SCHOOL OF MINES

DEPARTMENT OF MINERAL PROCESSING ENGINEERING

INTERNSHIP REPORT ON MESSEBO CEMENT FACTORY P.L.C

NAME ID NO

1. ABEL HAILE...................................................................................................................................AKU1002085

2. BINIYAM G/SEASSIE....................................................................................................................AKU1002741

3. BRI SELEMUN................................................................................................................................AKU1001338

4. FREHIWOT HAREGOT...............................................................................................................AKU1002657

INTERNSHIP START INTERNSHIP SUBMISSION

ON 05/03/2016 E.C ON 01/06/2016E.C

SUBMITTED TO: - Dr. Rao

Mrs. Trhas

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 ACKNOWLEDGEMENT

First and for most we would like to deliver our sincere gratitude to almighty of God for his
unpaid favor who aid us to achieve on this level. We have taken a lot of efforts in this
Internship program. However, it would not have been possible without the kind support and
help of many individuals and organizations; we would like to extend our greatest thank to all
of them. First, we would like to express our deepest thank to Aksum University shire
campus, Mr. Bereket (Aksum University Shire Campus School of Mines dean) and Mr.
Welegebrieal (Aksum University Shire Campus Mineral Processing Engineering Department
Head) for planning and organizing the internship program. We would like also thank to our
Excellency University advisor’s Dr. Rao And Ms. Trhas N. for their guidance and
suggestions during this internship work. next to our special thanks company supervisors Mr.
Teddros Abera and Mr. Geremedhin Hailu for providing us his instruction, guidance,
inspiration, and support throughout our internship program and who supported us both for
the technical and theoretical aspect for our internship program in the company respectively,
and we would like to express our deepest gratitude to all Messebo cement factory engineers
and workers. In addition, we wish to express our love and gratitude to our beloved family
and friends for their moral and financial support in this successful completion of this
dissertation and we would like to thank Mekelle University to give a dorm and other
important things like Wi-Fi. Generally, we would like a great appreciation for all the
community of the messebo cement factory that helps us from starting to end our internship
visit and report for their voluntariness to given importance of information and data.

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 ABSTRACT

This is our internship report, it contains all activities we did, observe and corporate with our
advisor. It is categorized in to five main chapters with including of some subtopics; the first
chapter provides the background of the company including organizational structure of the
company, objectives of the internship and Limitation and assessment of the company. The
second chapter contains resources of the raw materials and mining activities includes types
and source of raw materials, mining method and mining operation. The third chapter
contains work flow of the processing includes different sections in the production process of
cement in the messebo cement factory. The sections are crusher, pre-homogenizing storages,
proportioning unit, raw mill system, raw meal homogenization, kiln feed, pre-heater, pre- calcite,
kiln system, clinker cooler, cement mill and packaging and detail discussion of these section is
provided on this chapter. The fourth chapter contains over all safety and some hazards. The
last chapter contains conclusion and recommendation.

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TABLE OF CONTENTS

CONTENTS PAGES

ACKNOWLEDGEMENT................................................................................................................i

TABLE OF CONTENTS.................................................................................................................ii

LIST OF TABLES........................................................................................................................viii

ABBREVATION............................................................................................................................ix

ABSTRACT.....................................................................................................................................x

SYMBOLS.........................................................................................................................................

CHAPTER ONE..............................................................................................................................1

1. INTRODUCTION........................................................................................................................1
1.1 Back ground of Messebo Cement Factory PLC.....................................................................1
1.1.1 Vision of the company.....................................................................................................3
1.1.2 Mission of the company...................................................................................................3
1.1.3 Objectives of the company...............................................................................................3
1.1.4 Values of the factory........................................................................................................3
1.1.5 Customers or end users of Messebo cement factory........................................................4
1.1.6 Organizational Structure of the Company.....................................................................5
1.2 General Feature of the Messebo Cement Factory..................................................................6
1.2.1 Location and access of the company...............................................................................6
1.2.2 Climate and vegetation of the company...........................................................................6
1.3 Objective of the internship.....................................................................................................6
1.3.1 General objective.............................................................................................................6
1.4 Methodology...........................................................................................................................7
1.4.1 Pre-field...........................................................................................................................7
1.4.2 during field.......................................................................................................................7
1.4.3 Post field..........................................................................................................................7

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 1.4.4 Material use......................................................................................................................7
1.5 Limitation and assessment of the internship...........................................................................8
1.5.1 Limitation of the internship.............................................................................................8
1.5.2 Assessment of the internship...........................................................................................8

CHAPTER TWO...........................................................................................................................10

RESOURCES OF THE RAW MATERIALS................................................................................10

2.1 Types of Raw Materials........................................................................................................10
2.2 Source of raw material..........................................................................................................12
2.3 Source of energy of the factory............................................................................................13
2.3.1 Coal plant.......................................................................................................................13
2.4 Mining methods....................................................................................................................15
2.4.1 Surface Mining..............................................................................................................15
2.4.2 Underground mining......................................................................................................18
2.5 Mine Equipment and Machineries........................................................................................18
2.6 Mine operation......................................................................................................................18

CHAPTER THREE........................................................................................................................24

WORK FLOW OF THE PROCESSING.......................................................................................24

3.1 Processing plants..................................................................................................................24
3.2 Process flow description of Messebo cement factory..........................................................24
3.3 Crusher.................................................................................................................................25
3.3.1 Mechanical Component of Crusher...............................................................................30
3.3.2 Electrical component of crusher....................................................................................31
3.3.3 Particle size distribution of all raw materials.................................................................31
3.4 Material conveying mechanism............................................................................................32
3.5 Raw material storage............................................................................................................33
3.6 Proportioning unit.................................................................................................................38
3.7 Raw material mill.................................................................................................................40
3.8 Grit separator........................................................................................................................43
3.9 Cyclone.................................................................................................................................44
3.10 Bag filter.............................................................................................................................44

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 3.11 Controlled flowed storage silo (C.F-silo)...........................................................................45

3.12 Pyro processing (Preheater, kiln and cooler).........................................................................46

3.12.1 Pre-heater.....................................................................................................................47
3.12.2 Kiln..............................................................................................................................49
3.13 Clinker storage....................................................................................................................51
3.14 Cement mill..........................................................................................................................52
3.15 Types of cement product....................................................................................................55
3.16 Packing and Dispatch...........................................................................................................56

CHAPTER FOUR..........................................................................................................................58

SAFETY AND SOME HAZARDS..................................................................................................58

4.1 General information..............................................................................................................58

CHAPTER FIVE............................................................................................................................60

CONCLUSION AND RECOMMENDATION.............................................................................60

5.1 Conclusion............................................................................................................................60
5.2 Recommendation..................................................................................................................60

REFERENCES...............................................................................................................................62

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LIST OF FIGURES

Figure 1:Picture of the company......................................................................................................2

Figure 2: Organizational structure of cement factory PLC..............................................................5
Figure 3: Coal.................................................................................................................................14
Figure 4: Open pit mining..............................................................................................................15
Figure 5: Drilling machine.............................................................................................................17
Figure 6: Drilling bore holes..........................................................................................................17
Figure 7: Detonator cord................................................................................................................18
Figure 8: Emulsion.........................................................................................................................19
Figure 9: AMFO (Ammonium Nitrate with fuel oil).....................................................................19
Figure 10: Transporting machine...................................................................................................20
Figure 11: General flow sheet of MCF..........................................................................................22
Figure 12: Hammer crusher............................................................................................................24
Figure 13: Hopper..........................................................................................................................24
Figure 14: Apron feeders...............................................................................................................25
Figure 15: Roll hammer crusher.....................................................................................................26
Figure 16: Mechanical component of hammer crusher..................................................................28
Figure 17: Belt conveyer................................................................................................................30
Figure 18: Stacker..........................................................................................................................31
Figure 19: Chevron method...........................................................................................................32
Figure 20: Cone method.................................................................................................................32
Figure 21: Reclaimer machine.......................................................................................................33
Figure 22: Schematic of raw material proportioning process........................................................34
Figure 23: Ball mill and grinding media........................................................................................36
Figure 24: VRM (Vertical Roller Mill)..........................................................................................38
Figure 25: Cyclone.........................................................................................................................39
Figure 26: Bag filter.......................................................................................................................40

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Figure 27: CF-silo of MCF............................................................................................................41
Figure 28: Schematic diagram of pyro processing system.............................................................42
Figure 29: The flow of gases and materials in pre-heater..............................................................43
Figure 30: Kiln...............................................................................................................................45
Figure 31: Clinker silo of line two and line one respectively........................................................47
Figure 32: Schematic of finish milling system in a cement plant..................................................48
Figure 33: Cement mill..................................................................................................................48
Figure 34: CF silo...........................................................................................................................49
Figure 35: Packing machine...........................................................................................................50
Figure 36: Safety materials............................................................................................................52

