Summer Internship Report

MANGALAM CEMENT LIMITED

MORAK, KOTA

Prepared By:
Akshat Jain
B.Tech (Chemical Engineering Specialization in Refining and Petrochemicals)

University of Petroleum and Energy Studies

Dehradun, Uttarakhand

1
 ACKNOWLEDGEMENT
I am very happy to avail this golden opportunity of getting training at
Mangalam Cement Ltd. Plant. My greatest thanks to President of MCL at
Morak Mr. S.S. Jain who for permitting me to do the apprentice training in
the well established organization bestowed me with the ability and
potential to complete this Internship.

A lots of thanks to Mr. S.D. Arya (V.P (P&QA)) who allow mw and support
me to done my summer training in such a friendly environment.

I am also thankful to Mr. Anil Bhatt, Mr. Mashes Hastak, Mr. O.P. Gupta,
Mr. Raghavrndra who helped me to gain a lot of regarding the company and
cement industry and also provided me an opportunity to learn and understand
the working of industry as an internee.

I am also very greatful to Mr. Sudhanshu Pandey who played a role of polar
star for me in the company and whose experience taught me a lot about the
industry and the organization.

Before I go thick of the things, I would like to add few deepest words for the
people who were providing me information about the plants. This report is
a result of handwork of not a single person but many persons have aided by
volunteering their services to create this text. Their kindness thus
improving this report with their Additional technical knowledge has
contributed mightily to the quality of this work. I got much practical
knowledge which was not possible to gain in the university during studies.
And finally deepest and warmest appreciation to the whole team of
Mangalam Cement Ltd.
Akshat Jain

(7830860757)

2
 Executive Summery

This report covers an experience, which I got during my summer internship

at Mangalam Cement Ltd. in Morak.

As a chemical engineer firstly I was introduced in the both Laboratories

section. In the physical lab determination of quality and strength of the
cement and many other process that are done on this lab. For tasting
different types of equipments were also available in physical testing lbs. In
Chemical Lab different types of tests are conducted to determine different
properties of the product. Also different types of fuels are tested for their
inherent properties.

Then I was introduce in the processing unit . Through process (or CCR)
most of the machinery and system are operating. IN CCR I understood
operation of cement mill thoroughly, the clinker first come from the
clinker storage piles to the clinker hopper through the deep bucket
conveyor. Then transferred to the polycom, where it crushes and then fed
to cement mill for further grinding and mixing. There is also a recirculation
system, which again feed the coarse material to the polycom.The very fine
material from cement mill is then stored in the cement silo. From the
cement silo the cement is fed to the packers, where it filled in the bags of 50
kg.

Then I was introduced in the Raw Mill & Coal Mill section. In the field I
got the knowledge of various Instruments.

3
Contents:
1) Introduction
2) General layout of the plant
3) Cement Manufacturing Process
 Raw Materials
 Mines
 Crusher
 Stacker and Reclaimer
 Hopper
 Weigh Feeders
 Vertical Raw Mill
 Blending and storage Silos (mixing)
 Kiln and Cooling Section
o Coal Section
o Kiln section
o Cooler Section
 Cement Mill Section
o (Polycom/ Roller Press/Cement Mill/V-Sepa/Separator)
o Cement Silos
 Packing Plant
 Market

3) Laboratory Processes

4
 Introduction
Mangalam Cement Limited, the ISO 9001:2000, IS/ISO 14001:2004 and ISO
18001:2007 certified company was incorporated on 27th October 1976.
The company was promoted by Kesoram Industries & Cotton Mills Ltd., The
Century Spinning & Mfg. Co. Ltd., The Gwalior Rayon Silk Mfg. (Wvg.) Co.
Ltd., and Pilani Investment Corporation Ltd. Rajasthan State Industrial &
Mineral Development Corporation Ltd. (RIMC) also participated in the
promoters capital. As a B.K. Birla Group wing, the company is producing
cement in 43 grades, 53 grades and Portland Pozzolana Cement (PPC)
using the dry process and marketing under the brand name of "Birla
Uttam".
The Company started commercial production in March 1981 with an
installed capacity of 4 lakh tonne per annum of Cement. The Company then
took up two further expansion scheme envisaging increases in the installed
capacity from 4 tonne per annum to 20 lakh tonne per annum in between
1994 to 2005. The Company has recently expanded its capacity from 2.0
MTPA to 3.25 MTPA upgrading its Kiln I capacity by 0.5 MTPA in 2013 and
establishing a New Cement Mill of 1.25 MTPA in 2014. All the units of the
Company namely Managalam Cement and Neer Shree Cement are located
at Adityanagar - 326520, Morak, Distt. Kota, Rajasthan. Morak is 65 Kms
away from Kota towards Mumbai side on main Delhi-Mumbai train route.
The Company had set up two Captive Thermal Power Plant of 17.5 MW
each. The first power plant was set up in 2007 whereas the additional 17.5
MW power plant was set up in 2011. Apart from this, the Company also
owns 13 Wind Mills at Jaisalmer, Rajasthan with a capacity of 13.65 MW
generation per day. During the year 1996-97, the company had accredited
with ISO-9002 certificate in recognition of its quality systems.

