REPORT ON

JAYPEE REWA CEMENT PLANT

From 17th May to 12th June 2010

Submitted BY

SHASHANK G.I.T. ,JAIPUR Roll no-07EGJME053

Acknowledgement

No significant achievement can be solo performance especially. It took many very especial people to enable it and support it. Here I would like to acknowledge their precious co-operation and express my sicere gratitude to them.

I greatly thank to MR. k. VERABABU SIR (G.M. of Mechanical at JRC) has been very supportive and helping. it was his support that helped to complete the project , he always made that we were provided everything we needed.

My sincere thanks to MR. R.G. NIGAM SIR (Senior GM of Mechanical at JRC) and Raja Ram sir, Devendra Sharma sir and L.D. Kalwani sir who are always available for their kind help. Finally I thank to all the operator and attendant who also help us in field.

Mr. k.Verababu sir

(G.M. of mechanical)Jaypee Rewa Plant Jaypee Nagar Rewa (M.P.)

With a single minded focus to pioneer a myriad of feats in civil engineering, shri jaiprakash gaur , the founding father of jaiprakash associates limited acquired a diploma in civil engineering in 1950 from the university of roorkee. After a stint with government of U. P. he branched off on his own , to start as a civil contractor in 1958 with the steadfast determination to contribute in nation building. This has been possible with the active support of his honest colleagues such as shri s. k. jain, shri n. c. Sharma, shri raj kumar singh, shri rajendra singh shri p.v. vora, s. p. joshi, shri g. p. gaur, shri p. k. jainand young Generation ably headed by shri manoj gaur and sunil k. Sharma.

Milestones:Jaypee Group:year 1958: Undertook first entrepreneurial work as contractor in

mangrol in Kota.

Year1979 : jaiprakash associates private ltd.(JAPL) formed.

: uttra rasayan udyog ltd. Was formed for setting up

malathion Technical plant in sikandrabad(U.P.), which was

changed as Jaiprakash enterprises ltd.

Year1980: Hotel siddharth was set up.

Year1982: Hotel vasant continental was set up.

Year1986: commissioning of 1st unit of 1 Mn TPA Jaypee Rewa Plant.

: formation of jaiprakash industries ltd(JIL) by amalgamating

JAPL into Jaypee rewa cement plant.

Year1991: commissing of 2nd unit of 1.5 Mn TPA Jaypee Rewa

plant(JRP) in District rewa (M.P).

Year1992: Formation of Jaiprakash hydro power Ltd (JHPL).

Year1995: Formation JAiprakash power ventures Ltd (JPVL).

: Hotel Jaypee residency manor set up.

Year1996: commissioning of 1.7Mn TPA Jaypee Bela Plant (JBP) in

Distric Rewa ,M.P

Year1999: Jaypee palace Hotel, Agra set up.

Year2000: Acquisition of land Jaypee Greens Ltd.

Year 2001: Commissioning of .6 Mn TPA Jaypee Blending Unit in district

Allahabad in u.p. , The first of it’s kind in the country.

: Jaypee institute of information technology (Deemed

University Since November 1, 2004) at Noida U.P.

Year2002: Commissioning of 1.0 Mn TPA grinding unit in district

Ambedkar Nagar in U.P.

: Jaypee university of information technolog (State

university), Waknagha set up.

Year2003: commissioning of 25MW capative Thermal Power plant-1

At JRP.

: Formation of Jaiprakash Associates Ltd (JAL) Formed by

Merging JIL with Jaypee cement Ltd.

Year2004: Commissioning of 25MW capative Thermal Power Plant-2

At JRP.

: Commencement of Work for setting up 3MnTPA cement

Plant at Baga& Baghri in District Solan in H.P. and 1.5 MnTPA

Year2005: Successful completion of upgradation scheme enhancing

The total capacity of “Rewa Operation” to 7.0MnTPa.

: Shares of JHPL Listed on bse/nse. First hydro power

company to be listed in the country.

Year2006: setting up of Madhya Pradesh Jaypee Minerals Corporation

Ltd. (MPJMCL).

: commissioning of 38.5MW capative Thermal Power Plant-3

At Jaypee rewa plant.

: Railway siding operational at Jaypee bela plant.

: commencement of work for setting up a new green field

1.5 MnTPA cement plant in district sidhi,M.P.

: Acquistion of cement plants & Assets of U.P. state cement

Corporation limited (in Liquidation) of 2.5 MnTPA capacity.

: Acquistion of Gujrat Anjan Cement Limited for setting up a

Green field cement plant of 1.2 MnTPA capacity Bhuj,District

Kutch,Gujrat.

Year2007: Signing of MOU With Gujrat Mineral Devlopment

Corporation(GMDC) for setting up a new green Field cement

Plant of 1.2 MnTPA capacity, in JV in District Kutch, Gujrat.

: Signing of MOU with Government of H.P, or seting up a new

green field cement plant of 2.o MnTPA capacity in District

Chamba, H.P. Mineral Development.