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LIST OF TABLES

Table 1: Quality of limestone.........................................................................................................11

Table 2: Source of raw material and their composition.................................................................12
Table 3:Types of coal and their values...........................................................................................13
Table 4:Crusher specification.........................................................................................................26
Table 5: Crusher capacity and grain size.......................................................................................29
Table 6: Proportioning bins capacity line one and line two...........................................................35
Table 7:Dosimat feeder capacity line one and two........................................................................35
Table 8: Comparison between CF-silo line one and line two........................................................40
Table 9: Thermal energy optimization in pyro - processing..........................................................46

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ABBREVATION

CCR Central Control Room

CF-silo Controlled Flow silo

COK Kiln and Cooler

CRM Crusher and Raw Mill

CMP Cement Mill and Packing

Dep’t Department

ESP Electro Static Precipitator

LHHSR Low Heat High Sulphur Resistant

MBMP Messebo Building Materials Production

MCF Messebo Cement Factory

OPC Ordinary Portland Cement

PFD Process Flow Diagram

PLC Portland Limestone Cement

PPC Portland Pozzolana Cement

PCA Portland Cement Association

TDA Tigray Development Association

AF Apron Feeder

ANFO Ammonium Nitrate and Fuel Oil

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PLC Private Limited Company

ID Induced Draft fan

VRM Vertical Roller Mill

SYMBOLS

Al2O3 ….......Aluminium oxide (Shale)

CaCO3….... Calcium carbonate (Limestone)
CaO ….........Calcium oxide
SiO2……… Silicon oxide (Silica Sand)
CO2…......... Carbon dioxide
C3A.....……Tricalcium aluminate
C4AF…........Tetra-calcium alumina-ferrite (ferrite)
C2S…………Dicalcium silicate (belite)
C3S…............Tricalcium silicate(alite)

x
xi
 CHAPTER ONE

1. INTRODUCTION

Cement is a crystalline compound of calcium silicates and other compounds having hydraulic
properties, which reacts with water to produce strength-bearing lattices.
Cement is a powdery substance made by calcining lime and clay, mixed with water to form
mortar or mixed with sand, gravel, and water to make concrete, which is used for construction
that sets, hardens, and adheres to other materials to bind them together. The strength and
durability of concrete makes it one of the most useful materials developed by man.
Cement = clinker + additive(s)
Cement clinker is manufactured primarily from limestone, shale, silica sand and iron ore bearing
as raw materials. These materials are blended and finely comminuted to form the raw meal. The
process of manufacture of cement consists essentially of crushing and grinding of the raw
materials, mixing them intimately at certain proportions and burning them, usually in a rotary
kiln at a temperature of approximately 1450 ºC. The material sinters and partially fuses to
promote the formation of the clinker phases. The principal phases in the cement clinker are tri-
calcium silicate, Dicalcium silicate, tri-calcium aluminate and calcium alumina ferrite.
the clinker is then cooled and ground to fine powder with the addition of a few percent of
gypsum to form cement. The additive(s) can be gypsum, Pozzolana, and high-grade limestone
and the corrective material can be iron ore and silica sand.

1.1 Background of Messebo Cement Factory PLC

The name Messebo is derived from the name of nearest mountain known as “Messebo” which
is located around Mekelle town 790 KM far away to the north of Addis-Ababa in Tigray
regional state. The plant is located 7 km to the north-west of Mekelle town near Messebo hills.
Messebo cement factory, Private Limited Company (MCFPLC) is one of EFFORT
(Endowment Fund for the Rehabilitation of Tigray). The factory has two large mostly separated
lines which produce the same product. They were erected (implanted) at different time by different
companies or countries. These are known as line one and line two. Line one was implanted in

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1993 E.C by FLSmidth of Denmark Company and After the installation was completed
commissioning of its product was started in 2000 with best quality and at highest standard with
a capacity of 2000 tons / day and 5 stage cyclone preheater systems used for clinker production
and Line two in 2003 E.C by China Company. Most Ethiopians work on line one and are most
familiar with that, but in line two some China’s experts are working together with Ethiopians. The
investment capital of the first line is around ETB 1.3 billion and the second line is about ETB
2.2 billion and this Messebo cement Expansion project is inaugurated by his Excellency prime
minister Meles Zenawi on 18/10/2003 E.C. The most and modern technology usage is that of
the new which was china’s Company has clinker capacity of 3000t/d. The factory (line-2) is a
dry type rotary kiln system, latest pre-calciner technology and 6-stage cyclone pre-heater
systems used for clinker production. Also, it has bag filters rather than ESPs for dust collection
and gas treatment. The company is producing Ordinary Portland Cement (OPC), Portland
Pozzolana Cement (PPC), Portland Limestone Cement (PLC) and Low Heat of Hydration
Cement (LHHS). The factory's production capacity is 7,000 tons per day and 2,100,000tons of
cement annually. At present the company has 1800 permanent, 240 contract and 51 temporary
workers.

Figure 1:Picture of the company

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1.1.1 Vision of the company

 To enhance the assets of its welfare in such a way that assets are invested in profitable
lucrative business to as to continue its welfare activities on a sustainable base.
 MCF is highly committed and has social responsibility to support and be involved in the
development activities of the Tigray region in particular and the whole nation in general.
 To contribute to the social and economic development by investing in those business
areas which are neither covered by the government nor private businessman.
 To become the leading cement manufacturer in the country and become exemplary in
boosting derived privately owned businesses in the region and in the country at large.
1.1.2 Mission of the company

 Being competent in global market.

 Entering in a progressive development path.
 Being an exemplary company in a country.
 To assure its existence and become a profitable company a sustainable basis and support
the continuously growing for construction industry with the supply of construction
materials of acceptable quality and reasonable price.

1.1.3 Objectives of the company

 To create broadband sustainable market by supplying competitive product that fulfill

customer requirement.
 Enhance property ownership and ensure sustainable profit.
 Create conductive work environment.
 Develop human resources, Create job opportunities.
 Enhance regional development.
 Control/ remove causes for environmental pollution.

1.1.4 Values of the factory

 Commitment and hard working
 Team work
 Integrity (honesty)

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  Trust and empowerment
 Innovative (advanced) learning culture
1.1.5 Customers or end users of Messebo cement factory

Messebo cement factory PLC is one of the biggest suppliers of cement next to Durban Midroc
cement factory and Mugger cement factory. Currently due to the ongoing war Messebo, cement
factory is not producing any type of cement and those, which had already produced, sold at a
high cash rate at this time more than 1000 Ethiopian birr in a market.

In order to satisfy consumers, MCF PLC distributes several types of cement within reasonable
values to branch stores of cement in Addis Ababa, Bahir Dar and Dessie. Besides, it has a direct
distribution channel to Gonder, Ghambella, Weldia, Kanissia, Semera etc. Messebo cement
factory PLC builds governmental and nongovernmental institutions in Ethiopia. For instance,
governmental institutions like Tekeze hydroelectric power station, roads, Gilgelgibe
hydroelectric power station and currently the great Ethiopian renaissance dam (GERD) project
and etc. in addition to the governmental institutions there are several Non-governmental
institutions which include institutions built by contractors, concrete product manufacturers and
retail shop builder. The most widely used types of cement in Ethiopia are Ordinary Portland
Cement (OPC) and Pozzolana Portland Cement (PPC). Generally, the main consumers of the
plant’s production are the whole Ethiopian people for the purpose of huge buildings, Bridges,
dams, house buildings and small constructions. But, as a general the main customers of Messebo
cement factory (MCF) plc. Are:

 Building and road construction contractors

 Concrete products manufacturer
 Dam construction contractors; Ethiopian grand renaissance dam used to be one of the
main customers of the company but now a day it has stopped due to the transportation
cost.
 Household decoration decorators.

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1.1.6 Organizational Structure of the Company
The company has different functional departments, divisions, sections and units under the
umbrella of the general manager. The company has permanent, contract and trine employs with
different educational level and various experiences. The overall organization of the company is
as follows;

Figure 2: Organizational structure of cement factory PLC

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1.2 General Feature of the Messebo Cement Factory

1.2.1 Location and access of the company

Messebo cement factory is located around Mekelle town 790 KM far away to the north of
Addis-Ababa in Tigray regional state. The plant is located 7 km to the north-west of Mekelle
town near Messebo Hills. The Company is close to asphalt road and to the mekelle capital
city of Tigray region. So, the product of the company can access easily by the community.
1.2.2 Climate and vegetation of the company
The climate condition of Messebo cement factory was relatively hot. But it has various
climate condition from season to season. Means fluctuation of condition between summer
and winter by temperature and rain fall. In the morning climate condition is cold whereas
during the day time is relatively hot. The average temperature is around 24.5°c Plants in the
quarry of Messebo hill area are rare whereas inside the company the plants are relatively
populated. As a result, the climate inside the plant is cooler than the quarry site.

