SUMMER TRAINING REPORT

J.K WHITE CEMENT & WHITE CEMENT

BASED PUTTY–PRODUCTION
Submitted in partial fulfillment of the requirements for the degree
Of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

TRAINING AT

J.K. WHITE CEMENT WORKS GOTAN

TRAINING PERIOD: 01-07-2024 TO 31-08-2024
(60 DAYS)

SUBMITTED BY:- Bhupendra Singh Shekhawat

(MECHANICAL)

1
JK White Cement Works, Gotan
(Submitted by)

Bhupendra Singh Shekhawat

In

Partial fulfillment of

B. Tech. degree In

Mechanical Engineering

2
 ACKNOWLEDGEMENT

The successful completion of this Training marks the beginning of an ever

- going learning experience of converting ideas and concepts into real life,
practical system. This training was a quite a learning experience for me at
each step. At the same time, it has given me confidence to work in
professional setup. I feel the experience gained during the training will lead
me to gain the bright prospect in the future. First, I would like to give
thanks to Human Resource Development Centre, J.K. White Cement
Works, Gotan, for giving me the opportunity to work in this esteemed
industry, which not only has increased our awareness about latest fields but
also taught me the importance of team building. With the deep sense of
gratitude, I express my sincere thanks to Mr. Abhinav Jain (HOD
Mechanical Department), for active support and continuous guidance. I will
also like to thank Mr. Khushal Aseri and the other working staff members.
Without their invaluable support it would have been impossible for me to
fully understand the procedures.

Thank You BHUPENDRA SINGH

SHEKHAWAT
B.Tech (MECHANICAL)
GITS, Udaipur

3
 CERTIFICATE

This is to certify that Mr. BHUPENDRA SINGH SHEKHAWAT in Bachelor

of Mechanical Engineering (B.Tech), has completed Summer Training of 60
days during 01-07-2024 to 31-08-2024 from J.K. WHITE CEMENT WORKS,
Gotan (Nagaur) as partial fulfillment of Bachelor of in Mechanical Engineering.
The summer Training report and presentation by him is genuine work done by
him and the same is being submitted for evaluation.

Signature Mr. Vikram Singh Rathore

Head- HR and Admin
J.K. White cement works, Gotan

4
 CONTENTS
S.NO. NAME OF TOPIC

1. INTRODUCTION (HISTORY &ASPECTS OF ORGANISATION)

2. ABOUT J.K.WHITE CEMENT WORKS

3. GOALS &VISION OF J.K.W.C.

4. SPECIAL FEATURES OF J.K.W.C.

5. DEPARTMENTS OF PLANT

6. VARIOUS ENGINEER IN CEMENT PLANT AND THEIR ROLE

7. INTRODUCTION TO CEMENT

8. PROCESS &RAW MATERIAL FOR CEMENT

9. FLOW PROCESS DIAGRAM

10. MINING & CRUSHER SECTION

11. RAW MILL SECTION

5
 CONTENTS
S.NO. NAME OF TOPIC
12. KILN FEED

13. PREHEATER TOWER

14. ELECTROSTATIC PRECIPITATOR(E.S.P.)

15. COOLING TOWER (C.T.)

16. KILN

17. CLINKER STORAGE

18. PETRO-COKE MILL

19. CEMENT GRINDING MILL

20. PACKING SECTION

21. CENTRAL CONTROL ROOM(C.C.R.)

22. CONCLUSION & REFERENCE

INTRODUCTION
6
HISTORY, STRUCTURE AND ASPECT OF JK
ORGANISATION:

The family of JK hails from a small but beautiful town of Kanpur in Uttar
Pradesh. This is place from where the illustrious and magnificent history of the
JK Industrial House began. The JK Industrial House rests on the strong
foundations built on the vision, dedication, commitment and hard work of our
beloved and visionary leader late Shri Juggilal Singhania and Lala Kamlapat
Sighania. The name JK stands for the name of these great father and son.

Shri Gaur Hari Singhania (son of late shri Lala Kamlapat

singhania):
Shri Gaur Hari Singhania was one of the most progressive industrialists who
moved much ahead of his time. He was the chairman of many major industries
and was also a Director of several government bodies such as the Reserve Bank
of India, India Fund, Air India, Infrastructure Leasing and Financial Services,
ICICI and was a member of the Asian Institute of Management, Asian
Convertible and Income Fund, FICCI and Board of Trade. Leading Indian
Management bodies and business publications had conferred upon him several
awards such as `Businessman of the year` award, `Businessman Leadership`
award, `Management Man of the year` award and the `Rashtra Bhusan` award.
He was also posthumously awarded the first `JRD TATA Award for Corporate
Leadership`.

7
Shri Yadupati Singhania (son of Shri Gaur Hari Singhania):

Shri Yadupati Singhania was groomed to take over the mantle of the Group by
his father Shri Gaur Hari Singhania. He has been giving new thrust to
Marketing strategy ,expansion ,Core competence ,Benchmarking ,HRD etc ,so
as to make the group a truly Indian Multinational with Global vision, practiced
his engineering from the IIT.

