Lucky cement factory internship report

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LUCKY CEMENT COMPANY LIMITED

DEPARTMENT OF

MEHRAN UNIVERSITY OF ENGINEERING & TECHNOLOGY, JAMSHORO

(Internship Program Report)
LUCKY CEMENT LIMITED , KARACHI
Date : 22-06-2011 To 30-07-2011

Submitted To:
HUMAN RESORCE DEPARTMENT
Submitted By:

MOHAMMAD YOUNUS (08IN70)
SUHAIL AHMED PALIJO (08IN36)
MANSOOR ALI SOLANGI (08IN106)

PREPARED BY MOHAMMAD YOUNUS (08IN70) 1
SUHAIL AHMED (08IN36) &

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PREFACE
This report has been give by the
authors to convey the information about different
departments of lucky cement limited , which has been
visited during our industrial training. We have
discussed the different specifications , processing and
production of the department we visited. We
have tried to give some history of the processes ,
literature , survey and importance of the processing
as well.

MOAHAMMD YOUNUS (08IN70)

SUHAIL AHMED PALIJO (08IN36)

&
MANSOOR AHMED SOLANGI (08IN106)


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ACKNOWLEDGEMENT
First of all we would like to thanks Al-mighty Allah , The Most
Beneficent and Merciful . We are very happy to avail this
golden opportunity of getting training at lucky cement plant .
We are thankful to General Manager of Lucky cement plant
at Karachi Mr. Mashkoor Ahmed who provided us such a
valuable opportunity.

A lot of thanks to MECHANICAL Manager M.K PASHA who
provided us assistance in such a friendly environment.

We are Also thankful to

ASSISTANCE MANAGER SHAHID ZAMAN
ASSISTANCE MANAGER SAAD
SENIOR ASSISTANCE MANAGER HAFEEZ SHAHAB
For providing us information about the plants.
This report is a result of handwork of not a single person but
many persons have aided by volunteering their services to
create this text . Their kindness thus improving this report
with their Additional technical knowledge has contributed
mightly to the quality of this work. We got much practical
knowledge which was not possible to gain in the university
during studies.

Overall , we are thankful to all the Officers & the workers of Lucky cement
Ltd.


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CONTENTS

UNIT’S DISCRIPTION PAGE

INTRODUCTION
UNIT NO. 1 • INTRODUCTION TO CEMENT.
• TYPES OF CEMNT
• LUCKY CEMENT LIMITED
CONCRETE PROGRESS,
KARACHI.
• PRODUCTS. 7 to 11
• Quality policy , vision , mission &
values.
• Overall flow diagram of lucky
cement plant.

RAW MATERIAL USED…
UNIT NO. 2 • Limestone
• Clay
• Laterite 12 to 16
• Bauxite
• Slag
• Gypsum
• Coal
• Furnance oil


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LABORATORY
UNIT NO. 3 • Coal testing
• Limestone sample
• Latirite sample
• Bauxite sample 17 to 23
• Clay sample

CRUSHER
UNIT NO. 4 • Hammer crusher 24 to 27
• Production of crusher
• Limestone yard
•

UNIT NO. 5 PROPORTIONING TOWER 28 to 29
• Way feeder
• Decision of percentage of raw
material

UNIT NO. 6 GRIDING OF COAL 30 to 31

• Coal grinding
• Pulverize coal
• Coal mill
• Coal storage bin
• Fire extinguisher system
• Coal transportation to
• Pre-calciner
• main burner (klin)


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GRIDING OF RAW MATERIAL
• Transportation of ingredients
• Rotary valve 32 to 36
UNIT NO. 7 • I.D fan
• System fan
• Vertical raw mill
• Inlet of hot Air
• Outlet of Air
• Cyclones
• Air slides
• Bag house
• Bag house fan
• Outlet of extra gases
• Storage of powder grinded raw
material to the Silo
• Homogenization of grinded raw
material

CALCINATION AND HEAT
EXCHANGER
• Pre-heater
UNIT NO. 8 • Inlet of feed to pre-heater 37 to 39
• Construction of feed silo
• Rizor
• Cyclones of pre-heater
• Pre-calciner burner
• Pre-calcination
• Heat exchange
• Primary duck


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KILN AREA
• Introduction to kiln
UNIT NO. 9 • Ignition of kiln 40 to 48
• Reaction at kiln
• Formation of clinker
• Hard burning and soft burning
• Outlet of clicker

COOLING AND STORAGE
UNIT NO. 10 OF CLINKER
• Construction of cooler
• Cooler crusher
• Pan conveyer
• Storage of clinker

CEMENT MILL
UNIT NO. 11 • Proportionating tower
• Flow diagram of cement mill
• Roller crusher
• Crushing Separator
• Storage bin
• Ball mill
• Grinding aid
• Storage of cement

UNIT NO. 12 PACKING PLANT
• Loose cement
• Packed cement
• Loose cement storage and ship

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loading terminal at Berth – 25
west wharf , Karachi Port

UNIT NO. 13 QUALITY CONTROL LAB
• Collection of sample
• Testing of sample at different stages

UNIT NO. 14 POWER GENERATION
• Furnace oil generator
• Natural gas generator
• Dual fuel generator
• Generation of power house

UNIT NO. 15 OVER ALL PERFORMANCE OF
LUCKY CEMENT FACTORY
• Aims and missions

UNIT NO. 16 ENVIRONMENTAL SAFETY
• Global warming and the dangers
of GHG

UNIT NO. 17 CONCLUSION


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INTRODUCTION TO CEMENT
Cement is the non metallic bonding material used for construction
Or
Cement is binding material which is used in construction

HISTORY OF CEMENT
History of cement is very old as human civilization. Romans
used volcanic tuff mixed raw material for their construction .Egyptians
used it for the construction of PYRAMIDES.
In 1824 English man Joseph Aspdin, patented artificial
cement made by the calcinations of an argillaceous lime stone. He cal
edit “Portland” because concrete made from it resembles with a famous
building stone obtained from land near England

TYPES OF CEMENT
ASTM C150

There are five types of Portland cements with variations of the first three
according to ASTM( AMERICAN SOCITY OF TESTING MATERIAL )
C150.

1.COMMON or GENERAL PURPOSE CEMENT
It is generally assumed unless another type is specified. It is
commonly used for general construction especially when making precast
and precast-prestressed concrete that is not to be in contact with soils or
ground water. The typical compound compositions of this type are:

55% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 2.8% MgO, 2.9% (SO3),
1.0% Ignition loss, and 1.0% free CaO.

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A limitation on the composition is that the (C3A) shall not exceed fifteen
percent.

2. SULPHATE RESISTANCE CEMENT
Type II is intended to have moderate sulfate resistance with or without
moderate heat of hydration. This type of cement costs about the same as
Type I. Its typical compound composition is:

51% (C3S), 24% (C2S), 6% (C3A), 11% (C4AF), 2.9% MgO, 2.5% (SO3),

A limitation on the composition is that the (C3A) shall not exceed eight
percent which reduces its vulnerability to sulfates

3. RAPID HARDENING CEMENT
Type III is has relatively high early strength. Its typical compound
composition is:

57% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 3.0% MgO, 3.1% (SO3),

This cement is similar to Type I, but ground finer. Some manufacturers
make a separate clinker with higher C3S and/or C3A content, but this is
increasingly rare, and the general purpose clinker is usually used, ground
to a specific surface typically 50-80% higher. The gypsum level may also
be increased a small amount

4.LOW HEAR OF HYDRATION CEMENT
Type IV Portland cement is generally known for its low heat of hydration.
Its typical compound composition is:

28% (C3S), 49% (C2S), 4% (C3A), 12% (C4AF), 1.8% MgO, 1.9% (SO3),


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The percentages of (C2S) and (C4AF) are relatively high and (C3S) and
(C3A) are relatively low. A limitation on this type is that the maximum
percentage of (C3A) is seven, and the maximum percentage of (C3S) is
thirty-five.

