Internship Report
2010
Prepared by :
Tutmash Shafi Akhtar
Reg No :
SP07-BEC-85 ,
Batch-4 , Section A
:: Table Of Contents ::
4 Labortories 9
5 Coal yard, Coal mill feed area, coal mill, storage of 10
coal
Acknowledgement
Executive Summary
Dera Ghazi Khan Cement Company Limited is a strategic business unit of Nishat Group, which is
the largest industrial group in Pakistan. D.G. Khan Cement Co. is market leader with respect to
market share with about 11.4% market share. Apart from its competitors; its product is high priced
yet it has highest market share because of good quality. Its plant is situated in Dera Ghazi Khan and
Khair Pur and head office is situated at Lahore. Factory site Unit 1and 2 that is situated in very
remote area of Punjab, yet it proved a blessing for the company. Because it has all three basic raw
materials i.e. Lime stone, Shale, and Gypsum at one place.
It has three plants working two in D.G. khan and one in Khair Pur. First plant is old one and it is
Japanese plant. The other two plants are of F.L.Smiths, Denmark. Presently it has a total Installed
capacity of 14000 tpd(tons per day).Presently the company is also exporting the cement to
Afghanistan, Iraq, UAE and Russia. The team of the D.G. Cement is story of success of D.G.
Cement. The whole team is self-motivated and had played a vital role in the success of the
company.
Quarry:
Quarry is the place from where raw material in extracted. Drilling and blasting is done to extract
the material.A hole of about 10-15 m is drilled and ammonium nitrate in filled as an explosive in
Tutmash Shafi Akhtar (SP07-BEC-85) 4
Department Of Chemical Engineering, CIIT Lhr
Internship Report 2010
these holes. When this explosive is ignited the rocks are broken into pieces of
different sizes. These pieces sre then loaded on the dumper trucks and conveyod to the
crusher. It is located about 3-4 Km from the plant.
Quarry and raw materials:
1. Lime stone: This raw material is company owned and is extracted from the
nearby quarry Unit. Limestone has the highest composition in the cement
product. 76% of the cement constitutes of limestone.
2. Clay: Clay is another natural resource. This raw material is also company
owned. 24% of cement composition comprises of clay
3. Iron Ore, Bauxites and silica sand: Iron Ore is the only resource that is bought from
contractors. Iron Ore, Bauxites and silica sand are added in small quantities less then one percent
and it helps to strengthen the cement.
Description:
Raw material such as limestone, clay, marl and shale
are dumped into hoppers by dump trucks and entered
into a hammer crusher through an apron feeder. Inside
hammer crusher there are hammers each having a
weight of 100-102 kg. They rotate at a speed of 1200-
1300 rpm and is capable of crushing feed of very large
sizes.
Bag Filter :
The dust produced by crushing process
can cause damage to the equipment and
may produce dust, to overcome this
problem a bag filter is employed. A fan
blows air and all the dust goes to the bag
filter. Inside the bag filter a special type
of canvas cloth is used. When air passes
through this filter cloth, the dust particles
stick to the cloth and clean air passes
through. The dust particles are then
collected and sent to the conveyor. After
sometime when the filter is choked with
particles, Purging system is used in which high pressure air is used, this air
removes all particles from the filter cloth.
Composition analyzer ;
A composition analyzer is installed upon the feed conveyor belt. This analyzer
detects the composition of the feed before it goes to the storage pile. The
radioactive material used id “Clifornium”. Its half life is 2.5 years and its price is
84,00000. This element emits rays which pass
Storage Yard:
The crushed material is stored in the form of piles in
the storage yard. There are 6 piles in the storage yard. Mixed piles are used in
larger quantity where as high grade and additive piles are used in small quantity.
2 Mixed piles (limestone & clay)
2 High grade (pure limestone)
Iron ore (additive)
Bauxite (additive)
Stacker :
A stacker is a device which form conical piles of the
crushed material. Feed is conveyod to the stacker through
conveyor belts. This stacker then moves too an fro to make
a pile. The stacker belt is called “Jib” in engineering terms.