The JK Group has three clear strength:

1) Continuous investment in new technologies

2) Motivated and decentralized management
3) Strict accounting and monitoring system

INDUSTRIAL VIEW OF JK CEMENTS:

JK Cements Ltd includes:

1. JK White cement Works, Gotan (Nagaur)

2. JK Cement Works, Nimbahera

3. JK Cement Works, Mangrol

4. JK Cement Katni

5. JK Cement Plant, Gotan

6. JK Cement Works Plant, Mudhol

7. JK White and Grey Cement Fujairah (UAE)

8. JK Cement works Aligarh

9. JK Cement works Hamirpur

8
 ABOUT JK WHITE CEMENT WORKS

1. Today, J. K. Cement Ltd. is one of the largest cement manufacturers in

Northern India.

2. They are also the second largest white cement manufacturer in India by
production capacity. The white cement enjoys demand in the export market
including countries like South Africa, Nigeria, Singapore, Bahrain,
Bangladesh, Sri Lanka, Kenya, Tanzania, UAE and Nepal.

3. They have 35 years of experience in the Indian cement industry, which

they believe provides us with the skills to maximize production efficiency,
expand production capacity quickly and reduce costs.

9
4. Their WHITE CEMENT MANUFACTURING, GOTAN manufacturing
facility was chosen by the World Bank and Corporate with F.L SMITH
(DENMARK) as one of the four training centers in India to serve as the
“Regional Training Center” for Northern India. There are only four regional
training centers for the cement industry in India.

5. Architect of the Year Award (AYA) began way back in the year 1996 (1st
Architect of the Year Award). Awards were subsequently extended to
architects of neighboring countries from the year 2000 (7th Architect of the
Year Award).

6. J.K CEMENT LTD. is the holder of the ISO ENVIRONMENT

PROTECTION AND ENHANCEMENT AWARD .

7. This is the only plant after operated with the 5th HAVER PACKER machine
for cement packing and logistics enhancement.

9. It is also the winner of many quality awards such as TPM (Total Productive
Maintenance), ISO etc. & is working well to upgrade its certificates day by day.
All the employees have been made responsible to take care of all these awards
& to maintain the quality of the production as required by the certifying
authorities.

JK WHITE CEMENT PLANT SECTION

1. CRUSHER
2. RAW MILL
3. INSTRUMENTATION & ELECTRONICS
DEPARTMENT
4. ELECTRICAL DEPARTMENT
5. MECHANICAL DEPARTMENT AND WORKSHOP
6. CIVIL DEPARTMENT
7. KILN SECTION

10
 8. CCR (CENTRAL CONTROL ROOM)
9. PETROCOKE MILL
10.CEMENT MILL
11.PACKING PLANT
12.TECHNICAL DEPARTMENT
13.POWER GENERATION (THERMAX)
14.ENVIRONMENT LAB AND MANUAL’S DRAWING
LIBRARY
15.QUALITY CONTROL DEPARTMENT AND LAB
16.WALL PUTTY SECTION
17.DOLOMITE SECTION
18.EDP DEPARTMENT (ELECTRONICS DATA
PROCESSING)

ROLE PLAYED BY VARIOUS ENGINEER IN CEMENT

PLANT:

The various Engineers engaged in White Cement Plant are:

 Electronics and communication Engineers:

Their work is to maintain
the Automation in the industry, maintenance of the various Panels and
Instruments (PLC), providing the safety to the operator as well as on the
machine parts. Responsible for the Commissioning of the various equipment
at the instant call, to maintain the healthy communication network.

 Electrical Engineers:
Their work is to maintain the various Feeder Panel
for power supply, motor and drives maintenances, transmission and
distribution, power generation.

 Mechanical Engineers:
To develop the Drawing, chart and manual of
actual hardware large structure such KILN and MILL, Responsible for the
construction of various structure and new Project. Maintenance of various
mechanical hardware parts such as lubricating system.

 Civil Engineers:

11
 Responsible for constructing the base of the
organization and its future also.

 Production and Process Engineers:

To check whether the
production is going on its right way or not and the analysis of various factors
effecting the production.

INTRODUCTION TO CEMENT

CEMENT

In the most general sense of the word, cement is a binder, a substance that sets
and hardens independently, and can bind other materials together. The word
"cement" traces to the Romans, who used the term opus caementicius to
describe masonry resembling modern concrete that was made from crushed
rock with burnt lime as binder. The volcanic ash and pulverized brick additives
that were added to the burnt lime to obtain a hydraulic binder were later referred
to as cementum, cimentum , and cement.
Cement used in construction is characterized as hydraulic or non-hydraulic.
Hydraulic cements (e.g., Portland cement) harden because of hydration,
chemical reactions that occur independently of the mixture's water content; they
can harden even underwater or when constantly exposed to wet weather. The
chemical reaction that results when the anhydrous cement powder is mixed with
water produces hydrates that are not water-soluble. Non-hydraulic cements
(e.g. gypsum plaster) must be kept dry in order to retain their strength.
The most important use of cement is the production of mortar and concrete—the
bonding of natural or artificial aggregates to form a strong building material that
is durable in the face of normal environmental effects.
Concrete should not be confused with cement, because the term cement refers to
the material used to bind the aggregate materials of concrete.

