A Report

On

ULTRATECH CEMENT LIMITED

By

B BHARATH KUMAR REDDY

ACKNOWLEDGEMENT
To start with, we express our sincere gratitude to our SRM
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.
Our sincere thanks to Mr.Sudhakar Babu who was at the back of
everything during our stay here.
I would like to express my sincere gratitude to Mr.Ravichandra
sekhar and Mr.Raghunandhan who were directly involved in our
training without whose inputs, we could not have carried out the
training. We thank them for their valuable inputs and their
valuable time.
We also cannot forget the immense help given by Mr.Raju and
Mr.Harshavardhan Reddy the process department they were there
whenever we needed them.
We thank all the experts who gave us great guest lectures and
shared their vast knowledge and also their valuable experiences
with us. These lectures helped us to gain overall practical
knowledge.
We would also like to thank all the others from this unit who
directly and indirectly contributed to our training.

ABOUT BIRLA GROUP OF

INDUSTRIES

A US $40 billion corporation, the Aditya Birla Group is in the

League of Fortune 500. It is anchored by an extraordinary force of
over 120,000 employees belonging to 42 nationalities. The Group
has been ranked Number 4 in the global 'T
op Companies for Leaders' survey and ranked Number 1 in Asia
Pacific for 2011. 'Top Companies for Leaders' is the most
comprehensive study of organisational leadership in the world
conducted by Aon Hewitt, Fortune Magazine, and RBL (a strategic
HR and Leadership Advisory firm). The Group has topped the
Nielsen's Corporate Image Monitor 2013-14 and emerged as the
Number 1 corporate, the 'Best in Class', for the second
consecutive year.

Over 50 per cent of the Aditya Birla Group's revenues flow from its
overseas operations. The Group operates in 36 countries
Australia, Austria, Bangladesh, Brazil, Canada, China, Egypt,
France, Germany, Hungary, India, Indonesia, Italy, Ivory Coast,
Japan, Korea, Laos, Luxembourg, Malaysia, Myanmar, Philippines,
Poland, Russia, Singapore, South Africa, Spain, Sri Lanka, Sweden,

Switzerland, Tanzania, Thailand, Turkey, UAE, UK, USA, and

Vietnam.

Aditya Birla Group The Global Scenario

Around the world, they were known for:

A metals powerhouse, among the world's most cost-efficient

aluminium and copper producers. Hindalco-Novelis is the largest
aluminium rolling company. It is one of the three biggest
producers of primary aluminium in Asia with the largest single
location copper smelter
No.1 in viscose staple fibre
No.1 in carbon black
The fourth-largest producer of insulators
The fourth-largest producer of acrylic fibre
Among the top 10 cement producers
Among the best energy-efficient fertiliser plants
The largest Indian MNC with manufacturing operations in the USA
Aditya Birla Group The Indian Scenario

In India, here's what they have accomplished:

The largest fashion (premium branded apparel) and lifestyle
player

The second-largest manufacturer and largest exporter of viscose

filament yarn
The largest producer in the chlor-alkali sector
Among the top three mobile telephony companies
A leading player in life insurance and asset management
Among the top two supermarket chains in the retail business
Rock solid in fundamentals, the Aditya Birla Group nurtures a
culture where success does not come in the way of the need to
keep learning afresh, to keep experimenting.

Aditya Birla Group Beyond Business

Works in 3,000 villages
Reaches out to seven million people, annually, through the Aditya Birla Centre for
Community Initiatives and Rural Development spearheaded by Mrs. Rajashree
Birla
Focuses on healthcare, education, sustainable livelihood, infrastructure and
espousing social reform in India, Brazil and Egypt, as well as Philippines,
Thailand, Laos, Indonesia, Korea and other Asian countries

In India:
The Aditya Birla Group runs 42 schools, which provide quality education to
45,000 children. Of these 18,000 students belong to the underprivileged segment.
Merit scholarships are given to an additional 12,000 children from the interiors.
The 18 hospitals run by the Aditya Birla Group tend to more than a million
villagers.
In line with its commitment to sustainable development, the Aditya Birla Group
has partnered with Columbia University in establishing the Columbia Global
Centre's Earth Institute in Mumbai.

The idea of embedding CSR as a way of life in organisations has led to the setting
up of the FICCI Aditya Birla CSR Centre for Excellence, in Delhi.
The Aditya Birla Group transcends the conventional barriers of business because
we believe it is our duty to facilitate inclusive growth.

Contents
1.1 Cement manufacturing
1.2 Mining
1.3 Raw mill
1.4 Kiln
1.5 Cement Mill
1.6 Packing and dispatching

Ultra tech Cement Ltd. Bhogasamudram - a Grasim subsidiary

and a flagship company of the Aditya Birla group is the 11 th
largest cement producer in the world and the largest in India .The
plant is located at the border line between
Kurnool and
anantapur Districts and therefore also acknowledged as Andhra
Pradesh cement Works .The plant is ISO 9002,ISO 9001,ISO
14001&OHAS 18001 and ISO 17025 certified. The plant consists
of two phases-Phases I and Phase II .The total production capacity
is 18000 Tons per day.

