INTERNSHIP REPORT

PRODUCTION OF CEMENT

1|Page
Acknowledgment
By the grace of Allah almighty I get a chance to do internship in Thatta cement
plant and I have learnt a lot during this internship. I am writing maximum
knowledge that I gained during this period.
I would like to thank the management staff at Thatta cement especially with their
help I gained a lot of information regarding the cement industry and also to gave
me an opportunity to learn and understand the working of organization as an
internee. They gave me chance to improve my industrial skills that will surely help
me in the practical field.

Below given are the table of contents and data which I collected during my stay at
this plant. With my limited knowledge I have tried to cover all the portions of the
plant which I have visited during my internship.

2|Page
Contents
Acknowledgment.......................................................................................................2
1 History Of Portland Cement....................................................................................6
1.1 Introduction Of Thatta Cement Company Limited..........................................6
1.1.1 Location:....................................................................................................7
1.1.2 Initiatives:..................................................................................................7
1.1.3 Valued Customers:....................................................................................7
1.1.4 Our Products:............................................................................................8
1.1.5 Advantages:...............................................................................................9
2. Cement Production Process.................................................................................10
2.1 Quarry And Raw Material..............................................................................10
2.1.1 Drilling.....................................................................................................10
2.1.2 Blasting:...................................................................................................10
2.1.3 Raw materials..........................................................................................10
2.2 Limestone/Clay Crusher.................................................................................11
2.3 Storage Yard...................................................................................................11
2.4 Raw Mill Area.................................................................................................12
2.4.1 Raw Mill..................................................................................................12
2.4.2 Cyclone....................................................................................................13
2.4.3 Bucket elevator.......................................................................................13
2.4.4 CF Silo......................................................................................................13
2.5 Preheater.......................................................................................................14
2.6 Burning in a kiln.............................................................................................15
2.6.1 The burning process................................................................................15
2.7 Clinker Cooler.................................................................................................17
2.8 Electrostatic Precipitator (ESP)......................................................................18
3|Page
 2.9 Clinker Storage...............................................................................................18
2.10 Coal Mill.......................................................................................................18
2.11 Finish Mill and Slag Mill...........................................................................18
2.12 Packing Plant:...............................................................................................19
2.13 Reactions Occurring.....................................................................................20
2.14 Gases Produced and NEQS...........................................................................20
2.14.1 Sox:........................................................................................................20
2.14.2 NOx:.......................................................................................................20
2.14.3 CO:.........................................................................................................20
3 Laboratory.............................................................................................................21
3.1 Soundness Test:.............................................................................................21
3.2 Setting Time:..................................................................................................21
3.2.1 Initial Setting Time:.................................................................................21
3.2.2 Final Setting Time:...................................................................................22
3.3 Expansion Test:..............................................................................................22
3.4 Compressive Strength Test:...........................................................................22
3.5 XRF Spectrometry Test:..................................................................................23
3.5.1 About X-ray fluorescence spectroscopy:................................................24
3.6 Blaine Test:.....................................................................................................24
3.7 Oli Well Cement.............................................................................................25
4 Instrumentation Devices.......................................................................................26
4.1 Temperature Sensors:....................................................................................26
4.1.1 Thermocouples:......................................................................................26
4.1.2 Resistive Temperature Devices:..............................................................26
4.1.3 Infrared Sensors:.....................................................................................27
4.2 Vibration Sensors:..........................................................................................27
4.3 Pressure Transmitters:...................................................................................28
4|Page
 4.3.1 Absolute Pressure Transmitter:..............................................................28
4.3.2 Gauge Pressure Transmitter:..................................................................29
4.3.3 Differential Pressure Transmitter:..........................................................29
4.4 Flue Gas Analysis:...........................................................................................29
4.5 Protection Devices.........................................................................................30
4.5.1 Relay:.......................................................................................................30
4.5.2 Magnetic Contactors:..............................................................................30
4.5.3 Circuit Breakers:......................................................................................30
5 Power Plant...........................................................................................................31
Motors..................................................................................................................31
6 Auto Shop..............................................................................................................32
7 Civil Department...................................................................................................33
8 Water Supply System............................................................................................34
9 Suggestions...........................................................................................................35

5|Page
1 History Of Portland Cement
The use of concrete dates back to the Roman Empire. The Castle de San Angelo
was built in Rome in 138 A.D. The stone facing was stripped away hundreds of
years ago, exposing concrete that is still in good condition. In North America, it is
believed that the mission priests in charge of construction learned the secret of
making natural cement from the Native Americans of Mexico. The widespread
knowledge and use of natural hydraulic cement was demonstrated by a diversion
dam in San Diego, California. Some believe this was the first concrete structure in
America, built in about 1769.
In 1824, Joseph Aspdin, a British stone mason, obtained a patent for a cement he
produced in his kitchen. The inventor heated a mixture of finely ground limestone
and clay in his kitchen and ground the mixture into a powder creating a hydraulic
cement – one that hardens with the addition of water. Aspdin named the product
portland cement because it resembled a stone quarried on the Isle of Portland off
the British Coast. With this invention, Aspdin laid the foundation for today's
portland cement industry. The first large use of this modern-day portland cement,
and its first engineering use, was in a tunnel under the Thames River in 1828. The
first recorded shipment of portland cement to the US was in 1868. The first
portland cement manufactured in the US was produced at a plant in Coplay,
Pennsylvania in 1871.