12
TYPES OF CEMENT:
There are many types of cement in the market to suit every need. Some of them
which are included in the revised ISO: 456-2000 is as follows:

1) White Portland Cement.

2) Ordinary Portland Cement 33, 43, 53 grades (OPC), 53-S (Sleeper

Cement)

3) Portland Pozzolana Cement (PPC),

4) Portland Slag Cement (PSC)

5) Sulphate Resisting Portland Cement (SRC)

6) Low Heat Portland Cement

Even though only Ordinary Portland Cement is graded according to strength,

the other cements too have to gain a particular strength. 33, 43 and 53 grade in
OPC indicates the compressive strength of cement after 28 days when tested as
per IS: 4031-1988, e.g., 33 Grade means that 28 days of compressive strength is
not less than 33 N/mm2 (MPa) . Similarly for 43 grade and 53 grade the 28 days
compressive strength should not be less than 43 and 53 MPa respectively.

13
 PROCESS FOR CEMENT PRODUCTION

Cement is basically produced by two processes: - Dry & Wet. In JK WHITE

CEMENT dry process is used for cement production as it is less power
consuming & easy to manufacture. The basic raw material used for cement
production is the Limestone. JK Cement has its own mines for acquiring
limestone located near 40 km away from Gotan.The basic process for the
cement production is being described here under:-

RAW MATERIAL FOR CEMENT MANUFACTURING

MATERIAL NAME PERCENTAGE USE

Calcium carbonate 60-65% primary comp.

For Calcium Oxide.

Clay 1 for Silica 17-25% secondary comp.

Oxide.

Clay 2 for Aluminum 3-8% quick setting

Oxide

Feldspar Stone for 5-6% Hardness.

Ferric Oxide

Magnesium Oxide 5-4% To improve the Color

and hardness.

Gypsum for Calcium 5-3% To Increase settling time.

Sulphate

14
 FLOW PROCESS DIAGRAM

RAW MATERIAL CRUSHING RAW MATERIAL

YARD

KILN FEED RAW MILL RAW MILL

STORAGE GRINDING

CLINKER CEMENT GYPSUM

PYROPROCESSING & STORAGE
STORAGE GRINDING
QUENCHING

CEMENT
STORAGE
PETRO-COKE
GRINDING

RAW PETRO- PACKING & DISPATCH

FUEL OIL
STORAGE COKE
STORAGE

15
 CODES USED IN DIAGRAMS

HP – Hopper AB – Air Blaster

WF – Weight Feeder DC – Dust Collector

GF – Gravity Feeder FN - Fan

TU – Truck Unloader RC – Drag Chain

WP – Water Pump GP – Pneumatic Gate

VS – Vibrating Screen SU – Air Slide

HC – Hand Operated Crane HF – Hot Air Damper

RF – Reciprocating Feeder MF – Motorized Damper

BC – Belt Conveyor SG – Symetro Gear

BE – Bucket Elevator SR - Separator

CR – Clay Crusher CN - Cyclone

IC – Impact Crusher SV – Solenoid Valve

RAL – Rotary Air Lock BL - Blower

SC – Screw Conveyor CT – Cooling Tower

HE – Heat Exchanger HAF – Hot Air Fan

AD – Auxiliary Drive SGF – Smoke Air Fan

MINING AND CRUSHER SECTION

16
MINES:

The process of mining which is used here to extract Limestone from the
Earth is Open cast mining. The process of mining includes three things:

Prospecting: It is the process of finding potential at place from where very

useful & bulk quantity of limestone can be extracted.

Drilling: After providing with a better place for mining, the process of drilling
takes place, in which the place is drilled with the drilling machines, for inserting
the dynamites.

Blasting: After drilling holes, this place is blasted by blasting materials inserted
inside the drilled part to break the huge rocks into pieces.

These pieces of rocks are brought near to the crusher & are further processed.

CRUSHER SECTION:

PURPOSE: In every cement industry plant, a regular visiting of the

trucks loaded with different types of rocks (limestone, clay 1, clay 2, clay
3 feldspar stone) takes place. The purpose of the crusher section is to help
in the converting these stones into the fine material as it is easy to process
the material in its fine form.

17
RAW MATERIAL :-

The main raw materials used in the cement manufacturing process are
limestone, sand, shale, clay, and iron ore. The main material, limestone, is
usually mined on site while the other minor materials may be mined either
on site or in nearby quarries. Another source of raw materials is industrial
by-products. The use of by-product materials to replace natural raw
materials is a key element in achieving sustainable development.

