DG Cement Internship Report

INTERNSHIP REPORT
INTERNSHIP REPORT
DG KHAN CEMENT
KHAIRPUR PLANT
A REPORT ON: Electrical(components & instruments) Motors,Power Generators,

Programmable Logic Control(PLC) system,Preheater & Cooler,Kiln,Cement mill and
paking plant.
MADE BY
YASIR HAROON
Reg # BCE-SP08-090
YASIR HAROON (BCE-SP08-090)

ELECTRICAL (COMPUTER) ENGINEERING Page 1
INTERNSHIP REPORT
DEPARTMENT OF ELECTRICAL ENGINEERING INSTITUTE OF

INFORMATION TECHNOLOGY LAHORE CAMPUS
TABLE OF CONTENTS
Description Page No.

Introduction …………………………………………………………………………………………. 05
Nishat’s Founder ………………………………………………………………………………….. 06
Chairman ……………………………………………………………………………………………... 06
Chairman Message ……………………………………………………………………………….. 07
Block Diagram ……………………………………………………………………………………….. 07
Power Plant …………………………………………………………………………………………… 09
Quarry and Lime stone crusher ……………………………………………………………… 09
Storage Yard ………………………………………………………………………………………….. 11
Raw mill feed area,Raw Mill & conditioning tower ………………………………… 12
Labortories …………………………………………………………………………………………….. 14
Coal stroage yard,Coal mill …………………………………………………………………….. 15
CF silo ,Low bin,Preheater cyclone …………………………………………………………. 16
Gas Analyser ………………………………………………………………………………………….. 18
Kiln, Kiln motors, Clinker silo ………………………………………………………………….. 18
Cement mill feed area, Gypsum Crusher ………………………………………………… 20
Cement mills and Cement Silo ………………………………………………………………… 21
Packing Plant ………………………………………………………………………………………….. 22
Programe Able Logic Control(PLC) ………………………………………………………….. 22
Refused Derived Fuel(RDF) …………………………………………………………………….. 23

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Conclusion & Refrences ………………………………………………………………………….. 23
ACKNOWLEDGEMENT:
My greatest thanks to ALLAH Almighty who bestowed me with the ability and
potential to complete this Internship. Before I go into depth of the things, I would like to
add a few deepest words and also says thanks for the people who were part of this
report in numerous ways… people who gave unending support right from the stage the
internship was assigned. Particularly I also wish to thank the managerial staff at DG
Cement especially Mr.Safdar Kamal, Mr.Hafiz Sajid and Mr.Sarfarz Ahmad who helped
me to gain a lot of information regarding the company and cement industry and also
who provide me an opportunity to learn and understand the working of organization as
an internee. I am also thankful to Mr.Najam ,Mr.Rashid, Mr.Malik Saleem and
Mr.Faheem who played a role of polar star for me in the organization and whose
experience taught me a lot about the industry and the organization.
Except the support of these peoples may I will be not to able to got deep knowledge
about the plant, Mr. Sarfaraz Ahmad form E&I workshop helped me a lot and solve each
and every one of my problem at every step of my difficulties. Mr.Faheem AJM also helps
me to understand the working principle of motors and transformers used at plant. Mr.
Captain Khubaib the SDM of stores also helps me to understand the chain of command
of Nishat industry and also encourage me to go for my internship in strong way. Most of
all I am very much thankful to Mr. Safdar Kamal who selected me for internship and to
give me opportunity to improve my industrial skills that will help me in my future.
And finally deepest and warmest appreciation to the whole team of DG Khan Cement
Company