1.1 Introduction Of Thatta Cement Company Limited

Thatta Cement Company Limited was incorporated in 1980 as a public limited
company. It was a wholly owned subsidiary of the State Cement Corporation of
Pakistan (Pvt.) Limited. The manufacturing facility was commissioned in 1982. The
plant based on dry process technology, had a total installed capacity of 1,000 tons
per day of clinker. The plant was supplied by M/s. Mitsubishi Corporation, Japan.
In the year 2004, Government of Pakistan divested its shareholding from the
company through Privatization Commission.
The Company obtained listing on the Karachi Stock Exchange Limited as public
limited company in the year 2008. Share of Thatta
d over 233 acres of freehold land consisting of factory area, workers’ colony,
officers’ colony, commercial buildings and water reservoirs. Finest quality raw
material deposits are available close to the plant. These limestone and clay
6|Page
reserves are sufficient for about 100 years. In this respect, TCCL has the mining
rights for extracting limestone from 2,364 acres, shale/clay from 1,121 acres and
silica sand from 1,239 acres of land, respectively. The Company has further
acquired mining rights of limestone for a further area of 1,240.02 acres in
December 2010.
1.1.2 Initiatives:
Subsequent to the privatization, the management embarked on a number of
initiatives to improve performance and efficiency of the unit. These include:

 Induction of competent and experienced management personnel and

skilled workforce
 Capacity expansion by 50% (i.e. from 1,000 tonnes/d to 1,500 tonnes/d) of
clinker
 Refurbishment of 35 tons/hour cement grinding mill which was not
operational for almost two decades
 Securing ISO 9001:2008 certification
 Installation of 24 tons/hr coal grinding mill
 Establishment and installation of a modern, computerized state of the art
operations control system
 Conversion of the plant from furnace oil to multi fuel firing system (coal, gas
and furnace oil)
1.1.3 Valued Customers:
Some of their valued customers:
 Directorate General Procurement Army Dadex Eternit Limited
 Saima Construction & Developer Group Neelum Jehlum Hydro Electric
Project, AJK
 Frontier Works Organization Ssangyong Usmani Joint Venture
 Banu Mukhtar Limited China Fast Wind Power, Gharo
 Maqbool Constructions (Private) Limited Descon Engineering Limited
 China International Water & Electric Corporation Central Works
Organization
 Bahria Town Karachi Army Housing Directorate

7|Page
1.1.4 Our Products:
Ordinary Portland Cement:
Thatta OPC is unique in its Low Alkali content feature with a total content of
alkalies below 0.4 percent. Thatta OPC has an advantage that it can be used in
concrete made with aggregates that contain a form of silica which reacts with
alkalies if present in high proportion to cause an expansion which disrupts
concrete. Another special feature of the Thatta OPC is that it has low contents of
Tricalcium Aluminate. This helps to control the effect of spontaneous over-heating
in large masses of concrete and resistance to sulfate attack.
Thatta OPC prevents chemical attack and corrosion on RCC. Its low heat of
hydration makes it suitable for mass concreting. Its high early strength makes it
ideal for use in load bearing structures. Thatta OPC has a higher Blaine value and
fineness which facilitates denser concrete. Thatta OPC can be used in concrete
mortars and grouts. Thatta OPC is a technically advanced and cost effective
solution for construction above or below ground.

Sulphate Resistant Cement:

Thatta Sulphate Resistant Cement is suitable for application in areas affected by
salinity, coastal belts, piling work, dams etc. It gives protection from chemical
attack and corrosion. Its high early strength and low heat of hydration makes it
ideal for use in load bearing structures. Low alkali content is an additional feature
of Thatta SR Cement.
Portland Blast Furnace Slag Cement:
Thatta Slag Cement has excellent properties due to its higher fineness which
facilitates denser concrete, prevents penetration of chloride and sulphate solution
into the foundations. Thatta Slag Cement suits structures in hostile soil
environments with high salinity, harmful chemical agents which pose a risk to
foundation as well as the building. Thatta Slag Cement imparts better corrosion
resistance properties in reinforcement steel structures. Thatta Slag Cement can be
used in dams, bridges and earth retaining structures.

Ground Granulated Blast Furnace Slag:

GGBF Slag is ground to fineness of around 4,000 Blaine. It can be used for
blending with cement and also as a filler in foundations.
8|Page
1.1.5 Advantages:
The cement can be dispatched by road and rail as well in bulk tankers/containers.
Tremendous strength, better setting time, sulphate resistant properties, low heat
of hydration and low alkali content together with low expansion make Thatta
Cement an ideal building material both for above or below ground constructions.

2. Cement Production Process

The detail of production of cement process is given below.

9|Page
2.1 Quarry And Raw Material
Quarry is the place from where Raw Material is extracted. Drilling and Blasting is
done to extract the material. There are two types of quarry:
2.1.1 Drilling
Drilling is done in the quarry with the help of drilling machine, Crawler Drill
Machine that works on air compressor.
 The horizontal distance (Space) between two holes is 8 feet.
 Vertical distance (Burden) is approx. 2 feet.
 The Diameter of the hole is 75 mm.
 The depth of the hole is 15 to 25 feet.
 Drilling takes place after every two days period.

2.1.2 Blasting:
The powder explosive is blasted under a controlled process to get the rocks in the
form of pieces of different small sizes. This extracted material is loaded on
dumper trucks and conveyed to the crusher. The explosives used are ammonium
nitrate, nitro glycrine explosives which are provided by Biafo Industry Limited.

• 94% ammonium nitrate and 6% diesel is used.

• 50 holes are drilled and blast occur after every 25 seconds so that rocks
can be settled down. Last blast occurred in 50th hole after 2225 seconds.

2.1.3 Raw materials

The Raw Material used are given below
a) Lime Stone (80-85%):
This raw material is owned by company and is extracted from nearby quarry unit.
Limestone has the highest composition in the cement production.
b) Shale (15-20%):
Clay is another nature resource used in cement production. It contains Silicon in
abundance. Thatta Cement Company obtains Clay from Jungshah,30 km away
from site. 25% contribution in cement is of Silicon.

10 | P a g e
c) Additives (<1%): Iron Ore, Bauxite & Silica:
Iron ore is not extracted from quarry unit but it is bought from contractors. This is
added in very small quantity to strengthen the cement.

d) Gypsum (5%):
Gypsum is retarding agent and is used to increase setting time (to slow down
hardening process).

