INTRODUCTION

The Birla Corporation Ltd is a multi-products

conglomerate it pays significant role in the cement, jute,
pvc floor covering, auto trim and steel casting
industries. The corporate symbol of concentric circle
about a triangle represents this very multi dimensional
nature. The apex of the triangle is a visual
representation of the force that drives the entire
corporation, the unifying force in search of excellence.

The circles represent the inspiration to explore new

frontiers of growth.

Origin & Growth

Birla Corporation Limited is Flagship Company of

the M.P. Birla Group. Incorporated as Birla Jute
Manufacturing company Limited if 1919, it was Mr.
Madhav Prasad Birla who gave shape to the Company its
present form as the chairman of the company, Mr.
Madhav Prasad Birla transferred it from a manufacture
of jute good to a leading multi-products corporation with
wide spread activities. Under the chairman ship of Mrs.
Priyamvada Birla, the Company crossed the Rs. 2200.00
Crores turnover mark and the name was charged to Birla
Corporation Limited in 1998. Birla Corporation Limited
1
has products ranging from cement to jute good, PVC
floor covering, as well as auto trims (jute felt based car
interior manufactured with German technology).

After the demise of Mrs. Priyamvada Birla, the

Company continues to consolidate and grow under the
leadership R.S. Lodha who is now the chairman.

2
Location :- This plant is situated at chanderia Distt
Chittorgarh in Rajasthan State. This plant occupies an
area of about 1500 sqr. mtr. connected with the mines
which provides raw material for the production of
Cement.

Transportation :- The production of cement is so fast

and in heavy quantity then ultimately it needs the fast
response of marketing & transportation. Accordingly to
demand & sale of cement in market, management
makes arrangement of railways wagons and trucks etc.

Plants :- There are two plants into the field of

chanderia. One is Birla cement works (BCW) and another
one is Chittor cement works (CCW) along with the new
thermal power plants (29.8 MW.) & DG and safety
development.

Cement Division :- This division has six plants

Two at Satna – (SCW, BVC)
Two at Chittorgarh – (BCW, CCW) (Raj.)
One at Durgapur (WB) – DCW
One at Rae Bareli (U.P.)
Capacity of Plant :- BCW plant has installed total capacity
of 14.00 Lacs tones per annum. Its initial capacity was 2
Lacs tones and later it was increased to 4 Lacs Tones in
1971 by adding another kiln line in 1992, its capacity
increased to 6.00 Lacs Tones Annually.

3
 Its new plant CCW (Chittor Cement Works) started
production in the year 1986, with a capacity of 14 Lacs.
Tones of clinker per Annum.
Cement Grade :-
There are four grades of cement production in
Chittorgarh Unit as under:
1) 33 grade - Ordinary Portland Cement
2) 43 grade - Ordinary Portland Cement
3) 53 grade - Ordinary Portland Cement
4) PPC - Portland Pozzolana (Fly Ash
Based) Cement

4
 PREFACE

To introduce my self am Ankur Dangi student of

Gyan Vihar School of Engineering An Technology
Jaipur, Studying in 3rd year of B.Tech. Course with
Mechanical Branch.

We all know that an engineer is perfect only if he

has practical hand keeping in this view faculty of
engineering has kept a practical training period after
completion of 3rd academic year.

I took my training for 35 days in Birla Cement

Works. The training period conducted from 16 th May
2009 - 22nd June 2009.

It is my pleasure entire officer for acquainting me

with their guidance and cooperation.
I am very thankful to Mr. V.K. Hamirwasia
(President), Dr. S.K. Jain
(Dy. General Manager HRD) for allowing me to be the
part of this big concern.

I would like to thank Mr. R.K. Tripathi HRD for this

timely assistance and encouragement.

The training such a mill is a good experience for

me.

5
 Acknowledgement

Training is a referred to as the learning of activities

carried on for the Primary purpose and helping an
individual to acquire and apply his knowledge, skill
ability and attitude. It exposes the individual to the
actual practical conditions that is not possible thought in
the class room.

I convey my best regard to Mr. R.K. Jaiswal (Head of

Department Mechanical), Miss Shalini Pandey (Training &
Placement officer) Helping me arranging training
program in Birla Cement Limited.

I express my great sense of gratitude to the

management group who allowed me inplant training in
the renowned Industry and provide me golden
opportunity to enhance my practical knowledge.

And very special thanks to :

Mr. R.M. Tondon (Assistance Vice President,
Mechanical)
Mr. Subodh Soni (Manager Mechanical)
Mr. A.P. Nimawat (Department Manager)
Mr. Deepak Songara (Mechanical Engineer)

6
For quelling my queries for their worthful guidance and
cooperation at last but not the least again thanks to all
persons of organization

ANKUR
DANGI
VIth
SEMESTER
MECHANICAL

7
8
 SAFETY & ENVIRONMENT
It plays a very important role in the working of any organization like BCL.
The main role of this department is to internally monitor the guidelines give by
State Pollution Control Board (SPCB) and Central Pollution Control Board
(CPCB). There are around 60 conditions which are to be monitored to fulfill the
statutory requirement by SPCB / CPCB.

 This department is involved in production activity also i.e. from mining to

packing.
 This department looking pollution control and making reports of data.
 This also involves in waste management coal and water etc. Plantation in
33% area of land.
 This department checks the safety points and also welcomes the
suggestions of employees.
 This department provides the safety equipment, mask, helmet, gloves,
safety shoes, goggles etc.
 This department also arranges, employees medical test in ayear and
maintains a health report employee wise.
 This department checks the vibration testing of m/c.
 This department has also applied for ISO-14000 certification related to
environment.

SAFETY PRECAUTIONS DURING

MAINTENANCE
(MECHANICAL)

GENERAL :

1. Always wear safety helmet when working in field.

2. Follow the safety instruction given in the maintenance manuals and
required at site.
3. Don't horseplay during the work. It may cause accident.
4. Keep worries away and mentally present during the work.
5. Wear light fitting clothes and shoes.
6. Keep work area clean.
7. All guards must be taken in position before starting the machine.
8. All railing and fencing must be in their position after finishing the job.
9. All electrical work should be done by the electrician.
9
10. Before use of sling and ropes it should be properly checked.

10
 MANUFACTURING PROCESS IN BRIEF
The plant is a dry process plant having five-stage-preheater kiln with inhne
precalcinatpor.

The main raw material limestone mines from "JAI SURJANA" mines and
transported to the crusher site by dumpers, s crushed in a two stage:
A) Primary Crusher B) Secoidary crusher
in crushing plant to required size, thereafter it is transported by OLBC and is
preblended in a preblending yard by a stacker. This preblended limestone is
reclaimed by -a reclaimer and is fed - into the raw grinding mill hoppers through
weigh feeders along with a certain percentage, of laterite. Laterite percentage
varies according to the quality of the laterite, limestone and fuel. The required
fineness and stored into a CF Sio, from where it is taken out and fed into the
rotary kiln through suspension pre heaters. The feeding to the kiln is controlled
by `loss on weight' system. The material, raw meal thus fed into the kiln gets
heated' up as it travels down the kiln and finally gets sintered in the sintering
zone of the kiln were temp ranges from 1400-1500°C. Pulverized coal is used as
fuel. The product thus formed is called CLINKER is cooled in a great cooler
having forced air injection system. This cooled clinker is transported through a
pan conveyor into a Clinker Silo, which is then fed to cement grinding mills
hoppers. This again fed into the grinding mills along with allowed quantity of
Gypsum and conveyed pneumatically to the Cement Storage Silos. The
percentage of gypsum varies according to the quality of gypsum, clinker and the
final product Cement. In case of Pozzolana, certain percentage of Pozzolanic
material (fly-ash) is also ground in the cement grinding mills along with the
mixture of clinker and gypsum. The cement is extracted from the storage silos
and packed in polymer bags through rotary packers Ventomatic and dispatched
by Rail/Road.

This is the most modern plant contailed by process computers coupled with
online X-Ray analyzer.

11
 MINES

Mines are main pillar for any cement industry. The same thing is here also.

BIRLA CORPORATION LTD has its own mines Jai Surjana

Mines.

It is about 4 Km from cement unit. The mining lease fare 15.468 Km 2 in three
blocks viz, a, b & c was granted to BCW in 1964, after subsequent the company
has retained lease over 5.988 Km 2 of the area only presently mines are situated
at Jai Surjana & total mining area is 3.648 Km 2.

Earlier limestone of required grade was supplied to the cement plant from
Bherda mines up to 1997. Oh exhaustion of limestone of required grade at
Bherda, it has been reclaimed as water reservoir. Presently there are two pits
existing. Mines are on lease of 20 years expiring on 20 th June 2004. Company
pays royalty to Govt. at Rs.40/- per ton quality utilized. The net current
requirement of the plant, 10000 tons, of limestone raised from the mines,
crushed & dispatched per day. To reduce dust generation, water injection system
is adopting in drilling.

Quality of Raw Material

Total carbonates should be 81.5% for BCW & 80% for CCW which includes
CaCO3 & MgCO3.

MINING OPERATION

Drilling : -

12
 Mining operation starts from drilling holes with the help of drilling rn/c. To
raise limestone, bore holes of 4 inch dia are made up to a depth of 10 meters
(approx). These bored holes are made in the square matrix of 10 meters.

Blasting: -
In each borehole a proper mixture of high & low grade of explosive is

rammed at the rate of approx 2.7 Kg/m depth. The explosive is then blasted by

means of electric detonator so that the limestone boulders of max. size 800 mm

3 are formed.

Excavation: -
After blasting to collect the limestone by shovel & loaded in dumpers for

crushing. The limestone is transported to crushers through dumpers and

unloaded in hopper of crusher. The capacity of crusher is 1000 TPH.

Transportation: -
The crushed material is further transported to the CCW. through OLBC. The

transportation capacity of OLBC is 1200 TPH. This material is stacked in the

form of the piles by limestone stacker in CCW. It is further reclaimed and given to

CCW & BCW as per their requirement.

SPECIFICATIONS
1. Drilling : Diameter - 165mm

2. Machine : 1 BH - 10, 5 nos.

3. Blasting : Explosive, limiting values

4. Bucket cap : 3.3 - 4.0m3, 7 nos.

5. Loading : Excavators (1 back has 2, front & hydraulic)

6. Transportation: HRM-35 Dumpers, 19 nos.

7. Crushing : Double Impactors, 1000. TPH cap & product

(95% - 25mm)
13
8. Dispatch : 900 TPH by 3.8 Kms long OLBC system

9. Reclamation : By 4502 TPH, electromagnetic vibro feeder

14
 L.S. CRUSHER IN GENERAL

The main purpose of limestone crusher unit to crush the different size of
limestone rock into the desirable sizes. Limestone rock is usually available at the
surface of the earth and can be collected by open pit quarrying methods. Certain
deposits are low grade must be treated by beneficiation methods.

