Cherat Cement Company Limited Internship Report

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Summer Internship Report 2019

Acknowledgement:
After greatest thanks to Allah almighty who bestowed me with the ability and potential to complete
this Internship, I would like to add a few deepest words for the people who were part of this report in
numerous ways. People who gave unending support right from the stage the report was assigned.
Specially Engr.Wajid Ali (Lecturer at UET Peshawar) who supported me to avail this opportunity,
Engr. Hammad Ashraf, Engr. Muhammad Sohail, Engr. Zeeshan Khan and Engr. Ihtisham Zeb
(Trainee Engineers at CCCL), Engr. Rafi Ullah ( Senior Engineer at CCCL) and Engr. Azhar
(Production Manager) who played the role of polar stars for me in the organization and whose
experience taught me a lot about the industry and the organization.

Finally, I would also like to appreciate the whole team of Cherat Cement Company Limited
Nowshera.

Regards
Ravid Ghani (Internee)
Production Department
Cherat Cement Company Limited.

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
1
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

Table of Contents
1. Introduction to Cherat ..................................................................................................................... 5

1.1 Profile: ........................................................................................................................................... 6

1.2 Vision:............................................................................................................................................ 6

1.3 Mission: ......................................................................................................................................... 6

1.4 Core values: ................................................................................................................................... 6

2. Introduction to Cement ....................................................................................................................... 7

2.1 Cement: ......................................................................................................................................... 7

2.2 History: .......................................................................................................................................... 7

2.4 Types of cement: ........................................................................................................................... 7

2.5 Composition of cement: ............................................................................................................... 1

2.6 General manufacturing process: ................................................................................................... 1

2.7 General flow sheet: ....................................................................................................................... 2

2.8 Methods of manufacturing: .......................................................................................................... 2

2.8.1 Dry process: ........................................................................................................................... 2

2.8.2 Wet process: ........................................................................................................................... 3

2.9 Comparison of dry and wet processes:......................................................................................... 3

2.10 Main components and their role: ............................................................................................... 3

2.10.1 Tricalcium aluminate (C3A) ................................................................................................ 3

2.10.2 Tricalcium silicate (C3S) ..................................................................................................... 3

2.10.3 Dicalcium silicate (C2S) ...................................................................................................... 3

2.10.4 Ferrite (C4AF) ..................................................................................................................... 4

2.10.5 Magnesia (MgO) .................................................................................................................. 4

2.10.6 Sulphur trioxide.................................................................................................................... 4

2.10.7 Iron oxide/ Ferric oxide........................................................................................................ 4

2.10.8 Alkalis .................................................................................................................................. 4

2.10.9 Free lime .............................................................................................................................. 4

2.10.10 Alumina.............................................................................................................................. 4

2.11 Quality controlling parameters ................................................................................................... 5

2.11.1 LSF:...................................................................................................................................... 5

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
2
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

2.11.2 Alumina ratio: ...................................................................................................................... 5

2.11.3 Silica ratio: ........................................................................................................................... 5

3. Cement Manufacturing Process at Cherat Cement Company Limited .............................................. 6

3.1 Quarry Area ...................................................................................................................................... 6

3.1.1 Quarry: ....................................................................................................................................... 6

3.1.2 Drilling: ....................................................................................................................................... 6

3.1.3 Blasting:...................................................................................................................................... 7

3.1.4 Breaking: .................................................................................................................................... 7

3.1.5 Loading: ...................................................................................................................................... 7

3.1.6 Transportation: .......................................................................................................................... 7

3.2 Crusher Area ..................................................................................................................................... 8

3.2.1 Apron Hooper: ........................................................................................................................... 8

3.2.2 Apron belt: ................................................................................................................................. 8

3.2.3 Hammer crusher: ....................................................................................................................... 8

3.2.4 Bag filter: .................................................................................................................................... 9

3.2.5 Rotary valve: ............................................................................................................................ 10

3.2.6 Decanter:.................................................................................................................................. 10

3.2.7 Belt conveyor: .......................................................................................................................... 10

3.2.8 Magnetic separator:................................................................................................................. 11

3.2.9 Tension weight: ........................................................................................................................ 11

3.2.10 Preblending: ........................................................................................................................... 11

3.2.11 Piling is of two types: ............................................................................................................. 11

3.2.12 Longitudinal chevron pile:...................................................................................................... 12

3.2.13 Circular chevron pile: ............................................................................................................. 12

3.2.14 Additive yard: ......................................................................................................................... 13

3.2.15 Central blending silo (CBS): .................................................................................................... 13

3.2.16 Dosing silos: ........................................................................................................................... 13

3.3 Raw Press Area ............................................................................................................................... 13

3.3.1 Air flow: .................................................................................................................................... 14

3.3.2 Material flow:........................................................................................................................... 14

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
3
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

3.3.3 V Separator: ............................................................................................................................. 14

3.3.4 Bucket Elevator: ....................................................................................................................... 14

3.3.5 Roller press: ............................................................................................................................. 15

3.3.6 Cyclones: .................................................................................................................................. 15

3.3.7 Bag filter: .................................................................................................................................. 16

2.3.8 Chimney: .................................................................................................................................. 16

3.3.9 Continuous flow silo:................................................................................................................ 16

3.3.10 Storage bin: ............................................................................................................................ 16

3.4 Preheater and Pre Calciner ............................................................................................................. 17

3.4.1 Preheater: ................................................................................................................................ 17

3.4.2 Pre calciner: ............................................................................................................................. 18

3.5 kiln ................................................................................................................................................... 18

