Cement Processing Report

Cement Processing Report

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  Prepared by: Muhammad Ahmed( D-17-CH-71 ) [email protected] Duration period is 17 DECEMBER 2018 to 29 DECEMBER 2018
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  Context Introduction Quarry (Drilling) Blasting Crusher Stacker andreclaimer Raw mill Pre-heater & Kiln Cooler Grinding Packing Plant My suggestion
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  Introduction Lucky Cement cameinto existence in 1996 with a daily production capacity of 6,000 tons per day and rated amongst the few best plants in Asia. It has the tendency to become the hub of cement production in Asia. Lucky Cement Limited has been sponsored by Yunus Brothers Group (YB Group) which is one of the largest business groups of the Country. Quarry (Drilling) We visit the mining are that is consist of 11-kilometer width. In the mining, every time, Engineers reserved 4 lack ton crushed lime stone in the quarry for emergency. The mining area are divided into different sectors, we saw the sector 5, that is 1.5 kilometer long. I noticed some terminologies that are used by the Engineers, The distance between two drilling holes is called spacing. The spacing between two holes is 4.5 meter. Burden is the diagonal distance between the holes, and its length is 4 meters. The drilling holes depth (bench height) is 20 meters. The sub drilling depth is 1.5 meters. The drilling rod length is 3.09 meters. Drilling tip consist of black diamond. Blasting The unknown explosive is use for blasting. I saw and notice some specifications of blasting, Two types of explosive are used. 1) Low Explosive and 2) High Explosive. In a drilled hole, 20% of high explosive and 80% of low explosive is use, low explosive contains Ammonium Nitrate and fuel oil. Detonator cord is used for blasting, which burn 4000-5000 meter/min. Ignitor cord use for ignite the detonator cord, which burn 2 meters/110 sec. Delay relay is also use in the blasting, that delay 50 milliseconds in the blasting series. Spacing Burden
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  Crusher Lucky cement containsmultiple crusher for multiple purpose. It is the first process in the plant. This plant consists of Two lime stone crusher of capacity 1000 ton/h. • Generally, it works at 850-900 ton/hr., and 650-700 rpm. The hammer’s flywheel is run from 1000 kw motor. • It consists of 5 axils; each axil consists of nine hammers. • The Hammer is fabricated from 20% of steel and 80% iron. Two coal crusher of capacity 400 ton/h. One gypsum crusher of capacity 700 ton/h. After crushing, the material is going to the tunnel, here the magnetic separator is present that separate metal particles. Stacker and reclaimer STACKING and RECLAIMING are the 3rd andanimportant stepinthe cement production. In STACKING the feedfromthe Delivery tunnel is transportedto the LONG BELT,whichthenfurther carries the feedto the STACKING MACHINE or STACKER, the stacker makes pilesof the feeds. Thenthe feedis store intheware house. Raw mill Raw mill area mixed all the component of cement except gypsum, and also reduce the size of particles. The material consists of 80-85% of lime stone, 10- 15% clay, 8-10% silica, 4-5% lithriate. Mixed material is passes through the magnetic separator. This area consists of rotary feeder, vertical raw mill grinder (VRM), cyclones, bag house (bag filter) and silos. Rotary Feeder Rotary is used to feed the crushed material into the vertical roller grinder. It maintains the air lock system, which is most important for the process. Vertical Raw Mill (VRM)
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  It is thevertical roller mill grinder. It is consisting of one moving disk and four vertical rollers placed on the disk. The classifier is fitted on the top of the mill, which suck the fine particles. the capacity of grinder is 270 ton/hr. The circulating oil is also used for the lubrication of gear box of rotating disk. Cyclone Cyclone is used for the separating the fine particles from the flue gas. It is the high efficiency cyclone, it separates the 90% - 95% of fine particles. The flue gas and 5% of fine particles enter in the bag filter, and the separated fine particles goes to the silo for storage. Bag House Then the remaining particles enters in the bag filter, which is called bag house. Bag house consist of 20 chambers, each chamber contains 128 bags. Here the particles are separated and goes in the silo, and the flue gas discharge through chimney. Pre-heater & Kiln It has consisted of five cyclones. Frist is two in one cyclone and four are high efficiency cyclones and a pre calciner. Rotary kiln is the main equipment of cement production host. Cement rotary kiln mainly use for calcining cement clinker, mainly include the kiln cylinder, driving device, supporting device, thruster device, kiln head seal device, kiln tail seal device, kiln hood and other parts.
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  Temperature Reaction HeatChange 100 Evaporation of free water Endothermic 500 and above Evaporation of combine water, endothermic 900 and above evaluation of CO2 from lime, main reaction between clay and lime Exothermic 900-1200 Liquid formation endothermic 1200 and above Further formation of liquid endothermic Composition of Clinker Dicalcuim silicate (C2S) Tricalcium silicate (C3S) Tricalcium aluminate (C3A) Tetracalcium aluminoferrite (C4AF) Magnesium oxide in free state (M) Cooler This clinker cool down 1350C to 200C from cooler. 8 Fans are also used to force air through the cooler bed or grates. Then clinker is transfer from 60000 lack ton silo.
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  Grinder Cement mill isthe area where finally cement is manufacture by the addition of second stage raw materials (Slag, Gypsum and clinker). Packing Plant Lucky cement also exports loose cement by loading it into through bunker. Daily it exports ton per day. Loose cement storage and ship loading terminal at berth -25 west wharf Karachi port. My suggestion Compony should increase internship and job opportunities for the fresh engineers. I suggest that they provide cleaner, meadow, and healthy environment. I suggested that the company make a proper plan for safety control, firstly inform the visitor or internees about the emergency exit gate and assembly points.