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EXECUTIVE SUMMARY:
Dera Ghazi Khan Cement Company Limited (KhairPur Plant) a unit of NISHAT group is a
strategic business unit of Nishat Group, which is the largest and most growing industrial
group in Pakistan. D.G. Khan Cement Co. is market leader with respect to market share
with about 11.4% market share. Apart from its competitors; its product is high priced
yet it has highest market share because of good quality. Its plant is situated in Dera
Ghazi Khan and Khair Pur and head office is situated at Lahore. Factory site Unit 1and 2
that is situated in very remote area of Punjab, yet it proved a blessing for the company.
Because it has all three basic raw materials i.e. Lime stone, Shale, and Gypsum at one
place.
It has three plants working two in D.G. khan and one in Khair Pur. First plant is old one
and it is Japanese plant. The other two plants are of F.L.Smidth Denmark. Khair pur plant
is made by FLS a DENMARK company Khairpur plant has capacity of 6700TPD(Tons Per
Day) but the Khairpur plant has prodeuced 1400 TPD(Tons Per Day) on
average.Presently the company is also exporting the cement to Afghanistan, Iraq,
India,UAE, D.G.khan cement has also contract with ELEPHANT cement at SriLanka.
Now a day’s D.G.Khan cement (KhairPur) plant is stepping forward to clean the area
from garbage, a new plant which is in process called RDF (Refused Derived Fuel) which
will use the garbage and after processing its process which will be discuss later the
garbage will be thrown into KILN which will be used as fuel this will also decrease the
use of coal which is expensive and also helps to clean the city and economy of company
will increase.
The Power plant of D.G.KHAN cement (Khairpur) producing 32.3 MV of energy that are
fulfilling the requirment of energy for company. D.G.Khan cement (Khairpur) also have
Paper Mill that is producing the cement bags not for DG cement but as well as for
BESTWAY cement and PAKISTAN cement Paper Mill producing round about 16 lac bags
per day which is very good rate in a countary like Pakistan.

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INTRODUCTION:
N ishat is playing a significant role in the private sector by adding value to cotton
and the cotton based economy, Nishat Group ranks among the top five business
houses in Pakistan terms of sales and assets.
Nishat Mills Limited started out as a weaving unit with 500 semi automatic looms, later
on 10,000 spindles were added, laying the foundation of nation’s biggest textile
composite project. Today, Nishat Mills Limited is largest vertically integrated unit of
Pakistan. It comprises of 270,000 spindles, 740 state of the art shuttles-less and air jet
looms, a processing capacity of three million meters and stitching capacity of more than
one million meters per month, supported by a power generation plant with a capacity of
33.6 MW. Nishat Mills Limited is awarded the President of Pakistan’s Trophy for
Exports, being a Pakistan’s largest exporter in any category. Nishat Mills is also certified
with ISO 9001 certification and these awards reflect the quality of service available
under one roof.
Since its inception in 1951, the group has grown from a cotton house into a premier
business group. After almost half a century of undaunted success, the group has its
roots firmly planted into four core businesses i.e. Textiles, Banking, Cement and Power
Generation.

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NISHAT’S FOUNDER:
Yahya was born in 1918 in Chiniot. In 1947 when he was A man of

vision, courage and integrity, Mian Mohammad running a leather
business in Calcutta, he witnessed the momentous changes that
swept the Indo-Pak sub-continent and culminated in the emergence
of Pakistan. Like many of his contemporaries, he also migrated to the
new country to help establish its industrial base; his is a story of
success through sheer hard work and an undaunted spirit of
enterprise. Beginning with a cotton export house, he soon branched
out into ginning, cotton and jute textiles, chemicals and insurance. He
was elected Chairman of All Pakistan Textile Mills Associated
(APTMA), the prime textile body in the country. He died in 1969, at the age of 51 having
achieved so much in so short a time.
CHAIRMAN:
Today, Mian Mohammad Mansha, the Chairman of Nishat Group, like
his father, continue the spirit of entrepreneurship and has led the
Group to become a multi dimensional corporation, with wide ranging
interests.
Nishat has grown from a cotton export house into the premier business group of the
country with 5 listed companies, concentrating on 4 core businesses; Textile, Cement,
Banking and Power Generation. Today, Nishat is considered to be at par with
multinationals operating locally in terms of its quality products and management skills.

