A

INTERNSHIP REPORT
ON
“ cement manufacturing process “
SUBMITTED BY
Yash kumar soni

Raju sen

Deepak khandelwal

Deepak chouhan

Bhanaram

Final Year Mechanical Engineering.

Chartered Institute of Technology , Abu Road (Raj.)

SUBMITTED TO
Mr. Mukesh Gautam

Jk Laxmi cement , jkpuram

For Acadmic Year 2019-20

JK Laxmi cement Ltd

CONTENTS
● Introduction
● Cement
manufacturing process
● Kiln process
● Packaging of
cement

DECLARATION BY THE CANDIDATE

 We declare that the project report CEMENT MANUFACTURING PROCESS is
based on our own work Carried out during the course of our study under the supervision
of mr. mukesh gautam.
I assert the statement made and conclusion drawn are an outcome of my research
work. I fully certify that
1. The work contained in the report is original and has been done by me under the
general supervision of my supervisor.
2. The work has not been submitted to any other Industry for any other certificate.
3. We have used materials (data, theoretical analysis, and text) from other sources, we
have given due credit to them in the text of the report and giving their details in the
references.

INTRODUCTION
JK Lakshmi Cement Limited is a part of over 132 years old JK Organisation. An eminent
industrial house, with operations in India and abroad and having a leadership presence in the
fields of tyre, cement, paper, power transmissions and sealing solutions, dairy products and
textile.

JK Lakshmi Cement (JKLC) was set up in 1982– in a village in District Sirohi, Rajasthan. Today,
the company stands tall with an annual turnover of about Rs. 3000 Crores and an impressive
production of 13.30 million tonnes per annum.

JK Lakshmi Cement is the strength behind structures that India is proud of – Indra Gandhi Nahar
Pariyojna, Sardar Sarovar Project, Golden Quadrilateral , Mundra and Kandla Port stands to
name a few. It partners India’s leading corporations such as L&T, Reliance, NTPC and Essar to
create the new India’s success story. It is the brand choice across all section of customers such as
housing projects, roads and bridges , airports , factories and as well as the individual house
builder (IHB). Behind these numbers and achievements lies a story of grit, perseverance and a
thirst to excel through innovations in products ,using world-class technology .

Building better products through better technology

The true spirit of a leader lies in constant innovation and not resting on one’s laurels. JK Lakshmi
Cement proves it with “JK Lakshmi PRO+ Cement” in an all new avatar. The idea to develop
cement with superior qualities germinated in early 2014. A team of experts was put together to
analyze what the consumer wants. Once the latent needs of the consumers were identified, the
team further studied best manufacturing practices across the globe in order to fulfill this needs.
The result? A cement with 7+ astounding benefits in terms of strength, durability, finish, setting
speed, quality assurance, service and economy.
Today, JK Lakshmi PRO+ Cement is the talk of the town by being the best-in-class product and
has become the first choice among customers. Dealers across India have shown an
unprecedented enthusiasm and excitement towards this product.

A leader has the ability to think ahead of his times. For long, JK Lakshmi Cement’s felt that
traditional red bricks needed to evolve.
Hence, it came up with JKSmartBlox - Autoclaved Aerated Concrete Blocks.
A green product- it replaces traditional bricks , which uses cultivable top-soil and also consumes
very high energy during its manufacturing process.
JKSmartBlox is manufactured using fly ash, a waste product and is manufactured using world-
class German Technology.
They weigh less, are larger than traditional bricks and easy to work, with their unique tongue and
groove feature.
The result? Projects can be completed faster and with a better economy. What’s more, JK
SmartBlox is also environment friendly as it offers better insulation allowing substantial energy
saving.
The further firsts in JK Lakshmi Cement’s innovative ideas basket were:

● The concept of coloured bags for product differentiation .

● A waste heat recovery power plant.
● Introducing OPC 43 grade cement in North India.
Value Added Products which further fulfilled consumer needs from JK Lakshmi Cement’s
innovative ideas basket have been:

● Ready Mix Concrete (RMC) under the brand name ‘JK Lakshmi Power Mix RMC’
● India’s first premium branded Plaster of Paris (POP), JK Lakshmiplast
● Introducing OPC 43 grade cement in North India.

Our real strength lies in our manufacturing units and people

The real fuel that keeps alive JK Lakshmi Cement’s fire to perform better, lies in its manufacturing plants
spread across India at :

● Sirohi (Rajasthan)
● Durg (Chattisgarh)
● Kalol (Gujarat)
● Jharli (Haryana)
● Surat (Gujarat)
● Orissa
● Sikandrabad (Uttar Pradesh)
● Kathua (Jammu and Kashmir) and
● Palanpur (Gujarat).

