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Muhammad Naeem Zafar 09-MCT-50

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INTERNSHIP
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REPORT
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DG CEMENT
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KHAIRPUR PLANT
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JULY -2013

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Muhammad Saad Afzal 10-ect-38

REPORTED TO:

Mr. Safdar Kamal

Submitted By:
Muhammad Saad Afzal
10-ECT-38
([email protected] )
DURATION:
7thJuly – 7th August,2013

" DEPARTMENT OF ELECTRONICS ENGINEERING”

University of Engineering
and Technology, Taxila
(Sub-Campus Chakwal)

Sub-Campus Chakwal

University of Engineering & Technology, Taxila (Sub-Campus Chakwal)

Muhammad Saad Afzal 10-ect-38

CONTENTS
1. Introduction to D.G. Khan Cement Company ltd.
2. History of Cement
3. Cement Manufacturing
1. Process
2. Field Plan
3. Block Diagram

4. Cement Production
1. Raw Material
2. Quarry
3. Limestone Crusher
4. Bag Filter
5. Storage Yard
6. Stacker
7. Side Scraper
8. Reclaimer
9. Raw Mill Feed Area
10. Load Cells
11. Magnetic Separator
12. Raw Mill
13. CF Silo
14. Pre-heater
15. Rotary Kiln
16. Cooler
17. Conditioning Tower
18. ESP
19. Clinker Silo
20. Cement Mill

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Muhammad Saad Afzal 10-ect-38

21. OK Vertical Mill (Cement mill Type)

22. Cement Storage Silo
23. Packing

5. Central Control Room (CCR)

i) The DCS
ii) Networking
iii) The PLCs

6. Sensors and Transmitters

7. Waste Heat recovery plant(WHR)
8. Safety Measures

Introduction to D.G. Khan Cement Company Ltd.

NISHAT GROUP:
Nishat Group is one of the leading and most diversified business groups in South
East Asia. With assets over PRs.300 billion, it ranks amongst the top five business houses of
Pakistan. The group has strong presence in three most important business sectors of the
region namely Textiles, Cement and Financial Services. In addition, the Group has also
interest in Insurance, Power Generation, Paper products and Aviation. It also has the
distinction of being one of the largest players in each sector. The Group is considered at par
with multinationals operating locally in terms of its quality of products & services and
management skills.
Mian Mohammad Mansha, the chairman of Nishat Group continues the spirit of
entrepreneurship and has led the Group successfully to make it the premier business group
of the region. The group has become a multidimensional corporation and has played an
important role in the industrial development of the country. In recognition of his unparallel
contribution, the Government of Pakistan has also conferred him with “Sitara-e-Imtiaz”, one
of the most prestigious civil awards of the country.

D.G. Khan Cement Company:

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D.G. Khan Cement Company Limited (DGKCC), a unit of Nishat group, is the largest
cement-manufacturing unit in Pakistan with a production capacity of 5,500 tons clinker per
day. It has a countrywide distribution network and its products are preferred on projects of
national repute both locally and internationally due to the unparallel and consistent quality. It
is list on all the Stock Exchanges of Pakistan.
DGKCC was established under the management control of State Cement Corporation of
Pakistan Limited (SCCP) in 1978. DGKCC started its commercial production in April 1986
with 2000 tons per day (TPD) clinker based on dry process technology. Plant & Machinery
was supplied by UBE Industries of Japan.
Expansion -Khairpur Project:
Furthermore, the Group is also setting up a new cement production line of 6,700 TPD
clinker near Kalar Kahar, Distt. Chakwal, the single largest production line in the country.
First of its kind in cement industry of Pakistan, the new plant will have two strings of pre-
heater towers, the advantage of twin strings lies in the operational flexibility whereby
production may be adjusted according to market conditions. The project will be equipped
with two vertical cement grinding mills. The cement grinding mills are first vertical Mills in
Pakistan. The new plant would not only increase the capacity but would also provide
proximity to the untapped market of Northern Punjab and NWFP besides making it more
convenient to export to Afghanistan from northern borders.

