Ankittttttttttttttttttttttt.pptx

Nuvoco Vistas Corp. Ltd. (formerly Lafarge India Limited) has an established presence across all
major cities and towns in India. We respond to the needs driven by our customers, business
associates, shareholders, regional authorities and local communities. With our specialist solutions
under Cement, Aggregates and Concrete; we aim to enable and empower customers by bringing
innovation and ensuring sustainability to their construction.Nuvoco Vistas Corp. Ltd. (formerly Lafarge India Limited) has an established presence across all
major cities and towns in India. We respond to the needs driven by our customers, business
associates, shareholders, regional authorities and local communities. With our specialist solutions
under Cement, Aggregates and Concrete; we aim to enable and empower customers by bringing
innovation and ensuring sustainability to their construction.Nuvoco Vistas Corp. Ltd. (formerly Lafarge India Limited) has an established presence across all
major cities and towns in India. We respond to the needs driven by our customers, business
associates, shareholders, regional authorities and local communities. With our specialist solutions
under Cement, Aggregates and Concrete; we aim to enablesustainability and empower customers by bringing Nuvoco Vistas Corp. Ltd. (formerly Lafarge India Limited) has an established presence across all
major cities and towns in India. We respond to the needs driven by our customers, business
associates, shareholders, regional authorities and local communities. With our specialist solutions
under Cement, Aggregates and Concrete; we aim to enable and empower customers by bringing
innovation and ensuring sustainability to their construction.Nuvoco Vistas Corp. Ltd. (formerly Lafarge India Limited) has an established presence across all
major cities and towns in India. We respond to the needs driven by our customers, business
associates, shareholders, regional authorities and local communities. With our specialist solutions
under Cement, Aggregates and Concrete; we aim to enable and empower customers by bringing
innovation and ensuring sustainability to their construction.Nuvoco Vistas Corp. Ltd. (formerly Lafarge India Limited) has an established presence across all
major cities and towns in India. We respond to the needs driven by our customers, business
associates, shareholders, regional authorities and local communities. With our specialist solutions
under Cement, Aggregates and Concrete; we aim to enablesustainability and empower customers by bringing
innovation and ensuring sustainability to their Nuvoco Vistas Corp. Ltd. (formerly Lafarge India Limited) has an established presence across all
major cities and towns in India. We respond to the needs driven by our customers, business
associates, shareholders, regional authorities and local communities. With our specialist solutions
under Cement, Aggregates and Concrete; we aim to enable and empower customers by bringing
innovat

1. N UVOCO VISTAS CORP. LTD. P RESENTED BY A NKIT SHARMA Btech (7 th Sem) U nder The Guidence M r Naveen Kumar Vyas Executive- HR

2. C ERTIFICATE

3. CON T E N TS Introduction Cement Manufacturing Types of cement Flow Chart Mining Crushing Stacker and Reclaimer Vertical Raw Mill Preheater Rotary Kiln Cooler Grinding Roller Press Ball Mill Package and dispatch

4. INTROD U C TI O N Cement is the glue that holds the concrete together, and is therefore critical for meeting society's needs of housing and basic infrastructure such as bridges, roads, water treatment facilities, schools and hospitals. India is the world's second largest producer of cement after China with industry capacity of over 200 million tonnes (MT).

5. C E MEN T M A N U F A CT U R I NG Cement is made out of limestone, shale, clay mined out of quarry close to the plant. The raw material is crushed, and then heated at temperature in excess of 1000 degree Celsius in rotating kiln to become clinker. Clinker is then mixed with gypsum and ground to a fine powder to produce final grade of cement. The technology is a continuous process and is highly energy intensive. At present 93% of cement production in India is based on modern and environment-friendly dry process technology and only 7% of the capacity is based on old wet and semi-dry process technology.

6. T YPES OF CEMENT Ordinary Portland Cement (OPC). Portland Pozzolana Cement (PPC). Portland Blast Furnace Slag Cement (PBFS). Oil Well Cement. Rapid Hardening. Sulphate Resisting Portland Cement. White Cement etc.

