1.

INTRODUCTION

1.1 AN OVERVIEW OF THE COMPANY

Malabar Cements Ltd., a fully owned Govt. of Kerala Undertaking, is
synonymous with superior quality cements, vouched by customers spread across
the state of Kerala. The Company was incorporated in April 1978 and
commenced production in April 1984 at its Walayar plant. At Malabar Cements,
product improvement is not just a one-time strategy for boosting sales, rather a
quest of excellence. Perfecting the product quality is everybody's concern here.
Stringent quality control is exercised right from pre-blending raw materials,
clinkerisation, clinker grinding, and finally to cement packing.

Malabar Cements contributes to the developmental activities of the State by
supplying the basic construction material. Only Malabar Cements can supply its
cement, 'factory fresh', without any deterioration in the original strength either
due to moisture or humidity, within 12 hours anywhere in Kerala. With a
production capacity of 4.2 lakh tons of cement per annum, the unit at Walayar is
the largest. Thus the total installed capacity of MCL is 6.2 lakh tons. MCL is the
first public sector company to receive ISO Certification & to win the National
Award for best achievement in Energy Conservation. Till date, MCL has
experienced no loss of production due to labour unrest. In just over 15 years of
commissioning, Malabar Cements has been able to meet about 10% of total
cement consumption in Kerala. With the expansion plans in progress, the figures
are sure to rise further.

1.2 MALABAR CEMENTS PRODUCTS

1.2.1 MALABAR AISWARYA
Technical Specification
Malabar Aiswarya brings prosperity in many ways. It increases the life of
your structures by safeguarding against sulphate attack. Aiswarya offers high
quality at affordable price. Aiswarya generates less heat of hydration, and thus
reduces the formation of cracks. This product is best studied for constructions in
soil and water with excess alkali metals, sulphates, low magnesium oxide
content this provides shape stability for concrete structures. Aiswarya has
excellent strength and strength gaining capacity alumina, iron and acidic waters.
To obtain the best quality cement, only glassy granulated slag is used for
product manufacturing.


Product
Characteristics
IS 455-1989 Malabar Aiswarya
Compressive strength, MPa(kg/cm2)
3 Days 16(160) 23(230)
7 days 22(220) 34(340)
28 days 33(330) 45(450)
Fineness m2/kg(cm2/g) 225(2250) 290(2900)



1.2.2 MALABAR CLASSIC

Technical Specification
We take pride in developing the cement most suited to the south Indian climate,
through in-house studies and continuous researches in product improvement.
Malabar Classic, with scientifically proportioned sand and coarse aggregates, is
the most cohesive mix possible that surpasses the otherwise inherent drawbacks
of concrete like segregation and bleeding. The fly ash interweaved with Malabar
Classic makes it sulphate resistant-a basic property that cement should posses,
for constructions and structures in seacoasts and in alkaline waters. Malabar
Classic is best suited to resist alkali aggregate reaction, a defect eventually
resulting in excessive cracks and subsequent serviceability of structures.
Benefits
The extra fineness welded in to it allows Malabar Classic better coverage and
finish in wall and roof plastering. This in turn reduces the paint consumption.
With its superior strength properties, it is economical to use Malabar
Classic.10% cement is normally guaranteed. Using a design mix gain can go up
to 30%.
Product
Characteristics
IS 1489-1989 Malabar classic
Compressive strength, MPa(kg/cm2)
3 Days 16(160) 23(230)
7 days 22(220) 33(330)
28 days 33(330) 44(440)
Fineness
m2/kg(cm2/g)
300 320 (3200)

1.2.3 MALABAR SUPER

Technical Specification
Malabar Super offers better setting characteristics - prolonged initial set and
short final set timings; providing more time for concrete mixing and placing,
and less time for keeping the concrete undisturbed, free from movement and
vibration, the property engineers and mansions relish to have, in the cement they
work with. Malabar Super is finer when compared to normal OPC, and has the
best rate of hydrogen and strength gain.
Benefits
Malabar Super's superior setting properties, quick strength gain, and higher
finished strength, gives at least 10% cement reduction in volume batching. By
designing the mix, reduction in cement requirement can go beyond 30% under
good production and placement practices. Malabar super is therefore
economical.


Product
Characteristics
IS 8112-1989 Malabar super
Compressive strength, MPa(kg/cm2)
3 Days 23 (160) 29(290)
7 days 33(220) 40(400)
28 days 43(330) 53(530)
Fineness
m2/kg(cm2/g)
225(2250) 290 (2900)



1.3 CEMENT MANUFACTURING PROCESS

Important raw materials used in the manufacturing of Cement are Limestone,
Laterite and Gypsum. Limestone and Laterite are powdered and processed to
form an intermediate product clinker, which is grounded with Gypsum to
produce Cement. Essentially the process of manufacture of Cement consists of

1. Crushing and grinding the raw material to the required size and mixing
them together to form a homogeneous mixture.
2. Burning the mixture in the furnace called KILN to form a semi-fused
product called Clinker.
3. Grinding the clinker with small amount of Gypsum to produce the final
product Cement in a fine powder form.
In the cement plant the above mentioned processes are carried out in four stages.
1. Mixing and crushing.
2. Raw material grinding and homogenization.
3. Clinkerisation.
4. Cement grinding and Packing.