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CHAIRMAN MESSAGE:
Firmly believing in “Growth Through Professional Management” our corporate culture

is based on decentralization, delegation of authority, encouraging the acceptance of
responsibility and inculcating quality consciousness. It is our conviction that every
successful organization is a reflection on the commitment, dedication, and team spirit of
its employees, and Nishat is no exception. Our people are all imbued with this spirit, a
fact manifested in our rapid growth and low employee turnover.
We continue to strive to be a better group today than what we were yesterday, for our
clients, for our shareholders, for our investors, for the environment, for the community
and for our employees, for it is with them that we have achieved what we have. It is
with them that we will continue to surpass our past achievements.
Mian Mohammad Mansha
BLOCK DIAGRAM:
Block diagram of cement manufacturing in DG khan cement is given below the
decription of each and every part is given below the diagram.
Limestone Storage Yard Raw Mill feed area

CRUSHER Machine Operation of Stacker EP &Conditioning Tower
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Kiln CF Silo Coal Mill
Kiln Motors Preheaters and preclain Coal Mill Feed Area
Clinker Silo Cement Mill Feed Area Cement Silo
EP Cooler Gypsum Crushers Cement Mill
Paking Plant
Weigh Bridge

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POWER PLANT:
For continuous and smooth operations of the plant uninterrupted power supply is very
crucial. The company has its own power generation plant along with WAPDA supply. The
Company power plant consists of two Generators, these are dual nature generators that
can be run on GAS as well as on Diesel depends upon availability of fuel. In case if any of
supporting engine fails to work the company has Turbine Engine of CATERPILLARS so
that there is no load shedding at all. The two generators combine produce 32.2MV of
energy one generator produce 16.1MV and other one also of 16.1MV. Maintenance of
generators is made by staff of WARTSILLA.
QUARRY and LIMESTONES CRUSHER:
QUARRY
Quarry is the place from where raw material in extracted. Drilling and
blasting is done to extract the material. A hole of about 10-15 m is drilled and
ammonium nitrate in filled as an explosive in these holes. When this explosive is ignited
the rocks are broken into pieces of different sizes. These pieces are then loaded on the
dumper trucks and using conveyor belt to the crusher. It is located about 3-4 Km from
the plant. The motors that are used for moving the conveyor belt are INDUCTION
motors of 6 Kw of power.
RAW MATERIALS
The raw materials used for making of cement are given as follows

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Limestone
Is owend by company itself in DG Khan cemecnt, 95% of
limestone is used for the making of cement at plant. This limestone is
extracted by nearby Quarry and has the highest composition in cement.
Additive Materials
The additive materials that are mixed with limestone at raw mill feed area
are CLAY, IRON, BAUXITES and SILLICA SAND.
Gypsum
The remaining 5% of material is gypsum which is mixed with
Klinker material at cement mill and be ready for paking plant.
LIMESTONE CRUSHER:
The limestone crusher has capacity of 1500 tons/hour to
crush. Supplier of machinery is FL Smidth. Limestone and
raw material’s are dumped into hopper of capacity 1500
t/h by the dumper trucks. Inside the crusher machine
hammers are used each hammer has weight of 100 to
102 kg that is enough to crush any material. Also in
crusher the Squirral Cage Induction motors are used to
rotate the hammers and rotatry speed of motors is 1200
to 1300 rpm(Revolution Per Minute) so hammers will
rotate with approximately rotatery speed of 1300 rpm.
Then by using conveyor belts the crushed material from limestone crusher transferred
to the storage yard where it will be feed to CF silo by raw mill feed process.

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MAGNETIC particles such as iron etc if found in crushed

material on conveyor belts then before this material
stores in yard the iron and all other related materials
are attrcted by a magnet pole which is placed on end
terminal of conveyor belt.
STORAGE YARD:
Now the material form conveyor belt will be stored in storage yard. The crushed
material is stored in the form of piles in the storage yard. There are 6 piles in the storage
yard. Characteristics of all piles in storage yard are given as follows
 2 Mixed piles (limestone & clay)

 2 High grade (pure limestone)
 Iron ore (additive)
 Bauxite (additive)
STACKER
A stacker is a device which forms conical piles of the crushed material. Feed is conveyed
to the stacker through conveyor belts. This stacker then moves too an fro to make a
pile. The stacker belt is called “Jib” in engineering terms.
Now, for conveying this material from piles to the conveyor following equipment used
are as follows:
 Side scrapper(Picks the crushed feed from the piles through its feed belt called “Hoist”)
 Reclaimer(Used to throw feed down from the pile and has two arms called ‘’HARROWS’’ )

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RAW MILL FEED AREA:

The raw mill feed area has of 4 feed hoppers:
 Mixed feed hopper

 Pure limestone hopper
 Bauxite hopper
 Iron ore hopper
The capacity of first two hoppers is 800 tons while the
other two hoppers have a capacity of 600 tons. The feed from each pile is conveyed to
the hoppers through conveyor belts in relevant hoppers. Each hopper has 4 load cells.
Load Cells
These are sensing devices which tells the load being put on the hopper by the
feed. From these hoppers, the feed in required proportions are transferred by the belt
conveyor to the Raw Mill. A lot of dust is produced during the conveying of material, to
avoid this problem Bag Filters are installed. A Magnetic separator is also installed to
remove metal impurities.
RAW MILL:
The raw mill have total capacity of 500 tons/hour and the motors that are used in
raw mill are INDUCTION motors and have power of 4.3KW supplier of motors are FL
Smidth. There are three sections of raw mill that are described as follows,
 Table with three rollers
 Bottom scrapper
 Separator

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TABLE
The raw feed from the belt conveyor directly falls on the rotating table of the raw
mill. The table contains three crushing rollers. The raw fed is crushed to fine powder
with these rollers. The coarse particles are collected at the bottom of raw mill and
are sent to the vibrator from where they are sent to the raw feed belt conveyor and
again recycled to the ram mill for re crushing. The vibrator is use to handle the
quantity of the material being put on the belt.
SEPARATOR
At the top of the raw mill, there is separator section. Hot

gases from the kiln come from the bottom of the raw mill
and lift very fine particles with it. A suction fan with motor
power of 4500 Kw produces suction and sends dusty air
into the cyclones at the top. Here the dusty air rotates and
particles are separated from the air. These particles are
collected at the bottom of the cyclone and sent to the CF
silo with the help of air slides. The air which still contains
dust particles are separated in Conditioning tower and
Electrostatic precipitator.
BOTTOM SEPARATOR
Some fine particles from raw feed fall on the table, these particles are collected by
means of a bottom scrapper and sent to the CF silo.

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CONDITIONING TOWER
The air from the cyclones still contains the dust particles which must be
separated before the air is exhausted to the atmosphere. Air from the separator is
passed through conditioning tower. In conditioning tower, water is sprinkled through
very fine nozzles. The particles in the air get wet and settle down. These particles are
then conveyed to the CF silo via screw conveyor.
CLEANING OF THE (EP) ELECTROSTATIC PRECIPITATOR
In order to remove particles from the electrode. A “Wrapping” device is used. This
device hits the electrode as a hammer and particles fall down from it. These particles
are collected and conveyed to the CF silo via screw conveyor and this screw conveyors
runs by SQUIRRL CAGE Induction Motor.
LABORTARIES:
There are different laboratories for the determination of quality and strength of the
cement.
1:- Sample preparation Lab (Check samples of material used in kiln)

2:- Press Mill (Pressure exerted of 150 KN on dye which have material)
3:- X-ray Analysis (X-ray analysis check determine the composition)
4:- Chemical testing lab (It determines the time of consuming process)
5:- Physical testing lab (Determine strength of cement samples)

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COAL STORAGE YARD:

Coal yard is the area where coal is stored which is used for burning purposes in KILN.
There are different piles for the storage of local and imported coal. The coal is imported
from South Arica, and Indonesia. The coal is handled by a loader, the loader picks up the
coal and throws on a sieved net which separates bigger pieces of coal and stones form
it, before it goes to the tunnel.
From the tunnels the coal is placed on the belt conveyor which takes it to the coal mill
feed area. Pet Cole which is hard is also used in the coal feed.
COAL MILL FEED AREA
After the impurities are removed from the coal, it is chatted on the belt conveyor .A bag
filter is employed which sucks the coal dust and thus prevents the coal from being
wasted. The coal is then shifted to the coal storage hoppers.
COAL STORAGE HOPPERS
There are three hoppers for the storage of coal. Two hoppers are for the storage of local
coal and the other is for the imported coal. All the three hoppers have a capacity of 250
tons. The coal required in different proportions is chatted on the belt conveyor from the
hoppers. A bag filter is employed to remove coal dust. A magnetic separator is
employed to remove metal impurities. This belt conveys the raw coal to the raw coal
mill.