5. SULPHATE RESISTANCE
Type V is used where sulfate resistance is important. Its typical compound
composition is:

38% (C3S), 43% (C2S), 4% (C3A), 9% (C4AF), 1.9% MgO, 1.8% (SO3),

This cement has a very low (C3A) composition which accounts for its high
sulfate resistance. The maximum content of (C3A) allowed is five percent

About YUNUS Brothers Group
Lucky Cement Limited has been sponsored by Yunus
Brothers Group (YB Group) which is one of the largest business groups of
the Country based in Karachi and has grown up remarkably over the last
50 years. The YB Group is engaged in diversified manufacturing activities
including Textile, Spinning, Weaving, Processing, Finishing, Stitching and
Power Generation. The Group consists of a number of industrial
establishments other then Lucky Cement Limited, they include:

1. Lucky Textile Mills
2. Fazal Textile Mills Limited
3. Gadoon Textile Mills Limited
4. Lucky Energy (Private) Limited
5. Yunus Textile Mills

Lucky Textile Mills - established in 1983


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- Fully computerized weaving and stitching unit
- Consists of 3 weaving plants comprising of 800 looms, 250 stitching
machines, 3.4 million meter/month Grey fabric capacity, 83 million
meters/ annum processing and 15 million meters/ annum made ups
capacity
- Power generation capacity 6.20 MW
- Expertise in ready-made curtains and accessories for foreign markets

Fazal Textile Mills Limited - established in 1987

- One of the top spinning mill in the country with 59,508 installed spindles
- Produces 100% Grey Cotton Ring Spun Yarn and wide range of Blended
and Heather Yarns?
- ISO – 9001:2000 certified

Gadoon Textile Mills Limited - established in 1988

- First of the only two mills in the world producing Compact Core Spun
yarn
- 194,392 installed spindles. Produces high quality Compact yarn, Murata
Jet Spinning yarn, Core Spun yarn and 100% Grey Cotton Ring Spun yarn
- Also has a power plant of 34 MW
- OKO – Tex Standard 100 certified

Lucky Energy (PVT) Limited - established in 1993

- Captive power unit
- Supplies uninterruptible power to Lucky Textiles, Fazal
- Textiles & Lucky Knitwear
- Generation capacity of 17.4 MW

Yunus Textile Mills Limited - established in 1998

- State of the art machinery for weaving, printing and dyeing

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- Self power generation capacity of 14 MW
- 250 Air Jet looms installed
- Completely vertically integrated textile mill
- Major Player in home textile and garment exports

BUSINESS STRATEGY

To be the leading exporter of cement from Pakistan for the
regional countries as well as to explore other potential export markets. Our
future strategy is to explore investment possibilities outside Pakistan in the
cement industry to become a leading global producer.

EXPLORING AND ESTABLISHING EXPORT MARKETS

We have a firm commitment in exploring new markets for
sustainable business growth. Lucky Cement has been successful in
establishing its brand in several export markets including Middle East,
India, Sri Lanka and East and South African countries. We are also
planning to setup some offshore facilities to further strengthen our export
business on regular basis.

ABOUT LUCKY CEMENT LIMITED CONCRETE
PROGRESS, KARACHI.
Founder Mr. Abdul Razzak Tabba

Lucky cement limited concrete progress is Sponsor by well
known “Yunus Brothers Group” – one of the largest export houses of
Pakistan, Lucky Cement Limited currently has the capacity of producing
25,000 tons per day of dry process Cement.
Lucky Cement came into existence in 1996 with a daily
production capacity of 4,200 tons per day, currently is an omnipotent
cement plant of Pakistan, and rated amongst the few best plants in Asia.


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With production facilities in Pezu (Production capacity: 13,000 Tons per
day) as well as in Karachi (Production capacity: 12,000 tons per day), it
has the tendency to become the hub of cement production in Asia. Lucky
Cement Limited has been sponsored by Yunus Brothers Group (YB
Group) which is one of the largest business groups of the Country based in
Karachi and has grown up remarkably over the last 50 years.

PRODUCTS PF LUCKY CEMENT
Lucky Cement aims at producing cement to suit every user. The
following types of cement are available:

1. Ordinary Portland Cement
2. Sulphate Resistant Cement
3. Slag Cement

ORDINARY PORTLAND CEMENT (OPC)
Ordinary Portland cement is available in darker shade as well as
in light shades in Lucky Star with different brand names to suit the
requirement of users.
It is used in all general constructions especially in major
prestigious projects where cement is to meet stringent quality
requirements; it can be used in concrete mortars and grouts etc. Ordinary
Portland cement is compatible/consumable with admixture/ retarders etc.

SULPHATE RESISTANT CEMENT (SRC)
Sulphate resistant Cement’s best quality is to provide effective
and long lasting strength against sulphate attacks and is very suitable for
constructions near sea shores as well as for canals linings. It provides very
effective protection against alkali attacks.

SLAG CEMENT
Slag cement is also available for specific user requirements.
Slag cement, has been incorporated into concrete projects for over
a century to improve durability and reduce life cycle costs. Among its
measurable benefits in concrete are better workability and finish ability,

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higher compressive and flexural strengths, and improved resistance to
aggressive chemicals.

BRANDS AVAILABLE AT LUCKY CEMENT
• Lucky CEMENT (REGULAR) Lucky STAR
• Lucky GOLD Lucky SULPHATE RESISTANT CEMENT (SRC)

QUALITY POLICY
Quality of cement

ISO CERTIFICATION
Lucky's Cement plant is one of the best maintained plants of
Pakistan and is managed by qualified and expert cement field specialists.
The Company has also got ISO 9001:2000 certifications, for
manufacturing and sales of cement by UKAS Quality Management,
Pakistan National Accreditation Council and Moody International.

QUALITY MANAGEMENT
Lucky Cement always gives major emphasis in manufacturing
high quality cement through stringent quality control techniques and
computerized control systems using state of the art sophisticated
equipments like Distributed Control System (DCS), Programmable Logic
Controllers (PLCs) and on line X-Ray Analyzers. The Company has got
one of the best equipped laboratories, having all facilities for the analysis
of raw material, semi furnished product, furnished product and fuel, to
ensure the supply of high quality product to market.

The quality of Company’s cement has been tested and found to be superior
in many respects to the specifications mentioned in Pakistan and British
Standards.


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SUPERIOR STRENGTH, OPTIMUM SETTING TIMES AND
MINIMUM EXPANSION
These are the three benchmarks adopted by Lucky Cement
Limited which is emerging to be the largest cement plant of Asia and
committed to provide the best quality cement to its customers around the
globe through stringent quality control and application of most modern
quality control techniques.

SUPERIOR STRENGTH
The compressive strength is a very important factor of cement.
The Ordinary Portland Cement achieves its maximum strength in 28 days.
The Pakistan standard PSS 232-1883 (R) & British Standard EN 197 Class
42.5 N provides for 28 days strength of 5000Psi and 5950 Psi respectively
for mortar cubes. As compared to this Lucky Cement has a 28 days
compressive strength of more than 7,000 psi to bear heavy loads.

OPTIMUM SETTING TIME
Optimal initial & final setting times are ensured by adopting
special production parameters using most modern control techniques.