2.2 Limestone/Clay Crusher

Raw material such as limestone and clay are dumped into hoppers by dumper
trucks and entered into a Jaw crusher through an apron feeder.

 The capacity of hopper of jaw crusher is 150 tonnes.

 The capacity of Jaw crusher is 200 tonnes.
 The operating rpm of jaw crusher is 250.
 The final crushed obtains in size of 100 to 110 mm.
 The load of roller hammer crusher is 20 amp.
 The final size obtains by roller hammer crusher is 12 mm.

To deal with the magnetic particles, iron separator is used which is a magnet and
thus separates the ferric material out there. There are also a separate clay
hopper but mostly we used the same hopper.

Some of the machines or apparatuses present in crusher are following

2.3 Storage Yard

The yard on which we pile the crushed raw material is storage yard.
 There are two types of pile:
1. Horizontal
2. Cone
Horizontal pile is for limestone and cone is for shale.
 A pile which has length of 60 meters is equal to 1200 tonnes.

11 | P a g e
2.4 Raw Mill Area
The raw mill feed area consists of 3 feed hoppers:

I. Pure limestone hopper

II. Makli Shale hopper
III. Jangshahi Shale hopper

The capacity of first hoppers is 800 tons while the other two hoppers have a
capacity of 600 tons. The feed from each pile is conveyed to the hoppers through
conveyor belts in relevant hoppers. Each hopper has four load cells.

Load Cells are sensing devices from which the feed in required proportions is
transferred by the belt conveyor to the Raw Mill. A lot of dust is produced during
the conveying of material, to avoid this problem Bag Filters are installed.

2.4.1 Raw Mill

The raw material is collected in three hoppers. The capacity of limestone is 300 t,
Shale 1 is 110 and shale 2 is 110 t. The raw material from three hoppers is mixed
and send to raw for grinding. The hot gases from the preheater dries the mixed
raw material. After grinding the raw material is sent to classifier to separate the
required fined size particles. Now the fined sized feed is sent to silo via belt
conveyer.

 Raw mill contains a huge rotating disk, ball mill with the dimensions of
10.6m length and a diameter of 3.2m.
 The grinding media in the ball mill is balls made of alloy.
 There are three sections in the ball mill:
 1: Drying 2: Crushing 3: Grinding
 The total numbers of ball are 72, 35 in the 1 st section and 37 in the 2nd
section.
 Ball mill moves with the help of motor with an rpm of 16.6 and ball move
on it.

12 | P a g e
 Material on the rotating disk moves away toward the rollers due to
centrifugal force and thus grinded. Raw mill has a mechanism of hot gases
passing through it which takes very fine particles to the cyclones through
air separator and the coarse particles back to the raw mill by breaking their
kinetic energy. the temperature is up to 70-80 oC.

2.4.2 Cyclone
These are funnel type structures. Strong vacuum is created in them through dig
tubes suspended in their centres. Air with the grinded particles from the mill is
allow to come at very high velocity and move in circular manner due to the
designed shape of inlet. By this kinetic energy of material particles are broken
down and they are collected through rotary locks.

2.4.3 Bucket elevator

 Running belt has buckets attached to it.
 Material is filled into the buckets and the belt takes it to the destination
point It is a vertical belt conveyer.
 Used to transport material straight upward or downward.
 A belt runs in a straight vertical position.

2.4.4 CF Silo
The fine particles from the conditioning tower and electrostatic precipitator and
the powdered feed from the raw mill are conveyed to the bucket elevator. The
bucket elevator picks this feed and takes it to the top of the CF silo and then
throws it in. For burning 458 tonnes/hr is taken from the silo. In it flow of
material is counter current. CF silo have extract points. Air slides are also present
here. Here pressurized air is present at the bottom.

Specifications of a CF Silo:

Length = 54 m

Diameter = 22.4 m

Capacity = 25,500 ton

13 | P a g e
2.5 Preheater
Multistage preheaters and pre-calciners make use of the waste heat from the kiln
and clinker cooler to pre-heat and pre-process the kiln feed, and thereby allow for
considerable energy savings. Whenever economically feasible a wet process kiln
can be converted to a state-of-the art dry process production facility that includes
either a multi-stage preheater, or a multi-stage pre-heater and a pre-calciner.
Such transformations are usually feasible for new plants and major upgrades. Kiln
systems with five cyclone preheater stages and precalciner are considered
standard technology for ordinary new plants. Typical efficiency values that can be
obtained with the use of multi-stage preheaters and precalcination is provided in
the table below:

Process Fuel Consumption (GJ/t Clinker)

Wet Process 5.9 – 6.7
Long Dry Process 4.6
1 Stage Preheater 4.2
2 Stage Preheater 3.8
3 Stage Preheater 3.3
4 Stage Preheater 3.1
5 Stage Preheater 3.0 – 3.1
6 Stage Preheater 2.9

The feed is stored in silo after grinding in Raw mill, is transported to kiln feed bin
via bucket elevator and then transported to the impact flow machine to control
the amount of feed. Then feed is transported to the distributor just about
Preheater Cyclone 2N-2S and it will distribute the feed and send to Preheater
Cyclone 1N-1S. Preheater Cyclone 1N-1S will send the feed to 3N-3S and 3S-3N
will send into 5N-5S. Eventually, 5N-5S will sent the feed into kiln hose. The
Preheater 4 gets feed from 2N-2S and hot gases from 5N-5S.

Hot Gases from kiln and calciner will enter 5N-5S and from that cyclone the
exhaust gases will enter 3N-3S. From 3S-3N hot gases will enter 2N-2S and

14 | P a g e
eventually it will enter into 1N-1S. From 1N-1S, exhaust gases will sent to the Bag
filter.

2.6 Burning in a kiln

The next step in the process is to heat the blended mixture of raw ingredients (the
raw mix) to convert it into a granular material called cement clinker. This requires
maximum temperatures that are high enough to partially melt the raw mix.
Because the raw ingredients are not completely melted, the mix must be agitated
to ensure that the clinker forms with a uniform composition. This is accomplished
by using a long cylindrical kiln that slopes downward and rotates slowly.

