KESHAV CEMENT PLANT

INDEX

SI.NO CHAPTER
01 INTRUDUCTION KESHAV CEMENT
1.1Company profile
1.2 QUARRY
1.3 Crushing plant
(i) Primary crushing plant
(ii) Secendory curshing plant
1.4 RAW MILL
02 KILN SECTION
2.1 Wet procces kilns
2.2 Dry procces kilns
2.3 Hot clinker
2.4 Clinker cooler
2.5 Packing plant
03 INTRODUCTION TO CEMENT
3.1 History of cement
3.2 Types of cement
04 RAW MATERIALS
05 TECHNOLOGY OF CEMENT
06 MARKETING DEPARTMENT
07 LEARNING EXPERIENCE

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CHAPTER – 01

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Intrudution of Keshav Cement
• Shri Keshav Cement & Infra. Ltd. (KC&IL) (Formerly KAT WA UDYOG LIMITED) is the
Public limited Company incorporated in the year 1993 to manufacture Ordinary Portland Cement.

• KC&IL, is a public limited company with over 25 years in cement manufacturing & marketing.

• The inception of the company began with acquisition of a sick cement plant of 20 TPD (Ton
per day) in 1994. in present day the capacity of the plant is 600 TPD.

• The industry producing ordinary portland cement (OPC).

•. Ordinary Portland cement is Superior compared to other types of cement

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COMPANY PROFILE
COMPANY INFORMATION

Company Name M/S Keshav Cement and Infra Ltd

Address Plant-2 S.No.15/4, At Nagapur- 587122,

Post:Lokapur Tq:Mudhol Dist: Bagalakot

Head office “Jyoti tower” 215/2, Karbar Galli,6th Lane

Nazer Camp,
Vadagao Belagavi-590005
Constitution Public Limited Company

Year of Incorporation 2008

Products Ordinary Portland cement

Pozzolonic Cement, Blast Furnance Cement
and white Cement
Land area 35.05 Acres

Size of industry Medium Scale Industry

Capacity 800+ Ton per day

Brand Names Jyoti gold, Jyoti power and Keshav Cement

Market Reach Karnataka,Maharastra, Goa & keral

Technology used West German Technology

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

QUARRY

"The process of taking out stones from natural rock bed is known as quarrying

• The term quarry is used to indicate the exposed surface of natural rocks

• Quarry is the place where the raw materials are extracted by drilling and blasting.

• The main purpose of quarrying stones by blasting is to loosen large masses of rocks and for
quarrying hard stones

CRUSHING PLANT

"The crushing plant is one-stop crushing installation, which can be used for rock crushing,
garbage crushing, building materials crushing and other similar operations. crushing plants may
be either fixed or mobile."

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There are two types of crushing plant

1) Primary crushing

Specifications

• The capacity of the primary crusher is 30otons/hr.

• Three phase AC induction motor is installed to operate the primary crusher whose
specifications are 503hp, 1477rpm, 66oovolts.

• The outlet size of the limestone will be below 8omm

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2) Secondary crushing plant

• The capacity of secondary crusher is 100tons /hrs

• In this also Three phase AC induction motor is installed, with the specifications of 225hp,
146orpm, and 415volts.

• The outlet size of limestone will be below 4-6mm

• In between the primary to secondary crushing process a magnetic separator is placed

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RAW MILL

A Raw mill is the equipment used to grind raw materials into "raw mix" during the manufacture
of cement. It's mainly used in grinding raw materials and end products in cement plant.

• Raw mill is generally called cement raw mill, raw mill in cement plant, it refers to a common
type of cement equipment in the cement plant.

• Raw mixes are formulated to contain a correctly balanced chemistry for the production of
calcium silicates and fluxes in the kiln.

• A raw mixes limestone, clay, sand, coal in proper proportion

• Raw mix is then fed to a cement kiln, which transforms it into clinker.

Cement processing plan is a state owned enterprises engaged in the cement industry. The
problems that this factory has are such as frequent damage to the engine. The machine used in
cement production at the factory includes raw mill machines, kiln machine, and cement mill
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machines. The more often a machine is damaged; the average time between failures of a machine
is lower. So that it can cause the production process is hampered. In this study, the engine S
studied was the Raw Mill Machine at plant. The raw mill machine functions as a main materials
grinder in the initial milling process such as lime stone, silica stone ,clay , and iron sand to become
raw mix. To find out the frequency of damage to the machine or the time interval between damage
to the tool frequency of the damage to the machine or the time interval between damage to the
tool(MTBF) and the length of the time used to repare the tool(MTTR), The total product
maintenance (TPM) method is used to perform maintenance by optimizing the effectiveness of the
equipment and reducing sudden damage(breakdown) by first identification and then the cause of
the problem is identified using fish bone analysis and failure mode and Effect Analysis(FMEA)

Preheater

• The raw materials, before fed to the kiln, is preheated by the exhaust gases from the kiln. This
leads to reduction in the thermal load to the kiln.

