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SWAMI PARMANAND ENGG. COLLEGE

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SIX WEEKS TRAINING REPORT

ACC LimitedGagal Cement Works

The ACC Ltd., [ACC] is the largest producer of cement in India with annual turnover of about Rs.24,000 million. It has a large operation with 11 marketing offices spread all over the country with a network of 8000 dealers. In addition to the domestic operations, ACC extends its services to various parts of the world including operations and management of cement plants.

GAGAL CEMENT WORKS

Gagal Cement Works a unit of the Associated Cement Companies Limited, has two unites Gagal I and Gagal II. Gagal I was set up in the year 1984 and Gagal II was set up in the year 1994. Clinker production of Gagal I is 2800 TPD and of Gagal II is 3300 TPD. The total annual capacity of the plant is around 2.2 million tonnes. Both units are located at BARMANA in District BILASPUR of H.P.

CEMENT

Cement is finely ground hydraulic binding medium for mortar and

concrete, consisting substantially of compounds of CaO with SiO2,

Al2o3 and ferric oxide which have been formed by sintering or

fusion. ‘Sintering’ means burning at a temperature which cause partial fusion of the material

The main component of cement

Fe2O3

Iron oxide.

Al2O3

Alumina

SiO2

Silica

CaCO3

Lime stone

THE CEMENT MANUFACTURING PROCESS

1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted from the quarry.

Quarry face

1. BLASTING 2. TRANSPORT

3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are transported to the plant by conveyor. The plant stores the materials before they are homogenized.

quarry

3. CRUSHING & TRANSPORTATION

2. TRANSPORT : The raw materials are loaded into a dumper.

crushing

conveyor

Next

dumper

storage at the plant

loader

THE CEMENT MANUFACTURING PROCESS

1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.

1. RAW GRINDING

Raw grinding and burning

2. BURNING

2. BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to make cement.

conveyor

Next

Raw mix

kiln

cooling

Back

preheating

clinker

storage at the plant

Raw mill

THE CEMENT MANUFACTURING PROCESS

1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary additives and cementitious materials can also be added to make a blended cement.

1. GRINDING

Grinding, storage, packing, dispatch

2. STORAGE, PACKING, DISPATCH

2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in bulk or in bags to its final destination.

Back

clinker storage

Gypsum and the secondary additives are added to the clinker.

silos

Home page

dispatch

bags

Finish grinding

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