1.1 Cement manufacturing:

The raw materials used in the production of cement are:
1.
2.
3.
4.
5.
6.

Lime stones
Aluminous oxide
Ferrous Oxide
Gypsum
Fly ash
Slag

Lime stone the major raw material in cement production. Lime

stone mined from mines and crushed in a crusher, to the desired
size. The limestone along with other raw materials, aluminous
oxide and iron ore are added proportionately and ground fine in
Raw Mill, to about 20%-25% residue on 90 micron sieve. The raw
meal is heated to a storage called control flow silo. The Raw meal
is heated to a temperature of about 1450 degrees Celsius,
though series of cyclone separators, Pre calciner and kiln. During
the course of heating, carbondioxide is eliminated and Calcium
Oxide reacts with various radicals to form Tri Calcium Aluminate,
tetra calicium alumite ,di calicium silicate and Tri Calicium
silicate.

The resultant product is called as Clinker which will be in granule

form. The clinker leaves the kiln at about 1300-1400 degrees
celsius. The hot clinker is cooled rapidly by a series of fans. The
clinker is stored in clinker silos. Coal or oil is used for this process
tort convert from raw meal to clinker. Raw coal is pulverized in a
coal mill to powder to a size of about 13%-16% residue on 90
micron sieve. In A.P.C.W 3 types of cement are manufactured
1. OPC(Ordinary Portland cement)
2. PPC(Pozzolana Portland cement)
3. PSC(Portland slag cement)

Limestone is the major raw material in cement and is mined

from captive mines and crushed to the desired size fraction at a
rated output of 1200TPH.APCW is having two vertical roller mills
of rated capacity 265TPH with 20% residue on 90micron sieve ,
each for raw material grinding .The coal meal is stored in two fine
coal bins, one for kiln firing and the other for Calciner firing . The
final stage is grinding of clinker and other additives in to cement.
There are two cement mills with roller press capacity 161 TPH(on
OPC basis) at a specific surface of 3000cm2/g each. The cement
mills are deducted /vented throughESPs
(Electrostatic
Precipitators). At APCPW there are six silos of 4600m3 storage
capacity for storing the cement.
The cement is packed in bags with the help of six electronic
packers operating round the clock. The packed cement is
dispatched to various destinations by road and rail. De-dusting of
the packing machine is done by jet pulse filters(JPF). The material
handling conveyors at transfer points in the plant are vented or
dedusted through dust collectors .Some of the clinker transported
to Arakkonam grinding unit by railway wagons as per the
requirement at their end.

The power requirements of the cement plant and its auxiliaries

are partly met through 2nos of D. G. sets of 12 MW capacity,
installed within the plant premises and the balance power is
drawn from state power grid.

1.2 Mining:
Mining is the process of extraction of valuable minerals or other geological
materials from earth. Ore is a mixture of aggregated minerals. Mineral is the
dominating material in the ore. Narji limestone is present in A.P.C.W, which is
sedimentary type of rock. The age of limestone is more than 800 million years. The
maximum depth in mines is 36m. There are 4 benches of each having depth 9m.
The top layer of the mines is covered with black soil of 1.5m depth. Daily
production of limestone in A.P.C.W is 12500 metric tons.

Process:
Several processes taking place in mining operation at A.P.C.W. are listed below
a)

Drilling

b)

Blasting

c)

Excavation and Transportation

d)

Crushing and Stacking.

Drilling:
Drilling is the process of making columns for blasting operation and to excavate
limestone for quality testing. The sample, which is obtained from drilling, is to
analyze the quality. Drilling machines are used to drill up to 10m depth to fill
explosives.

Blasting:

Detonator is used for initiation and ignition. Explosives produce shock waves
inside the rock to blast. The shock waves generated, travel through the solids and
reflect from the free space. This causes blasting. This, is coves drilled column,
which is filled with the explosives, is covered with the sand, which is known as
Stemming.

Excavation and Transportation:

The blasted material is loaded into dumpers using excavators. This process of
dozing is referred to the gathering of material after the blast. Dumpers are heavy
trucks that take the limestone from blast area to the hopper in the crusher unit. The
capacity of each dumper used in A.P.C.W. is 35tons.

Crushing and Stacking:

The limestone dumped in the hopper is feed by apron feeder undergoes a crushing
process to get an output diameter within the range of 25-75mm. This crushed
limestone is sent to stacker through conveyor belt.
The monitoring of the whole process is automatized. Stacker is used to stores the
crushed limestone. The capacity of stacker in A.P.C.W. is 45,000 tons.

1.3 Raw mill:

Raw mill is one of the main parts in the cement manufacturing industry. It is the
equipment used to grind raw material into raw mix during the manufacture of
cement. Raw mix is then fed into a cement kiln, which transforms it into clinker,
which is then ground to make cement in the cement mill. The below image is a
flow sheet for a raw mill.

