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REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT

FOR

Four Month Industrial Training

At

AMBUJA CEMENTS LTD.

(From 2/JAN/2017 to 30/APR/2017)

SUBMITTED BY-

MANMEET SINGH

Mechanical Engg.

1419733

Rayat Institute of Engineering and Information Technology

Railmajra, India
CERTIFICATE

Rayat Institute of Engineering and Information Technology, Railmajra

TO WHOM IT MAY CONCERN

I hereby certify that MANMEET SINGH Roll No 1419733 of Rayat Institute of


Engineering and Information Technology, Railmajra has undergone 4 month industrial
training from 2/JAN/2017 to 31/APR/2017 at our organization to fulfill the requirements
for the award of degree of B.Tech. (ME). During his tenure with us we found him sincere and
hard working. Wishing him a great success in the future.

Signature of the Student

Signature of the SUPERVISOR (S)


ACKNOWLEDGEMENT

The authors are highly grateful to the Dr. Ajay Goyal, Principal, Rayat Institute of
Engineering and Information Technology, Railmajra, for providing this opportunity to carry
out the 4 month industrial training at AMBUJA CEMENTS LTD.

The constant guidance and encouragement received from Mr. Satbir Singh Bajwa Dy.
Director T&P, RIEIT Railmajra has been of great help in carrying out the project work and is
acknowledged with reverential thanks.

The authors would like to express a deep sense of gratitude and thanks profusely to _
___________Director/CEO of Company. Without the wise counsel and able guidance, it
would have been impossible to complete the report in this manner.

The authors express gratitude to other faculty members of Information Technology


department of RIEIT for their intellectual support throughout the course of this work.

MANMEET SINGH
INTRODUCTION

It is says that as the famous proverb NEED IS MOTHER OF INVENTION". As the starting
time of the earth, the man was live in jungle, after that because of some invention he found
cottage and he use it as their house. After that he made a house by using brick, sand, and clay.
After that time man makes great invention and it is CEMENT. And it is also known as the
great revolution in the earth. GUJARAT AMBUJA CEMENT LTD. was set up in 1986. The
main purpose of cement is construction of houses and buildings. Because of cement it is
possible to build up one floor to hundred floors. Once found of cement there are arising
thousands of company every after short time. And in it is one of the best company of the
world. And it is started in 1983.
HISTORY

History means the pass events of the unit Gujarat Ambuja Cement Ltd., (G.A.C.L.) it
ishandled by Sekhsaria & Neotia Group. Which has launched in 1983? The project
was decided to locate at Mahuva in Bhavnagar District and unfavorable circumstance the
location is change and it is establish in some other place. And it is finally establish in the
place at Vadnagar, Taluika Kodinar in Junagadh District.. Gujarat Ambuja Cement Ltd.
is a Public Limited Company. It purchased their new land for factory building and
housing colony. They were also motivated by the co-operation of G.E.B. who agreed to
provide 19 MVA power for the plant. Even our Railway provides transportation services
between Kodinar to Vadnagar plant.The construction of entire plant commenced in March
1985 and completed in August 1986. The company started its commercial production
in1986.As passing of the time, the golden period came for the Ambuja came into
being"GUJARAT AMBUJA CEMENT LTD" (G.A.C.L.). Theydeveloped its other branches
in our country India.
PLANTS IN INDIAHEALTH AND SAFETY RULES

NAME OF PLANT STATE LOCATION TYPE


OF UNIT
Gujarat Ambuja Himachal Pradesh Darlaghat Grinding
Unit
Gujarat Ambuja (G) Punjab Ropar Grinding
Unit
Gujarat Ambuja (G) Punjab Bhatinda Grinding
Unit
Ambuja Cement Ltd. Rajasthan Pali Dry
Ambuja Cement Gujarat Kodinar Dry
Ambuja Eastern West Bengal Sankrail Grinding
Unit
Ambuja Eastern Maharashtra Chandanpur Dry
1. I ACCESS AND CONTROL RISKS BEFORE STARTING ANY TASK.

2. I ONLY PERFORM ACTIVITIES FOR WHICH I AM AUTHORIZED.

3. I NEVER OVERRIDE AND MISUSE HEALTH AND SAFETY DEVICES.

4. I DO NOT WORK UNDER THE INFLUENCE OF ALCOHOL OR DRUGS.

5. I REPORT ALL INCIDENTS.

SAFETY EQUIPMENTS (PPES)

HELMET
GLOVES
NOSE MASK
GOOGLES
REFLECTIVE JACKET
SHOES
EAR PLUGS
CONSTITUENTS OF CEMENT

Portland cement is manufactured by crushing, milling and proportioning the following


materials:

1. Lime or calcium oxide,CaO:from limestone, chalk, shells, shale or calcareous

rock.