SOUNDENESS
By using most modern Kiln feeding system, it is ensured that
lime entering into the Kiln should be in such a shape that it should totally
combine with oxides during the burning process. The result is that the
frees lime content is very low and soundness of Lucky Cement is less than
1 mm which is far better than 10 mm prescribed by Pakistan Standard PSS
232-1983 ( R) and / or British Standard EN 197 Class 42.5 N.
Lucky Power Generators is one of the best maintained power
generation facilities of the country and is maintained and operated round
the clock by expert engineers and technicians.

VARIETY TO SUIT EVERYONE
Lucky Cement aims at producing cement to suit every user. At
present, it is producing Grey Portland Cement and also Sulphate Resistant
cement. The customers are able to get Portland Cement both in dark shade

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as well as in light shade with different brand names to suit the requirement
of user. The Portland cement specifically made for prefabrication industry
with a lower setting time is also available. In addition, the plant also
produce Slag cement for specific users.
Overall flow diagram of lucky cement plant.


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Schematic explanation of Portland cement production

There are three fundamental stages in the production of Portland cement:

1. Preparation of the raw mixture
2. Production of the clinker
3. Preparation of the cement


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RAW MATERIAL’S
Cement is manufactured into two stages
First stage :
from crusher to kiln
Second stage :
from clinker yard to cement mill
That’s why raw material is also divided into two stages

First stage raw material Second stage raw material
Lime stone Clinker
Clay or Lucky clay Gypsum
Latirite Slag
Bauxite

Following basic raw materials are generally used in the manufacture of
cement

LIMESTONE
Limestone is a sedimentary rock composed largely of the mineral calcite
(calcium carbonate: CaCO3). The deposition of limestone strata is often a
by-product and indicator of biological activity in the geologic record.
Calcium (along with nitrogen, phosphorus, and potassium) is a key
mineral to plant nutrition: soils overlying limestone bedrock tend to be
pre-fertilized with calcium. Limestone is an important stone for masonry
and architecture, vying with only granite and sandstone to be the most
commonly used architectural stone. Limestone is a key ingredient of
quicklime, mortar, cement, and concrete. The solubility of limestone in
water and weak acid solutions leads to important phenomena. Regions
overlying limestone bedrock tend to have fewer visible groundwater
sources (ponds and streams), as surface water easily drains downward
through cracks in the limestone. While draining, water slowly (over
thousands or millions of years) enlarges these cracks; dissolving the

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calcium-carbonate and carrying it away in solution. Most well-known
natural cave systems are through limestone bedrock.

uses include:

• The manufacture of quicklime (calcium oxide) and slaked lime
(calcium hydroxide);
• Cement and mortar;
• Pulverized limestone is used as a soil conditioner to neutralize acidic
soil conditions;
• Crushed for use as aggregate—the solid base for many roads;
• Geological formations of limestone are among the best petroleum
reservoirs;
• As a reagent in desulphurization;
• Glass making, in some circumstances;
• Added to paper, plastics, paint, tiles, and other materials as both
white pigment and cheap filler.
• Toothpaste
• Suppression of methane explosions in underground coal mines
• Added to bread and cereals as a source of calcium

SEDIMENTARY ROCK
Sedimentary rock is one of the three main rock types (the others being
igneous and metamorphic rock). Sedimentary rock is formed by deposition
and consolidation of mineral and organic material and from precipitation
of minerals from solution. The processes that form sedimentary rock occur
at the surface of the Earth and within bodies of water. Rock formed from
sediments covers 75-80% of the Earth's land area, and includes common
types such as limestone, chalk, dolostone, sandstone, conglomerate, some
types of breccia, and shale.)

CLAY
Clay is a naturally occurring material composed primarily of fine-grained
minerals, which show plasticity through a variable range of water content,

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and which can be hardened when dried and/or fired. Clay deposits are
mostly composed of clay minerals (phyllosilicate minerals), minerals
which impart plasticity and harden when fired and/or dried, and variable
amounts of water trapped in the mineral structure by polar attraction.
Organic materials which do not impart plasticity may also be a part of clay
deposits.

LATRITE
Latrite is redish brown color and it contains iron content ,
.It is less harder than gypsum but harder than limestone.

BAUXITE
Bauxite is the most important aluminium ore. It consists largely of the
minerals gibbsite Al(OH)3, boehmite γ-AlO(OH), and diaspore α-
AlO(OH), together with the iron oxides goethite and hematite, the clay
mineral kaolinite and small amounts of anatase TiO2. It was named after
the village Les Baux in southern France, where it was first discovered in
1821 by the geologist Pierre Berthier.

SLAG
Slag is the mixture of iron and some metallic impurities. It is obtained
from steel mills. The cement made from slag is full of strength.

GYPSUM (Ca SO4)

It is obtained from the N.W.F.P
And 5% is added with clinker obtained from kiln in cement mill and then
grinded to get cement.
It is used for refresh ness of cement.


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MANUFACTURING AIDS
• COAL
In lucky cement industry coal is the major source of fuel, for this
purpose coal is imported from
1. south Africa
2. Indonesia

Some time lucky also uses a mixture of south African and Indonesian coal.

• FURNANCE OIL

Furnace oil is also used in cement industry for burning the kiln initially.
It help us to maintain the temperature of the kiln.


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LABORATARY
When plant is designed it is decided that which type and
quality of raw material is used for the manufacture of desired product.
So a laboratory is established that take care of the raw material which is
suitable for the plant.
For this purpose the samples of raw material is checked
at the time of purchasing. For ensuring the good quality of the product.

TITRATION

Laboratory also decide the titration or ratio of raw material
used in the plant . In practice, the raw material for rawmix is controlled
by frequent chemical analysis (hourly by X-Ray fluorescence analysis,
or every three minutes by prompt gamma neutron activation analysis).
The analysis data is used to make automatic adjustments to raw
material feed rates.

TESTING

In lucky cement industry a laboratory is also working
for the same purpose that every sample of raw material is checked
before and After purchasing the raw material. Fuel used for burning in
the kiln is also tested because of some safety reasons.

TESTING OF COAL

Coal is the main fuel in cement industry that why it is tested
very .
Testing of caol has been didvided into three stages
• Presence of moisture
To find the moisture in coal a coal sample is get from the fresh
supply or last day or present morning truck
Then sample is divided into two categories
1. Crushed coal

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2. Grinded coal

Crushed coal is used to find the RM (Received Moisture) by using
moisture analyzer

Powdered or Grinded coal is used to find the TM (Total Moisture) by
using moisture analyzer

Air moisture is find by taking the coal in a glass dish and weight and place
it in decicator to remove moisture with the help of silica gel and after 30
minutes put out the dish and weight it .