Limestone from the mines is sent to impact crusher where it is crushed to 70mm
thickness. This crushed limestone from rubber belt conveyors is send to limestone
stacker. Using Harrow rake car limestone from stacker is transferred to hoppers. In
the same way shale, bauxite, iron ore is transferred to their respective hoppers. The
resultant mixture is now sent to vertical roller mill comprising of a table, gearbox,
motor, three equidistant and inter connected rollers and blades where the material
is sent sideways at a speed of 25rpm.
Pressure is applied by the hydraulic pump for rotation of the grinded particles
from the mills. The dynamic separator separates the fine and coarse particles. The
coarse particles are again recycled back to stacker by vibro feeder. The fine
particles are then sent to the four cyclones of 5600mm diameter each where the
dust particles at the bottom of bucket elevator.
These particles are then sent to reverse air bag house for dust collection. Apart
from the dust particles the particles collected from the cyclones are send to silo
from flux slides and belt conveyors. The particles from these bucket elevators are
sent to silos. The product of the raw material that is stored in the silo is known as
raw meal and the particle size is about 96microns.

1.4 Rotary kiln:

A furnace or oven for burning, baking, or drying, especially one for calcining lime
or firing pottery.

Pre-heater:
It is heating equipment used for heating the raw meal before it is sent to the kiln for
clinkerization. It is a six stage pre heater with a total of 13 cyclones in 2 different
strings namely kiln string (6 cyclones) &calciner string (6 cyclones+1 calciner)
each of different size, which at the end of the heating process raises the
temperature of the raw meal to about 900 c.

Rotary kiln

Kiln:
It is a huge rotary furnace with a 220mm thick internal brick lining. It is of length
75 meters and 4.75meters diameter, rotating at a variable speed of 4.6 rpm. The
clinkerization process takes in the kiln. The kiln is run by a DC motor. The
temperatures inside the kiln can go up to 1400 c. There are three zones in the kiln
namely calcining zone, burning zone and cooling zone.

Kiln

Cooler:
This device cools the clinkers, which are formed in the kiln to 170 c. The cooler
consists of a moving plate and a fixed plate. The moving plate of each other is inter
connected and they move at the rate of 25 strokes/min. It consists of 13 fans, which
are of forced draft type, a water injection system and a temperature scanner.

Grate cooler

Hammer crusher:
Due to the formation of clinker, the material size is around 90mm. The hammer
crusher helps in crushing the clinker to the required size of 30mm and 60mm. It is
of lower cost compared to jaw crushers and impact crushers.

Hammer crusher

1.5 Cement Mill:

A.P.C.W consists of two cement mills. Each mill has a roller press of 160 TPH
capacities. This output rating is done on OPC (Ordinary Portland Cement) basis.
The clinker and gypsum are fed via the three-weigh feeders. All conveyors and
feeders run on the principle of Load X speed. The clinker feeders are discharging
via a change over gate to a reversible conveyor belt to the elevator, feeding the
roller press feed bin. At the last conveyor belt and before the feed hopper, a

magnetic separator and a metal detector are installed. When this metal detector is
activated, then a changeover gate is changing position directing the metal to a
container placed on the ground floor. In this way no metal will enter the roller
press. The gypsum is fed via a changeover gate to another conveyor belt feeding
directly to the ball mill.
The mixture of clinker and slag coming from roller press and send to the grit
separator. The coarse material falling through the grit separator is returned to the
elevator feeding the roller press feed bin. The fresh clinker feed and coarse
material returned from the grit separator (mainly clinker) are pressed in the roller
press. The material passing through the roller gap is compressed or crushed and the
particle size is considerably reduced.

In the grit separator, the material is de-agglomerated and the coarse material is
separated. In the 2nd stage SEPAX separator the fines are separated. The coarse
material is returned via a weighing unit to the ball mill inlet for grinding. The dust
is transported to the cement silos. The de-dusted air is then evacuated via the
chimney to the atmosphere.
The product of the cement mill is final form of cement. This is send to packing and
dispatch, which is the interface of plant production and prospective consumers.

1.6 Packing and Dispatch:

Cement from the Cement Mill is stored in silos, each of 6000 tons capacity. We had
totally six silos two for OPC, one for PPC, three for PSC cement is transported
from silos too the screw conveyors through feeding chutes. This is then fed in to
the vibrating screen through bucket elevators for particle separation. Vibration
screen consists of a mesh (4mm x 4mm), which separates the fine particles from
coarse particles. These fine particles are further transported to the feed hopper. A
jet pulse filter is connected to the feed hopper so as to minimize the pollution. The
feed hopper is provided with a level indicator to indicate the cement level and a
knife gate to block the excess cement. For bulk-loading cement is transported
through flux-slides from the hopper. For truck loading and wagon loading cement
is fed in to the rotary van feeder, which regulates the cement flow to the packers.
Essential features of packing and dispatch unit:
a) Ventomatic Packers
b) Wagon, Truck and Bulk Loading
c) Dispatch to various parts of South India
d) Programmable Logic Control (PLC)
e) Plant in A.P.C.W.