Now, for conveying this material from piles to the
conveyor follweing equipment sre used :
Side scrapper
Reclaimer
Side scrapper :
Side scrapper is a device which picks the crushed feed
from the piles through its feed belt called “Hoist”. This belt
has a number of small buckets of low capacity. When this
belt moves, the buckets picks feed from the pile and put it
on the belt conveyor. Side scrapper in used for those piles
which are required in low quantity like bauxite and iron
ore.
Reclaimer :
Reclaimer is an equipment which is used to throw feed dowm from the pile. It has
two ams called “Harrows” These harrows are inserted into the pile, when they
move sideward, the feed drops down the pile. This feed in then collected by high
capacity buckets installed in the bottom of the reclaimer. These buckets pick the
feed and put it on the the belt conveyor. It is a large capacity equipment and for
those piles which are required in high quantity like Mixed Pile.
Load Cells : These are sensing devices which tells the load being put on the
hopper by the feed.
From these hoppers, the feed in required proportions is transferred by the belt
conveyor to the Raw Mill. A lot of dust is produced during the conveying of
material, to avoid this problem Bag Filters are installed. A Magentic separator is
also intalled to reomove metal impurities.
Raw Mill:
Capacity: 500 tons/hr
Motor power : 4300 kw
Supplier : FLSmidth
Table:
The raw feed from the belt conveyor directly falls on
the rotating table of the raw mill. The table contains 3
crushing rollers. The raw fed is crushed to fine powder
with these rollers. The coarse particles are collected at
the bottom of raw mill and are sent to to the vibrator
from where they are sent to to the raw feed belt
conveyor and again recycled to the ram mill for
recrushing. The vibrator is use to handle the quantity of the material being put on
the belt.
Seperator :
At the top of the raw mill, there is separator section. Hot
gases from the kiln comes from the bottom of the raw mill
and lift very fine particles with it. A suction fan with motor
power of 4500 kw produces suction and sends dusty air into
the cyclones at the top. Here the dusty air rotates and
particles are separated from the air. These particles are
collected at the bottom of the cyclone and sent to the CF
silo with the help of air slides. The air which still contains
dust particles are separated in Conditioning tower and
Electrostatic precipitator.
Bottom separator:
Some fine particles from raw feed fall on the table, these particles are collected by
means of a bottom scrapper and sent to the CF silo.
Conditioning tower:
The air from the cyclones still contains the dust particles which must be separated
before the air is exhausted to the atmosphere. Air from the separator is passed
through conditioning tower. In conditioning tower, water is sprinkled through very
both corona wires. Dusty air passes through these corona wires and the particles
get negatively charged. The negatively charged particles in air are then attracted by
the positively charged electrode and the particles stick with it and clean air is
exhausted from the chimney.
Coal yard :
Coal yard is the area where coal is stored which is used for burning purposes.
There are different piles for the storage of local and imported coal. The coal is
impoted from South Arica, and Indonesia. The coal is handled by a loader, the
loader picks up the coal and throws on a sieved net which separates bigger pieces
of coal and stones form it, before it goes to the tunnel.
Kiln Motors:
There are two kiln bases on which motors are installed which impart rotary motion
to the kiln.
Kiln hood:
The hot material form the kiln falls into the kiln hood at the end which has an
angular sieve. When material passes through it it attains the shape of clinker. Now
this clinker is sent to the cooler.
Clinker cooler :
The clinker cooler is used to lower the clinker temperature. There are ID fans
which take fresh air from the atmosphere and send it to the cooler. At the bottom
of the cooler there are reciprocating rails which move with the help of hydraulic
motors. These rails convey the clinker forward to the clinker crusher.