1.3 Objective of the internship

1.3.1 General objective

 The general objective of this internship program is to build up our practical skill in mineral
processing industry.

1.3.2 Specific objective

 It creates understanding about the way of drilling and blasting.
 It creates understanding about the way of crushing and transportation of raw
materials.
 It creates understanding about grinding of raw materials.
 It creates understanding about separators like cyclone and bag filter.
 It helps to know the way of homogenizing the raw materials.
 Creates understanding about size control and the way of clinker production.

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1.4 Methodology

1.4.1 Pre-field
 We gather information that relates with the company
 Taking related courses before visiting the company
 Put individual thinking.
1.4.2 during field
 Taking photo, videos, data
 Collecting data and real information about the company
 Measure the depth and width of each bore holes to know how much amount of
ammonium nitrite is needed to blast limestone
 Measure the distance of bore hole space and burden space to get proper blast
during blasting of limestone
 Asking the community of the plant
1.4.3 Post field
 After the conducting field work writing report
 Further reading for additional information
 Evaluation of the company
 Give any comments about the company
1.4.4 Material use
Different types of camera like phone
Writing equipment like pen, exercise book, paper
Personal computer
Measuring equipment(meter)
prevalence data (like softcopy, module of the company e.tc) &reference book.

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1.5 Limitation and assessment of the internship

1.5.1 Limitation of the internship

 At the first week of internship there was difficult to get car, to go to quarry area.
 Lack of sufficient reference book and data
 There is no internet access
 Shortage of safety materials
 Some idlers are not working/rotating
 Luck of accurate measurement during drilling bore holes
 Luck of efficient bag filter causes loss of fine material through the chimney
 During the time of collecting data we asked the same question for different
workers under the same occupation and we will get different answers. In this case
we could not select and trust the right information.
 The companies have no any computer lab. Due to this reason we faced a problem
in order to analyse the reports.
1.5.2 Assessment of the internship
1.5.2.1Interms of upgrading theoretical knowledge
 The internship is important to relate the theoretical knowledge that has been learned in class
with the practical knowledge gained from the company.
1.5.2.2Interms of improving practical skill
 Create understanding about mining operation.
 Helps to know the way of drilling and blasting.
 Helps to understand how raw materials transport from quarry to the storage hall in
the plant.
 Helps to know method of reclaim and stack (pile) raw materials in storage hall.
 Helps to know how the Hammer crusher reduces the size of the feed.
 Create understanding how to control the flow rate, temperature and pressure of the
process industry.
 Understand way of burning of fine materials in kiln and the flow of gas and
material in pre-heater.

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  Understanding of different types of problems that can occur during mineral processing
and possible ways to address these problems.
1.5.2.3 Interms of improving industrial solving capability
From the intern ship program, we have developed skill how to solve industrial problems using the
following procedures;
 Identifying the problem
 Gathering information about the problem
 Break the problems in to part
 Identify proper solution
 Select best solution
 Take an action
 Examine result
1.5.2.4 Interms of improving team playing skills
 Team work allows to make friends and to enjoy a better social experience when
studying and working.
 We have developed how to make a better decision, creating participation,
involvement and generating a diversity of ideas.

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 CHAPTER TWO

RESOURCES OF THE RAW MATERIALS

Now Messebo cement factory currently produces two types (OPC, PPC) of cement. But
based the order of customers they can produce four types of cement. These cements are
different by their raw material composition.

2.1 Types of Raw Materials

The raw materials are extracted from different areas. Lime stone and shale are extracted from
quarry (where the mining activity is performed) and which is located 2 km away from the crusher
site where as the other raw materials are brought from nearby area that is gypsum from
hagereselam, iron ore from wukro, pozzolana from wejerat and silica sand from shiguashugi.
These raw materials are grouped in to: Calcareous (lime), Argillaceous (alumina), Siliceous
(silica) and Ferriferous (iron). Messebo cement factory totally uses six types of raw materials
Messebo cement factory uses six different raw materials to produce four different types of
cement types. These cement types apply the raw materials in different amount or level to meet
their characteristic level of hardness, settling time and strength.

Raw materials: material used for the cement production

I. Main raw materials: are the basic raw materials used in higher amount in the
production of cement and those are limestone and shale.
II. Corrective raw material: are raw material that used in secondary to main raw
material in amount and those are silica sand and iron ore
III. Additive raw materials: these raw materials are used during the cement milling
process to produce the final product which is a gray colour cement. Three types of
additive raw materials which are, gypsum, pozzolana, and high-grade lime stone.
Those additives determine the type of final cement product.

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 In Messebo cement factory in order to produce different types of cement, we need raw
materials. Raw materials are extracted from the earth through mining and quarrying. Messebo
cement industry uses six total raw materials as input to produce the final product cement. These
are;

1) Limestone (CaO): is the most important non-metallic raw material used for industrial and
agricultural purposes. It is the main constituent for manufacturing of cement, which imparts
cementing property to cement. This type of raw material is found around the plant owned
hill, which is conveyed by approximately 3km belt conveyor to the storage hall after blasting
and crushing. messebo cement factory uses 75-80% limestone as raw material. In limestone
the quality is determined by its Cao composition.
Note: Limestone involves high-grade, medium-grade and low-grade limestone.

Quality of limestone Percentage of Cao (%)

High grade of limestone > 48
medium grade of limestone 47 – 48
Low grade of limestone 44 – 47

Table 1: Quality of limestone

2) Silica sand (SiO2): is a corrective raw material and used for clinker production.in this raw
material the chemical component is Silicon oxide (SiO 2). This plays a major role in imparting
strength to concrete. Silica undergoes the chemical reaction with calcium to form di- calcium
silicate (C2S) and tri-calcium silicates (C3S). Excess silica adds strength to cement but it prolongs
the setting time.

3) Shale (Al2O3): The shale quality is mostly determined by composition of Cao and Al 2O3. these
forms complex compounds with silica and calcium to impart setting property of cement. It acts as
a flux and lowers the clinkering temperature. Use of an excess amount of alumina quickens
setting time but reduces the strength of cement. Depth of shale in the Quarry site is 7m.

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4) Iron ore (Fe2O3): is a corrective material used for the production of cement in order to
increase the strength of produced cement. This is mainly responsible for imparting colour to
cement. The hardness and strength are also improved to a certain extent.

5) Gypsum (CaSO4.2H2O): Gypsum is a soft white or grey mineral consisting of hydrated

calcium sulphate. It is one of the most abundant minerals and occurs more abundantly in
association with limestone. The quality of gypsum is adequate for use in cement production to
control setting time of cement. The chemical component in this is sulphuric oxide.

6) Pozzolana: Is finely divided siliceous or siliceous and aluminous material that reacts
chemically with slaked lime at ordinary temperature and in the presence of moisture to form
strong slow-hardening cement. Now messebo cement factory instead of pozzolana raw material
dolerite is used.

2.2 Source of raw material

The raw material such as limestone and shale are mining from near messebo whereas iron ore,
silica sand, Gypsum and pozzolana type of raw material are brought from another place. Where
the Sources of raw materials are given in the table below.

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 Raw material Location Distance(km) Oxide Composition

Limestone Messebo 3 CaO 48.5-52%

Al2O3 1.6-2.9%

Shale Messebo 3 Al2O3 20-40%

SiO2 6-15%

Silica sand Shigashigo 17 SiO2 70-80%

Iron Ore Wukro 34 Fe2O3 40% and above

Pozzolana Wejerat 77 Al2O3, Fe2O3, 70% and above

SiO2

Gypsum Hagereselam 48 SO3 40-50%

Table 2: Source of raw material and their composition

2.3 Source of energy of the factory

MCF consumes high amount of energy. Energy can be gas, liquid or solid. From this MCF, use
oil from liquid, coal and sesame husk from solid energy. Generally, source of energy for
Messebo cement factory includes:

 Electrical energy
 Furness oil
 Coal

2.3.1 Coal plant

Coal -is fossil fuel made from the remaining of dead body of plants under high temperature
through millions of years? The raw material coal comes from jimma and South Africa. The South

13
Africa coal and Jimma coal are differing in their calorific value and in their age. Their calorific
value is as follows:

Type of coal Calorific value (k calorie/kg of fuel)

South Africa coal 5000-6800

Jimma coal 3000-4500

Table 3:Types of coal and their values

The coal plant has its own instruments starting from crusher up to the last coal mill. The raw
mill for coal plant is vertical mill like that of cement plant. After we get the last stage of this plant
the powder will go to pre calciner and kiln. Primary fuel combustion occurs in the kiln burning
zone. Secondary burning takes place in a special combustion chamber between the rotary kiln
and the preheated. In this chamber up to 60% of the total fuel can be burnt in a typical
precalciner kiln. This energy is basically used to calcine the raw meal, which is almost
completely calcined when it enters the kiln.

