PowerPoint Presentation

In plant training reportinUltraTech Cement Limited

Submitted by:P.Bharath Kumar Reddy

ACKNOWLEDGEMENTTo start with, I express our sincere gratitude to our VIT University and Mr.G.M.Krishna, the president and the unit head of Ultra tech cements Limited, A.P. Cement Works, for allowing the students to undergo in plant training in ultra tech cements limited.

I would like to express my sincere gratitude to Mr.Abdul Rasheed and Mr.Raghunandhan who were directly involved in our training without whose inputs, i could not have carried out the training. I thank them for their valuable inputs and their valuable time.My sincere thanks to Mr.Bharath Kumar who was at the back of everything during my stay here.I also cannot forget the immense help given by Mr.Purushotham and Mr.Somi Reddy the process department they were there whenever I needed them.

COMPANY OVERVIEW

About Aditya birlaA metals powerhouse, among the world's most cost-efficient aluminum and copper producers.No.1 inviscose staple fibreNo.1 incarbon blackThe fourth-largest producer ofinsulatorsThe fourth-largest producer of acrylic fibreAmong the top 10cementproducersAmong the best energy-efficientfertilizerplantsThe largest Indian MNC with manufacturing operations in the USA

The Indian ScenarioThe largest fashion(premium branded apparel)and lifestyle playerThe second-largest manufacturer and largest exporter ofviscose filament yarnThe largest producer in the chlor-alkali sectorAmong the top threemobile telephony companiesA leading player inlife insuranceand asset managementAmong the top two supermarket chains in the retail businessAmong the top 6bpo companiesThe largest manufacturer of linen fabric.

Vision And Values To be a premium global conglomerate, with a clear focus on each of the businesses.Our missionTo deliver superior value to customers, shareholders, employees and society at large.Our valuesIntegrity :Acting and taking decisions in a manner that is fair and honest.Commitment :On the foundation of integrity, doing all that is needed to deliver value to all stakeholders.

ContinuedPassion :An energetic, intuitive zeal that arises from emotional engagement with the organization.

Seamlessness:Thinking and working together across functional groups, hierarchies, businesses and geographies.

Speed :Responding to internal and external customers with a sense of urgency.

Ultra Tech cement overviewUltra tech is India's largest exporter of cement spanning export markets in countries across the Indian ocean and the middle east. Ultra tech and its subsidiaries have a presence in 5 countries through 12 composite plants, 1 white cement plant, 1 wall care putty plant, 1 clinkerisation plant in the use, 16 grinding units (12 in India, 2 in use and 1 each in Bahrain and Bangladesh) and 6 bulk terminals (5 in India and 1 in sir lank) and 101 rmc plants.Most of the plants have iso 9001, iso 14001 and ohsas 18001 certification. In addition, two plants have received ISO 27001 certification and four have received SA 8000 certification.

UltraTech's products include ordinary Portland cement, Portland Pozzolana cement and Portland blast-furnace slag cement.Ultratech cement is the ultimate 360 building materials destination, providing an array of products ranging from grey cement to white cement, from building products to building solutions and an assortment of ready mix concretes catering to the varied needs and applications.

Ordinary Portland CementOrdinary Portland cement is the most commonly used cement for a wide range of applications. These applications cover ordinary, standard, high strength concretes, masonry and plastering works, precast concrete products for e.g., Blocks, pipes etc., And specialized works such as precast and prestressed concrete.

Portland slag CementUltratech premium's composition comprising high quality clinker blended with judicious amounts of superior blast furnace slag having high glass content, gypsum devoid of deleterious materials and optimum PSD (particle size distribution) ensures its unsurpassable performance year on year.Ultratech premium is extensively used for mass concrete applications like large foundations, dams, concrete roads among others. It is ideal for RCC in marine and aggressive environments due to its superior resistance to attack of sulphates and chlorides. It can be used for structures below the ground and for those that are in contact with water. Ultratech premium, with superior 28-day compressive strength, forms an ideal solution for critical applications such as slabs, columns, beams and roofs.

Portland Pozzolana CementPortland Pozzolana cement is ordinary Portland cement intimately blended or interground with pozzolanic materials such as fly ash, calcined clay, rice husk ash etc.Pozzolanas by themselves do not have cementitious properties but reacts with calcium hydroxide in the presence of moisture at normal temperature to form compounds having cementitious properties.The concrete produced by using Portland Pozzolana cement has high ultimate strength, is more durable, resists wet cracking, thermal cracking and has a high degree of cohesion and workability in concrete and mortar.

Manufacture of Cement

Portland cements are made by grinding a mixture of limestone, clay and other corrective materials, viz. Laterite, bauxite ,etc. Essential constituents mainly are lime, silica, alumina and iron oxide. The process of manufacturing consists of grinding of raw materials into fine powder, mixing them intimately and burning in a kiln at about 1400 deg. C. The resultant product is called clinker. Clinker is cooled, ground to fine powder with gypsum. The end product is cement.

FLOW PROCESS OF OF CEMENT MANUFACTURING

Traditional Manufacture of Portland Cement1. Stone is first reduced to 50mm size

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2.Raw materials are ground to powder and blended.

3.Burning changes raw mix chemically into cement clinker.

3.Burning changes raw mix chemically into clinker. Note four stage preheater, flash furnaces, and shorter kiln.

4. Clinker is ground with gypsum into portland cement and shipped.

Clinker

Gypsum22BRIEF EXPLANATIONLimestone is excavated from mines. Sometimes clay or any other raw material is added to improve the quality of raw material excavated.Huge and large lime stones now dumped into crusher to convert the stones into small and manageable chunks of around 20mm size.Limestone obtained from crusher goes for quality check. Now after sorting out unsuitable limestone passing through conveyer belt it goes to vertical raw mill for grinding material.