Introduction:

Jaypee Rewa Cement:- Jaypee rewa cement is sub division of Jaiprakash Associates Ltd. Jaiprakash Associates is one of the biggest construction company in india. Mr. Manoj Gaur is the Executive chairman of this company and its head office is in New Delhi.

Jaypee Rewa cement is single largest production Unit. Its annual production is about 3.3 Million ton. There are two units installed for the production of clinker namely U-1 &U-2 .

Unit-1: Supplied by Krupp. Plysious (Germany) . 1.5 million ton capacity was commission in dec. 1986.

Unit-2: Supplied by F. L. Smidth (Denmark) 1.8 million ton capacity was commission in April 1991.

Jaypee cement produce following type’s of cement with different brand name. it’s all products are very popular in the market.

Brand Name:

1.Master builder(OPC 43)

2.OPC53S/T40

3.JAypee cement(PPC)

Cement Manufacturing process

1-Mining: The cement manufacturing process starts from the mining of limestone , which is the main raw material for making cement. Limestone is exacavated from open cast mines after drilling and blasting and loaded on to the dumpers which transport the material and unloaded into the hoppers of limestone crusher.

2-Crushing Stacking & Reclaiming of Limestone: The l/s crusher crush the Limestone to minus 80mm size and discharge the material onto a belt conveyer which take it to the stacker via the bulk material analyser. The material is stacked in longitudinal stockpiles . Limestone is extract transversely from the stockpiles by the reclaimers and conveyed to the Raw Mill hoppers for grinding of raw meal.

3-Crushing Stacking & Reclaiming of coal: The process of making cement clinker requires heat . coal is used as the fuel for providing heat. Raw coal receive from the collieries is stored in a coal yard. Raw coal is drop on a belt conveyer from a hopper and is taken to and crushed in a crusher. Crushed coal discharge is stored in a longitudinal stockpiles from where it is reclaimed by a reclaimer and taken to the coal mill hopper grinding of fine coal.

4-Raw Meal Drying/Grinding & Homogenisation: Reclaimed l/s along with some laterite stored in their respective hoppers is fed to the Raw mill for fine grinding. The hot gasses coming from the clinkerisation

section are used in raw mill for drying and transport of the ground raw meal to the electrostatic precipitator /Bag house, where it is collected and then stored and homogenized in the concrete silo. Raw meal extracted from the silo(ne called kiln feed ) is feed to the top of the preheater for pyroprocessing.

5-Clinkerisation: Cement clinker is made by pyroprocessing of kiln feed in the preheater and the rotary kiln. Fine coal is fires as fuel to provided the necessary heat in the kiln and the precalciner located at the bottom of the 5/6 stage preheater. Hot clinker discharged from the kiln drops on the gate cooler and gets cooled. The cooler discharged the clinker onto the pan / bucket conveyer and it is transported to the clinker stockpiles/silp. The clinker is taken from the stockpiles/silo to the ball mill hoppers for cement grinding.

6-Cement Grinding & Storage: Clinker and Gypsum(for OPC) and also Pozzolana(for PPC) are extracted from their respected hoppers and feed to the cement mill. These ball mills ground the feed to a fine powder and the mill discharge is feed to an elevator, which takes the material to a separator, which separates fine product and the coarse the latter is sent to the mill inlet for regrinding and the fine product is stored in concrete silo.

7-Packing: Cement extracted from silos is conveyed to the automatic electronic packers where it is packed in 50 Kgs polythene bags and dispatched in trucks.

Mining

The major raw material for cement manufacturing is limestone. Limestone is excavated from open cast mines after drilling and blastin and loaded onto the dumper which is transported the material and unloaded into hopper of the limestone crusher.

Equipment Used in mining:

1. Compressor drilling machine.

2. Shovels/Excavators-for lifting material onto dampers.

3. Dumper- for carrying material.

4. Buildozers.

5. Payloaders.

Explosive:

1. Amonium nitrate(Fuel oil)

2. Nitroglycerine.

3. Amonium nitrate and slurry explosive.

Steps of Mining:

1. The first step of mining l/s the l/s has been located.

2. Limestone mining is to remove the mines.

3. The third step is to be taken as drilling.

4. After drilling blasting is done.

Drilling and Blasting:

1. The large hole blasting method is not pre-dominated in quarrying in open pit.

2. The depth of the holes are more then 12m and 100-150mm dia.

Lime Stone CrusherLime stone crusher is the lead role playing equipment in this section. The raw lime stoe is carried out from the mines is introduced to the lime stone hopper through hole pack dumper of capacity 32 tons. The feed inside the impact crusher first enters to the crushing chamber with help of apron feed encounters. The impact bars mounted over the rotor &revolving with the circumfrencial velocity of 30-40 m/sec. Material are blown bars and stick on a impact arm. Here materials are initially install to hold these grinding bars. The squire impact arm is install just behind the impact path and having 12 liners. When the material get crushed enough for transportation towards stacker. A bag house is also installed to control the dust loss and pollution control.

