Page | 1

Report
On
Industrial Visit
At
ACC Limited
Chaibasa Cement Works
P.O. Jhinkpani
Singhbhum (W)-833215
Jharkhand, India.




Page | 2









The Industrial Visit was undertaken by:
1. Rohit Vishal Pandey
2. Souvik Kumar Mandal
3. Shounik Datta
4. Abhik Mandal

We had visited Chaibasa Cement Works for 3 days from 22
nd
June to 24
th

June, 2009. The permission for the above was received from respected sir,
Tapash Satpati.










Page | 3







Chaibasa Cement Works, The Front View of the Plant

Introduction
Chaibasa Cement Works established in 1946 is the oldest Cement manufacturing
plant in India. It has a capacity of 4000 tonnes per day with a work force of 500
people per work shift of 8 hours. Though the Kiln Processing part has been
Page | 4

completely modernized and computerized the Cement Manufacturing part still
uses primitive machinery which after modernization runs by computers. For
meeting its demands the Cement Plant has its very own Power Plants. The first
one is a 6 MW Power Plant originating in 1946 and another 15 MW modernized
Power Plant. The whole power consumed by the plant ranging from limestone
source in Rajanka Lime Stone Mines to finished products of 75 kg Cement sacks is
met by these power plants. The Plant uses water that is liberated from the mines
during blasting and crushing operation.

In this report I have divided the plant into six sections and each section have been
further discussed.
The 6 sections are:
1. Lime stone Excavation Page | 6
2. Kiln Process Page | 8
3. Clinker Formation Page | 12
4. Power Plant Page | 13
5. Coal Section Page | 17
6. Cement Production and Packing Page | 19

Lime stone Excavation
The first step in Lime Stone excavation is Blasting of the Rajanka
Lime Stone mines which are around 2.5 kms away from the plant.
Blasting and drilling of lime stone is done between 12.45 pm to 2 pm
daily. Next the lime stones are crushed in Crushers and the big sized
blocks are reduced to smaller sizes. The lime content is around 40 %
Page | 5

which is rather poor. These lime stones are transported to the plant
in Pipe conveyers which connect the plant to the mines.
Now these raw lime stones are stacked in to different stacks using
Stacker based on percentage content of lime. After Stacking,
Reclaimation is performed by the Reclaimer which homogenizes the
lime from stacks.

Kiln Process

Iron Ore and Bauxite (both constitute about 5 %) along with High
Grade lime (since Rajankas quality is poor) and Rajankas limes are
poured in separate Hoppers. High Grade lime is produced in the
plant by Froth Floatation Process inside the plant to produce slurry.
All these constituents from the different hoppers are supplied to the
Vertical Roller Mill (VRM), where they are mixed and the exhaust is
transported to a Bag House where Suspended Particulate Matters
are cleaned from the air before leaving the exhaust which is a mean
to reduce pollution.
The matter from the VRM is transported to the Blending Silo
and is then elevated to the preheater section at a height of 139 m
using blowers. Here in a series of 4 cyclones the mixture is
preheated and then in the 5
th
cyclone it is calcined.
Coal firing is provided from here, the matter we receive from the
5
th
cyclone is called the Kiln Feed and is directly fed to the Kiln which
is a long rotating cylinder inclined at an angle of 4 so that the feed
Page | 6

slides to the other end where two pipes bringing coal and hot air
which burn and simultaneously the feed burns at about 920 C.


Clinker Formation

The output from the kiln is called clinker and is transported via Clinker
Transport to the cement production section. Simultaneously the
clinkers are cooled using 11 fans. These fans blow air on the outer side
of the clinker and is subsequently cooled. The exhaust from the fan is
used to supply hot air to the VRM as well as to the preheater thus the
ultimate exhaust for the atmosphere is at a lower temperature thus
again reducing pollution. The clinkers are stored in Clinker Silos.


Power Plant
Chaibasa Cement Works has two Power Plants:
1. 15 MW New Plant
2. Captive 6 MW Plant
The 6 MW Plant was built in 1946. It has two Boilers. One of them
has been modernized and the other one is primitive and is not in use. It
requires bituminous coal to work but present government norms
allows only peat and lignite in boiler heating purposes. The only
Page | 7

working boiler connects to a Turbine which rotates at 9000 rpm and
subsequently to a Condenser along with pump and exhaust. It does not
have modern fans and is not computerized. It uses primitive methods
for operation.
The 15 MW Plant is considerably newer one and is fully modernized
and computerized. It uses two Boilers to heat water. Heat is supplied
from burning coal supplied by huge belt conveyers. The steam
produced is used to rotate the Turbine at about 7700 rpm which
subsequently rotates the shaft connected to the Generator. The steam
is cooled in the condenser whose exhaust is used to preheat the air
leading to coal channels.
Both these plants suffice the power consumed by the Chaibasa
Cement Works and the adjacent colony. If there is a problem with any
of the plants there is a backup supply of batteries which can supply
alternative power to the plant for about 6 hours. If more power is
needed they receive it from Jharkhand State Electricity Board. Rarely
do they need it; their own plants are enough to satisfy its needs.


Coal Section
The plant requires 600 tonnes of powdered coal per day. The site
does not have coal mines and so coals have to transported. It is mainly
done from Purulia and Dhanbad. Coals are collected and stored so that
Page | 8

it can meet the plants demand and if there is shortage in coal, its own
collection can be used for few days without interruption in production.
Coals are transported from reserves via belt conveyers and are
crushed in Coal Crusher in smaller pieces. They are fed into the Coal
VRM and are then transported to Kiln using blowers and other part of
coal is transported to the heating section of boilers inside the power
plant.

Cement Production and Packing
Clinker from Kiln is finally converted into cement after a series of
processes. Firstly the clinkers are transported via huge pipes and ducts
to Cement Mills with the help of blowers from the Clinker Silos. There
are a total 7 Cement Mills in the plants. They were built in 1946 and
still use all primitive machinery.

Conclusion
The Visit to Chaibasa Cement Works had been very important for us
since this visit made us practically realize the true field of our job. The
wide gap between bookish knowledge and practical life is clear. The
hard environment condition in which we have to work nonstop and
how the working of machines governs our life and any irregularity in
the behavior of the machine is the greatest challenge of any mechanical
engineer.