A

Vocational Training Report on

Overall Cement Manufacturing Process
At

Prepared by:
MILAV GOHIL

Roll No.: 18BCH035

Chemical Engineering Department
Institute of Technology
Nirma University
2021

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 CONTENTS

PREFACE

ACKNOWLEDGMENT

INTRODUCTION

COMPANY PROFILE & LOCATION

TYPES OF PLANT LAYOUT

RAW MATERIALS USED IN THE MFG. OF CEMENTS

TYPES OF CEMENTS

TYPES OF MFG. PROCESSES

PROCESS AND TYPES OF IMPACT MACHINES

WATER TREATMENT PLANT

LEARNING

CONCLUSION

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 PREFACE
Industrial training plays a vital role in the progress of future engineers. Not only does it provide
insights about the future concerns, it also bridges the gap between theory and practical
knowledge.

In this report, I’m going to describe my experience about the Internship period. It contains my
learnings about the equipment on industrial scale, professional behaviour required in industry,
importance of punctuality, improvement in decision making skill, stress management during
hard time etc.

As an engineer in the industry, he needs to have both practical and theoretical knowledge. With
increase in environmental issues every day, one needs to keep the emissions under the GPCB
and CPCB norms. As we from pilot scale to industrial scale, the risk level also increases same
fold. Different safety measures are taken in different equipment to minimise the risk or hazards.

As the raw materials obtained does not have same composition, so additives are added
accordingly to obtain the optimum composition. This skill improves with experience. After the
product is finished and obtained, it has to pass through QC (Quality Check) department. Once
it checks all the required parameters, it is then packed and sold in the market.

These 30 days internship has provided me an extensive experience of how things happen and
are carried out in industries. It has helped me understand the bridge that is built with time
between the theoretical and practical engineering. What we study in colleges is same and at the
same time different at industrial level. So, in order to be a better chemical engineer than others
than one needs to apply their concepts correctly at the required time.

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 ACKNOWLEDGMENT
I’m immensely grateful to Ambuja Cements Ltd for providing me the opportunity as an
Intern in the company. I’m really grateful to Mr. Naresh B. Gohil for their constant support
and guidance throughout the course of the internship.

I met wonderful people and professionals who guided me throughout the journey. Helped me
with various concepts and questions around the plant. Everyone was really helpful and
cooperative.

I would also like to thank

1. Mr. Shailendra Singh

2. Mr. Ishwar
3. Mr. Vinod Mehta
4. Mr. Paresh Trivedi
for making me understand each and every equipment and process thoroughly.

It was a great learning during this whole period. I look forward to put through these skills that
I’ve learnt. It’ll play a huge role in my career development.

Last but not least, I would like to thank Mr. S. S. PATEL, Head of the Chemical Engineering
Department, Nirma University for giving me the chance to enhance my knowledge in the
field of chemical engineering through this practical training.

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 INTRODUCTION
“Production” is the basic activity of all the industrial units. All other activities revolve around
this activity. We can say that production activity is nothing but the step conversion of one from
of material into another either chemically or mechanically. The end product of the production
activity is the creation of goods or services for the satisfaction of human wants. The production
activity is the process which the goods are produced or utility enhanced.

According to E Buffa,

“Production is the process by which goods or services are created”.

This department is situated in the CCR Building. The whole process is computerized, where
process operating persons closed monitor the whole plant operation from the visual display.
Computerized process system control with the field instrumentation ensures the steady &
smooth operation of unit. The whole process is displayed on the computer & any change of the
problem in the process is easily identified so that necessary step can be taken immediately.

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 COMPANY PROFILE AND LOCATION
Ambuja Cements Ltd. was earlier known as Gujarat Ambuja Cements Ltd. It is a company
which has been promoted by Gujarat Industrial and Investment Corporation Ltd., and other
promoters which is now taken over by world renowned HOLCIM group.

Ambuja Cements Ltd, a member of Holcim - global leader in innovative and sustainable
building solutions, is among the leading cement companies in India and is known for its hassle-
free, home-building solutions. Its unique products tailor-made for Indian climatic conditions,
sustainable operations and initiatives that advance the company's philosophy of contributing to
the larger good of the society have made it the most trusted brand in Indian cement industry.

Few noteworthy achievements by Ambuja Cements:

• Co-processed ~94,000 tonnes of plastic waste becoming two times plastic negative.

• The first company in India to use green fuel on captive ships. Ambuja takes a giant step
in reducing its carbon emissions by 25%.

• It has been 4 times water positive.

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 TYPES OF PLANT LAYOUT

There are 4 types of plant layout.

