1

Training Report Of First Two Modules By Mechanical Trainee Engineers

Submitted by: ENGR. ZUKHRUF BADR

ENGR. UZAIR AHMED

ENGR. OSAMA AMJAD

ENGR. ALI RAZA MANSHA

Training Incharge:

MR. SAFDAR KAMAL

DG Cement Company Limited, Khairpur Plant Pakistan

2

ACKNOWLEDGEMENT

ALLAH ALMIGHTY, the only single source of certainty and knowledge for us in this

universe. We are very much thankful to ALLAH ALMIGHTY for bestowing us with this

report.

Heartiest thank to Mr. Safdar Kamal, out training incharge, with full fledge respect

and protocol whose towering personality always enlightens the passions to achieve

our goals! Whose kind counseling tips and courteous attitude always backed us up

to go on conquering the horizons of knowledge and skills.

Also regards to, head of departments of DGKCCL Khairpur plant, for affectionate and

respectful attitude towards us.

3

Dedication

We are much pleased to declare our whole module to the name of Mr. Safdar

Kamal. He is our ideal due to his punctuality and hardworking. He is brave person.

He has capability to work anything which no one can do. we shall respect him till our

end of breathing.

4

Contents ACKNOWLEDGEMENT ......................................................................................................................................... 2

Dedication ........................................................................................................................................................... 3

Safety and Fire fighting ........................................................................................................................................ 7

SAFTEY: ............................................................................................................................................................ 8

FIRE FIGHTING DEPARTMENT: ......................................................................................................................... 8

Fire extinguishers and its other types: ............................................................................................................ 8

TYPES OF FIRE: ................................................................................................................................................. 9

EMERGENCY ALERTS & PRECAUTIONS: ........................................................................................................... 9

ASSEMBLY POINTS: .......................................................................................................................................... 9

RDF PLANT ......................................................................................................................................................... 10

FLOW DIAGRAM: ........................................................................................................................................... 10

Introduction: .................................................................................................................................................. 10

HOPPER:......................................................................................................................................................... 10

PRE-SHREDDER: ............................................................................................................................................. 10

VIBRATING SCREEN: ...................................................................................................................................... 10

AIR KNIFE: ...................................................................................................................................................... 11

RE-SHREDDER: ............................................................................................................................................... 11

STORAGE BIN: ................................................................................................................................................ 11

SCRAPPER: ..................................................................................................................................................... 11

SCREW CONVEYOR: ....................................................................................................................................... 11

DRAG CHAIN: ................................................................................................................................................. 11

CONVEYOR BELT: ........................................................................................................................................... 11

TYRE TREATMENT .......................................................................................................................................... 11

SUPER CHOPPER: ....................................................................................................................................... 12

RE-CHOPPER: ............................................................................................................................................. 12

MAGNETIC SEPARATOR: ............................................................................................................................ 12

RAW MEAL PRODUCTION .................................................................................................................................. 13

Material flow sheet: ...................................................................................................................................... 13

INTRODUCTION TO RAW MEAL: .................................................................................................................... 13

MATERIAL FLOW IN RAW MEAL PRODUCTION: ............................................................................................ 14

RAW MEAL PRODUCTION AREA PARTS: ........................................................................................................ 14

LIMESTONE CRUSHER: ................................................................................................................................... 14

MECHANISM OF LIMESTONE CRUSHER: ....................................................................................................... 14

ADDITIVE CRUSHER: ...................................................................................................................................... 15

STORAGE YARD: ............................................................................................................................................. 16

5

MATERIAL FLOW FROM HOPPERS TO RAW MILL: ........................................................................................ 17

RAW MILL: ..................................................................................................................................................... 17

MECHANISM: ................................................................................................................................................. 17

Preheater and Kiln area ..................................................................................................................................... 19

Preheater: ...................................................................................................................................................... 19

Electrostatic precipitator (EP): ...................................................................................................................... 19

Kiln: ................................................................................................................................................................ 19

Coal mill: ........................................................................................................................................................ 19

Cement mill ....................................................................................................................................................... 20

Introduction: .................................................................................................................................................. 20

Cement mill: .................................................................................................................................................. 20

Flow sheet: .................................................................................................................................................... 20

Bag filter: ....................................................................................................................................................... 21

Marginal silo: ................................................................................................................................................. 21