In fact in the limestone crusher unit size reduction of limestone rock takes
place in which larger size of limestone rocks are cut or broken into smaller
pieces. Thus by reducing the particle size we can also increase the reactivity of
the solids. It also permits the separation of unwanted ingredients.

Though the limestone rock may be broken into three or four different ways,
But since we decide coarse, medium or fine products of limestone rock,
therefore we prepare to use impactors rather than compression which usually
gives coarse reduction of hard solids with few fines.

However, it is found that the limestone crusher unit doesn't yield a uniform
product. Whether, the feed is uniformly sized or not. The product always consists
of mixture of particles of different sizes. It is also seen during the operation of
crusher unit that of the feed (limestone) rock is homogeneous. The shape of
individual units i.e. crushed limestone product in the product is quite uniform for
maintaining the uniform size of product sieve analysis is done everyday.

On the whole it is found that the main objective of the crusher unit of C.C.W.
is to produce small particles from large pieces (below 25 mm). Smaller particles
are desired because of their shape size and number.

L.S.HOPPER
The limestone rock proper quarry is directly dumped into the limestone
hopper having capacity of about 130 tons at a time. Proper care is needed to see
that the size of limestone dumping because of the size of the limestone rock is
not acceptable and if it is dumped into the hopper it will effect the damage of
apron conveyor and grizzly feeder directly.

15
 1. Capacity of L.S. Hopper : 130 Tons per day
2. Max. Feed size permissible to the Hopper : 1.3x1.1 x1.01 meters
3. Density of limestone rock : 1.4 Tons/cu.m
4. Mass=Density x Volume

APRON CONVEYOR
Apron conveyor consists of a fabricated frame which is indented by two
heavy-duty endless chains. The chains are supported and guided on the top of
the frame by rollers and are supported on the return side by return rollers. Apron
heights are used for conveying the material (limestone). The drive arrangement
consists of a d.c. Moto by a gearbox to drive the counter shaft of the conveyor by
a flexible coupling. The counter shaft in turns drivers the main, shaft by means of
a bull gear paired to the countershaft to the main drive shaft.

SPECIFICATION OF APRON CONVEYOR

1. Capacity of the conveyor : 500 TPH
2. Max. Lump Size : 1.3 meters
3. Apron Feeder centers : 9.0 meters
4. Speed of feeder : 7.2 rpm (max.) 0.72 rpm (min.)
5. Width of Apron conveyor feeder : 1.80 meters
6. Height of drop of ore : 10 meters
7. Reduction gear box ratio : 100:1
8. Motor power : 50Kw, 45 Kw D.C.
9. Motor speed : 1500 rpm
10. Minimum depth of ore in hopper : 1.5m

GRIZZLY FEEDER

A grizzly feeder, in general consists of a grid of parallel metal bars set in an

inclined stationary frame. The slope and the path of material (lime stone) are
usually parallel to the length of the bars. Large feed, from the apron conveyor
and slide to the tails discharge and small lumps fall through a separator collector
(CR-3 belt conveyor directly).

16
 In cross-section the top of each bar is wider than the bottom so that the bars
can be made fairly deep for strength without being choked by lumps passing
through. The space between the two bars is found to be about 8 inches.

COMPOUND IMPACTOR

Description : - The compound impactor combines primary and

secondary crushing in one machine and avoids the problem and investment of a
closed circuit operation the arrangement of two rotors both turning in the same
direction results in the very high reduction ratio, resulting in a perfect ball mill
feed. Simultaneously it reduces a large amount to a much smaller size which
reduces the load on the ball mill resulting in considerable saving in operational
cost.

Specification : -

1. Feed Material : Lime Stone

2. Maximum feed size : 1300 x 100 x 1000
3. End product Size : 95% below 25 mm
4. Capacity : 500 TPH
Motor Rating :-
1. Primary Rotor : 525 KW 950 RPM (Syn)
2. Secondary Rotor : 525 KW 950 RPM (Syn)
3. Primary Rotor Speed : 350 RPM
4. Secondary Rotor Speed : 500 RPM
5. Primary Rotor Driven Pulley : 360 pcd
6. Primary Rotor Driving Pulley : 725 pcd
7. Secondary Rotor Driven Pulley : 995 pcd
8. Secondary Rotor Driving Pulley : 725 pcd

OPERATING CONDITION :-
1. 120-180 mm gap for front impact arm
2. 50-80 mm gap for rear impact arm
3. 50-80 mm tapering gap at the top
4. 25-50 mm tapering gap at the bottom
5. Maximum permissible temperature for bearing 80° C
6. Normal permissible temperature for bearing 50-70° C

DESIGN AND OPERATING PRINCIPLE

The housing of the impactor is of welded plate construction within which the
rotors are installed on rigid bottom housing. The two-rotor turn in the same

17
direction the feed enters the crusher through the inlet into the primary crushing
chamber providing for primary reduction before entering the secondary crushing
chamber where the secondary rotor with much higher speed provides for further
reduction. The impact arms are adjustable and they are supported on the
spindle, which allows them to retracted when in crushable material enters or over
feeding takes place.
BDC GROUP

BDC IN GENERAL : The major function of a bag dust collector is to

collect dust coming out from different belt conveyors, grizzly feeder, impactors
etc. into a dust hopper and it is again discharged to the conveying system by
means of a screw conveyor thus B.D.C. Performs these three main function.
1. Suction dust particles of limestone take place and this dust is collected
into the B.D.C. hopper.
2. Dry compressed air is down from the top of the B.D.C. causing dust to
collect into the bags.
3. B.D.C. reduces pollution due to dust particles by fines to the
atmosphere.

DESCRIPTION OF BDC

1. NOZZLE HOUSE : It consists of nozzle tippers and pressure

tanks with electrically operated cleaning valves of diaphragm type are included in
the nozzle house.

2. BAG PLATE : The bag plate of bag dust collector consists of a

number of sheets divided into different section with the provisional of holes for
bag
attachment it is also equipped with gauges for better distribution
arrangement.

18
 3. FILTER CASING: The casing of the B.D.C. is delivered in two
parts
1. Top part of casing
2. Bottom part of casin
These parts are welded together.

19
 4. INLET & DISTRIBUTION ARRANGEMENTS :
It is equipped with an inspection door and have damper for the construction
of filter carrying and to the connecting gas dust.

The distribution box consists of an outer sheet box with bottom along the
entire length, the filter casing covering about the 60% length of the filter caring
from the dust hopper.

5. DUST HOPPER : The dust opper is designed with a purpose to

store dust and equipped with a screw conveyor, the volumetric weight of the dust
collected into the hopper should not be more than 1400 kg/m3 it has also been
equipped with an inspection door.

MOTER DETAILS :

1. Power: 55KW
2. Speed: 1455RPM
3, AMPS: 96A
4. Voltage: 415 V
5. TYPE: 3 dia. 50 Hz, induction motor.

COMPRESSOR OF BDC:

The main function of a compressor is to take suction at a pressure below

atmosphere and discharge against atmospheric pressure. This is a multi-stage

unit containing a series of impellers on a single shaft rotating at high speed in a

massive casing. Internal channels leads from the discharger of one impeller to

the inlet of the next. These machines compress enormous volumes of air up to

30000 ft/minute at the outlet pressure of 2 atm.

20
 STACKER

STACKER IN GENERAL

Stacker has been designed for stacking the crushed limestone pieces leading
to pile formation. Thus, the stacker achieves limestone blending through
multistage horizontal layers, building up the stockpiles. In the present case, the
total stockpile formation takes place in 350 layers at an approximately constant
feed rate.
The luffing boom stacker continuously stacks material on the stockpile with
the Chevron method stocking. In the `Chevron Method' of stocking, each layer
has the same amount of material and these large numbers of layers ensure high
blending efficiency.
Material is received from the stacking conveyor LSB-3, from which it is
transferred to the boom conveyor, which deposits it on the stockpiles. The boom
conveyor can be luffed or lowered by a boom winch. The stockpile build up starts
from an empty stockpile when the boom is in lowest position and the machines is
standing at the center of the outer cone. The stacker now travels the length of
the stockpile to deposit material in horizontal layers. The end cone program in
the cone areas to achieve blending in these areas controls the stacker. When the
material height reaches to a certain level i.e.; 12.75 meters but now 11.75 meters
is max. Height, the boom is automatically raised for a fixed time. This process is
repeated till the boom has reached the highest position i.e.; 11.75 meters. Thus,
the stockpile is full of its capacity.

When the stockpile is completely formed, the sacker shifts over to the other
stockpile area for other stockpile formation.

OPERATION BY STACKER TO FORM PILES

The main function of the luffing boom stacker is to stack material

continuously on the stockpile with the chevron method of stacking. By means of
tripper and stacker arrangement along a common track, the transfer of material
to the stacker can be affected at any position of stacker along the stack pile.
Thus it also enables a uniform discharge over an entire length of stacker travel.
21
 The tripper discharge on the boom either `A' or 'B' conveyor through a
discharge chute. The boom is provided with a winch type luffing arrangement.

The boom of the stacker initially kept in low position and the discharge point
of the boom conveyor just above the middle of the pile. Now the boom starts to
run between two definite limit switches, through a circuit with time control. In this
way the boom starts to run from inner zone to outer zone of the pile for a
different period of time. When the particular height of layer is built up the boom is
raised to next higher position.

DESCRIPTION OF STACKER

 Main carriage consists of wheel assemblies, drive unit consisting of motor,

high speed coupling, break gear box, chain sprocket dry, low speed coupling
carriage fabricated from heavy steel plates and sections, drive base frame,
rail anchors, buffers and rail scrapers.
 Gantry type structure consists of columns and flows fabricated from heavy
steel plates and sections.
 Boom consists of structure steel consisting of walkways and hand railings on
both sides of conveyor, head cum take up pulley, tail turn drive pulley, snub
pulley, carrying impact and return idlers, high speed coupling, gear box with
internal hold back, internal scrappers, external scrappers, skirt board, take
up arranged pull cord and belt sway and zero speed switches.
 Luffing switch consists of motor high and low speed coupling, break,
gearbox, sheave assembly and wire rope.
 Tripper carriage - It consists of wheel assemblies of heavy steel plates.
Tripper body consists of carrying and return idlers, ripper head and bend
pulleys, two ways discharge chutes with manually operated gate, external
scraper, material sensor flap switches and zero speed switches, pull cord,
belt sway switches, walk ways, buffers, rail scrapers.
 Totally enclosed operators cabin - There is a power panel and control disc
has been provided in this cabin surrounded by toughened glass. The cabin is
provided with seat, light, fan and blower with filter.