14
 Figure 3: Coal

2.4 Mining methods

Mining method is removal of over burden and ore from the ground with underground and surface
mining.

2.4.1 Surface Mining

Surface mining is essentially that of mining coal, copper and iron ores and the nonmetallic
minerals like shale, gypsum, rock, sand and stone.

15
 Figure 4: Surface mining

First, the overlying soil and rock layers (over burden) are removed. The raw material is then
fractured with explosives or machines, and loaded on to dumpers for haulage from the mine
site. There are two surface mining used by Messebo quarrying of raw material.
2.4.1.1 Open pit Mining
This is bench-shaped excavation, normally by rope-or hydraulic shovels with trucks carrying
both ore and waste. Drill and blast are most often used. Waste is dumped outside the mined-
out area or dump site since no room is available within the pit. Waste is placed as close to the
edge of the pitas possible, to minimize transport costs.

Benches are normally excavated 15m in height in between which is a crest on which the haul
road is placed. This type of mining is done for limestone and shale near the factory.

16
 Figure 5: Open pit mining

2.4.1.2. Open cast mining

The over burden is cleared and removed using large earth moving equipment’s such as
shovels and trucks ore excavators and trucks. Drill and blast are most often used, which
makes the process cyclic. This over burden is put in to the previously mined (empty) strip.
Generally, overburden is removed from the mine top layers and stacked along periphery of
mined area. This type of surface mining is done at the quarry site of gypsum in Hagere-Selam.
When all the over burden is removed, the under lying gypsum in the block may be drilled and
blasted (if hard) or ripped (if soft or friable), and loaded on to trucks for transport to a
crushing.

17
2.4.2 Underground mining
Raw material in which all extracting operations are conducted beneath the ground surface is
termed as underground mining. Underground mining methods are usually employed
under the following consideration

 Spatial/ geometric characteristics of the deposit concerned: shape, size, thickness, depth.
 Strength of the hanging wall, footwall, and ore body.
 Economic value of the ore and grade distribution with in the deposit.
 Generally, the underground mining is not employed in Messebo Cement Factory because
it is practiced for expensive and minimum quantity mineral ore of mining operation.
Thus, it is costly for mining of huge material like cement.

2.5 Mine Equipment and Machineries

 Earth moving machineries: used for clearing of the over burden materials up to 12 m
depth.

 Rig machine: is crawler mounted drilling machines for bore holes preparation at the clear
site and used for sampling.
 Dozers: are used for extracting limestone from ground area.
 Loaders and Front shovel excavators: blasted fragments are loaded to the dumper and trucks
is by the help of dozers and front shovel excavators

 Dumpers: are used to transport and dump blasted fragments of limestone and shale to the
crusher to crush.
 Trucks: are used for transport and dump the blasted fragments of iron ore, silica sand,
gypsum and pozzolan at another crusher to crush.

2.6 Mine operation

Quarry: In cement factory the first process is raw material quarrying. This means that the
specified area that originates the raw material or raw material preparation area.

18
 Quarry is a place where mining activity is performed. Quarry in messebo cement factory is
located 3km away from the plant. Limestone and shale are brought from the quarry but the other
raw materials (iron ore, silica sand, gypsum and Pozzolana) are brought from another place.
Quarrying is the breaking of the rock in a safe and economic way and transporting the result
to a plant for further reduction in size, which consists of raw material blasting, loading, and
transporting to a crusher.
❖ Quarrying operation consists of the following steps: -
1. Area clearing: is removing out the over burden material. The over burden material is removed up
to 12-meter depth by the earth moving machinery. The method of removals and machinery
usages relatively to the overburden nature, depend on:

 Strength and hardness

 Thickness of the layer
 Load bearing capacity
 Susceptibility to weathering
2. Drilling: bore holes at the clear site by drill or rig machine, the size of bore hole it may be 4
inch (100mm) or 6 inch (150mm) in diameter and the height is 15 meter and 18 meters
respectively.

Figure 6: Drilling machine

19
  Borehole Spacing: It is the distance between adjacent blast holes in a row, measured
Perpendicular to the burden space. Close spacing caused crushing and Holes spaced too
far apart will result in inadequate fragmentation.
 Burden Spacing: It is the distance perpendicular to the borehole space. Too small a
burden can result in excessive air blast and fly rock; on the other hand, too large a
burden can result in improper fragmentation and excessive ground vibration.
messebo cement factory uses a triangular drill, because this type of drill is used for
in high grade value of raw material.

Figure

7: Drilling bore holes

3. Blasting: is making of fragments of raw material from the ground surface using chemical
explosive. There are two systems of blasting in messebo;

 Electrical: -electrical system of blasting uses detonator which connects with emulsifies
and grounded it in the bottom of bore holes and it can expose immediately with in
microseconds.

 Non-electrical: –the non-electrical system of blasting uses detonator inserted in to the

Emulsion and grounded it inside the boreholes after that fill the boreholes with ANFO and
lastly with soil. All the wires of detonator connected with surface connector line by line

20
 and surface connectors connected with safety fuse. Finally, it will burn or explode
slowly.

In Messebo cement factory there are three explosive materials for blasting the rock
formation after drilling the bore holes. Those explosive materials are:

Detonator cord
Emulsion
ANFO (ammonium nitrate with fuel oil)

A. Detonator cord: is a thin, flexible, plastic tube usually filled with Pentaerythritol tetra nitrate
(PETN) exploding at a rate of approximately 4 miles/second. It is a high-speed fuse which
explodes rather than burns, and is suitable for detonating high explosives.

Figure 8: Detonator cord

21
B. Emulsion: an explosive material containing substantial amount of oxidizer dissolved in
water droplet surrounded by an immiscible droplet fuel or droplet of an immiscible fuel

Figure 9: Emulsion

C. ANFO (ammonium nitrate with fuel oil): is a widely used bulk explosive mixture. It
consists of 99.5% of porous ammonium nitrate (NH 4NO3) that acts as the oxidizing magnet
and absorbent for the fuel. In messebo cement factory the overall blasting technique is
generally as follows; first a bore holes of 4 inch or 6 inch in diameter having thickness of 15m
or 18m respectively are drilled then the detonator cord will be inserted in to the bore holes and
buried with the emulsion and filled with the ANFO and fill it with soil up to1m thickness above
the ANFO. The soil should be compacted. After doing all those detonator cord discharged
with 1.5volt by a blaster machine. Due to this 1.5 volt the detonator cord will be ignited and
the solid ANFO starts changing in to a gas, then this gas having an elevated temperature will
be compressed in to a high pressure this rise in temperature and pressure causes a shock or a
detonation wave and hence an explosion.

22
 Figure 10: ANFO (Ammonium Nitrate with fuel oil)

4. Loading & transporting: is transporting extracted (rock pieces) raw materials from
quarry site to crusher plant by dumpers (can carry 40-50 tone), Sino truck, or ASTRA truck.
The blasted material is loaded in to dumpers and trucks with the help of excavators, Loaders
and Front shovels to transport the raw materials to the crusher hopper.

Figure 11: Transporting machine

23
 CHAPTER THREE

WORK FLOW OF THE PROCESSING

3.1 Processing plants

The processing plant has two large mostly separated lines which produce the same product.
They were erected (implanted) at different time by different companies or countries. These lines
are known as line one and line two. Both line one and line two are equipped with hammer
crusher that has different crushing capacities, storage hall, proportioning unit, raw meal for line
one and vertical raw meal for line two, kiln, cement mill and cement packing machine.

3.2 Process flow description of Messebo cement factory

The whole process of cement manufacturing in messebo cement plant, which consists of two
separate cement production lines can be summarized in to the following processes: -

 Quarrying
 Crushing
 Raw material Storage and Transportation
 Proportioning or raw mix
 Raw material Grinding, separator
 Raw meal storage, homogenization and transportation
 Pyro processing (Raw meal preheating, Calcination, Clink erization, Rotary kiln,
Clinker cooling) and Clinker storage
 Cement grinding and storage
 Cement packing and Dispatch

24
 Figure 12: General flow sheet of MCF

3.3 Crusher

Crusher is the process of reducing of the large size of raw materials in to smaller size. The rock
materials run through a crusher that turns rock in to smaller pieces. The quarried limestone is
normally in the form of big boulders, ranging from a few centimeters to meters in size. These
varying sizes of limestone need to be crushed by different crusher to a size of about <75mm (line
two) and <25%mm (line one and additive) in order to be prepared for finished grinding in
vertical roller mills and ball mills respectively. Messebo cement factory have three hammer
crushers for the two production lines. Materials that are transported from the mining area are
directly feed to the hopper and transported by apron feeder to inlet roller and finally to hammer
crusher.