RAW MATERIAL PREPARATION :-

Mining of limestone requires the use of drilling and blasting techniques.

The blasting techniques use the latest technology to insure vibration, dust,
and noise emissions are kept at a minimum. Blasting produces materials in a
wide range of sizes from approximately 1.5 meters in diameter to small particles
less than a few millimeters in diameter.

Material is loaded at the blasting face into trucks for transportation to the
crushing plant. Through a series of crushers and screens, the limestone is
reduced to a size less than 100 mm and stored until required.

Depending on size, the minor materials (sand, shale, clay, and iron ore) may or
may not be crushed before being stored in separate areas until required.

Process and Components involve in the crushing of the material:

Crusher Mouth: The loaded truck goes at the mouth of the crusher mouth.
Then the operator operate the 3 phase induction motor operates a piston to lift
the truck in the back downward position approx. around 45 degree to allow the
rock to drop into the mouth of the crusher.

An ALARM get evoke when the angle of inclination is 45 degree.

Motor used in lifting: 3 phase induction motor.

Sensor used: Limit switch

PUSH FEEDER: The Push Feeder is the vibrator used to push the large stones
into the crusher hammer section.

18
CRUSHER MILL: The crusher mill consist of the hammer. The hammer
continuously applied over the large bulky stone and the crushing of stones takes
place.

MOTOR RATING for CRUSHER: 143.5KW

VIBRATING SCREEN: The material after the screw conveyor and dust
collector through the conveyor belt comes to the vibrating screen. The Vibrating
screen consist of a fine 1000 micron filter sheet. This sheet separates down the
fine particle form the stone big particle.

The small particle are allowed to pass to the yard after filtration. The large
stony particle are again send out to the ball hammer crusher for fining. The two
belt system (forward and backward) are used.

Fig shown: The Vibrating screen of the Crusher.

19
FILTER SCREW: The raw material stones are put into the crusher and from
where the filter screw allows the fine particle to move through the forward belt
conveyor belt.

DUST COLLECTOR: During the hammering process of crushing, a large

amount of dust is produced. Due to the GOVT. pollution act this dust cannot be
exposed to the environment directly. The Dust collector consist of the bag, the
bag are allowed to filled with the dust, the differential pressure valves are used
to check the DP above and below the bag. When the DP(differential pressure) is
much high then the set point value. Then the solenoid valve are used for purging
or cleaning of the bag. The purging is done by inserting a very high pressure
into the each individual bag probe by the solenoid valve excitation. The
purging led to the settling of the useful material in the form of dust and the
clean air with some useless material exposé into the environment air.

Sensor or transducer used: solenoid valve, differential pressure valve.

Source for solenoid valve: Compressor air and signal to excite the solenoid
coil.

In the DUST COLLECTOR, the solenoid valves are connected in series, and
each individual solenoid valve is provided with the 24 volt excitation voltage.

20
PROCESS IN CRUSHING PLANT :-

1. Firstly lime stone comes to industry by using trucks transportation from

mining.

2. Lime stone has big particles in mining, so trucks are unloaded by using
truck unloader in crushing plant.

3. This unloader passes the stones to a hopper which is situated in bottom of

unloader.

4. Hopper passes the stones to impact crusher by using reciprocating feeder.

5. In impact crusher, stones are crushed in small particles like less than 30
mm.

6. These particles are passes to vibrating screen by using belt conveyor.

7. A dust collector is provided on belt conveyor to absorb dust on belt

conveyor.

8. Through the vibrating screen, greater than 22 mm size particles are passes
to crusher again by using return belt conveyor.

9. Less than 22mm size particles are stored in yard by using belt conveyor.

10. Place for storage of fine lime is known as raw mill yard, there is also
storage of two types of clay, felt spark.

21
 RAW MILL SECTION

In Raw-mill section, this conveyed material is transferred into hopper which

feeds and regulated amount of material to the mill. This feeding is carried out
with TFG (Triple Feed Gate) or weigh-feeder, which is a hydraulic gate used to
avoid overfeeding of material in mill. Raw-Mill consists of large rollers, which
is used to grind this crushed material into fine powder. This fine powder is
collected & is stored in Raw-mill silos, which is called Raw-Meal for Kiln.

Raw mill section consists of:

1. Clay1 and clay 2 common crusher.

2. Limestone crusher.

3. Clay 3 (Feldspar mill).

4. Dryer mill.

5. Raw mill.

6. Two separators.

7. ESP.

8. Raw Mill Fan.

9. Silo.

Discussion :-

The material from the yard is carry to the three hopper, one for limestone,
second for clay 1 and third for clay 2 with the help of conveyor belt mechanism.
The material from the hopper is taken out with the help of the weigh-feeder.

DRYER:-

1. The material from the crusher of clay and limestone is put into the dryer mill.

22
2. The Dryer mill is the long cylindrical mill of 3.2 m diameter.