Dust collection :
A suction fan is installed which sucks the product dust from the cooler and send it
to the electrostatic precipitator. In EP dust is removed and clean air is exhausted to
the atmosphere through a chimney. The dust particles are to the deep pan conveyor
by a screw conveyor.
Clinker crusher :
Tutmash Shafi Akhtar (SP07-BEC-85) 17
Department Of Chemical Engineering, CIIT Lhr
Internship Report 2010
When the clinker cools and hardens then it is sent to the clinker crusher
installed after the cooler. Big stones of clinker are crushed to small pieces. The
crushed clinker is dropped on the deep pan conveyor at the bottom of the conveyor
which conveys it to the clinker storage.
Clinker storage :
The clinker from the deep pan conveyor is stored in the
clinker storage. Its capacity is 110,000 tons. Its length is
60 m and its width is 46 m. There are 3 gates at the
bottom of the clinker storage from where the clinker is
sent to cement mill through belt conveyor. Besides the
main clinker storage bin, there is a temporary clinker
storage hopper with a capacity of 1400 tons. If the
temporay hopper is also full then the clinker is removed
from the hopper and dumped into clinker storage yard.
Cement mill feed area :
There are 2 cement mills and 6 hoppers (3 for each mill) in the cement mill feed
area.
The 1st hopper contains the clinker which is major constituent of the cement. The
cement contains 95 % clinker which is conveyed through weigh feeder to the main
belt conveyor which takes it to the cement mill.
Gypsum addition :
The crushed gypsum from a separate crusher is conveyed by belt conveyor to the
cement mill. It is mixed in the clinker while crushing. Gypsum is added to about 4
– 5 %. Its purpose is to increase the settling time of the cement.
Mixing of additive :
The additive which is pure limestone is also added in the cement mill. Its added to
about 2 %. Its function is to increase strength of cement.
A bag filter collects dust from the main belt and a magnetic separator remove
metallic impurities from entering into the cement mill.
Metal detector ;
Cement Mills :
Cement mills specifications OK 36-4 :
Capacity : 175 ton/hr
Motor power : 3400 kw
Supplier : FLSmidth
The feed which is free from impurities falls on the
table of cement mill which contains three rollers.
Each roller has weight of 35 tons and the clearance
between table and rollers is 0.5 mm. These rollers
move hydraulically using nitrogen gas as hydraulic
fluid. The rollers crush the feed to a very fine powder.
The air slides conveys the ground product to the
bucket elevator which lifts it to enter into the 1st
storage silo.
Storage silos :
Specifications of storage silos :
Capacity : 21,000 tons
Length : 45 m
Dia : 22.4 m
There are 3 cement storage silos in which crushed
cement is stored uptill packing.. To convey the cement
to the other 2 silos air slides are used. From these silos
the cement enters air slides by air circulations through
blowers. Now these air slides take the cement to the
packing plant.
Schematic view of silo. The old cement was blocking the air slides as well as
bridging preventing the flow of cement from the silo. Sockets installed above
discharge gates and lower air slides proved the ideal solution to blocking of silo
and can be used whenever there is build-ups.
Packing Plant :
The packing plant comprises of 6 packers and 12
terminals. Each packer has a capacity of 100 tons/hr.
The cement bags are attached manually to the rotating
packer which fills the cement bag. When the bag is
filled upto the required weight , it automatically falls
on the conveyor balt which takes the bags to the roller
conveyor. From these rollers the bags slide to
different channels and finally cement bags are loadsed
on the trucks fro dispatch.
Tutmash Shafi Akhtar (SP07-BEC-85) 20
Department Of Chemical Engineering, CIIT Lhr
Internship Report 2010
Refrences :
www.sick.com/.../cement/Pages/cement.aspx
www.siamrefractory.com/cement_cyclone.php
www.freepatentsonline.com
www.freepatentsonline.com
www.lwbref.de/en/markets/cement-lime-industry/
Prepared By :
Tutmash Shafi Akhtar
Chemical Engineering,CIIT Lahore
Batch-4
Section-A