Power Generation:
For continuous and smooth operations of the plant uninterrupted power supply is
very crucial. The company has its own power generation plant along with WAPDA supply.
The installed generation capacity is 23.84 MW.

Environmental Management:
DG Khan Cement Co. Ltd., production processes are environment friendly and comply with
the World Bank’s environmental standards. It has been certified for “Environment
Management System” ISO 14001 by Quality Assurance Services, Australia. The company
was also certified for ISO-9002 (Quality Management System) in 1998. By achieving this
landmark, DG Khan Cement became the first and only cement factory in Pakistan certified
for both ISO 9002 & ISO 14001...

HSITORY OF CEMENT

England first made Portland cement early in the 19th century by burning powdered
limestone and clay in his kitchen stove. By this crude method he laid the foundation for an
industry which annually processes literally mountains of limestone, clay, cement rock, and
other materials into a powder so fine it will pass through a sieve capable of holding water.
Cement is so fine that one pound of cement contains 150 billion grains.
Portland cement, the basic ingredient of concrete, is a closely controlled chemical
combination of calcium, silicon, aluminum, iron and small amounts of other ingredients to
which gypsum is added in the final grinding process to regulate the setting time of the
concrete. Lime and silica make up about 85% of the mass. Common among the materials

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Muhammad Saad Afzal 10-ect-38

used in its manufacture are limestone, shells, and chalk or marl combined with shale, clay,
slate or blast furnace slag, silica sand, and iron ore.
Each step in manufacture of Portland cement is checked by frequent chemical and
physical tests in plant laboratories. The finished product is also analyzed and tested to
ensure that it complies with all specifications.

CEMENT MANUFACTURING

Two different processes are used in the manufacturing of Portland cement.

1. Dry Process
2. Wet Process
In the wet process, the raw materials are properly proportioned then ground with
water, thoroughly mixed and fed into the kiln in the form of ”slurry" (containing enough water
to make it fluid).
In the dry process, raw materials are ground, mixed, and fed to the kiln in a dry state.
In other respects, both the processes are same.
A complete overview of cement manufacturing process is as below……

Field Plan:

University of Engineering & Technology, Taxila (Sub-Campus Chakwal)

Muhammad Saad Afzal 10-ect-38

Raw Material

Crushing and
Piling

Grinding in Raw
Mill

Constant FeeD
SILO (CF silo)

Pre - heating

Burning in Rotary
Kiln (1500ºC)

Cooler (90ºC)

Clinker Silo

Cement Mill + 5%
gypsum

Packing +
Storage
Layout (Block Diagram):

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Muhammad Saad Afzal 10-ect-38

Explanation:
1. The cement manufacturing process begins when limestone, the basic raw material
used to make cement, is transported by dumper trucks to the crusher plant from the
limestone quarry 3-4 kilometers away.
2. The limestone is combined with clay, ground in a crusher and fed into the additive
silos. Sand, iron and bottom ash are then combined with the limestone and clay in a
carefully controlled mixture which is ground into a fine powder in a roller mill.
3. Then, the fine powder is heated as it passes through the Pre-Heater Tower into a
large kiln, which has length of 66 meters and diameter 5.5 meters. In the kiln, the
powder is heated to 1500 degrees Celsius. This creates a new product, called
clinker, which resembles pellets about the size of marbles.
4. The clinker is combined with small amounts of gypsum and limestone and finely
ground in a finishing mill (cement mill).
5. The cement manufacturing process consists of many simultaneous and continuous
operations using some of the largest moving machinery in manufacturing. A number
of sensors and computers allow the entire operation to be controlled by a single
operator from a Central Control Room (CCR).

Cement Production

RAW MATERIAL:

1. Lime stone
2. Clay
3. Iron ore, Bauxite & Silica
4. Gypsum

1. Lime Stone:
This raw material is owned by company and is extracted from nearby quarry unit.
Limestone has the highest composition in the cement production.

2. Clay:
Clay is another nature resource used in cement production.

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3. Iron ore, Bauxite & Silica:

Iron ore is not extracted from quarry unit but it is bought from contractors. This is
added in very small quantity to strengthen the cement.