3. The Dryer mill consist of the two chamber or section.

4. The input chamber is filled with the steel balls and output chamber is filled with
ceramic balls.

5. The material after dust removal, crushing, etc. get mixed up and pass into the
raw mill.

6. The motor rotating the raw mill is provided with that of the flow valve or RTD
to measure the bearing temperature.

7. The raw mill rotates and a suction fan on the outlet side to suck the fine(mixed)
material.

8. The motor used for running the mill is synchronous motor of 1000 KW rating. It
is also provided with that of gear box for running the motor.

9. The motor is provided with the RTD to measure the bearing temperature. It is
around of the range of 150 degree Celsius.

10.The oil lubrication is also provided with that of 1000KW motor and for the mill
for providing the smoothness and cooking of the bearing. The HP-LP
lubricating system is used here.

23
 RAW MILL:-
1. All the material clay1, clay2 and limestone, feldspar from their respective mill
to a common final raw section mill is known as Raw mill.

2. The motor used for driving the Raw mill is of 1050 KW. The Raw mill motor
is provided with the RTD and its normal operating is 150 to 200. The hot air is
supplied across the raw mill input.

3. The dust produced during the production outlet of the raw mill is put into the
ESP for dust settling and smoke removal.

4. The raw mill is provided with the grease system for HP-LP lubricating
system.

5. The Folaphone Sensor helps in detecting the level of the charge in the raw
mill.

6. The material from the outlet of the raw mill is move to the silo with the help of
bucket elevators.

24
 Rotating Raw mill

Silo (RAW MILL STORAGE):-

Silo is the cylindrical structure of large height to store the material for long
purpose and on a large scale. The two silo after the raw mill is double storage
silo building. The height of the silo building is 27.1m and diameter is of
around 9.3m. The level of the filling of the silo is measured by the help of the
analog sensor known as the Radar sensor.

25
 SILO
Weigh Feeder (for the discharging of material from the hopper):

The material from the hopper is taken out as per the % requirement through the
weigh feeder as shown in fig.

1. The weigh feeder consist of hopper outlet at its top and the material
comes out through the hopper is driven or controlled by the rotary
encoder through a motor controlled which is also by VFD panel in panel
room as shown in fig
2. The material falls over the conveyor belt is move on in the forward
direction by the weigh feeder.

3. The motor driving the conveyor belt controlled by VFD and speed is
detected by the encoder.

4. The motor is provided with the Proximity Sensor to detect the motor
running status.

RAL AND WEIGH FEEDER

26
 RAW MILL DIAGRAM
1.YARD TO DRYER:-

YARD
BC
B
C

HP HP HP HP
1 2 3 4
F.S CLA CLA LIM
W/F W/F W/F W/F
BC
BC

BC

HP VS
F/S 5 CR

MILL B F.S
E
CR
BC

DRYER

27
2.DRYER TO SILO: B.
AS
E
BC
B. L
E R E
L L V
A
E RAW
DRYER V T
A MILL O
T AS R
O
R

SR SR
S S
O/P
C C

SC

B. SC
E
S S
L
E C C
V
A
SILO SILO
T
1 2
O
R

AS

28
PROCESS IN RAW MILL SECTION:-

1. Firstly, crushed lime stone, clay 1,clay 2,feldspar are stored in raw mill
yard.

2. Material from yard is taken in separate hoppers one by one by using belt
conveyor.

3. Every hopper has a weigh feeder for control of flow of material.

4. Feldspar is passed to feldspar mill by using belt conveyor & after

grinding ,it passed to a hopper by using bucket elevator.

5. Clay 1 & 2 are crushed by crusher.

6. Lime is passed to vibrating screen from which, less than 6 mm particles

are passed to main belt conveyor & more than 6 mm particles are passed
return to V.S..

7. Feldspar, clay 1,clay 2 & lime are mixed in a fixed ratio on main belt
conveyor and passed to DRYER.

8. After drying process, material is passed to raw mill through bucket

elevator and then belt conveyor.

9. RAL is provided on input of raw mill(80 ton/hr),material is mixed and

grinded in raw mill &then material passed through air slide to bucket
elevator & then to separators (two) using A.S.dividing by diverter.

10.In seperator, coarse material is returned to raw mill & fine material is
passed to screw conveyor to air slide & then using elevator, material is
stored in SILO 1 & SILO 2.

29
 KILN FEED SECTION

IN kiln feed section, Material is to be ready for heating (preheating) in

preheater tower. Passing of material from raw mill silo to preheater tower using
SC,BE,HP, is called kiln feed section.

DIAGRAM OF KILN FEED SECTION

Silo Silo
sc
1 2

PH
E
L
g g
E
a a WH V
t t E
e e L A
E T
sc
V SFF O
A R
PH T
O
R

30
 PREHEATER TOWER

Consist of:

1. 5 stage preheater (height 80 m).