The main production processes are as follows-

1. Crushing and transportation.
2. Pre blending and storage.
3. Raw material grinding, blending and storage.
4. Clinkerisation.
5. Coal grinding and storage.
6. Cement grinding and storage.
7. Cement packing and Loading.

1.3.1 CRUSHING AND TRANSPORTATION

Material required for manufacture of cement that is transported and fed into the
primary hopper. Limestone is crushed using primary crusher and the material is
transported to the intermediate Limestone hopper through a conveyor belt with
the help of a vibro-feeder the material from the hopper is fed to the secondary
hopper crusher which further reduces the size of the material. During secondary
crushing dust is released.

The bag dust collector is employed to collect the released dust particle and filter
it form the secondary crusher in transported through a conveyor to a storage
bunker. The material to the next section, is transported from the hopper is to the
factory with the help of mono cable Ariel ropeway system.


1.3.2 PREBLENDING AND STORAGE

The material transported through the rope-way are fed into the hopper and then
transported to the stack yard through the belt conveyor. Mined material are
accumulated in layer one over the other for several days. Each day from the
stacker, reclaimer extracts the material as a cross section wise. Limestone and
laterite are also conveyed through a belt conveyor. After crushing into required
size the mixture is fed into the respective hopper.









FIG.1.STACKER


1.3.3 RAW MATERIAL GRINDING, BLENDING AND STORAGE

The materials limestone, laterite and sweetener limestone which are in separate
hopper are fed to the raw mill with the help of three weigh-feeders through belt
conveyor. Master ratio setter (MRS) controls the weigh feeder proportional
ratio.

Raw mill consists of three chambers, one drying chamber and two grinding
chambers. In the drying chamber the material is dried using hot gas from the
kiln. These materials are grinded in grinding chambers using grinding balls. The
grinded material is centrally discharged through the air slides and bucket
elevators into the turbo air separator, which separates the material into fine and
coarse particles.

Fine particles are transported into the silo through belt bucket elevator. The
coarse particles are again fed into the mill for further grinding. The silo has two
sections namely blending section and storage section. In blending section the
powdered materials are blended for hours. If any deviations are found in the
proportional ratio a control signal is fed back to the MRS to correct the
proportional ratio. The material is stored in storage section of silo.


FIG.2 SILO

The stored powdered materials from the silo are extracted by pneumatic valves
and are fed through bucket elevator to the load cell hopper. The load cell in the
hopper weights the powdered material. The material extracted from the load cell
hopper is weighed with the help of electronic weigh-feeders. The output of the
load cell is given to the PID controller through signal conditioner.

The set point value is given to the PID controller. The PID controller controls
the DC motor using DC drive panel to keep the hopper level a set point value.
The weighed material from the weigh feeder is discharged to the top of the
preheated tower through bucket elevator. A pneumatic pump is also provided to
convey the material. Incase if the other one falls a bag dust collector is also
provided for collecting the dust particles released during the process.

1.3.4 CLINKERISATION

Materials extracted from the preheated tower are allowed to push through a four
stage suspension pre-heater. The suspension pre heater has seven eye-cones, in
which the third, fourth and fifth are double stream and second is single stream.
The cyclonic action is generated with the help of the action of pre heater fan.
Hot gas from the kiln is sucked and passed such that the materials are heated to
some temperature of about 300 400C at the top and 900 1000C at the
bottom.


FIG.3 KILN

Due to the gravitational effect in the material discharged downwards are fed into
the kiln. The hot air from the kiln which is forced upwards is collected at the gas
conditioning tower (GCT).

Using water spray system, accomplish of the gas temperature of motorized
values to PID controller. After cooling, one gas is passed through the top, which
separate the dust particles are through back to the process. The process, which
takes place inside the kiln, is called Calcination. On the pre heater outlet and
in the kiln inlet Oxygen and Nitrogen oxide gas analyzers are provided.

Inside the kiln the material is heated to a temperature of about 1300
0
1400
0
C.
The product obtained from the kiln is called clinker. Grate cooler cools the
clinker to a temperature of about 100
0
150
0
C. The clinker is transported to
stockpile through bucket conveyor and is stored there.


FIG4. GRATE COOLER

1.3.5 COAL GRINDING AND STORAGE

The coal from the wager is fed to the crusher through belt conveyor. The crusher
reduces the size of the coal and fed in the hopper. Coal is extracted from the
hopper and is fed into the coal mill. The grinding media ball inside the coal mill
grinds the coal and is fed into the bridge separator. It separates the fine and
coarse particles. The coarse particles are again fed into the coal mill.