Equipment Used in Crushing:

1. Crusher.

2. Apron conveyer – for feeding l/s to crusher.

3. Bag filter – for collecting dust.

4. Belt conveyer- for transporting crushed material.

Material Inlet size =1-1.5m

Material outlet size=75-80mm

Technical Specification of limestone crusher:

Unit-1 Unit-2Capacity 650TPH 900TPH

Type APPM/1822 APPM/1822

Motor(KW) 780 1200

Rpm 1000 1000

Make L&T L&T

This section is worked with Following equipment:

1. Impact crusher.

2. Magnetic separator

3. Limestone stacker& reclaimer

4. Bag filtor

5. Apron feeded

6. Limestone hopper & laterite hopper

The important mode of transportation in this section is belt conveyer.

Main component of impact crusher:

Housing: housing of impact crusher is of studly steel fabricated and consist of three part.

Rotor: The rotor in the impact crusher is of s-type construction secured to the shaft by locking assembly. The blow bar are placed in to the rotor from the side and are secured against lateral moment by a suitable locking device at the extreme end. The rotor is dynamically arranged to avoide any undesireable stress on the bearing.

Blow bar: Blowbar is made from high quality alloyes steel. After the certain period in operation the blow bar can be taken out from the rotor and turned to other side or exchange.

Wear plates: housing is fitted with the resistance wear plates which are secured in position by special fastners which can be changed as and required.

Impact Arm: The impact crusher is fitted with the impact arm. The impact arms are each suspended in the housing parts by means of knock out spindle and can be adjusted the desire gap setting from out side.

Hydraulic system: Impactors are depend on their size normally supplied with a hydraulic arrangement for setting of gap for grinding path lifting of the rear top housing.

Magnaetic Separator: A magenatic separator is installed just above belt conveyer between crusher and stacker. When the magenatic material are comes along with limestone ,they get seprated by magnetic separator. In the magnetic separator a permanent magnet and a continually moving belt beinfin use.magnetic materials are

attached by magnet due to cont. rotating of belt , material get seprated on removal of magnetic field.

Gamma Matrics: A gamma matric analyzer being used for analyze the chemical composition of lime stone. It also known as cross belt analyzer. In gamma metric analyzer we are using specily gamma rays, the gamma rays are fall on material and return back, according to absorption rays in to material we can determine the chemical composition of lime stone .

Stacking Of Lime stone: There are two main method being used for stacking of lime stone in cement industry. They are……..

1. Chevron Method2. Windrow Method

Technical Specification of Lime Stone Stacker:

Make =MANTAKRAF

Capacity=1400TPH

Reclaimer:

Reclaimer which is used in our industry is bridge type scrapping reclaimer. The bridge on which the racking down device is mounted accommodates a scraper chain conveyer whose blades shift the dis lodged material along to collacting belt conveyer that extent along one edge of stackpile. Reclaimer having harrow assembly. Reclaimer moves on a track for fast travel A.c. Motor being used and for slow traveling d.c. moter being used. Harrow are moves to and fro motion on an rack

car which is driven by a motor. A limit sensor is installed for reverse and forword motion of harroe assembly. According to pile we can adjust the inclination of harrows. When harrows are moves they are scrap the material of each layer of stockpiles and material slides down due to gravity. A scraper chain take out the material and fed to belt conveyor material now get transported forwords limestone hoppers.

Technical Specification of Reclaimer:

Unit-1

Capacity =400TPH

Make =Bulkau walf(India)

Unit-2

Capacity =550TPH

Make =Cimmco(India)

Raw mill:

This section is working with the fine grinding of raw material up to 90 microne for proper burning & proper calcinations of raw material. Jaypee Rewa Plant have two raw mill. In Unit-1 krupp polusius mill has the capacity of 320TPH and unit-2 loesche mill has capacity of 440TPH installed for grinding of raw material. The mill are designed in a modular fashion and can be equipped as required with four rollers. Each roller together with rocker arm which is rigigly clamped the pedestal in whch the rocker arm is mounted and a hydro-pneumatic spring system represent a power unit.

Technical Specification of VRN unit-1:

Make Krupp polysius

Type LM K 54/27

Capacity 320 TPH

Classifire LNV

Gearbox RENK AG(2003)

Speed Ratio 990/23.53 RPM

Motor 3600KW(BHEL)

Feed Size 90mm+2%

Product Size 90micron -12%

Number of Rollers 2,In pair

Storage Silo C.B. Silo

Working principle of crupp polysius Mill:

The material to be grounded is feed to the roller via an air lock. It drops the material in to the rotating grinding table thus transport under the grinding rollers. The double groove grinding rand and the adjustable height dam rings cause formation of material bed. The crushed material is transported out words over the edge of table, caught in to gas stream escaping from nozzle ring and conveyed to classifier locating directly above the grinding chamber. Classifier is classifies the finished product , taling falls back in to middle of grinding table. Where as finished material is conveyed to esp by gas flow.

