Cherat Cement Company Limited Internship Report
Cherat Cement Company Limited Internship Report
Cherat Cement Company Limited Internship Report
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
1.2 Vision:............................................................................................................................................ 6
2.10.10 Alumina.............................................................................................................................. 4
2.11.1 LSF:...................................................................................................................................... 5
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
2
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
3.1.3 Blasting:...................................................................................................................................... 7
3.2.6 Decanter:.................................................................................................................................. 10
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
3
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
2.5.7 Reactions:................................................................................................................................. 20
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
4
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
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.
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.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
7
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
1
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
2
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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Summer Internship Report 2019
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.
2.10.10 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
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
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
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
5
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
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.
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
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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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.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
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.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
Totalizer
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.
Longitudinal chevron
Circular chevron
Cone pile
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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Summer Internship Report 2019
area of triangle=
where S= (a+b+c) / 2
and a, b, c are the sides of the triangle.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
12
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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Summer Internship Report 2019
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.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
o k = coefficient varying from 1.2 for fed buckets to 2.0 for nodular material with high
scooping resistance
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)
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
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.
2.3.8 Stack:
Gases from the bag filter are sent to the environment through this stack.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
Figure 18 preheaters
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
17
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
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.
3.5 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
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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Summer Internship Report 2019
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.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
19
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
F= fuel feed rate, Kg/h= 450t/d= (450 x 100) Kg/ 24 hr= 18750 Kg/h
D= diameter= 4.9m
Putting these values, we get heat loading= 6.1 x 106 kcal/m2/h
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
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
20
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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Summer Internship Report 2019
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.
3.6.4 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.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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Summer Internship Report 2019
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.
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
Summer Internship Report 2019
RAVID GHANI
DEPARTMENT OF CHEMICAL ENGINEERING
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UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR
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