22
 RECLAIMER

The bridge type scrapper reclaimer operates on the existing completed

stockpiles and reclaims material from the inner and cone side i.e. perpendicular
to the director of stockpile formation and takes off the whole slice of material.
Thus the reclaimed slice is blended by itself. For the start of an operation the
reclaimer is first located near to the periphery of inner end cone. The angle of
inclination of harrow is adjusted to .suite the slope of the stockpile. The reclaimer
is sequentially started on manual mode, In sequence starting the scrape of chain
drive start first followed by harrow wagon teeth dig inside the stock pile and
loosen the material and also help it to slide down the slope in a controlled
manner thereby resulting in effective blending. This is being achieved by
reciprocating motion of harrow wagon. A great number of showels move the
material in a transverse motion to the reclaiming conveyor from which it is
transported to the further implant conveyor.

RECLAIMER'S ATTACHMENTS

The reclaimer generally consists following parts attached with the reclaimer
for different purpose.
1. Harrow 2. Travel drive unit. 3. Limit Switches.
4. Emergency stop facility. 5. Totally enclosed cabin 6. Cable reeling drum.

SPECIFICATIONS

1. Reclaimer capacity : 450 TPH

2. No. of buckets in scrapper chain : 82
3. Harrow angle : 38°
4. Length of teeth on harrow : 1.75 feet (avg.)

STARTING SEQUENCE

When LSB-4 belt conveyor is running

WARNING

SCRAPER CHAIN

TRAVEL DRIVE

HARROW
RAW MILL
23
 The main purpose of this unit is to grind the crushed material (output of the
crusher unit) in powder form. Grinding of the crushed limestone is necessary so
as to increase their surface area. We can increase the reactivity of the solid by
the grinding process. More surface area is better for heat treatment during kiln
operation. The raw material`; for grinding mill is available directly by crusher or
through pile arrangement.

In dry process cement plant, the grinding of .limestone takes place with 'the

help of some percentage of laterite. The desirable percentage of laterite with

limestone is about 2-3%. The laterite is responsible for gray colour of cement

and it helps raw material to burn a sily in the kiln. In this unit the different grades.

of limestone mix together and maintain total carbonate.

The grinding operation takes place in raw mill which is different types
according to design.
Eg: - 1) Roller mill. 2) Ball mill. 3) Tube mill etc.

In roller mills grinding operation takes place by compression of rollers and

ball mills it is by impact agitation.
In B.C.W. the type of grinding mill is ball mill and the desirable size is found
out by sieve analysis The desirable size of ground material for this plant is as
follows:
23-24% residue from 170-mesh sieve
7-8% residue from 72-mesh sieve.

The ground raw material, which is ground in desired proportion of limestone

and laterite, is stored in C.F.Silo (Control Flow Silo) for homogenization.

All over the main objective of raw mill unit of this plant is to produce desired
size powder from average 25 mm pieces of limestone and laterite.

24
TRANSPORTATION OF LIMESTONE, LATERITE &

SWEETENER

The laterite and sweetener come from hoppers by push feeders PFI & PF2
on belt Conveyor. The belt conveyor discharges the material on either RM I belt
conveyor or on RM 2 belt conveyor as required.
The reclaimed material from stockpiles comes on belt conveyor LSB4. This
belt conveyor discharges the material on RM I belt conveyor or on RM 2 belt
conveyor as required.

In ease of any fault in reclaimer or belt conveyor LSB4, The. material comes
on belt conveyor LSB5 directly from the crusher.. The belt. conveyor LSB5
discharges the material on the RM 1 belt conveyor or on RM 2 belt conveyor as
required.
In case of LO hopper . filling.. the RM 1 belt conveyor or RM 2 belt conveyor
discharges the material directly in to the hopper.

HOPPER

The reclaimed material from the limestone reclaimer comes on the rubber
belt conveyor RM 1 or RM 2. If LSB 4 belt is faulted thn the material (without
stockpiling) comes on RM 1 or RM 2 through the LSB 5.

In CCW there are three hoppers viz. LO1, L02 & L03 which are called as

raw .mill hopper LO1 for limestone mix, LO2 for limestone high and L03 for

laterite. LO1 is directly filled with material through RM 1 & RM 2. For filling of

LO2 & LO3 a reversible belt conveyor is installed at the top both hoppers which

receives material from RM 1 & RM 2.

The capacity of these hoppers are as follows:

S.No_ HOPPER CAPACITY(TONS)

1. LO 1 434
2.. LO 2 823
25
 3. L03 492

WEIGH FEEDER

It is used to discharge desired quantity of the ni.aterial from hopper. The

weigh quantity of material pass through weigh feeder: Flow of material is

controlled by its belt speed, because the quantity `~'f material that is passing

from weigh feeder is directly proportional to- its belt speed. If belt speed is high

then material will pass in more quantity Game as on low speed of belt the less

quantity of material .will pass.

The whole equipment lives, in.: hanging position on `I' type bolts. Four load

cells are situated under the .belt and rollers because the belt runs on rollers. The

load cells convert the, weight of material -in form of volt to measure the quantity

of the material. A motor is situated at one end ao drive the belt.

For protection of weigh feeder it is to be noted that the weigh feeder should

be work/run in desired limit. It should neither on very less speed nor on very

high. This limit is called SUITABLE RANGE OF WORKING.

PRINCIPLE OF WEIGH FEEDER

w = X [A2 - D2]
2By

where, W= Weight
A= Distance between tail pulley and heat pulley
B= Calibration hole to chute center distance

26
 D= Distance between tail pulley and Chute center
Y= Belt speed

RAW MILL (BALL MILL)

This is the main equipment in which the grinding process occurs. This type of
mill is classified according, process and chambers.

According to design the mills are of these types:

1. Roller Mill (Vertical Raw Mill)
2. Tube Mill
3. Ball Mill
According to process the mills are of these types:
1. Open Circuit Mill
2. Closed Circuit Mill
According to chambers (compartments) the mills are of these types:
1. Mono Chamber Mill
2. Multi Chamber Mil
In this cement plant the closed circuit ball mill of mono chamber is situated.

GRINDING PRINCIPLE

There are different sized balls in the mill. For better grinding of solids (stones)
the big size balls are at initial part of the mill and for fine grinding of small stones
small sized balls are kept at the end part of the mill.

There are two types of liners mounted inside the mill shell. The initial part of
ball mill has the stepped-up liners that help in rising of balls. From these liners
the balls rise up due to rotation of mill. When the mill passes 90 0 rotation the
balls also gets lifted up to 900 and fall on the material directly. This reaction is
known as IMPACT. From this reaction the coarse grinding occurs.

And the end part of the mill has the classifier liners; the balls are rugged with
the help of these liners. Due to this reaction the friction occurs between the balls,
so that this reaction is called ATTRITION.

27
 The critical speed of mill' is that speed of rotation at which the centrifugal
force neutralizes the force of gravity which influences the grinding balls, the
grinding balls do not fall and rotate with mill shell.

GRINDING IN RAW MILL

The AO 4 belt conveyor directly discharges the material into the mill inlet.
The (mixture of limestone and laterite) enter in the mill and at first come into the
mill drum drier. Here the moisture is removed from the mixture by the contact of
the gases, which are sucked from the preheater by the raw mill fan. This part of
the mill is called 'DRYIN CHAMBER'. The drum drier consists of lifters that lift the
material for better contact of the material and the heat.

In the initial part of the mill the stepped liners are mounted with bolts.
Here the 90 mm — 50 mm balls are available. The stepped up liners help to
raise balls with the mill rotation.
When the mill rotates the balls rise and fall down on the material and
other balls due to this, coarse grinding takes place.
Now due to the movement of the mill and the suction of the hot gases the
material slides towards the next part of the mill. Due to the `attrition reaction' and
friction the particle size reduces to a greater extent and converts into powder
form.
After this the material slides towards outlet through diaphragm. The
diaphragm allows to pass desired size particles to the other side.
A water nozzle is also situated at the center of the mill inlet. This nozzle
spray in the mill controls the mill temp. According to the requirement.
The grinding media are usually steel balls in compartment 1st and a
charge of small cylindrical rod pieces with their length equal to there diameter
cast, of a special alloy in compartment 2nd. It should be hard, though not so
brittle that they are crushed during grinding.

TWO RULES

1. The mill must never be loaded with such a heavy total charge of
grinding media that the motor cannot drive the mill continuously without being
overloaded. When grinding coal or washable materials, it may be permissible to
give the mill a smaller charge then above.
2. The mill must never be run with full or partial charge of grinding media
unless material is simultaneously supplied to the mill or present in it. Otherwise
lining or grinding media may get damaged.

SPECIFICATIONS
28
Length : 8.51 m Diameter: 4.8 m
Volume :154.6 m3 RPM :14.9
Power : 3300 Kw Amps : 350 A
Fhola fan : 66% Inlet temp of mill : 90°C
Outlet Temp. of the mill : 65°C

OSEPA SEPARATOR

Osepa most fines have been classified as product, whereas the conventional
separator has been returned for further grinding. This atters the greatest
efficiency of the osepa separator.

The material fed to. the O-Sepa is directed on the dispersion plate located on
the top of the rotor by the feed chutes . It is then distributed by centrifugal force
into the annular gap between the rotor and the guide vanes, the buffer plate
providing an impacting ring to direct the material down into the separation zone.
The product is carried by the air flow through the separator into the center of
the rotor and exits the separator through the outlet duct located on the top with a
high angle bend The rejects are collected in the hopper and are discharged
through the flap valve at the bottom .There are three location for gas flow to
enter the osepa.

Primary air is comprised of the mill vent air and ambient air entering through
a bleed air damper . Secondary air comprises of vent air from auxiliary
equipment in the grinding circuit and ambient air entering also through a bleed
air damper. Primary & secondary air both enter. tangentially into the upper
housing of the osepa separator .Tertiary air is also ambient air and enters the
hopper through inlet ducts with dampers.

