ARYA INSTITUTE OF ENGINEERING AND

TECHONOLOGY KUKAS JAIPUR

PRACTICAL SUMMER TRAINING ON

ADITYA BIRLA GROUP
ULTRATECH CEMENT KOTPUTLI
Submitted to:
Submitted By
Deepak Sharma
Satypal gurjar
HOD EE. Dept.
14EAIEE094
Aiet (kukas)
 INTRODUCTION

The word "cement" traces to the Romans,

who used the term opus caementicium to
describe masonry resembling modern
concrete that was made from crushed rock
with burnt lime as binder. The volcanic ash
and pulverized brick additives that were
added to the burnt lime to obtain a hydraulic
binder were later referred to as cementum,
cimentum, cment, and cement.

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 ULTRATECH CEMENT & ITS
HISTORY
The first cement unit was set up at Porbanda in 1914 with a
capacity of 1,000 tones per annum.
The Aditya Birla Group is the 10th largest cement producer in
the world & the 4th largest in Asia.
Ultratech Cement Limited It is India's 2nd biggest cement
company and Indias largest exporter of cement clinker based
in Mumbai, India .
O P Puran malka is the present director of ultratech cement.
The revenue of the organisation in 2010-2011 was
13,496.58crore and profit was 1,404.23crore
It was incorporated on 24 August 2000 as L&T cement Limited.
Cement business of Lerson & Tourbo Limited demerged &
vested in company in 2004.
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4
DEFINITION
Chemically it is a finely ground mixture of
calcium silicates and aluminates which
set to a hard mass when treated with
water. These are called as Hydraulic
Cements (Portland Cement) and those
setting in air are Non Hydraulic cements
(Ordinary Lime)

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 CLASSIFICATION OF CEMENT
Natural Cement: Obtained by
calcinating and pulverizing natural cement
rock of argillaceous and clay with lime stone.
It does not have sufficient strength and is
cheap and quick setting & have hydraulic
properties.
Pozzolana Cement: Volcanic ash
containing silicates of calcium, iron and
aluminium when mixed with lime and heated
produces this cement.
Portland Cement: It consists of
compounds of lime, silica, alumina and iron.
When mixed with water it forms a paste which
binds the rock, sand and gravel to form
concrete 6
GRADES OF PORTLAND CEMENT

GRADES OF PORTLANDCEMENT

33 grade General Construction like plastering, finishing

works etc, where strength is not required.

43 grade Useful for structural works, precast items etc,

Strength development is faster than 33 grade.

53grade Used for multi-storey buildings, precast pre-

stressed items, bridges, tall structures, etc. Develops very
fast strength and speeds up construction.

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Raw Materials Necessary for
Portland Cement Manufacture
Must Provide the Following

Calcium
Silica
Alumina
Iron

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MANUFACTURE OF PORTLAND CEMENT

Crushing
Mixing (Wet Process)
Mixing (Dry Process)
Grinding (Ball Mill and Tube Mill)
Storage of Ground Materials
Burning Drying Zone
Calcination Zone
Clinkering Zone
Grinding Retarder
Dispersing Agent
Water Proofing
Packaging

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CLINKR GYPSM

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 CRUSHING

This is the first step in the

manufacture of Portland Cement.

Jaw crushers of various sizes are

employed for the crushing purpose.

Raw materials are crushed by

crushers till the size of the raw
material reduces to of an inch.

It is than send for either Wet

process or Dry process. Wet
process is universally employed
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 GRINDING
Grinding can be done in two stages
Ball Mill
Consists of cast iron drum
containing iron and steel balls of
different sizes. The principle used in
ball mills impact and shear produced
by large no. Of tumbling and rolling
balls.
Tube Mill
Ball mill grinding is followed by tube
mill grinding. Tube mill is conical at
the discharge end with separate inlet
and outlet.
Slower is the feeding speed finer is
the product coming out of the tube
mill. 13
 STORAGE OF GROUND
MATERIALS
The ground materials containing 30-40% of water is stored in
separate tanks equipped with agitators.

This step is followed by process of burning.

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 BURNING

Slurry is burnt in rotary klin where actual chemical changes takes place.
Klin is long steel cylinder 30-40 meter in length, 2-4 meter in diameter, lined
by refractory bricks. It is inclined at gradient of 0.5-0.75 inch and can be
rotated at the desired speed.

The material is introduced in the klin from the upper end as the klin rotates
material passes slowly towards the lower end.

Klin is heated by burning pulverized coal or oil and temperature is maintained

at about 1400-1500C. At clinkering temperature actual chemical reactions
takes place. 15
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Manufacturing of Portland Cement

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TESTING OF CEMENT
1. Field testing

2. Standard consistency test

3. Fineness test

4. Soundness test

5. Strength test

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 FIELD TESTING
Open the bag and take a good look at the cement, then
it should not contain any visible lumps.

Colour of cement should be greenish grey.

Should get cool feeling when hrusted.

When we touch the cement, it should give a smooth &

not a gritty feeling.

When we throw the cement on a bucket full of water

before it sinks the particles should flow.
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STANDARD CONSISTENCY
TEST

Used to find out the percentage of water required

to produce a cement paste of standard
consistency.
This is also called normal consistency.

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 FINENESS TEST

The fineness of cement has an important bearing on the rate

of hydration, rate of gain of strength, evolution of heat.

Finer cement offers greater surface area.

Disadvantage of fine grinding is that it is susceptible to air

set & early deterioration.

By determination specific surface by air permeability method.

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 SOUNDNESS TEST
It is very important that the cement after setting shall not
undergo any appreciable change of volume.

This is due to high proportion of magnesia & calcium sulphate.

Therefore magnesia content in cement is limited to 6%.

Gypsum 3-5.

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 STRENGTH TEST

This is the most important of all properties of hardened

cement.

Due to excessive shrinkage and cracking the strength

tests are not made on heat cement paste.

Standard sand is used for finding the strength of cement.

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PACKAGING

The ground powder is packed by

automatic machines in a bag.

This is then dispatched to the

markets where it is sold

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 CHARACTERISTICS OF CEMENT
When water is added to initiate dry mixtures of cement and
sand, hydration of cement starts and it will binds and
particles as well as the surrounding surfaces of masonry and
concrete.

The proportion of cement and sand will decide the strength

of mortar.

A richer mix than 1:3 proportion is prone to shrinkage.

Solid surface are provided by well proportioned mortar.

A leaner mix is not able of closing the voids in sand.

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COMMON APPLICATIONS OF
CEMENT
Building (floors, beams, columns, roofing, piles, bricks,
mortar, panels, plaster).

Transport (roads, pathways, crossings, bridges, sleepers,

viaducts, tunnels, stabilization, runways, parking).

Water (pipes, culverts, kerbing, drains, canals, weirs, dams,

tanks, pools).

Agriculture (buildings, processing, housing, feedlots,

irrigation).
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THANK YOU..