Now through conveyer belt powered from of RM comes to blending silos to mix them homogeneously.Before calcination it comes to preheating and then to kiln for calcination @tempo of 1400-1500 degrees cAfter calcination RM get cooled to get gray coloured nodules which is called clinker. Then clinker stored in silos for further processing on cement milling. Clinker when mixed with gypsum produces cement

SIGNIFICANT COMPONENTS IN CEMENT MILL

1. Vertical Roller Mill

Introduction to Vertical Roller Mill

Vertical roller mill is a new kind of large-scale grinding mill which is designed specially to solve the problems of low capacity and high consumption of industry mills. With decades of years research, vertical roller mill is designed and manufactured based on a advanced design idea. Now it has found its extensive application in the mining ,chemistry, non-metallurgy and other hundreds of industries.

Working Principle of Vertical Roller Mill

The motor drives the grinding table to turn through the speed reducer. At the same time, hot air comes into the roller mill from the air inlet. The materials fall down the centre of grinding table from the feeder.Because of the centrifugal force, the materials move to the edge of grinding table from the centre.The materials are crushed by the grinding roller when they passes the groove on the grinding table. The crusher materials continue to move to the edge of the grinding table until they are taken away by the airstream. Then the bigger materials fall down the grinding table and the process of crushing continues.

When the materials in the airstream pass the separator on the top of the mill, the materials fall down the grinding table from the taper filler under the force of guide leaf blade. The fine powder comes out with the airstream, and is gathered by the dust catcher of the system. The powder gathered is the final product of roller mill.In the process of the contact of airstream , the materials are dried to meet the clients need at the proper moisture.Through the adjustment of the angle between the separator and the leaf of winds direction (not suitable to the small type of vertical mill), and also the speed of the separator rotor, it can reach the proper fineness of the materials

Packaging Department

Rotary Packer Packaging Process

Vibrating Screen

SIGNIFICANT COMPONENTS IN PACKING PLANTS

Introduction to vibrating screenThe vibrating screen is a kind of sieving equipment of international advanced level, used in ultratech on the basis of carrying on the advantages of traditional screens and absorbing the outstanding technology from abroad. It is widely used for grading and screening materials in the following fields: minerals, quarry, building materials, water conservancy and hydropower, transportation, chemical industry, smelting and so on.

Working principle of vibrating screenThe vibrating screen adjusts the amplitude by tube-shaped violent vibration screen of eccentric shaft and eccentric blocks. The body moves like a circle, in order to make the materials screened.

MATERIAL HANDLING EQUIPMENTS

Manual cut off gates are made of M.S. Steel body, consisting of slide plate, stuffing box, spindle and hand wheel / chain pulley. These types of gates are at the time of maintenance or erection / commissioning.MANUAL CUTOFF GATE

FLOW CONTROL GATEFlow control gates have a key role in any kinds of plants operations as it is the equipment which gives the feedback about the material passing through the line and controls the flow of the material as per the requirement. Flow control gates are designed and supplied with a provision of 0-100% output flow, which can be set as per the desired output These types of gates are motorised or with pneumatic actuator.

32PNEUMATIC CUTOFF GATE

Play an important role at the time of power failure These gates are specially designed considering the different aspects of the running operations and as per requirement, they get closed or open quickly at the time of power failureJunction Box / Diversion Unit is a part of fluid airslide and is useful to turn the fluid slide at 300 degrees Junction boxes are designed with matching inlet & outlet flanges of the fluid slide with aerated bottom and air inlet.DIVERSION BOXES

CONVEYERSAconveyor systemis a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in thematerial handlingandpackagingindustries. Many kinds of conveying systems are available, and are used according to the various needs of different industries.

BELT CONVEYERSConveyors are durable and reliable components used in automateddistributionand warehousing.Rubber conveyor belts are commonly used to convey items with irregular bottom surfaces, small items that would fall in Between rollers, or bags of product that would sag between rollers.Belt conveyorsare usually built with two or more pulleys, with a constant movement of the conveyor belt rotating to move product. One or both of the pulleys are powered, moving both the belt and the product on the belt onward.Belt conveyors can come with flat bed or on rollers.SCREW CONVEYERAscrew conveyororauger conveyoris a mechanism that uses a rotating helicalscrewblade, called a "flighting", usually within a tube, to move liquid or granular materials.They are used in many bulk handling industries. Screw conveyors in modern industry are often used horizontally or at a slight incline as an efficient way to move materialsHey usually consist of a trough or tube containing either a spiral blade coiled around a shaft, driven at one end and held at the other, or a "shaft less spiral", driven at one end and free at the other. The rate of volume transfer is proportional to the rotation rate of the shaft.

Aeration Conveyor (Air Slide)Air slides are used to gravity- convey powders by passing low-pressure air through a porous membrane media and into the bed of the material being handled.The criteria are particle size, moisture content and temperature.The absence of moving parts and low power requirements make air gravity conveying the most economical way to convey fine materials over short or long distances.These conveyers can be used at a minimum angle of 8 degrees.

DEEP PAN CONVEYER Suitable for handling hot material like clinker in horizontal And inclined profile up to 45 degree. Pans are pressed in high capacity presses using special dies which imparts high strength and ensures very less spillage of handled material.Special alloy steel chain links are provided which have high abrasion resistance. These chain links are with non back bend type construction, which ensures no spillage of the material during loading and horizontal conveying.Alloy steel rollers are with ball bearings which offer very less friction and are provided with special seals.BUCKET ELEVATOR

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