Synopsis

On
Industrial Training
ACC Ltd., Gagal Cement Works, Barmana (H.P)
Submitted as a part of course curriculum for

Bachelor of Technology
In
Mechanical Engineering

Submitted To:

Submitted By:

Head of Mechanical Engg. Department

Name: Vikramjeet Singh

Uni. Roll no.1284352

(Session: 2011-2015)
Department of Mechanical Engineering
GURU RAM DAS INSTITUTE OF ENGINEERING & TECH.
Lehra Bega, Bathinda-151001, Punjab (INDIA)

TABLE OF CONTENT

1. COMPANY PROFILE
2. LISTS OF CEMENT PLATS
3. GAGAL CEMENT WORKS AN OVERVIEW
4. OVERVIEW OF CEMENT MANUFACTURING PROCESS

Company Profile
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1. ACC (ACC Limited) is India's foremost manufacturer of cement and concrete.

ACC's operations are spread throughout the country with 17 modern cement
factories, more than 50 Ready mix concrete plants, 21 sales offices, and several
zonal offices. It has a workforce of about 9,000 persons and a countrywide
distribution network of over 9,000 dealers.

2. Since inception in 1936, the company has been a trendsetter and important
benchmark for the cement industry in many areas of cement and concrete
technology. ACC has a unique track record of innovative research, product
development and specialized consultancy services. The company's various
manufacturing units are backed by a central technology support services centre
- the only one of its kind in the Indian cement industry.

3. ACC has rich experience in mining, being the largest user of limestone. As the
largest cement producer in India, it is one of the biggest customers of the
domestic coal industry, of Indian Railways, and a considerable user of the
countrys road transport network services for inward and outward movement of
materials and products.

4. Among the first companies in India to include commitment to environmental

protection as one of its corporate objectives, the company installed
sophisticated pollution control equipment as far back as 1966, long before
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pollution control laws came into existence. Today each of its cement plants has
state-of-the art pollution control equipment and devices.

5. ACC plants, mines and townships visibly demonstrate successful endeavours in

quarry rehabilitation, water management techniques and greening activities.
The company actively promotes the use of alternative fuels and raw materials
and offers total solutions for waste management including testing, suggestions
for reuse, recycling and co-processing

6. ACC has taken purposeful steps in knowledge building. We run two institutes
that offer professional technical courses for engineering graduates and diploma
holders which are relevant to manufacturing sectors such as cement. The main
beneficiaries are youth from remote and backward areas of the country.

7. ACC has made significant contributions to the nation building process by way
of quality products, services and sharing expertise. Its commitment to
sustainable development, its high ethical standards in business dealings and its
on-going efforts in community welfare programmes have won it acclaim as a
responsible corporate citizen. ACCs brand name is synonymous with cement
and enjoys a high level of equity in the Indian

Corporate OFFICE
CEMENT HOUSE, 121, Maharshi. Karve . Road, Mumbai 4000 020

Regional office:
Eastern Region ,Northern Region, South West Region
Kolkata
New-Delhi
Pune

 LIST OF CEMENT PLANTS

Cement Plants:
1. Bargar Cement Works Distt. Bargarh ( Orissa )
2. Chaibasa Cement Works Distt. Singhbhum ( Jharkhand )
3. Chanda Cement Works Distt. Chanderapur ( Maharashtra )
4. Damodar Cement Works Distt. Purulia ( West Bengal )
5. Gagal Cement Works Distt. Bilaspur ( Himachal Pradesh )
6. Jamul Cement Works Distt. Durg ( Chhattisgarh )
7. Kymore Cement Works Distt. Katni ( Madhya Pradesh )
8. Lakheri Cement Works Distt. Bundi ( Rajasthan )
9. Madukkarai Cement Works Distt. Coimbatore ( Tamil Nadu )
10. Sindri Cement Works Distt. Dhanbad ( Jharkhand )
11 Tikaria Cement Works Distt. Sultanpur ( Utter Pradesh )
12. Wadi Cement Works Distt. Gulbarga ( Karnataka

GAGAL CEMENT WORKS AN OVERVIEW

Gagal Cement Works a unit of the Associated Cement Companies Limited, has two unites
Gagal I and Gagal II. Gagal I was set up in the year 1984 and Gagal II was set up in the year
1994. Clinker production of Gagal is 2800 TPD and of Gagal II is 3300TPD. The total annual

capacity of the plant is around 6100 TPD. Both units are located at BARMANA in District
BILASPUR of H.P

 KIND OF PRODUCT

Ordinary Portland Cement (OPC) in different grades i.e. 33GR, 43GR, 53GR and
Portland Pozzolona Cement (PPC).BIS (Bureo of Indian Standard).

The company has registration to

ISO 9002 & ISO14001
Tricalcium Aluminate (C3A)
Tetracalcium Alumino ferrite (C4AF).

 OVERVIEW OF CEMENT ANUFACTURING PROCESS

Cement manufacturing consists of raw meal grinding, blending, pre-calcimine, clinker burning
and cement grinding. In short ,lime stone and other materials containing calcium, silicon,
aluminum and iron oxides are crushed and milled into raw meal. This raw meal is blended and
heated in the preheated system to initiate dissociation of carbonate to calcium oxide and
carbon dioxide. The secondary fuel is fed into the pre heater to keep the temperature
sufficiently high. Then meal is fed into the rotary kiln for reaction between calcium
oxide and other elements to form calcium

silicates and other aluminates at temperature upto 1450 degreecalcius.Primary fuel is used to
keep temperature high enough in burningzone to chemical reaction takes place.
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The raw materials used are lime stone, shale, iron ore and gypsum. The lime stone provided by
nature and Iron-ore comes from BIHAR and RAJASTHAN. Firstly we get the 70mm
size limestone with the help of crusher and stock it with the help of stacker through belt
conveyor. In Raw mill / VRM section, limestone, shale, quartzite & Iron ore are fed
in measured quantity through weigh feeders. In the mill the mixture further reduces the size
to the desired fineness. The finer product separated by air separator is goes to the
Electro-static precipitator & then to the blending silos and coarse material is fed
back into the mill Inlet. Raw mill / VRM s controlled by central control room. The
set point for chemical composition of the raw meal and fineness of the material is
given by the Laboratory department. From raw mill the raw meal is fed to the
blending and the storage silos .In the blending part of the silo, further
homogenization of raw meal takes place so that a constant quality is maintained. In
storage part the raw meal is stored so that it may be fed at the desired rate. From there the
material is fed to the low lift pumps (L.L.P.s) with the help of bucket elevators. Low lift
pumps feed the material or raw meal to the pre heater cyclone. To reduce the
requirement of heavy coal injection in the kiln ,95%of the calcinations occurs in
the M.F.C., D.D.F. vessels and cyclones of preheating zone. About 60%of the coal
firing is done at pre-calciner section itself. Raw meal which is almost calcined
enters from the one end of the kiln. From the other end of the kiln the pulverized
coal is fired. Various chemical reactions occurs as the raw meal progresses from feed end to
the burning zone , where intermediate phases consisting of CaO, Al2O3,
Fe2O3 become liquid and because of the rotation of kiln CaO and silica combine
with liquid to form nodules called clinker. At the lower end of the kiln the temperature reaches
to about 1450degree centigrade. Due to such high temperature the physical and the
chemical characteristics of the raw meal changes. Clinker that comes out of the
kiln is at a very high temperature and has to be cooled to facilitate.
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