Note; the principle of crushing of the three crushers (line1, line2, and additive) is the same but
the only difference is

25
  The number of hammer (for line 1 and additive is 32 and line 2 has 64 hammer)
 Capacity (the capacity production of line 1 and additive crusher is 450ton/hr., and the
capacity production of line2 crusher is 900-1000ton/hr. when it was new but now it
crushes around 900ton/hr.)
 And lines 1 has inlet roller and chain rode

A crusher is a machine designed to reduce large rocks in to smaller rocks, gravel, or rock dust. It
is used to reduce the size, or change the form, of materials so they hold material between two
parallel or tangent solid surfaces, and apply sufficient force to crush the material.

Figure 13: Hammer crusher

Hopper: - is funnel-shaped receptacle container for delivering raw materials for crushers. The
raw material for cement production comes from the quarry, the grain size is less

26
Figure 14: Hopper
 than900×1100×1000mm.

Apron feeder: - it is used to transport the collected raw material from hopper to the inlet roller.
Apron Feeders are designed for varying applications, from light to severe-duty that requires moving
high tonnages of coarse material too severe for other types of feeders. The continuous steel belt of the
Apron Feeder is made up of over lapping flights or pans that are connected to and supported by
steel chains with the underside rein forced and designed to with stand impact loading.

Figure 15: Apron feeders

The inlet rollers accurately control the feed to the crusher and ensure a smooth and even flow
of material, whether one or two inlet rollers are used depends on the method of feeding the
crusher. The apron feeder, which is normally used, maintains a consistent feed rate and requires
only one inlet roller. The types of crushers in Messebo cement factory are: -

27
A. Crusher unit for line-1(32 hammer number)
This type of crusher used by Messebo cement factory is geared hammer crusher with inlet
roller. The main motor of this type of crusher is geared motor which convert electrical
energy to mechanical energy. It’s also safety pin function as emergency stop switch and
limit switch to prevent the main motor from damage. Crushing operation is impact
crushing, between hammers and breaker plate.

B. Crusher unit for line-2(64 hammer number)

This type of crusher is double rotor single stage hammer crusher, with two main motor. This
type of crusher has two motor related at same direction. The crushing mechanism of this
line-2 is impacting, shearing, and compression between hammers and breaker plate between
hammer and grate.

Figure 16: Roll hammer crusher

C. Additive or corrective crusher (32 hammer number)

This type of crusher is used for crushing corrective and additive materials.it is single stage
hammer crusher with one main motor. It has a rotor which rotates to crush the material at
high speed. The crushing mechanism is similar to geared hammer of line-1.

28
❖all the three crushers are hammering type crushers and their specification is described in the
following table.

Table 4:Crusher specification

NO
Parameter Crusher line Crusher Line Two Additive Crusher
one

1 Model EV 200*200 2NPC1818 double PCF2018single stage

rotor

2 Capacity 450 t/h 900-1000 t/h 450 t/h

production

3 Power consumption 0.7 kw 0.9 Kw 1.7Kw with its

for one tone reclaimed
limestone

4 Inlet roller Yes NO(Anvil) NO(Anvil)

5 Crushed material All raw Limestone and shale All Additive raw
material material

6 Mill feed size 95% < 25 mm 95% < 75 mm Similar with line one

5 % > 25 mm 5 % > 75 mm

7 Number of 32 64 32
hammers

8 Stage Single stage Double stage Single stage

9 chain scraper Yes No No

10 safety pin Yes No No

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3.3.1 Mechanical Component of Crusher
1. Housing
Is welded metal construction which is divided in to a number of sections which are assembled by
mechanical means, the rotate top part is a part of housing which is opened by hydraulics cylinder
valves. The bottom section carries the bearing of the crusher for inlet roller & hammer rotor
constitutes the support structure for the number of the outlet grate the entire top section of the
crusher.
2. Inlet roller
The inlet roller shaft runs in roller bearing of which the two bearing on the drive side are
equipped with the location ring. the shaft carries hubs on which the roller casing is mounted on
the shock absorbing rubber pads.

3. Hammer rotor
The rotor is core of the crusher .it consists of hammer hung disk. End disk. Hammer. Hammer
shaft. Big bolt wheel bearing &bearing support. the hammers are arranged so that two successive
rows of hammer are displaced by the width of hammer relative to each other.
4. Breaker plate
It is adjusted using a manually operated hydraulic cylinder which can be fitted in various
positions depending on the direction break plates is displaced.
5. Outlet grate
Consists of primarily of the members & grate bars, the grate can be adjusted using the hydraulic
cylinder when hammer & grate plate bars us worn. The grate adjustment is necessary to adjust
the gap between grate &rotor for keeping the normal discharge size & capacity &increasing the
usage of hammer.

30
 Figure 17: Mechanical component of hammer crusher

Key:

1= hammer rotor 2= inlet roller 3= hammers

4= outlet grate 5= railway for sliding 6= breaker plate adjustment
7= spare hammer 8= top part (housing) 9= hydraulic tool for opening
10= main drive station 11= membrane station 12= drive station for inlet roller
3.3.2 Electrical component of crusher
The crusher & the crushed raw material transportation system include many electrical
equipment’s like motor, circuit breakers, internal distribution board, cables, transmitter receiver.
Programming logic control (PLC), solenoid valves, sensors & lighting system, the function of
motor is to rotate the shafts & the shafts changes the electrical energy to mechanical energy to
the other shaft connected gear mechanism.

3.3.3 Particle size distribution of all raw materials

The particle size of material can be controlled by decreasing and increasing feed flow for fining
or coarsening respectively. For line one crusher grate plate is adjusted in 25-35mm with hammer
difference to crush the material 95% ≤ 25mm and for additive or corrective crusher and line two
limestone and shale crusher the grate is adjusted between 36-40 mm to bring 95% ≤ 75 mm and
the maximum not more than 100mm distribution.
Table 5: Crusher capacity and grain size

31
 Crusher type Capacity Grain size(underflow)

Crusher line-1 400-450tone per hour 25mm

Crusher line-2 900-1000tone per hour 75mm

Additive/corrective crusher 400-450tone per hour 25mm

3.4 Material conveying mechanism

Materials are conveyed by belt conveyor and some places by apron feeder plate mechanism. The
conveying mechanism is supported motors and by other auxiliaries like pulley and idlers.
A. Apron plate feeder: - is used to convey different kind of particulate, lumpy material in
horizontal or inclined direction; apron plate feeder is composed of head driving device, tail unit,
take set, chain, through plate device and frame.

Figure 18: Apron plate feeder

32
B. Belt conveyor: - is like long sheet made up of rubber that is used for transportation of
crushed raw materials from crushed to pre-homogenizing storage & to other places, conveying
raw as material by belt conveyor or includes drive station, drive pulley, scrapper, take up station,
plough deflector. Counter weight, belt conveyor cover frame & idler. belt conveyor is a long
sheet made up of rubber that which is used for transportation of crushed raw materials from
crusher to pre-homogenizing storage and to other places.

Figure 19: Belt conveyer

3.5 Raw material storage

It is a longitudinal storage hall, which consists of stacker and reclaimer machines. It stores
limestone, shale, silica sand, iron ore, gypsum and pozzolana. Crushed materials are going to the
storage hall through belt conveyor. There are three storage halls; these are: -
a. Additive material storage: - for gypsum, iron ore, silica sand and pozzolana (dolerite)
b. Line 2 material storage: - for shale and limestone

33
c. Line 1 material storage: - for limestone, shale, silica sand, iron ore, gypsum and pozzolana
(dolerite).
The stacker is electrically controlled equipment which stack raw material either in chevron or
cone shape system. The stacker is electrically controlled equipment which stack raw material
either in chevron or cone pile system. Reclaimer is used for reclaiming of limestone and shale,
and discharging it to a conveyor system leading to an intermediate silo through belt conveyor.
Silica sand and iron ore are feed to the hopper by loader and transported through belt conveyor to
the proportioning unit. Within the raw material storage there are a lot of sensors those indicate
the stacker where to perform its application.