Inherent moisture is the moisture which is possessed by the coal it self so
it can be calculated as follows
Total moisture - Air moisture = Inherent moisture
• Loss on ignition
To calculate the loss on ignition we have to first calculate the volatile
matter
Then by using formula we can calculate loss on ignition

• Presense of sulphur

TESTING OF RAW MATERIAL

Following basic raw materials are used in the lucky cement industry to
check this thing that the purchased raw material is suitable or not for plant
raw materials are tested .
• Limestone
• Bauxite
• Latrite
• Clay
• Gypsum
• Slag


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For testing the above raw material X-Ray Flourescence Spectrometry
method is used it is a Computer operated machine in which a ring sample
is introduced .
This machine takes few minutes and give as two things
1. name of compound or element present in the sample
2. concentration of the element or compound

some X-Ray Flourescence Spectrometry results are given
below

lime stone at crusher

L.O SiO Al2 Fe2 Ca Mg SO Na2 K2 Cl LS S A
.I 2 O3 O3 O O 3 O O F M M
42. 3.8 0.77 0.92 52. 1.1 0.0 0.19 0.1 0.0 4.3 2.2 0.8
69 68 7 1 3 5 3 4 3

Clay

SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O K2O Cl LSF SM AM
68.57 12.48 4.29 4.3 1.48 0.01 0.84 2.43 0.14 0.02 4.09 2.91
74.06 11.29 5.15 2.82 1.39 0.02 0.89 2.16 0.16 0.02 4.51 2.19

Latrite

SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O K2O Cl LSF SM AM
17.81 7.41 48.51 7.79 0.51 0.11 0.34 0.08 0.05 0.09 0.32 0.15
29.22 9.25 45.05 4.32 0.47 0.04 0.35 0.11 0.36 0.03 0.54 0.21


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CRUSHER
HAMMER CRUSHER

In lucky cement industry hammer crusher are used for crushing the lime
stone
The hammer crusher contain 5 rows and 9 hammers in each row it means
that hammer crusher has 45 hammers.

A hammer mill is a machine whose purpose is to shred material into fine
particles. They have many sorts of applications in many industries,
including:

WORKING AND CONDITION

The basic principle is straightforward. A hammer mill is essentially a steel
drum containing a vertical or horizontal rotating shaft or drum on which
hammers are mounted. The hammers are free to swing on the ends of the
cross, or fixed to the central rotor. The rotor is spun at a high speed inside
the drum while material is fed into a feed hopper. The material is impacted
by the hammer bars and is thereby shredded and expelled through screens
in the drum of a selected size.

Small grain hammer mills can be operated on household current. Large
automobile shredders can use one or more 2000 horsepower (1.5 MW)
diesel engines to power the hammer mill.

The Screen less hammer mill uses air flow to separate small particles from
larger ones. It is designed to be more reliable, and is also claimed to be
much cheaper and more energy efficient than regular hammer mills.

PRODUCTION OF CRUSHER

In lucky cement industry two lime stone crusher are Assembled both are
hammer crusher
Hammer mill at lucky reduces the size of I meter stone into 70 to 80 mm

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The crushing capacity of hammer mill is 800 to 900 ton/hour .
The weight of each hammer is 120 kg .

LIMESTONE YARD
A yard is made for the storage of crushed limestone in form of
piles .
A limestone pile being built by a boom stacker and prehomogenization of
pile is made with the help of reclaimer.
Crushed limestone is transported by a 90 m long belt to the storage yard
then it drop the material on chand belt then chand belt drop on boom belt
then with the help of boom stacker piles are made then after
prehomogenization the lime stone is transported to the proportionating
building by buckets then on long belt .


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PROPORTIONATING TOWER
INTRODUCTION

In lucky cement there is a Proportionting tower. It is a building which
store raw material Silos of individual raw materials are arranged. It has
hoppers which provide feed to weigh-feeder. Accurately controlled
proportions of each material are delivered onto the belt by weigh-feeders.
The proportion of raw material is decided by Laboratory usually luck
cement industry works on following titration .

• limestone 75 to 85 %
• purchase clay 6 to 7 %
• lucky clay 5 to 6 %
• bauxite 1 to 2 %

WEIGH FEEDER

Weigh feeder is a machine which weigh’s the material according to the
defined composition and supply to the conveyer belt which take the
material to the work place.

Decision of proportion of raw material for grinding.

. In practice, the raw material for rawmix is controlled by frequent
chemical analysis (hourly by X-Ray fluorescence analysis in the
laboratory, or every three minutes by prompt gamma neutron activation
analysis). The analysis data is used to make automatic adjustments to raw
material feed rates.


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VERTICAL RAW MILL or RAW MILL
These are the standard form in modern installations, occasionally called
vertical spindle mills. In a typical arrangement, the material is fed onto a
rotating table, onto which steel rollers press down. A high velocity of hot
gas flow is maintained close to the dish so that fine particles are swept
away as soon as they are produced. The gas flow carries the fines into an
integral air separator, which returns larger particles to the grinding path.
The fine material is swept out in the exhaust gas and is captured by a
cyclone before being pumped to storage. Feed size can be up to 100 mm.
Roller mills are efficient, using about half the energy of a ball mill, and
there seems to be no limit to the size available. Roller mills with output in
excess of 800 tonnes per hour have been installed. Unlike ball mills, feed
to the mill must be regular and uninterrupted; otherwise damaging
resonant vibration sets in.

. In the case of a dry process, the rawmill also dries the raw materials,
usually by passing hot exhaust gases from the kiln through the mill, so that
the rawmix emerges as a fine powder. This is conveyed to the blending
system by conveyor belt or by a powder pump.

VRM section in Lucky cement plant
In lucky cement plant the Vertical raw mill is used for the grinding
of Raw material and coal.

Approximately 180 to 210 tons of feed per hour is provided to the
VRM . According to the introduction of VRM there are some rollers in the
mill. VRM at lucky has 4 rollers weight of each roller is 22 ton.

Inlet temperature of VRM is 287 C for 230 ton/h feed acorrding
to design capacity


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VRM (Vertical Raw Mil) or Roller Mill.


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GRIDING OF COAL
COAL MILL

In Lucky Coal mill is the place where coal is grinded into fine powder for
this purpose a small Roller mill or VRM (Vertical Raw Mill) is used.

COAL GRINDING

Grinding of coal Also take place in a small roller mill or VRM (Vertical
Raw Mill) but it has only two Stationary Rollers other working is same as
define above for the VRM .

Coal mill design capacity is 25 tons/h and its inlet temperature is 92 C .

PULVERIZE COAL

Fine powdered coal is called Pulverize coal. The coal is grind to fine
powder because the fine coal is very easy to burn in the kiln or PC (pre-
calciner)

COAL STORAGE BIN

After Grinding the coal is stored in a bin whose capacity is 100 tonn but in
lucky cement only 25 to 30 % bin is filled because coal can catch fire from
the surrounding.

FIRE EXTINGUISHER SYSTEM

A latest fire extinguisher system is installed in the Coal mill area which is
fully automatic and can Also be control through the PLC(Programmable
Logic Controller).


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COAL TRANSPORTATION TO
1. Pre-calciner (PC)
2. main burner (kiln)

The Grinded coal is used as a fuel in PC and kiln so it is transported to
them through the Delta Blowers.

In Lucky 4 Delta Blowers are used , 2 are used for transportation of coal to
the PC and 2 are used for the transportation of coal to the main Burner at
kiln


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GRINDING OF RAW MATERIAL
After deciding the ratio of raw material at proportioning tower the next
step is grinding of raw material.
In Lucky cement Industry Vertical Raw Mill is used for Grinding the raw
material.

VERTICAL RAW MILL USED FOR GRINDHING THE
RAW MAERIAL

The raw materials are next ground together in a rawmill.
VRM used here is consisting of 4 continuously moving Rollers. The
fineness of rawmix is specified in terms of the size of the largest particles,
and is usually controlled so that there are less than 5%-15% by mass of
particles exceeding 90 µm in diameter. It is important that the rawmix
contains no large particles in order to complete the chemical reactions in
the kiln,

TRANSPORTATION OF INGREDIENTS
The Silos of individual raw materials are arranged (Proportionting tower)
over the feed conveyor belt. Accurately controlled proportions of each
material are delivered onto the belt by weigh-feeders. Passing into the
rawmill, the mixture is ground to rawmix.

