DARLA GHAT

SOLAN
SUBMITTED TO :
Er. BEANT SINGH
H.O.D. of Mechanical Deptt.
SUBMITTED BY :
PAWAN KUMAR SAH
ROLL NO. 100531131316
BRANCH : M.E.-8
th
SEM.
BATCH : 2010-2014.
INTRODUCTION
Ambuja Cement Ltd. (ACL) was established at Darlaghat, Village-
Suli, Tehsil Arki, district Solan, in the year 1994. The plant is located
45km.from Shimla & approx 2km. from Darlaghat. As India is the
second largest producer of cement in the world. This cement industry
is one of the few industries in India to achieve global
competitiveness. The Cement industry matches world standards on
all parameters. The quality of cement compares with internationally
accepted Britain & American standard. Also companies productivity,
energy efficiency & Environment standards among the best in the
world. The company starts its Commercial production in 1995 having
a rating capacity of 1.5 to 2 million tones per annum, now around 2.5
million tons per annum. The company has always maintained the
corporate philosophy of sustainable development. The company has
been adjusted the best & the most effective mines in its area by
Indian Bureau.

PROCESS MACHINE
Limestone mining Mine Plant
Cursing Crusher
Grinding Raw mill
Homogenization CF Silo
Pre-heating Pre-heater
Burning Kiln
Cooling Cooler
Storage + add Gypsum Clinker Silo
Grinding Cement Mill
Storage Cement Silo
Package Packaging Plant
Dispatch Dispatch Machine
(By road or sea)
Details of Process
)1 Lime stone stockpile
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Details of Process
)1 Lime stone stockpile
40
The most and important for cement and clinker is limestone, at about
80% part in finished product. Those types of basic raw material are requirement that is
half more than finished product means if 100-tons cement required, than 150-tons
limestone required.gcw have their own mine for limestone. There mine plant is 3 km
away from the mail production plant all material is reach at plant through belt conveyor.
2) Crusher
The limestone find from mine. After mining the limestone it crushed by
crusher. Crusher crushed the stone type limestone into some powder like form. Its
capacity of crushing is 950tones per hours. Than it collect and stocked as piles by
dumpers. In the store the crushed stone is stacked in several layers by the stacker so that
a variation in quality of incoming limestone is evened out.
3) Grinding
The machine, which grinds the raw material, is called RAW MILL. That
converts raw material into powder form by grinding it. Crushed limestone, shale &
hematite are fed in the required proportion to the raw grinding unit.
6) Homogenization
In this stage mixed powder from raw mill transfers to CF Silo, where
some additives are added to mixture. Here drying process of raw material is also carried
out, because the basic raw material contains some moisture.
7) Preheating & Calcinations
Before moving the mixture to Kiln, the powder must obtain some
temperature. Pre-heater performs that task. Calcinations is defined as removing of
carbon-di-oxide and other organic matters from the raw material. The process of
calcinations before Kiln reduces the thermal load in the rotary Kiln. The advantage of
this system is that the Kiln capacity increases by 2-2.5 times.
6) Burning
The precalcined raw material is fed into the rotary kiln and coal is
fired at a temperature of 1600-1800 degree centigrade on the other end. Here after
burning process the powder form is transferred into small stone type form, which
is called Clinker.
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8) Cooling
The clinker is cooled in cooler, because it is very hot after passing though
a very high temperature. There are three high power fans, which reduces
the temperature
of the clinker. Cooler brings down the temperature of clinker from 1200
centigrade to
200 centigrade.
9) Store
Clinker is stored in the Clinker Silo. For converting it into cement,
gypsum is mixed and grinded further in grinding process.
10) Grinding
In this stage raw material is passed to Cement Mill, where the clinker and
gypsum are mixed and grinded to make powder form. Here some needed
chemical are
also added to mixture. This grey mixture is called cement.
11) Storage
Cement is stored in Cement Silo in powder form before packing. From
cement silo, needed quantity is taken for packing, while the bulk quantity
without
packing is goes to Jetty though conveyer belt.
12) Packing
Packing plant for packing of cement in bags is located in the plant itself.
13) Dispatch
After packing, cement is dispatched to various locations through road or
sea. Here cement is loaded in truck by machine automatically
Types of cement
.
Ordinary Portland Cement (OPC)
Portland Pozzolona Cement (PPC)
Portland Slag Cement
White Portland Cement
Oil Well Cement
Low Heat Portland Cement
Super Sulphated Cement, High Alumina Cement

FLOW CHART OF MATERIAL FLOW IN PLANT
STACKING AND RECLAIMING


RAW MATERIAL GRINDING

The reclaimed lime stone from BC-7 is then conveyed to raw lime
stone hopper and the additives (shale, red ochre & iron ore) are
conveyed to raw material hoppers through BC-8 & BC-9. The desired
amount of lime stone & additives are fed to a common belt conveyor
BC-10 through Weigh Feeders and then in to the raw mill through BC-
11.

There are four raw material hoppers below which there are four weigh
feeders, which are respectively:

Limestone weigh feeder
Equipment No 10 WF 1
Type Electronic weigh
feeder TLD 160/1.2V
Capacity 500 TPH
Material Limestone
Bulk density 1.4-1.6tonns/Cu. M
Belt width 1600 MM
Pulley centre 2800 MM
Feed to discharge 2600 MM
Drive unit 5.5 KW D.C

FLOW OF RAW MILL

BC10
BC11
B
U
C
K
E
T

E
L
E
V
A
T
O
R

(
1
0
B
E

1
)

BC12
RAW MILL
FROM J.D.
TO RAW
MILL FAN
AS 1
AS 2
AIR
SLIDE 3
2
0
B
E

2

BLENDING SILO
C.B.
RAW MEAL FEED
(CALCINER)
RAW MEAL FEED
(KILN)
CYCLONES
Coal mill
BAG FILTER
THE BAG HOUSE / BAG FILTER IS GENERIC NAME OF AIR POLLUTION CONTROL EQUIPMENT IT IS
DESIGNED AROUND THE USE OF ENGINEERED FABRIC FILTER TUBES, ENVELOPES OR CARTRIDGES
IN THE DUST CAPTURING, SEPARATION OR FILTERING PROCESS UNICON PROVIDES RELIABLE AND
EFFICIENT BAG FILTERS AND BAG HOUSE SYSTEMS.