3.5.1 Size parameters: ...................................................................................................................... 18

3.5.2 Bricks: ....................................................................................................................................... 19

2.5.3 Retention time: ........................................................................................................................ 19

3.5.4 Thermal load: ........................................................................................................................... 19

3.5.6 Volume loading/ degree of filling: ........................................................................................... 20

2.5.7 Reactions:................................................................................................................................. 20

3.5.8 Temperature zones: ................................................................................................................. 20

3.6 Clinker cooler area .......................................................................................................................... 21

3.6.1 Cooler: ...................................................................................................................................... 21

3.6.2 Bag filter: .................................................................................................................................. 21

3.6.3 Electrostatic precipitator: ........................................................................................................ 22

3.6.4 Chimney: .................................................................................................................................. 22

3.6.5 Clinker silo: ............................................................................................................................... 22

3.7 WHR power plant:........................................................................................................................... 22

3.7.1 AQC and SP boiler: ................................................................................................................... 23

3.7.2 Steam Turbine: ......................................................................................................................... 23

3.7.3 Condenser: ............................................................................................................................... 23

3.7.4 Pump: ....................................................................................................................................... 23

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
4
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

3.8 Vertical mill area: ............................................................................................................................ 23

3.8.1 Vertical mill: ............................................................................................................................. 24

3.8.2 Cement silo: ............................................................................................................................. 24

3.9 Packing and shipping:...................................................................................................................... 24

3.10 Quality control LAB ....................................................................................................................... 25

3.10.1 Chemical LAB:......................................................................................................................... 25

3.10.2 Physical LAB: .......................................................................................................................... 25

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
5
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

1. Introduction to Cherat
1.1 Profile:
 Cherat Cement Company Limited was incorporated
in1981.
 Cherat Cement started production in February 1985.
 Its main business activity is manufacturing,
marketing and sale of Ordinary Portland Cement
with the brand name of ‘Cherat’.
 The Company's annual installed capacity is around
2.4 million tons.
 The plant is located at Village Lakrai, District
Nowshera, Khyber Pakhtunkhwa (KPK) province.
 The Company’s 2nd production line of cement
became operational in January 2017.
Figure 1-CCCL profile pic
 Due to plant's geographical position, it is ideally
located to export cement to Afghanistan as well as cater the local market needs in the KPK,
FATA, Punjab and Azad Kashmir.
 The Company is registered on Pakistan Stock Exchange Limited and is also an ISO 9001 and
14001 certified.
 CCCL has also installed 3rd Cement line at its current location with annual clinker capacity of
2.1 million tons.

1.2 Vision:
 Growth through the best value creation for the benefit of all stakeholders.

1.3 Mission:
 Invest in projects that will optimize the risk-return profile of the Company.
 Achieve excellence in business.
 Maintain competitiveness by leveraging technology.
 Continuously develop our human resource.
 To be regarded by investors as amongst the best blue-j chip stocks in the country.

1.4 Core values:


 Always deliver the best quality product to their customers
 Maintain the highest level of integrity, honesty and ethics.
 Use technology to continuously improve their processes.
 Develop the capability of their workforce on an ongoing basis.

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
6
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

2. Introduction to Cement
2.1 Cement:
A powdery binding substance made with calcined lime and clay. It is mixed with water to
form mortar or mixed with sand, gravel, and water to make concrete. It is a key ingredient of concrete
and the world’s most widely used building material.

2.2 History:
 Joseph Aspdin of Leeds patented Portland cement in 1824 for a ground mixture of calcined
limestone and clay.
 The designation 'Portland cement' was originally due to a
resemblance in color and character to limestone found on
the Isle of Portland off the south coast of England.
 The recognition that high temperature clinkering (C.3S
formation) greatly improved performance is attributed to
Tsaac Johnson in 1845.
 Joseph Ransom patented the rotary kiln in England in
1885. The air-suspension cyclone preheater was patented
by Vogel-Jorgensen in Czechoslovakia in 1932 and
introduced commercially by Humboldt in 1952. The first
pre calciner on a cement kiln was also built by Humboldt in
1966 and the flash calciner with separate tertiary duct was
Figure 2-Joseph Aspdin
developed by IHI in 1973.

2.4 Types of cement:


 Ordinary Portland cement
 White cement  Air entraining cement:
 Hydrographic cement  Sulfate resisting cement
 colored cement  Expansive cement
 Portland pozzolana cement  Blast furnace slag cement
 Rapid hardening cement  High alumina cement
 quick setting cement
 Low heat cement

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
7
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

2.5 Composition of Cement:


 The composition of Portland cement varies from plant to plant due both cement specifications
and mineralogy of available materials.
 An approximate analysis for raw mix on ignited basis, or for clinker, is:

Component Percentage Component Percentage


CaO 65- 68% Mn2O3 0.1- 3%

Si O2 20- 23% TiO2 0.1- 1%

Al2O3 4- 6% SO3 0.1- 2%

Fe2O3 2- 4% K2O 0.1- 1%

MgO 1- 5% Na2O 0.1- 0.5%

2.6 General Manufacturing Process:


 Crushing, screwing, and stockpiling the raw materials
 Calculating the proportions of raw materials
 Preparing the raw mix by blending
 Feeding the raw mix into rotary kiln
 100oC: Free water is evaporated.
 150-300oC: Loosely bound water is evaporated.
 500oC: More firmly bound water is evaporated.
 600oC: MgCO3---------- >MgO + CO2
 900oC: CaCO3---------->CaO + CO2
 Reaction between lime and clay starts.
 1300oC: Major compound formation starts.
 1300-1400oC: clinker forms C3A, C2S, C3S, C4AF)
 Clinker cooled and stored.
 Clinker is ground with gypsum.
 Storing and marketing.