ROTARY VALVE

Rotary valve is a valve which control the flow of feed at raw mill and
helps in maintaining the pressure in the mill.
I.D FAN

I.D fan or induce Draft fan is the fan which provides hot air to the VRM
from the preheater. It also produces negative pressure in the kiln and
preheater.


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SYSTEM FAN

System fan is also an I.D fan but it is used for the suction of air from the
VRM through the cyclones. It sucks the hot air from the VRM and send it
to Bag house. It also works for maintaining the negative pressure into the
VRM.

TRAVELING OG HOT AIR

In the plant area or VRM area the hot Air flows from one place to another
through the Ducts.

Ducts are pipe lines of very big dia which are used for transportation
purpose.

CYCLONE

A cyclone is a conical vessel into
which a dust-bearing gas-stream is
passed tangentially. This produces a
vortex within the vessel. The gas leaves
the vessel through a co-axial "vortex-finder".
The solids are thrown to the outside edge
of the vessel by centrifugal action, and leave
through a valve in the vertex of the cone.
Cyclones were originally used to clean up
the dust-laden gases leaving simple dry
process kilns.

In lucky cement plant 4 cyclones are used in the VRM area which purify
the hot gas which is coming from VRM .


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AIR SLIDES

Air Slides is a mean of transportation in the cement plant it take the
material from one place to another with the help of air. Bags and blowers
are used in air slides. Air slides are normally used at the bottom of
cyclones.

BAG HOUSE

Bag house is a collective name of many bag filters. Bag house has 20
chambers and each chamber contains 104 bags. It is also known as Dust
Collector or Fabric filters.
In lucky the most common type of bag filters are used which operates with
a velocity of about 0.01 m/s across the bag surface.

BAG HOUSE FAN

Bag house fan is a suction fan which helps the bag house in filtering the
hot air from cyclones. If it does not work properly then there is a need to
shutdown the plant because it also helps in producing the negative pressure
and prevention of atmosphere from pollution.

OUTLET OF EXTRA GASES

The bag house remove fine raw mix particles from the hot air then
remaining extra gases containing SOx , NOx , CO and CO2 released in the
atmosphere.

STORAGE OF POWDER GRINDED RAW MATERIAL TO
THE SILO
Raw material in required ratio is grinded by the Vertical Raw mill is
separated by the cyclones is sent to the __65__ m silo having capacity


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__3300___ tons with the help of air slides, screw conveyers and bucket
elevators .
This silo is also used to give feed to the pre-heater

HOMOGENIZATION OF GRINDED RAW MATERIAL

As the raw mix is stored in the silo that’s why its need to homogenize it
for this purpose heavy compressor are used which through's air from the
downward due to which a continuous motion occurs in the material and
Homogenization of grinded raw material takes place.


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CALCINATION & HEAT EXCHANGE
Raw material enters the pre heater for pre heating before sending to the
rotatary kiln it is also known as four stage tower it is about 87m high
,consisting of cyclones , riser duct (gas duct) and pre calciner,(pc).
To conserve energy most modern cement plants pre heat raw material
before they enter the kiln using the exhaust gases from kiln itself.

In Lucky cement plant a 5 stage pre-heater is used.
Pre-heater is divided into two section
• Cyclones of pre-heater .
Where heat exchange takes place between the feed (raw mix) and hot
air .
• Precalciner (P.C)
Where calcinations takes place . In pre calciner abut 75-80% calcination
(formation of cao) take place by decomposition of CaCO3 into CaO &
CO2.
CaCO3___________CaO+CO2 (calcination)

To understand a pre-heater completely I have given a 4 stage pre-heater
description with diagram.

Gas-suspension preheaters
Cutaway view of cyclone showing air path
The key component of the gas-suspension
pre-heater is the cyclone and the precalciner.
A cyclone is a conical vessel into which a
dust-bearing gas-stream is passed tangentially.
This produces a vortex within the vessel.
The gas leaves the vessel through a co-axial
"vortex-finder". The solids are thrown to the
outside edge of the vessel by centrifugal action,
and leave through a valve in the vertex of the cone. Cyclones were
originally used to clean up the dust-laden gases leaving simple dry process
kilns. If, instead, the entire feed of raw mix is encouraged to pass through

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the cyclone, it is found that a very efficient heat exchange takes place: the
gas is efficiently cooled, hence producing less waste of heat to the
atmosphere, and the raw mix is efficiently heated. This efficiency is
sphere,
further increased if a number of cyclones are connected in series.

4-Stage preheater, showing path of feed
Stage
MANSOOR ALI SOLANGI (08IN106
(08IN106)

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The number of cyclones stages used in practice varies from 1 to 6. Energy,
in the form of fan-power, is required to draw the gases through the string
of cyclones, and at a string of 6 cyclones, the cost of the added fan-power
needed for an extra cyclone exceeds the efficiency advantage gained. It is
normal to use the warm exhaust gas to dry the raw materials in the raw
mill, and if the raw materials are wet, hot gas from a less efficient
preheater is desirable. For this reason, the most commonly encountered
suspension preheaters have 4 cyclones. The hot feed that leaves the base of
the preheater string is typically 20% calcined, so the kiln has less
subsequent processing to do, and can therefore achieve a higher specific
output. Typical large systems installed in the early 1970s had cyclones 6 m
in diameter, a rotary kiln of 5 x 75 m, making 2500 tones per day, using
about 0.11-0.12 tonnes of coal fuel for every tones of clinker produced.

A penalty paid for the efficiency of suspension preheaters is their tendency
to block up. Salts, such as the sulfate and chloride of sodium and
potassium, tend to evaporate in the burning zone of the kiln. They are
carried back in vapor form, and re-condense when a sufficiently low
temperature is encountered. Because these salts re-circulate back into the
rawmix and re-enter the burning zone, a recirculation cycle establishes
itself. A kiln with 0.1% chloride in the rawmix and clinker may have 5%
chloride in the mid-kiln material. Condensation usually occurs in the
preheater, and a sticky deposit of liquid salts glues dusty raw mix into a
hard deposit, typically on surfaces against which the gas-flow is
impacting. This can choke the preheater to the point that air-flow can no
longer be maintained in the kiln. It then becomes necessary to manually
break the build-up away. Modern installations often have automatic
devices installed at vulnerable points to knock out build-up regularly. An
alternative approach is to "bleed off" some of the kiln exhaust at the kiln
inlet where the salts are still in the vapor phase, and remove and discard
the solids in this. This is usually termed an "alkali bleed" and it breaks the
recirculation cycle. It can also be of advantage for cement quality reasons,
since it reduces the alkali content of the clinker. However, hot gas is run to
waste so the process is inefficient and increases kiln fuel consumption.


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Cement plant pre heater Designed by Polysius, this new plant includes a
four-stage precalciner with a 158-foot (48-meter) long by 13-foot (4-
meter) diameter two-station kiln to produce 2,500 tons per day of clinker.
Air Cannons were not included in the design of this new plant. But based
on his 25 years in the cement industry, Production Manager Tom Messer
knew they would be required to avoid shutdowns due to blockages of the
material flow through the kiln pre-heater. “I’ve seen the problems that can
arise from plugs and choking of the pre-heater,” Messer explains. “I’ve
seen the high labor costs and the production losses that come from having
to shut down the tower to break up a blockage.”

Messer and Martin Engineering developed a plan for the installation of 45
big blasters and air canons on the brand new pre-heater. Crews from
Martin Engineering’s Martin Services group installed the pre-heater air
cannon system. Feed is entered from feed silo to risor of cyclone 2.

