In plant training report

in
UltraTech Cement Limited

Submitted by:
P.Bharath Kumar Reddy

ACKNOWLEDGEMENT

To 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 birla

A metals powerhouse, among the world's most costefficient aluminum and copper producers.
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 fertilizer plants
The largest Indian MNC with manufacturing
operations in the USA

The Indian Scenario

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
Among the top 6 bpo companies
The largest manufacturer of linen fabric.

Vision And Values

To be a premium global conglomerate, with a clear focus on each of the
businesses.
Our mission
To deliver superior value to customers, shareholders, employees and society at
large.
Our values
Integrity : 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.

Continued

Passion : 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

overview
Ultra 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 Cement

Ordinary 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 Cement

Ultratech 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

Portland Pozzolana Cement

Portland 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

Cement

1. Stone is first reduced to 50mm size

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

Gypsum

BRIEF EXPLANATION

Limestone 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 c
After 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
Silos

Bucket Elevator

Hopper (PPC or
OPC ) Thought Air
Slides

Vibrating Screens

Roto Packer

Conveyor Belt

Packaging Process
Bags For Transit

Rotary Packer

SIGNIFICANT COMPONENTS IN PACKING PLANTS

Vibrating Screen

Introduction to vibrating screen

The 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 screen

The 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 CUTOFF GATE
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.

FLOW CONTROL GATE

Flow 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.

PNEUMATIC 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 failure

DIVERSION BOXES
Junction 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.

CONVEYERS
A conveyor system is 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 the material handling and packaging industries.
Many kinds of conveying systems are available, and are used according to the various
needs of different industries.

BELT CONVEYERS
Conveyors are durable and reliable components used in
automated distribution and 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 conveyors are 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 CONVEYER
A screw conveyor or auger conveyor is a mechanism that
uses a rotating helical screw blade, 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 materials
Hey 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
CHAIN TYPE

BELT TYPE

THANK YOU