4. Gypsum:
Gypsum is retarding agent and is used to increase setting time (to slow down
hardening process).
QUARRY:

Quarry is the place from where raw material is extracted. Drilling and Blasting is done
to extract the material. Then this extracted material is loaded on dumper trucks and
conveyed to the crusher.
Drilling:
Drilling is done in the quarry with the help of drilling machine. A space of 10-
15m is created for the powder explosive.

Blasting:
The powder explosive is blasted under a controlled process to get the rocks in
the form of pieces of different small sizes.

LIMESTONE CRUSHER (1500 t/h):

Raw material such as limestone, clay and shale are dumped into hoppers by dumper
trucks and entered into a hammer crusher through an apron feeder. Inside hammer crusher
there are hammers each having a weight of 90-98 kg.They rotate at a speed of 1200- 1300
rpm and is capable of crushing feed of very large sizes.

Bag Filter:

The dust produced by crushing process can cause damage to the equipment and
may produce dust, to overcome this problem a bag filter is employed. A fan blows air and all
the dust goes to the bag filter. Inside the bag filter a special type of canvas cloth is used.
When air passes through this filter cloth, the dust particles stick to the cloth and clean air
passes through. The dust particles are then collected and sent to the conveyor. After
sometime when the filter is choked with particles, purging system is used in which high
pressure air is used, this air removes all particles from the filter cloth.

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STORAGE YARD:

The crushed material is stored in the form of piles in the storage yard. There are 6
piles in the storage yard. Mixed piles are used in larger quantity where as high grade and
additive piles are used in small quantity.
1. 2 Mixed piles (limestone & clay)
2. 1 High grade (pure limestone)
3. 1 Iron ore (additive)
4. 1 Bauxite (additive)

STACKER:
Stacker is a device which forms conical piles of the crushed material. Feed is
conveyed to the stacker through conveyor belts. This stacker then moves too and fro to
make a pile. The stacker belt is called “Jib” in engineering terms.

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SIDE SCRAPER:

Side scrapper is a device which picks the crushed feed from the piles through its feed
belt called “Hoist”. This belt has a number of small buckets of low capacity. When this belt
moves, the buckets picks feed from the pile and put it on the belt conveyor. Side scrapper in
used for those piles which are required in low quantity like bauxite and iron ore.
RECLAIMER:

Reclaimer is equipment which is used to throw feed down from the pile. It has two
arms called “Harrows” These harrows are inserted into the pile, when they move sideward,
the feed drops down the pile. This feed in then collected by high capacity buckets installed in
the bottom of the reclaimer. These buckets pick the feed and put it on the belt conveyor. It is
large capacity equipment and for those piles which are required in high quantity like Mixed
Pile.
RAW MILL FEED AREA:

The raw mill feed area consists of 4 feed hoppers:

1. Mixed feed hopper
2. Pure limestone hopper
3. Bauxite hopper
4. Iron ore hopper
The capacity of first two hoppers is 800 tons while the other two hoppers have a
capacity of 600 tons. The feed from each pile is conveyed to the hoppers through conveyor
belts in relevant hoppers. Each hopper is installed on load cells.
LOAD CELLS:
These are sensing devices which tells the load being put on the hopper by the feed.
From these hoppers, the feed in required proportions is transferred by the belt conveyor to
the Raw Mill. A lot of dust is produced during the conveying of material, to avoid this problem
Bag Filters are installed. A Magnetic separator is also installed to remove metal impurities.
MAGNETIC SEPARATOR:

A magnetic separator is installed on the feed belt. It attracts and removes metal
objects from the feed which are collected in the bin.

(Load Cell) (Magnetic Separator)

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RAW MILL:

Raw mill involves the mixing of extracted raw materials to obtain the correct chemical
configuration, and grinding them to achieve the proper particle size to ensure optimal fuel
efficiency in the rotary kiln and strength in the final concrete product. In “DGKCC” Dry
process is used.