Pre calciners

% of North American Capacity using Precalciners


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Mean Daily Output (tonnes) of North American Kilns

In the 1970s the precalciner was pioneered in Japan, and has subsequently
, sub
become the equipment of choice for new large installations world world-wide[7].
The precalciner is a development of the suspension preheater. The
philosophy is this: the amount of fuel that can be burned in the kiln is
e
directly related to the size of the kiln. If part of the fuel necessary to burn
the rawmix is burned outside the kiln, the output of the system can be
increased for a given kiln size. Users of suspension preheaters found that
preheaters
output could be increased by injecting extra fuel into the base of the
preheater. The logical development was to install a specially designed
combustion chamber at the base of the preheater, into which pulverized
coal is injected. This is referred to as an "air through" precalciner, because
"air-through"
the combustion air for both the kiln fuel and the calciner fuel all passes
through the kiln. This kind of precalciner can burn up to 30% (typically
20%) of its fuel in the calciner. If more fuel were injected in the calciner,
the extra amount of air drawn through the kiln would cool the kiln flame
excessively. The feed is 40 60% calcined before it enters the rotary kiln.
40-60%

The ultimate development is the "air separate" precalciner, in which the
"air-separate"
hot combustion air for the calciner arrives in a duct directly from the
ustion
cooler, bypassing the kiln. Typically, 60 75% of the fuel is burned in the
60-75%
precalciner. In these systems, the feed entering the rotary kiln is 100%
calcined. The kiln has only to raise the feed to sintering temperature. In
feed
(08IN106)

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theory the maximum efficiency would be achieved if all the fuel were
burned in the preheater, but the sintering operation involves partial melting
and nodulization to make clinker, and the rolling action of the rotary kiln
remains the most efficient way of doing this. Large modern installations
typically have two parallel strings of 4 or 5 cyclones, with one attached to
the kiln and the other attached to the precalciner chamber. A rotary kiln of
6 x 100 m makes 8,000–10,000 tonnes per day, using about 0.10-0.11
tonnes of coal fuel for every tones of clinker produced. The kiln is dwarfed
by the massive preheater tower and cooler in these installations. Such a
kiln produces 3 million tonnes of clinker per year, and consumes 300,000
tones of coal. A diameter of 6 m appears to be the limit of size of rotary
kilns, because the flexibility of the steel shell becomes unmanageable at or
above this size, and the firebrick lining tends to fail when the kiln flexes.

A particular advantage of the air-separate precalciner is that a large
proportion, or even 100%, of the alkali-laden kiln exhaust gas can be taken
off as alkali bleed (see above). Because this accounts for only 40% of the
system heat input, it can be done with lower heat wastage than in a simple
suspension preheater bleed. Because of this, air-separate precalciners are
now always prescribed when only high-alkali raw materials are available
at a cement plant.

TARGET OF PRE-HEATER

Pre-heater is used for heat exchange and calcinations .
In lucky cement plant Pre-heater’s inlet temperature is 800 to 1000 C and
out let temperature is 250 to 280 C .
The raw material is burned in the pre-heater for 52 seconds and then it is
sent to kiln . 75-80 % calcination is done..
It increases the production capacity, it reduces the specific heat
consumption also reduces specific power consumption.
ADVANTAGE OF PRE-HEATER

• Improved kiln operation efficiency.
• Reduced production cost.

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• Environmental protection.

INLET OF FEED TO PRE-HEATER

Feed is entered through the feed silo in the risor of cyclone 2 with help of
bucket elevators.

CONSTRUCTION OF FEED SILO

The capacity of this silo is mentioned above here I want to tell u that
below the silo there is a bin where feed to pre-heater is homogenized and
weighed the capacity of this bin is 100 ton .
This bin is connected to 8 gates of air slides which opens in the opposite
pair of two and provide feed to the main air slide on the rate of 215 Ton/h.

BIN STORAGE AND SILOS

Bins are cylindrical or rectangular vessels of concrete or metals .a silo is
tall and relatively small in diameter .a bin is not so tall and usually fairly
wide .silos and bins are loaded from top by some kind of elevator.
Discharging is done from the bottom .

PRESSURE IN BINS AND SILOS

When solid or semi solids are placed in a bin or silo the lateral pressure
exerted On the wall at any point is less than predicted from the head of
material above that point .there usually is friction between walls and
solids. The friction Force at the wall tends to off set the weight of solid
and reduces the pressure exerted by mass on the floor of container .in
general when height of solids column is greater than about 3 times
diameter of the container ,additional solids have no effect on the pressure
at the base.


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FLOW OUT OF BINS

solids tend to flow out of any openings near the bottom of bin but are best
discharged through an opening in the floor .flow through a side openings
tends to be un certain an increase the lateral pressure on the other side of
bin while the solids are flowing.
When out let at bottom of a bin containing free flowing is opened , the
material immediately above the opening begins to flow . one of two flow
pattern will develop , depending on steepness of the walls in the bottom
section of the bin and on the coefficient of friction between the solids and
the bin walls. tunnel flow develops in the bins with a shallow cone angle
or with vertical walls and central opening in the floor. here a vertical
column of solids above the openings moves downward with out disturbing
the material at the sides. eventually lateral flow begins ,first from the top
most layer of solids.
The rate of flow of solids by gravity through a circular opening in the
bottom of a bin depends on the diameter of the openings and on the
properties of the solid
With cohesive solids it is often hard to start flow .once flow does start,
however, it again begin in the material directly above the discharge
opening. sticky solids and even some dry powder adhere strongly to
vertical surfaces and have enough shear strength to support a plug of
considerable diameter above an open discharge .thus to get flow started
and to keep the material moving , vibrators on the in walls , internal plows
near the bin floor, or jets of air in the discharge opening are often needed.

PRE-CALCINER BURNER

Pre calciner burner is composed of two chambers vortex chamber and
reaction chamber ,the vortex chamber is situated at the end of tertiary air
duct ,close to the entry to the kiln gases , they can therefore get
preliminarily mixed. the tertiary air is drawn from the middle part of the
burner and is therefore of medium temperature about 750 to 850 C. in
these conditions a condensations of volatile components of the feed occurs

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on the grains of raw material and they are recycled to the kiln ,which
allows the formations of accretions on the walls of precalciner to be
avoided. the raw mix is fed to side upper part of reaction chamber, while
in lower part 2 burners are arranged readily round the shaft of the chamber.
Due to vortex motion of the gases in the of the gases in the axis of
reaction chamber negative pressure is developed, facilitating the
introduction of the grains of the fuel and meal to the fuel and meal to the
inside chamber.

PRE- CALCINATIONS

A first principle model of cement precalcination system is developed for
the purpose of controller’s design and synthesis. The dynamic model is
based on the mass and energy balance principle and consists of a set of
ordinary differential equations. Based on some logical assumptions, the
model not only considers the reaction mechanisms but also reduces the
complexity of precalciner system. The model is divided into a preheater
sub model and a calciner sub model. Separate sub model for preheater and
calciner are initially developed and coupled together to build an integrated
model. The model takes the gas content into account and can obtain the
values of all key output variables in precalcination process.

OVERALL PRE-HEATER PROCESS

In lucky cement plant feed is entered in the risor of cyclone 2 than hot air
take the feed to Cyclone 1A and 1B,
outlet of cyclone 1A and 1B drop the material in risor R-3 than hot air
take the material to C-2 ,
out let of C-2 drop the feed into R-4 than hot air takes the material to C-3 ,
outlet of C-3 drop the material into R-5 than hot air takes the feed into C-4
,
the outlet of C-4 drops the material in P.C. where calcinations of raw mix
take place . here two burners are used for this purpose fresh air is also
given to the burners. Burners use pulverize coal for burning . the
temperature of P.C is 850 to 900 C and has an pressure of -813 pascal ,

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After the calcinations hot air takes the material in C-5 through the goose
neck of P.C. ,
This reaction takes place in the calcination zone
CaCO3 → CaO + CO2
(lime stone) (lime)

The outlet of C-5 drops the material into KILN INLET OR SMOKE
CHAMBER OR INLET CHAMBER .