1. PROCESS LAYOUT
In this type of layout, all machines performing similar type of operation at one location.
In which, several products may be share a machine to make its full use. The process
rather than the product has the dominating role. This type of process is more suitable
for job order type of production.

2. PRODUCTION LAYOUT
In this type of layout, the machines are arranged in the sequence as required by the
particular product. This is also known as “The product Line Layout”. In this layout, one
product goes to all the machines lined up, in the mfg. required by its mfg. The product
is more suitable for continuous flow production with few items of production.

3. COMBINED/MIXED LAYOUT
Generally, pure process is not found in practice. So, a proper combination is made in
order to best suit the production process. A proper compromise reaping the benefits of
both is made possible in this type of layout.

4. JOB SHOP LAYOUT

In this type of layout, there is processing of job production & hence the system is very
flexible. The layout depends upon the analysis of the universe of orders received

RAW-MATERIALS USED IN CEMENT MFG.

1. LIME STONE
It is one of the raw-materials of the cement. As the company is situated at the place
which have a very rich resource of lime stone. All the requirements of lime stone is

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 full filled by the nearby mines, which is owned by the company itself. The lime stone
is transported from mines to the plant with the help of tractor/trucks.
2. GYPSUM
It is one of the waste products of chemical plant. Gypsum is added to the clinker &
grinded to from the cement. It is added to increase the settlement time of cement. It is
added to clinker in the ratio of 95:5.
3. SAND STONE/ SILICA
Silica is added to the cement to give the strength to the cement. It is generally
produced from the mines near the Chotila area
4. RED CLAY
It is one of the raw materials of cement mfg. It is produced from Nagesri, which is
nearer to Una.
5. FLY ASH
It is the waste product, which arises from the burned coal from the thermal power
plants. This is one of the raw materials of the cement mfg. It is produced from the
thermal power plants of Sabarmati & Jamnagar.

TYPES OF CEMENTS

There are mainly two types of cement given below.

1. O.P.C (Ordinary Puzzolona Cement)
• Fly ash is additionally about 10% to 20%.
• It increases its workability.
• It is not produced in the company.
• It is mainly used with plaster due to increased workability.
2. P.P.C (Portland Puzzolona Cement)
There are 3 brands/qualities of the cement production under these categories.

• Grade – 33
• Grade – 43
• Grade – 53

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 Company makes generally cement of Grade – 53. It is the quality normally sold by
the company.
Grade – 53 means that if 1m of cube of piece of cement kept in the water for 28 days
& after that it should be able to bear 53 mPa pressures & should not crumble up
according to std. British norms.

TYPES OF CEMENT MFG. PROCESSES

1. DRY PROCESS
In this process, raw materials are ground in dry state & raw meal is fed directly to the
burning equipment. The temperature of the exit gas from suspension preheater is about
550 to 575 K. Dust conc. in the exhaust gases leaving the kiln is generally 50-75 gm/Nm
cube. Resistivity of dust is also very high.

Multicyclones are used as a dust collector, which doesn’t not achieve prescribed
emission limit. So, kiln needs cooling prior to pass any dust collector. When kiln gases
are used for drying raw materials in the raw.

2. SEMI DRY PROCESS

In semi dry process, the raw materials are ground in the dry state but half amount of
water is required & the ground raw material is molded by addition of 10 – 22% of water
& fed to the burning equipment. The gas outlet conditions are suitable for the
installation of E.S.P. (Electro Static Precipitator). The gas temperature is about 100 –
150 deg C & the dew temperature is about 65 deg C. Fabric filters aren’t used as the
dust collector, for deducting the process as it causes problems of clogging of bags.

3. WET PROCESS
In this process, the raw materials are ground in wet state, so that the resultant slurries
consist about 40 – 50% of water which is fed to the burning equipment. The raw mix
grinding equipment & crushing equipment are different which are used in dry & semi
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 dry process. The kiln gas temperature is normally below the 450 K. Due to the waste
of water, this process is not more widely used in the modern cement plants.

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 PROCESS AND TYPES OF IMPACT MACHINES

1. MINING AND TRANSPORTING OF LIME STONE

Lime stone is mined from open cast quarry by conventional drilling & blasting method.
The blasted material is excavated by hydraulic excavator & loaded into the dumper having
the capacity of 35 MT. The dumpers carry the material to the crushing plant for size
reduction. Marl, a calcareous raw material is dug out by ripping as it very soft & loose.
Lime stone is also ripped by hydraulic ripper.

2. SURFACE MINER
Surface miner is the latest equipment used at locations close to agriculture fields &
villages. It cuts & then loads the scraped limestone into dumpers which carry the
material to the crusher.