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
1
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

2.7 General flow sheet:

Figure 3 flow sheet

2.8 Methods of manufacturing:


2.8.1 Dry process:
 Limestone or chalk and clay are crushed into gyratory crusher to get 2-5 cm size pieces.
 Crushed material is ground to get fine particle into ball mill or tube mill.
 Each material after screening stored in a separate hopper.
 The powder is mixed in require proportions to get dry raw mix which is stored in silos
(storage tank) and kept ready to be fed into the rotary kiln.
 Raw materials are mixed in required proportions so that average composition of the final
product is maintained properly.

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
2
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

2.8.2 Wet Process:


 Raw materials are crushed, powdered and stored in silos.
 The clay is washed with water in wash mills to remove adhering organic matter.
 The washed clay is stored separately.
 Powdered limestone and wet clay can flow in channel and transfer to grinding mills where
they are intimately mixed, and paste is formed known as slurry.
 Grinding may be done either in ball mill or tube mill or both.
 The slurry is led to correcting basin where chemical composition may be adjusted.
 The slurry contains 38-40% water stored in storage tank and kept ready for feeding to a rotary
kiln

2.9 Comparison of Dry and Wet Process:


Criteria Dry process Wet process
Hardness of raw material Quite hard Any type of raw material
Fuel consumption Low High
Time of process Lesser Higher
Quality Inferior quality Superior quality
Cost of production High Low
Overall cost Costly Cheaper
Physical state Raw mix (solid) Slurry (liquid)

2.10 Main Components and Their Role:


2.10.1 Tricalcium aluminate (C3A)
 Low content of C3A makes the cement sulfate resistant.
 Gypsum reduces the hydration of C3A, which liberates a lot of heat in the early stages of
hydration.
 C3A does not provide any more than a little amount of strength.
 Type I cement: contains up to 3.5% SO3 (in cement having more than 8% C3A).
 Type II cement: contains up to 3% SO3 (in cement having less than 8% C3A)

2.10.2 Tricalcium Silicate (C3S)


 C3S causes rapid hydration as well as hardening.
 It is responsible for the cement’s early strength gain an initial setting.

2.10.3 Dicalcium Silicate (C2S)


 As opposed to tricalcium silicate, which helps early strength gain, dicalcium silicate in
cement helps the strength gain after one week.

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
3
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

2.10.4 Ferrite (C4AF)


 Ferrite is a fluxing agent.
 It reduces the melting temperature of the raw materials in the kiln from 3,000°F to 2,600°F.
 Though it hydrates rapidly, it does not contribute much to the strength of the cement.

2.10.5 Magnesia (MgO)


 The manufacturing process of Portland cement uses magnesia as a raw material in dry process
plants.
 An excess amount of magnesia may make the cement unsound and expansive, but a little
amount of it can add strength to the cement.
 Production of MgO-based cement also causes less CO2 emission.
 All cement is limited to a content of 6% MgO.

2.10.6 Sulphur Trioxide


 Sulfur trioxide in excess amount can make cement unsound.

2.10.7 Iron oxide/ Ferric oxide


 Aside from adding strength and hardness, iron oxide or ferric oxide is mainly responsible for
the color of the cement.

2.10.8 Alkalis
 The amounts of potassium oxide (K2O) and sodium oxide (Na2O) determine the alkali
content of the cement.
 Cement containing large amounts of alkali can cause some difficulty in regulating the setting
time of cement.
 Low alkali cement, when used with calcium chloride in concrete, can cause discoloration.
 There is an optional limit in total alkali content of 0.60%, calculated by the equation Na2O +
0.658 K2O.

2.10.9 Free lime


 Free lime, which is sometimes present in cement, may cause expansion

2.10.10 Alumina
 Cement containing high alumina can withstand frigid temperatures since alumina is chemical-
resistant.
 It also quickens the setting but weakens the cement.

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
4
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

2.11 Quality Controlling Parameters:


 There are three main parameters that controls the quality of cement

 Lime saturation factor (LSF)


 Alumina ratio (alumina modulus)
 Silica ratio (silica modulus)

2.11.1 LSF:
 The Lime Saturation Factor is a ratio of CaO to the other three main oxides.
 The LSF controls the ratio of alite to belite in the clinker.
 A clinker with a higher LSF will have a higher proportion of alite to belite than will a clinker
with a low LSF.
 Typical LSF values in modern clinkers are 0.92-0.98, or 92%-98%.
 Calculated by the formula

LSF=CaO/ (2.8SiO2 + 1.2Al2O3 + 0.65Fe2O3)

2.11.2 Alumina Ratio:


 Ratio of alumina to ferrite
 This determines the potential relative proportions of aluminate and ferrite phases in the
clinker.
 An increase in clinker AR (also sometimes written as A/F) means there will be proportionally
more aluminate and less ferrite in the clinker.
 In ordinary Portland cement clinker, the AR is usually between 1 and 2.
 Calculated by the formula.
AR=(Al2O3/(Fe2O3)

2.11.3 Silica Ratio:


 Ratio of silica to alumina and ferrite
 A high silica ratio means that more calcium silicates are present in the clinker and less
aluminate and ferrite.
 SR is typically between 2.0 and 3.0

 Calculated by the formula


SR = SiO2/ (Al2O3 + Fe2O3)

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
5
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

3. Cement Manufacturing Process at Cherat Cement Company Limited

3.1 Quarry Area


3.1.1 Quarry:
 Quarry is the place from where raw material is extracted by drilling and blasting.
 It is located about 3-4 Km from the plant.
 In Cherat there are three quarries Shahi 1, Shahi 2, and new quarry also called lokat.
 Shahi 1 operations are in company control while that of shahi 2 are in contractor control.
 Shahi 2 provides pure limestone called Khatak limestone that is why this quarry is also called
khattak quarry.
 In each quarry there are five benches, varies with respect to compositions of the raw material
and every bench have a specific height.
 There are five processes taking place in quarry area.

