MAJOR PROJECT PRESENTATION

PROJECT TITLE- Study of cement manufacturing unit for Star Cement

( Guwahati Unit )

Submitted by
Akash Arun Baruah (Reg.No.- 201600166)

Under the Guidance of

Mr P.P. Das
Internal Guide
Assistant Professor 1

Mr. Satish Kalita

External Guide
(STAR CEMENT GUWAHATI UNIT)
DEPARTMENT OF MECHANICAL ENGINEERING
SIKKIM MANIPAL INSTITUTE OF TECHNOLOGY
MAJHITAR, RANGPO, EAST SIKKIM-737132
 CONTENTS
• Introduction
• Mass flow diagram
• The process of making cement
• Market Analysis regarding cement plants
• Energy Management regarding cement plants
• Pie charts, tables and percentage calculations regarding cement
plants
• Maintenance chart on the machinery equipments
• Technical datasheet of machinery equipments
• Problems which arises in a cement plant
• Reference
 INTRODUCTION

Star Cement Limited is the largest cement manufacturer in north east India. It
has established itself as the most accredited brand of the region on grounds of
both quality and fair pricing. Star Cement Limited is listed on National Stock
Exchange (NSE) and Bombay Stock Exchange (BSE). The Company's institutional
customers comprise Larsen & Tourbo, National Hydro Power Corporation, Public
Works Department, Indian Railways and Ministry of Defence.Star Cement Limited
is one of the most profitable cement manufacturers in North East India because:-
•of its prudent locational advantage
•of its timely raw material linkage
•of its proactive capacity expansion
•of its expert brand positioning
Cement is a material which is highly compatible to the earth's eco-
system and most adaptable to sustainable development. Cement is a
fine powder which sets after a few hours when mixed with water,
and then hardens into a solid, strong material.
Cement is mainly used to bind fine sand and coarse aggregates
together in concrete. Cement is a hydraulic binder, i.e. it hardens
when water is added to cement powder.
The types of cement which are produced in the plant are as follows:-
•PPC cement (Portland Pozzolana Cement), which is high on
demand.
•OPC cement (Ordinary Portland Cement), which is in order on
demand basis.
•ARC cement (Anti Rust cement)
•Slake cement
(PPC) is manufactured by a combination of pozzolanic materials, clinker,
gypsum, flyash. Pozzolana is an artificial or natural material that has silica in it
in a reactive form.

(OPC) is manufactured as a powder by mixing limestone and other raw

materials which consist of argillaceous, calcareous and gypsum. It is preferred
in places where there is a need for fast construction and setting time

Cement as we know it was first developed by Joseph Aspdin, an enterprising

19th-century British stonemason, who heated a mix of ground limestone and
clay in his kitchen stove, then pulverized the concoction into a fine powder.
The result was the world's first hydraulic cement: one that hardens when
water is added. Aspdin dubbed his creation Portland cement due to its
similarity to a stone quarried on the Isle of Portland, off the British coast. In
1824, this brilliant craftsman obtained a patent for what would prove to be the
world's most ubiquitous building material, laying the foundation for today's
global Portland cement industry.
MASS FLOW DIAGRAM
THE PROCESS OF MAKING CEMENT
TRUCK TIPPLER
In the truck tippler area the clinker is first arrived by trucks from the star Cement Meghalaya
unit. The clinker material is then unloaded from trucks using hydraulic cylinders. Stoppers are
installed in the truck tippler area to hold a grip of the trucks for smooth unloading.Once the
material is unloaded, it's is transferred to the clinker stockpile through the belt
conveyors.Magnetic separator boxes are installed above the belt conveyors at regular intervals
to remove impurities and unnecessary particulates from clinker material

.
CLINKER STOCKPILE
The clinker stockpile stores the clinkers in bulk
quantities through the truck tippler via the belt
conveyors.Once all the clinker gets transferred in
the clinker stockpile it dumps the clinker at the
bottom known as clinker stockpile yard.
HOPPER BUILDING
The hopper building holds particulate matter
such as flyash, gypsum slowly and properly
dispenses in the bottom and then further
transfers takes place via the belt conveyors.
MILL BUILDING
The mill building grinds all the hard and solid
materials and particulates such as clinker, flyash,
gypsum etc. into fine grey powder using the
vertical roller mills.The newly mixed material is
then transferred to the silo.The output material
is then transferred to the bin and later on to the
flow control gate which is attached to the
automated packers.
PACKERS
The Enexco Roto Packers evenly discharges the
cement bags in multiple belt conveyors where
the final products go into the truck loading area
via the spiral discharge chute.
LOADING AREA
The final cement bags are then transferred to
the trucks via the belt conveyors.The trucks carry
the load to the urban areas where the cement
consumer markets are concern
 MARKET ANALYSIS
REGARDING CEMENT PLANTS
 ENERGY MANAGEMENT
REGARDING CEMENT PLANTS
 PIE CHARTS , TABLES AND
PERCERTAGE CALCULATIONS
REGARDING CEMENT PLANTS
Geographical segment wise major cement plants percentage in India