S:NO STAGES TEMP
PRESSURE

1 Klin 900-950
2.6-3.6
2 Riser duct 10-
11
3 P.C 900-930 8-
10
4 Cyclone -4 810-850
18-12
5 Cyclone-3 750-770
30-35
6 Cyclone -2 550-600
40-55
7 Cyclone -1 350-380
55-65
8 I.D fan 350- 370
65-70
9 Secondry 1100-1150 ---
---
10 Tertiary 630-670 --
----


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PRIMARY DUCT

A method and apparatus for controlling the combustion of fuel
modules charged into a preheater or precalciner kiln above the transition
shelf, typically into the riser duct, is described. The apparatus includes a
sensor for providing signals indicative of the status in the region of
combustion of the fuel modules, and a controller for a fuel module feed
mechanism is provided to receive signals indicative of the status of the
combustion region and adjust the rate of delivery of the fuel module into
the combustion region responsive to the sensed conditions in the
combustion region.


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KILN AREA

INTRIDUCTION TO KILN

Cement kilns are used for the pyroprocessing stage of manufacture of
Portland and other types of hydraulic cement, in which calcium carbonate
reacts with silica-bearing minerals to form a mixture of calcium silicates.
Over a billion tonnes of cement are made per year, and cement kilns are
the heart of this production process: their capacity usually define the
capacity of the cement plant. As the main energy-consuming and
greenhouse-gas–emitting stage of cement manufacture, improvement of
their efficiency has been the central concern of cement manufacturing
technology.

Kiln is consist of 4 zones ;
• Calcinations zone
• Transition zone
• Burning zone
• Cooling zone

Kiln used at Lucky cement plant is
• 64 meter in length ,
• total dia of kiln is 4.3 meter and effective dia is 3.9 meter .
• Slop of kiln is 3.5 %.
• Migration of kiln is 4-5 rpm.


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THE ROTARY KILN

General layout of a rotary kiln

The rotary kiln consists of a tube made from steel plate, and lined with
firebrick. The tube slopes slightly (1
. (1–4°) and slowly rotates on its axis at
between 30 and 250 revolutions per hour. Rawmix is fed in at the upper
end, and the rotation of the kiln causes it gradually to move downhill to the
other end of the kiln. At the other end fuel, in the form of gas, oil, or
pulverized solid fuel, is blown in through the "burner pipe", producing a
large concentric flame in the lower part of the kiln tube. As material moves
under the flame, it reaches its peak temperature, before dropping out of the
before
kiln tube into the cooler. Air is drawn first through the cooler and then
through the kiln for combustion of the fuel. In the cooler the air is heated
by the cooling clinker, so that it may be 400 to 800 °C before it enters the
kiln, thus causing intense and rapid combustion of the fuel.

Kiln are typically stopped only for a few days once or twice a year for
essential maintenance.

IGNITION OF KILN

Some time once or twice in a year kiln is shutdown for
maintenance purpose . after the the completion of maintenance the kiln
is again ignited.

(08IN106)

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For the ignition of kiln first of all furnace oil is used
because it has higher calorific value 9760 cal Furnace oil used for kiln
main burner is first treated in a boiler to decrease its viscosity at
minimum level due to which it flows very well. when the required
initial temperature of kiln is maintained than kiln is burned on pulverize
coal whose calorific value is 5800 cal .
As we know that oxygen is necessary for ignition that’s
why blowers are used which provides fresh air to the main burner.

KILN PROCESS

IN LUCKY CEMENT PLANT

After pre heating and pre calcinated material enters in burning and clinker
zone of kilns where temp ranges from 1000C-1350C. Here CaO reacts
with other oxides to form cementeous materal. Burning of kiln involves
the following steps ;
1. evaporation of free water at temperature upto 100 C
2. removal of absorbed water in clay material 100-300 C
3. removal of chemically bounded water 450-900 C
4. calcinations of carbonate materials 700-850 C
5. formation of C2S, Aluminates and ferrite’s 800-1250 C
6. formation of liquid phase melt > 1250 C
7. formation of C3S 1330-1450 C
8. cooling of clinker to solidify liquid phase 1300-1240 C
9. final clinker microstructure frozen in clinker < 1200 C
10. clinker cooled in cooler 1250-100 C

the final product as it comes out the kiln is known as clinker .

REACTION AT KILN

Following major reactions take place inside the kiln. )


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2CaO + SiO2 → 2CaO.SiO2
(Dicalcium silicate)
3CaO + SiO2 → 3CaO.SiO2
(Tri Calcium Silicate)

3CaO + Al2O3 → 3CaO.Al2O3
(TRI CALCIUM ALUMINATE)
.
4CaO+AlO3+Fe2O3 → 4CaO.Al2O3.Fe2O3
(Tetra Calcium Aluminum Ferrate)

FORMATION OF CLINKER

At about 1280 0C And above clinker is formed which is in the form of
compound that is known as cement compound. The composition of clinker
is as followed .

COMPOSITION OF CLINKER

C3S 55-56%
C2S 21-22%
C3A 5-6(FOR OPC)
C3A <3.5(FOR SRC)
C4AF 12-13(FOR OPC)
C4AF 16-17(FOR SRC


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OUTLET OF CLINKER

AT ABOUT 1280 C And above clinker is formed which is in the form
of compound that is known as cement compound . hot clinker is dropped
into the cooler.
OUTER VEIW OF KILN


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COOLING AND STORAGE OF CLINKER
In lucky cement a grate cooler is used to cool the clinker . These coolers
have two main advantages: they cool the clinker rapidly, which is desirable
from a quality point of view, and, because they don't rotate (rotating
coolers used in early ages) , hot air can be ducted out of them for use in
fuel drying, or for use as precalciner combustion air.

FAN FOR COOLER.

8 Fans are also used to force air through the cooler bed or grates.

CONSTRUCTION OF COOLER

This consists of a perforated grate through which cold air is blown,
enclosed in a rectangular chamber. A bed of clinker up to 0.5 m deep
moves along the grate. The grates are moved with the help of a hydraulic
system.

COOLER CRUSHER

Rotary crushers are used at the out let of a cooler. These crushers crush the
big pieces of cooled clinker into small ones.

PAN CONVERYER

Pan conveyer is the medium used for transportation of material in heavy
amount. It consist of a chain of pan joined with each other in the form of a
belt. Motors are used to run them.

STORAGE OF CLINKER
Cooled clinker from the cooler is transported to the clinker storage yard
with the help of pan conveyer.


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CEMENT MILL
Cement mill is the area where finally cement is manufacture by the
addition of second stage raw materials (Slag , Gypsum and clinker) it
consist of following parts

Diagram of CEMENT MILL

Flow diagram of cement mill

Roller press or crusher
Crushing Separator
Storage bin
Ball mill
In lucky cement plant the cement mill is used is actually a ball mill.

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The length of ball mill is 13 meter . it is divided into two chambers .
Its 1st chamber is 3 meter long and 2nd chamber is 10 meter long .
The efficiency of ball mill depends on the size and weight of media or
grinding medium.
Media size in 1st chamber is 30,40,50 and 60 mm and in 2nd chamber is 10
x12 , 12x14 mm .
Weight of media in ball mill is 180 ton .