Grounded material falling through the nozzle ring is transported from discharge ring via an air lock in to recalculating bucket elevator. After passing through trap iron separator these return are passed back to grinding table via mill feed chute. Materisl of table is cast steel and interchanging grinding rings are made of wear resistance material. Grinding on material bed of grinding table which is rotate by motor and gear box. Each grinding roller is mounted on anty friction bearing on excel firmly clamped in to roller supports. The roller pair are guided bypins in corresponding guides on housing in such a way that they can move vertically and tilt about horizontal axis. This allows good adaptation to any changes in grinding bed height and means that the entire grinding area remains effective all time.

Raw Mill unit-2: Raw mill is one of the most important section of cement plant. In raw mill raw material is grounded enough to increase sufficient reactive surface area. So that,material can burn fasily.

The roller grinding mill can be delivered in various sizes. The characterization is described in smart form. For example:-LM50.40

In JRP vertical roller mill is used to grind the raw material. VRM consist of four roller, which on functioning rolls over a circular table. This table is rotated with the help of a shaft attached to motor.material is introduced from the top of the VRM. Material falls down on table,and on coming in b/w roller and table get crushed. Roller and table have some specified minimum clearance b/w them, any material of large size than that clearance gets crushed inside VRM. Rollers are hydraulically supported to exert specified force on material. Crushed material gets lifted with the highly pressurized air and is taken out through an outlet to ESP.

Technical Specification of VRM unit-2:

Make Loeshe

Type LM 50.4

Capacity 450TPH

Classifier LNV

Gear box MAAG

Speed ratio 990/26RPM

Motor 5000Kw/BHEL

Feed size 100mm+2%

Residue 18%on 90 micron

No of roller 4

Storage silo C.F. silo

Working of loesche Mill:

Raw material comes into raw mill from hopper through a belt conveyer via triple gate. The main function of triple gate is to prevent the entrance of falls air and to give air seales material flow. When material comes b/w rotor and roller they are crushed in to fine powder due to action of compression and alteration. Roller are hydraulically activated, a 65 bar pressure exerted by oil being used to operate the rollers. Hydraulic system is connected with rollers through connecting rod and rocker arm. Due to rotating of table, the material which is not crushed enough is rejected from mill and feed to reject bucket elevator through vibro feeder. Exit gasses from preheater and pre-calciners fed to raw mill via setting chamber to dry the raw material and to lift the fines the nuzzling velocity of air is 40-50 m/sec.

A classifier is installed just above the mill it classifies fines and course. Fineness of materials can be increased by increasing the speed of the classifier.

VRM is divided into three parts, they are:

1. Gas chamber.

2. Grinding chamber

3. Classifier

Gas Chamber—

In gas chamber, hot air from PC fan and PH fan enters lifts the material upward due to the counter flow. Material is taken to the cyclones by the air.

Grinding chamber— In grinding chamber, grinding of material takes place b/w four rollers and the rotating table. Material in grinding chamber is introduced from hopper by belt conveyer through triple gate.

Classifier— A classifier is the top most rotary part of the vertical roller mill. Here classification of material occurs. Fine particles pass through classifier and coarse particles are rejected and recycled for regrinding. According to the fineness required speed of the classifier rotor can be adjusted.

Electrostatic precipitator: Electrostatic precipitator the dust loaded gas to flow through the chamber usally the horizontal direction in which it passes through one or more high voltage electric from by alternate discharge electrodes and plate type collective electrodes.

Under action of the electric fields the dust particle which have become electrically change by the negative gas ion which are formed the discharge electrodes and attached them to the particle fly to the collecting electrodes and are deposited there the dust is rust from this electrodes by rapping and thus fall into the receive hopper at the base of the precipitator the electric charge acquired by the dust particle depend sustainability on their specific electric resistance in the lower range of opting temperature the specific resistance increase with rising temp as a result of diminishing surface couductivity.

Blending Of Raw Meal:The meal from the mill need storage and blending become different chemical composition of lime stone in different lot. They may vary the quality of lime stone.

Silo: Silos are huge construction of concrete and iron with aeration units to stone and blend the fine material such as raw material.

Continuous Blending Silo(C.B. Silo): It is suitable where sufficient degree of pre homogenization has take place.The raw meal is deposited in silo through several opening the actual blending take place during emptying of raw meal through the silo feed bins.

Continous Fluidize Silo: The raw meal is completely fluidized by admission of compressed air through the suitable inlets at the bottom of the silo. The air penetrates the mass of raw meal into the silo and reduces the inter particle friction forces. A circulatory motion is formed and thus homogenization is take place.

Preheater Tower:

As the name explains “Preheater Tower” is place to use for preheating the raw material. The material which comes from cf or cb silo. In other words preheater is a device in which heat transfer takes place fron hot

gases which comes from kiln due to counter current flow of material and hot gases. The raw mill is heated about 850oc before it enter it the kiln preheater with calcined system is most economical and hence the length of kiln is reduce preheater in Unit-1 and five stage in unit-2 with separator line calciner. These suspension preheaters are work in kiln string & pyro string with pre-calciner string successfully.