To heat the kiln, a mixture of fuel and air is injected into the kiln and burned at
the bottom end. The hot gases travel up the kiln to the top, through a dust
collector, and out a smokestack. A variety of fuels can be used, including
pulverized coal or coke, natural gas, lignite, and fuel oil. These fuels create
varying types and amounts of ash, which tend to have compositions similar to
some of the aluminosilicate ingredients in the raw mix. Since the ash combines
with the raw mix inside the kiln, this must be taken into account in order to
correctly predict the cement compassion. There is also an increasing trend to use
waste products as part of the fuel, for example old tires. In the best-case
scenario, this saves money on fuel, reduces CO2 emissions, and provides a safe
method of disposal.

2.6.1 The burning process

This description refers to a standard dry-process kiln. Such a kiln is typically

about 60 m long and 4 m in diameter, has a downward slope of 3-4%, and rotates
at 1-2 revolutions per minute.

The raw mix enters at the upper end of the kiln and slowly works its way
downward to the hottest area at the bottom, undergoing several different
reactions as the temperature increases. It is important that the mix move slowly
enough to allow each reaction to be completed at the appropriate temperature.
15 | P a g e
Because the initial reactions are endothermic (energy absorbing), it is difficult to
heat the mix up to a higher temperature until a given reaction is complete. The
general reaction zones are as follows:

2.6.1.1 Dehydration zone (up to ~ 450˚C): This is simply the evaporation and
removal of the free water. Even in the “dry process” there is some adsorbed
moisture in the raw mix. Although the temperatures required to do this are not
high, this requires significant time and energy. In the wet process, the
dehydration zone would require up to half the length of the kiln, while the dry
process requires a somewhat shorter distance.

2.6.1.2 Calcination zone (450˚C – 900˚C): The term calcination refers to the
process of decomposing a solid material so that one of its constituents is driven
off as a gas. At about 600˚C the bound water is driven out of the clays, and by
900˚C the calcium carbonate is decomposed, releasing carbon dioxide. By the end
of the calcination zone, the mix consists of oxides of the four main elements
which are ready to undergo further reaction into cement minerals. Because
calcination does not involve melting, the mix is still a free-flowing powder at this
point.

2.6.1.3 Solid-state reaction zone (900˚ - 1300˚C): This zone slightly overlaps, and
is sometimes included with, the calcination zone. As the temperature continues
to increase above ~ 900˚C there is still no melting, but solid-state reactions begin
to occur. CaO and reactive silica combine to form small crystals of C2S (dicalcium
silicate), one of the four main cement minerals. In addition, intermediate calcium
aluminates and calcium ferrite compounds form. These play an important role in
the clinkering process as fluxing agents, in that they melt at a relatively low
temperature of ~ 1300˚C, allowing a significant increase in the rate of reaction.
Without these fluxing agents, the formation of the calcium silicate cement
minerals would be slow and difficult. In fact, the formation of fluxing agents is the
primary reason that portland (calcium silicate) cements contain aluminum and
iron at all. The final aluminum- and iron-containing cement minerals (C3A and
C4AF) in a portland cement contribute little to the final properties. As the mix

16 | P a g e
passes through solid-state reaction zone it becomes “sticky” due to the tendency
for adjacent particles to fuse together.

2.6.1.4 Clinkering zone (1300˚C – 1550˚C): This is the hottest zone where the
formation of the most important cement mineral, C3S (alite), occurs. The zone
begins as soon as the intermediate calcium aluminate and ferrite phases melt.
The presence of the melt phase causes the mix to agglomerate into relatively
large nodules about the size of marbles consisting of many small solid particles
bound together by a thin layer of liquid. Inside the liquid phase, C3S forms by
reaction between C2S crystals and CaO. Crystals of solid C3S grow within the
liquid, while crystals of belite formed earlier decrease in number but grow in size.
The clinkering process is complete when all of silica is in the C3S and C2S crystals
and the amount of free lime (CaO) is reduced to a minimal level (<1%).

2.6.1.5 Cooling zone: As the clinker moves past the bottom of the kiln the
temperature drops rapidly and the liquid phase solidifies, forming the other two
cement minerals C3A (aluminate) and C4AF (ferrite). In addition, alkalis (primarily
K) and sulfate dissolved in the liquid combine to form K2SO4 and Na2SO4. The
nodules formed in the clinkering zone are now hard, and the resulting product is
called cement clinker. The rate of cooling from the maximum temperature down
to about 1100˚C is important, with rapid cooling giving a more reactive cement.
This occurs because in this temperature range the C3S can decompose back into
C2S and CaO, among other reasons. It is thus typical to blow air or spray water
onto the clinker to cool it more rapidly as it exits the kiln.

2.7 Clinker Cooler

The clinker cooler is used to lower the clinker temperature. There are Induced
Draft (ID) fans which take fresh air from the atmosphere and send it to the cooler.
At the bottom of the cooler there are reciprocating rails which move with the
help of hydraulic motors. These rails convey the clinker forward to the clinker
crusher. It has four chambers.

17 | P a g e
2.8 Electrostatic Precipitator (ESP)
It removes air and dust by electrodes. Small hammer present it drop the dust to
hopper. Its mechanism based on crona effect. Very high voltages produced in EP .
The gases coming from rotary furnace after cooling enter ESP and then evaded to
atmosphere. Now these gases have temperature 300_360 Celsius and used in
waste heat recovery plant. The efficiency of ESP is 99.9%.

2.9 Clinker Storage

The clinker from the deep pan conveyor is stored in the clinker storage. Its
capacity is 12700 tonnes. Its length is 27.2 m and its height is 27 m. There are
gates at the bottom of the clinker storage from where the clinker is sent to finish
mill through belt conveyor. Besides the main clinker storage bin, there is a
temporary clinker storage which is dumped into clinker storage yard if the silo is
filled.