1. Stacker

❖ the main application of stacker is filling the raw material storage

It receives crushed stone / coal from the crusher. It consists of a movable carriage which moves
on rails along the proposed stock piles. Length of travel is equal to length of two piles when they
are lineally arranged plus some more. Stacker belt goes over this movable carriage and drops
material it is carrying on a cross belt which reaches up to the canter of the stock pile and which
can slew upward and downwards pivoted at the feeding end. Material is dropped from this belt as
the main belt moves at a predetermined rate along the pile. When cross belt reaches the end of its
travel, carriage starts in reverse and deposits another layer on the pile. Pile thus gets built up in
layers.

Figure 20: Stacker

34
MCF is used two types of stacking method. These are:

A. Chevron method: lime stone and shall are arranged in this method because these two raw
materials needs to homogenized by reclaimer the raw materials contains two or more than two
minerals for instance lime stone contains low grade and high-grade lime stone, shall contains
iron, alumina, magnesia etc arranged by stacker. Longitudinal stores: The Chevron method
material is deposited by the stacker moving to and from over the center line of the pile. The
Chevron stacking method causes segregation of the material with fine particles in the central part
of the pile and coarse particles on the surface and at the bottom of the pile. To ensure proper
blending a Chevron pile must therefore be reclaimed from the face of the pile, working across the
entire cross section.

Figure 21: Chevron method

35
B, Cone method: iron ore, silica sand, additives are arranged in this method by stacker. The
Cone Shell method is often used in cases where homogenization is not necessary. The pile is
formed by depositing material in a single cone from a fixed position. When this conical pile is
full, the depositing of material moves to a new position and a new cone is formed against the
shell of the first one. This process continues in the longitudinal direction of the store until the
stockpile is complete.

Figure 22: Cone method

Comparison of chevron and cone shell method

❖ Chevron method

 Good blending

 Large amount of material (large pile)

 Stacker travelling

❖ Cone method

 Less blending
36
  Small amount relatively

 No movement of stacker

2. Reclaimer
Reclaimer is a machine which is used for pre-homogenizing and loading of the raw materials
from the storage in to the proportioning unit. A reclaimer has a plough for pre-homogenizing
purposes and a chain scraper for loading the homogenized raw materials in to the outgoing
belt conveyer. The reclaimer helps in feeding a homogenized limestone and shale by mixing rich
quality with low grade and discharging it to a conveyor system leading to an intermediate silo
through belt conveyor. Silica sand and iron ore are feed to the hopper by loader and transported
through belt conveyor to the proportioning unit.
The three main applications of reclaimer are:
 Homogenizing the raw materials
 Transporting
 Filling the belt conveyor

Figure 23: Reclaimer machine

37
There are two types of reclaimer. These are bridge type and side cantilever scrapper Reclaimer.

A. Bridge reclaimer: it is designed to homogenize and handle for longitudinally stacked piles. In
the old-line only bridge type Reclaimer for (limestone and shale) found to reclaim limestone and
shale material. Two separate bridge type reclaimers one for limestone and the other for shale are
installed to homogenize the particulate materials and to convey the homogenized material from
the piles to the outgoing belt conveyer. Silica sand and iron ore are loaded by a loader to the
hopper in line one.

B. Side reclaimer: it is found in line two and in additive storage house. Side cantilever reclaimer
founds in the additive and corrective material storage used to transport material to their
respective area i.e. to proportioning bins and cement bins.

Note that; the reclaiming capacity of all reclaimer found in MCF are 250TPH.

3.6 Proportioning unit

The proportioning bins are used for temporally storage and proportioning of raw materials before
entering to the mill for grinding.

Flow diagram of proportion unit: -

38
 Figure 24: Schematic of raw material proportioning process

The crushed materials are stored in pre-homogenizing storage hall. In the storage hall
materials are stacked and pre-blending through stacker and Re claimer in their pile. From the
storage hall materials are reclaimed to transport to the proportion unit and in the proportion unit
there are four bins to store for the four materials (limestone, shale, silica sand and Iron ore). The
proportioning bins are used for temporally storage and proportioning of raw materials before
entering to the mill for grinding. Raw materials are proportioned through the dosimat feeder
which is placed under each four-proportion bin to transport in common belt to the next
grinding process.
Table 6: Proportioning bins capacity line one and line two

Raw Bins capacity for Line Bins capacity for Line

Materials One two
Limestone 400 700
Shale 200 300
Silica sand 100 300

Iron ore 160 300

39
 Function and capacity of dosimat feeder
Dosimat feeder is an accurate gravimetric proportionate device for the raw materials such as
slag, limestone, pozzolana, clay etc. The main function of dosimat feeder are used for
measuring the gravimetric proportioning device for the raw materials and used for
transportation. The other function of dosimat feeders are used to extract the raw materials
from the bins and the constant feed rate maintained.
Table 7:Dosimat feeder capacity line one and two

Raw Normal design line one in Normal design line two in

Material tone/hour tone/hour
Lime
Stone 350 350
Shale 50 50
Silica 45 50
sand
Iron ore 15 15

3.7 Raw material mill

The function of the raw mill grinding installation is to produce a homogeneous raw meal which
can give good burning condition in the kiln, sufficient quality. The raw mill is designed to
handle the raw material with their specific characteristics like grind ability, moisture content,
stickiness and abrasiveness. The raw meal fineness is normally measured as the residue on
a 90 sieve, where the required fineness to ensure good burn ability varies for 10% - 20%
residue to 90μm sieve. Raw mill is used for drying and grinding application. Two types of
Raw Mills are used for grinding raw material i.e. ball mill and vertical roller mill (VRM).
❖The ball mill uses in line -1 with different sizes for grinding purpose ranging from 20mm-
90mm and these are placed at the different parts of the mill.
◆ 90mm balls- in the inlet part of the mill
◆ 60mm balls- inside the mill

40
 ◆ 30 mm balls –inside of the mill
◆ 20mm balls- at the out let of the mill

Figure 25: Ball mill

❖The raw mill uses in Line -2 uses vertical roller mill and it works hydraulically.

The VRM combines the drying, grinding and separation processes in to just one unit. In VRM,
raw material from the feed mouth fells in to the center of mill stone, which moved to the edge of
mill under the action of centrifugal force.

In VRM the grinding material is goes to the separator, fine material sends out to the cyclones by
the suction of the mill fan whereas the course materials retained to the separator for further
grinding.

◆ Drying process in raw mill (line one)

Drying is the process where the major part of the moisture in feed removed before the material is
taken in to the grinding compartment; this helps in order to simple the grinding system in the
grinding compartment. The heat source may be cleaned gases or may be supplied from separate
heat generator source.

◆ Grinding process in raw mill (line one)

The grinding process is performed in the second compartment of mill in grinding chamber. The
grinding chamber is charged a grinding media steel balls ranging from 90mm to 20mm in

41
diameter. The lining is classifying means the largest balls preferably are in the inlet end and the
smallest at the outlet end of the mill. This ensures the grinding efficiency. The grinding process
in the ball mill is performed by means of impact and attrition, compression forces.

❖ Impact force: when the balls fall down hit the material particles and the force will divided in
to two or more pieces to the material particles.

❖ Attrition force: material particles are sheared between balls lifted up by the turning of the
mill and balls moving downward (not falling).

❖ Compression force: when the material is between the balls, then it will be compressed.

◆ Drying process in VRM (line two)

The process air consists mostly of waste gas from kiln, pre-heater, and cooler. Drying occur
during transport through the grinding and separating process stages. This drying gas is used for
drying the moisture of the raw materials before grinding.

◆ Grinding process in VRM (line two) Grinding process in vertical raw mill is affected by
external force. Particle point in materials crystal and cohesion force between crystals is damaged
by impact and grinding which transform big blocks of materials to small particles and powdered.
Small part of grinding work is transfer to free surface energy of solids and makes material from
new surface. Most part of work to heat which goes in to improve grinding efficiency.

42
 Figure 26: VRM (Vertical Roller Mill)

3.8 Grit separator

Grit separator allows the grinded raw material (powder) to cyclone; it is placed above the
raw mill. It takes the powdered raw material from the center of the raw mill to cyclone. It
separates the course materials and sends useful (fine) material to cyclone. Coarse material is
sent to girt return belt conveyor and then to 2nd chamber in raw mill for grinding. It uses two
types of separator.

1. Static separator: This is not used motors and is not moving. These are limited to the
admissible material load for inlet and low separation efficiency. This type of classifier is
used in cyclones.
2. Dynamic separator: It has a moving part and it is motorized with rotating plate to
disperse particles with a small axial selection turbine with high separation efficiency.