• In keshav cement plant, there is 5 stages of preheater and having six cyclone separators.

• A process in which calcium oxide and carbon di oxide are produced from calcium carbonate is
known as calcinations process.

In the second stage, raw mix is fed into the kiln & gradually heated si contact win che hot gases
from: make full use of heat in the kiln, reduce the energy consumption of clinker production, and
reduce the room required

• 70 to 110 °C- Free water is evaporated.

• 650 to 900 °C- calcium carbonate reacts with SIO2 to form belte (Ca25104).

• 900 to 1050 C- the remaining calcium carbonate decomposes to calcium oxide & CO2

• 1300 to 1450-°C - partial (20-30 %) melting takes place, & belite reacts . with calcium oxide to
form alite (CaO-SiO4).

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Advantages of cement preheater

• High productivity:

the cyclone preheater adopts multistage cycle suspension preheating to improve the production
rate.

• Low investment:

due to the reasonable structure of cyclone preheater, reduce the problems of

equipment , cost –effective , low investment and higher benefits .

• Low energy consumption:

make full use of heat in the kiln, reduce the energy consumption of clinker production, and
reduce the room required

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CHAPTER – 02

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Kiln section

• Cement kilns are used for the preprocessing stage of manufacture of Portland and other types
of hydraulic cement, in which calcium carbonate reacts with bearing minerals to form a mixture
of calcium silicates. °.

The kiln is a 3.0*45 m long cylindrical steel lined with special heat resistant refractory.

• The kiln is inclined downwards at an angle and rotates continuously. A temp zone is
maintained in the kiln, with maximum temp of 1400 °C.

• The excess air is de dusted in an ESP.

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Wet Process Kilns

The original rotary cement kilns were called ‘Wet process’ kilns. In their basic form they were
relatively simple compared with modern development. The raw meal was supplied at ambient
temperature in the form of slurry

The wet process kiln may be up to 200m long and 6m in diameter. It has to be long because a lot
of water has to be evaporated and the process of heat transfer is not very efficient.

Quite a few wet process kilns are still in operation usually now with higher tech bits bolted on
however new cement kilns are of “dry process”

Dry process kilns

In a modern works the blended raw material enter the kiln via the pre heater- tower. Here hot
gases from the kiln are used to heat the raw meal. As a result the raw meal is already hot before it
enters the kiln

The dry process is much more thermally efficient than the wet process

As the meal passes through the burning zone, it reaches clinkering temperature of about 1400c-
1500c.Nodules from as the burning zone is approached. When the clinker has passed the burning
zone, it starts to cool, slowly at first, then much more quickly as it passes.

Hot clinker

• Cement clinker is a solid material produced in the manufacture, of Portland cement. Clinker
occurs as lumps or nodules, usually 3 millimeters (0.12 in) to 25 millimeters (0.98 in) in
diameter.

• Clinker consists of various calcium silicates including alite and belite. Tricalcium acuminate
and calcium aluminoferrite are other common components.

• Portland cement clinker is made by heating a homogeneous mixture of raw materials in a

rotary kiln at high temperature.

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• The products of the chemical reaction aggregate together at their sintering temperature, about
1,450 °C (2,640 °F)

• The clinker surface and its reactions in different electrolytic solutions are investigated by
scanning electron microscope and atomic force microscopy.2:38 pm

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Clinker cooler

• Clinker cooler is a kind of heat exchange device that transfers heat from high-temperature
clinker to low-temperature gas.

• The clinker cooler is also called as cement cooler, which is used to cool the clinker

• cement cooler also provide hot-air for rotary kiln and Clinker, it is the main equipment of heat
recovery for burning system.

• From the environmental and cost point of view, the cooler reduces energy consumption by
extracting heat from the clinker.

• The cooled clinker is then conveyed either to the clinker store or directly to the clinker mill.
The clinker store is usually capable of holding several weeks supply of clinker.

Function of clinker cooler

• To improve the quality of clinker, increase the grind ability of cement;

• Recovery the waste heat of clinker, increases the heat efficiency of rotary kiln, and reduces the
heat consumption.

• Reduce clinker temperature by cooling, easy to transportation and storage of clinker.