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 3. IMPACT CRUSHER

Impact crusher is used to crush the material obtained from primary/secondary blasting to
the size which doesn’t exceed 90 mm. The crusher capacity is 600 t/p. But on avg. the
output works out to be 200-300 t/p. The crushed lime stone now 75 mm downgraded is
moved by series of conveyors for stacking.

4. STACKER

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 The modern stacker reclaimer is now used in most of the cement plants. The stacker is
used to stack the crushed materials in horizontal layers as it comes from the crusher in
the pre-blending yard for pre-homonizing.

5. RECLAIMER

Reclaimer is a bridge type portal scraper. Reclaimer cuts the stock pile across the width
of the stack in the process. It restricts the variation of CaO in the crushed lime stone to
less than 1% by minimizing quality variation in the raw-materials.

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 6. RAW MATERIAL HOPPERS

The above figure shows the raw material hopper. It then feeds the material from one
stock pile to via belt conveyor which in turn discharges the material into the raw
material hopper. As per the quality requirement, the materials from these hoppers are
conveyed to the raw mill on the belt conveyor equipped with the material flow diverter
at the hopper end.

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 7. RAW MILL
The raw-materials are fed to raw-mill by means of conveyor. The materials are ground

to the desired fineness in the raw mill. In the modern plants, the vertical grinding mills
are installed. Ground powder is blown upward by air. Fine particles are sent back again
to the raw-mill for further grinding & it improves the grain size distribution of the
cement particles.

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 8. PRE-HEATER

The most modern pre-heaters have five or six

stages. The temperature of the material fed from the
top is increased in stages from 573 K to 1500 K as
hot gas at temperature of 1273 K is blown against
the falling material. The material from the bottom
of the pre-heater is fed to the rotary kiln.

9. ROTARY KILN

The rotary-kiln is the heart of the cement plant. The length of the rotary-kiln is reduced
thereby resulting in saving of maintenance cost & power requirements. The kiln
revolves at the speed of about 3 rpm. It is lined with brick lining & is slightly inclined

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 away from the pre-heater to allow the heated raw-materials to roll down to the outlet.
The coal is then pulverized in the vertical coal-mill stored in the silo. The pre heated
raw materials roll down the kiln & get heated at 1575 K.

10.CLINKER STACKING YARD

The above fig. shows the inside view of the clinker staking yard. Clinker which gets
formed in the kiln is then passed from the cooling arrangement called ‘grate cooler’.
The clinker is passed from grate cooler till the temperature drops to 370 K. As the
clinker gets cooled, lumps are formed. A clinker crusher is provided at the end of grate
cooler to crush the larger clinker lumps.
Clinker from the clinker yard is then transferred by a pan conveyor to the hopper. The
feed from the hopper is then transferred to the belt conveyor & taken to ball mill. The
clinker ‘Raw Cement’ has tendency to flash set on addition of the water. So, small
amount of gypsum is required to be added before the final grinding.

11.CYCLONIC SEPARATOR

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 Closed circuit grinding is a process that actually ensures an even size of cement
particles, using the most scientific means. This is done by a device called a “High
Efficiency Cyclonic Separator” which controls the grinding process. The oversize
particles pass via several cones inserts into the grit collection from for recirculation into
the grinding process. After grinding, the cement is collected in the hopper.

12.BALL MILL

The cement mill contains chromium steel balls of various sizes which roll within the
mill & grind the mixture. After the initial grinding in the ball mill, the material is ready
for separation so as to arrive at the optimum particle size required. Closed circuit
grinding is a process that actually ensures an even size of cement particle, using the
most scientific means.

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 13.PACKING PLANT

The most of the modern cement plants have electric packing plants having provision to
account for the weights of empty bags of different types & to ensure a 50 kg net weight
of cement bags with in 200 gm. of limit. These bags are automatically discharged from
the packer onto the conveyor belts to different loading areas. The mfg. of the cement
packing bags made out Paper, P.P. (Poly Propylene), H.D.P.E. (High Density Poly
Ethylene). Cement is so also supplied in bulk instead of conventional packing in 50 Kg
bags.

WATER TREATMENT PLANT

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 WTP_Flow
chart_Diagram.xls
(Double click to expand)

The water treatment plant follows the process of Reverse Osmosis for the purification of water.
The water is obtained from the raw wells and different locations followed by pre-treatment, 1st
R.O plant, 2nd R.O plant, Deaerator and finally to boiler. The whole follows the method of Zero
Discharge System. The rejected stream is also utilised at various places which is explained
below.