The Primary & secondary air creates a vortex in the separation zone of the
separator , which is further enhanced by the stationary guide vanes located
around the rotor. The rotor comprises of horizontal vortex is formed and vertical
flow adjusting blades which. provides the final classification of the product . Initial
classification is done by the vortex formed in the classification zone . Final

29
particles which are discharge into the hopper are also classified by the tertiary air
which provides counter flow in the hopper.

30
O-SEPA FAN

The osepa fan .circulate the air from multi=c clone separator to osepa
separator. Its sucks the air from top of the multi-cYelone and gives to the osepa
separator.
1. Power : 730 Kw
2. Amps : 80A
3. Voltage : 6600 V
4. RPM : 991

The air which is circulated by the osepa fan, part of duct goes to the
BDC( Bag Dust Collector). The object of this fan is to circulatethe air v itli fine
material.

MULTI CYCLONE SEPARATOR

Multicyclone separator is a combination of two or more than two cyclones. In

this plant there are six cyclones, which are combined together in Multicyclone
separator. It has no motor drive or any other electrical device. The material gets
separated into fine & coarse due to cyclonic reaction.

The fine material of osepa separator goes to the Multicyclone separator. The
osepa fan circulates the air froth Multicyclone to osepa separator.

As material enters tangentially into the first two cyclones & then go to
remaining cyclones. As. we have discuss before the material separates in the
Multicyclone by cyclonic reaction. Due to this reaction the fine material gets lifted
up & is sucked by osepa fan. Sum parts of this sucked material go to the BDC.
The coarse material falls down in the multicyclone & is collected in the hopper.
This collected material is discharged into UO-4 from where it goes to the C.E.
Silo for storage & homogenization.

CYCLONE SEPARATOR

31
 The Cyclone Separator has a simple structure .It looks like a cyclone in which
the material gets separated into fine & coarse due to cyclonic reaction.

BAG DUST COLLECTOR

Bag dust collector in which dust is removed from the gas stream by passing
the dust-laden gas through a fabric of some type (e.g. woven cloth, felt, or
porous membrane).

These devices are surface filters in which dust collects in a layer on the

surface of the filter medium and the dust layer itself becomes the effective filter

medium. The pores in the medium are usually many times the size of the dust

particles, so that dust collection efficiency is low until sufficient particles have

been collected to build up, a. "Precoat" in the fabric pores.

The open lower ends of the bags are fastened over opening in the tube sheet

that separates the lower dirty gas inlet chamber from the upper clean gas

chamber. The bag support, from which the bags are suspended are connected to

a shaking mechanism. The dirty gas lows up into the filter bag and the dust

collects on the inside surfaces of the bags. When the gas pressure drop rises to

a chosen upper limit as the result of dust accumulation the gas flow is stopped

and the shaker is operated giving a whipping motion to the bags. The dislodged

hags dust falls into the dust hopper located below the tube sheet. If the filter is to

be operated continuously it must be constructed with multiple compartments, so

that individual compartments can be sequentially taken off line for cleaning while

the other compartments continue operation.

In BCW raw mill unit the dirty gases come in BDC from a part of duct of

osepa fan. The collecting dust go to the air slide VO-2 & the gases exhaust in

the atmosphere_ from the stake with help of S0-3 fan.

32
 AIRLIFT

Airlift is the pneumatic material handling equipment, which is widely used for the
conveying of powdered material. ln BCW unit there are only two airlifts. One for
conveying material up to the top of the CF Silo and another for conveying
material up to the preheater. In the air lift the material flows with air, which
compresses the material forward. The pressure of this air is 14 Kg/cm2. This
pressurized air compresses the material and lift it forcedly up to a certain height
as per the applied pressure. In the BCW this airlift is stand-by for the bucket
'elevator means, when the bucket elevator i s stripped or damaged then this
airlift is used and secondly, due to the high power consumption in case of air lift.

C.F. SILO [CONTROLLED FLOW SILO]

This is the continuous flow silo for blending and storage of cement raw mix,
called the CF Silo, which extracts the material simultaneously at different rates
from a number of outlets in the Silo. bottom. The CF Silo is a continuously
operating blending and storage of cement plant for raw mix, which is used in the
production of cement.

In order to achieve a high degree of homogeneity in a continuously operating

flow-through silo with out air agitation, two conditions must be met : -

1. All the raw mix in the silo must be dept in constant movement towards the
outlet openings.
2. The raw mix passing the silo must have different residence times.

This is achieved by the operating principle of the C.P. Silo, which extracts raw
mix at different rate from several points in the silo bottom, & mixes the streams
from the, various outlets. This in fact divides the silo into a number of flow rates;
this process being followed by final blending in a small-operated kiln feed. A kiln
feed with stable chemical composition is thus obtained. The C.F. Silo is provided
with programmable control unit for its extraction equipment.

The raised bottom is supported on six main columns and, the kiln feed or
blending tank is positioned underneath. The silo bottom is provided with seven
extraction outlets called segments. The material continuously supplied to the
silo. The top deck of the silo is equipped with standard features • including a
manhole, over & under pressure valves, & level indicators. At the center of each
hexagonal sector an outlet opening is located, supplied with a conical steel
cover. These steel covers are designed to reduce the pressure above the
outlets, & to ensure extraction from the aerated part of the silo bottom.

33
 In actual operation- homogenization is performed by using three of the seven
discharge outlets simultaneously, each blower aerating only one sub sector at a
time. This distribution results in low power consunmption.

34
 KILN FEED

As we know that from W, AO, bin of CF Silo ground and homogenized

material comes at the kiln feed gate, from where it discharges into A20 S/C. This
screw conveyor discharges the material either in the airlift or in A-19 bucket
elevator as per requirement. If airlift in circuit the material reach to A-21 diverter
by compressed air. Here one way goes to again CF Silo and for re-circulating
other way goes to A22 diverter. The one way of A-22 diverter goes to first stage
of the pre heater and other way for second stage of pre heater.

In case of when bucket elevator is in circuit the screw conveyor discharge the
material in to the bucket elevator. This bucket elevator lifts up the material &
discharges into A-17 air slide. From where the material goes to the pre heater
first stage feedbox by a rotary feeder.

In this section generally the bucket elevator. is used in circuit, the airlift
comes to use as standby equipment for elevator.

KILN UNIT IN GENERAL

The main purpose of this unit is to make clinker by raw material. The raw
material available in the storage silo and feed to the kiln section by any suitable
mechanical or pneumatic equipment. During the clinker formation the raw
material pass through different reaction &. heat treatment. The main functions
taking place in this unit are as follows: -
1. Drying of material
2. Calcination of material
3. Burning of material
4. Cooling of material

These functions are completed to following sub units and equipments: •

1) Pre heater 2) Calciner
3) Kiln 4) Cooler

35
 The size of produced clinker shouldn't be more than 25 mm for better
grinding in cement mill. In cement technology there are man types of kiln but in
CCW the sixth stage pre heater rotary kiln with pre calcinator is installed.

PREHEATER

Pre heater is used for the preheating of the material calcinations of material
before it enters into the kiln. To increase the output efficiency of the calcinations,
the preheater is designed as calcinations zone. In BCW the single string six
stage suspension pre heater- with pre claimer is used The looking of pre heater
like a tower in which cyclones are connected with ducts. In this pre heater there
are six cyclones and precalciner. Some details about each stage are as follows:-

STAGE l

There are two cyclones connected together. of same size. Tlie size are
smaller than left all cyclones.... These are known as "Twin Cyclones". The
representation of these cyclones is A-51 & ;A-61. Their upper ends connected
with a duct, which is connected pre heater fan. This fan sucks the whole air from
kiln. These cyclones are connected to A-52 cyclone top by another duct, in this
duct the raw material is fed by pneumatic & mechanical systems : The bottom of
both cyclones is connected to A-53 cyclones & a flap valve is also situated
between these. The average temp. & pressure in these cyclone line are as
follows;-

SNO. A-51 A-61

1 Twin Cyclone gas temp 368°C 359°C
2 Twin Cyclone mat. temp. 354°C 343°C
3 Twin Cyclone pressure 610 MMWG 616MMWG

STAGE II

The cyclone which is installed on this is denoted by A-52 Cyclone. This is. A.'
bigger cyclone than Twin Cyclones. The upper duct of this cyclone is connected
to Twin Cyclones by a duct in which the raw material goes into A-51 &; A_.61
with hot air. This cyclone is connected with A-53 cyclone by an another duct in
which the raw material comes into A-52 cyclones by hot air. The bottom of this
cyclone is connected to A-54 cyclone with a duct but flap. valve- is also fix
between them. In this cyclone the temp is higher than A-Si &A-61 cyclones
&lesser than A-53 cyclone. For A-52 cyclone:-

1 Gas Temperature 570°C

36
 2 Material Temperature 560°C
3 Pressure in Cyclone 550 MMWG

STAGE III

In this stage the A-53 cyclone is situated in which the material comes from A-
52 cyclone by arising duct. The size is same of A-52 cyclone. & A53 cyclone. It is
connected by A-52 cyclone from it's top by a duct. The temperature in cyclone is
higher than A-52 cyclone & lesser than A-54 cyclone,, but pressure is greater.

1. Gas. Tem erature In A-53 Cyclone 714 C

2. Material Temperature In A-53 Cyclone 695 C
3. Pressure In A-53 Cyclone 395 MMWG

The material goes to A-54 Cyclone from this cyclone by a rising duct.

STAGE IV

In this stage the A-54 cyclone is situated. The temperature in this cyclone is
higher than A-53 cyclone. The material begins to heat in this cyclone & is about
completely evaporated. Material now hoes to precalciner for calcinations from it's
bottom area to pass flap valve.

1. Gas Temperature In A-54 Cyclone 838° C

2. Material Temperature In A-54 Cyclone 815 ° C
3. Pressure In A-54 Cyclone 260 MMWG

STAGE V

The cyclone which is installed on this is denoted by A-55 Cyclone. The

material comes into this cyclone from precalciner & goes directly into the kiln
inlet. This cyclone is connected to A-54 cyclone by a rising duct. The
temperature in cyclone is higher than A-54 cyclone & pressure is lesser than A-
54 cyclone.

1. Gas Temperature In A-55 Cyclone 895 C

2. Material Temperature In A-55 Cyclone 880 C
3. Pressure In A-54 Cyclone (Top) 140 MMWG

37
 4. Pressure In A-54 Cyclone (Cone) 135 Mh!1WG'

STAGE VI
A pre calciner is installed in this stage.