Cement silo: ................................................................................................................................................... 21

Packing plant: ................................................................................................................................................ 21

QUALITY CONTROL ............................................................................................................................................ 22

INTRODUCTION: ............................................................................................................................................ 22

FUEL CONSUMPTION: .................................................................................................................................... 22

FUEL TEST: ..................................................................................................................................................... 22

ANALYSIS: ...................................................................................................................................................... 22

X-RAY ANALYZER:........................................................................................................................................... 23

Fluorescence: ................................................................................................................................................. 23

Diffraction: ..................................................................................................................................................... 23

FUEL TESTING LABS: ...................................................................................................................................... 23

Note: .............................................................................................................................................................. 23

Compressor House ............................................................................................................................................ 24

Flow diagram: ................................................................................................................................................ 24

Compressor: .................................................................................................................................................. 24

Dry unit: ......................................................................................................................................................... 24

Centrifugal pumps: ........................................................................................................................................ 24

Types of valves: ............................................................................................................................................. 25

Butterfly valve: .......................................................................................................................................... 25

Ball valve: ................................................................................................................................................... 25

Gate valve: ................................................................................................................................................. 25

Non return valve: ....................................................................................................................................... 25

6

Safety valve: ............................................................................................................................................... 25

Color coding of pipes: .................................................................................................................................... 25

Waste heat recovery plant (WHR) ..................................................................................................................... 26

Block diagram of WHR: .................................................................................................................................. 26

Boiler: ............................................................................................................................................................ 27

Turbine: ......................................................................................................................................................... 27

Generator: ..................................................................................................................................................... 27

Condenser: .................................................................................................................................................... 27

Pump: ............................................................................................................................................................ 27

Cooling tower: ............................................................................................................................................... 27

Steam traps: .................................................................................................................................................. 28

Deaerator: ..................................................................................................................................................... 28

De mineralization (DM) process: ................................................................................................................... 28

Oil and gas power plant ..................................................................................................................................... 29

Flow sheet: .................................................................................................................................................... 29

I.C engine: ...................................................................................................................................................... 29

Generator: ..................................................................................................................................................... 29

Fuel treatment unit: ...................................................................................................................................... 29

Storage tank: ................................................................................................................................................. 30

Grid station: ................................................................................................................................................... 30

Bearings ............................................................................................................................................................. 31

Nomenclature of bearings: ............................................................................................................................ 31

Paper Mill .......................................................................................................................................................... 32

Introduction and process of Paper mill: ........................................................................................................ 32

Paper Mill Flow chart: ................................................................................................................................... 32

7

Figures:

Figure 1 .............................................................................................................................................................. 10

Figure 2 .............................................................................................................................................................. 13

Figure 3 .............................................................................................................................................................. 15

Figure 4 .............................................................................................................................................................. 15

Figure 5 .............................................................................................................................................................. 17

Figure 6 .............................................................................................................................................................. 17

Figure 7 .............................................................................................................................................................. 19

Figure 8 .............................................................................................................................................................. 20

Figure 9 .............................................................................................................................................................. 21

Figure 10 ............................................................................................................................................................ 24

Figure 11 ............................................................................................................................................................ 24

Figure 12 ............................................................................................................................................................ 26

Figure 13 ............................................................................................................................................................ 29

Figure 14 ............................................................................................................................................................ 32

Tables:

Table 1 ............................................................................................................................................................... 16

Table 2 ............................................................................................................................................................... 16

8

Safety and Fire fighting

SAFTEY: The equipment used for personal safety is known as “PPE”. It is abbreviation of Personal

protective equipment.

The equipment provided for safety is as follow:

Helmet

Safety shoes

Spectacles

Ear plugs

Safety vest

FIRE FIGHTING DEPARTMENT:

There is a fire fighting department for any kind of emergency and to bring back the conditions to

normal. The systems installed for this kind of operations are as under.

1. Hose Reek System:

This system consists of a reel, having 100 feet long water pipe. According to situations, with

the help of this pipe we can make jet or shower for controlling any emergency.

2. Sprinkler System:

This system provide sprinkle of water when needed at the time of emergency. This system is

U.S.A made, company name is “Glow Company”. Whenever the temperature of the space

where the system is installed rises above 68 C, sprinkle automatically bursts.