1.Northern Segment -
(41 / 41+48+82+26+24) x 100%
=18.55%
=18%

2.Eastern Segment –
(48 / 41+48+82+26+24) x 100%
=21.7%
=22%

3.Southern Segment –
(82 / 41+48+82+26+24) x 100%
=37.1%
=37%

4.Western Segment –
(26 / 41+48+82+26+24) x 100%
=11.7%
=12%

5.Central Segment –
(24 / 41+48+82+26+24) x 100%
=10.8%
=11%
Segment wise installed capacity of cement

1.Northern Segment-
(88.24 / 88.24+68.18+168.17+62.52+56.99) x 100%
=19.73%
=20%

2.Eastern Segment –
(68.18 / 88.24+68.18+168.17+62.52+56.99) x 100%
=15.24%
=15%

3.Southern Segment –
(168.17 / 88.24+68.18+168.17+62.52+56.99) x 100%
=37.61%
=38%

4.Western Segment –
(62.52 / 88.24+68.18+168.17+62.52+56.99) x 100%
=13.98%
=14%

5.Central Segment –
(56.99 / 88.24+68.18+168.17+62.52+56.99) x 100%
=12.7%
=13%
India‟s total installed capacity is 444 Million Tonnes (MTs) and
stood second largest cement producer in the world. Southern
segment has the largest contribution in cement production of
India and it has a largest capacity with 168 MTs followed by
Northern Segment 88.24 MTs, Eastern
segment 68.18 MTs, Western segment 62.52 MTs and Central
segment 56.99 MTs. It is found from the study that Rajasthan
state stands first with installed capacity of 60.30 MT, followed by
Andhra Pradesh 60.02 MT, Tamilnadu 40.69 MT, Madya Pradesh
38.49, Karnataka 37.70,
Maharastra 31.46 MT, Gujarath 31.06 MT and Telangana with
29.14 MT
MAINTENANCE CHART ON
THE MACHINERY
EQUIPMENTS :-
TECHNICAL DATASHEET OF
THE MACHINERY
EQUIPMENTS :-
Radical Discharge Conveyor
TECHNICAL SPECIFICATION/ DATA SHEET-

Equipment: Radial Discharge Conveyor for radial throw off(For Clockwise Packer)
Model: C/C 1400x 950 Ht.
Function: To transport the filled bags /packet received from p acking machine to other
conveyors.
Capacity: 1800 bags/pkts per hour (of 50 kg. each)
Material to be conveyed: Filled cement bags/packet.
Speed of conveyor: 0.64 mtr/sec.
Drive motor: geared Motor – 1.5 KW with output RPM 56 & motor of F insulation
Drive pulley: Dia 218 x 950 Lg.
Driven pulley: Dia 218 x 950 Lg.
Carrying idler: 2 Sets with Idlers in trough.
Belt: 800 width with special 'U'profile belt.
Supply voltage: 3-Phase AC, 415 V, 50 Hz.
G.A. drawing no.: 01125 00066 0 & 02125 00048 2

FOR BAG CLEANING DEVICE-

Fan with motor: 12 m3/min. ( This Capacity of Fan to be used bothfor Radial Tangential
conveyor's Bag Cleaning Device)
Pressure: 63 M bar
Roto Packer
TECHNICAL SPECIFICATION/DATA SHEET-

Equipment: ROTO PACKER ( Anti clockwise Rotation)

Model: 16 SRPE.
Capacity: 240 T/4800 bags/hour (of 50 kg. each)/HDPE-P/ Paper Laminator bags with sufficient perforation.
Accuracy: On average of 20 consecutive weighments within+ 150 gms.
No. of spouts: 16 (working).
No. of discharge point: 2
No. of operator required: 2
Material to be handled: Cement Powder (OPC/ PPC / slag)
Material temperature: 90 to 100° C.
Moisture content: NIL to dry.
Speed of Packer: 2.0 rpm
Function: for filling & simultaneous weighing of cementpowder in inner valve type of bags of HDPE/paper.
Functiond power: 92KW
Average power consumption: approx 32KW
Compressed air required: 100 N m³/hour at 6 bar pressure.
Quality of compressed air required: Instrument quality air free of moisture & oil
Dedusting requirement: Approx. 32000 m'hour at 80 mm WG on the duct connected to inlet of packer.
Other requirement: 1 No. CVT required to be provided by client.
Supply Voltage: AC, 3 phase, 415 V# 10 %, 50 Hz 3 %.
G.A. drawing no.: 01011 00009 1

Electrical drawings no.-

Control panel: 04411 00046 0 (23 Sheets).