PRECALCINER

The pre heater kilns reached the limits in dimensions that gave rise to
considerable operational and constructional design problems. These kiln
diameters became so large that the refractory life Problems are caused frequent
and costly kiln dog n times. Then there was also a question of possibility of using
the low-grade fuels. Precalciners are essentially suspension pre heater kilns that
are equipped with secondary firing system attached to the lower stage of the pre
heater tower.

This allowed kiln manufacturers to construct smaller diameter kiln without

sacrificing kiln output. A pre calciner produces 50 — 70 % more clinker than a
conventional pre heater kiln of equal diameter.

Here it is situated on Vi stage and at the top of the smoke gas chamber. A
firing comes from coal promote coal firing in the precalciner. This is denoted by
P.C. or A-56 and another duct coinmg from the collar parallel to the kiln is called
HAD (Hot Air Duct). This duct fulfills the in the P.C. for O 2 requirement to burn'
the coal. In the P.C. 85-90% calcinations is to be completed. During calcinations
the following reaction takes place -

CaCO3 CaO + CO2

The temperature of P.C. is higher than all the cyclones in the pre heater.

1. Temperature Of Material 867 0C

2. Temperature Of Gas 958 0C
3. Pressure At Calcines 89 MMWG
4. Pressure At Cone 82 MMWG

This is the nearest part of the kiln from the pre heater. This is called as
Smoke Gas Chamber. In this chamber the exhaust gases of the kiln come by
suction of pre heater fan. There are 17 air blasters fixed to clean the coating
from the smoke gas chamber wall' inside.

38
1 Gay Temperature erature 8950 C
2. Material Temperature 885°C
3: Pressure 70 MMWG

39
 KILN

In the CCW plant a modernized kiln is established which is the heart of the
plant. There is a short rotary kiln with pre-calciner. In the kiln the process of
burning of raw material is completed.

STRUCTURE

If we look at the kiln, it's look like a cylindrical hollow pipe which rotate on
rollers. The kiln rotates anticlockwise in this plant. It rotates by the GIRTH GEAR
which is connected & driven by motor. With the fimction of kiln rollers kiln is
supported or balanced. The kiln drive assembly & girth gear is installed between
the first & second tire from the preheater. A pipe is seen besides the kiln which
come from kiln hood & go towards the P.C. is known as HAD A water pump is
also used for the cooling of bearing which is installed with motor assembly. A
camera is situated at the outlet side of kiln near the burning pipe. At the inside of
kiln near the outlet a firing nozzle is fixed in the burning pipe. The burning pipe is
situated at the center.
Because of high temperature existing inside the kiln during the clinker
manufacturing process it is necessary to protect the steel shell of the kiln with
refractory lining. If this protection was not provided the shell would disintegrate
with in a few hours. In a kiln refractory usually consists of bricks of special
composition & sizes. High alumina bricks are also used in HAD to protect dust
shell from being damaged.
The feed is introduced into the upper end of the kiln by various methods. The
hot product is discharged from the lower end of the kiln into cooling device.
Rotary kiln shells are of all welded construction Riding rings are forged or cast
steel, supports rollers are also forged or casted & rarely of tool steel. Main
beating as sleeve type normally bronze. Gearing is single helical or spur gear
lubrication usually is an automatic spray type.
Heat recovery devices are utilized both with in & outside the kiln these results
in an increase. m kiln capacity or a decrease in fuel consumption. Efficient air
seals are essential for proper, operation of kiln.

40
ZONE OF HEATING

1. Dry zone at feed end, where moisture is removed.

2. Heating Zone, the charge is heated to the reaction temperature that is the

"decomposition temp." for limre stone or "burning temp." for cement.

3. Reaction zone, in which the charged is burned; decomposed, reduced,

oxidized, etc.

when the material enters the kiln it's temp is about 900 0 C. this is partially
catered material. Remaining 10% calcinationsis done in calcinations zone.

CaCO3 CaO + CO2

In pre heating zone the reaction taking place in succession are raising the
feed temp to the evaporative temp. evaporating the free water, liberating the
chemically combined water & rising the feed to the calcining temperature.
Calcinations is the action through which carbon dioxide is driven from lime stone.
In the kiln the feed is raised part way up the arch as the kiln turns following a
path perpendicular to the kiln axis. At a certain point gravity causes the mass to
slide down the kiln shell in a forward direction and the movement is then
repeated. In this manner the feed advances in a zigzag path each rise & slide
advancing all parts of the feed a few insides.

The temp. in the kiln increases towards the burning zone. Normally the
process of calcinations completes a few feet behind the burning zone. Kiln feed
that is not completely calcined 90 0 before it enters the burning zone is difficult to
burn and is one of the main, causes of upset kiln condition. Complete
calcinations of the kiln feed before it enters the burning zone is essential to
proper burning of clinker. Now the material slides towards burning zone.

41
HEATING THE KILN FEED

Heat from hot gases to the feed bed occurs only at the surface of the bed that
is exposed to the gas. Thus the temp. of the bed is lowest in the center & highest
on the surface. In the burning zone the kiln feed being now in a rather sticky
condition is in a constant stage of agitation as added by the rough & uneven kiln
coating it rises along the upward moving side of the kiln then tumbles back.
Because of this tumbling action the surface layer constantly being folded back
into the mass of the feed where the hot particles then transfer heat to the colder
particles by conduction. Mean while, new particles are being exposed to
radiation from the hot gas & process is continuously repeated.

In the burning zone the lime stone with mixture containing silica alumina &
ferric oxide with small percentage of other oxides, is heated up to the sintering
temp. & become viscous. This is called clinkering and is manifested by the
lignifying of the clinker constituents. In the rotary kiln the largest amount of heat
transfer occurs by radiation and conduction where as heat transfer by convection
occurs only in small amount. Although there are many more occurrences of heat
transfer the following examples explain some of the more prominent heat
exchanges that takes in a rotary kiln –

Radiation-:

Flame -- Feed Bed

Hot Kiln wall -- Feed Bed

Conduction-:

Heat From Kiln Interior -- kiln Shell

Kiln Chain -- feed Bed

42
 On the 10000 C to 11000 C formations of the CF2,CAF,C2S,CF,C5A & C2 As
completed. The formation of the most important compound C 3S does not start
until the feed has reached a temp. of approx 1260°C. On the 1300 —1400. °C
temp. the main component of the cement C 3A., C3S, C2S. & CAF is completed &
the free time has completely disappeared in this plant the temp. line about 1200 -
1300°C This temp is the temp on which the clinker has to be burned in order that
it can be of good quality. This clinkerisation formed as nodules. So that it is also
known as Nodule Size Formation. The shape of clinker is like a nodule because
of kiln rotation. The prepared clinker discharge into the cooling device (cooler).

THE COMBUSTION REACTION

Successful operation of a rotary kiln requires an adequate source of heat that

will first raise the kiln to the desired operating temp. and will then maintain this
temp. by compensation for the various heat losses occurring in the kiln system
including the heat required for the process. An operator must always remember
the triangular relationship that leads to combustion.
If any one of the three links is missing, no combustion will take place. When
complete combustion takes place CO2, H2O (water vapour) and SO2 are formed.
C + O2 CO2
2H2 + 202 2H20
S+O2 SO2

However, when incomplete combustion takes place, then instead of carbon

dioxide the combustion product is carbon mono-oxide.
2C+O2 2CO2

HEAT PROFILE

Temperature differs through out the kiln and a very important factor is the.
temp. difference between the material and the gases at any given point in the
kiln. A recorder chart of the gas temp. shows gas temp. only and this temp never
corresponds to the temp. of the material in the same location. Also the gas temp.
shows a considerable change but the material temp. remains unchanged for
several minutes after. This applies to the feed bed behavior within the rotary kiln
itself.

43
CLINKER BURNING IN THE KILN
There are the following techniques for burning clinker in the rotary kiln: -
"Vary the kiln speed, fuel rate and the induced draft fan speed in any
combination to maintain the proper burning zone temperature and a constant kiln
back-end temperature for a given feed rate."
This is sometimes referred to as "burning a kiln from the rear.

ADJUSTMENT OF FLAME DIRECTION

On some rotary kilns, the primary air pipe is fixed slightly below the center of
the kiln, in an effort to offset the flame buoyancy. Most kilns, however, have
facilities for adjusting the position of the primary air pipe and the burners, thus
the operator can change the flame direction and to a limited degree, change the
shape of the flame. Every adjustment in the primary air pipe and the burner
position will bring about a change in the flame characteristics and can therefore
affect burning conditions in the burning zone.

AIR FOR KILN

The amount of air drawn through the rotary kiln is governed and controlled
slowly by the induced draft (I.D. Fan) located at the feed end of the kiln. The
origin of the air going to the kiln is: -
1. The hot secondary emanating form the cooler directly.
2. The moderately heated primary air entering through the burner pipe.
3. The parasite air that enters through the leaks and opening in the kiln hood
area.

SPECIFICATIONS

1. Length 62 m
2. Diameter 3.95 m, Effective 3.55 m .
3. RPM 3(max.),2.8(min.)
4. Output 2750 TPD
5. Calciner zone temperature 850 C — 900 C
6. Burning zone temperature 1300°C — 1400°C
7. Kiln shell temperature 150 C — 200°C
8. Clinker nodule size 25 min (max.)
9. Slope of kiln 4% of length
10. Type of refractory High Alumina Bricks::
11. Types of gear Girth Gear
12. Motor power 135 Kw
13. TOR :25%
FEED RATIO
44
 The feed ratio on the controller is now arbitrarily set at 1.00 The relationship
is expressed by the equation :-
Smax Wmax.r2
S2 W2

In which,
Smax = Max. kiln speed in RPH
S2 = Required klin speed
Smax = Max. kiln speed in RPH
Wmax = Max. feed rate in TPH at max kiln speed and ratio of 1 .00
W2 = required feed rate
r2 = required feed ratio.

TRAVEL TIME

The time required for the feed. to move through the kiln.

T = 11.4L
NDS
In which;
T = Travel time (minutes)'
L = Length of the kiln
N = Speed of the kiln
D = Internal diameter of the kiln
S = Slope of the kiln

BURNABILITY INDEX

Burn ability Index = CS

C4AF + C3A
The higher the content of C3 with corresponding lower contents in C 4 AF or

C3A, the harder the clinker is to burn,

% CALCINATION
45
 Percent the kiln feed is calcined after it leaves the pre heater vessels and
enter the rotary kiln proper.
% .CALCINATION = C - D X 100
C
Where
C = Ignition loss of fresh kiln feed
D = Ignition loss of feed after pre calcinations.