 Drilling
 Blasting
 Breaking
 Loading
 Transportation

3.1.2 Drilling:
 Drilling is done by hydraulic crawl machine which usually works on the phenomena of air
pressure (compressor).
 Holes are made with a drill bit so hole diameter depends
upon the diameter of the drill bit.
 Drill bit diameter is of different sizes, smallest diameter
is 38 mm and largest is 105 mm in cherat quarry.
 The hydraulic crawl machine is using three rods during
drilling of 9-meter hole, each rod is 3-meter-long
 It consumes 130-liter diesel while drilling 100-meter
holes.

Figure 4 Hydraulic Crawl Machine

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
6
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

3.1.3 Blasting:
 ANFO and WABOX are used as blasting agents.
 ANFO is AN/FO (ammonium nitrate/fuel oil), consists of 94% ammonium nitrate (NH4NO3)
(AN) and 6% fuel oil (FO). Its efficiency decreases when the fuel oil is in greater amount.
 2.5 bags are pour down in one hole of length of 60 feet, each bag is 40 kg in weight.so in one
hole 100 kg ANFO is used.
 total number of holes is 20 so total amount of ANFO in these holes is 2000 kg
 WABOX is suitable for all types of rock blasting operations. It is manufactured in different
grades, namely 80, 60 and 40 percent.

3.1.4 Breaking:
 Breaking is done by jack hammer, Hitachi 200 excavator, in control
with PIR and CO company.
 Hammer weight is 2 ton and length are 5.5 feet.
 This machine consumes 70-80-liter diesel per day.
 Jack hammer takes 1 hour and 44 minutes to break 1 ton of
limestone Figure 5 jack hammer

3.1.5 Loading:
 For loading, hydraulic shovel and some excavators are used which
perform excavation and loading at the same time.
 dozer fill the dumpers in 5 or 6 buckets, each bucket capacity is 7 to
8 tons.
 one dumper is filled by 23 buckets in 5 minutes. and capacity of the
bucket is 1.65 tons.
Figure 6 Excavator
3.1.6 Transportation:
 For transportation CAT & perlini and Hino from PIR and CO
company are used to transport the raw material from a quarry to
crusher area.
 CAT & perlini carry 40 to 45 tons while Hino carry 30 tons in one
trip.
 dumper cycle time from crusher to crusher is 39 minutes.
 dumpers takes13 seconds in unloading and 6 minutes in loading.
 Hino consumes 5.2 litter/cycle Figure 6 perlini dumper

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
7
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

3.2 Crusher Area


3.2.1 Apron Hooper:
 The raw materials from quarry area are transported through a
dumper to a Hooper called apron feeder or apron Hooper.
 Capacity: It has capacity of 300 ton.
 Feed: laterite, slate, pure limestone and mixed limestone
 Feed size: less than 1500mm. Figure 7 Apron Hooper

 A hook hanged from the top on the Hooper for picking up


oversize particle and to avoid choking of the hoper.

3.2.2 Apron Belt:


 Apron belt is used to transport the raw material from apron feeder to the hammer crusher.
 Inclination: inclined at an angle of 20 degrees towards the crusher.
 Structure: Belt is made of metallic plates having a certain gap to bypass the fine material
from crusher.
 Metallic bars: There are metallic bars on the belt to avoid the slipping of material due to
inclination of the belt.
 Capacity: It has a capacity of 1200t/hr.
 Motors: Belt is operated by two synchronized VFD (variable frequency drive) motors each
motor is of 55KW.

3.2.3 Hammer Crusher:


 Type: double horizontal rotor hammer crusher.
 Shafts and Hammers: there are six shafts on each rotor
and eight hammers on each shaft so 48 hammers on each
roller and total 96 hammers, each hammer has a weight of
155kg.
 Motors: rotors are rotated by 800kw motors. Voltage
supplied to these motors is 6.3KV.
 Grade Bar and Umbrella Screen: There is a grade bar
between the rotors and an umbrella screen under each
Figure 8 Hammer Crusher
roller. Grade bar avoids the direct downward flow of
material and umbrella screen will define the product size.
 Feed and product size: feed size is less than 1500mmand product size is less than 50mm.

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
8
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

 Crushing Phenomena: impact phenomena between the hammer and grade bar while attrition
phenomena between the umbrella screen and rotor.
 Motor Power: Formula used for crusher power calculation is given below.
kW = √3 x A x V x σ /1000 three phase power formula
Power factor (σ) is a measure of inefficiency and is defined as the cosine of the phase angle
between current (A) and voltage (V).
 SES Sensor: sense rotation of the motor and rotor shaft, installed on the nondriving side of
the motor.
 Vibration Sensor: sense the axial and radial vibration of the crusher casing, for hammer
crusher its frequency is 3.5mm/s.