2. Gas Analyzer.
3. Cooling Tower.
4. ESP
5. Smoke gas fan.
6. 3 Heat Exchanger.

Role of smoke gas fan: The smoke gas fan works

as a Air suction fan, it sucks the air by making the
cyclone the dust particle get fall down at the
bottom of each cyclone.

 The preheater consist of the 3 heat exchanger ,

the hot air+dust led to the heating of the pipe,
the hot pipe convert the cold air into the hot
air.
 The outlet of the heat exchanger, the hot air is
utilized in the dry mill, raw mill, the kiln.

Advantages: Preheating is necessary to raise the

temperature of raw meal and to utilize waste heat
for further calcinations of kiln feed.

31
DIAGRAM OF PREHEATER SECTION:-

SC A
I
CN

1
H.E.

CN

A
CN
I
3

CN

A
I CN

CALCINER
KILN

32
PROCESS IN PREHEATER TOWER:-
1. Firstly, material is passed on top (5th stage) floor of the tower by
using bucket elevator & then received on inlet of 1st cyclone.
2. Hot air is received from kiln to calciner & then from CN 5 to
CN 4 to CN 3 to CN 2 to CN 1 &then returned to heat
exchanger and cooling tower.
3. Material is received on inlet of CN 1 with hot air & a cyclone is
generated in cyclone.
4. Material is passed to inlet of CN 2 due to cyclone generating &
received in CN 2 with hot air.
5. Cyclone is generated in every cyclone stage & process is
continued so material received to CN 5.
6. Material is passed to kiln inlet from CN 5.
7. Material at inlet is fully preheated due to cyclones generating in
various temp. in each cyclone:-
CN 1 = 340° C
CN 2 = 380°C
CN 3 = 630°C
CN 4 = 680°C
CN 5 = 847°C

33
 ESP (ELECTROSTATIC PRECIPITATOR)

Introduction:
Bag houses and Precipitators are used for effective dust collection. Both are
quite efficient. Although they collect dust in a vastly different manner. The
primary difference between them is that Precipitators have a constant pressure
drop and variable performance, while Bag houses have a variable pressure
drop and constant performance.

The Precipitation Process:- The complete precipitation process consists of

five basis steps.

1). Gas distribution into the treatment zone

2). Particle charging/corona discharge (gas conduction)

3). Deposition of the dust on to the collector plates.

4). Accumulation of the dust.

5). Removal of the collected material.

Working Principle:

Electrostatic precipitator is an apparatus which cleans process gases by using

electrical forces to remove solid particles carried in the gas stream. The dirty
gases are passed through an intense electrical field set up between electrodes of
opposite polarity. The discharge electrodes -so called because of the corona
discharge which results from the application of high voltage-impart a negative
charge to the particles. These particles are then attracted to the collector
electrodes which are positive with respect to the discharge electrodes and in
practice are connected to ground through the structure or through ground cables.

34
The particles build up into a layer on the grounded collecting electrodes until a
rapping force is applied to the electrodes to dislodge and break up the layer into
agglomerated sheets which are heavy enough to fall into the hopper without
being re-entrained.

Precipitator Components:

Housing / Shell:

Exterior sheet metal/stiffened casing, penthouse or insulator Compartments,

support columns and beams, hoppers.

Treatment zone :

Perforation plates, wires/ discharge electrodes, collecting plates/ Electrodes.

Structural components:

Lower discharge electrodes frames, upper discharge electrodes frames, Plate

support system.

Other important component:

Rappers and vibrators, rapper controls, purge air system, insulators.

Most industries have smoke or dust problem of some kind. The smoke can be
made up of solid or fluid particles suspended in the gas. Sometimes the particle
are waste which must be removed for removal for reason of hygiene and
comfort before the gas is released into the atmosphere. Equally, after the
materials may be useful product which must be recovered for the purpose to be
profitable. For the control of dust, Electrostatic Precipitator is often used.

Parameter Description Unit Values

35
 Design Criteria 1. Quantity m3 100000
2. Temperature
°C 170

General 1. Total m2 1386

Collecting
area 1
2. No. of
mm 5
Chamber
3. Plate
thickness of
Casing
Dimension 1. Field width M 4.40
2. Field height
3. Field length m 7.00

m 4.50

Power Pack 1. No. of high 2

voltage
rectifier
2. Peak voltage
KV 110
of rectifier
3. Second
current of
rectifier mA 440

Insulator Material Porcelain

Collecting Type C
electrodes

It is seen that principle of electrostatic precipitator has four phases:-

1. Corona formation or ionization.

2. Charging of particles.

3. Migration and precipitation of particle.

4. Removal of deposited dust.

36
Advantages of using ESP:-

1. Low pressure drop.

2. Low sensitive to high pressure.

3. Accuracy up to 99.5%.

4. Low maintenance required.

COOLING TOWER

 The material supplied to the ESP must be under the certain temperature
range otherwise it affects the performance of the ESP.
 Gas is cooled at ±3c of the respective application outlet set point during
normal condition.
 The water spray is based on the PID controller principle. The water
booster pumps required to deliver the flow and pressure to the valve rack.