GRATE COOLER

The self-contained construction of the grate cooler provides the means to

keep the area clean the grate cooler ensures the complete control of the
secondary air and the clinker temperature. The heat losses of tills cooler by
radiation or convection are extremely low. The grate cooler develops an initial
cooling of the clinker this fact is of great importance for the formation of the C 3S
(tricalcium silicate). This cooler allows for clinker input temperature of about
1360 1400°C, but in this plant it carries 1200 —1275°C only . This temp is
reduced by excessive air cooling up to 90°C.

Originally the.grate coolers constructed with 15° slope. The slope of the,
grate was first lowered: to 10° and later to 5°; at the end of this trend the
horizontal grate cooler, was finally developed. The grates of reciprocating grate
cooler are driven by variable, speed motors; the no. of grate strokes varying from
4 — 22 per minute. The size of grate plate is 300 x 410 mm and the thrust length
is 120 mm. There are 9 fans besides the grate cooler for the passing of air.
These fans function at various places or heights.

Thus the main function of. the grate cooler is to cool the hot clinker coming
from the kiln. Small sized clinkers and desired crushed clinker particles
discharge into a drug chain, which is installed below the hoppers, and drug chain
discharges the clinker into D.D.B.C.

46
Specifications

Prop KW RPM AMPS VOLTS PRESS. FLOW MAKE

.
1S 110 1485 192 415 511 664 NGEF
1R 90 1484 152 415 658 299 Kirloskar
1L 90 1484 152 415 687 381 Kirloskar
2R 90 1484 152 415 564 397 Kirloskar
2L 90 1484 152 415 565 482 Kirloskar
V4 125 1486 223 415 418 781 Kirloskar
V5A 110 1485 192 415 279 818 NGEF
V5B 110 1485 192 415 214 795 NGEF
V6 200. 1490 355 415 141 1171 NGEF

1. The hot air from the cooler is very useful to save the extra cost. One part

of this air goes to P.C. by hot air duct to fulfill air requirement in P.C.

Another duct goes to coal mill where it is used in drying of coal. And third

duct goes to the E.S.P.

CLINKER TRANSPORTATION

The kiln discharge, clinker, goes to the cooler. After cooling the clinker comes

into the drag chain. This drag chain discharges the clinker into the JO-1 and JO-

1A D.D.B.C. as per requirement These D.D.B.C. falls the material into L-1 JO-3

intermediate bin in case of truck or dumper loading. Otherwise these D.D.B.C.

discharge the material into JO-6 & JO-.6A D.D.B.C.

The JO-6 & JO-6A D.D.B.C. directly discharge the material into the clinker

silo for storage. From clinker silo the clinker is sent to the cement mills for

grinding.

47
 HAMMER MILL
Hammer mills for pulverizing & disintegration are operated at high speeds.
The rotor shaft may be vertical or horizontal generally the later. The shaft carries
hammers sometimes called beaters. The hammers may be T-shaped elements
stirrups bars or rings fixed or pivoted to the shaft or to discs fixed to the shafts.
The rotor runs in a housing containing grinding plates or liners. The clearance.
maintained between the rotor and the liner is important with respect to the
fineness of the product. The grinding action results from the impact and attrition
between lumps or particles of the material being ground the housing and the
grinding material. A cylindrical screen or grating usually encloses all or a part of
the rotor. The fineness of the particles can be regulated by changing the rotor
speed, feed rate or clearance between hammers and grinding plates as well as
by changing the no. and type of hammers used and the size of the discharge
openings. A replaceable liner for the mill housing cover is made with multiple
serrations which are designed to promote the head-on breakage of the particles
thrown against the walls by the rotating hammer. An air feeder can be supplied to
project the feed particles in front of the hammer tips to provide a more direct
blow and thus increase the mill efficiency.

The hammer mill is made in many types and sizes and can be used. on many
types of shaft materials than any other type of the machine. The feed must be
non-abrasive with a hardness of 1.5 or less. Thus this mill reduces. the big size
of the clinkers in desired size and reduced the clinker fall into the drug chain by
hoppers. This drag chain conveys and discharges the whole clinker which is
received from the cooler, into the D.D.B.C.[Deep Down Belt Conveyor].

CLINKER SILO
Clinker silo is the storage for the clinker. In this plant there is only one clinker
storage silo. The purpose of the silo is not only for storage but also for
preventing clinker from the moisture. Because when moisture comes in
contact.with then it loses its strength so it is very imp. purpose of clinker silo.

In this clinker silo, the clinker comes from the D.D.B.C. and for preventing
from moisture it is maintained at 80-100°C. There are four vibro feeders that
work at the bottom of the clinker silo. The construction of this silo is same as that
of the homogenization silo except the extracting segments. Some technical data
are: -

1. Diameter 22.4 meters

2. Height 39.8 meters, Effective 39 meters).
3. .Capacity 20808 tons
4. Temperature 80 C —1.00 C
48
 FUELS

Fuels used in the burning of the rotary kiln are classified into three groups: -

1. Liquid fuels
2. Gaseous Fuels
3. Solid Fuels

LIQUID FUELS

Liquid fuels used in the combustion in the rotary kiln are almost of the Bunker
B or Bunker C type. These are residual oils from refineries after the more volatile
products in the oil have been removed. Because both types fall into the class of
heavy oils, they have to be pre-heated before they can be pumped or atomized.

GASEOUS FUELS
Liquefied petroleum .gas, hydrogen and coal gas are used in some
industries. Gaseous fuel firing or rotary kilns in the cement industries are almost
done with natural gas because it is the cheapest of all the gases. Natural gas
offers several advantages for the kiln operator, as it needs no preparation such
as drying, grinding or pre heating and combustion takes place readily once the
gas has mixed with proper amount of air and ignition temp. has been reached..
The burning zone is much cleaner.

SOLID FUELS

The main solid fuels are wood, coal, coke, and charcoal. Wood as fuel cannot
satisfy the ever-increasing demand of the industries so coal is mainly used as
solid fuel.

COAL

This is the main fuel At first it was used by the blacksmith and then for iron
and steel industry, for melting the raw materials in the furnace. But now the coal
is consumed in greater amounts through out the World as compared to
consumption of any other fuel.

49
TYPES OF COAL

In the course of coalification of the coal forming processes the water and the

gases formed in the original decayed vegetation product are slowly eliminated

and the nature of the ultimate substance or coal left behind depends on the

extent of the coalification. The amount of material which vaporizes by the action

of heat on the coal in the form of gases known as volatile matter varies

considerably and determines the rank of coal. These are the general kinds of the

coal in use: -

1) Peat
2) Lignite
3) Bituminous
4) Anthracite

In BCW, the Bituminous coal is used. It is the most important variety of coal.

It is soft and widely used as a fuel. It contains higher percentage of volatile

matter and thus when distilled, it gives off large quantity of gases and tar that are

used in many chemical industries. So commercially the bituminous coal is very

important. It bums with a long bright smoky flame. It has a higher: carbon content

than peat and lignite. Its approx composition is

Carbon — 83.5 %

Hydrogen — 5 %

Oxygen —5%

Ash — 6.5%

The calorific value of this fuel is 8300 Kcal / Kg.

50
 COAL CRUSHER

In this plant the coal is transported by wagons and trucks. From wagons it
comes from KOTA and from trucks it comes from KANDLA. The major quantity of
coal is transported by rail wagons. This coal is already crushed but the coal
pieces are larger than required so it must be crushed for better grinding in the
coal mill.
The crushing of coal takes place in the coal crusher. In CCW there are
two crushers for crushing the coal and both are single roller impact crusher. One
is used for truck-transported coal and the other one is used for wagon
transported coal. Both crushers are of 100 TPD capacities.

IMPACT CRUSHER

Size reduction in impact crusher is achieved in three steps. In the first

procedure, the main reduction is carried out by striking i.e. by impact of the
impellers bars to the crusher feed. The purpose of the breaker plates arranged
inside the crusher is to function as deflecting plates; the material thrown against
them, is reflected back into the crusher department, where it is again hit by the
impellers bars, until it leaves the crusher through the slot between the rotor and
the lower edge of the breaker plate.
The second size reduction process is carried out by the impact of the
material of the breaker plates.

The third size reduction step occurs by crushing of the material chunks
against each other. However in this system the pre-dominant component size is
the effect of the impact. The breakage or size reduction follows along the natural
cleavage liners where cohesion is low.

The wagons at first are unloaded by the wagon tripper in the hopper. The
hopper discharges the coal on the belt conveyor the push feeder. This raw coal
is conveyed by the belt conveyor up to the crusher. After crushing the coal goes
on to the stacker belt conveyor. The stacker made the stockpile of this coal.

The crushed materials of the wagons come on the stacker belt. This
stacker stocks the piles of this crushed coal. The stacker makes two piles which
have 7 meters height. The stacker is operated with modern mechanism. For
reclaiming these piles there is a reclaimer beside the stacker. This is also made
by L & T. This reclaimer is also modernized and aligned with modification. The
main purpose of the reclaimer is to homogenize the layer coal.
51
 COAL MILL IN GENERAL,

The main purpose of this mill is to grind the coal. The coal grinding is
necessary for better efficiency during firing in the kiln. The raw material for the
coal mill comes from the coal crusher by the belt conveyor.

The main function of this unit is to increase die surface area of the coal by
grinding and evaporates the moisture from the coal. The main machine for this
function is coal mill which can be different types in different plants. In BCW the
ball mill of single chamber is used to grind the coal.

The max size of the material, which enters the coal mill may be 25 mm. The
output of the coal mill is in powder form. The main object of this unit is to grind
the coal evaporate the moisture and send to kiln for firing.

HOPPERS

There are two hoppers to store coal for grinding in the mill. They are
denoted by LO-1 &LO-2. The look of these hoppers is like vertical cylinders
having cone shape at bottom At the top of these hoppers a B/C, CLB-13, is
installed. When this belt moves towards LO-1, it fills the hopper and same in
case of LO-2. The capacity of both hoppers is :

1. LO-1 : 285T
2. LO-2 : 285T

At the bottom of each hopper feed tables are situated to discharge the
coal from hoppers.