5
 RAW MATERIALS
The following row material required in the production process:

 Morak Lime Stone (MLS): Limestone is the highest composition in

cement product. In MCL, MLS is used as a main product. This raw
material is extracted from the nearby mines. The composition of MLS
is cement is 60-69%.
 High Grade Lime Stone (HGLS) : Sometime if we can’t get sufficient
composition of Calcium Carbonate in MLS or if we get high amount of
Silica in MLS then we add HGLS in raw mix to get a proper
composition.
 Bauxite: It is also utilizing as a corrective material to enrich the
proportion of Al2O3 % in the raw mix and act as a flux in the burning
process.
The compositions of Alumina in cement are 6-9%.
 Gypsum: It plays a very important role in controlling the rate of
hardening of the cement. During the cement manufacturing process,
upon the cooling of clinker, a small amount of gypsum is introduced
during the final grinding process. Gypsum is added to control the
“setting of cement”
 Iron ore(blue dust): The cement production process usually results
in the release of potentially risky hydrocarbon gases into the
atmosphere. To prevent this, mill scale is added to the combustion
area as the cement clinker is being produced.
 Fly Ash: It is used in the production of pozzolan portland cement
(PPC). It contributes to the properties of the hardened concrete
through hydraulic or pozzolanic activity,or both.

6
 General layout of the plant

Crushing

Mining

Staker and
Reclimer

Hoppers

Weigh Feeder
Raw Mill

7
 Kiln
Blending $ Storage
Silo

Cooler

Central Stock Pile

Cement Mill Section & Silos

Packing Section
Packers and Marketing

8
 MINING
Open cast mechanized method of mining has been adopted for
development and limestone production by making systematic benching
pattern in the mining pits. General sequences followed for rising of
limestone at Morak Limestone (MLS) are as below:

 Demarcation of area for mining as per planning.

 Cleaning of demarcated surface
 Removal of top soil & stored separately
 Putting drill holes of 115 mm diameter for charging of explosive
 Blasting of drill hole for breaking of lime stone / overburden
 Removal of over burden
 Excavation of limestone
 Transportation of Limestone up to crusher hopper
 Backfilling of mined out area
 Spreading top soil on backfilled / reclaimed area
 Development of green belt on reclaimed area.

9
 CRUSHER
Generally speaking, crushing denotes the size reduction process that
breaks down the material to a particle size suitable as feed for the next
main stage i.e. grinding. Employed, crushing is taken to mean reducing the
particle size to between 80 mm to 20 mm.

After mining the limestone comes to crusher section. At first raw materials
drops with the help of dumper in limestone hopper. From hopper this
material goes to Apron Feeder, this apron feeder convey the material to
Grizzly. In this Grizzly two perforate plates are fixed, that is called top and
bottom grizzly in top grizzly having 100 mm dia holes. From this holes of
plate, less than 100 mm material is screen and fall to bottom grizzly. Above
100 mm material will gone to crusher for crushing, in the bottom grizzly
plate has 75 mm dia holes. This plate has further screening the material.
Above 75 mm sized material is goes to crusher and less than 75 mm
material goes to belt conveyor. Here one vibrating screen is provided for
screening the material. In this vibrating screen two perforated plates are
provided top and bottom side. From top plate above 50 mm size material
belt and less than 50 mm sized material comes to bottom perforated plate.
From bottom perforated plate less than 10 mm sized material goes to reject
belt and above 10 mm material goes to next belt. After this, material finally
goes to stacker belt.

10
Description :
Raw material such as limestone, bauxite, HGLS are dumped into hoppers by
dump trucks and entered into a hammer crusher through an apron feeder.
Inside hammer crusher there are hammers each having a weight of 100-
102 kg. They rotate at a speed of 1200-1300 rpm and is capable of crushing
feed of very large sizes into 80 to 20mm size.