2. Silica, SiO2: from sand, old bottles, clay or argillaceous rock.

3. Alumina, Al2O3: from bauxite, recycled aluminum, clay.

4. Iron, Fe2O3: from clay, iron ore, scrap iron and fly ash.

5. Gypsum, CaSO4.2H20: found together with limestone.

TYPES OF CEMENT

1. ORDINARY PORTLAND CEMENT(OPC)


2. POZZOLANA PORTLAND CEMENT (PPC)
3. OPC 53SUPER
4. OPC 43SUPER
PLANT LAYOUT
TIPPLER

There are four tipplers in this plant ,which are used to unload the trucks and trailers.

COMPONENTS USED IN TIPPLER-

1. HYDRAULIC SYSTEM,
2. HOPPER,
3. BAG FILTER,
4. SCREW CONVEYER,
5. FANS,
6. BELT CONVEYOR
CLINKER STORAGE SILO

It is used to store the clinker, which is unloaded from trucks by Tippler


CEMENT GRINDING MILL

There are four grinding mills in this plant.

TECHNICAL SPECIFICATIONS OF MILLS-

NO. DRIVE MOTOR GEAR BOX BEARINGS


MILL- SINGLE 2800 KW SBN- TRUNION
1,2,3 800(FLENDER)
MILL-4 DOUBLE 2500 KW SBN- SLIDE SHOE
800(ELECON)

GRINDING CAPACITY OF MILLS

MILL-1,2,3- 80TPH
MILL-4- 150TPH
GRINDING BALL MILL

A ball mill is a type of grinder used to grind and blend materials for use in mineral dressing
processes, paints, pyrotechnics, ceramics and selective laser sintering. It works on the
principle of impact and attrition: size reduction is done by impact as the balls drop from near
the top of the shell.
A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell
may be either horizontal or at a small angle to the horizontal. It is partially filled with balls.
The grinding media is the balls, which may be made of steel (chrome steel), stainless steel,
ceramic, or rubber.
The inner surface of the cylindrical shell is usually lined with an abrasion-resistant material
such as manganese steel or rubber. Less wear takes place in rubber lined mills. The length of
the mill is approximately equal to its diameter.
COMPONENTS OF GRINDING MILL

1. BEARING
2. GRINDING MEDIA
3. MOTOR
4. GEAR BOX
5. AUXILLARY DRIVE
6. DRIVE SHAFT (HOLLOW)
7. GEAR COUPLING
8. GRID COUPLING
9. PINION
10. GIRTH GEAR
11. LINERS
12. HP HYDRAULIC PUMP
13. LP HYDRAULIC PUMP
AIR SLIDES

It is used to convey the cement particles.


AIR SLIDES

Air slides are used in the cement industry to secure smoothly loading/unloading bulk cement
powder transport by truck (silo), train (wagon) or boat, silo discharge, mixing, storage,
distribution and transport bulk cement powder.
These airslide fabrics are used for the pneumatic conveying of fine dry products like cement,
also called pulverulents. The airslide consists of a chamber separated by a permeable cloth.
The chamber is inclined at a very slight angle (as low as 1.5). Compressed air is injected into
the lower chamber which then goes through the media and fluidises the cement powder.
The cement then behaves like a fluid and flows down the length of the chamber.
Air slides are used to transport solids with high flow rate over long distances. Airslides
provide an efficient and low energy system with a minimum maintenance for transport bulk
as well as smooth mass flow. Powder moves on the fluidization conveyor. The conveyor
doesnt move. It is the airflow through the airslide fabric that removes the friction between
the powder and the textile materials: the powder flows smoothly and evenly. Energy
requirements are minimal because only a small volume of air at a low pressure is required to
move material.
The other names are: aero cloth, airslide canvas, airslide conveyor or belts, aeration pads,
fluxo channels fluids, Airslide is a semi-permeable textile cloth which allows air to pass
through but not the products.
BUCKET ELEVATORS

Bucket elevators are used for horizontal conveying of cement particles. There are two types
of elevators are used in this plant. Which are Chain Bucket elevator and Belt bucket elevator.
BUCKET ELEVATORS

