AMBUJA PPT

DARLA GHAT SOLANSUBMITTED TO :Er. BEANT SINGHH.O.D. of Mechanical Deptt.SUBMITTED BY :PAWAN KUMAR SAHROLL NO. 100531131316BRANCH : M.E.-8th SEM.BATCH : 2010-2014.

INTRODUCTIONAmbuja Cement Ltd. (ACL) was established at Darlaghat, Village-Suli, Tehsil Arki, district Solan, in the year 1994. The plant is located 45km.from Shimla & approx 2km. from Darlaghat. As India is the second largest producer of cement in the world. This cement industry is one of the few industries in India to achieve global competitiveness. The Cement industry matches world standards on all parameters. The quality of cement compares with internationally accepted Britain & American standard. Also companies productivity, energy efficiency & Environment standards among the best in the world. The company starts its Commercial production in 1995 having a rating capacity of 1.5 to 2 million tones per annum, now around 2.5 million tons per annum. The company has always maintained the corporate philosophy of sustainable development. The company has been adjusted the best & the most effective mines in its area by Indian Bureau.

PROCESS MACHINELimestone mining Mine PlantCursing CrusherGrinding Raw millHomogenization CF SiloPre-heating Pre-heaterBurning KilnCooling CoolerStorage + add Gypsum Clinker SiloGrinding Cement MillStorage Cement SiloPackage Packaging PlantDispatch Dispatch Machine(By road or sea) Details of Process)1 Lime stone stockpile40

Details of Process)1 Lime stone stockpile40The most and important for cement and clinker is limestone, at about80% part in finished product. Those types of basic raw material are requirement that ishalf more than finished product means if 100-tons cement required, than 150-tonslimestone required.gcw have their own mine for limestone. There mine plant is 3 kmaway from the mail production plant all material is reach at plant through belt conveyor.2) CrusherThe limestone find from mine. After mining the limestone it crushed bycrusher. Crusher crushed the stone type limestone into some powder like form. Itscapacity of crushing is 950tones per hours. Than it collect and stocked as piles bydumpers. In the store the crushed stone is stacked in several layers by the stacker so thata variation in quality of incoming limestone is evened out.3) GrindingThe machine, which grinds the raw material, is called RAW MILL. Thatconverts raw material into powder form by grinding it. Crushed limestone, shale &hematite are fed in the required proportion to the raw grinding unit.6) HomogenizationIn this stage mixed powder from raw mill transfers to CF Silo, wheresome additives are added to mixture. Here drying process of raw material is also carriedout, because the basic raw material contains some moisture.7) Preheating & CalcinationsBefore moving the mixture to Kiln, the powder must obtain sometemperature. Pre-heater performs that task. Calcinations is defined as removing ofcarbon-di-oxide and other organic matters from the raw material. The process ofcalcinations before Kiln reduces the thermal load in the rotary Kiln. The advantage ofthis system is that the Kiln capacity increases by 2-2.5 times.6) BurningThe precalcined raw material is fed into the rotary kiln and coal isfired at a temperature of 1600-1800 degree centigrade on the other end. Here afterburning process the powder form is transferred into small stone type form, whichis called Clinker.41

8) CoolingThe clinker is cooled in cooler, because it is very hot after passing thougha very high temperature. There are three high power fans, which reduces the temperatureof the clinker. Cooler brings down the temperature of clinker from 1200 centigrade to200 centigrade.9) StoreClinker is stored in the Clinker Silo. For converting it into cement,gypsum is mixed and grinded further in grinding process.10) GrindingIn this stage raw material is passed to Cement Mill, where the clinker andgypsum are mixed and grinded to make powder form. Here some needed chemical arealso added to mixture. This grey mixture is called cement.11) StorageCement is stored in Cement Silo in powder form before packing. Fromcement silo, needed quantity is taken for packing, while the bulk quantity withoutpacking is goes to Jetty though conveyer belt.12) PackingPacking plant for packing of cement in bags is located in the plant itself.13) DispatchAfter packing, cement is dispatched to various locations through road orsea. Here cement is loaded in truck by machine automatically

Types of cement.Ordinary Portland Cement (OPC)Portland Pozzolona Cement (PPC)Portland Slag CementWhite Portland CementOil Well CementLow Heat Portland CementSuper Sulphated Cement, High Alumina Cement

FLOW CHART OF MATERIAL FLOW IN PLANT

STACKING AND RECLAIMING

RAW MATERIAL GRINDING

The reclaimed lime stone from BC-7 is then conveyed to raw lime stone hopper and the additives (shale, red ochre & iron ore) are conveyed to raw material hoppers through BC-8 & BC-9. The desired amount of lime stone & additives are fed to a common belt conveyor BC-10 through Weigh Feeders and then in to the raw mill through BC-11.There are four raw material hoppers below which there are four weigh feeders, which are respectively: Limestone weigh feederEquipment No 10 WF 1TypeElectronic weigh feeder TLD 160/1.2VCapacity 500 TPHMaterial LimestoneBulk density 1.4-1.6tonns/Cu. MBelt width 1600 MMPulley centre 2800 MMFeed to discharge 2600 MMDrive unit 5.5 KW D.C

FLOW OF RAW MILL

Coal mill

BAG FILTERTHE BAG HOUSE / BAG FILTER IS GENERIC NAME OF AIR POLLUTION CONTROL EQUIPMENT IT IS DESIGNED AROUND THE USE OF ENGINEERED FABRIC FILTER TUBES, ENVELOPES OR CARTRIDGES IN THE DUST CAPTURING, SEPARATION OR FILTERING PROCESS UNICON PROVIDES RELIABLE AND EFFICIENT BAG FILTERS AND BAG HOUSE SYSTEMS.