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COAL MILL
Coal mill at DG Khan cement has capacity of 52 tons/hour (in case of mixed coal) and 26
tons/hour (in case of pet coal), the total capacity of motors used in coal mill are 600KW
and these are all INDUCTION motors supplied by FL Smidth.
Coal mill has three sections these are given below
1:- Table
2:- Roller
3:- Bottom Scraper
The function of these section is approximately same as described in raw mill.
CF (CONTINUES FLOW) SILO:

The fine particles from the conditioning tower and
electrostatic precipitator and the powdered feed from
the raw mill are conveyed to the bucket elevator. The
bucket elevator picks this feed and takes it to the top
of the CF silo and then throws it in CF silo.
Specifications of a CF silo
Length = 54 m Diameter = 22.4 m Capacity =

25,500 tons

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AIR CIRCULATION
After the feed is stored in the silo bin. Now for the movement of feed in the bin, air is
blown from the bottom through different points in CF silo. These points are located at
the base of the CF silo.
Due to air circulations, fine particles are sent to air slides from where they are
transferred to Low bin (Loss of weight bin). The capacity of low bin is 118 tons. The feed
from the low bin is sent to a bucket elevator which lifts it to the preheater.
PRE HEATER
The bucket elevator puts the material on the top of second cyclone. The hot gases from
the kiln flow with very high velocity in countercurrent direction. The hot gasses lift the
particles from the particles from the top of 2 nd cyclone and put it on the top of the 1sr
cyclone. From there the material falls on the top of the 3 rd cyclone and sends it into the
2nd cyclone. Then the material falls on the top of 4 th cyclone and hot gases take it into
the 3rd cyclone. Then the material falls on the top of the 5 th cyclone and hot gases take it
into the 4th cyclone and finally into the 5th cyclone preheater.
During this complete cycle, the hot gases foe in the countercurrent direction. These
cyclones serve the purpose of preheating the feed material with hot gases of kiln.
There are total 10 cyclone preheaters. 5 are on the right side of the precalciner and 5 on
the left of the precalciner. The temperature of feed increases as the feed flows
downwards the preheaters.

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PRE CLAINER
The feed from the 5th cyclone preheater falls into the precalciner which has burner with
a supply of coal and furnace oil. Here the calcinations of feed material take place due to
burning. Exchange of heat also takes place in the precalciner. CO2 is evolved and
exhausted in the atmosphere and the feed is entered into the kiln riser at high
temperature. Some of the feed directly goes to the kiln without going to the precalciner
through separate pipes.
GAS ANLYSER:
Gas analyser is basically a sub station in preheaters. It is located at 1st floor of preheater
cyclone’s. In gas analyser there are basically three analyser three tunes, or you can say
three cylinders which have CO2,O2,S02& B respectively in each cylinder. Main purpose
of this gas analyser is to clean the gases before sending them to the KILN for burning
process and for cleaning the gases we send NH2 nitrogen into cylinders one by one to
obtain (0,0,0) value so that gas is free from dust etc and safe to send to KILN. Three
analyser machines are used manufactured by ABB are used.
KILN:
The preheated feed from the kin and the preheaters enter into the kiln riser. From the
kiln riser the feed enters into the kiln. The material that comes out from KILN is called
Clinker.
SPECIFICATION’S
The kiln has length of 66 meters, diameter of 5.5 meters, its rotatry speed
depends upon the feed into kilnif there will be more feed kiln rotate little bit
fastly and if the feed is not so much its rotatry speed may goes down. Inner part
of kiln has refractory type so that it prevents the outside envoirment from high
temperature. Outside material also protect the envoirment, on outside there are

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induced draft fans that sense temperature and if

temperature rises from a limit the fans will turns on
automatically and if temperature not exceed this limit the
fans will remain off there main function is to keep outside
temperature down.
KILN MOTORS
There are two base ends of KILN and motors are installed
on these bases which tends to rotate the kiln, these are
large INDUCTION motors that have very high starting
TORQUE so that kiln moves.
KILN BURNER
One end of the kiln have huge burner having a supply of coal, furnace oil and air. The
burner emits a flame which is prolonged with high pressure air. The flame burns the
material and the product is formed.
KILN HOOD
The very hot material from kiln falls into kiln hood which has an angular
sieve,when material passes through the kiln hood it becomes CLINKER and now
this CLINKER will sent to the clinker cooler.
CLINKER COOLER
Clinker cooler is used to down the temperature of Clinker. The Induction fans
take air from atmosphere and send it to clinker cooler and the conveyor belt at
the bottom takes this cool clinker and send it to the clinker crusher.
A suction fan is installed which sucks the product dust from the cooler and send it to the
electrostatic precipitator. In EP dust is removed and clean air is exhausted to the
atmosphere through a chimney. The dust particles are to the deep pan conveyor by a
screw conveyor.