3.2.4 Bag Filter:


 Type: pulse jet bag filter
 Function: The dust produced by
crushing process can cause damage to
the equipment and may produce dust,
to overcome this problem a bag filter is
employed. A fan blows air and all the
dust go to the bag filter
 Structure: There are five chambers
and in one chamber there are 8 cages.
Cage is covered by polyethene cloth. A
solenoid valve is also used here.
 Working principles: When air passes
through this filter cloth, the dust
particles stick to the cloth and clean air
passes through it. After sometime when
the chamber is choked with particles,
perching system is used in which Figure 9 Bag Filter
high pressure air is used, this
air removes all particles from the filter
cloth.
 Advantages:
 High collection efficiency
 High air-to-cloth ratio (6 to
10 ft/min
 Aggressive cleaning action
Figure 10 Bag Filter
 Continuous process
 Strong woven bags

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
9
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

 Lower bag wear


 Smaller space required
 Disadvantages:
 Dry compressed air required
 Restricted to low to medium temperatures
 Unable to function with high humidity gases

3.2.5 Rotary Valve:


 Also called rotary air lock.
 Prevents the suction of dust from screw conveyor area by the ID fan,
because of the buckets.

3.2.6 Decanter:
 Decanter removes the moistures form air and provides dry air to the Figure 10 rotary valve
bag filter
 If instead of dry air wet air is entered to the bag filter, then chocking of the canvas cloth will
occur.

3.2.7 Belt Conveyor:


 Material: Pure limestone, laterite, slate and mixed limestone.
 Function: The crushed materials are transported through a belt conveyor for Preblending.
 Structure: Belt conveyor consists of two or more pulleys. Either one or both pulleys are
powered. The powered pulley is called the drive pulley while the unpowered pulley is called
the idler.
 Width: About 500mm
 Thickness: About 10mm
 Flow rate: 1200 ton/ hour
 Built accessories:
 Built retainer
 Side roller
 Bottom roller
 Scrapper
 Guide roller
Figure 11 Belt Retainer, guide roller, side roller, and drift
sensor

RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
10
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019

 Totalizer

3.2.8 Magnetic Separator:


 Location: A magnetic separator is installed on the
belt that transport crushed material from crusher to
the pre blending area.
 Function: It attracts and removes metal objects from
the crushed material.
Figure 12 Magnetic Separator
 How: The magnetic particles are adsorbed on the
surface of the belt in the magnetic field region and removed to the non-
magnetic region.
 Separable Particles: Magnetic separator is used for particle size below
3mm magnetite, pyrrhotite, roasted ore, ilmenite and other materials.
 Magnet Intensity: 1200MT.

3.2.9 Tension weight:


Figure 13 Tension
For controlling dislocation of belt during startup and to lose the belt if required. weight

3.2.10 Preblending:
 The crushed materials are transported through a belt conveyor and stored in their respective
yards either additive yard or central blending silo (CBS).
 There are four piles, mixed pile of limestone and clay, pure limestone, laterite and slate.

3.2.11 Piling is of two types:


 chevron pile: chevron pile is of two types

 Longitudinal chevron

 Circular chevron
 Cone pile

Figure 14 different types of piles

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3.2.12 Longitudinal Chevron Pile:


 Mass of material stacked in the form of longitudinal chevron is calculated from the density
equation.
Density = mass/volume
ρ = m/v
 In order to calculate mass of chevron pile we need to calculate its volume; chevron pile is half
cone at one side then an extended triangle and finally a half cone again, so volume of chevron
pile is volume of cone plus volume of extended triangle.
V= Volume of cone + Volume of extended triangle
Volume of cone
V cone =1/3 (hπr2)
h= hight of cone (Hight of pile)
volume of extended triangle= area of triangle x length of triangle

area of triangle=
where S= (a+b+c) / 2
and a, b, c are the sides of the triangle.

3.2.13 Circular Chevron Pile:


 Circular chevron pile is a rotated longitudinal chevron pile.
 Volume of the pile is calculated by the following formula.
Volume= Area x Hight of the pile.
And area= π (R2 – r2) – (θ/2) x r2
 Where “R” is the radius of the outer circle while “r” is the radius of the inner circle and “θ” is
the angle between stacker and reclaimer (segment o the circle where there is no material).
Thus, volume of the CBS pile is
Volume= [π (R2 – r2) – (θ/2) x r2] x H
And mass of the material is
m= ρ x V = ρ x [π (R2 – r2) – (θ/2) x r2] x H
where “ρ” is the bulk density of material stored in CBS.

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DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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3.2.14 Additive Yard:


 The piles of pure limestone (high grade limestone), laterite and slate are stored in additive
yard.
 There is one stacker for piling and one side reclaimer for transporting the materials to the
dosing silos.

3.2.15 Central Blending Silo (CBS):


 The mixed pile of limestone and clay is piled and reclaimed continuously here.
 The material is piled in the form of circular chevron pile.
 Product size is 35mm to 55mm. the equipment used here is consist of the following parts.

3.2.16 Dosing Silos:


 Quantity: There are three dosing silos and 4th one is under
construction.
 Materials: laterite, slate, pure limestone (PI) and mixed
limestone of CBS.
 Capacities:
 Laterite =230 ton
 Slate =230 ton
 Mixed limestone: 790 ton.
 Pure limestone: 200 ton, under construction.
Figure 15 dosing silo
 Before construction of PI silo, either laterite or slate silo is
made empty for PI temporarily.
 Load cells: Each silo is having a weigh feeder/load cell at the bottom to provide the material
in required proportion to the raw press.