2.10 Coal Mill

In TCCL, Vertical Coal mill is used currently. Prior to this, furnace oil was used it
is expensive so coal was being used to make product economically. Coal is
imported from Indonesia and the size of coal is 40-60 mm.
 Coal is stored in storage yard then it is sent into hopper and hopper will
sent it into roller grinding machine to make fine powder.
 The fine powder coal is sent to the two hoppers that have capacity of 65
tonnes and 55 tonnes.
 These hoppers send coal to the burner and pre-calcinar with the rate of 7
tonnes and 5 tonnes per hours respectively.

2.11 Finish Mill and Slag Mill

In TCCL there are two mills in the final process one is Finish mill and the other is
Slag Mill. The main purpose of both of them are same. The function of them is to
produce two products at the same time otherwise it is also used to increase the
rate of production. The product capacity of Finish Mill is 85 tonnes/hr, while that
of Slag Mill is 35 tonnes/hr.

18 | P a g e
Clinker is stored in clinker silo then it is transported to the hopper via conveyer
belt and bucket belt. Others hoppers are also there that contain gypsum, slag and
limestone. A mixed and proportional feed is sent to raw and slag mill from the
hoppers and grinded.

The grinded feed is stored in the SRC, HSRC and OPC silo for storages that is
transported via conveyer belt and bucket belt.

2.11.1 Clinker Grinding

When the clinker cools and hardens then it is sent to the ball mill which is
installed after the cooler. Big stones of clinker are grinded to fine powder.
Gypsum is also added in here to control the quality. The fine material is than
dropped on the deep pan conveyor at the bottom of the conveyor which conveys
it to the storage. There are three storage silo each with a capacity of 3000
tonnes. In first silo there is Ordinary Portland Cement (OPC), in second silo there
is SLAG Cement, and in third silo there is

2.11.2 Storage Silos

Specifications of Storage Silos:

 Capacity: 75,00 tons

 Length: 42 m
 Diameter: 17 m

There are 3 cement storage silos in which crushed cement is stored up till
packing. To convey the cement to the other 2 silos air slides are used. Now these
air slides take the cement to the packing plant.

2.12 Packing Plant:

The packing plant comprises of rotary Packer which has eight nozzles to fill the
eight bags at same. Packer has a capacity of 2400 bags/h. The cement bags are
attached manually to the rotating packer which fills the cement bag. When the
bag is filled up to the required weight, it automatically falls on the conveyor belt
19 | P a g e
which takes the bags to the roller conveyor. From these rollers the bags slide to
different channels and finally cement bags are loaded on the trucks foe dispatch.

2.13 Reactions Occurring

 First of all, lime stone is taken it is heated upto 100 Celsius at this stage
bounded moisture is removed
 Now from 100_500 Celsius bonded water is removed.
 At third step at 88 Celsius CaCO3 is converted into CaO and CO2 which
escapes as it is in gaseous stage.
 Now in CaO silicon dioxide SiO2, Aluminium trioxide Al2O3 and Iron oxide
Fe2O3 is added which then converted into clinker which is intermediate
cement compound. In this C3S, C2S, C3A, C4AF are present. At normal Cao
and SiO2 not react at 2000 Celsius but with traces element they react at
1400 Celsius.
 Now in last step gypsum is added into clinker and cement is formed.

2.14 Gases Produced and NEQS

Sox which is SO2, NOx which is NO2 , CO is being produced here.

2.14.1 Sox:
As imported coal is used from Indonesia and it have 0.5% sulphur so Sox produced
is negligible. NEQS National Environment Quality Standard states that 1700
mg/Nm3 Sox can be present in one cubic and the analyzer detect that 80 mg/Nm3
is being produced on this plant.
2.14.2 NOx:
For NOx calciner provide reducing effect and reduces NOx. NEQS NOx standard is
1200mg/Nm3.
2.14.3 CO:
According to NEQS the quantity of CO can be 800mg/Nm3.

20 | P a g e
3 Laboratory
There are several physical tests that are done in Laboratories for the qualitative
analysis of cement of different types.
 Expansion test
 Setting time
 Residue On 90 µ %
 Compressive Strength
 Blaine Test
 Bomb Calorimeter test
 XRF Spectrometry Test

3.1 Soundness Test:

It is conducted by sieve analysis. 100 gms of cement is taken and sieved through
sieve 90µ for fifteen minutes. Residue on the sieve is weighed. This should not
exceed 10 per cent by weight of sample taken.

3.2 Setting Time:

Initial setting time and final setting time are the two important physical properties
of cement. Initial setting time is the time taken by the cement from adding of
water to the starting of losing its plasticity. Final setting time is the time lapsed
from adding of the water to complete loss of plasticity. Vicat apparatus is used for
finding the setting times. Vicat apparatus consists of a movable rod to which
consists of three rods. An indicator is attached to the movable rod.
3.2.1 Initial Setting Time: 500 gms of cement is thoroughly mixed with 125 ml of
water for standard consistency and vicat mould is completely filled and top
surface is levelled. 1 mm square needle is fixed to the rod and gently placed over
the paste. Then it is freely allowed to penetrate. In the beginning the needle
penetrates the paste completely. As time lapses the paste start losing its plasticity
and offers resistance to penetration. When needle can penetrate up to 5 to 7 mm

21 | P a g e
above bottom of the paste experiment is stopped and time lapse between the
addition of water and end if the experiment is noted as initial setting time.
3.2.2 Final Setting Time: The square needle is replaced with annular collar.
Experiment is continued by allowing this needle to freely move after gently
touching the surface of the paste. Time lapse between the addition of water and
the mark of needle but not of annular ring is found on the paste. This time is
noted as final setting time.