We want India to grow with us

We want India to grow with us.Our success story will always remain incomplete if it remains
limited to our company and products. We believe in sharing our success with the society and
helping them build a better life on their own. Here are some of our initiatives:

● Naya Savera, a basic health care center

● Akshaya Kaleva, a food distribution programme
● Adult and Women Literacy Programmes for families in Sirohi Rajasthan.
● Sahyogi Sanrakshan Club for masons. The club offers insurance to masons, thus securing
the future of their families.

We are grateful that our initiatives have been appreciated and generously bestowed with awards
like :

● Smt. Vinita Singhania – Vice Chairman & Managing Director - JK Lakshmi Cement
honored with ET NOW CSR Leadership "Lifetime Achievement Award " 2018.
● Global Business Icon Awards 2018
● Action and Lakshya Quality Circle awarded par Excellence in NCQC 2017
● India's Best Companies to Work for - 2017

Over millions of satisfied consumers, many awards and recognitions fuels the motivation of
Team JK Lakshmi Cement to reach still greater heights. Each day ushers a new promise, a new
idea and a new journey. And as we all know, the story has just begun.

“Success does not happen with one event. It happens as a result of

many small steps one takes to achieve their desired outcome. Every
day take one small step and watch the magic happen.”

Cement manufacturing process

Following three distinct operations are involved in the manufacturing of normal setting or
Portland ordinary cement:

1. Mixing of raw materials

2. Burning
3. Grinding

MIXING OF RAW MATERIALS

The raw materials such as limestone or chalk and shale or clay may be mixed either in dry
conditioner or in wet condition.The process is accordingly known as the dry process and wet
process of mixing.

● Dry Process:-figure shows the flow diagram of mixing of raw materials by dry process.

● Wet Process:-the flow diagram of mixing of raw materials by wet process is shown in
fig.
BURNING

Burning is carried out in the rotary kiln which is shown in fig 6–3.It is having a length of 90 -120
meters and a diameter of 2.5–3 meters. It is arranged in a way that the kiln rotates 1–3
revolutions per minute. The corrected slurry is charged into the upper end of kiln.Coal in finely
pulverized form,fuel oil and gas are the common fuels for burning these kilns. As shown in fig
,the portion near the upper end is known as dry zone .Water of slurry evaporates at this zone
.When slurry descends to the next zone, the temperature increases and in next section co2 from
slurry is evaporated. Small lumps called nodules are formed at this stage. These nodules passes
through zones of high temperature and finally reaches the burning zone where the temperature is
around 1500^C.

At this zone nodules are converted to small greenish blue balls which are known as clinkers .The
clinkers are very hot(almost 1000C) when they coming out of the kiln. They are cooled and
collected in containers of suitable sizes
GRINDING

The clinkers obtained from the rotary kiln are grounded in tube mills .A small quantity of
gypsum is also added to control the initial setting time of cement.Finally the cement is fed to the
packer machines.

The flow diagram of burning and grinding process are shown in fig 6–4
ROLE OF AN MECHANICAL ENGINEER
There are various roles of a mechanical engineer in a cement plant. It depends on which
department you're assigned to.

Inspection/Methods: Your work involves routine checks of a certain part of cement plant
(Roller/Ball Mills, Kiln, Baghouse, Crusher, etc) whichever area you are assigned to. There are
basic and specific levels of inspection which you are required to carry out following a schedule,
with or without a team. Generally following a checklist to check for equipment health. During
shutdown/breakdown, you're expected to find anomalies or causes for the breakdown.
Execution: Your work involves carrying out the tasks, from a work order issued in SAP or other
ERP softwares, following directly by the observations made by the inspectors. You will be
assigned a gang of technicians and unskilled workers whom you have to instruct what to do and
how to fix the problem. You'll also do routined fixing/replacing of worn out parts of plant areas
you're assigned to. During shutdown/breakdown, you're expected to fix the anomaly that has
caused it in the first place.

Production: You will operate the whole plant from a Central Control Room, using a DCS
system. You have remote access to all parts of the plant on a computer screen, as well as live
video streaming of internal part of kiln, packing plant and other areas to give you an edge in
decision making. You're expected to be sharp and alert in order to start/stop/vary the parameters
of the plant as and when required. Expected to follow orders through mobile walkie talkie
devices, accompanied by a patroller who gives you observations about the plant.

In almost all cases, you're required to man-manage the workers to carry out the task, and not get
directly involved in handling/touching the plant. Basically, a supervisor.
WHAT WE LEARN