3. Foaming System:

A foam is applied to the emergency area, which makes a layer over it and cuts off the supply

of oxygen. AFF chemical is used for this purpose. This chemical is added to H2O by 3%.

4. Fire Tender System:

It is a fire fighting vehicle and is loaded with multiple kind of equipment for extinguishing the

fire.

5. Fire Hydrant System

Fire extinguishers and its other types: Fire extinguishers are of following types

I. H2O

II. CO2

III. DCP (dry chemical powder)

IV. Foam

V. Halotron

9

It is used on moisture sensitive appliances, where others can damage them like

computers and other electrical appliances.

TYPES OF FIRE: Class A solid material e.g. wood, coal etc.

Class B liquid material e.g. petrol diesel etc.

Class C gaseous material e.g. natural gas etc.

Class D chemical materials e.g. petrochemicals etc.

Class E electrical materials

Class K kitchen items like food materials

EMERGENCY ALERTS & PRECAUTIONS:

In case of any kind of emergency a siren sound can be heard after intervals. The power of this

siren is 7 HP. The precaution is that whenever the siren is heard, everyone has to get to the nearest

assembly point. Whenever the clearance happens a continuous siren is heard for 1.5. To 2 minutes.

ASSEMBLY POINTS: It is the place where everyone has to gather at the time of emergency. There are 8 assembly

points.

10

RDF PLANT

FLOW DIAGRAM:

Figure 1

Introduction:

RDF is the abbreviation of ‘Refused Derived Fuel’. The municipal wasted here is screened,

shredded and then finally burnt to generate heat energy, which is later used in pre heater. The plant

is Germany made and the name of company is VECOPLAN.

Following are the components and processes of this plant.

HOPPER:

Hopper is a conical type of container and provides passage for the municipal waste containing

paper, polyethylene bags, clothes etc. to the pre-shedder.

PRE-SHREDDER: Here the municipal waste enters through hopper and this material is chopped into small

particles. Pre-shredder consists of two rotating rollers having cutting knives. As the material comes

in between these moving rollers, it is chopped into small pieces.

The capacity of pre-shredder is 30-35 tones/hour.

VIBRATING SCREEN:

The material after chopping in pre-shredder than enters the vibrating screen through

conveyor belt. In vibrating screen the soil from the material is removed and separated by vibration

action. The soil is than taken out through rejection belt and the material is passed to next stage.

Hopper Pre-Shredder Vibrating

Screen

Air Knife

Re-Shredder Storage Bin Scrapper Scrapper

Screw

conveyor

Drag Chain Conveyor

Belt

11

AIR KNIFE:

In Air knife, stones and other heavy particles from the material are removed. In this process

air is entered from downside, the light particles like paper, bags, clothes etc. are lifted up in a duct

and sent to next stage and the heavy particles like stone or other material are left behind and are

separated through rejection belt.

The air blower pressure is 5 bar.

The air flow rate is 9800m3/hour.

RE-SHREDDER:

There are two re-shredders. Each consisting of two rotating rollers, having knives for

shredding action. The material is shredded here to a very small size.

Capacity of 1st shredder is 20 tones/hour.

Capacity of 2nd shredder is 06 tones/hour.

STORAGE BIN: The shredded material is then sent to storage bin,where it is stored. There are four storage

bins.

The capacity of each storage bin is 250 tones.

Total capacity of four storage bin are 1000 tones.

SCRAPPER: The material stored in storage bin is then removed by scrapper to the next stage gradually.

SCREW CONVEYOR: The material is further conveyed with the help of screw conveyor to the drag chain. It is a type

of conveyor with the help of which material can be transferred from one place to another.

DRAG CHAIN:

It is also a type of conveyor, used to convey material to other locations. Here is attached a

moisture detector, which checks the amount of moisture for burning process.

CONVEYOR BELT: The material by the help of conveyor belt is then transferred to pre-heater for the final

burning process.

TYRE TREATMENT Rubber tires are also used as a fuel for generating heat. These tires a firstly shredded to a

small size and then used.

12

Following are the main components of this process.

SUPER CHOPPER: The tires are entered in super chopper where its size is reduced up to 100 mm. The motor of

super chopper is operated hydraulically and the hydraulic oil is cooled by cooling unit, which consists

of a blower.

Capacity of super chopper is 06 tones/hour.