3.3 Expansion Test:

This test is conducted to find free lime in cement, which is not desirable. Le
Chatelier apparatus is used for conducting this test. It consists of a split brass
mould of diameter 30 mm and height 30 mm. On either side of the split, there are
two indicators, with pointed ends. The ends of indicators are 165 mm from the
centre of the mould.
Properly oiled Le Chatelier mould is placed on a glass plate and is filled completely
with a cement paste having 0.78 times the water required for standard
consistency. It is then covered with another glass plate and a small weight is
placed over it. Then the whole assembly is kept under water for 24 hours. The
temperature of water should be between 24°C and 50°C. Note the distance
between the indicator. Then place the mould again in the water and heat the
assembly such that water reaches the boiling point in 30 minutes. Boil the water
for one hour. The mould is removed from water and allowed to cool. The distance
between the two pointers is measured. The difference between the two readings
indicate the expansion of the cement due to the presence of unburnt lime. This
value should not exceed 10 mm.

3.4 Compressive Strength Test:

We take 185 gms of cement and then mixed it with the three samples of sand
each with a quantity of 185 gms so, the total weight is 555 gms now blend this
mixture with 10% of water to make a slurry in auto motar mixer for 2 minutes.
The mix is placed in a cube mould of 70.6 mm size (Area 5000 mm2) kept on a
steel plate and prodded with 25 mm standard steel rod 20 times within 8 seconds.
Then the mould is placed on a standard vibrating table that vibrates at a speed of

22 | P a g e
12000 ± 400 vibration per minute. A hopper is secured at the top and the
remaining mortar is filled. The mould is vibrated for two minutes and hopper
removed. The top is finished with a knife or with a trowel and levelled. After 24 ±
1 hour mould is removed and cube is placed under clean water for curing.
After specified period cubes are tested in compression testing machine, keeping
the specimen on its level edges. Average of three cubes is reported as crushing
strength. The compressive strength at the end of 3 days is 23 MPa and that at the
end of 7 days is 33 MPa and at the end of 28 days is 43 MPa.
Residue on 90 µ %
We need to determine the fineness of cement by dry sieving as per IS: 4031 (Part
1) – 1996.The principle of this is that we determine the proportion of cement
whose grain size is larger than specified mesh size.
The apparatus used are 90µm IS Sieve, Balance capable of weighing 10g to the
nearest 10mg.
Procedure to determine fineness of cement
Weigh approximately 10g of cement to the nearest 0.01g and place it on the
Alpine jet sieve. Agitate the sieve by swirling, planetary and through suction, until
no more fine material passes through it. Weigh the residue and express its mass
as a percentage R1, of the quantity first placed on the sieve to the nearest 0.1
percent. Gently brush all the fine material off the base of the sieve. Repeat the
whole procedure using a fresh 10g sample to obtain R2. Then calculate R as the
mean of R1 and R2 as a percentage, expressed to the nearest 0.1 percent. When
the results differ by more than 1 percent absolute, carry out a third sieving and
calculate the mean of the three values.
Reporting of Results
Report the value of R, to the nearest 0.1 percent, as the residue on the 90µm
sieve.

3.5 XRF Spectrometry Test:

Firstly, for XRF spectrometry we made a sample of cement and mix with them
with wax pills to make them a binder after then we put them in the Horzog
grinding machine to grind them so that if we pass them through a sieve of 45µ,
residue should be less than 10%. After this we use this grind and fill it in the ring

23 | P a g e
of Horzog press which works on the principle of hydraulic press after this our
sample is ready to be tested in the XRF
XRF is an analytical technique that can be used to determine the chemical
composition of a wide variety of sample types including solids, liquids, slurries and
loose powders. XRF is also used to determine the thickness and composition of
layers and coatings. It can analyse elements from beryllium (Be) to uranium (U) in
concentration ranges from 100 wt% to sub-ppm levels.
XRF is a robust technique, combining high precision and accuracy with
straightforward, fast sample preparation. It can be readily automated for use in
high-throughput industrial environments, plus XRF provides both qualitative and
quantitative types of information on a sample. Easy combination of this ‘what?’
and ‘how much?’ information also makes rapid screening (semi-quantitative)
analysis possible.
3.5.1 About X-ray fluorescence spectroscopy:
XRF is an atomic emission method, similar in this respect to optical emission
spectroscopy (OES), ICP and neutron activation analysis (gamma spectroscopy).
Such methods measure the wavelength and intensity of ‘light’ (X-rays in this case)
emitted by energized atoms in the sample. In XRF, irradiation by a primary X-ray
beam from an X-ray tube, causes emission of fluorescent X-rays with discrete
energies characteristic of the elements present in the sample.
The technology used for the separation (dispersion), identification and intensity
measurement of a sample’s X-ray fluorescence spectrum gives rise to two main
types of spectrometer: wavelength dispersive (WDXRF) and energy dispersive
(EDXRF) systems.

3.6 Blaine Test:

The most common method for characterizing the surface area of a cement is the
Blaine air permeability test, which is described by an ASTM standard. This test is
based on the fact that the rate at which air can pass through a porous bed of
particles under a given pressure gradient is a function of the surface area of the
powder. A chamber of known cross sectional area and volume is filled with a
known mass of cement, and then the time required to pass a known volume of air
through the powder is measured. While the surface area can in theory be
calculated explicitly from this data, in practice the surface area is determined
24 | P a g e
through an empirical equation developed by measuring powders of a known
surface area using the same instrument. The resulting value, called the Blaine
fineness, is today expressed in units of m2 /kg, although in previous times it was
expressed in cm 2/g. The Blaine fineness of OPC usually ranges from 300 – 500
m2/kg (3000 – 5000 cm 2 /g).