The fine particles are transported to the fine local hopper. The fine coal is then
fed into the weigh-hopper through twin-screw feeder. The load cell in the
hopper weighs the powdered materials. The output of the load cell is given to
the PID controller through the signal conditioner. A set point value is given to
the PID controller. The PID controller controls the PC motor using DC thyristor
panel to keep the hopper level at the set point value.

The fine coal form the weigh-feeder pumped to the kiln using a primary fan.

1.3.6 PRIMARY GRINDING AND STORAGE

In MCL three types of cement are manufactured. They are Malabar Super
OPC (Ordinary Portland Cement) 43-grade cement, Malabar Classic PPC
(Portland Puzzalano cement) and Malabar Aiswarya, PSC (Portland Slag
Cement). In Malabar classic, 25 30% Fly ash and 50% gypsum is added with
clinker to get the mixture. Malabar Aiswarya, which is slag cement is used in
coastal areas, to resist corrosion which is not extensively manufactured here. It
is a mixture of slag, gypsum and clinker. The material from the hopper is
extracted and is fed to the cement mill through weigh-feeders. The material is
grinded using grinding media balls.


FIG.5 CEMENT BALL MILL


Due to the grinding process the temperature is developed inside the cement
mill. The temperature exceeds 120
0
C the property of the cement may be
changed. To prevent this internal water spray system is provided using a PID
controller and a motorized valve. The sprayed water will get evaporated which
given the temperature set point, above the boiling point of water. The
temperature is measured using RTD.

The material from the cement mill is fed into the separator which separates
the fine and coarse particles. The fine particles are conveyed using a bucket
elevators or pneumatic pump to the cement silos. An ESP (Electrostatic
Precipitator) is used to control the pollution. An exhaust fan driven by a variable
speed drive DC motor sucks the gas. The dust collector is also used for
collecting dust.

1.3.7 CEMENT PACKING AND LOADING

The cement from the silos are extracted and fed into the rotary screen
through bucket elevators. It removes the metal part in the cement if present.
There fine particles are thus fed in to the hopper. From the hopper, cement is fed
to the packing section. There are two types of packers are in MCL. They are
electronic and mechanical packers. The collection bags from these rotary
packers are transported through belt can loaded in trucks and wagon.














1.3.8 RAW MILL SPECIFICATIONS

Name of equipment - Raw mill
Type - Central discharge ball mill
Purpose - To grind and dry the raw meal
Feed size - 20mm
Output size - 90 microns
Capacity - 120 TPH
Length - 14.07 m
Diameter - 4.2m
Mill speed - 15.1 rpm
Power at shaft - 2340 KW
Lining plate material - Mild steel
Main bearing type - Journal
Drive bearing type - Self aligning journal bearing
Mill lubrication type - Ring lubrication
Flood lubrication
Periodicity - Every 200 hours
Shell weight - 81 ton
Mill head weight - 24.3 ton
Lining weight - 80.2 ton
Gear box weight - 15 ton
Pinion weight - 2.94 ton




INTRODUCTION TO THE PROJECT
The major raw material limestone for the cement production is taking from the
MCL captive mines called PANDARATHU LIMESTONE MINES. It is situated
10 KM away from the plant. The raw material lime stone is generated by the
various mining process such as drilling, blasting, excavating, transporting and
crushing in the Primary & secondary crushers. Belt conveyors are used to transport
the Raw materials to the hopper, where it is temporarily stored and fed to the raw
mill.
In present scenario there are only three hoppers for the raw materials MCL
Limestone, cement grade and laterite. There is no separate hopper for sweetener
addition. Sweetener is mixed with limestone and added .Due to this there is a huge
wastage of sweetener. Our project is to design and install a new hopper for feeding
sweetener and hence the wastage of sweetener is reduced and it reduces production
cost. Saving of raw materials is one of the objectives of this project because,
saving raw materials means preserving of our resource.


2.1 AIM OF THE PROJECT
Aim of our project is to design and install a new hopper for adding sweetener.
Presently there are three hoppers present for the raw material addition. The three
raw materials are MCL Limestone, cement grade and laterite.
The total carbon content of MCL Limestone is 78%-82% and the silica content is
more 14%-18% and cement grade consists of 76%-80% of carbon and the silica
content is less than MCL Limestone. It consists of 5%-10% of silica. Laterite
mainly consists of aluminium oxide and ferrous oxide.
The raw materials and additives are feeded through the hoppers in to raw mill via
belt conveyors. In the raw mill the raw materials are heated and grinded in to fine
particles to obtain homogeneous mixture. The product obtained from raw mill is
known as raw meal. Raw meal consists of carbon, silica, aluminium oxide and iron
oxide.
The total carbon content of the raw meal should be around 78% to obtain good
quality cement. This value is taken as a standard value of carbon content. If the
carbon content in MCL Limestone obtained from the quarry is high then the raw
meal carbon content will also be high, so there is no need of additive. In case the
carbon content of limestone from the quarry is low additives like sweetener is to be
added to increase the carbon content of raw meal.
In present scenario there are only three hoppers. Sweetener is mixed with
limestone and added .Due to this there is a huge wastage of sweetener. Our project
is to design and install a new hopper for feeding sweetener.