A bucket elevator, also called a grain leg, is a mechanism for hauling flowable bulk materials
(most often grain or fertilizer) vertically.
It consists of:
1. Buckets to contain the material;
2. A belt to carry the buckets and transmit the pull;
3. Means to drive the belt;
4. Accessories for loading the buckets or picking up the material, for
receiving the discharged material, for maintaining the belt tension and for enclosing
and protecting the elevator.
A bucket elevator can elevate a variety of bulk materials from light to heavy and from fine to
large lumps.
A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend
entirely on the action of centrifugal force to get the material into the discharge chute and must
be run at speeds relatively high. Inclined elevators with buckets spaced apart or set close
together may have the discharge chute set partly under the head pulley. Since they don't
depend entirely on the centrifugal force to put the material into the chute, the speed may be
relatively lower.
Nearly all centrifugal discharge elevators have spaced buckets with rounded bottoms. They
pick up their load from a boot, a pit, or a pile of material at the foot pulley.
CEMENT SILO

Cement silo is used to store the final produced cement particles. Height of this silo is 40 m.
There are four cement silos.
GEAR BOX

There are different types of gear boxes are used, which have different speed ratios according
to the requirement of system.

FLENDER ELECON

SBN-800 GEAR BOX


GEAR BOX

Two meshing gears transmitting rotational motion. Note that the smaller gear is rotating
faster. Since the larger gear is rotating less quickly, its torque is proportionally greater. One
subtlety of this particular arrangement is that the linear speed at the pitch diameter is the same
on both gears.

MODELS USED IN AMBUJA CEMENTS LIMITED


1.SBN 800

2.SBN 225

3SBN 100

4.SCN 225

5.KBN 100
MOTORS

There are different motors of different powers are used with different RPMs.
SHAFT COUPLINGS

A coupling is a device used to connect two shafts together at their ends for the purpose of
transmitting power. Couplings do not normally allow disconnection of shafts during
operation, however there are torque limiting couplings which can slip or disconnect when
some torque limit is exceeded.
The primary purpose of couplings is to join two pieces of rotating equipment while
permitting some degree of misalignment or end movement or both. By careful selection,
installation and maintenance of couplings, substantial savings can be made in reduced
maintenance costs and downtime.SHAFT COUPLINGS

FLUID COUPLING
BUSH PIN COUPLING

GRID COUPLING

GEAR COUPLING LOVE JOY


COUPLING
FANS AND BLOWERS

FAN

BLOWER
FAN AND BLOWERS

FAN

A fan moves large amounts of gas with a low increase in pressure: you'll find these in your
home.

BLOWER

A blower is a machine used for moving gas with a moderate increase of pressure: a more
powerful fan, if you will. By changing the angle of the blades, a blower will be able to push
air in any direction you want it.
TYPES OF CONVEYORS

BELT CONVEYOR

DEEP PAN CONVEYOR


CHUTE CONVEYOR

SCREW CONVEYOR
CONVEYORS
A conveyor system is a common piece of mechanical handling equipment that moves materials
from one location to another. Conveyors are especially useful in applications involving the
transportation of heavy or bulky materials. Conveyor systems allow quick and efficient
transportation for a wide variety of materials, which make them very popular in the material
handling and packaging industries. Many kinds of conveying systems are available, and are used
according to the various needs of different industries.
BELT CONVEYOR
Belt conveyors consists of two powered pulleys with a continuous loop of belting material used
to convey products. Belt conveyors are the most economical powered conveyor and are typically
used for conveying products over long distances, at high speeds, or for incline/decline
applications.
SCREW CONVEYOR

A screw conveyor or auger conveyor is a mechanism that uses a rotating helical screw blade,
called a "flighting", usually within a tube, to move liquid or granular materials. They are used in
many bulk handling industries. Screw conveyors in modern industry are often used horizontally
or at a slight incline as an efficient way to move semi-solid materials, including food waste,
wood chips, aggregates, cereal grains, animal feed, boiler ash, meat and bone meal, municipal
solid waste, and many others. The first type of screw conveyor was the Archimedes' screw, used
since ancient times to pump irrigation water.

They usually consist of a trough or tube containing either a spiral blade coiled around a shaft,
driven at one end and held at the other, or a "shaftless spiral", driven at one end and free at the
other. The rate of volume transfer is proportional to the rotation rate of the shaft. In industrial
control applications the device is often used as a variable rate feeder by varying the rotation rate
of the shaft to deliver a measured rate or quantity of material into a process.

Screw conveyors can be operated with the flow of material inclined upward. When space allows,
this is a very economical method of elevating and conveying. As the angle of inclination
increases, the capacity of a given unit rapidly decreases.
The rotating part of the conveyor is sometimes called simply an auger.

CHUTE CONVEYOR

Chute Conveyor is one of the least expensive methods of conveying material. It is the simplest
example of gravity-operated conveyor. Chute conveyor is used to provide accumulation in
shipping areas; a spiral chute can be used to convey items between floors with minimum amount
of space required. While the chute conveyors are economical, the main limitation of chute
conveyors is the lack of control over the items being conveyed. The packages may tend to shift
and turn so that jams and blockages occur.