37
  The dust from Preheater cyclone is being supplied to the cooling tower
for cooling before sending to the ESP.

Design Condition:

Parameter Preheater Alkali bypass

Inlet Volume 228400 15000

(Am3/HR)

Outlet Volume 189472 120606

(Am3/HR)

Inlet Temperature © 260 300

Outlet Temperature © 130 140

Water requirement 8.79 6.36

(m3/HR)

Comp. Air requirement 570 435

(Nm3/hr)

Nozzle supplied (#)side (6)MM-11 (4)MM-1

ROTARY KILN

A Kiln is a big rotating cylinder about 72 m long, 3.2 m in diameter. Here the
continuous heating of this preheated material takes place at around 1200-1600
o
C. The Kiln cylinder is tilted to an angle of 3-4 degrees and is rotating at about
3 to 5.5rpm to make the material flow in one direction only.

 Every day, the mechanical department is responsible for the reading of

the temperature below its surface.

38
  The Rotary kiln is also provided with the internal bricks on its internal
surface. These bricks help in the heating of the charge.
 The temperature of the kiln is being measured by the help of
thermocouple at its feed.
 The temperature is also sensed by the x ray sensor, sends the signal to the
CCR.

Fuel used:

1) AFR , LDO and FO.

2) The petrocoke is also used as it is cheap and serve as a fuel replacing the
large quantity of LDO into small one.

Outlet side Material feed

 The LDO oil is being pumped by the 33 HP motor, having 75-80 mm at

the rate of 1000 lit/hr.

39
  The steam is also passed along at outlet section to allow the formation of
granules, and for the purpose of decreasing the temperature.

Decolorizer Section:

 In this section, hot clinker coming out from kiln is fed. This hot clinker is
cooled from quenching produced by water pump. This cooled clinker is
stacked in clinker stock piles. The clinker is then fed to dryer (dry mill)
for cooling and then to the cement mill for further processing.

PROCESS IN KILN TO CLINKER STORAGE:-

1. FIRSTLY, clinker is collected in coolers on kiln & then it received in

dryer by using drag chain mechanism.

2. Material in the form of dust in kiln is sucked by a pipe & it supplied

directly on dryer inlet.

3. Clinker is dried in dryer & then it passed to clinker yard by using belt
conveyor mechanism.

4. Material from dust collector which is located on dryer outlet, is also

received on same belt conveyor.

5. IN Dryer, moisture is gained by dryer & clinker is fully dry &cool.

6. In case of maintenance of dryer, clinker is directly received by another

drag chain & then passed to clinker yard by using belt conveyor.

40
 PETRO-COKE MILL SECTION

This mill is used for provide main firing in kiln.

DIAGRAM FOR PETRO-COKE MILL:-

SC

B. HP
E. FAN

AIR
COKE SEPRATOR
STORAGE W/F big
FINE
RA fine
BC L

BH
s
c P-C
MILL

S/F S/F
Rejected coke 1/2 /3 R R

HOPPERS
SC

41
PROCESS IN PETRO-COKE MILL:-

1. Firstly coke is received in elevator by using belt conveyor from storage of

coke.

2. Then it stored in a hopper by using elevator & screw conveyor.

3. Then material is passed to petro coke mill through weigh feeder & rotary
air lock.

4. In mill, coke is grinded in fine power between three tires, ungrinded coke
is returned to elevator & grinded coke is passed to separator.

5. Separator passed fine coke to a bag house & coarse coke again to mill.

6. Fine coke is received on screw conveyor through screw feeder & rotary
air lock.

7. Screw conveyor passed coke to three hoppers, one is used for reduction
firing, other for main firing , third for calciner firing.

CEMENT GRINDING MILL

Before feeding to cement mill, the clinker is further mixed with definite amount
of Gypsum, which determines setting time for cement. This mixed material is
then fed to cement mill, where this mixed material is further grounded in fine
powder, forming cement. This cement thus produced is stocked in huge silos
equipped with packing plant at the bottom from where the cement bags are
filled, weighed & packed & hence supplied to the market through various
transporters.

42
Chemical used in Cement Mill: the Tee (ethylene titrate) is mixed with the
clinker, the chemical help in preventing the final cement grinding in the mill to
get stick with the grinding media (steel balls and ceramic balls).

The final prepared Cement is pass on to the SILO for storage from where it is
taken out for packing in packer plant.

PROCESS IN CEMENT MILL SECTION:-

1. Firstly, clinker, hygrade & gypsum are stored one by one in separate
hoppers through belt conveyor.

2. Then clinker with tee dozing, hygrade &gypsum are mixed in a fixed
ratio on a belt conveyor through weigh feeder.

43
3. This mixture is passed to cement mill inlet.