2.2 LIMITATIONS OF THE PRESENT HOPPER SYSYTEM
Sweetener cannot be feeded separately.
Present hopper system increases the wastage of sweetener.
Sweetener is costly, thus present hopper system is not economical.
Time and energy consumption is more in present system.
It affects the overall production.

2.3ADVANTAGES
1. It reduces the wastage of sweetener.
2. Presently the sweetener is added by mixing it with limestone, even if the carbon
content of limestone from quarry increase, the added sweetener cannot be
removed. Installation of a new hopper will fix this problem.

2.4 SPECIFIC OBJECTIVE
Preserve sweetener
Reduce wastage



2.5 GENERAL OBJECTIVE OF STUDY
Design of a hopper 250 tons
Design the way feeder
Design belt conveyor




3. HOPPER

A hopper is a large pyramidal shaped container used in industrial processes to hold
particulate matter that has been collected from expelled air. Hoppers are usually
installed in groups to allow for greater collection quantity. Raw material enters the
hopper from the collection device. For example, in bag houses are shaken or blown
with compressed air to release caked on dust from the bag. Precipitators utilize a
rapping system to release the dirt. The crumbling dust falls into the hopper. Once
the dust in the hopper reaches capacity, it is released through an opening in the
bottom with a diameter of about 8-12. Hoppers are rectangular in cross section
but have sides that slope at about a 60 angle. Slanted sides make it easier to
remove the ash. Conveyors are sometimes used to carry away the particulate.
Hoppers are used in industry for protection and storage of powdered materials.
Hoppers must be designed such that they are easy to load. More importantly,
hoppers must be designed such that they are easy to unload. The way the hopper is
designed affects the rate of flow of the powder out of the hopper, if it flows at all
. Also, the way the hopper is designed affects how much of the stored material can
discharge and whether there mixing of solid sizes or dead space that reduces the
effective holding capacity of the hopper Hoppers are used to feed raw materials
like MCL Limestone, Bauxite, and Laterite. In cement factories, cement grade and
sweeteners are used as additives for keeping the carbon content at 78%-82%
steadily in raw meal.


3.1 HOPPER CLASSIFICATION

On the basis of material used for construction, hoppers are classified in to:
1. Concrete hopper
2. Steel concrete

3.1.1CONCRETE HOPPER
Construction of Hopper using reinforced concrete is much more costly than steel.
But it is more durable and requires less maintenance; on the long run RCC is more
profitable. The abrasion in concrete is less when compared to steel and it will not
corrode .The life period of concrete hopper is much more .




3.1.2 STEEL HOPPER
The initial investment required for the construction of steel hopper is much less
than the concrete hopper. The abrasion is more in steel hoppers and corrosion also
occurs. Frequent maintenance is required for the steel hoppers. The life period of
steel hopper is less when compared to concrete hoppers.


3.2 HOPPER FLOW MODES
Mass Flow - all the material in the hopper is in motion, but not necessarily at the
same velocity
Funnel Flow - centrally moving core, dead or non-moving annular region
Expanded Flow - mass flow cone with funnel flow above it

3.2.1 MASS FLOW MODE
Mass flow silos provide first-in, first-out flow with all of the material in motion
during discharge. Flow is uniform and reliable; feed density is independent of head
of solids in the bin; there are no stagnant regions, so material will not cake or spoil;
sifting segregation is minimized; and residence time is uniform, so fine powders
deaerate.

ADVANTAGES OF MASS FLOW

Flow is more consistent
Reduces effects of radial segregation
Stress field is more predictable
Full bin capacity is utilized
First in/first out

DISADVANTAGES OF MASS FLOW
Wall wear is higher (esp. for abrasives)
Higher stresses on walls
More height is required

3.2.2 FUNNEL FLOW MODE
Many vessels discharge bulk solids in a funnel flow pattern, where some of the
material moves while the rest remains stationary. Funnel flow discharge is
acceptable if the bulk solid is coarse, free-flowing, not prone to cake, and if
segregation is not important.


FIG

ADVANTAGES OF FUNNEL FLOW
Less height required

DISADVANTAGES OF FUNNEL FLOW
Ratholing
A problem for segregating solids
First in/last out
Time consolidation effects can be severe
Silo collapse
Flooding
Reduction of effective storage capacity

3.2.3 EXPANDED FLOW MODE

Expanded flow, which is a "hybrid" flow pattern, develops when a mass flow silo
hopper is placed below a funnel flow hopper. The mass flow hopper is designed to
activate a flow channel in the funnel flow hopper, which is sized to prevent the
formation of a stable rathole. The major advantage of an expanded flow over mass
flow is headroom savings.