3.3 Raw Press Area


 From dosing silos, the raw materials are transported to the v separator belt conveyor through
an inclined belt conveyor and then through the v separator belt conveyor it falls in the v
separator.
 Over the v separator belt conveyor there is a bag filter to control the dust produced during
falling of the material.
 In this area material is contacted with hot air to dry it before grinding and then to separate fine
and bulk particles.

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3.3.1 Air flow:


The hot gases coming out from PC through SP boiler and a direct line are sucked through an ID fan
and at the outlet of the fan the hot gas stream is divided into two streams, one stream is provided to
the coal mill and the second one is entered to the bottom of the v separator, which dries the material
for grinding and separate the fine particles from bulk particles. Air from v separator contain fine
particles so it is passed through the cyclone to separate fine particles at the bottom and the air coming
out from the top, which is then sent to the bag filter to remove fine particle and then sent to the
atmosphere through a chimney.

3.3.2 Material flow:


From dosing silos the ra material are transported to the v separator
at a rate of 470T/h, where it combines with the hot air and grin
material coming from the raw mill through the elevator, here the
separation of fine materials occurs with air from bulk particles, in
cyclone the fine material is separated and sent to the CF silo through
an elevator while the bulk material from v separator goes into the
raw mill which is sent to the v separator through an elevator after
grinding, means there is a cyclic flow of material in v separator and
the raw mill.

3.3.3 V Separator:
 Raw material falls in the v separator from the top over the
inclined metallic pates called distribution plates.
Figure 16 V separator
 hot air is interred from the bottom.
 Here the fine and course materials are separated through air.
 Distribution plates: The distribution plates can disperse the particles so that to increase the
surface area and maximum contact of air and material occurs.
 Fine materials go with air on the top while coarse material comes down due to gravity.
 Top stream goes to the cyclone while bottom stream falls on the elevator on the bottom.

3.3.4 Bucket Elevator:


 Elevator takes the coarse material to the top of roller press.
 Power required for bucket elevator motor can be calculated by the following formula.
kW = k.C.H/367
Where
o C = load, tons/hour
o H = height. (m)

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o k = coefficient varying from 1.2 for fed buckets to 2.0 for nodular material with high
scooping resistance

3.3.5 Roller Press:


 Flow: The bottom stream (coarse material) from the v separator are sent to the roller press
through bucket elevator, here the material is grinded and sent to the top of the v separator
through a bucket elevator.
 structure: roller press consists of two rollers, one is fixed while the other is moveable,
motion to the second roller is provided by the hydraulic system using nitrogen gas stored in
cylinder.
 Universal joint: this joint join the motor shaft to the
roller shaft and is used to support the back and forth
motion of the moveable jaw.

3.3.6 Cyclones:
 Hot gases along with fine particles comes out from
the top of v separator and enter the cyclone.
 Here separation of particles and air occurs by
centrifugation.
 There are three main parts which are to be
considered in designing.
 Dip tube (made of thimble plates)

 Cylindrical portion Figure 17 Cyclone


 Conical portion
 The particle collides with dip tube at the angle of 45 degree due to which some of the particle
are disturbed and then fall to the bottom of the cyclone. The remaining air and particles passes
through the Dip tube and enter to the next cyclone the process repeat until complete
separation between particle and air occurred.
 By increasing cylindrical portion, the heat transfer will increase while increasing the conical
portion the separation will be maximum.
 There are three forces acting on the materials.
 Centrifugal force
 Gravitational force
 Pressure force
 The centrifugal and pressure forces can’t be varied, separation can be controlled by
centrifugal force (speed of rotation).
 By increasing the speed of rotation, the separation increases but should be at optimum speed.

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 At very high-speed material would not be able to go down while at very low speed
distribution of the material will not occur and so minimum or no separation will occur.

3.3.7 Bag filter:


 Air coming out form the top of cyclones enters bag filter.
 Here further separation of fine particles from air occurs.
 Mainly to avoid dust flow into the environment and recover grinded material.
 The air is sent to the chimney while fine material is collected at the bottom.
 After passing through a rotary valve it falls on the main air slide.

2.3.8 Stack:
 Gases from the bag filter are sent to the environment through this stack.

3.3.9 Continuous Flow Silo:


 Material from the bottom of cyclones and bag filter are sent to the bottom of bucket elevator
through an air slide.
 Now to the top of CF silo by bucket elevator.
 Its capacity is about 45000ton.

3.3.10 Storage Bin:


 From CF silo the material is transported to the storage bin through bucket elevator.
 This storage bin helps to operate the preheater onward area up to 7 days even if there is any
fault in raw press.
 It has a capacity of 250ton.
 At the bottom of storage bin there are two flow meters.
 Pfister
 Impact flow meter
 These flow meters measure the flow of material to the preheater.

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3.4 Preheater and Pre Calciner


3.4.1 Preheater:
 from CF silo material is transported to the preheater through bucket elevator and then entered
to the riser of cyclone 3 through air slide.
 Type: Preheater of line 3 is double while that of line 1 and line 2 is single stage.
 flow:
 The bucket elevator puts the material in the rising duct of 3rd cyclone.
 The hot gases from the kiln flow with very high velocity in countercurrent direction.
 The hot gasses lift the particles from the rising duct 3rd cyclone and put it on the top
four cyclones C1A, C1B, C1A and C1B.
 From there the material falls on the top of the 2nd cyclone and sends it into the 3rd
cyclone.
 Then the material falls on the top of 5th cyclone and hot gases take it into the 4th
cyclone.
 then the material falls into the pre calciner at different position, one stream enters at
the center and second stream enters at the bottom, this distribution is for maximum
contact between the coal, material and hot gases.
 The hot gases from the kiln takes the material from PC to cyclone 5 and from here it
goes into the kiln.