4. In mill, this mixture is grinded in a fine powder i.e. called cement.

5. This powder to separator by using air slide through bucket elevator.

6. Separator passed coarse powder returned to cement mill, & fine powder
to belt conveyor .

7. This conveyor passed cement to cement silo through bucket elevator.

PACKING SECTION

1. The plant consists of total of 5 Packer machines.

 Two 1 kg packers.
 One 5 kg packers.

44
  Two 40/50 kg packers.
2. The HAVER ROTO PACKER is one of the latest advanced PACKERS.

CENTRAL CONTROL ROOM (C.C.R)

 CCR consist of the PLC with their I/O module, PC’s, and SCADA
software.
 Programmable Logic Controller ( PLC ) is a special purpose computer
with digital processing capabilities, designed for real time control in
industrial and manufacturing applications.
 This is the place from where the whole automation of the plant is being
controlled and operated.

45
  To accomplish this long process for definite amount of mixing & process
control for controlling various processes of the plant, as it is operated
fully automatically, that is, no manual operation is needed, for which an
upgraded & better control system is needed. And for making the control
system functional & to take care of various electronic measuring systems,
where the field electronics have its necessity.
 The plant is equipped with PLCs (Programmable Logic Controls)
controlling the whole processes of the plant from a single office namely
CCR (Central Control Room) with PCs controlling the operation of each
machine in the plant all around 24 hours driving each & every electrical
machines with definite supplies & frequency for accomplishing cement
manufacturing.

SCADA (By F.L SMITH):

SCADA stands for the “Supervisory Control And Data Acquisition”.

SCADA provides the animation Approach to the user for handling and
operating the every part of the plant very easily by sitting in the CCR.

Features of SCADA:

 SCADA provides the user compatibility access.

 It provides the alarms for the critical condition.
 It provides the recipe management facility.
 It provides the care safety and security to the instrument and Workers.
 It provides the security towards the redundancy and theft condition by the
accurate calculation and storage of data.
 It provides us the various Real and Historical trends.

46
 SILO TO PACKING:-

SC
Lime/
cement/ B
gyp. E
HP HP HP HP SILO
BC
LI CE G D

AS
DA
P
DA
WH P
WH
DL
WH WH
P
DL
P

MIXER
1 MIXER

SC

SC

HOPPER B HP
E

PACKING
M/C

47
PROCESS IN DOLOMITE MILL SECTION:-
1. Firstly, dolomite is passed to mill inlet through belt conveyor.
2. Dolomite is grinded in fine powder in mill then it passed to elevator
through air slide.
3. Dust collector is provided on mill outlet.
4. Elevator passed material to a separator through again air slides.
5. Separator separates the fine & coarse material.
6. Coarse material is returned to mill inlet through air slide & then duct.
7. Fine material is passed to cyclone from which material is passed to
dolomite silo through screw conveyor ,elevator & then air slide.
8. Dolomite is stored in a hopper by using another elevator & screw
conveyor.
9. Lime, cement & gypsum is also stored in separate hoppers by using an
another elevator.
10.Two chemicals(D.A.P & D.L.P) are stored in four other hoppers by
manual lifting.
11.DLP &DAP are mixed in a weighing hopper & then supplied to small
hopper.
12.Lime& gypsum and then cement &dolomite are mixed in another four
weighing hoppers.
13.This mixture and chemical mixture are again mixed in two mixers.
14.This mixture is called putty.
15.Now, putty is stored in a big hopper through screw conveyor.
16.Putty is passed to another small hopper through screw conveyor & then
elevator.
17.A packing machine is provided on bottom of hopper, where packing
operation is done.

48
 CONCLUSION

The 60-day internship at JK. White Cement Works Limited (JKWCWL) was an invaluable
experience that significantly contributed to my understanding of mechanical engineering
within the cement industry. Through hands-on learning, observation, and active participation,
I gained practical knowledge that complemented my academic studies.

Key
Takeaways:

1) Practical Application of Theory: The internship allowed me to apply

theoretical concepts learned in the classroom to real-world situations. This
practical exposure helped bridge the gap between academic learning and
industrial practice.

2) Technical Proficiency: I developed a solid understanding of the operation

and maintenance of key mechanical equipment used in cement
manufacturing. This included crushers, mills, and kilns, as well as an
understanding of the entire cement production process.

3) Safety Awareness: I learned the importance of safety protocols and

procedures in an industrial setting. This knowledge is crucial for ensuring a
safe working environment and preventing accidents.

4) Teamwork and Communication: Collaborating with engineers,

technicians, and other staff improved my teamwork and communication
skills. These are essential for effective collaboration and professional
development in any industry.

5) Problem-Solving Skills: The ability to troubleshoot and solve mechanical

issues was significantly enhanced. This skill is vital for addressing and
resolving operational challenges in a manufacturing environment.

Personal
Growth

The internship also contributed to my personal growth by:

• Enhancing my time management skills.
• Improving my adaptability to new and challenging situations.
• Building my confidence in handling professional responsibilities.

49