3.3 PROBLEMS WITH HOPPER
Ratholing/Piping
Funnel Flow
Arching/Doming
Insufficient Flow
Flushing
Inadequate Emptying
Mechanical Arching
Time Consolidation Caking

3.3.1.RATHOLING/PIPING

FIG
3.3.2 FUNNEL FLOW
It is caused due to
Segregation
Inadequate emptying
Structural issues






3.3.3 ARCHING / DOMING




In arching or doming ,a cohesive arch prevent the material fro2.3.4m exiting the
dome


3.3.4 INSUFFICIENT FLOW




It is caused when the outlet size is very small and when material is not sufficiently
permeable to permit dilation in conic section.

3.3.4 FLUSHING
Uncontrolled flow from a hopper due to powder being in an aerated state
Occurs only in fine powders (rough rule of thumb - Geld art group A and smaller)
It is caused due to improper use of aeration devices, collapse of a rat hole

3.3.5 INADEQUATE EMPTYING




It usually occurs in funnel flow silos where the cone angle is insufficient to allow
self-draining of the bulk solid.





3.3.6 TIME CONSOLIDATION CAKING
Many powders will tend to cake as a function of time, humidity, pressure,
temperature. Particularly a problem for funnel flow silos which are infrequently
emptied completely














4. BELT CONVEYORS

A belt conveyor system consist essentially of an endless belt of resilient material
connected between to flat pulleys and moved by rotating one of the pulleys by the
electric motor. Normally material is fed on the belt near the other and pulley. The
moving belt carrying the material towards the driver pulley is likely to sag between
the two end pulleys due to its self-weight and pay load. That is why the belt is
supported both on the carrying side and tile return side by a number of rollers,
called the idlers. As the belt is always under tension, it is prone to elongation
resulting in slackness over the pulleys and loss of tension and power. That is why
some kind of devices for tensioning the belt is incorporated in the system. This
tensioning device is known as take-up arrangement. The system is inherently very
simple.

Belt conveyors have attained a dominant position in transporting bulk materials
due to a number of inherent advantages like the economy and safety of operation,
reliability, versatility and practically unlimited range of capacities. In addition,
they are suitable for performing numerous processing functions while supporting a
continuous flow of materials between operations.

Belt conveyors are most versatile and widely used mechanical conveyors. They are
used for transportation, feeding, discharging bulk solid material. This conveyor is
suitable to almost dry type of material free flowing solid to met stocky and lumpy
powers. Normally belt may be convoyed at angle of inclination of up to 22 degree.
The bulk material on the conveyor is discharged over the drive pulley of other
conveyors.

The capacity of belt conveyor depends on speed, shape and width of belt, method
of feeding and solid properties. Belt conveyor are the most common form of
material handling system used in manufacturing and mining industries thermal
plants and in construction projects.

Heavy industries like steel, fertilizer, chemical and cement etc. cannot function
without the belt conveyors. In construction project the belt conveyors are used for
handling. The material in asphalt plant, crushing and screening plants, aggregates
mixing plants etc. in coal mining and other mining industries these are used for
handling coal or other raw materials. The belt conveyors are capable of conveying
large quantities of material continuously over considerable long distance at a fast
speed.

For transporting the material for short distance conveyors may be a portable or a
fixed unit. When a belt conveyor system is to be used to transport for a
considerable distance up to several kilometers in such causes, the system consists
of number of flights. Each flight is a complete conveyor unit discharging its load
on the tail end of the successive unit. Belt used in the system are costly and hence
needed to be carefully
maintained. The belts are generally made of rubber cover cotton or rayon laid up in
the plies. The strength of the rubber belt depends on number of plies, canvas plies.
Wooden wire mesh and steel belts are also used depending up on the strength
required for the conveyor to conveying various types of materials, their quantity to
be transported etc. Belts are specified by width, number of plies and weight of each
layer of ply.

4.1 TYPES OF BELT CONVEYORS
According to position:
(a) Stationary
(b) Mobile.
(c) Portable.
According to Path of Belt Conveyor:
(a) Horizontal.
(b) Inclined.
(c) Mixed type.
According to their Design and Application:
(a) General purpose conveyors.
(b) Special purpose conveyors for ores, conveyor for carrying food.
(c) Underground conveyors.
(d) Special purpose conveyors such as oil resisting, heat resisting, submerged.
(e) Above water.
(f) Air supported.
(g) The conveyors may be troughed and flat, may be inclined upward with or
without curvature in vertical plane.