3.7 Oli Well Cement

A special kind of cement is also produced in Thatta Cement, which is basically
used in oil wells. As is it resistive to oil and its derivatives so in the oil well this
kind of cement is used in such types of wells thus it is manufactured and supplied
on demand. So, for this type of cement special tests are also applied to check the
quality of the cement.
 HPHT Consistometer for thickening time, in this type of test it describes the
detail of thickening or hardening the material during the pumping.
 Atmosphere Consistometer for free fluid, in this type of test we check the
emitting of water during settling.
 Compressive Strength, in this test we check the strength of the cement that
how much pressure it could resist.

25 | P a g e
4 Instrumentation Devices
There are several instruments and used in cement industry are given below.
 Temperature Sensors
 Pressure Transmitters
 Vibration Sensors
 Actuators

4.1 Temperature Sensors:

4.1.1 Thermocouples:
Thermocouples are voltage devices that indicate temperature by measuring a
change in voltage. As temperature goes up, the output voltage of the
thermocouple rises - not necessarily linearly.
Often the thermocouple is located inside a metal or ceramic shield that protects it
from exposure to a variety of environments. Metal-sheathed thermocouples also
are available with many types of outer coatings, such as Teflon, for trouble-free
use in acids and strong caustic solutions.
Thermocouples measure voltage change and signify temperature.

4.1.2 Resistive Temperature Devices:

Resistive temperature devices also are electrical. Rather than using a voltage as
the thermocouple does, they take advantage of another characteristic of matter
which changes with temperature - its resistance. The two types of resistive
devices we deal with at OMEGA Engineering, Inc., in Stamford, Conn., are metallic,
resistive temperature devices (RTDs) and thermistors.
In general, RTDs are more linear than are thermocouples. They increase in a
positive direction, with resistance going up as temperature rises. On the other
hand, the thermistor has an entirely different type of construction. It is an
extremely nonlinear semi conductive device that will decrease in resistance as
temperature rises.
Resistive devices change in resistance as temperature shifts.

26 | P a g e
4.1.3 Infrared Sensors:
Infrared sensors are noncontacting sensors. As an example, if you hold up a
typical infrared sensor to the front of your desk without contact, the sensor will
tell you the temperature of the desk by virtue of its radiation - probably 68°F at
normal room temperature.
In a noncontacting measurement of ice water, it will measure slightly under 0°C
because of evaporation, which slightly lowers the expected temperature reading.

4.2 Vibration Sensors:

Chaos sometimes begins with a low rumble or a small shake. If a sensor is
involved, it might be measuring the first vibrational movements of an earthquake
or a mechanical failure in an industrial setting. It’s typically noise that gives us the
first clue that trouble looms—and if trouble is what you’re trying to avoid, there
can be two aspects of vibration you should pay close attention to:
1. The monitoring of vibration
2. Maintenance based on sensor data to avoid future issues
Why monitor vibration? Vibrations produced by industrial machinery are vital
indicators of machinery health. Vibration analysis is used as a tool to determine a
machine’s condition and the specific cause and location of problems, expediting
repairs and minimizing costs. Machinery monitoring programs record a machine's
vibration history. Monitoring vibration levels over time allows prediction of
problems before serious damage can occur.
Critical to vibration monitoring and analysis are machine-mounted sensors. Three
parameters representing motion detected by vibration monitors are
displacement, velocity and acceleration. Mathematically related, the parameters
can be taken from a variety of motion sensors. Selection of a sensor proportional
to displacement, velocity, or acceleration depends on the frequencies of interest
and signal levels that are involved.
Displacement sensors are used to measure shaft motion and internal clearances.
Non-contact proximity sensors sense shaft vibration relative to bearings or other
support structure. The sensors are used in low-frequency (1 to 100 Hz)
measurement and measure low-amplitude displacement typically found in sleeve-
bearing machine designs. Piezoelectric displacement transducers solve issues
27 | P a g e
associated with mounting non-contact probes and are more suitable for rolling
element-bearing machine designs. Piezoelectric sensors yield an output
proportional to the absolute motion of a structure.
Velocity sensors are used for low to medium frequency measurements (1 to 1000
Hz) and are useful for vibration monitoring and balancing operations on rotating
machinery. They have lower sensitivity to high frequency vibrations than
accelerometers and are therefore less susceptible to amplifier overloads.
Overloads compromise low amplitude, low frequency signals. Traditional velocity
sensors use an electromagnetic coil and magnet system to generate the velocity
signal. Today, piezoelectric velocity sensors are becoming popular due to
improved capabilities and their rugged nature.
Accelerometers are the preferred motion sensors for most vibration monitoring.
They measure low to very high frequencies and are available in a variety of
general purpose and application-specific designs. The piezoelectric accelerometer
is reliable, versatile, unmatched for frequency and amplitude range, and popular
for machinery monitoring.
Five main features must be considered when selecting vibration sensors:
measuring range, frequency range, accuracy, transverse sensitivity and ambient
conditions. Measuring range can be in Gs for acceleration, in/sec for linear
velocity (or other distance over time), and inches or other distance for
displacement and proximity.
Frequency is measured in Hz and accuracy is typically represented as a percentage
of allowable error over the full measurement range of the device.
For the ambient conditions, such things as temperature should be considered, as
well as the maximum shock and vibration the vibration sensors will be able to
handle.

4.3 Pressure Transmitters:

Pressure transmitters are essentially used in measuring various types of process
pressures. We have:

4.3.1 Absolute Pressure Transmitter: This transmitter measures the pressure

relative to perfect vacuum pressure.
28 | P a g e
4.3.2 Gauge Pressure Transmitter: This transmitter measures the pressure
relative to atmospheric pressure at a given location. When the pressure gauge
reads 0 PSI, it is means pressure is atmospheric.

4.3.3 Differential Pressure Transmitter: This transmitter measures the difference

between two or more pressures introduced as inputs to the sensing unit. They are
used to measure the pressure drop across an oil filter for example. They are also
popularly used to measure flow or level in pressurized vessels.