Sprout panel: 04417 00001 0 (09 Sheets).
Tangential Discharge Conveyor
TECHNICAL SPECIFICATION DATA SHEET-

Equipment: Bag Discharge Conveyor for tangential throw off. (For clockwise Packer)
Size: 3.150 M c/c x 720 Ht.
Function: To transport the filled bags /packet received from packing machine to other conveyors.
Capacity: 1800 bags/packets/hr (of 50 kg. each)
Material to be conveyed: Filled cement bags /packet.
Size of bags: 600 x 450 x 150.
Speed of conveyor: 0.64/0.82 mtr/sec.
Drive motor: Geared Motor - 1.5 KW with output RPM 56 & motor of F class insulation.
Drive/Driven pulley: diameter 218 x 950 Lg.
Plummer block: SNA 511 with bearing 2211K + H311 sleeve.
Carrying idler: 88.9 x 950 Lg.
Return idler: diameter 88.9 x 950 Lg.
Belt: 800 width rough top special profile belt (Waviness pattern)
Supply voltage: 3-Phase AC, 415 V, 50 Hz.
G.A. Drawing No.: 01126 00077 0 & 02126 000700

For Bag cleaning device-

Fan with motor: 12m3/min ( The capacity available in Radial conveyer sufficient for this also.)
Pressure: 63 m bar
 PROBLEMS WHICH ARISES IN A
CEMENT PLANT
1. Inadequate Production
The main factors responsible for shortfall in production are less superior and costly machinery, drastic
power cuts ranging from (20-75)% in various cement producing states, shortage of coal, inadequate
availability of wagons and limited availability of furnace oil.

2. Manufacturing Cost Problems

The major raw materials for the cement industry are limestone, coal, power, dolomite and gypsum for
which cement has become a high cost product itself. Due to its expensive costs, both manufacturing and
non-manufacturing have gone up. Although the industry is largely under private sector, Government
controls more than 40% of the cost. Power, coal and freight costs are all regulated by government bodies,
such as state Electricity Boards, Coal Monopolies and the Railways.

3. Operational Inefficiency
This affects the cost of production operational inefficiency both internally and externally of the company.

4. Operating Cost
In the case of all other industries, there was a rise in the cost of cement production. But some of the
major cost rises were due to the government policies. The wagons shortage for the cement transport was
always a serious issue. Power, coal and freight constitute about (15-20)% each of the total cement cost
while capital cost forms (20-30)%.
5. Less Supply of Cement
The cement industry has recorded ample profits and growth and so has the construction industry.
Going forward, the mega-infrastructure building guarantee that the construction industry will
continue to grow rapidly. The demand for cement will remain high because of the obvious
linkages. There is an actual demand and supply gap emerging. The cement industry doesn't have
too much additional capacity and the commodity doesn't transport so imports and inter-regional
supplies are not easy to organize.

6. Infrastructural Problems
The fewer infrastructure facilities is one of the main problems faced by the cement industry. The
infrastructure facilities mean the facilities of availability of adequate quantity and quality of coal,
railway wagons regularity of power supply, sea-port, bridges, roads and canals, which is of very
essential for optimizing capacity utilization in cement industry. It is because the cement plants are
located in close proximity to the lime stone deposit regions, which are not appropriately linked
with rail, road, power and communication services which affect to the cement industry.

7. Policies and Regulations of Government

The policies and regulations formulated by both state and central government not only encourage
the industry but also have adversely affecting the cement industry. The various steps taken by
government such as excise duty increase in railway fright, reduction in loading capacity of trucks,
high electricity duty, sales tax, power tariff, demonetization etc negatively affects the cement
industry.
8. Administrative Problems
Administrative problems include the workers problems, sales,
distribution of cement, work environment and maintenance of
safety measures problems etc.

9. Low Per Capita Consumption of Cement

The per capita consumption of the cement of the country is very
low. It is 190 kgs per year as compared to world average of 443 kgs
and 1683 kgs.

10. Other Problems

The other problems of cement industry in India include
environmental problems, location problems, low export, under
development of rural market etc
 REFERENCE
1. Nagaraja Rao, B.S., and Chandar K., 1980, Vol I & II, “A Study of Cement
Industry in India – Occasional Papers, Reserve Bank of India.
2. NCAER, 1978, “Cement Industry in India – Problems and Prospects,National
Council of Applied Economic Research, New Delhi.
3. Poddar V., 1966, “Cement Industry Vol-I and Vol-II, Dalmianagar: Fohtas
Industries”, pp 124-129.
4. Ramaswamy, T., 2003, “Public Enterprise in India: Objectives and
Performance”, Himalaya Publishing House, Mumbai.
5. Shilpa Choudary, 2008, “Impact of MNCs on Indian Cement Industry” ICFAI
Jurnl of Management, Vol. VII, No. 3
6. Vijaya Raju, S., 1986, “Industrial Relations in Cement Industry of Coastal
Andhra Pradesh – A Study of Workers Management and Union Management
Relations, Ph.D thesis, Acharya Nagarjuna University, Guntur.
THANK YOU!