4.2 COMPONENTS OF BELT CONVEYORS
Figure shows the general arrangement of a belt conveyor system. The essential
features of belt conveyor system than be described with reference to. It consists of
a driving pulley (1) at the head end and takes up pulley (2) at the tail end, both
being accommodated in a steel frame (3) an endless belt (4) connects the two
pulleys on both runs, and supported by suitable roller-type supports, called the
idlers. At the upper side of the conveyor, also called the carrying side, because the
pay load is carried on this side, the belt is supported by idler (5). At the other side,
also called the return side because usually there is no pay load, the belt is
supported by a stationary runway instead of idlers. In some special installations
both the upper and lower sides transport loads (usually unit load) simultaneously in
opposite direction. The driving pulley (1) receivers its rotation from drive unit (7).
The material to be conveyed is loaded on the belt by one or more feed-hoppers (8),
mounted over the discharged over the driving pulley (1) in to discharge spout (9).
However, discharge can be arranged at any point along the conveying run by
means of special discharge devices. At the tail-end side, a device, called the take-
up arrangement (10), is attached with the take up pulley (2) to keep the belt under a
minimum tension, so that the bell does not slip over the pulleys due to extension of
its length. Belt cleaner removes material adhering to the belt face. It is usually
located near the driving pulley (1).
BELT CONVEYOR SYSTEM



4.3 ADVANTAGES OF BELT CONVEYORS
(a). Noiseless operation.
(b). Large length of conveying path.
(c). Lower power consumption.
(d). Long life.
(e). Adaptability to different types of goods.
(f). Ability to carry almost any bulk materials.
(g). High reliability of operation.
(h). Can transport material in any direction.

4.4 APPLICATIONS OF BELT CONVEYORS
Belt conveyors are employed to convey a great variety of bulk materials and also
unit loads along horizontal or gently inclined paths. Such duties can be performed
within the factory shed or in outdoor work. Within the factory shed belt conveyors
are also employed to carry article of lightweight in line-production from one
operation to another. Belt conveyors are used to mechanize material handling
operations in foundries to distribute molding sand, mould-cores and cast articles.
Belt conveyors are used for carrying coal, ores and minerals in power plants,
mining industries, metallurgical process plants, for handling food building
materials belt conveyors are frequency employed.
(a) Capacities of a belt conveyors system may range from 500 to 5000 m3/hr
and more. The distance covered for belt conveyor systems be as small as 50 m (for
indoor work) to 5 km. for supplying raw material from mine area. Used for
conveying various bulk and unit loads along horizontal or slightly inclined paths.
(b) Used in foundry shop.
(c) Transferring building materials, fossil minerals, grains store.
(d) Used in wheel plant.
(e) Ice-cream plant.
(f) Power plants.
(g) Bakeries.
(h) Confectionery.
(i) Feed and flour mills.
(j) Laundries.
(k) Textile.
(l) Ceramic.
(m) Chemical plant.
(n) Ship yards.
(o) Post office.
(p) Supply depots.

4.5 LIMITATIONS OF BELT CONVEYORS
(a). Accumulation difficult.
(b). Complicated marshalling.
(c). The loss of light weight bulk material away as dust or spilled from the belt
along
its path is another or objects able features.
(d). Continuous or periodic monitoring of belt is necessary.
(f). Heat affects the material of belt.

4.6 MATERIALS OF CONSTRUCTION
The composition of a conveyor belt can be considered in two parts:
A. The Carcass, whether ply type (textile) or steel cord construction, which must
have sufficient strength to handle the operating tensions and to support the load.
B. The Covers, which must have the required physical properties and chemical
resistance to protect the carcass and give the conveyor belt an economical life
span.

The general properties and the application usage of the more economical available
reinforcement fabrics and rubber compounds are discussed in this section.

4.7.PARAMETERS

BELT CAPACITIES
For maximum haulage efficiency, conveyors should be operated fully loaded at
maximum recommended speed. Belt capacity is dependent upon these inter-related
factors like belt width, belt speed, material density, surcharge angle, inclination.




BELT WIDTH
Minimum belt width may be influenced by loading or transfer point requirements,
or by material lump size and fines mix. Trough ability and load support
restrictions, will also influence final belt width selection.
BELT SPEED
Possible belt speed is influenced by many factors, importantly the loading,
discharge and transfer arrangements, maintenance standards, lump sizes etc.

MATERIAL BULK DENSITY AND SURCHARGE ANGLE
Due to undulations of the belt passing over the conveyor idlers, the natural angle of
repose of the material is decreased. This decreased angle known as ANGLE OF
SURCHARGE is one of the most important characteristics in determining carrying
capacity as it directly governs the cross sectional area of material on the belt and
hence the "volume" being conveyed. With materials which slump readily, such as
fine powders or dust, or on long conveyors where the load may settle,
consideration should be given to using a reduced surcharge angle for capacity
determination, and may require the compensatory use of other factors (such as
greater belt width or speed) to provide the required capacity.

INCLINATION ANGLE
The angle of inclination of a conveyor changes the carrying capacity. The load
cross-section area of an inclined load is reduced when viewed in a vertical plane as
the surcharge angle is reduced perpendicular to the belt. An approximation of the
reduced capacity can be determined by multiplying the horizontal capacity by the
Cosine of the inclination angle. Effectively the capacity reduction is usually less
than 3%.

TROUGHING ANGLE
For standard 3 roll idlers, the most common trough angle is 35 although trough
angles from 20 to 45 are not uncommon. Steeper trough angles give increased
capacity but can have consequences for convex and concave curves and transition
zones.