FEED TABLE

The main function of any feed table is to discharge the material in a weigh
quantity. The weighing of the material occurs by the revolution of the feed table
and quantity of material controlled by speed of feed table. Because discharged
material is directly proportional to feed table speed.

52
 COAL MILL

The material discharged° from feed table and comes into the mill. As coal
enters into the mill first it comes in the drying chamber of the mill. Here the
material comes into the contact of the hot air with the help of the drier. The drier
makes the better contact of the coal and heat with the help of the lifter. For
drying of coal in the mill from the hot air a hot gas generator works as alternate
for drying, which is situated besides the coal mill inlet?
In the initial part of the mill the coarse grinding is completed by big size
balls due to impact reaction and at the end part of the mill the fine grinding
occurs with the help of the small grinding balls due to attrition of balls and mill
shells. The ground material- slides towards outlet due to rotation and suction of
the mill and pass the diaphragm and is sucked by a fan into the separator SO-1
where coarse material -goes to the mill for regrinding.

SPECIFICATIONS

1. Length of the mill 4.963 m

2. Diameter of the mill 3.457 m
3. Output of the mill 25 TPH
4. Inside temperature- Inlet 150°C — 200°C
Outlet 55°C — 60°C
5. RPM of the mill 15.7(approx)
6. Type of the separator G.T.Separator
7. Ball sizes 60, 50, 40, 30, 25, 20; 15 mm
8, Type of the bearing Slide shoe bearing
9 Material: of the balls Ducrodan
10. Power 730 kw
11. Amps — Stator 80 A
Rotor 420 A
12. Volts—Stator 6600 V
Rotor 1075 V

JO —3 SCREW CONVEYOR

This screws conveyer is situated at the top of fine coal bins. The JO-3
screw conveyer is reversible screw conveyer. It consists of two motor drives one
rotate it in clockwise and another is anticlockwise direction.

53
 GYPSUM CRUSHER

In this plant the gypsum is transported by trucks only The trucks are
unloaded at gypsum hopper. It is very necessary to crush the uneven lumps of
gypsum for better mixing in cement mill. A push feeder is -installed at the bottom
of the gypsum hopper. The trucks are unloaded on the gypsum hopper's screen
because of the gypsums formation in uneven lumps so some lumps remain at
the screen that are broken manually. Nov the push feeder pushes the gypsum on
the belt BC-1. This belt conveyer carries the small lumps up to gypsum crusher.

In this plant gypsum is a hammer crusher Hammer crushers are widely

used in the cement industry. They are used in size reduction of hard to medium
hard L.S. and sometimes for crushing.

Generally two types of hammer crushers are used-single rotor and double
rotor crusher. In both types of crushers the crushers feed first passes through
the upper or primary grid. This follows preliminary size reduction of the material
by the impact hammers. The final crushing then occurs on the bars of the lower
grid because of the two grids with different spacing the hammer mills can be
considered two stage crushers. An adjustment of the grid spacing controls the
final particles size the final particles size is approximately equal to one half of the
grid spacing.

The grid spacing of the grid is generally 25 to 30 mm. Higher moisture

content of the crusher feed requires larger spacing up to 60mm. The gypsum
after crushing comes on to the belt conveyer BC-2. This belt discharges the
material on BC-4 conveyer fro CM- I because this belt discharges the gypsum on
KLB-5 belt conveyer.

54
 CEMENT MILL IN GENERAL

The main purpose of this mill is to grind the clinker. The grinding of clinker
is necessary to make in powder form, which is called "cement". Gypsum is also
used as retarder which is added during the grinding. Gypsum comes to this unit
from gypsum yard. Clinker also comes on the belt conveyer from clinker silo.
Thus the main function of this unit is to prepare the cement from grinding of
clinker and gypsum.

Generally the ball mills are used for grinding of clinker. In the ball mills the
grinding takes place from different of balls, during the impact and attrition
reaction. The size of cement grains known as fineness of cement is denoted by
Blains. The blain of cement changes according to their fineness. The 53 grade
cement's Blaine is higher than 43 grade and 33 grade cement. The main object
of this unit is to prepare cement with desired proportion of clinker and gypsum.

STRUCTURE OF CEMENT MILLS

In BCW there are two cement mills for clinker grinding and both are ball
mills. The outlook of cement mills is like horizontal hollow pipe of large diameter
which is tapered from both hands. It rotates on bearings with the help of electric
motor and symetro gear. The motor gives the power to the rotating devices and
the symetro gear maintaining the r.p.m. The type of bearings for both mills is of
minion type. The friction in these bearings is minimized by lubrication. Two water
nozzles are fixed at both sides of mill in center for water spray and to control the
inside temperature. Both mills are centrally driven. Another water system is fixed
for 'cooling of bearing this system controls the temperature from becoming high
because at high temp bearings may get damaged. From outside there are so
many bolts on the mill shell. A sound detector is situated near the mill to measure
the folaphone in control room. At the inlet of the mill the moving shaft of the mill
is connected to the symetro gear shaft with the fluid coupling. The main work of
this coupling is to prevent the mill and motor from shocks and damage: in any
accidental condition.
There are six manual holes on the mill shell of both mills to go inside the
mill. Both cement mills are of two chambers. Inside the first chamber a drier is
situated at the mill inlet. In this chamber the stepped and classifier liners are
fastened with the shell periphery by bolts. These liners prevent the mill shells
from getting damaged in this chamber the big size ball's are there.

55
 The length of second chamber is larger than the first one. The ground
material, which is able to pass from the diaphragm, reaches in the next
compartment. This compartment is known as second chamber. In this chamber
the drag pebs firers are fastened with the milk shell. These liners also prevent
the mill shell 'from- getting damaged and give a very. good help in grinding. In
this chamber the small size balls and silpebs are filled of different sizes.
The size, of balls is 40mm to 25mm and of silpebs 15x15mm,
15x12mm,12x12mm and 10x10mm.

TRANSPORTATION OF MATERIAL FOR CM-1

From the bottom of the clinker silo the clinker comes on the belt conveyor
KLB-1 or KLB-1A The function of the vibro feeder is that it vibrates and the
material comes; on the belt and proceeds.
Both KLB-1 and KLB-1A B/C discharge the material on the b/c KLB6. At
the end of the KLB-6 belt conveyor there are 9 diverters for diverting the material
either on the clinker hopper or the KLB-6 b/c. Now from gypsum push feeder and
pozzolona push feeder the material comes on the VG-1 or VG-2 b/c and both
these b/c discharge it on BC-4 b/c and BC-4 b/c drops the material on KLB ,5. At
the end of theKLB-5 belt a diverter is there for diverting the material in the
gypsum hopper LO-3 or at the KLB- 6A b/c The KLB-6A b/c is reversible b/c so it
discharges the material either in LO-2 pozzolana hopper or in LO-1 clinker
hopper. From there it goes in the CM-1.

CEMENT MILLS
This mill is a close circuit mill and generally prepare 53 & 43 grade
ordinary Portland cement in this plant.

HOPPERS

For this cement mill there are three storage hoppers for storage of clinker,
gypsum and pozzolona. These are indicated as code names LO-1, LO-2 and
LO-3 hoppers. The looking of these hoppers is like vertical cylinder having
conical shape at bottom.
LO-1 hopper is for clinker storage LO-2 for pozzolona and LO-3 for
gypsum. The capacities of these hoppers are as follows: -
1. LO- l :2901
2. LO-2 :208T
3. LO-3 :3201
56
GRINDING OF CLINKER IN THE CEMENT MILL-1
Now the material enters the mill inlet. The ratio of clinker and gypsum is:
generally kept about 95 % - 97 % clinker and 3 % - 5 % gypsum for 53 grade
ordinary Portland cement. After entering the mill it comes into the drier of the mill.
The lifter pushes the material towards the first chamber. In the first chamber the
coarse grinding occurs by big size balls due to impact reaction. The stepped and
classifier liners help the balls in this reaction. The ground material, which is able
to pass across the diaphragm, reaches the second chamber. IN this chamber the
small size balls are filled and dragpeb liners help them in fine grinding of the
material due to attrition reaction.

The material temp inside the mill is about 125°C to 130°C and gas temp.
is about 115°C to 120°C. For the control of material temp., the water nozzles
start to spray the water as required. The material slides towards the outlet. Now
this ground material is "cement". After grinding the material goes to the air slide
M-16.

SPECIFICATIONS

1. Length of I chamber 5m
Length of II chamber 5.5m
Total length 11. 5m
2. Diameter of I chamber 3.8m
Diameter of II chamber 3.8m
3. RPM of the mill 16.65
4. Folaphone 58%
5. No. of chambers 2
6. Ball sizes( in I chamber) 90, 80, 70, 60mm
( in I chamber) 20, 15mm
7. Capacity of the mill 80 TPH (53 Grade
8. Types of liners(I chamber) Stepped and classifier
(II chamber) Drag peb
9. Gas temp. in the mill 1150 C-1200 C
10. Diaphragm temp. 110°C — 120°C
11. Cement temp. in the mill 125°C — 130°C

AIR SLIDE M-13

57
 This air slide is situated near the mill outlet. The material discharged by
the mill after grinding passes through this air slide. Air slide M-13 conveys the
material and discharges into the bucket elevator JO-l. Thus main function of this
air slide is to convey the material from the sill to the bucket elevator JO-1.

1. Power 2.2 KW
2. Amperes 4.3 A
3. Voltage 415 V
4. RPM 2030

BUCKET ELEVATOR JO-1

The air slide M-13 discharges the material in this elevator. The elevator
lifts the material by buckets and conveys it on a certain. height and discharges in
into the bucket elevator JO-3. There is no standby equipment for this elevator.
This is a single media to transport the material up to the aor slide JO 3. If this
elevator fails in any condition then mill will. stop running automatically.

1. Power 45 KW
2. Amperes 77 A
3. Voltage 145 V
4. RPM 1470
5. Make Kirlosker

BAG DUST COLLECTOR

This is another dust collecting equipment in This unit. The dust particles
with air and gas are sucked from different air vent points by the PO-3 BDC fan.
Dust enters in the BDC chamber with air and the dust gets collected on the
outside of the bag and air passes through the bag . After a certain pause during
the pursing, the collected material fall into the dust hopper and comes into the S-
24 S/C through an air sluice PO-2. And air with very fine particles of dust goes
into the atmosphere from the BDC-fan.

58
ELECTRO STATIC PRECIPITATOR (ESP)

This is the main de-dusting equipment in this unit. A part of air from O-sepa fan

duct is sucked by ESP fan into the ESP.