RE-CHOPPER: In re-chopper the size of the tires is further reduced to 20 mm.

Capacity of re-chopper is 15 tones/hour.

MAGNETIC SEPARATOR: The rubber tires also contain stainless steel wires, which are separated by a magnetic

separator. The tire is then sent further for burning process.

13

RAW MEAL PRODUCTION

Material flow sheet:

Figure 2

INTRODUCTION TO RAW MEAL:

The main ingredients of cement are

Clay (10-15%)

Limestone (80-85%)

Additives(bauxite and laterite 5% )

14

When all these ingredients are mixed together and grinded in a form of powder than this is

called as raw meal and it is stored in raw meal silo that is also called as CF silo. Raw meal production

starts from crusher and ends at the raw meal silo.

MATERIAL FLOW IN RAW MEAL PRODUCTION: Clay and limestone are crushed in main crusher, than they are send to the storage yard with

the help of belts similarly for the crushing of additives we have different crusher, its main purpose is

to crush the iron ore (laterite) and alumina (bauxite).From here material is send to the yard with the

help of belts .Piles number 1 and 2 are of additives, 3 and 4 are of HG (high grade) limestone, 5 and

6 are mix piles (limestone and clay). From yard the material is send to the 4 hoppers. There are four

hoppers or bins hopper number 1 is for mix material, 2 for HG limestone, 3 for iron ore and last one

is of additives. Material is then send to raw mill in a proper ratio. Raw mill grinds the material and

thus raw meal is achieved and sucked by fan in cyclones and then with the help of air slides and

bucket elevator it is send to the CF silo.

RAW MEAL PRODUCTION AREA PARTS:

Limestone crusher

Additive crusher

Storage yard

Hoppers

Raw mill

CF Silo

Dust collectors

LIMESTONE CRUSHER:

Type: Hammer type crusher Hammer weight: 92 to 95 kg approx.

Capacity: 1500t/h Rotor drive source: 1540 kW motor (with reduction gear box)

Input size: up to 2m

Output size: 125mm

Number of shafts on rotor: 4

Number of hammers on each shaft: 12

Total hammers: 48

MECHANISM OF LIMESTONE CRUSHER: Limestone crusher consist of following components

1. Dropping throat

2. Apron feeder

3. Inline roller

4. Main rotor

5. Grate bar

15

Limestone is dropped from the dropping throat with the help of dumpers. Limestone pieces are

of usually up to 2m large. With the help of apron feeder material is thrown on the main rotor but

before the rotor there is in line roller that gives proper rotation or direction to the material so that

the material can be easily crushed by the hammers of main rotor. After that there is a grate bar which

only allows pieces up to 125mm or less to pass through it. Clay is also mixed with it. From here the

material drops on the belts and goes to the storage yard where stacker makes the piles.

PGNA(prompt gamma neutron activation analyzer) is attached on the belt that is going to the yard

from limestone crusher. It checks the proportion of material after every five seconds and sends it to

the quality department. This system helps us to maintain the correct ratio of clay and limestone in

mix piles (pile# 5, 6). The symbol of crusher in the main flow sheet is this

Figure 3

ADDITIVE CRUSHER: Type: Hammer type crusher Hammer weight: 90 kg approx.

Capacity: 50t/h Rotor drive source: 200 kW motor (with reduction gear

box)

Number of shafts on rotor: 4

Number of hammers on each shaft: 18

Total hammers: 72

Additive crusher is used to crush the additives iron ore and bauxite. it is smaller is size then

the limestone crusher but its mechanism is same as that of limestone crusher. From here the material

is directly send to the hoppers when plant is running but when plant is not in running the crushed

material is stored in the storage yard. Its area code is 113. Material is supplied from crusher to the

storage or hopper in this way

113BC200 113BC100 113BC400 storage

113BC500 hoppers

Figure 4

16

STORAGE YARD:

6 piles are made in the storage yard,

Pile #

Material Capacity

Pile #1 Bauxite

1500t

Pile #2 Iron ore

2800t

Pile #3 HG lime stone

3000t

Pile #4 HG lime stone

3000t

Pile #5 Mix

35000t

Pile #6 Mix

35000t

Table 1

Stacker makes pile # 3,4,5&6 while pile # 1,2 are created with the help of hoppers