Figure 18 preheaters

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 During this complete cycle, the hot gases flows in the countercurrent direction. These
cyclones serve the purpose of preheating the feed material with hot gases of kiln. The
temperature of feed increases as the feed flows downwards
 Structure: There are total 10 cyclone preheaters. 5 are on the right side of the pre calciner
and 5 on the left of the pre calciner

 Flaps valve: flaps valve are controlling the flow of material from one cyclone to another,
material weight should overcome on weight of flaps valve.

 Splash box: also called dispersion plates, connected at the bottom duct of each cyclone, to
disperse the particles and increase area of contact between material and hot gases.

 Air canon: also called air blaster, avoids sticking of material to the walls of cyclone.

3.4.2 Pre calciner:


 The feed from the 4th cyclone preheater falls into the pre calciner which has burner with a
supply of coal and furnace oil.
 Coal and furnace oil are distributed at four different position of the PC. Here 95%
calcinations of feed material take place due to burning.
 Exchange of heat also takes place in the pre-calciner.
 CO2 is evolved and exhausted in the atmosphere and the feed is entered the kiln riser at high
temperature.
 Some of the feed directly goes to the kiln without going to the 5th cyclone.
 There is three type air coming into the PC these are primary, secondary and tertiary.

3.5 kiln
 Heart of the cement industry
 5% calcination takes place here.
 Rate (rpm): 5rpm

3.5.1 Parameters:
 Diameter: inner diameter is 4.9m and outer diameter is 5.4m
 Length: 64m
 Thickness: 25mm
 Cross Sectional Area: (π D2)/4, putting inner and outer diameter to get respective areas.
 Inner cross-sectional area= 18.8m2
 Outer cross-sectional area= 22.89m2

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 Surface area: (π D L), putting inner and outer diameter to get respective surface areas
 Inner surface area= 984.7m2
 Outer surface area= 1085.18m2
 Volume: {(π D2)/4} x L, putting inner diameter to get the volume
 Volume= 1204.48m3

3.5.2 Bricks:
 made of magnesite and calcium carbide.
 360 and 320 bricks are used in kiln for insulation.
 320 is used for kiln of diameter 3m and 620 is used for kiln
of diameter 6m. so we use both.

2.5.3 Retention time:


 Time taken by a unit volume of feed material from inlet to
outlet.
 Retention time mainly depends on the physical properties of Figure 19 620 and 320 bricks
material and rpm of the kiln.
 Calculated by the formula
T= (11.2 x L)/ (r D θ)
L=length=64m
r= rpm=5
D= diameter=4.9m
θ = slope in %= 1.72
 putting values, we get retention time =21minutes

3.5.4 Thermal load:


 Thermal load is the heat supplied per unit area per
unit time.

 Heat loading should not normally exceed 6 x 106


kcal/m2/h
 Calculated by the formula
Figure 20 kiln
2
Heat loading, kcal/M /h = F x GCV/ (π
D2)/4
Where

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F= fuel feed rate, Kg/h= 450t/d= (450 x 100) Kg/ 24 hr= 18750 Kg/h

GCV= gross calorific value of fuel, kcal/kg=6200Kcal/kg

D= diameter= 4.9m
 Putting these values, we get heat loading= 6.1 x 106 kcal/m2/h

3.5.6 Volume loading/ degree of filling:


 %age of the kiln volume that is filled by the feed material.
 Mainly depends on the kiln retention time and degree of pre calcination of material at kiln.
 Calculated by the formula

% loading = 0.035 Wt/LA


Where

W = clinker production, t/h=


A = effective cross-sectional area, m2
 Putting these values, we get volume loading =

2.5.7 Reactions:
 MgCO3---------- >MgO + CO2
 CaCO3----------------> CaO + CO2
 CaO + Al2O3------------> CA
 CaO + SiO2------------> CS
 CA + 2C---------------> C3A
 CS + 2C--------------> C3S
 C2S + C------------> C3S
 CA + F +3C--------> C4AF

3.5.8 Temperature Zones:


 Calcining zone
 Safety zone
 Upper transition zone
 Burning zone
 Lower transition zone
 Cooling zone.

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DEPARTMENT OF CHEMICAL ENGINEERING
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3.6 Clinker Cooler Area


3.6.1 Cooler:
 Type: Pendulum double stage grate cooler.
 Hot clinker heat is exchanged with ambient air.
 The ambient air is supplied by 11 centrifugal fans of pressure 1095 Pa and 110KW power, in
which two are recycling some portion of the chimney gases.
 Four streams of the hot air and one clinker stream are coming out from cooler
 Secondary: goes with in the kiln to the PP
 Tertiary air: goes to the PC through an individual duct abbreviated as TAD.
 One stream goes to the air quenching cooler
 One stream goes direct to the electrostatic precipitator, joins with the outlet stream of
AQC.
 Material flow:
 From kiln clinker is poured into the kiln inlet distribution system ( KIDS).
 KIDS consist of dispersion plates, when material falls on it, they get dispersed and
bed becomes of optimum Hight.
 KIDS prevent the snowman phenomena.
 Plates: Cooler consist of two types of plates moveable and fixed plates.
 Moveable plates move in forward and backward direction with 360mm displacement.
 These plates are slightly inclined so that to make the flow easier.
 Before the crusher vibration of plates is 11 per minute while after crusher it is 14 per
minute.
 If bed height increases from optimum level, then vibration of plates will increase to
push material fastly.
 Zero point: The point in cooler at which the air is divided into mainly two streams, one
stream of TAD and secondary air going to cooler and second stream of AQC and ESP.
 Roller Crusher: from kiln the materials comes to the cooler in the form of bulks, in order to
crush these bulks a single roller crusher is installed in the midway of cooler.