There are three sections of Raw Mill.

1. Table with 3 rollers
2. Bottom scrapper
3. Separator
RAW MILL STORAGE (CF Silo):
After Raw mill, the ground materials composition is checked again and then it is
stored in CF silo a Storage which provides constant feed of material to Pre-heater.
PRE-HEATER:
The most important activity in cement manufacturing is clinkering (burning) of raw
material. Clinkering takes place in the kiln and the Pre-heater system.
Pre-heater systems supply heat from the hot kiln gas. Now Material is fed to Pre-heater
which Increase the temperature of grinded material up to 900 ˚C. Pre-heating is necessary
because in kiln temperature is 1200 ˚C to 1600˚C. So if material is fed directly to this
temperature it will burn out. It consists of number of cyclones and material is fed to top most
cyclone and get out from bottom most.
BURNING IN KILN:
Hot air and gases are used to heat the material in kiln and temperature increased up
to 1300ºC to 1600ºC. After kiln material is ready to be used if someone needs at this stage.
COOLING:

After kiln the hot material is cooled to 90 ºC and the cooled material is called clinker.

GAS CONDITIONING TOWER:

The conditioning tower is used to reduce the temperature and to increase the
moisture level of the dusty exhaust gas from the kiln, before it is passed through the bag
house and ESPs. It is called a conditioning tower because it conditions the hot gas, thus
making it more suitable for the ESP and bag house to extract dust from it.

ELECTRO-STATIC PRECIPITATOR (ESP):

The Electrostatic Precipitators are used in cement plants particularly for removal of
dust from the exit gases of cement kilns and from the exhaust air discharged by dryers,
combined grinding and drying plants, finishing mills and raw mills through water injection.

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Muhammad Saad Afzal 10-ect-38

Through ESPs, the dust-laden gas is made to flow through a chamber usually
horizontally, during which it passes through one or more high voltage electric fields formed
by alternate discharge electrodes and plate type collecting electrodes.
By the action of electric field, the dust particles, which have become electrically
charged by negative gas ions which are formed at the discharge electrodes and attach
themselves to the particles, fly to the collecting electrodes and are deposited there. The dust
is dislodged from these electrodes by rapping and thus falls into the receiving hopper at the
base of the precipitator casing.

(Electro-static Precipitator)

CLINKER SILO:

In this clinker silo clinker is stored. Clinker is also purchased by people for number of
purposes as it is ready form of cement and is used widely in concrete road making and in
numerous other procedures.
CLINKER & GYPSUM STORAGE:

The output of the kiln is stored before it is fed to the cement mill for conversion to
cement. This storage is called clinker storage, if it is used for clinker storage purpose.
Another storage space is used for gypsum storage, and is known as gypsum storage.
CEMENT MILL:

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Muhammad Saad Afzal 10-ect-38

During the final stage of Portland cement production known as finish milling, the
clinker is ground with other materials (which impart special characteristics to the finished
product) into a fine powder. Up to 5% gypsum is added to regulate the setting time of the
cement.Many plants use a roll crusher to achieve a preliminary size reduction of the clinker
and gypsum. These materials are then sent to ball or tube mills which perform the remaining
grinding. The grinding process occurs in a closed system with an air separator.
This air separator divides the cement particles according to size. Material that has not been
completely ground is sent through the system again.
1. This plant has 2 cement mills each having 175 ton/hour.
OK VERTICAL ROLLER MILL:

The OK mill combines the drying, grinding and separation processes into just one
unit, which simplifies the plant layout. And because it operates at a low noise level, outdoor
installation is feasible – substantially reducing civil construction costs and improving the
working environment.