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CLINKER CRUSHER
When the cool clinker falls into clinker crusher then the big stones of clinker are crushed
into small pieces and this material now send to the clicker silo.
CLINKER SILO
Clinker silo is 60 m high and its width is 46 m. There are 3
gates at the bottom of the clinker storage from where the
clinker is the clinker from the deep pan conveyor is stored
in the clinker storage. Its capacity is 110,000 tons. Its length
is sent to cement mill through belt conveyor. Besides the
main clinker storage bin, there is a temporary clinker
storage hopper with a capacity of 1400 tons. If the
temporary hopper is also full then the clinker is removed
from the hopper and dumped into clinker storage yard.
CEMENT MILL FEED AREA:

There are two cement mills at the plant and there are total six (6) hoppers in cement
mills (3 for each mill) in feed area.
The 1st hopper contains the clinker which is major constituent of the cement. The
cement contains 95 % clinker which is conveyed through weigh feeder to the main belt
conveyor which takes it to the cement mill.
Remaining 5% material is (GYPSUM+ADDITIVE MATERIAL).
MIXING OF GYPSUM & ADDITIVE MATERIALS

The crushed gypsum from a separate crusher is conveyed by belt conveyor to the
cement mill. It is mixed in the clinker while crushing. Gypsum is added to about 4 – 5 %.
Its purpose is to increase the settling time of the cement . The additive which is pure
limestone is also added in the cement mill. It’s added to about 2 %. Its function is to
increase strength of cement.

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CLEANING PROCESS
To clean cement from stones or metal particles there are sensors in cement mills before
Paking that allows to comes out only cement not stones etc, and also a metal detector
also installed that attract every metallic particle and the pure cement goes to cement
mill silo.
CEMENT MILLS:
There are two cement mills at the plant and each of them
has capacity of 175 tons/hour and the motors that are used
in cement mills are of 4300KW of power and manufactured
by FL Smidth. The feed which is free from impurities falls on
the table of cement mill which contains three rollers. Each
roller has weight of 35 tons and the clearance between
table and rollers is 0.5 mm. These rollers move hydraulically
using nitrogen gas as hydraulic fluid. The rollers crush the
feed to a very fine powder. The air slides convey the ground
product to the bucket elevator which lifts it to enter into
the 1st storage silo.
CEMENT SILO
There are 3 cement storage silos in which crushed cement is

stored until packing. To convey the cement to the other 2
silos air slides are used. From these silos the cement enters
air slides by air circulations through blowers. Now these air
slides take the cement to the packing plant.
Capacity of storage silos is 21,000 tons, length is 45 meters

and diameter is 22.4 meters.

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PACKING PLANT:
The packing plant comprises of 6 packers and 12
terminals. Each packer has a capacity of 100 tons/hr.
The cement bags are attached manually to the rotating
packer which fills the cement bag. When the bag is
filled up to the required weight, it automatically falls
on the conveyor belt which takes the bags to the roller
conveyor. From these rollers the bags slide to different
channels and finally cement bags are loaded on the
trucks for dispatch.
WEIGH BRIDGE
Every truck or loader of cement that comes out from packing plant have to go for weight
if the weight exceed than a limit loader will be turned back for accuracy, so weigh
bridge also plays an important role.
PROGRAM ABLE LOGIC CONTROL (PLC):

Program Able Logic Control (PLC) is the main controlling area of the plant. Plant is
controlled by CCR (Computerized Control Room) which have different sections like IT
Dept., Exchange, Laboratories, Control Room, and PLC. PLC Dept. have to look after that
while every component in plant is working properly or not if there will be any fault
according to Automation they have to remove that. Plant has ten (10) major PLC’s main
controlling PLC port is of SEIMENS Co Ltd. Signals send to control room by underground
wiring of cable Fiber optics also used for long distances.

