SUBMITTED BY :GAURAV BOSE

INTRODUCTIONBirla group and the Indian

history are intertwined.Ghanshyam Dasji Birla, the

first of the Birla's was closely associated with freedom struggle.

BCW is a unit of mp MP Birla group of Birla corporation Limited.

The product “BIRLA PLUS CEMENT” is one of the market leaders and continuous to consolidate it’s leading position in the market.

BCW is one of the most modern cement plants.

ISO 9001:2001 and ISO -14001 Certifications.

MINESThe basic raw material required is limestone.

This limestone requirement of cement plant is met from captive mines.

Mining Lease of 760.692 hectare.

STACKER & RECLAIMER Linear luffing non-slewing type of stacker is

used. This makes roof type stockpile. Stacker can move to and fro on the rail by

means of motor. A control room for speed, boom distance and other activities.

LIMESTONE RECLAIMER (BRIDGE TYPE) Reclaimer we loosened the material of pile. Materials loosened by the harrows slides down the pile slope. At the base of the pile it is scrapped by the shovels of the scraper and carried away to the belt conveyor.

PARTS OF A RECLAIMER:Travel BogiesBridge GidersHead GidersScraper chain guideImpact tableHarrows

RAW & COAL MILLMaterial gets grind by VRM in powder form.VRM is ideally suited for combined grinding and

drying.Capacity : 300TPH (RAW MILL)

40 TPH (COAL MILL)

Main units of Mill sections are as follows:

Vertical Roller Mill Dy. Separator Bag house Bucket elevator Air slide & screw conveyors MAIN PARTS OF ROLLER MILL HOUSING ROLLER PAIR NOZZLE RING HYDRAULIC INSTALLATION DAM RING

STORAGE SILO

Silo consists of : Silo Material distribution Central chamber Outer chamber

SILO DETAILS SILO HEIGHT : 76 m SILO DIAMETE : 22m CAPACITY : 26,000 T

KILN SYSTEMMost essential part of a cement plant and has to be

operated continuously for as long as possibleThe major components of the kiln system are. Preheater Pre calciness Kiln Tube Clinker grate cooler The main function of the Preheater cyclone is the preheating of the raw meal, from outlet hot gases of kiln.Every stage cyclone performs the two functions. It heats up the raw meal in the gas stream. It separates the raw meal and discharges it via the meal chutes.

KILNThe rotary kiln consists of a steel tube with a length to

diameter (L/D) ratio between 10 and 38.The inclination of 2.5 to 4.5% together with a drive to

rotate the kiln about its axis at 0.5 to 4.5 revolutions per minute.

Kiln has these parts: Rotary kiln tube Supporting roller stations Kiln tyre Rotary kiln drives Rotary kiln longitudinal guide (Thruster block)

CLINKER COOLING & STORAGEGrate coolers are preferably used in modern installationsThe speed of cooling influences the ratio between the

content of crystalline & liquid phase in the clinker.CLINKER STORAGE PILE Capacity : 60000 MT

CEMENT MILL In the cement mill various equipment’s are used for various

purposes. In cement mill area we first mix gypsum in clinker and then effeminate the mixture to make cement.

WEIGH FEEDER BELT CONVEYORS

POLYCOM SEPARATOR

CEMENT MILL CARDAN SHAFT

BUCKET ELEVATOR CLINKER HOPPER

PACKING PLANT

The EEPL HAVER ROTO PACKER, is rotating valve bag filling machine for packing easy flowing powdery material and granular bulk material into bags with simultaneous weighing of the bulk material from 10 – 50 Kg.

Capacity : 180 tphNozzle Dia. : 55 mmSpouts No.s : 12

POLLUTION CONTROL EQUIPMENTBAG FILTERS cyclone

ELECTRO STATIC PRECIPITATOR

SAFETY Safety is utmost requirement for any plant because by taking proper

measures against accident we can increase the profit of company and can save manpower from injury.

ACCIDENT: Unwanted undesirable events which has potential to hit injury to a person or a loss of property”

CAUSE OF ACCIDENT: Unsafe act- 85-90% Unsafe condition- 10-15% UNSAFE ACT: UNSAFE CONDITION: Lack of knowledge No provision of safety

attachment Lack of attention Leakage of oil, water, steam etc Hurry Dust fumes & temperature Violating safety Condition of Ladder/scrapped/stair Overconfidence Worry, Lack of experience, Fatigue

Significant learning during the training period Three Cement Mill Shutdowns

One Raw Mill Shutdown

PROJECT (EXTENSION) AT A GLANCE