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Coal section

•. Coal is used as a feed to the kiln. Not only does it react with the raw meal to form clinker, but
it also burns as a fuel thereby providing thermal energy to the kiln ° The produced coal is
crushed and then fed to a roller mill fitted with high efficiency dynamic separatols.

• The pulverized coal is collected in a bag house or an ESP. the fine coal is stirred in bins from
which it is extracted, weighed and pumped into the kiln and the calciner lines of preheated.

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Electro static precipitator(ESP)

. An electrostatic precipitator (ESP) is a filtration device that removes fine particles, like dust

and smoke, from a flowing gas using the force of an induced electrostatic charge minimally
impeding the flow of gases through the unit.

Cement mill A cement mill is the equipment used to grind the hard, nodular clinker from the
cement kiln into the fine grey powder that 1s cement.

• Portland clinker is the main constituent of most cement. In Portland cement, a little calcium
sulfate (typically 3-10%) is added in order to retard the hydration of tricalcium aluminate.

• Cement milling is the largest user of electric power on a cement plant, and because they can
easily be started and stopped, it often pays to operate cement mills only during "off-peak"
periods when cheaper power is available.

• There are two cement mills, whose capacities are 25 and 15 tons/hr respectively.

2:40 pm

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Packaging plant

• Cement is stored in concrete silos, in this plant capacity of silo is 1OO tONS.

• It is then extracted from the bottom of the silos by screw conveyors and packed into the bags of
50 kg by rotary multi spout packers (i.e 6 spout packers) with electronic weighing system.

• Each spout packers has capacity to pack 15tons cement per hour.

• The stacks of cement bag is controlled by semi automated arm.

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CHAPTER – 03

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INTRODUCTION TO CEMENT:
• A cement is a binder, a substance used for construction that sets, hardens and adheres to other
materials, blinding them together. • India is the world's second largest producer of cement after
china with industry capacity of over 200 Million Tones.

• It is used with fine aggregates to produce mortar for masonry, or with sand and gravel
aggregates to produce concrete also used in construction, usually inorganic, often lime or
calcium silicate based and can be characterized as being either hydraulic or non-hydraulic.

• Hydraulic cements (e.g., Portland cement) set and become adhesive due to a chemical reaction
between the dry ingredients and water

•. Non-hydraulic cement will not set in wet conditions or under water, rather it sets as it dries and
reacts with carbon dioxide in the air.

HISTORY OF CEMENT:

• Throughout history, cementing materials have played a vital role and were used widely in the
ancient world.

• The Romans found that a cement could be made which set under water and this was used for
the construction of harbors.

• This cement was made by adding crushed volcanic ash to lime and was later called a
pozzolanic cement, named after the village of Pozzuoli near Vesuvius

• Joseph Aspdin took out a patent in 1824 for "Portland Cement," a material he produced by
firing finely-ground clay and limestone until the limestone was calcined.

• He called it Portland Cement because the concrete made from it looked like Portland stone, a
widely-used building stone in England.

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TYPES OF CEMENT

• Cement is mainly classified into two categories depending on the hardening and setting
mechanism. These are

1) Hydraulic Cement

Hydraulic Cement is a product used to stop water and leaks in concrete and masonry structures.
It is a type of cement, similar to mortar, that sets extremely fast and hardens after it has been

mixed with water .

2) Non-hydraulic Cement

A less common form of cement is non-hydraulic cement, . such as slaked lime (calcium oxide
mixed with water), hardens by carbonation in contact with carbon dioxide, which is present in
the air.

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Other types..

• Along with these main types, depending on the composition and characteristics there are many
types of cement. Followings are the other cement types:

1) Ordinary Portland Cement (OPC)

2) Portland Pozzolana Cement (PPC)

3) Rapid Hardening Cement

4) Quick Setting Cement

5) Low Heat Cement

6) Sulphate Resisting Cement

7) Blast Furnace Cement

8). High Alumina Cement

9) White Cement

10) Colored Cement

11) Air Entraining Cement

12) Expansive Cement

13) Hydrophobic Cement

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CHAPTER – 04

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RAW MATERIALS

The most commonly used Raw materials are as

• Lime stone: It is the main constituent used in cement manufacturing. It is responsible for
imparting the cementing property to cement.

• Clay: the plasticity of cement mortar is increased by the presence of clay.