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REFUSED DERIVED FUEL (RDF) :

Refused Derived Fuel (RDF) is the under construction project at DG Cement Plant. I
would like to briefly explain its features,
RDF indirectly will clean the city from garbage all the garbage from nearby cities will
bring to RDF and a CRUSHER which using a SQUIRRL CAGE (INDUCTION MOTOR) low
starting torque producer will cut-off the garbage into small pieces that will be conveyed
by conveyor belts to storage yard and from there it will be cleaned from stones and
metallic materials using same technology as discussed before in cement mills. From
preheaters this garbage will be thrown into KILN for burning purposes.
RDF have 6 motors that I have seen during my stay in DG Cement these all are SQUIRRL
CAGE motors that will move the conveyor belts and each motor have 4300KW of power.
REFRENCES:
www.google.com
www.wikepedia.com
www.sick.com/.../cement/Pages/cement.aspx
www.siamrefractory.com/cement_cyclone.php
www.freepatentsonline.com
www.lwbref.de/en/markets/cement-lime-industry/

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CONCLUSION:
Now at the end I would like to conclude my experience in industry. That was my first
ever industrial tour and this was such a great experience I gain lot of knowledge about
industries that will be helpful for me in future. Being an engineer I simply got a direction
for my future by this internship.
Finally I would like to thanks all staff of DG Cement (Khairpur) plant for such a kindness,
each and every person at factory site help me in every possible way without any kind of
hesitation.
Engr. YASIR HAROON
Reg # BCE-SP08-090
BATCH 13, SECTION B
COMSATS Lhr

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A REPORT ON: Electrical(components & instruments) Motors,Power Generators,

YASIR HAROON (BCE-SP08-090)

DEPARTMENT OF ELECTRICAL ENGINEERING INSTITUTE OF

Description Page No.

YASIR HAROON (BCE-SP08-090)

Conclusion & Refrences ………………………………………………………………………….. 23

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)

Yahya was born in 1918 in Chiniot. In 1947 when he was A man of

YASIR HAROON (BCE-SP08-090)

Firmly believing in “Growth Through Professional Management” our corporate culture

Mian Mohammad Mansha

Limestone Storage Yard Raw Mill feed area

Kiln CF Silo Coal Mill

Kiln Motors Preheaters and preclain Coal Mill Feed Area

Clinker Silo Cement Mill Feed Area Cement Silo

EP Cooler Gypsum Crushers Cement Mill

YASIR HAROON (BCE-SP08-090)

QUARRY and LIMESTONES CRUSHER:

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)

MAGNETIC particles such as iron etc if found in crushed

 2 Mixed piles (limestone & clay)

YASIR HAROON (BCE-SP08-090)

RAW MILL FEED AREA:

 Mixed feed hopper

YASIR HAROON (BCE-SP08-090)

At the top of the raw mill, there is separator section. Hot

YASIR HAROON (BCE-SP08-090)

CLEANING OF THE (EP) ELECTROSTATIC PRECIPITATOR

1:- Sample preparation Lab (Check samples of material used in kiln)

YASIR HAROON (BCE-SP08-090)

COAL STORAGE YARD:

COAL MILL FEED AREA

COAL STORAGE HOPPERS

YASIR HAROON (BCE-SP08-090)

CF (CONTINUES FLOW) SILO:

Length = 54 m Diameter = 22.4 m Capacity =

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)

induced draft fans that sense temperature and if

YASIR HAROON (BCE-SP08-090)

CEMENT MILL FEED AREA:

Remaining 5% material is (GYPSUM+ADDITIVE MATERIAL).

MIXING OF GYPSUM & ADDITIVE MATERIALS

YASIR HAROON (BCE-SP08-090)

There are 3 cement storage silos in which crushed cement is

Capacity of storage silos is 21,000 tons, length is 45 meters

YASIR HAROON (BCE-SP08-090)

PROGRAM ABLE LOGIC CONTROL (PLC):

YASIR HAROON (BCE-SP08-090)

REFUSED DERIVED FUEL (RDF) :

YASIR HAROON (BCE-SP08-090)

Engr. YASIR HAROON

BATCH 13, SECTION B

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)

YASIR HAROON (BCE-SP08-090)