7. P ERCENTAGE C ONTENTS OF CEMENTS 1.Ordinarily Portland Cement Clinker - 90.50% Gypsum - 4.00% Fly ash - 5.50% 2.Portland Pozzolana Cement Clinker - 66% Gypsum- 4% Fly ash - 30% 3.Portland Blast Furnace Slug Cement Clinker - 70% Gypsum- 6% Slag - 24%

8. F LOW CHART OF CEMENT MANUFACTURING

9. Overview of Mining Operations The first step of cement production is mining operation . The mining operations may be broken down into three processes: Prospecting : Based on the report submitted by the Geological Survey of India, prospecting is done to verify the tonnage of limestone. This is done by drilling holes and testing the samples. Development: Once the limestone reserves have been proven, development activity starts. Mine development work includes the activity of removal of top soil and rock overburden. In order to expose the limestone, top layer of block cotton soil/lateritic soil, ranging in between 1 to 3 mtrs . is removed. Mining :   Mining activities: After the development mining activities may be subdivided into Drilling Primary blasting Secondary blasting

10. CRUSHING A fter the mining operation limestones are feed into the crusher Principles of material breakage used in crusher – Crushing defined as “pressing between two hard bodies so as to break into fragments” Rock particles striking a hard object Rock particles striking other rock particles within the crushing chamber.     Selection of crusher Depends on: Maximum Feed size Product specification (size + shape characteristics) Throughput – (production rate) Location Plasticity and Moisture content “Stickiness” (clay content) Hardness Abrasively/wear costs Capital costs.    

11. Types Of Crusher:-  Jaw Crusher Gyratory (Cone) Crusher Hammer Crusher Roller Crusher Jaw crusher Hammer Crusher

12. Cone Crusher

13. Roller Crusher

14.  Crusher Benefits Capacity Cone crusher High reduction ratio, heavy duty chassis and track frame, 230tph Hammer crusher It produced spacified top size without the need for a closed circuit crushing system 900tph Roller crusher High capacity, low horsepower 10-50tph Jaw crusher Economical to operate with via clutch and highly fuel efficient direct dry system 500tph

15. S TAKER & R ECLAIMER

16. S TAKER & R ECLAIMER Now a days stacker with fixed or movable booms (which can be raised and lowered) are used for covered as well as for outdoor blending beds. A drawback associated with fixed boom stacker is that dust nuisance may arise. Reclaimer is a machine which removes material from stockpiles. The materials are dislodged from the pile by the action of a raking down device which sweeps across the cross-sectional face. Harrows are triangular structures fitted renewable teeth and so inclined as to suit the angle of repose of the stockpile material. Subtype Bridge type scraping reclaimer. Bridge type mounted bucket wheel reclaimer Bucket wheel reclaimer with slewing boom  

17. VERTICAL RAW MILL

18. RAW MILL After the stacking & reclaiming, the limestones are feed to mill for grinding. The most common equipment is Vertical Roller mill. The term “Vertical mill” denotes equipment with the following basic characteristics: A rotating, circular grinding table that turns around a vertical shaft. Spherical, cylindrical, tapered rollers (the grinding elements) that are pressed into (grooved) roller surface of the table. A source of pressure on the rollers (weight, hydraulic pressure, springs, etc.). A stream of gas flowing upwards around the table, entraining and drying the material. A separator mounted directly on the mill housing.

19. VERTICAL RAW MILL In Chittorgarh cement plant they are using VRM as raw mill to grind raw material like limestone,Sweatner,red orcher,laterite etc. It’s a Pfeiffer VRM. Vertical Raw Mill Capacity: Grinding Fineness: Product Moisture: Main Drive System- Motor Type: Power: Voltage: Speed: 400 TPH 90 µm ≤ 0.5% YRKK900-6TH 4600 KW 6.6 KV 995 RPM

20. PREHEATER Manufacturers CEMTEK GROUP LTD. PURPOSE- used for 5000t/d cement production line to preheat and decompose raw meal. The 5000t/d kiln preheater system with the tiff calciner. Its structure includes cyclone, air duct, discharge pipe, Calciner, feeding pallet in feeding chamber etc.   The preheater system consists of cyclone, air duct, discharge pipe, feeding chamber etc. R aw meals feed into the system from the inlet of the C1-C2 air duct With ascending gas flow, T he raw meal enters into the C1 cyclone through the air duct in this cyclone raw meal are collected by vortex, pass through the discharge pipe of C1, and enter into the C2-C3 air duct. There is a spread box in the outlet of the discharging pipe in order to make the material more disturbing in ascending gas flow. so the raw meal and gas flow can get sufficient heat exchange. The process of the other cyclones above for C4 is the same as stated above.