PRE-TREATMENT OF WATER:

Multi-Grade Activated Carbon Softener (SF) Micron Cartridge

Filter (MGF) Filter (ACF) Filter (MCF)

• Purpose: • Purpose: • Purpose: •Purpose:

Removal of Removal of Removal of Removal of
suspended colour, odour, hardness suspended solid
impurities. free chlorine. causing ions impurities
• Media: • Media: • Media: •Media:
•Pebbles •Pebbles •Cation Na+ •5 micron
•Quartz •Quartz Cylex resins cartridge
•Mixed Sand •Activated
Carbon

Softener is filled with ion exchange resin (R-Na), capable of exchanging its sodium ion with
hardness causing calcium and magnesium ions.

These reactions occur during the softening of the water:

2R-Na + Ca2+ → R2Ca + 2Na+

2R-Na + Mg2+ → R2Mg + 2Na+

In continuous running of softener all the sodium ions of the resin (R-Na) get replaced with Ca
or Mg ions and resin get converted to R2Ca or R2Mg. In this condition the resin is said to be
exhaust.

1st R.O Plant:

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 The water obtained after pre-treatment is divided into three streams, 50% goes to 2nd R.O
Plant, 25% to soft water storage tank and remaining to Reject tank.

The 1st R.O plant consists of 3 high pressure pump which feeds the water to membrane
pressure vessel, where the reverse osmosis takes place.

The permeate water is stored in storage tank and the rejected water stream is sent to Zero
Discharge Scheme.
Pre-Tretaed Water

Mixed Bed Storage Tank

Membrane
HP Pump Permeate
Pressure Vessel
2nd R.O Plant
Membrane
HP Pump
Pressure Vessel
Membrane Zero Discharge
HP Pump Reject
Pressure Vessel Scheme

2nd R.O Plant:

The water here is obtained from 1st R.O Plant and it also follows a similar process.

The reject water is recycled to the raw water tank and permeate water is sent to the storage
tank.

Before finally storing into storage tank, the treated water is passed through Mixed Bed (MB)
where the traces of TDS are removed and Demineralised Water is obtained.

ION EXCHANGE METHOD IN MIXED BED:

Cation Exchange:

R-H+ + Na+ → R-Na + H+

2R-H+ + Fe2+ → R2-Fe + 2H+

Anion Exchange:

R-OH- + Cl- → R-Cl + OH-

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 R-OH- + SiO2- → R-SiO2 + OH-

H+ & OH- ions formed, combine to produce Water

H+ + OH- → H2O
Permeate (1st R.O Plant)

Membrane
HP Pump Permeate Mixed Bed Storage Tank
Pressure Vessel
Membrane
HP Pump
Pressure Vessel
Membrane
HP Pump Reject Raw Water tank
Pressure Vessel

ZERO DISCHARGE SCHEME:

Plant final discharged water is collected in the final reject tank & there after used for clinker
cooler in cement mills

Waste water discharge sources: -

1. MGF, ACF backwash discharge

2. Softener regeneration discharge

3. Mixed bed regeneration discharge

4. Cooling tower blowdown discharge

5. Boiler blow down discharge

ZERO DISCHARGE WATER PARAMETER: -

pH – 7.8

TDS – 1200 to 1400 ppm

Chlorides – 490 ppm

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 COD – 25 ppm

Sulphate – 60 ppm

WATER REQUIREMENT FOR CLINKER COOLER & FIRE WATER SYSTEM

Around 100 M3/Day in clinker cooler.

PHOTOS:

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 LEARNING
During this training, we learnt many things like –

• We learnt that Personality is our mirror, so develop the personality for required situation
& how to behave with the managerial person.
• How to manage time & do our work successfully. Time is important for our work, so
first give priority for our important work.
• We should do our work with adjustment in each & every situation.
• We learnt H.R. functions like requirement selection, placement, industrial relation, P.F.
training & development, manpower planning, safety, corporate social responsibility etc.
• How to do organization work.
• Prepare yourself for any kind of work & improve your self-confidence.
• How to make our carrier & duties regarding to the job, how to do work successfully for
this.
• Concentrate your mind on your own work.

CONCLUSION
In the industrial training of 1st June, 2021 to 30th June, 2021 in “AMBUJA CEMENTS
LIMITED”.
As a student of B.Tech. – Chemical Engineering, this vocational training helps me to
increase my knowledge and skills. In classroom, we only study the books but in the training
one can know that how to apply these theories in practice. So, this vocational training helped
me in gaining such knowledge of practical life.

The vocational training will help in future. Here I learnt many aspects like how to handle
the workforce, how to interact with workers and colleagues, how to plan about anything,
management of production procedure, etc.

During the training, I have got full co-operation from the managers, officers and workers
of the Ambuja Cement Ltd. And also, they provide their valuable time as well as precious
suggestions about practical business

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