Reaction occurs in pre-heater:-

Temperature – range Type of Reaction100-300oc Loss of water

400-600oc Removal of inherent gases

500-600oc Structural change in silicate phase

600-850oc Dissociation of carbonate

Main part of suspension Pre-heater:

1. Cyclone: The cyclone is use for separation of raw meal from gas flow. For improving the separating efficiency of cyclones of top most preheater stage. We have designed as double separator.

2. Gas Duct: The gas duct are to join the individual cyclone stages to each other. The raw meal coming from next higher stage end in the gas duct underneath. The raw meal particles are entering by the upward flowing gas stream and taken to the next cyclone. The heal exchange is achieved by con-current flow. The gas ducts b/w stage 1 and 2 consist of the cylindrical suction.

3. The Double Flow Box: These are used for raw meal pipes in preheater system the flaps are consist in such a manner that a minimum flow of raw mill is always maintain. The full material causes a upward and downward moment of the pendulum flaps and thus and upward and downward rocking motion of the lever arm with counter weight penetrating the single flaps. The upward and downward forces of flaps is remains constant.

4. Raw Material distributor: It is integral part of raw meal ducts and spits a downward flowing stream of raw meal in to raw

meal duct. Basically the distributor has a two fold function.

Calciner:

The main purpose of the precalciner is to let the calcinations process take place out side the rotary kiln. It causes in sufficient reduction of thermal load of the kiln burning as approximately 60% of total fuel is burn in to calciner. This has made possible to increase the production in the given size to about double compared to a conventional dry process kiln with suspension preheater.

The calciner consist of a vessel lined with heat resistance bricks.Calcine has three inputs and one output.

Input-

1. Fuel as Pulverized coal.2. Preheated material to approx 800oc3. Hot gases from kiln/coolers at 800oc

Output-

Hot gases including combustion products and co2 from the calcinations process and material in form of dust carried with the hot gases.

Technical specification of Precalciner:

Coal firing 60%

Temperature 1000oc

Calcination 95%

Burner 2 nos

Burner capacity 20TPH

Amount of coal fire 18TPH

Rotary kiln: Kiln is cylindrical rotary equipment rotating on supporting rollers at about 3.5 RPM. Discharge in its completing calcinations reaction. Firing is done from kiln outlet with the help of burner pipe.

Technical specification of Rotary kiln:

Unit-1 Unit-2Make Krupp Polysius FLS

Precalciner SLC SLC

Diameter 4.4M 4.75M

Length 65M 75M

Capacity 4500TPH 5500TPH

Rpm 4.0 3.8

Burner pipe Duflex Swirlex

Slope 3.5oc 4.ooc

Fuel Used Coal/pet coke Coal

Thrust roller Hydraulic Hydraulic

Thermal Load 14.07 14.44

Supporting Roller 6nos 6nos

Construction:

a. Kiln inlet (consist seal, grease pump, lines, cylinders etc)

b. Girth gear(Gear, pinion, spray system)

c. Thrust roller(Hydraulic cylinder, oil line)

d. Supporting roller& tyre(Consist of bearing, chair plate, bolts etc)

e. Kiln outlet seal(s.s shims, crown shell, seal)

f. Burner pipe(consist of air pipe, coal pipe, diesel pipe etc)

Kiln inlet: Kiln inlet is seated by sealing arrangement. Greasing is done by pneumatic pump seal. It consist of 10-14 segment so it can be mounted and disassembled from kiln inside. A conical section forms an extension of the inlet ring. A brick retaining ring has been mounted at the end of conical section.

Girth Gear: Kiln is rotating by Gear – pinion arrangement. Girth gear is mounted on kiln with the help of spring plates.

Thrust Roller: The function of thrust roller is to control axial moment of kiln in both upward & downward.

Supporting Roller & Tyre: Supporting roller are for support of kiln. They are in contact with tyre which are fitted in kiln shell.

Kiln Outlet: There is a sealing arrangement in kiln outlet.

Burner Pipe: It is for firing of fine coal into the kiln. Air is controlled by damper and fine coal by solid flow meter. Duplex type of burner is used in kiln unit-1 and swirlex type burner is used in kiln burner unit-2.

Kiln cooler: Technical Specification of Grate cooler:

Type Folax

Make FLS(Germany)

Capacity 5500 TPD

Size 37.8m length*5.1m width

No. of gates 4 nos

No. of cooling Air fan 11 nos

Clinker cooler has two main function to perform. They are:-

1. To cool the hot clinker quickly.2. To provide necessary air for burning of coal in precalciner and kiln.

After introducing of red hot clinker into the cooler, mechanically driven gates moves it to the rear end of cooler. Three pair of gates are installed inside the cooler. A single pair consist of fixed gate and movable gate. Too and fro moment of movable gate pressurized which cools it quickly.