4.4 Flue Gas Analysis:

A cement kiln is a cylindrical furnace. From one side of the kiln, pieces of lime
stone enter this furnace, and a hot flame is at the other end. The inside
temperature is around 1200 oC. At this high temperature, the limestone is heated,
and it breaks into calcium oxide, and carbon dioxide.
CaCO3 ------ > CaO + CO2.
This process is known as calcination. From the CO2 content, the efficiency of
calcination is known to the operator. Also they can judge on the final cement
quality. Hence it is very important to
measure the CO2 at the Cement Kiln .
In the pre-heater, the ball mill, and the raw mill, air ingress from outside, will
increase the false air, and thus reducing the heat available. This air enters inside
because of negative pressure, and because there are cracks or openings in the
stack. Inside the stack, the heat produced can’t be effectively used in the process
because of false air. So it is very important to measure this false air in all above
locations.
In a ball mill and raw mill, O2 & CO is also checked for effective or complete
combustion. Improper combustion will increase CO content.
 In a Cement Kiln – measuring CO2 directly using an IR (infrared) sensor.

 At the pre-heater, ball mill and raw mill – O2 content is checked to monitor
the change in false air, due to air ingress.
29 | P a g e
  Combustion in ball mill and raw mill – O2, CO, CO2 measured to check
effective and complete combustion.

The testo solution for the above cement applications is a testo 350 with O2, CO,
and a CO2 IR sensor . It is recommended to use a Peltier Chiller, and a fresh air
valve. This will help long term measurements, and also take care of moisture that
may be present in stack gas.

4.5 Protection Devices

4.5.1 Relay:
It is an electrically operated switch. It is used to connect two terminals of power
circuit with low control voltage. Its working principal is based on electromagnet.
DC source is applied to it and coil present in it gets energized to form an
electromagnet. The energized coil attracts the metallic piece towards its self to
connect two terminals of power circuit with each other. In this way power circuit
gets completed with low control voltage. Some auxiliary contact is also present
for control and indication purposes.

4.5.2 Magnetic Contactors:

In 3-phase circuits, a Magnetic Contactor is used instead of relay. It makes and
breaks 3 contacts at same time because any delay in phase availability can be
very harmful for machine. The working principal of contactors is magnetization of
coil. The coil is energized by an external dc or ac source. When coil gets energized
it pulls out a mechanical assembly which in turn makes or breaks power contacts.
Some auxiliary NO and NC contacts are also available for indication and
interlocking purposes.

4.5.3 Circuit Breakers:

It is an electromagnetic automatic switch which operates when current drawn by
machine is not as per requirements C.Bs are of different types depending on their
working principal i.e electromagnetic and thermal type. Electromagnetic type
operates when coil inside it gets energized by main power source current, only
when current exceeds some specific value. Thermal type operates under working
principal of bimetallic strips, made by special selected metals for specific ratings.

30 | P a g e
5 Power Plant
For continuous and smooth operations of the plant uninterrupted power supply is
very crucial. The power is supplied to the huge machinery with the help of

 From WAPDA of 132 KVA.

 From Company Power Station of 11 KVA
The company has its own power generation plant along with WAPDA supply. The
power provided by WAPDA is converted to 6.3 KV by the step down transformer.
The Company power plant consists of Seven Generators. There are seven gas
generators each with the capacity of 3.3 MVA. There are also two stepdown
transformers that convert the voltage to 6.3 KV. The details of the transformers is
given below.

Connection Type Capacity (MVA)

For Wapda 15
For TCCL Power Station 20-26

Motors
Motors of the following power are being used mainly.
Name Power (kW)
Limestone Crusher
Kiln
Raw Mill
Finish Mill

31 | P a g e
6 Auto Shop
The purpose of auto shop is to provide the services to production and mechanical
department. The list of services is given below.

SR.N Services Total quantity

1 MF-Tractor-240 1
2 Compressor PDR-600 1
3 Lincon Welding Plant 2
4 Bulldozer 1
5 MF-Tractor-375 1
6 Dump Truck QY-17 1
7 Wheel Looder-120 1
8 IZUSU Truck TD- J50 2
9 Fork Lifter FD-20 1
10 Fork Lifter FD-45 1
11 M.A.N Generator 200KVA 1
12 Cement Tanker 2
13 Concreate Mixing Machine 1
14 Truck Crane 80-T 1
15 Volvo Dump Truck R-32 1
16 Belarus Tractor MTZ.50 1`
17 Fork Lifter FD-30 1
18 Fork Lifter FD-50 1`

32 | P a g e
7 Civil Department
The main function of civil department is to check all the maintenance work done
on the plant site as well as on the colonies site. On the plant site, there main focus
is on the Kiln, Preheater, Burner, and Cooler. As they have to apply insulation
boards, insulation wool and chemical insulation boards in order to make the
processes taking place safely.

33 | P a g e
8 Water Supply System
 TCCL gets its water from KB (Kalari Baghar) feeder, Indus river.
 Water is transported through a paved channel into two ponds which has a
capacity of 1 crore and 1.3 crore respectively.
 The distance of paved channel is 1000m and the distance between pond
area and site reservoir is 3347 meters.
 The diameter of the pipe is 6 inches.
 The paved channel has a width of 2 feet and a height of 3 feet.
 Three pumps are installed at pond area that pumps water to the site
reservoirs with the rate of 600 gal/min.
 The capacity of site reservoirs is 24 lakhs gallons each.
 There is a bed filter with the capacity of 3.2 gallons.
 Two pumps are installed at site reservoirs that supply water to industry,
officer colony, worker colony, and for gardening for drinking and industrial
purpose.
 Water is cleaned by chlorination method on weekly basis.
Water Supply Water consumption
Industrial Use 50000-60000 gal/day
Grid Station 5m3/hr per engine
Worker, officer Colony 250000gal/day
Gardening 24000gal/day

34 | P a g e
9 Suggestions
 Data regarding to internship should be provided at first day, so that
internee go through the process taking place.
 There should be a common room in which people could be able to give
suggestions freely.
 Internet should be provided for research purpose.

35 | P a g e