Bag Filter : The dust produced by crushing process can cause damage
to the equipment and may produce dust, to overcome this problem a bag
filter is employed. A fan blows air and all the dust goes to the bag filter.

11
Inside the bag filter a special type of canvas cloth is used. When air passes
through this filter cloth, the dust particles stick to the cloth and clean air
passes through. The dust particles are then collected and sent to the
conveyor. After sometime when the filter is choked with particles, purging
system is used in which high pressure air is used, this air removes all
particles from the filter cloth.

Magnetic separator :
A magnetic separator is installed on the
feed belt. It attracts and removes metal
objects from the feed which are
collected in the bin.

Stacker and Reclaimer: A stacker is a large machine used in bulk

material handling. Its function is to pile bulk material such as limestone,
ores and cereals on to a stockpile. A reclaimer can be used to recover the
material.

Stacker: A stacker is a device which form conical piles of the crushed

material. Feed is conveyod to the stacker through conveyor boom belts.
Boom belt drop this material on ground on its side and make a pile. These
piles length is 105 metre. And width is 35
metre. This stacker then moves too and fro to
make a pile. Now, for conveying this material
from piles to the conveyor follwing equipments
are used.

Reclaimer:
Reclaimer is equipment which is used to throw feed
dowm from the pile. It has two arms called “Harrows”
These harrows are inserted into the pile, when they
move sideward, the feed drops down the pile. This
feed in then collected by high capacity buckets
installed in the bottom of the reclaimer. These buckets
pick the feed and put it on the belt conveyor. It is large
capacity equipment and for those piles which are12
required in high quantity like Mixed Pile.
 Raw mill Feed area
The raw mill feed area consists of 4 feed hoppers:

 Morak Lime stone(MLS) Hopper

 High Grade limestone hopper
 Bauxite hopper
 Iron ore hopper

VERTICAL RAW MILL:

There are 3 sections of a raw mill.

 Table with rollers

 Bottom scrapper
 Separator

The Vertical Mill particularly suitable for the grinding of medium-hard to

soft minerals but may yet be used for grinding comparatively hard
substances. This roller mill is ideally suited for combined grinding and
drying.

The conveyor belt conveys the raw mix to VRM. On this belt equipped with
magnetic separator and metal detector just before the VRM. The belt moves
on two pulleys around the magnet the belt has angle plate, which pushes
the iron pieces and magnet pick it up and transfer away by a chute. Metal
detector detects the presence of any metal, which is not separated by

13
magnetic separator. This thing avoids any damage to the rollers and mill
parts.

The material to be ground is feed to the roller mill and its falls directly on
to centre of the grinding bowl and for conversion it carried under the
rollers by the rotation of the bowl. By the centrifugal force the crushed
material is flung outwards over the edge of grinding bowl and entered in
the stream of gas from nozzle ring. All of the material injected from the
grinding bowl or a certain portion of it is carried in the gas stream to the
dynamic separator located above the grinding chamber. Part of the
materials to be ground is feed via a bucket elevator to the separator or the
feed chute.

The separator classifies the material entered in the gas stream into
finalized product and oversized. The oversized material falls back on to
the centre of grinding bowl, while the finished product is carried by the gas
stream to the ESP where it is precipitated. In this mill two roller parts run
on a rotating grinding bowl. The principle of the two twin roller units leads
to a lower speed differential between the rollers and the grinder. Exhaust
gases coming out from the fifth stage cyclone of suspension preheater are
made to pass through gas conditioning tower where the fine particles of
kiln feed are scrubbed with water. The temperature of the exhaust gas is
lowered from 3250C to 2500C app.

Coal yard : Coal yard is the area where coal is stored which is used for
burning purposes. There are different piles for the storage of local and
imported coal. The coal is 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.

There are 3 sections of a coal mill similar to the raw mill:

 Table with rollers

 Bottom scrapper
 Separator

14
 Kiln Section
Precalcination, Burning And Kiln Feed:

It was recognized quite early that the heat liberated in the rotary kiln can,
besides being used for the actual processing feed material, advantageously
be utilized for preheating the material. The precalcining principle and its
applications have been developed more particularly in Japan and Europe. A
feature which all precalcining system have in common is that the supply of
fuel is divided between two firing units i.e. two burners pipe or sets of
burners, one is in the kiln and other in the suspension preheater.

Process:

Every Cyclone stage basically performs the following two functions:

 It heats up the raw meal in the gas stream.

 It separates the raw meal and discharged it via the meal chute.