43
3.9 Cyclone

The function of cyclone is based on the separation of the solids from the conveying gas by
centrifugal force. The clean gas is vented via the dip pipe at the upper part of the cyclone in
to downstream aspiration system. Separated solids are discharged to the bottom. There are
different types of velocity distribution inside the cyclone. These are tangential, axial and
spiral. Dusty gas comes in through a rectangular inlet in a tangential direction. After entering
the gas is forced in to a spiral, dawn ward motion. Main parameters for efficient separation
are:
 Diameter of the cyclone: This is one parameter for efficient in separation for the
cyclones. If the diameter of the cyclone is high it is difficult for separation.
 Height of the cyclones: If the height of the cyclone is very high separation efficiency
will be high, if there is no the separation will be low.

Figure 27: Cyclone

3.10 Bag filter

The function of bag filter is used to separate the dust from a flow of gas or air. The gas is
released to the atmosphere and the dust is goes to the CF silo. Bag filters are used in all part of
cement plant. Both for deducting of the extensive rang transport of storing and feeding
equipment’s and deducting process machinery. The structure of bag filter is made up of a fabric
bag crafted using different kinds of fabrics and a motor that powers a machine. Bag filters are
considered to the most efficient among all dust collectors because it can attain efficiency level up to

44
99%. In cement industry bag filters are often termed by the machine system to which they are
connected kiln filter, cement mill filter, coal mill filter, separator filter, silo filter and crusher filter. The
controllers in Messebo cement factory is by time set.

Figure 28: Bag filter

3.11 Controlled flowed storage silo (C.F-silo)

The CF-silo uses for storage and homogenization of raw meal, also provides for continuous
blending of raw meal. Extraction equipment for the silo bottom with compressed air supply,
which consists even outlet boxes with slide gates. One junction box below the silo bottom to
collect the raw meal extracted from the silo leads in to blending tank placed below junction
box. The raw meal leaves the blending tank is transported by air slide and then pneumatic
conveyor (air lift) to the cyclone pre-heater. The capacity of silo in MCF is10000 ton and
14400 ton for line-1 and line-2, respectively.
The main advantage of CF-silo is the following:
 High reliable extraction
 It is used as storage of raw mix and for homogenization
Table 8: Comparison between CF-silo line one and line two

Line one CF silo Line two CF silo

Has seven extraction cones Has only one big cone
Each cone divided in to six triangular Has eight air slide outlets
segments

45
 Each segment has five extraction boxes Each air slide has six small air slides
In a time three are in work In a time two air slides in extraction
Capacity of low bin is 34 ton Capacity of low bin is 85 ton
Capacity of CF silo is 1000 ton Capacity of CF silo is 14400 ton

Figure 29: CF-silo of MCF

The kiln feed is transported to the pre-heater through different conveying mechanism. In line one
the kiln feed enters to the pre-heater by air lift using two big blowers. But in the line two the kiln
feed is conveyed through bucket elevator.

3.12 Pyro processing (Preheater, kiln and cooler)

The term pyro processing defines a process in which materials are subjected to high temperatures
(typically over 800 °C) in order to bring about a chemical or physical change. It is the only
process in a cement manufacturing industry where chemical reactions are takes place. In order to
increase the efficiency of the kiln, the pyro- processing section is divided in to different sections
such as pre- heaters, pre calciner system, kiln system and cooler system.

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 Figure 30: Schematic diagram of pyro processing system

3.12.1 Pre-heater

Pre-heaters are cyclones arranged vertically in series, and supported by a structure known as the
pre-heater tower. The type and operation of the pre-heater may also an important influence on the
fuel energy consumption of a cement kiln plant. The thermal efficiency of the pre-heater depends
on the number of the stages.

The proper function of the pre-heater cyclone is to the reduced energy consumption by pre-heater
raw material. The heat source for pre-heater is the hot gas that comes from the calciner and kiln
burners. Pre-heaters enable the raw material to be preheated before entering the kiln. The raw
meal is introduced at the inlet duct in the top-most stage of the pre-heater. It is subsequently pre-
heated by hot counter current gas flow as it is continuously collected and passed down different
cyclones from preheater to the calciner.

The two production lines of the company have their own pre-heater-cyclone with in the same
working principle but have different cyclone numbers. Line-1 has five cyclones whereas line-2
has six cyclones. Generally, preheater cyclones have the following functions:

 Separate particles from the gas stream

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  Improve thermal efficiency of the energy intensive process
 Improve environmental benefit to the overall kiln operation

Figure 31: The flow of gases and materials in pre-heater

The purpose of pre-heater cyclone is to pre-heat the raw meal prior to it entering the kiln. Hot
gases from the kiln flow from bottom to the top, while materials are feed in the top and flows
down in the kiln. In MCF there are five cyclones for line one and six cyclones for line two
each have different application.

Pre calciner: The decomposition process of CaCO3 in to CaO and CO2 is called calcination or
decarburization. In pre-heater 95% of the calcination process takes place. The energy required for the
endothermic decarburization reaction (calcinations) is obtained from hot rotary kiln gases and
additional combustion of fuel. Hot air from the clinker cooler, so-called tertiary air is utilized as
combustion air.

The main function of pre-calcination is

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  Reduces the thermal load of kiln burning zone
 Increase the production rate of clinker
 Provides the possibility of using fuels of less quantity
 Reduces the thermal load of kiln burning zone

Both physical and chemical changes take place in the pre-heater.

A. Chemical changes: decomposition reaction is under gone in pre-heater cyclones.

 Decomposition of Meta kaolinite: Al2O3.2SiO2→Al2O3+2SiO2

 Decomposition of carbonate minerals: Heat+MCO3→MO(s) +CO2
B. Physical changes: water is removed during this process by physical process drying. And
dehydration of the meta-kaolinite (a clay compound), free water is removed and dry meta-
kaolinite remains for further chemical process.

3.12.2 Kiln

It is long, cylindrical, slightly inclined furnace that is lined with refractory to protect the steel
shell and retain heat with in the kiln. The kiln is 4.6 m in diameter and 70 m long. The function
of the rotary kiln is first to convert CaCO 3 to CaO and to react with silica aluminium oxide and
ferric oxide to form clinker. Kiln is the back bone of the cement plant that is used for burning of
the raw meal. The kiln capacity of Messebo cement factory for line-1 and line-2 is 2000t/d and
3000t/d respectively. The rotary kiln has five zones:

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 Figure 32: Kiln

1. Calcination zone: the remaining 5 –10 % of unclaimed raw is decarbonized and a

considerable C2S formation takes place. The temperature of the material slowly rises along
the zone from800–950ºC.
2. Heating zone: in this zone the raw meal forms liquid phase due to temperature rise
about1330ºC and there is formation of belite(C2S), aluminates(C3A), ferrite(C4AF).
3. Transition zone (Liquid zone): nodulation or clinker formation begins due to the liquid
phase and the temperature is 1350ºC.
4. Burning zone: which is the formation of alite (C 3S) reaches its critical value and
temperature reaches1400-1450ºC.
5. Cooling zone: Begin when the material starts to solidify. In this zone the material may
agglomerate, but this is only due to the cooling and solidification of the clinker liquid.
3.12.3 Cooler
The main function of cooler is to cool the clinker and transfer the energy to air. The hot clinker
from the Kiln is cooled with the help of atmospheric air in the grate cooler. Inside the cooler, fixed
and movable rows of plate with holes are arranged. The atmospheric air is blows through the
holes of the cooler plates, and cools the hot clinker accumulated over the plates. This blowing of the
air is carried out with the help of cooler fans. The grate cooler consists of water injection, cooling air
fans and built hummer crusher at the cooler outlet. Cooler uses14 fans for line two and 9 fans for line

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one. The clinker cools to a temperature of about 80 – 100ºc above ambient temperature. Clinker
finer than 25mm is discharged through cooler outlet grid to the clinker conveyor system, where
clinker course than 25mm passes through a clinker crusher before discharging on the pan conveyor.
Part of the air, used to cool the clinker is sucked by the Pre-heater fan, and it is used as secondary
air for burning the coal inside the Kiln.

Table 9: Thermal energy optimization in pyro - processing

Unit operations Function Process performance

Pre-heater Drying and -Vaporization of physical absorbed

pre-heating
- Vaporization of chemically bonded water

-Preheating the raw meal before feed to kiln

Calciner Calcining - Decomposition of MgCO3 and CaCO3

- Partial formation of C2S

Rotary kiln Sintering - Complete decomposition of CaCO3

- Formation of C2S, C3A, C4AF and C3S
Cooler Cooling - Cooling clinker to lowest possible temperature
- Recovery of heat as secondary and tertiary air

Pan conveyor: is used to transfer the clinker from the cooler in to clinker silo because the
clinker contains high temperature. The clinker-silo is a continuous operation homogenizing
and storage silo for feeding and extraction of clinker for cement production.