IDLER CONFIGURATION
The most common configuration for idler rollers is 3 rolls of equal length. Other
configurations from flat belt to 5 roll idlers and with unequal roll lengths are
sometimes used. For wide belts, 5 roll suspended idlers are not uncommon.







5.WEIGH FEEDERS

5.1 GRAVIMETRIC FEEDING
The gravimetric feeding method involves either weighing a requested quantity as a
batch or feeding a constant mass flow over time. The choice depends on the
process that can be made continuously or in batch mode.

PRINCIPLE OF OPERATION
Platform weigh feeders: The feeders are mounted on stable platforms with high-
performance weighing technology.
Applications: Small to medium feed rates
Loss-in-Weight-Feeders with three load cells: The hopper and feeder are mounted
in a frame. Weight calculation is carried out by three robust load cells.
Application: Multi-component feeding systems in the food industry and chemical
applications.
Hybrid feeders with tare- compensated weighing system:
The weight of the hopper and feeder is compensated by a spring or a
counterbalance which ensures that only the bulk material in th hopper is weighed.
This means that the complete resolution of the load cell is available.
ADVANTAGES
Highly precise feeding concentrating on feeding accuracy and consistent metering
Exact reproducibility of the feed flow
The modular design makes disassembly quick and easy
Resistance to external influences such as shocks and oscillation

5.2 VOLUMETRIC FEEDING
Accurate metering of bulk solids is achieved using a spiral helix, screw, rotary
valve, rotating agitator, vibrating tray or cylindrical stator. Even in the volumetric
mode, the feedrate remains constant under the condition of a repeatable fill level
and an even bulk density of the powder which provides a continuous filling degree
of the metering helix.

Important parameters for a precise dosing:
1. Uniform subsequent flow in the hopper by means of agitator and adapted auger
shape
2. Uniform bulk density and feeding in helix and screw by using intromitters.
3. Correct selection of the auger and metering tube
A linear volumetric feeder is also a prerequisite for a good gravimetric feeding.
ADVANTAGES
Robust construction, almost unlimited life
Hygienic models
Optimal adaptation to existing installations by variable length adaptation of
the metering screws
High linearity of the feeders on the entire capacity range
Large product entries ensure a optimum filling of the metering screw
Different metering helixes and executions with homogenizer are available
for various product requirements
Wide capacity range
A variety of different outlets and hopper sizes allow an optimal adaptation to
the process and the existing installation situation



5.3 WEIGH BELT FEEDER
A weigh belt feeder enables a continuous, controlled product flow. The bulk
material is transported over a weighing section, placed in the feeder frame. The
federate is calculated and the speed of the belt adjusted to maintain a constant feed
rate.

If the purpose of the belt feeder is to register the throughput only, the speed of the
belt remains constant and the mass flow and cumulative weight is registered.

5.4 FEEDING CONSIDERATIONS
Gravimetric feeders measure the flows weight in one fashion or another, and then
adjust feeder output to achieve and maintain the desired set point. Volumetric
feeders, again by definition, dont weigh the flow. Volumetric feeders operate by
delivering a certain volume of material per unit time which is then translated into
an inferred weight-based flow rate by the process of sampled calibration.
As such, volumetric feeders, while simple and relatively inexpensive, are open-
loop devices in the sense that they cannot detect or adjust to variations in the
materials density. For materials whose density does not vary significantly,
volumetric feeders may perform to the required accuracy. However, the density or
flow properties of many if not most materials varies significantly enough to
warrant gravimetric feeding if accuracy requirements are at all demanding. Most
feeder manufacturers have the resources to determine whether a given material can
be fed volumetrically at the required accuracy, or if a gravimetric feeder is
required.

5.5 FEEDER ACCURACY
Feeder accuracy it is necessary to address three separate and distinct areas of
feeder performance: repeatability, linearity and stability. Repeatability reports how
consistent the feeders discharge rate is at a given operating point, linearity
assesses how accurately the feeder discharges at the requested average rate over its
full operating range, and stability gauges performance drift over time
Repeatability
This measure of feeder accuracy, commonly termed precision, is the performance
statistic most familiar to feeder users. It quantifies the short term level of
consistency of discharge rate. Repeatability is of importance to quality assurance
because it measures the expected variability of the discharge stream, and hence of
the product itself. The repeatability measurement is made by taking a series of
carefully timed consecutive catch samples from the discharge stream, weighing
them, and then calculating the + standard deviation of sample weights expressed as
a percentage of the mean value of the samples taken. The measurement is typically
performed at the nominal intended operating rate of the feeder. (If the feeder is to
operate over a wide range of rates, repeatability measurements may be taken at
several points within the range.) Traditionally, repeatability has been expressed at
two standard deviations (2 Sigma) over minute-to-minute sample periods.
However, due to the increasing demands of downstream processing equipment and
end product quality standards, some processors are now specifying repeatability at
up to 6 Sigma or sampling periods as short as several seconds. Where such short
sampling periods are required, a corresponding lowering of precision is to be
expected.
Linearity
Note that the repeatability statistic reveals nothing at all about whether the feeder is
delivering, on the average, the targeted rate. Repeatability only measures
variability of flow rate. Rather, it is the linearity statistic that reports how well the
feeder delivers the desired average rate throughout the feeders operating range.
Perfect linearity is represented by a straight-line correspondence between the set
point and the actual average feed rate throughout the feeders specified turndown
range from its design full scale operating point.