Grinding aid
Glycol is used as grinding aid in ball mill . due to high temperature
gypsum under goes hydration so lumps form in the mill which chock the
out let of ball mill so glycol stops this phenomena

Storage of cement


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PACKING PLANT
LOOSE CEMENT

Lucky cement also export loose cement by loading it into through
bunker. Daily it export ton per day.
loose cement storage and ship loading terminal at berth -25 west
wharf karachi port

PACKED CEMENT


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QUALITY CONTROL LAB
COLLECTION OF SAMPLE

For quality management samples of material and cement is taken from
following places ,

• Query
• Limestone yard
• Proportionating building
• Vertical Raw mill Air slide
• Raw mix silo
• Preheater
• Cooler
• Ball mill

Testing of sample at different stages

ANALYSIS OF COAL

In order to access the quality of the coal the following two types of
analyses are made.
• PROXIMATE ANALYSES
• ULTIMATE ANALYSES

PROXIMATE ANALYSIS

It is the analyses on compound basis which involves the following
determinations.
1.moisture

INTERNSHIP PROGRAME

2.volatile matter
3.ash
4.fixed carbon
1. MOISTURE:
about 1gm of finaly powdered air dried coal sample is weighed in a
crucible . the crucible is placed inside an electronic hot air oven
maintained at 105_110 0C the crucible is allowed to remain in oven for 1
hour and then taken out. (with the help of pair of tongs) cooled in a
desecator and weighed .
loss in weight is reported as moisture on % basis.
FORMULA FOR FINDING MOISTURE

% of moisture =( loss in weight / weight of coal taken )*100

2.VOLATILE MATTER

the dried sample of coal left in a crucible in crucible in (1) is then covered
with a lid and placed in an electric furnace(muffle furnace) maintained at
925+25oC or 925-25oC .the crucible is taken out of the oven after 7
minutes heating. The crucible is cooled 1st in air then inside dedicator and
weighed again loss in weight is reported as volatile matter i,e
Formula For Finding Volatile Matter

volatile matter (v m) = loss in weight due to removal of volatile matter x
100
wt of coal sample taken
3.ASH
the residual coal in the crucible in (2) is then heated without lid in a
muffle at about 500C for half an hour .the crucible is taken out cooled 1st
in air then in desiccators and weighed ,heating, cooling and weighing is
repeated till a constant weight is obtained the residue is reported as ash on
%basis.

FORMULA FOR FINDING % OF ASH
The % of ash = wt of ash left x 100

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wt of coal taken

4.FIXED CARBON

% of fixed carbon = 100 -% of (moisture + volatile matter +ash)

ULTIMATE ANALYSIS

It is the analysis on elemental basis which involves the following
determinations.
1. carbon and hydrogen
2. Nitrogen
3. sulpher
4. oxygen

1. CARBON AND HYDROGEN;
about 0.2gms of accurately weighed coal sample is burnt in a
current of oxygen in a combustion apparatus .C and H of the coal are
converted into CO2 and H2O respectively. The gaseous products are
absorbed respectively in KOH and CaCl2 tubes of known weights, the
increase in weight of these tubes are then determined

C + O2 → CO2

2KOH + CO2 → K2CO3 + H2O

CaCl2 + 7H2O → CaCl2 .7H2O

% OF C = Increase in weight of KOH tube x 12 x 100
Weight of coal sample taken x 44


INTERNSHIP PROGRAME

% of H2= increase in weight of CaCl2 tube x 2 x 100
weight of coal sample taken x 18

1. NITROGEN

About 1 gm of accurately weighed powdered coal is heated with
concentrated H2SO4 along necked flask called kejeld’s flask, after the
solution becomes clear it is treated with excess of KOH and LIBERATED
AMMOUNT is distilled over and absorbed in a known volume of standard
acid solution. The unused acid is then determined by lack titration with
standard NAOH FROM the volume of acid by ammonia liberated % of N
in coal is calculated as follows

% OF N =volume of acid used x normality x14 x 100
weight of coal taken

3.SULPHER
Sulpher is determined from washings obtained from the
known mass sample of coal used in a bomb calorimeter for
determination of calorific value during determination. Sulpher is
converted into sulphate , the washings are with barium chloride solution
BaCl2, when BaSO4 is precipitated this filtrate washed and heated to
constant weight.

% of sulphur in coal = wt of bariam sulphate obtained x 32 x 100
233 x wt of coal sample taken in bomb

4.Oxygen
Oxygen determined by
% of oxygen = 100 - % of (C + S + H + N + Ash


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POWER GENERATION
There is also a power generation plant in lucky cement industry. 11
generators are used some of them required furnace oil and some Natural
gas.

Furnance oil generator or Dual fuel generator

There are 2 dual fuel or furnace oil generators are used. Dual fuel
generators are those which uses furnace oil and natural gas as fuel for
power generation. Each generator produces 7.4 Mega Watt electricity.

Natural gas generator

There are 9 other generators used to generate electricity by natural gas.
• 5 of them is of CAT MAC company and has an efficiency of
generating electricity nearly 5.9 Mega Watt.
• 3 of Roll Royce company having efficiency of 6.9 Mega Watt.
• 1 of Roll Royce company having efficiency of 8.5 Mega Watt

Generation of power house

In lucky cement industry total power consumption is 48.5 Mega Watt .
Power house can generate 75 Mega Watt electricity.


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OVERALL PERFORMANCE OF LUCKY CEMENT
LIMITED
Aims and missions
F uture plan

Expansion plan

Our Company has emerged as the largest exporter of cement in Pakistan.
We have been able to capture new markets where our brand is now very
well established and known for its high quality of cement produced by us.
The location of our Karachi project is ideal for exports by sea for which
we have already setup state-of-the-art infrastructure at Plants & Karachi
Port.

Currently the total production capacity of Lucky Cement is 25,000 tons
per day. Our Company has adopted the same hybrid technology experience
for this expansion plan which was earlier used for the existing production
lines by acquiring the latest technology fuel consuming components from
European suppliers with the combination of Chinese plant and machinery
which helps to minimize expansion cost. It will ensure great efficiency for
producing cement at lower cost.

The power requirement for the expansion lines will be met through captive
gas based power generation for which additional supply of gas has been
arranged.


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ENVIRONMENTAL SAFETY

GLOBAL WARMING AND THE DANGERS OF GHG

WASTE HEAT RECOVERY
Lucky Cement, being aware of Global warming and the dangers of GHG,
has decided to play an active role in participating in reduction of global
warming and creating an environmental friendly atmosphere. In this regard
Lucky cement has taken a step to contribute in this Global effort to control
carbon emission.

Lucky Cement Limited is now in the process of installing a waste heat
recovery system which will utilize the waste heat generated during clinker
production into electrical power with zero emission of carbon and without
consuming any fuel. This effort of producing 25 MW electricity, although
a costly effort , but looking at the circumstances both nationally and
internationally will help in contributing in production of electricity in a
nation where the power generation sector is in crisis and in a world which
feels the dangers to environment and global warming.


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CONCLUSION
Lucky cement industry is a day by day growing industry and counted in
Pakistan’s most biggest and popular industry.

We have observed all units process and operations used in a chemical
industry and got good working experience in lucky.

Internship is most important for the engineering students as it develops
confidence and practical knowledge in students during their studies.

As far as the production of lucky concrete progress plant is concerned,
it is in very huge quantity and of good quality.

Lucky is famous for manufacturing OPC of very good quality.


INTERNSHIP PROGRAME

(08IN106)

Lucky cement factory internship report

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