Clinker cools down gradually as it moves, due to the air blow by the fans which is taken from the atmosphere. Air falling over clinker is highly pressurized which cools it quickly.

Clinker escaping out of the cooler is fed to a hammer crusher, since lumpy material requires crushing. Crushed material is transported to clinker silo through deep bucket conveyor. Temperature of clinker escaping out of cooler is about 208oc.

Grate Cooler operation:

The grate cooler operates with a cross current principle in which the clinker is moved across the grate while cooling air blow in from below through the grate and clinker layer. The hot clinker falls from kiln and forms clinker bed on he grate and transported through the cooler over alternatively fixed and reciprocating grates. At the inlet of first great clinker is quenched and spread evently across the cooler width by the increased cooling air. The grate is fabricated to be as possible to obtained a thick clinker layer and a uniform distribution of air through the clinker bed in the interest of heat recovery.

During the clinker transport from the cooler a part of dust and small size clinker is falls from the grates and collcted into hoppers under the grates. The drag chain and rotary air lock system fed these clinker and dust in clinker transport system. A dust collection ESP is also installed beside the cooler known as cooler ESP. Exhaust gases from collection is fed to the ESP for dust collection.

Grate cooler consist of:-

Cooling grate Plates Standard Plates Cooling housing Drive unit Grate aeration system Clinker crusher Conveying unit(DBC) Cooling fan

Hammer Crusher: In discharge of cooler hammer crusher is provided consisting of a rotor with shaft. Hammer are mounted on each row. Hammer are casted made of high chrome or manganese steel. Clinker is crushed to size 15-25mm by hammer crusher.

Coal Mill:

The raw mill is grounded dried swept away by fan through the separator to bag filter or ESP. finally it is stored in to the fine coal bin

hot air for coal mill is supplied by cooler exhaust hot gases or preheater outlet gases before GTC circulation. The function of coal mill is to ground suitable grate coal and for feeding the same in to the kiln and calciner in fluidized form. Coal from stock yard is fed for stacking and reclaiming in to the stacker and re-claimer. Pre-homogenized raw coal is feed in to the coal mill hopper with the help of belt conveyer. The raw is then fed to the coal mill VRM via weigh feeder, drag chain and screw conveyer.

Technical Specification of Coal Mill:

Unit-1 Unit-2Make Krupp Polysius Loesche

Type RM K 25/12 26.3

Capacity 35TPH 55TPH

Gear box MAAG MAAG

Motor(Kw) 700 750

No. of roller 2 in pair 3

Important Parameters Of Coal:

Residue on 90 micron=18-20% Residue on 212micron=0.4-1% Moisture =1.5% Volatile Matter =20-30% Ash content =28-32%

Coal Mill Classifier:

Unit-1 Unt-2Make LNV LNV

Gear Box Sew MAAG

Input rpm 1480 1500

Motor(Kw) 37 50

Coal Mill:-

Coal Mill is an important integral part of cement plant. Here large size of approx size 600mm, is ground fine to the size of 90 micron. Coal from coal mill is used to feed kiln and calciner. Outlet tem of coal from coal mill is different in different seasons. It is 70-750c in dry season and 80-840c in rainy season.

Coal from mines is initially crushed at crusher site. Coal is then sent to stacking making mixture homogenized. Reclaimer picks up the coal and coal is fed to the coal mill hopper through belt conveyer. Coal taken out from hopper is feed inside VRM with the help of a screw conveyer which is mounted just below the hopper. Coal inside VRM is grounded between roller and table.

Hot air from cooler ESP fan is taken inside VRM and is used for drying of coal. Fine coal from VRM moves to the cyclone, where most of the coal is separated from air and the coal which does not get collected due to ultra fine size is separated with the help of ESP.

LV separator is for separating coarse and fine particles.

Now, coal is fed to screw conveyer through rotary lock, which transport it to the FK pumps. Two FK pump delivers material to the storage bins.

There are two Storage bins, They are:-

1. Kiln Bin2. Precalciner Bin

Fine Coal is then transported to the kiln and precalciner by kiln firing FK pump and precalciner FK pump respectively.

Coal Mill(Unit-1):-

The material to be grounded is fed to the roller mill via weigh feeder and drag chain. It drops the material in to rotating grinding table thus transport under the grinding roller. The double groove grinding rand and the adjustable height dam rings cause formation of material bed. The crushed material is transport out ward over the edge of table, caught in to gas stream escaping from nozzle ring and conveyed to classifier locating directly above the grinding chamber. Classifier is classified the finished product and tailing. Tailing falls back in to middle of grounding table. Whereas finished material is conveyed to bag filter by gas flow. The reject of mill is fed towards the reject side and removed manually.

Grinding is performed by total of two rollers, combined into two roller pair and rolling on material bed of grinding table which is rotating by motor and gear box. Each grinding roller is mounted on anti friction bearing on an excel firmly clamped in to the roller support. The roller pair are guided by pins in corresponding guides on housing in such a way that they can move vertically and tilt about horizontal axis. This allows good adaptation to any changes in grinding bed height and means that the entire grinding area remains effective at all time.