2. Key benefits:

1. 20-50% less energy use than ball mill systems

2. For Portland cement, slag and blended cements
3. High productivity with stable, reliable operation
4. Easy maintenance; low maintenance costs
5. Effective drying when grinding blast furnace slag or blended cements
with wet components
6. Consistent cement quality with easy-to-adjust quality parameters
7. Long lifetime
8. Simple, compact layout
3. Design advantages:

1. Simple layout and fewer machines in the mill circuit ensure high run-
factor and low maintenance costs

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Muhammad Saad Afzal 10-ect-38

2. Roller and table profile improve operating stability and reliability

3. Special design features for iron removal during slag grinding minimize
wear
4. Optimal wear protection on all internal surfaces extends lifetime
5. Flexibility to operate with two or four rollers guarantees long-term
availability
6. Segmented roller wear parts made of the hardest possible material
without the risk of cracking; very suitable for hard facing
7. Segments are reversible, enabling use of their full width for maximum
longevity
CEMENT STORAGE SILO:

Once the production of Portland cement is complete, the finished product is

transferred using Bucket elevators and conveyors to large, storage silos in the shipping
department.
4. This plant consists of 3 cement silos each having capacity of 22000 tons.
PACKING:
Most of the Portland cement is transported in bulk by railway, truck and barge or in
multiwall paper bags. Bags are used primarily to package masonry cement. Once the
cement leaves the plant, distribution terminals are sometimes used as an intermediary
holding location prior to customer distribution. The same types of conveyor systems used at
the plant are used to load cement at distribution terminals. DG Cement is the only cement
producing company which has their own paper plant for the production of cement bags and
then automatic loading terminals. The Packing unit at DG is one of the best units where a
large scale automation is used. There are six packing units which can be operated in both
ways manually as well as automatically.
The automatic packing units are installed which are capable of packing the bag of the
standard weight and the size. There is an intelligent system which monitor the weight and in
case of little error the bag is returned to the storage. The wide range of proximity sensors
and precise robotic actions are used

CENTRAL CONTROL ROOM (ccr)

It is the nerve center of the cement plant since all equipment is controlled from this
place. It is the place from where all the process parameters are controlled.
All the processes in the plant are controlled through the CCR. Where inputs and outputs are
changed and whole plant is monitored.
Numbers of software’s are used, such as;
1. Software’s of imported machines were along with them.
2. Ps7(Siemens)

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Muhammad Saad Afzal 10-ect-38

3. ERP(Oracle Based)
The whole automation of the plant is controlled through DCS. The control
rooms of different units like packers or the raw mill can directly be controlled in CCR. The
communication between different units of plant consist to major parts.

1 Networking between different units.

2 The PLCs.
3 The DCS

Networking between different units.

The communication between different units and the PLCs is done through different
mediums either wired or wireless. The mediums used in DG cement for the Networking
are
i) Ethernet
ii) Profi_Bus(Process field Bus)
iii) Fiber Optics
iv) Co-axial cable
v) RS232
Different intelligent switches, Hubs and standards of IT are used for the control and
communication of the whole plant.
A redundant communication system is used in DG which prevents the failure of
communication. The redundant mean there is a parallel setup along with the working
setup of networking. The above mediums are selected as per their requirement and the
distances. For example the fiber optics is used to attain high speeds at long distances.
The Profi_Bus is one of the best communication medium used in the plant which has
high data rate and it is just like a common cable.

The PLCs.
The PLCs used at DG cement for automation and control of plants in the DCS are of
different companies
I) The Allen Bradley PLC-5 series
Allen Bradley, now owned by Rockwell, were one of the original PLC originators (and
actually have the USA copyright on the name PLC). They have been responsible for
much of the development of the ideas used in PLCs and have succeeded in maintaining
a fair degree of upward compatibility from their earliest machine without restricting the
features of the latest.

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II) The Siemens Simatic S7 range

It has become widely used in Europe in the early part of the 1990s.Even widely used
industry.S7 is the latest version with high memory and more I/O s. Programming
techniques for all PLCs are almost same although the manufacturers of different PLCs
have some restrictions in programming also. Common programming languages are
1) Ladder Logic
2) STL
3) FBD
4) SCL

The DCS
DCS means the distributed control system. In the DCS someone can control the
systems on distant areas with in a country but in SCADA someone can control plants at
remote locations even in different countries. In DG cement plant the FLSmidth have
their own DCS system