3.13 Clinker storage:

There are mainly two clinker storages in the company that are open yard and clinker storage
(silo). If the cement mill requires cold clinker, it is better to use from the open yard whereas,
clinker storage is required if warm clinker is required. The material is continuously supplied to
the clinker silo though an inlet located in the centre of the clinker silo top. The clinker from the
clinker storage transfers by belt conveyor in to the cement mill. There are two types of clinker
storage open yard and closed storage. The capacity of open yard is2000tons for both line-1 and
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line-2 cement production. And the capacity of closed storage is 20, 000tons and 40,000tons for
line-1 and line2, respectively.

Figure 33: Clinker silo of line two and line one respectively

3.14 Cement mill

The cement mill is that of closed-circuit ball mill. Clinker from the clinker storage is then
transported into cement mill proportion and the additives like gypsum; primary limestone and
pozzolana from the raw material storage are fed into apron feeder by manual power and then
transported into cement proportion unit through, bucket elevator and transported to the cement
mill through one reversible belt conveyor. In case of line one; there is one closed ball mill and
two closed ball mills in case of line two. The mill has two chambers separated by a
Cambodian diaphragm which is an efficient screening diaphragm. Material after being crushed
in the primary compartment and grinding in the second compartment in the mill will be
convoyed by air slide and bucket elevator to another air slide and then enter the rise pipe of
air separator. Dusts that collected by bag filter will transported by screw conveyor and air
slide to the air slide at mill outlet where the dusts will mix with the output product and
together in to the air separator for selection and separation. Coarse dusts will enter in to air slide
through the reject valve and then go back to the mill after the measuring of impact flow meter.
Where, fine dusts are brought in to a cyclone by airstream to collect and separate gases and fine
dusts. The fine dusts are transported through air slide, screw conveyor, finally to the cement
silo.

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Process description of cement mill
Clinker from the clinker storage, gypsum from gypsum storage, pozzolana from pozzolana
storage, and additives from additives storage are transported into a common belt through the

Figure 34: Schematic of finish milling system in a cement plant

dosimat feeder. The material in the common belt conveyor enters to bucket elevator and
temporally stored in the small bin above the roller press. Installing storage bin before the roller
press is important in maintaining the feeding rate of materials to roller press. Materials are
compressed, pressed and grinded in the roller press with one fixed and other movable rollers for
the purpose of size reduction.

here in case of line one there is no roller press because balls with 90 mm diameter are provided
and they can crush materials of size up to 100mm.in case of line two the roller press is essential
because the largest ball within the two closed ball mills are 60 mm. due to this case it consumes
power and takes long time to crush. The materials from the roller press enters to crushing
separator. The crushing separator receives sticky materials from the roller press and activates size
reduction by centrifugal percussion and smashing. Then they enter to cement mill. The materials

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Figure 4: Cement mill
are correctly proportioned in the proportion unit based on the type of cement product to be
produced.

CEMENT SILO
The finished cement is transport from cement mill to store in cement silo then packing. In line-1
there are two silos of 16 m diameter and 44m height for a capacity of10,000ton each and 3 silos
in line-2 having the same parameter. The diameter is identical to the homogenizing silo in order
to reuse the same form work for construction. The final homogenizing cement from the cement
silo is fed into packaging through air slide and bucket elevator transportation system.

Figure 35: CF silo

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3.15 Types of cement product

1. OPC (Ordinary Portland cement)

OPC is the first product of Messebo cement factory and the most energy consumable cement
due to high percentage of clinker. It is also the most expensive cement due to high energy
consumption. The percentage composition of OPC is clinker=90-95%, Additives=5% and
Gypsum=5%. It is more applicable for high building in fast constriction because of its high
heat release cement and has early strength.
2. PPC (Portland pozzolana cement)
PPC is called low heat release cement and contains pozzolana which is aluminum silicate
burned by volcanic eruption in its composition. It is more expensive than PLC due to long
distance transporting of pozzolana. Messebo cement factory produces PPC in high amount
than the other. The percentage composition of PPC is clinker=70-75%, Gypsum=5% and
Pozzolana=20-25%.
It is mainly applicable form as sieve construction because it recesses relatively low heat.
3. PLC (Portland limestone cement)

PLC is a type of cement contains raw material limestone in its composition. The percentage
composition of PLC is clinker=70%, Gypsum=5% and high-grade Limestone=25%. It is
more applicable for masonry and plastering
4. LHHSR (low heat high sulfur resistant) cement
LHHSR is types of cement called special cement and contain raw material limestone in its
composition. It is the most energy consumable cement due to high percentage of clinker than
the other types. The percentage composition of LHHS is 95% clinker and 5%

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3.16 Packing and Dispatch

Packing is another well-organized zone which receives the finished cement product from the
control flow-silo by flux slide to fill the cement in the bagel and it has weight sensor that
indicates how many kilo grams of cement is fill in the bagel cement from silo is extracted and
fed to the rotary screen with the help of air slides and bucket elevators. The rotary screen removes
the foreign particles present in the cement, and is fed to the packer hoppers from where the
cement is then fed to the respective packers for weighing and packing. Two types of packers
are in use. One is mechanical type rotary packer and other is electronic type rotary packer. The
cement is packed in 50kg bags and is conveyed to Lorries or wagons for dispatch.
There are two packing machines and four packing machines in line-1 and line-2 respectively
which are manual loading machines. Each packing machines has a capacity of packing 200t/h
and 8-bags at a time. The packed bags are transported to the trucks for the sake of transportation.

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Figure 36: Packing machine

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 CHAPTER FOUR

SAFETY AND SOME HAZARDS

4.1 General information

The employer will have to instruct his staff on accident risks, on devices for operator safety, on
risks of noise emission and on the general accident prevention rules foreseen by the
international standards and by the legislation of the Country where the machine will be
installed.
 Before starting the work, the operator must be perfectly aware of the features of the
machine, of the position and functioning of all the controls and safety devices, in
addition the operator must have read this manual in its entirety.
 The machine must be operated exclusively by operators who have followed the training
performed by the technicians and who have completely understood the instructions of
this manual.
 The instructions, warnings and general accident prevention rules of this manual
have to be strictly followed.
In Messebo processing plant, Operators use Safety materials as they listed below;
 Over all cloth (Gabon)
 Mask (protects dust, gases and others)
 Hand glove
 Eye protection (Eye glass)
 Ear muffler (Ear plug)
 Safety Shoes (Foot wear)
 Head met
 Shield during electrical blasting

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 Figure 37: Safety materials

CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 Conclusion

Messebo cement factory is well known through the country due to its international
organization standard qualified product and the strength of attitudes to focus on the profit of
the product. In addition to this; from this internship program it can be conclude that generally
this report includes all process flow starting from quarry express about mining, extraction and
the basic raw material they use such as limestone, Shale, iron ore, Pozzolana/dolerite, silica
sand and gypsum. Where as in storage homogenizing in chevron method, cone method and

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 additive and corrective storage are expressed in well, then to proportion them, use proportion unit
from this unit materials transported to raw mill or ball mill. The force appears centrifugal force,
gravitational force and bounce force in separate due to gas flow and material flow.CF-silo and
its control flow, pre-heating, five kiln zones; Calcinations zone, heating zone, transition zone,
burning zone, cooling zone. Four types of cement Portland limestone cement (PLC), ordinary
Portland cement (OPC), low heat high sulfur resistant cement (LHHSR), Pozzolana Portland
cement (PPC).

5.2 Recommendation

 Over burden material is dumped over on the source of raw material, so it is

recommended to dump it on studied area.
 Huge amount of materials is losing to the environment in the form of dust because of in
efficient bag filters through the chimney, so it is better to use efficient bag filters to reduce
the loose of materials to the environment.
 We need to recommend that in the line one the kiln feed is conveyed to top preheater by
the air lift blower which exposes us to more cost. so, we must change them to bucket
elevator which is less cost.
 There is high amount of energy loss in the pyro processing system as we observed, it
is recommended that this energy loss should be used in reverse for example by
generating electricity from the heat released from the kiln wall using different heat
exchangers and use this generated electricity as a source of electrical energy for some
processes.

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REFERENCES

1. communication with F. M. Miller, CTL, Skokie, Illinois.

2. Different soft copies available in the company.
3. Gathered data from our advisors.
4. Industry Applications, Vol. IA-23; No. 2; March/April, 1987.
5. Isaac, S.A., & Hashim, H. (2015). Low carbon measures for cement
plant-are view. Journal of cleaner production,103,260-274.
6. Kling, F. E (1949). U. S. patent No.2,477,623. Washington, DC: U. S.
Patent and Trademark office.
7. Messebo cement factory manual document.
8. Rawks, Ronald L., and Chadbourne, John F., “Modifications to Pre calciner
Kiln Combustion.

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