Coal Mill(Unit-2):-

Raw coal comes in to coal mill from hopper through a drag chain and screw conveyor the entrance of fails air is avoid to give air sealed material flow .when material comes between rotor and roller they are crushed in to fine powder due to action of compression and alteration . Roller are hydraulically activated ,hydraulic system is connected with rollers through connecting rod and rocker arm .Due to rotation of table ,the material which is not crushed enough is reject and remove manually .Exhaust gasses from cooler is fed to the mill for the drying and lifting of fine coal.

Fine material is then classified by classifier located directly above the table oh mill .Fines are then fed to the cyclone separator for separation of fines from contaminant gases ,and tailings are fall back on the table for further grinding ,Maximum separation takes place in the cyclone and the ultra fine material is get separated by ESP ,Now, coal is fed to screw conveyor through rotary lock ,which transport it to the FK pumps .Two FK pump delivers material to the storage bins.

1. Kiln bin

2. Precalciner bin

Classifier:

A classifier is the top most rotary part of the vertical roller Mill . Here classification of materials occurs .Fine particles pass through classifier and course particles are rejecter and recycled for regrinding. According to the fineness required speed of the classifier rotor can be adjusted.

Cement Mill:

In this section the clinker exerted from clinker silo through belt conveyer fed to the ball mill along with fly ash and gypsum to grind in powder form. For making OPC clinker grind along with gypsum and for PPC clinker is grounded along wiyh gypsum and fly ash. The homogenized product of cement mill is stored in to the specified cement storage silo.

Technical specification of Cement Mill:

Cement mill-1 Cement mill-2 Cement mill-3 Cement mill-4

Type Compound two chamber ball mill

Compound two chamber ball mill

Compound two chamber ball mill

Compound two chamber ball mill

Speed 15.85RPM 15.85RPM 14.8RPM 15.0RPM

Capacity 110TPH 110TPH 150TPH 120TPH

Motor 2400Kw 2400Kw 3000Kw 5000Kw

Separator

Type o-sepa o-sepa o-sepa o-sepa

Drive 225kw 225kw 300kw 250kw

Process:-

The material to ground is extracted in certain portion from storage hopper, this mixture is uniformly fed to the mill by means of feeding device. Feed material enters the first grinding chamber of ball mill through the inlet device.In this chamber the material is pre-crushed due to catering action of grinding media, the pre-crushed material flow through a slotted lifter wall in to a fine grinding chamber where it is ground in to end fineness. The material flow through the slot of lifter wall in to discharge device.

The air sucked through the mill by the fan serve for material transport aeration and hence for cooling of grinding chamber. It contains a considerable amount of fines therefore, the dust laden gases is handle to the dedusting plant (bag house of ESP) via a pre separator called multi cyclone. Pre separator material is led together with the lifter dust to the finished mill product. It is mixed and handled as end product to the finished cement storage silo.

Cement Mill: Cement Mill(Ball Mill) consist of mainly:-

A rotating Steel cyclone shell cylindrical shell supported at both ends on turn-on/slide shoe bearing.

Liners for protecting the inside surface of the shell.Diaphragrms for driving the mill into two or more compartments.Grinding balls.Mill cooling system.

Details of Liners:

The line which protect the shell from wearing action of clinker and additives, also help in the grinding process.

In the second compartment ”classifying” liners are used which help to segregate the grinding media according to it’s size larger balls towards the compartment. Small balls towards the discharge end.

Diapharagms: Mill diaphargms are provided with slots through which material and venting air pass from 1st compartment to 2nd

compartment.

Grinding Media: The mill chambers are partially filled with steel ball having diameter ranging from 90mm to 60mm in 1st compartment and from 50mm ball to 17mm ball in 2nd compartment.

Heat Generation:

During grinding heat is generated in the mill which if not controlled would raise the temperature and effect cement quality.

The grinding heat is dissipated by injecting atomized water in the mill chamber which on evaporation cools down the mill to acceptable.

Dynamic Separator: Material is fed in separating disc in the separating chamber inside dynamic separator. The spread material is divided into grift lines by a recirculating air current built by a fan fall on inner core. Fine particles get separated from reconciliatory air. Counter vanes with adjustable length are fitted above the separator plate to control the fineness of particles. The fan separator disc and

counter vanes can be driven by single drive. The separator is preferred for coarse separation due to the lower specific consumption.