University of Engineering & Technology, Taxila (Sub-Campus Chakwal)

Muhammad Saad Afzal 10-ect-38

The DCS system and the automation provides the following facilities to the engineers at
plant
i) Simple and safe process control
ii) Intuitive operation and visualization
iii) Powerful system engineering tools with common interface simplify the
engineering and save money throughout the entire plant life cycle.
iv) Online modification possible throughout the system
v) System openness at all levels makes plant enhancements easy
vi) Redundancy at all levels makes high availability scalable to your need
vii) Flexibility and scalability simplify plant improvements
viii) Automation solutions avoid injury to human and damage to equipment and
provide high process availability at same time
ix) Easy handling for the operators due to self-explaining standards

Instruments, Actuators, and Sensors

The sensors connected to the process can be as simple as a limit switch or can be
as complicated as an on-line X-ray analyzer. Examples of traditional discrete
(switch) sensors include the classic limit switch, temperature switch, pressure
switch, flow switch, level switches of numerous designs, photo eyes, and input devices
such as push buttons and pilot lights. Switches are digitaldevices that provide a
simple contact which indicate theirstate: on or off. Instruments such as thermocouples
or pressure transmitters are analog devices capable of providing a continuous range of
measurement readings from 0 to 100% of range and reporting their data with a changing
voltage or current output. As for outputs, motor starters and solenoids are generally
digital devices, opening or closing depending on whether they are fed with power
from a system output or not. Other actuators, such as valve positioners and
adjustable speed drives, are variable and will accept a 4–20-mA control signal
command them to go to 0–100%of their range

.
Pressure Transmitter Temperature Sensor (RTD)

Most instruments today can be enhanced in with intelligent versions. These intelligent
instruments have on-board microprocessors that allow for functionality beyond the basic
measurement of the primary variable. They can monitor and report additional process
variables, support
Multiple configurations, totalize flow, and monitor and report on their own health. Often,
they have significant on-board diagnostics. Motor starters can now monitor various
aspects of the health of the motor. They can report current, phase voltage, motor power,

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motor power factor, and running hours and can tell you exactly why a trip occurred
(i.e., overload, ground fault, or short circuit?). They can even tell you when the coil in
the contactor is about to fail. Likewise, variable frequency drives can report the same .

Flow Meter control valve

On the plus side, these intelligent instruments can tell you far more about your process
than simply the temperature or pressure at a single point. The information given by an
intelligent motor starter can help in managing energy costs and predicting motor failures
before it happens. Furthermore, if you suspect fault with one of these instruments, the
on-board diagnostic information can often lead you directly to the cause if the
device has not already notified you of the problem on its own. To setup and
configure intelligent instruments correctly we need to have proper knowledge about the
instruments. For all of these types of instruments, the additional information can
Only be accessed remotely or in real time if you add a serial communication line to the
instrument in addition to or in lieu of the primary voltage, current, or contact output.
Otherwise, data are trapped in the device and only available at the local display.

Waste Heat Recovery Plant

The total power requirement of the plant is about 34 MW. To meet the requirement the DG
have a power plant at khairpur. The plant have two Generators of about 12.5 MW each
running on the Fuel. The fuel used there is LFO and the natural gas for the engines.
The DG cement group took a major and environment friendly step for the power generation
as well as environment protection. The project activity is the installation of Heat recovery
steam generators. The waste heat generated at the cement plant in the clinker production
process is vented to the atmosphere. In WHR plant this heat is used as a fuel. The steam is
produced with help of water according the famous Kalina cycle. The steam with high
pressure is used to run the turbine. The total production of WHR at Khairpur plant is 8 MW.

SAFETY MEASURES
Following Safety Measures are observed there;
1. Safety Helmets(white for Engineers and yellow for sub engineers)
2. Ear bugs.
3. Safety boots.
4. Special uniform for workers.
5. Emergency Fire Exit.
6. Carbon Dioxide cylinders.
7. Fire Alarming system.

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8. Fire Extinguishing Water pipes.

University of Engineering & Technology, Taxila (Sub-Campus Chakwal)