Side scraper operates on the pile #1,2,3and4 .It collects the material from piles and throw it

on the belt which further supply the material to the hopper

Reclaimer works on pile #5 and 6. It collects the material and send it to the hopper

HOPPERS:

There are four hoppers or bin to feed four ingredients to the raw mill. Each hopper is provided

with rotary feeder that is controlled by CCR. So CCR and QC lab controls the material ratio or we can

say that correct proportion of raw mill feed is controlled by Rotary feeder that can be operated from

CCR. The four hoppers are

Hopper # Max Capacity(t) Tripping value(t)

Mix(clay+limestone) 311BI100

730 750

Limestone HG 311.BI200 700 750

Iron ore(laterite) 311.BI300

540 570

Additives(bauxite) 311.BI400

315 333

Table 2

17

Figure 5

MATERIAL FLOW FROM HOPPERS TO RAW MILL:

311. BI100 311. WF150

311. BI200 311. WF250 311. BC600 311. BC630

311. BI300 311. WF350

311. BI400 311. WF450

321. RM100 321. BC010

Figure 6

RAW MILL: Manufacture: FLSmidth number of rollers: 3

Fan Motor: 4300kw weight of each roller: 60 t

Capacity: 500tph

Model name: Atox 52.5

Table diameter: 5.25m

MECHANISM:

The raw feed from the belt conveyer directly falls on the rotating table of the raw mill. The

table contains 3 crushing rollers. The raw feed is crushed to fine powder with these rollers. The coarse

particles are collected at the bottom and are sent to the vibrator from where they are sent to the

raw feed belt conveyer and again recycled to the raw mill for re crushing. The vibrator is use to handle

the quantity of material being put on the belt. At the top of raw mill there is a separator section. Hot

gases from the preheater comes from the bottom of the mill a suction fan with a motor of 4500kw

produces the suction and sends dusty air into the cyclones at the top. Here the dusty air rotates and

air is separated from dust nearly 80% dust from air is separated in four cyclones. These four cyclones

sent the crushed material to the CF silo with the help of air slides and bucket elevator. The air stills

18

contain 20 % dust particles in it that air is separated in conditioning tower and electrostatic

precipitator. In conditioning tower water is sprayed that separates the dust from air. In EP dust

particles are charged and then collected on the wall then after some time hammer hits the walls and

the dust falls down and supplied to the CF silo. Raw takes hot gases from pre heater so it reduces the

moisture from 7% to 1%. In CF silo the Raw meal feed is homogenized to 10:1 thus raw meal is ready

to be feed in preheater.

19

Preheater and Kiln area

Preheater: It is in-line double string five stages consigner. In the past, Off-line consigner use. But its

drawback is that it do not direct feed from RAW mill to kiln. Double string means at both sides’

cyclones are present. Five stages mean total five cyclones are present on preheater. At consigner and

kiln 900 ton/day coal use to produce 7000 ton/day. 17% ash allow in cement according to ISO

standards. At different heights of consigner, temperature is different. 900 degree centigrade

temperature at the upper side of consigner. Induced fan use on both strings which uplift the material.

Electrostatic precipitator (EP):

It removes air and dust by electrodes. Small hammer present it drop the dust to hopper. It

can collect 20 to 20 ton/hr material.

Kiln: Kiln name is ROTAX-2. Its maximum revolution are 4.5 per minute. Mostly it run at 4.1 to 4.3

rpm. Hydraulic system use for self-aligning of bearing. Its diameter is 5.5 m and length is 65.5 m. 7 to

10 min material stay in kiln at 4.3 rpm. It takes approximately 24 hours for pre heating. Otherwise

fuel more use.

Coal mill: Fine coal temperature we maintain in coal mill less than 70 degree centigrade and oxygen

level less than 9% to prevent fire. In coal mill bag filters we use anti-static material bags. Here two

carbon dioxide cylinders are also present for the time of emergency. Coal meal production flow sheet

is given below:

Figure 7

20

Cement mill

Introduction: Its area start from gypsum and clinker bins. These bins store material. Total five bins present

in cement mill area. Two two bins for clinker and gypsum while one for slag. Slag bin capacity 280

ton and others have 360 ton capacity. At cement mill area two mills are making cement. Material

feed to cements mills by two belt conveyors. 511bc600 and 512bc600 feed cement mill 1 & 2

respectively.