Size of Ball charges In Chambers:

Ball Size in 1st Chamber Ball Size In 2nd Chamber90mm 50mm80mm 40mm70mm 30mm60mm 25mm

20mm17mm

Amount of Ball chargers in Compound Mill:-

First Chamber:

90mm=17.5 Tons80mm=21.0 Tons70mm=17.5 Tons60mm=13.0TonS Total=69.0 Tons

Second Chamber:

50mm=13.0 Tons

40mm=15.0 Tons

30mm=16.5 Tons

25-17mm=120.5Ton

Total=165 Tons

o-Sepa Air Separator:

It gives sharp classification and save energy in grinding process. The material is introduced to the o-sepa air separator which is then directed on the dispersion plate. The plate is located on the top of rotor by feed clutch. The material is then distributed by centrifugal force in the angular gap b/w rotor and guide vanes it is then followed by buffer plate which is directed the material into the center or rotor. It exit the separator through outlet duct located on the top. The reject are collected in bottom and are discharge through a wall locating at the bottom.

There are three location for air flow to the separator, the primary air comprises mill bent and ambient air, inters through the inlet path in to the separator, secondary air comprised of bent air from equipment in guiding unit and ambient air inters the separator through the separator opening. Both primary and secondary air create a vertex in separating of the separator. Fine particles which are discharge in to the hopper are also classified by tertiary air. Rotor speed can be adjusted by the variable speed drive motor. O-sepa air separators are highly efficient they classifies a higher proportion of feed particle in to product and reject.

Sepol Air separator:

This type of separator is of single rotor type and was developed by F.L. Smidth. Its design is simple, compacting and highly efficient. The material is fed in to the separator from the mill in to an upward flow of air duct below the separator this results through dispersion of material. Proper dispersion of material is very important for obtaining the high separating efficiency. Suspended material flows into the separator via vertical guide vanes which maintain the uniform velocity and distributing of material. Guide vanes are also serves as collecting plates from coarse material reject from the rotor coarse fraction falls back into the reject cone from where it is discharge

through the opening. The fine or finished material leaves the separator with the flow of air and is collected in cyclone or in bag filter.

Air entering at the bottom of sepol air separator can either fresh or dust loading and it permits any degree of recirculation. When fresh air is used. Fines and tailings are cooled down to 70-75 deg. There by reducing mill cooling requirement, the complete dispersion of material is riser duct combined with uniform distribution of air not only gives high efficiency but also produces low degree wear on the separator internal liner.

Packing Plant:

In this section the cement is extracted from several cement silos and fed to the rotary packer for packing in to the bags. The weight of each bag is 50kg.

Process:

There are six silos in JAYPEE REWA PLANT. Each silos heaving specified type of cement. Cement is extracted from silo at eight aeration fluidized points, there are 2-3 air slides are installed below each silo for transportation of cement in to packet bucket elevator. The cement from silo through air slides fed to the bucket elevator. Cement is then passes through the vibratory screen, these screens are used for retaining the over size material and reject it because the over size material is harm full for roto packer cement which passes through the screen comes into storage hopper above each packer.

This hopper having minimum and maximum level indicator. A rotary feed valve is used to control the material level in packing machine. Cement is now fed to packer hopper and then to packing machine and spillage hopper is installed to collect the return of cement below the roto packer.

Technical specification of Rotary Packers:

Old Packing Plant:-

Packer-1 Packer-2 Packer-4 Packer-3RPM 4.5-5 4.5-5 4.5-5 4.5-5

Capacity 80-90TPH 80-90TPH 80-90TPH 80-90TPH

Spout 6 6 6 6

Make EEPL_HAVER EEPL_HAVER EEPL_HAVER EEPL_HAVER

New Packing Plant:-

Packer-5 Packer-6 Packer-7RPM 4.5-5 4.5-5 4.5-5

Capacity 100-120TPH 100-120TPH 100-120TPH

Spout 8 8 8

Make EEPL_HAVER EEPL_HAVER EEPL_HAVER

Major System in A Roto Packer:

Bag Holding and Release System:-a) Bag chair cylinder- After releasing of a bag from spout as

spout advances, towards the operator the bag chain cylinder operators and the bag chair cylinder operates and bring the bags in position. When targeted 50kg weight is

reached this cylinder causes tilting of bag chair and bag discharge on belt conveyer.

b)Bag Holding cylinder- When a bag is applied on spout bag holding cylinder ,cylinder holds the bag in position. It holds the bags till target weight is being achieved.

c) Limit Switches:- Each spout has two limit switches one for sensing the position of spout before discharge on belt and other for sensing the position of spout after the bag are discharge.

Electronic Weighing System:- The electronic weighing system is provided is to measure the weight on bag chair with the help of load cell and also perform various logic control. This can give various facilities like counting of bags and totaling of weight etc.

Working Of Roto Packer:

The cement is discharge by the impeller through the filling spout in to the bags standing on saddle, which is guided parallel by the road. The load is transmitted from the saddle through the tension rod to the equal arm weight beam comprising two levers inter connecting by cross piece. The weight box is suspended from weight-beam. The damper’s function only when the left arm of weigh beam is descends. For quickly cutting of feed flow when specified filling weight has been achieved. The upper flange of the cross piece causes the small weight to tilt the spring on the damper assist this action. On removal of load the right arm of weight beam is rises, this action is done again and again to fill the cement in to the 50kg bags.