The ‘A’ type cyclone is fed from above the exit gas containing raw meal
when leaving the calciner flows via the calciner bend to the cyclone. In the
cyclone the raw meal is separated and passed on by the meal chute to the
kiln inlet. The exit gas flows through the dip pipe and the intermediate
piece into the next higher gas duct.

The ‘B’ type cyclone is fed from the blow. The raw meal fed into the gas
duct is conveyed into the cyclone by exhaust gas. In this cyclone the raw
mill is separated and passes through the meal chute.

The Preheater is five-stage suspension type preheater. The kiln feed

material with air reaches to the top of silo may be diverted to the silo. It
enters into the output gas steam, from cyclone no. 4. The hot gas stream
from Cyclone no. 5A and 5B simultaneously efficient heat exchange takes
place between the raw material and hot gas than they are separated in the
twin cyclones. Gas makes it way to GCT through the preheater fan and the
raw meal passes down to enter outlet gas steam of the cyclone no. 3 is lifted
by it and enters cyclone no.4. Swirl in it exchanging heat and separates
from air. The air passes up and material passes down to exit gas stream of

15
cyclone no.2. The same process is followed. The gas enters in cyclone no.3
heat exchange takes place material is pass down to the exit gas stream of
cyclone no.1, material is lifted to cyclone no.2. The gas passes up and the
preheated kiln feed material enters Precalciner from cyclone.

In this system of preheating, exit gases of kiln are used to heat up the kiln
feed. In this manner lot of heat energy is utilized in preheating. The
temperature of kiln feed is maintained step by step when its move down.
The top cyclones are high efficiency cyclones, so that no material leaves the

preheater.

Kiln hood:
The hot material form the kiln falls into the kiln hood at the end which has
an angular sieve. When material passes through it attains the shape of
clinker. Now this clinker is sent to the cooler.

Clinker cooler :
The clinker cooler is used to lower the clinker temperature. There are ID fans which take fresh air
from the atmosphere and send it to the cooler. At the bottom of the cooler there are reciprocating
rails which move with the help of hydraulic motors. These rails convey the clinker forward to the
clinker crusher.

Dust collection:
A suction fan is installed which sucks the product dust from the cooler and
send it to the electrostatic precipitator. In EP dust is removed and clean air
is exhausted to the atmosphere through a chimney. The dust particles are
to the deep pan conveyor by a screw conveyor.

When the clinker cools and hardens then it is sent to the clinker
crusher installed after the cooler. Big stones of clinker are crushed to small
pieces. The crushed clinker is dropped on the deep pan conveyor at the
bottom of the conveyor which conveys it to the clinker storage.

Storage :

16
The clinker stock pile is covered with shade to protect clinker from Bin. The CSP has 14
feed hoppers are called ‘Zero Hopper’ in which material is fed with the help of Pay
loader.

Cement Mills
Introduction
By grinding is understood comminuting of materials to a powder. The
clinker discharge from the kiln has to be ground to a fine powder which
with the admixture of some gypsum is the finished product of the whole
process: Cement – This final clinker grinding operation is often suffered to
as finish grinding. The object of grinding is, more particularly, to increase
the specific surface of the material – which conforming to a desired particle
size distribution – to such an extent as to obtain adequate reactivity for the
next stage in the cement manufacturing process or adequate reactivity in
the finished product (the cement) itself. The single compartment tube mill
is a ball mill. The materials to be ground are passed through the grinding
compartment and mechanically discharge through a discharge lifter
diaphragm.

Process
The material to be ground is fed through the inlet device directly into the
grinding compartment of the single compartment tube mill. The grinding is
effected by a special mill lining and the grinding media.
The special mill lining ensures that the ball charge becomes finer towards
the mill outlet. The ground material is discharge from the mill through the
discharge lifter diaphragm via the discharge device. The air swept through

17
the mill system serves to the draw of the heat generated in the grinding
process and to support the material flow.
The water injection also draws off such heat wearing parts can be taken
into the tube mill through the manholes. Any required inspection of the
grinding compartments is also performed through the main holes. From
clinker stockpile clinker is transported to clinker hopper at Polycom feed
hopper by the help of belt conveyor and same manner gypsum is also
conveyed to gypsum hopper from gypsum yard after crushing and
screening. Clinker and gypsum hopper are equipped with weigh feeder.
Which are transfer clinker and gypsum in required proportion ratio to
roller press with the help of belt conveyor for initial grinding. These belt
conveyors are equipped with magnetic separator and metal detector to
separate any metal piece. A bypass belt is there, which may takes this
material to Polycom or as reject depending on choice. In the Air separator
the material is drop from the top. The rotated fan produced centrifugal
force produced on the material which distributes it even way to in between
a stationary case and rotating vertical guide vans, the fan suck the air with
fine particles inside separator and then transported to multi cyclones. In
multi cyclones fine particles are separated. The fine material is transported
to bin by air slides and coarse material is recycled to Polycom. The fine
material is transported to cement storage silo and coarse material to
cement mill. ESP is also provided here which separated fine dust from air
and passes them to aerosol or bucket elevator. The cement is transported
to cement silo. There are two cement silos. The cement is transported
either silo depending on its grade by means of P.G. Conveyor.