3.6.2 Bag Filter:


 Due to lowering in temperature of the stream from AQC, the dust particles are more visible
and separable.
 The dust is removed in the bag filter

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 At the bottom of this bag filter there is drag chain instead of screw conveyor.
 Dust particles removed are sent to the main clinker built.

3.6.3 Electrostatic Precipitator:


 Electrostatic precipitator works on the principle
of coulomb law that same charges repell while
opposite charges attract each other.
 Main parts: Corna wires, hammers shaft and
transformers.
 Working principles: by collision with the
corona wires the particle is splits into positive
and negative ions. These negative and positive Figure 21 EP
ions are dust particles collected by the
collecting plates. The collecting plates are continuously hammered to separate the collected
particles. After hammering the dust particles are collected at the bottom and conveyed to the
clinker conveying belt by screw conveyor.

3.6.4 Stack:
 Through this stack, the gases coming out from electrostatic precipitator are exhausted to the
environment.
 Some portion of this hot stream is recycled to the cooler by two centrifugal fans from the
bottom of the chimney.

3.6.5 Clinker Silo:


 The cooled clinker comes into the clinker silo from cooler through a bucket conveyor belt.
 Clinker storage point.

3.7 WHR Power Plant:


 Heat energy of the steam coming from AQC and suspension preheater boiler is utilized to
produce 8MW electricity.
 main units of WHR are:
 Boiler: AQC and SP boiler located.
 Turbine: located in WHR.
 Condenser: located in front of WHR
 Pump: located with the side wall of condenser

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DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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3.7.1 AQC and SP boiler:


 AQC: Heat transfer occurs between the hot air stream coming from cooler and water. The
outlet air stream joins the direct stream of hot air from cooler going to electrostatic
precipitator. The hot water stream (steam) goes to the waste heat recovery (WHR) power
plant.
 SP boiler: In SP boiler heat transfer occurs between the hot gases coming out from preheater
and water stream. Steam are produced here.
 Steam produced in SP boiler and AQC are combined and sent to the turbine.

3.7.2 Steam Turbine:


 Here heat energy of the steam from AQC and SP boiler is converted into mechanical energy
to rotate the turbine shaft which produces 8MW to 9MW electricity.
 Temperature of the steam lowers.

3.7.3 Condenser:
 The hot water coming from turbine may have some vapors, in order to pump it to the boilers
this stream must be condensed.
 The turbine hot water stream is condensed and sent to the pump.

3.7.4 Pump:
 It pumps the condensed water to the SP boiler and air quenching cooler.

3.8 Vertical mill area:


 Gypsum crusher and dosing silos:
 Gypsum (CaSO4) is crushed through a crusher and sent to its dosing silo through a belt
conveyor.
 In vertical mill area there are three dosing silos one is for clinker, 2nd one is for crushed
gypsum and the 3rd one is for pure limestone.

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3.8.1 Vertical mill:


 Functions: there are three main functions performed by the vertical mill.
 Grinding
 Separation
 Drying
 transportation
 Grinding: when material is passing
from center of table to the nozzle ring,
it is grinded between the rollers and
grinding table.
 Separation: Hot gases are entered
from the bottom to the mill, which lifts
the fine particles and leaves the coarse
Figure 22 Vertical roller mill
material on the grinding table. The
fine material along with dust are
collected in the bag filter, which separates them.
 Drying: during lifting of the fine material through hot gases, drying also occurs.
 Transportation: The hot gases are utilized to transport the material from grinding table to the
dust separator.
 Structure: there are two main parts disk and rollers, both are rotating and the material
between disk and roller is crushed. There are six rollers in this vertical mill. There is a
classifier at the top which separates the fine and coarse material.
 Grinding phenomena: grinding occurs through compression and shearing.

3.8.2 Cement silo:


The final product of the vertical mill is the cement stored in the cement silo.

3.9 Packing and shipping:


 From cement silo the cement is transferred to the hoofers above the packing machine through
an air slide.
 Bags are filled with automatic packing machine.
 Each bag has a weight of 50kg.
 After filling of the bags, it is put on a belt conveyor.
 Belt conveyor conveys to the trucks.
 Truck transport the bags to the demand location.

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DEPARTMENT OF CHEMICAL ENGINEERING
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3.10 Quality Control LAB


 Quality Tests on cement are carried out to check the strength and quality of the cement used
in construction.
 It helps to identify the usage of cement for different purposes based on its durability and
performance.
 For quality control, in cherat cement company limited there are two laboratories
 Physical LAB
 Chemical LAB.

3.10.1 Chemical LAB:


 Chemical LAB mainly includes the composition test for cement and calorific value test for
coal.
 Composition test:
 In this test we find the cement composition.
 For composition test XRF and XRD machines are used.
 A sample of 1gm is taken, pressed and placed in XRF and then processed, which tells
its composition.
 From composition then we find the values of LSF, AM and SM.

3.10.2 Physical LAB:


 In physical test are performed for different physical properties such as
 Fineness test
 Consistency test
 Setting Time test
 Strength test
 Soundness test
 For strength test cement and silica with one third ratio are mixed in mortar, then a paste is
formed and finally a cube is formed from the paste. The paste is placed in water container and
after desired interval the strength is determined.

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DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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