln for clinkering. This grinding is done
using either ball mills or vertical roller mills (VRM).

VRM uses the compression principle to grind the raw

material.

The main advantage of VRM is higher grinding

efficiency and ability to accept material with higher
moisture content.

Normally the energy consumption level in VRM is

10 to 20 percent lower than in ball mills.

VRM
05 Blending and Storage Silo

In order to blend and homogenize the raw materials

properly, continuous blending silos are used.
As there are various sources of raw materials, it becomes
necessary to blend and homogenize these different
materials efficiently to counteract fluctuation in the
chemical composition of the raw meal.

06 Preheater

Clinkering takes place in the kiln and the preheater

system.Preheater systems offer heat transfer from the
hot kiln gases.
07 Gas Conditioning Tower and ESP
The conditioning tower is used to reduce the temperature and to increase the moisture level
of the dusty exhaust gas from the kiln, before it is passed through the bag house and ESPs.

The Electrostatic Precipitators are used in cement plants particularly for removal of dust
from the exit gases of cement kilns and from the exhaust air discharged by dryers,
combined grinding and drying plants, finishing mills and raw mills through water injection.

08 Kiln
A kiln is the heart of any cement plant.

It is basically a long cylindrical-shaped pipe, and

rotates in a horizontal position. Its internal surface is
lined by refractory bricks. Limestone and additives
are calcined in this. The output of the kiln is called
clinker.
09 Cooler

The clinker coming out of the kiln is hot. It is cooled

in a set-up called a cooler. In the cooler, cold air is
blown to effect heat exchange between hot clinker
and cold air.

10 Deep Bucket Conveyor

The deep bucket conveyor is essentially an equipment to

lift material vertically.
11 Clinker Storage
The output of the kiln is stored before it is fed to the
cement mill for conversion to cement.

12 Gypsum Storage

The storage space is used for gypsum storage.

13 Coal Mill Building
The coal mill building houses the
mill for grinding lumpy coals. This
fine ground coal is used for burning
in the kiln.

14 Cement Mill and Bag House

Clinker, along with additives, is ground in a
cement mill. The output of a cement mill is the
final product viz. Cement.

The term bag house is applied to large filters

containing a number of tubular bags mounted in a
usually rectangular casing. The dust laden air is
drawn through them by suction.
15 Cement Storage Silo

The cement storage silo is used for storing the finished

product – cement.

16 Packing and Dispatch

The cement is packed with the

help of a rotary packer and finally
dispatched to the market.
17 Central Control Room

It is the nerve center of the cement plant since all equipment is controlled from this
place. It is the place from where all the process parameters are controlled.
Gantt Chart of 6 weeks Training