1. Cement Manufacturing And Packing SUBMITTED BY : DINESH MAHAJAN SECTION : m3902 REGD NO. 10903225

2. COMPANY PROFILE AMBUJA GROUP Ambuja Cements Ltd., was founded by Narotam Sekhsaria in 1983 with a partner, Suresh Neotia. Sekhsaria’s business acumen and leadership skills put the company on a fast track to growth. The Company commenced cement production in 1986. The global cement major Holcim acquired management control of ACL in 2006. Holcim today holds little over 46% equity in ACL. The Company is currently known as Ambuja Cements Ltd

4. Cements are considered hydraulic because of their ability to set and harden under or with excess water through the hydration of the cement’s chemical compounds or minerals There are two types: Those that activate with the addition of water And pozzolanic that develop hydraulic properties when the interact with hydrated lime Ca(OH) 2 Pozzolanic: any siliceous material that develops hydraulic cementitious properties when interacted with hydrated lime. HYDRAULIC CEMENTS: Hydraulic lime: Only used in specialized mortars. Made from calcination of clay- rich limestones. Natural cements: Misleadingly called Roman. It is made from argillaceous limestones or interbedded limestone and clay or shale, with few raw materials. Because they were found to be inferior to portland, most plants switched. (http://pubs.usgs.gov/of/2005/1152/2005-1152.pdf) Types of Cement

5. Quarry face 1. BLASTING 2. TRANSPORT 3. CRUSHING & TRANSPORTATION Primary Crusher Cenveyor Diper Storage at the plant Loader

6. 1. RAW GRINDING 2. BURNING Raw mix Rotary Kiln Cooling Preheating Clinker Storage at the plant Secondary Crusher Conveyor

7. 1. GRINDING 2. STORAGE, PACKING, DISPATCH Clinker Storage Gypsum and the secondary additives are added to the clinker. Dispatch Finish grinding Bags

8. PACKING MACHINE:- Packing machine is a rotating log-filling machine for packing easy flowing powdery and granular bulk materials into valve bogs, with simultaneous weighing of the bulk materials from 10 to 50 kg. Presently, two types of packing machines are used in the cement industry, namely the ROW or Inline Packing machine assigned for lower capacities, and the Round or Inline – Packing machine for higher capacities. Row or Inline – Packing machine The designation of this type of packing machine is derived from the fact that several filling spends are arranged in one row or inline. The Round Packing Machine In 1930, F.L. smithy and Co. sold its first round or rotary automatic packing machine, designated by the manufacturer or “Rotary flux packer”. The Rotary Packing was developed to achieve, higher packing capacities. In this machine the spends are mounted on the bottom of the cylindrical container relating on a vertical shaft.

9. Construction & Function Air & Power Connections. Rotary drive unit. Maintenance free bearing unit Product Inlet. Weather / Control panel. Filling Station. Bog stool. Spillage return / de-dusting Packer bin level Control Bottom Bearing.

10. Operation of the Packing Machine The Cement drops by gravity into the packer tank and then down into the impeller compartment. The impeller blades drive the cement through the orifice and the filling spont into the log. The log is held lightly on the filling sport by the log holding cylinder, and rests on the log chair or saddle. The orifice is automatically closed by the gate cylinder, and the saddle assumedly tilts into a forward Position with the help of Boy discharge cylinder, which causes the filled log to drop off the tilling spont and fall an to the felt conveyor located under the log discharge end.

11. AIR & POWER CONNECTIONS : The Compressed air to the rotating section is fed via the upper section of the Rate Packer through a rotary union. The compressed air supply for the operation of packer N/C is between 4 kg/cm 2 to 6 kg/cm 2. The electrical supplies of all the spont motors of the packing machine are connected with 415 volts, 3-phase supply.

12. 2.ROTARY DRIVE UNIT The continuously regulated geared motor provides the drive of the Rotor packer through the V-bell pulley, the V-belts and the V- belt pulley of the main gearbox. The main gearbox is supported on a spherical bearing so as to load deep groove ball bearing evenly at all time. The spherical bearing rests on the supported frame, which is connected to the supporting beams. The labyrinth seal and the rotating shaft seal protect the gearbox against dust gelting in from the packer silo.

13. 3.MAINTENANCE TREE BEARING UNIT This bearing unit consists of one spherical roller bearing, one gear and a pinion filled with a lubricating oil of servo cress 460.

14. 4.PRODUCT INLET The product i.e. material inlet is connected below the rotary feeder outlet. The filling level detector connected to the stationary cover of packer that consists of lever. When the cement is filled in side the packer tank up to a particular level, the detector gets activated which in turn stops the rotary feeder. Similarly when the level falls by filling the cement in to valve bags, the lever de-activates the detector (proxy), which in turns start, the motor of the rotary feeder. So the rotary feeder controls the cement inlet in to the packer silo

15. 5.WEIGHER / CONTROL PANEL The Control panel consists of pneumatic solenoid blocks and microprocessor circuit separately. The Pneumatic solenoid blocks consists of Fans (4) no ’ s of solenoids for the purpose of bag holding. Bog discharging and other two solenoids for slide gate operation for fine feed and course feed. The microprocessor circuit consisting of 6 No ’ s of electronic cards.

16. 6.FILLING STATION All the filling spouts hove a common material storage hopper. These comprise of multi opening independent stand-alone halting outlets depends upon the no of spouts as its bottom part. Each out let is equipped with the impeller box. The filling shaft is carried in the bearing box and has an impeller blades assembly, which carry the impeller blades. Between the liner plates, slide plate is moved with on opening for the material flow. The compressed air gate cylinder operates the slide plate.

17. 7.BAG STOOL The bag Stool is suspended with its weight on load cell. The leaf springs (Spring plates) installed at top and bottom serve for horizontal and vertical guidance of the bag stool. When the bag is placed on the filling spout, the bag sensing / proximity switch is actuated, the bag holding cylinder gets air,