Cement mill: Mill name is “OK36-4”. Its turning table diameter is 3.64m. Its capacity is 175 ton/hr. It contain

four rollers. Each roller weight is 34 ton. These rollers are mounted on spherical roller bearing. For

roller alignments nitrogen gas use. Rollers dive by heavy motors in which hydraulic oil present. This

oil is cooled by water coming from cooling tower. During the cement making process, material also

remove by rollers due to extensive grinding. This material is recovered by hard facing. “MAGG

Company” give gears of raw mill and cement mill.

In cement mill air separator present which suck the grinded material upward direction. Grade

bar do not allow larger diameter cement which come back for more grinding.

Flow sheet:

Figure 8

21

Bag filter:

DG cement largest bag filter present after the cement mill. It has 4480 bags in it. Bag filter

actually use to absorb the dust. Bag material of different types use in different bag material. Mostly

use materials are polyester, normax and anti-static. In coal mill bag filters anti-static material use.

Normax material can bear high temperature.

Bag filter purging may be time base or pressure type. Rotary valve open for dropping down

the material on belt conveyor from bags. Bag filter may have 56, 68, 112, 256 bags according to size.

Marginal silo: When we do not want to store clinker in clinker silo. Then we pour down into marginal silo.

Below this silo dumper present which take the material and put into clinker yard.

Cement silo:

Three cement silo present. Each has capacity of 21000 ton and area 14000 m3.

Packing plant: It has six packers. Each packer has 2400 bag/hr capacity. On two packers shooter also present.

While some also manual. Manual has lesser efficiency.

Figure 9

22

QUALITY CONTROL

INTRODUCTION: There are 4 components (Mix material, HG Limestone, Iron Ore and Bauxite) which are

grinded together and make raw meal. Before the storage yard where these 4 materials are stored

there is an analyzer known as PGNAA (Proton Gamma Neutron Activation Analyzer).Now after that

when raw meal is made at the output of this raw meal there is another analyzer for quality check and

then sent to CF Silo. Raw meal and Kiln feed has a difference that raw meal is heterogeneous and kiln

feed is homogenous. Quality department has to set the ratio at which blending should be done in CF

Silo and the ratio is 1: 10. Kiln feed is tested by laboratory with the help of X-Rays. After testing this

is then sent to clinker feed and calcination is done and removal of CO2 is done. When calcium

carbonate is heated at 900 degree CO2 is eliminated and lime is formed. Then lime is heated with

silica and iron at 1400 degree and form silicate components. In clinkerization process clinker is tested

after every 1 hour. There are online analyzers and sample points are there at every point after clinker

formation. Gypsum is added to increase the setting time the smaller the size of clinker the greater

will be the setting time.

FUEL CONSUMPTION:

Furnace oil is initially used for preheating. And elsewhere coal is used for heating and

imported coal come from South Africa.

FUEL TEST:

Following things are tested for fuel test

Moisture

Ash

Sulphur

Heating value

ANALYSIS:

There are two methods for analysis which are as follows

Approximate analysis (properties of fuel testing e.g. Volatility etc.)

Ultimate analysis (properties of element testing e.g. carbon, sulphur, oxygen etc.)

Final product testing is known cement testing and following things are tested

Compressive strength

Expansion time

Setting time

They are combine known as physical testing and this is done to meet the standards (PS232) and

this is Pakistan standards. There are two types of cement Ordinary Portland Cement (OPC) and SRC

and the only difference between these is dry calcium silicate is less than 5% in SRC.

23

X-RAY ANALYZER:

There are two different type of X-Ray Analyzer which are as follows:

X Ray Fluorescence ( XRF)

X Ray Diffraction (XRD)

Fluorescence:

Whenever the primary rays fall on some material electrons from the inner shell are emitted

and electrons from the outer shell come inside and meanwhile coming inside emit some rays and

these emitted rays are called Fluorescence.

Diffraction: When we pass some X Rays through crystals these rays are diffracted through crystal lattice

at some angle and these diffracted rays tell the structure of the crystal lattice. This phenomena is

known as Diffraction.

FUEL TESTING LABS: In DG Cement there is also a fuel testing labs consisting of following equipment’s

Thermo gravimetric Analyzer

Sulphur Carbon Analyzer

Bomb Calorimeter

Note:

Gross heating value of Furnace Oil is 10,500 k.cal/kg and Gross heating value of local coal is

5000 k.cal/kg.

