jaypee cement project report

7/29/2019 jaypee cement project report

1/29

DRONACHARYA COLLEGEOF ENGINEERING

Greater No ida

Presented By

Sandeep Kumar


2/29

Manu factu r ing Process Of Cement


3/29

CONTENTS

Manufacturing Process Of Cement (a) Mines

(b) Blasting

(c) Transportation

(d) Crushing and transportation

(e) Raw Mill

(f) Raw Mill Silo

(g) Preheater

(h) Rotary Kiln

(i) Cooler

(j) Clinker Silo

(j) Gypsum Mixing Tank

(j) Cement Mill

(k) Cement Mill Silo

(l) Packing Plant


4/29

CEMENT MANUFACTURING PROCESS

Quarry face

loaderdumper

1. BLASTING2. TRANSPORT

crushingconveyor

storage at

the plant

3. CRUSHING & TRANSPORTATION


5/29


preheating

kiln

coolingclinker

2. BURNING

storage at the

plant

conveyor

Raw mill

Raw mix

1. RAW GRINDING


6/29


clinker

storage

Gypsum and the secondary additives are added

to the clinker.

Finish grinding

1. GRINDING


7/29


silos

bags

dispatch

2. STORAGE, PACKING, DISPATCH

clinker

storage

Gypsum and the secondary additives are added

to the clinker.Finish grinding

1. GRINDING


8/29

1.MINES

1.MINES:-It is the area which is required for the extraction ofthe limestone,done by the mining engineers.

Usually this mines is spread over a large area.

Mines


9/29

2.BLASTING

2. BLASTING :-The raw materials that are used tomanufacture cement (mainly limestone and clay) are

blasted and extracted from the quarry or mines.

Mines

loader


10/29

5.GRINDING THROUGH THE RAW MILLS

Ball mills is used for grinding the raw material (lime stone) in to

small particles of 90 micron size. Ball mills consist of three chambers.

(a) Dry Chamber- Moisture is removed from the raw material by passinghot air.

(b)1st Chamber- Consist of balls size varying from (60mm to 90mm).

(c)2nd Chamber- Consist of balls size varying from (25mm to 50mm).

Ball mills consist of two diaphragm.

(a) Intermediate diaphragm b Dischar e dia hra m.

Raw mill

conveyor


11/29

BALL MILL SPEED

Vcrit: critical speed balls stay on the mill wall due to centrifugal force

NO GRINDING POSSIBLE!

i

crit

D

42.3

V

Vmax: maximum speed circa 75% of the criticalspeed

i

max

D

31.7V

Di = diameter inside liners


12/29

RAW MILL OR BALL MILL


13/29

INTERMEDIATE DIAPHRAGM

adjustable lifters

diaphragm segment

cone

slotted plates


14/29

DISCHARGEDIAPHRAGM


15/29

6.RAW MILL SILO

6.SILO:-Raw mill silo is a cylindrical building usedfor storing the grinded raw material in huge

amount,before feeding it into the peheater.

In K# 4 unit of the dalla cement factory two silo is

used,having height about 75m.

Blending Capacity- 1500tn

Storing Capacity- 3000tn

Each Silo having two parts

1-Blending (Top),2-Storage(bottom)


16/29

SILO


17/29

7.PREHEATER

PREHEATER:-Preheater is used for preheating and calcination ofthe ground raw material,before feeding it into the kiln.

In K#4 unit four stage preheater are have been installed.

Preheater is also used to increase the thermal efficiency of the hot gases

and calcination of the lime stonewhich is fed in powder form.

No. of preheater are inversely proportional to the length of the kiln.

Capacity of the plant depend upon the no. of pre-heaters stage and size

preheater


18/29

SINGLE STAGE

PRE-HEATERS


19/29

8.ROTARY KILN

KILN:-Kiln is used for making clinker after 60-70% calcinationin preheater section which is directly connected to kiln inlet

In k#4 unit,kiln is inclined at 3% of the kiln length which is 68m

long and 4.3m dia.

Capacity of K#4 kiln is 1500TPD.

The temp. at the inlet of the kiln is about 1000C and at outlet is

about 1350C.

kilnclinker


20/29

ROTARY KILN


21/29

COOLER:-Cools the hot clinker falling on it from kilnfrom 350 degree to 120 degree.

Cold atmospheric air is blown through the duct fan on

the slow moving bed,having reciprocating grates onwhich hot clinker falls and get cooled.

After cooling the clinker from 1350C to about 200C andit is carried out through the cooler.

9.COOLER

cooler

clinker


22/29

COOLER


23/29

10.CLINKER SILO

CLINKER SILO:-Silo is the storage cylindrical tank ofabout 60m height in which the cliker is stored and transported

by the convyer belt to the silo.

Blending capacity-No. blending is needed.

Storing capacity-14000tn

conveyor

clinker

storage


24/29

11.GYPSUM MIXING TANK

After carrying out the clinker from the silo through the air slide

gypsum and secondary additives is added to the clinker.

Gypsum plays an important role in the setting time of the

cement,it decreases the setting time of the cement and

becomes easier to work with the cement.

conveyor

Gypsum is added to the clinker.


25/29

12.CEMENT MILL

Ball mills is used for grinding the mixture of cliker,gypsum andother additives.

Ball mills consist of three chambers.

(a)1st Chamber- Consist of balls size varying from (90mm to 60mm).

(b)2nd Chamber- Consist of balls size varying from (50mm to 40mm).

(c)3rd Chamber- consist of balls size varyingfrom(30mm to 20mm).

Ball mills consist of two diaphragm.

(a)Intermediate diaphragm no.1

(b) Intermediate diaphragm no.2

(c) Discharge diaphragm.

Cement millconveyor


26/29

CEMENT MILL


27/29

13.CEMENT SILO

CEMENT SILO:-After grinding the mixture of clinker andgypsum into fine powder,cement is manufactured and stored in

the silo.

In k#4 two silo are in use,having height about 70m.

Capaci ty s ingle si lo -3500tn

Total capacity -7000tn

silo

s

14 PACKING PLANT


28/29

14.PACKING PLANT

Now at the last cement from the silo is carried out to

the packing plant through the air slide and is packed in

the polyster bags and loaded to the trucks using

packing machine, belt conveyor , truck loader andtrains,send to different parts of the country.

bags

Jaypee Cement


29/29

THANK YOU

jaypee cement project report

Documents

Transcript of jaypee cement project report