Stability
A perfectly performing feeder is worth little if it cant maintain its performance
over the long haul. Many factors can potentially contribute to performance drift
such as feeder type, control and weigh system stability, the handling characteristics
and realized by selecting a feeder designed for stable, drift-free operation.
variability of the material, the feeders mechanical systems, maintenance, and the
operating environment itself. Drift is detected by calibration checks, and is
typically remedied by a simple weight span adjustment. In the stability diagram
above right, line A illustrates a condition in which the feeder has drifted far out of
calibration. Nowhere throughout the feeders operating range does the measured
rate equal the set rate. By adjusting the feeders weight span setting the linearity
curve is rotated so that perfect correspondence between set and measured rate can
be established at any given point (e. g. 90% full scale for line B, or 50% full scale
for line C). The user will ultimately determine the appropriate frequency of
calibration checks based on operational experience, but the question of stability is
worth considering when purchasing a new feeder. Significant and ongoing cost
savings in maintenance labour, off-spec product, and potential process downtime
can be realized by selecting a feeder designed for stable, drift-free operation








DESIGN OF HOPPER


Mill operation = 100 Tons per hour
Approximate working hours = 20 hours
Mill production per day = 2000 tones per hour
Sweetener addition per day = 10 % maximum

= 200010%
=2000(10/100)
=200 metric ton per day
So the maximum sweetener addition per day is 200 metric ton .so the hopper to
be installed is of 250 metric ton.






Dimensions of hopper:
Length = 10300 mm
Breadth = 6000 mm
Height = 4300 mm

CALCULATIONS
(10.3/4.3)6 = 14.37
Perimeter = 14.372
= 29
= 1229
= 348
Wall thickness = 250 mm
Volume = 348 0.25
= 87 85 cubic meters





WEIGH FEEDER SPECIFICATION

Capacity - 6 to 60 tons/hour
Size of belt - 800 mm 3.5
Type - Electronic
Weight - 2.4 tons
Head and tail pulley - 400 mm
Roller for carrying slide - 63.5 mm
Roller for return slide - 63.5mm
Snub roller - 88.9mm
Speed of belt - 0.13 M/s







BELT CONVEYOR SPECFICATIONS


Capacity - 70 TPH
Weight - 4 tons
Speed - 30m per minute
Type - 20 degree troughed
Number of feed point - One
Material handled - sweetener
Size of material - 15 mm
Bulk density - 1200 kg per m2
Type of take up - screw type
Conveyor length - Ten
Conveyors lift - nil





SUGGESTIONS


In the existing system there are only three hoppers for the raw materials MCL
Limestone, cement grade and laterite. There is no separate hopper for sweetener
addition. Sweetener is mixed with limestone and added .Due to this there is a huge
wastage of sweetener. Our project is to design and estimate cost a new hopper for
feeding sweetener. Sweetener is a costly additive; its cost is Rs.3000 per ton. By
installing a new hopper the wastage of the sweetener can be reduced, hence it
reduced the production cost. It also reduces wastage of time and labour.
The hopper can be constructed using steel or reinforced concrete. We are
proposing concrete hopper. The installation cost of concrete hopper is more than
steel hopper but in the long run concrete hopper is better. It is more durable and
resistant to abrasion and corrosion. Steel hopper corrodes easily and requires
frequent maintenance works. The newly constructed hopper can also be used for
feeding of other raw materials when needed.
Hence, it is suggested that this proposal be considered and implemented





CONCLUSION


Malabar Cements Limited is the only profit making Public Sector Company
manufacturing cement in Kerala. I understood the organization setup of the
company and the different department functions for the better production and
efficient working of the organization.
This project deals with the proposal for the installation of a new hopper for
sweetener addition at the raw mill section. It also focused on the Design, Financial
& Technical feasibility study. I have thoroughly analyzed the components required
for a hopper. Also studied and identified the general problems in the hopper.
I have given much emphasize on the design part of the hopper, belt conveyor and
weigh feeder. The specifications of the belt conveyor and weigh feeder are
tabulated.
The Initial investment of the proposed project is around Rs.60 lakhs only; ROI for
this modification will be obtained within a year. The cost benefit analysis of this
project is the most attractive part of this project. I got a best opportunity to carry
out the study and design of hopper.




REFFERENCE


1. www.caricement.com
2. www.malabarcements.com
3. www.conveyorbeltguide.com
4. www.mines-engineer.com
5. CEMENT AND ENGINEERING NEWS 6
th
EDITION
6. STRUCTURAL ENGINEERS HANDBOOK by MILO SMITH
7. www.fennerdunlopamericas.com
8. www.weighbeltfeeders.com