We use 53 grade standards for testing cement strength. We break 70.7mm cube and the

strength required for breaking this cube tells us the strength of the cement. For 28 days we

have 63 Mega Pascal strength of Cement.

24

Compressor House

Flow diagram:

Figure 10

Compressor:

There are 8 compressors. 7 working at a time and 1 for emergency which has lesser capacity.

Rest compressor capacity is 8.5 bar pressure each. Its company name is ATLAS OPCO and model

GA200 W. All compressors are screw type. Each compressor has 3 oil filter and 1 oil separator.

For lubrication, roto inject oil use 108 liter per compressor.

Figure 11

Dry unit:

This unit used to remove moisture from compressed air. Because moisture cause corrosion

of machine parts. It contain silica gel. It absorb moisture when air pass through it. In dry unit heater

also present which dry silica gel.

Centrifugal pumps: Three pumps present in compressor house. Two work at a time and one for stand by position.

Each has 2 bar pressure. These pumps are manufactured by “KSB PUMPS”. It is German company also

working in Pakistan. Pumps use here for compressor cooling. Pump suck water from cooling tower

Rotary

compressor

Filter

Chiller Filter

Vessel Dryer Unit

25

which is installed far away from compressor house. Cooling tower has cooling capacity up to five

degree centigrade. Pin type coupling use for joining of pump to duct.

Types of valves:

Butterfly valve: These valves present at compressed air pipe lines of larger diameter.

Ball valve: These are present at smaller diameter air pipe line.

Gate valve: It was on water pipe lines. In this valve small plunger present. It stop the passage in pipe when

we close valve.

Non return valve: This valve use for unidirectional flow. It allow the fluid forward motion but prevent reverse.

Safety valve: At the top of vessels, this valve present. When pressure increase from specific value in vessel,

it open and release the pressure.

Color coding of pipes:

1. Red color pipe show, this is for firefighting.

2. Green color use for fresh water.

3. Grey color use for air lines.

4. Blue color use for treated water.

26

Waste heat recovery plant (WHR) It is largest waste heat recovery plant of world. It has capacity of 8.6 MW. It invented by

scientist whose name was “Kalina”. Kalina system is efficient of low temperature sources e.g.

geothermal energy and waste heat recovery. It works on Rankine cycle. It contain two HRVG’s (heat

recovery vapor generator) at preheater strings and one at cooler side. Gases coming from preheater

temperature is 310-320 degree centigrade and WHR chimney temperature is 110 degree centigrade.

WHR made by FLSmidth Company. WHR efficiency is 24-25%.

Block diagram of WHR:

Figure 12

Heat Source HRVG

LP

Recuperator

LP

Condenser

LP

Pump

HP

Recuperator

Separ

ator

HP

Condenser

HP

Pump

Cooling

Tower

27

55% Ammonia- Main Solution

33% Ammonia- Basic solution

24% Ammonia- Lean solution

90% Ammonia- Rich Solution

Hot Gas

Cooling Liquid

Boiler:

Here three boiler use. These are gas tube boiler. In the boiler, water ammonia mixture use.

We use ammonia to enhance the water energy storage capacity. 55-60% ammonia solution use.

Percentage of ammonia at different points of WHR are vary according to situation. All boiler have

three main sections i.e. economizer, evaporator and super heater. But one boiler have two extra

sections i.e. condensate preheater (CPH) and flash super heater (FSH). After the super heaters of

other two boilers steam also come in FSH of his boiler. In the boiler we use treated water for minimize

the scaling. From two boilers we use partial heat because rest heat use to remove moisture from

RAW Mill. At third boiler use complete heat.

Turbine:

In WHR turbine install of General Electric (GE) Company. Its rated capacity is 10 MW. It is

working on 8.6 MW. It is axial flow back pressure turbine. Its working rpm is 4200. It has 11 stages

and last stage has titanium coated blades.

Generator: ABB company generator use in WHR. The medium which join generator to turbine is gear box.

Generator rpm is 1500. Its oil also cooled by cooling tower water.

Condenser:

In WHR, shell and plate type four heat exchanger use. Water come from cooling tower which

cool and convert steam into water. In the condenser lean solution of ammonia come. It separate

earlier from water. Because due to ammonia heat dissipation of water decrease.