21. PREHEATER

22. ROTARY KILN

23. ROTARY KILN TECHNICAL DATA Diameter of kiln Length of kiln Slop Number of supporting device Capacity Rotating Speed Power of main drive Power of auxiliary drive 4.8 m 72 m 3.5% 3 6000 t/d Driven by main drive - 0.4 to 4 rpm Driven by auxiliary drive – 9.52 r/h 720 KW with 1500 RPM 55 KW with 1480 RPM

24. PYRO PROCESSING During this process raw meal material is converted to clinker. This requires a selected mixture of raw materials, at very high temperature, in a specialized kiln system. Fuel(coal, oil) is fired to sinter the raw material . Calcium(C), silicon (S), aluminum (A) & Iron (F) in raw materials react to form main clinker minerals. The phases in clinkers are- C3S-Alite or C3S contributes to early strength formation, Has a high heat of hydration C2S-Belite hardens slowly & contributes to later strength. It has a low heat of hydration compare to C3S.The content of C2S in low heat cement used for the castings of large foundations is high. C3A-It sets quickly and contributes to early strength but minimally to final strength . C3A also has a high heat of hydration. Higher concentrations of C3A can react with sulphate causing expansion and crack formation exposing more C3A leading to further penetration of sulphates. C4AF-imparts a dark colour to the cement

25. COOLING ZONE / COOLER Type Capacity Aerated area Stroke times Temperature of inlet Clinker Temperature of outlet Clinker TC – 12102 6000 T/D 119.3 m 3 15 ~ 18 /m 1450 65+ Ambient Temperature °c The cooler will  act as a source of hot air for the preheater and the rotary kiln . It will boost the clinker production line's thermal efficiency. At the same time, the clinker production line's energy consumption levels decline. It warms up air to generate waste heat power. Modern clinker coolers  have an air flow perpendicular to the clinker flow, absorbing thermal energy . This hot air is used almost entirely as secondary air for combustion in the rotary kiln, or as tertiary air to the tertiary air duc

26. COOLING ZONE / COOLER

27. GRINDING GRINDING PRINCIPLE   Two types of motions of balls do finish grinding in ball mills. First clinker is crushed by cascade motion of balls, which occurs in step liner zone then it is finish ground by attrition due to cataract motion of balls in classifying liner zone. This mechanism is depicted below.   FINISHED GRINDING Crushed Clinker is mixed with gypsum & fed into Cement Mill for fine size reduction. Gypsum is added to control setting time of cement. Circuit Types: Open circuit Ball Mill, Closed circuit Ball Mill, Roller Press with Ball Mill, Vertical roller mil circuit. Horro mill Depending on final Cement requirements Fly ash or Slag is added along with Clinker. Mostly the finish grinding of clinker is done by BALL MILLS. These are called ball mills because they have manganese steel balls of different sizes inside them.  

28. ROLLER PRESS Roller presses are mainly used as a pre-grinder for capacity increase. Specific energy for grinding is significantly reduced when used in conjunction with ball mills. Integral grinding with a high recirculation rate. Applies the concept of high-pressure transfer through a bed of material. Pressure across the bed has a compacting effect on material which is crushed and gradually reduces size Stability ensured by uniform feed control Can be utilized in various configurations Specific energy for grinding is significantly reduced when used in conjunction with ball mills.

29. ROLLER PRESS

30. ROLLER PRESS PARAMETERS- Output increases proportionally with: Diameter Length Speed of the press. Of course, there is also an influence by the- Profile of the surface, Rejects to RP and fresh feed, Moisture of feed to RP Material type

31. BALL MILL A ball mill is a type of grinder used to grind or blend materials for use in mineral dressing processes, paints, pyrotechnics, ceramics, and selective laser sintering. It works on the principle of impact and attrition: size reduction is done by impact as the balls drop from near the top of the shell.   Specification Capacity Power of main motor Rotating speed of mill Weight of grinding media Effective length Effective inner diameter Total weight 420 t/h 3550 KW 15.6 RPM 230 t 12.5 m 4.05 235 t

32. BALL MILL

33. PACKING AND DISPATCH Cement packing machine is a kind of cement equipment which is necessary for the production of bagged cement. It is mainly used to complete the automatic packing of cement and other powder materials with good fluidity, such as fly ash, gypsum powder, cement additives, etc. Most of the cement plants are using roto pakers these days for packing. After the packing in bags, it is sent to different area by trucks/railway transport .

34. PACKING AND DISPATCH

35. T HANK YOU….

36. A NY QUERY ?