ACC

CHAIBASA
MENTOR :Mr.
D.K.Sharma
GM
Production

PRESENTED BY :SANCHIT AGARWAL

&
ABHINAV JHA

INTRODUCTION
A. Name of the Company : ACC Cement
B. Annual plant throughput :- 1.2 million tonnes
C. Feed Material : Limestone
D. Total production capacity of the plant per annum : 1.2
million tonnes
E. Total power consumption : 25 MW (full load)
21 MW (average load)
F. Name of the Mines : Rajanka mines
G. Feed Grade(limestone) : 55-57% CaCO3 , 20-25% silica
H. Product Grade : 80-87% CaCO3, 2-3% silica
I.
Reject Grade : 18-22% CaCO3
J. Percentage enrichment : 23-28%
K. Power factor of the plant = 0.97
L. Power factor of each motor = 0.85

MAJOR SECTIONS OF THE PLANT

Crushing plant
Grinding section
Flotation cell
Thickener
Main process section
Cement mill
Storage facilities
Bag house

CRUSHING PLANT
1) Primary Crusher
) type IMPACT CRUSHER
) feed size 3 x 2.5 m
) product size 50 mm
) capacity 1000 tph
) speed 999 rpm
) power 1000 kw
2) Secondary Crusher
) type HAMMER MILL
) feed size 50 mm
) product size Dry 18 mm with 10 to 12%
retained
Wet 22 mm with 10 to 12%
retained
) capacity 120 tph
) power 120 kw

GRINDING SECTION
type of grinding mill BALL MILL

feed size 18 mm
product size 90 micron with 10% retained
size 2.9 x 5 m
motor capacity 800 kw
capacity 75 tph
total ball load 40 tonnes
Ball size : 75mm 18 tons
65mm 8 tons
50mm 8 tons
40mm 6 tons
type of liner Mn steel
type of grinding chamber single &
hypersteel
ball mill recirculating load 180 %
% CaCO3 recovery 65-70%
% CaCO3 in rejects 20-28%

FLOTATION CELL
Reagents : frother Rosin (0.11 kg/litre)
collector Industrial soap (0.025 kg/litre)
pH regulator Caustic soda (0.5 kg/litre)

Rougher cell :

no. of Rougher cells : 2 x 4 cells

capacity of each cell : 17 m3/hr
feed grade : 69-70% CaCO3
product grade : 76-78% CaCO3
rejects grade : 18-20% CaCO3, silica > 42%

Cleaner cell

no. of cleaner cells : 1 x 6 cells

capacity of each cell : 8.5 m3/hr
feed grade : 76-78% CaCO3
product grade : 86-87% CaCO3, 7-8% SiO2

THICKENER
Mixer Basin 1 :
Diameter : 24.34 m
Capacity : 2470 m3

Mixer Basin 2 :
Diameter : 24.28 m
Capacity : 2071 m3

High Rate Thickener :

Diameter : 120 ft
Capacity : 3783 m3

PRIMARY CRUSING
UNIT
MINES

VIBRO
FEEDER

IMPACT
CRUSER
CROSS BELT
ANALYSER

PIPE CONVEYOR

PIPE
CONVEYOR

LOW GRADE
LIMESTONE

HAMMER
MILL

BALL MILL

RAKE
CLASSIFIE
R

HIGH GRADE
LIMESTONE
REAGENT
S

CONDITIONI
NG TANK

FLOTATION UNIT
MIXER
BASINS

COCENTRA
TE

(1 ROUGER AND 1
CLEANER)

T
A
I
L
I
N
G
S

HI-RATE
THICKNER

MAIN PROCESSING SECTIONS

VRM(Vertical Rolling Mill)
total capacity : 340 tph
high grade limestone feed : 210.8
tph
iron ore feed : 2.8 tph
bauxite feed : 8.3 tph
slurry(low grade limestone) : 70
tph
feed size : 90-212 micron
power : 1500 KW
bed RPM : 17.26 rpm
pressure : 140 bars

ROTARY KILN

feed rate : 271 tph

calciner coal : 10.63 tph
kiln coal : 5.3 tph
kiln rpm : 3 rpm
kiln angle : 2-3 degree

MAIN PROCESS SECTION BLOCK

DIAGRAM

CEMENT MILL
Total no. of mills : 5
Ball Mill 1 & 2 (open circuit)

power 650 kw
capacity : 15 tph
gypsum : 12%
fly ash : 2%
clinker : 86%

Ball Mill 3 , 4 & 5 (closed circuit)

power 1500 kw
capacity : 45 tph
slag : 42%
gypsum : 5%
clinker : 53%

CLINKER
HOPPER

GYPSUM
HOPPER

CEMENT (BALL)
MILL

SEPRATOR

CYCLONE

BAG HOUSE
PACKAGING
HOUSE

CEMENT SILO
EXHAUST
CHEMNEY

CEMENT
MILL

STORAGE
Clinker Silo
FACILITIES
capacity : 1,11,900 tons
effective volume : 74,600 m3
bulk density : 1.5 tons/m3

Blending Silo
capacity : 1,92,000 tons
bulk density : 1.25 tons/m3

BAG HOUSE
no. of modules : 16
no. of bags in each module : 216
bags
total no. of bags : 2156 bags
bag length : 1,100 mm

ADVANTAGES OF PIPING
CONVEYOR
Reduction in limestone corrosion
Reduction in dust pollution
Less wear and tear
Best for the slopy routes from mines to
plant
Long working life

MAIN AREA OF FOCUS DURING

TRAINING
Crusher
s

Flotation
cell

Grinder
s

reagent
s
Mine filling
operation

Reject
18-22%
grade

Thickene
r

86-87%
grade

65-66%
grade

Roughe
r (4
cells)
76-77%
grade
Cleaner
s (6
cells)

TYPES OF
OPC (Ordinary portland cement)
PRODUCTS
gypsum
PSC (Portland slag cement)
gypsum + slag(35-70%)

clinker +

PPC (Portland pozzolana cement)

+ gypsum + fly ash(15-35%)
F2R (Premium product)
+ slag(42-44%)

clinker +

clinker

clinker + gypsum

ACC Plus
clinker + gypsum + fly ash(2023% with 50% of fly ash from Tata and other
50% from ACC power plant)

THANK
YOU