Packing Plant :
18
 The packing plant comprises of 6 packers and 12terminals. Each packer
has a some capacity. 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 balt 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, railway and
others means of transport for dispatch.

Laboratories’ :

There are different laboratories for the determination of quality and

strength of the cement. Different types of tests are conducted to determine
different properties of the product.

Also different types of fuels are tested for their inherent properties:
for example:

 Fineness of coal
 Humidity level of coal
 Calorific value of coal
 Composition of feed material and product
 Settling time of cement
 Residual material

Following are the different labs available :

X-ray analysis :

Now, the sample dye is put into an x-ray analysis machine to determine its
composition. The sample is place for 2 mins in the machine. The x-ray
machine is controlled by a computer software. This software restricts the
machine to determine up to a limit of 6 to 8 elements. After 2 mins , the
percentage of each element in a particular sample is shown on the
computer screen. The x-ray machine is very fast in producing accurate
results.

Chemical testing lab :

19
Chemical testing of a cement sample is done to determined its composition.
It was a slow and time consuming process, but now days x-ray analysis is
used due to its speed and accuracy. In chemical testing lab in spite of x-ray
analysis, samples are also tested by manual experimentation.

Complete Analysis Of Raw Mix :

The product gained from vertical raw mill that is the raw mix, goes for the
chemical analysis where we check the content of calcium carbonate, silica,
magnesium oxide, aluminium oxide, ferrous oxide and many more minor
components.

Following steps are involved in the chemical analysis of raw mix:

1. Take 0.5 gm of sample and 2gm of fusion mixture in Pt crucible.

2. Ignite the mixture about 900-1000 C.

3. Now, take 0.5 gm of the ignited sample and add 10ml of water and 10ml
of HCl.

4. Then, put the sample for baking i.e. heating at 60-70 C.

5. Add 1:1 HCl and again warm the sample.

6. Filter the mixture by No. 40 What man Filter Paper.

7. Wash the filter paper for 4-5 times by hot distilled water.

8. Now take out filter paper and ignite it at 1000-1100 oC in muffle furnace.

9. The dry material retained in the crucible will give the SiO2 content.

10. Take the filtrate in 300 ml beaker for R2O3 test.

11. Add 2gm aluminium chloride solid and methyl red indicator.

12. Heat the mixture up to boiling.

13. Add drop wise ammonia solution (1:1) up to ppt of R2O3 appeared.

14. Now, filter the mixture by No. 41 filter paper.

20
15. Wash the filter with hot Ammonium Nitrate (2% solution) for 4-5 times.

16. Take ppt and put it in oven for drying.

17. Ignite the dry ppt in weighted platinum crucible at 900-1000 OC.

Formula used for the calculation of R2O3 :

% R2O3 = [(Crucible Wt+ Sample Wt after ignition)-(Initial wt of

empty crucible)]* (100/0.5)

Physical testing lab:

In physical testing lab, physical tests of different cement samples are done
to check its properties.

Following are the equipment available is physical testing lab:

 Weigh balance
 Turbula mixer
 Tensile strength machine
 Water bath and curing tank
 Compression testing machine
 Motor mixer

Physical Analysis:

In physical analysis, the following test is carried out in the plant to check
the quality of cement.

 Standard Consistency Test

In this test, we can calculate the quantity of water in cement paste.

 Expansion Test

This is done by two methods,

21
  Le - Chateliar Method
 Autoclave Method

 Compressible Strength Test

By this, we can calculate the grade of cement in 3 days, 7 days and 28 days.
These grades are 43 grade OPC and 53 grade OPC and PPC.

Refrences :

www.sick.com/.../cement/Pages/cement.aspx

www.siamrefractory.com/cement_cyclone.php

www.freepatentsonline.comwww.freepatentsonline.com

www.lwbref.de/en/markets/cement-lime-industry/
22
 Prepared By:
Akshat Jain
B.Tech (Chemical Engineering Specialization in Refining and Petrochemicals)

University of Petroleum and Energy Studies

Dehradun, Uttarakhand

23