• Iron ore: The Main Function of Iron Ore in the Cement Is While Melting / Burning of Raw
Meal in Kiln Iron Ore Melts Itself and Liquidize the Material to Easy Pass from Kiln, Avoid
Coating in the Kiln and It Supports Perfect Formation of Clinker

Use of cement

 Production of Concrete
 Construction purpose
 Building (floors, beams, colomns,roofing)
 Transport(rodads,pathways,crossings,bridge)
 Water(pipes ,drains, canals)
 Agriculture(irrigation, housing)

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Types of cement

 ordinary Portland cement(OPC)

 Portland pozzolana cement(PPC)
 Oil well cement
 Rapid hardening
 White cement,etc..

Raw material

 Limestone
 Sand
 Shale
 Clay
 Iron ore

Cement manufacturing process

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CHAPTER – 05

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Technology of Cement

 The technology is a continuous process and is highly energy intensive.

 At present 93% of cement production in india is based on modern and environment-
friendly dry process technology and only 7%of the capacity is based on old wet and semi-
drv process technology.

The cost cement

 29% energy
 27% energy
 32%labour
 12%depreciation

Evolution of Indian cement industry

 A Kolkata based company started manufacturing cement in 1889.

 After the economic reform in1980 the government control on cement industry was
liberalized

Geographical segments

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Major player in Indian cement industry

Regional capacity

Current status

 Our country responsible for 7-8 percent of global cement production.

 139 large cement plants
 365 mini cement plants
 Cement sales16.26 million tones.
 India is the second largest cement market in the world after china.

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Growth rate

 India would require overall cement capacity of around 480 million tonnes.
 This would mean the industry will have to add another 150 million tonnes of capacity
during the period.
 According to the latest report form the working group on the industry for the 12th five –
year plan(2012-17)

Factors that will drive growth in the sector

 Housing segment growth is leading to higher demand for cement for home building.
 Governments 12th five year plan focuses on increasing infrastructure (upgraded airports,
ports, railway expansion etc…..) to drive construction activity.
 Cement and gypsum products sectors in India is attracted foreign direct investment.

Indian cement industry life cycle

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Constraints:

Targeting

To produse more capacity.

Less cost and less labours.

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CHAPTER – 06

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Marketing department
Presently the cement brand Keshav cement is very popular in the regional cement market. Company
supplies in North Karnataka, Goa and some parts of Maharashtra.

This brand is made to reach bigger market like Bengaluru, Pune and Mumbai currently due to aggressive
marketing and using innovative techniques, the brand “Keshav cement” is being sold at premium prices.
Due to capacity limitations the company is not able to supply to the bigger markets as mentioned above.
Since there are no cement plants in Goa and nearby Maharashtra areas like Kolhapur, satara, Sangli etc
the company has potential market in these areas. Since the promoters already have their own trucks and
other fleet it is felt that the company will not pace any difficulty in both procurement of raw materials
and supply of cement in the market with his arrangement the company will have an edge over the
companies has far has selling price is concerned.

Selling price of cement:

Bagalkot -340 RS
Goa - 360 RS
Maharashtra -360 RS

Advertising and sales promotion activities

Trade shows:

It is a forum where manufacture can display their products to productive buyers. Keshav cements has a
regular engagement with civil contractors and the general public via these trade shows it is generally
carried out by the management team once in 6 months.

Deals/discounts are offered to resellers in the form of price reduction during certain periods of the year.

Advertisement:

 Wall painting
 Newspaper ads
 Hoardings

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CHAPTER – 07

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"My personal experience"

I had a great experience in doing my project on internship program in "Shri Keshava cement and infra
Ltd" Lokapur.

I am grateful to the external guide Mr.S.K.Sarwade General Manager.

I have learned so many aspect about the manufacturing of cement, marketing procedure and work culture
of the employee towards their work.

At the end I had chemical verification and testing about cement strength in the laboratory.

I entered the factory without any expectations but at last I had great experience about the factory and
work procedure.

Now I want to share some memory about my internship program

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Acquired knowledge
 Knowledge of cement factory
 Knowledge about work procedure of cement factory in India
 Understanding organization structure and important
 Working culture of cement factory
 SWOT ANALYSIS
 Information gathering, coordination processing date
 Time management in delivering the project
 Value of hard work
 Gained knowledge about management and process
 Marketing ways

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Conclusion

• Efficient working with time management.

• Good working equipments with large area provided.

• Lot of learn here with high experienced working staff.

• Allowing students to visit, learn and do internship in the factory is really appreciable.

• Good relationship between staff and management.

• Time management like shift of the work place is simple and regularly followed by the workers.
° Highly progressive day by day and workers satisfied with company.

• Product is good quality, with good transportation to the other area

• Good packing of product with accurate quantity, and one can able to carry easily.

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