In the ESP the air with dust passes through a high voltage area, where

the material particles divert. in the form of the ions. The -ve charged ions are

collected on the positive plates After a certain time period the collected material

falls into the ESP hopper by hammering from where it goes to the P-12 screw

conveyor. An air sluice is also situated after P-12 SC. This air sluice prevents

false air to go in it to pass the P-13 air sluice the material comes into the S-24

S/C where it mixes with the SO -4 S/C material.

The very fine particles with gases are discharged in the atmosphere by

the P-16 ESP fan.

59
 PACKING PLANT

In BCW there are four packers of VENTOMATIC, Germany make. The

capacity of each machine is 96 TPH and there are four silos of 6000 tons
capacity. Silo, 1 & 4 contain 43 Grade and silo 2 contains 53 Grade and silo 3 is
used for PPC. The daily average dispatch of BCW is 5000 metric ton. Both CCW
& BCW have facility to load trucks and broad gauge wagons and meter gauge
loading is done at Chanderiya yard.

OVERVIEW OF EQUIPMENT

This packing line of the products in powder form is equipped with different
elements or-machines that, depending on clients requirements, aims at
optimizing the plant productivity. The principal elements of this plant are
Vibrating Screen
Feed Hopper
Rotary Hopper
Packing Machine
Discharge Belt

This kind of line is usually served by a feeder: or loader, whose task is to

carry the product to be packed to the top- of the vibrating screen. The vibrating
screen is designed to act as a filter in order to avoid the introduction of lumps in
the productive cycle. It is connected to the feed hopper by means of a bellow
elastic chute.

The feed hopper consents to dose the product and to guarantee its
constant presence, when it is requested by the further plant.
The actual dosing is performed by a butterfly valve and by an appropriate
vane feeder whose capacity is checked.
The heart of the packing lime is the bag packer available in different types
of models.
The bag packer is -equipped with a storage hopper connected with
different cones depending upon the no. of spouts the packer is equipped with.
The task of the packer is to fill, following Some programmable cycles, the
bags with available product.

60
 Different packing parts can be mounted on the hag packer- called spouts.
Each spout is independent of one another and they are all controlled by
appropriate electronic units (VENTODIGIT). The electronic, units control the
performance at the filling, weighing and bag discharging.
The bag packer can have different configurations (GEO/GEV) and in turn
each can have many loading units or spouts.
The bag packer GEO is equipped with spouts with a horizontal turbine
while the GEV has a vertical turbine.

FLOW OF MATERIAL

The flow of material rises from the bucket elevator to reach the vibrating
screen, to be settled in the storage hopper. The former is equipped with control
systems (sensors) placed inside the hopper. These sensors control the
extraction system and keep the level as steady as possible.
Then the flow of material passes through the rotary vane feeder equipped
with alternate gear to adjust the level of material in the packer hopper. The
sensor, by which the bag packer is equipped, serves the purpose of rotary vane
feeder in order to keep the level as steady as possible. The flow of material is
then directed to the spouts most part of this is in the bag whereas a very small
part of is scraps in the form of bust, overflows the dust is sucked up and
collected by means of a sucking chute in the lower hopper. The reject is then
separated the dust is gathered by a screw conveyor and led back into the
conveying cycle.

DEDUSTING SYSTEM

The whole packing line is protected by a deducting system It keeps the

area next to the plant clean in order not to affect the health of the operator. The
critical zones are put under depression i.e. the feed hopper the packer cover the
discharge belt the footboard the inner board for the quick discharge or for the
spouts depression.
The hoppers placed under the footboard at the same level as that of the
packer not only put the zone under depression but also allows the reclaim and
the collection of the dispersed material.
61
DIFFERENT MACHINES & MODELS

The impeller of the bag packer has a wide range of applications. There
is a variety in the appearance of the production models. One important
difference found is the shape associated with the posit on of the impellers. Other
differences are connected to the degree of the integration and automation in the
production model.
In the cement and similar product industry the characteristics of the
product to be bagged as well as the product conditions are very different. The
product is characterized by its granule fluidization and eventual aggressiveness.
The process may create different and variable conditions of temperature and
fluidization.
The choice of the bag packer allows the answer to different need
determined by the particular process and product employed. The electronic
control of the packing cycle endows the plant with a larger flexibility in order to
be adapted to the process condition variability (start up and stop temperature
and humidity product variations fluidization conditions etc.).

The impellers adopted in the bag packer are divided in:

1) Horizontal impeller (GEO)
2) Vertical impeller (GEV)

The difference between the two types is due to the motion of the product in
relation to the turbine during the packing process.
In horizontal impeller the direction of the product" to he filled is on the rotary
plane of the rotary plates in such conditions the product between the plates is
centrifugated in counter-current towards the product to feed creating a sort of
turbulence and apparently trouble. Actually the product is mixed and does not tend to be
compacted inside the impelIer. The feeding of the impellers occurs by the product flow
along the inclined plane opposite the rotary shaft.
In the vertical impeller the direction of the product is saute as that of the rotating
axle. In such condition there is no contrast between the product present in the turbine
and the product ingoing which having a larger passage zone available tends to fill
completely the spaces among the plates. As there are no ways of vent the vertical
impeller tends to compact the product against the walls, before being packed.

62
 Having these to facts in grind some basic principle for choosing between
the two different types of impellers can be indicated :

1. Product with normal thickness (up to 4.000 Blaine) which tends to

desarate quite easily is rather to be packed by a horizontal impeller.
2. Product with high thinness (more than 4.000 Blaine) which tends to keep
a large amount of airy is rather to be packed by a vertical impeller.

The typical product of first kind is cement Portland 325.

The pozzolanic cement of high fineness cement with high resistance

425-525 lime and talcum belong to second type.

VIBRATING SCREEN
It is preferred over rotary screen because the former has a large
production capacity and requires less space for installation. Its function is to
separate eventual lumps from the product. It is normally supplied with a steel
grid made from 2.5 mm diameter steel- wire and, with a mesh size of 4X4 mm.
The normal amplitude of oscillations is about 4 -5 mm with a cadence of
frequency of 1400 — 1500 rpm. The amplitude may vary if there is a change in
position or quantity of the eccentric mass (W) placed on flywheel of the
transmission shaft. The finer the material the more elevate the number of motor
resolutions must be. The richer the material is of air, the more it tends to slide on
the mesh or glide offs the screen. In such conditions it is useful to increase the
motor resolutions.
It is important to consider the screen capacity or its filtration capacity because an
excessive feeding quantity will cause a product overflow from the lump discharge
channel.

FEED HOPPER
The feed hopper looks like a big silo. Three sensors with the purpose of
checking the levels of the product are placed inside.
The sensor (a) serves the purpose of checking the minimum level of the
product and will eventually send a signal or start the loading line or better the
opening of the product delivery.
The sensor (b) is an emergency sensor if at any time for any reason the
hopper is filled excessively the plant stops running.

63
The constant flowing of the product between the minimum and the maximum, as
well as a constant pressure of the material which is the quantity of the product
contained in the hopper represents the ideal condition.
It is important to place the minimum sensor (a) in a, position to secure a
sufficient quantity of product so that while the bag packer is operating there will
be enough time to reload the hopper; in other words the hopper must never go
empty.
Another important condition for proper operation is the placing of the
micro (b) for the maximum product. This micro must be placed in a position to
avoid the hopper from being completely filled up in such a case the material
would be intercepted by the EMERGENCY micro (c) and consequently the whole
plant would be stopped.
It is important to place the EMERGENCY micro (c) as high as possible
about 10 cm from the cover in order to assure a minimum accumulation before
stopping the loading line.
Loading cells may be implied instead of sensors in order to secure a more
regular pressure (flow) of product.

DISCHARGE BELT

The discharge belt is a passive part of the packing and conveying

process. It is necessary that the bags fall on the belt well aligned.

The bag when rejected from the packing machine has a rotary movement
and is trough inertia is conveyed in the direction of the bag packer external
diameter tangent. It is pushed by imparting a radial force parallel to its centrifugal
force. The result of these two forces coincides with the bag trajectory. During the;
passage from the packing machine to the discharge belt the gravity force and the
imparted force by the belt itself gravitate on the bag and when the bag gets in
contact with the belt. The result from these forces aims at obtaining the right and
central position of the bag on the parallel belt.

The discharge belt is equipped with an exhaust hood which performs an

appropriate dedusting action. It is necessary to take care of the intervention time
for the bag throwing in order to avoid any damage caused by the mentioned
hood.
64
ELECTRONICALLY CONTROLLED SPOUTS

The bag packer is the heart of the packing line, and is more complex and
technologically advanced unit.
Basically the machine consists of a tank containing and settling the
product, a variable quantity of spouts, an angular setting sensor and a signal
control transmission system. The packing machine is also equipped with a
keyboard placed outside the machine.
The spout is made of one stiff frame with assembled motor, vane pump
and accessories (such as sensors, actuators, dedusting pipes etc.) the relevant
electrical equipment, the electronic control unit and the electro valves, as well as
some devices of the setting and transmission system (packer external devices)
are placed on the tank inside the special boxes.

The number of spouts on the machine may vary from 4-12, depending

upon the request. The spouts may be in turn be fitted with various devices.

 Fluidization of the product to be bagged (standard)

 Quick discharge (upon request)
 Personalized diameter nozzle (depending upon the product to be packed)
 Mechanical or pneumatic bag locking system (depending on the type of
the bag)
 Pneumatically adjusting saddle
 Intercepting system of the flow of the product
 Weighing system with load cell
 Mechanical or pneumatic bag discharging system

The bag packer is equipped with partitions plus safety and protection
devices. Other bag packer parts are:
1) Dedusting system with external dedusting hopper

2) Loading hopper systems

3) Discharge screw conveyors

65
 The positions in which the different functions of the cycle are executed are
from time to time detected by different devices.

ELECTRONIC EQUIPMENT

The electronic equipment. consists of four electronic cards

- The weighing card

- The processing card (CPU)

- The power card

- The display card

The display .visualizes the gross weight of the bag the anomalies of the

equipment & the possible errors & or alarms of the loading cycle. The

management of the weighing & control cycles is performed by a microprocessor

which senses the weight of the loading material at a 20 gm. nip resolution & a

measurement range for 20 to 50 Kg. Each electronic unit works independently,

allowing one to exclude one or more spouts without compromising the operation

of the others. The same unit controls directly the various devices of the packing

cycle & carry out the following functions:

- Bag locking

- Bag product emission

66