Pump: Axial flow centrifugal pumps use of FLOW SERVE Company. These are multistage pumps. It

use to feed the water in boilers.

Cooling tower:

Induced draft counter flow cooling tower use. It has three cells. It has different components.

Fill is made by PVC material which use to increase contact time between water and air. Drift

eliminator here also present make by same material. It prevents water vapors go to atmosphere.

28

Steam traps:

Before steam expand into turbine, it was from different pipes. We know that at the bend of

pipes, steam condensate. Steam traps use to take condensate from bends.

Deaerator: It use to separate the oxygen bubbles from water.

De mineralization (DM) process: It is doing by two methods in WHR.

1. Reverse osmosis (RO)

2. Electrode de ionization (EDI)

29

Oil and gas power plant It is a power plant which produce electricity by the internal combustion (I.C) engines. Its

capacity is 33MW. It is captive power plant. 200g diesel use to produce one kilowatt of electricity.

Similarly in summer and winter natural gas use 0.24 cm3/kwh and 0.27 cm3/kwh respectively. Price

of unit produce by gas and furnace oil is six and seventeen rupees respectively. WAPDA unit price is

14 rupees. Power plant efficiency is 45%.

Flow sheet:

Figure 13

I.C engine: Engines of WARTISLA Company present. Its project of operation and maintenance also given

to same company. Two engines present with 16.5 MW capacity each. These are 18 cylinder engines

and can work by try fuels i.e. gas, diesel, and gas and diesel mixture. Diesel use as pilot in engine for

auto ignition. In the engine no spark plug present.

Generator: Three generator are present. Two couple with I.C engine for producing electricity and one for

future plan. Gear box couple I.C engine with generator and also decrease rpm for increasing torque.

Generator cooled by treated water. After cooling, water go in pipe line towards cooling tower pipe

lines. In cooling tower untreated water cooled. Both pipe lines come in contact and treated water

cooled as a result of it.

Fuel treatment unit: Furnace oil pass from fuel treatment unit where carbon, wax, small metal parts and other

types of unwanted things separate. This treatment unit only use for furnace oil.

Fuel

treatment unit Storage tank Buffer tank

Day tank Generator I.C engine

Electricity

30

Storage tank:

There are two storage tank with each capacity of 1000 ton.

Grid station:

In grid station two transformer present with 20 MW and 26 MW capacity. Input of

transformer is 6.3 KV. Lines which come from WAPDA go to CT/PT. then go to transformer after

passing to jumper and disconnector respectively.

31

Bearings

Nomenclature of bearings: Different types of bearing show by different digit representation. Four digit bearing is always

ball bearing e.g. 6205, 6206 etc. These digits tell about dimensions, bore, type of bearing etc.

its example is given below:

Internal diameter

6 2 0 5

Type of bearing

Dimensions (width and height)

When last two digits are “00”, “01”, “02”, “03”, then bore size of bearings are 10mm, 12mm,

15mm, 17mm respectively. For “04” and greater digits we multiply it with five to get the bore size of

bearing.

Five digit bearing is always roller bearing.

Internal diameter

2 2 2 0 5

Type of bearing

Dimensions (width and height)

Bearings less than 10mm bore represents by three digits. Its last digit show directly bore size

without multiplication.

Internal diameter

6 2 3

Type of bearing

Dimensions (width and height)

When “2RS” or “2Z” written after the four or five digit bearing, its mean at both side rubber

seal or at both side metallic seal respectively.

If C1, C2, C3 etc. also write, these are the different size of clearances between ball/ rollers and

outer race.

C1> C2> C3

32

Paper Mill

Introduction and process of Paper mill: Paper mill of Nishat group is making cement paper bags for different

cement industries. Paper mill is equipped with highly automated machines. Craft paper is used to

make paper bags; craft paper is imported from Sweden, Spain, and Austria. Craft paper roll is of 1 ton

and from that we can make nearly 6000 bags. Paper mills of different plies can be made with this

machine Nishat paper mill makes usually 2 and 3 ply paper bags. Process starts from the mounting of

paper roll on real stand after that paper goes to the printer and only the bottom layer is printed.

Paper printing is done with water based ink. Printing can be done in four different colors. Perforation

is the next step. After that the papers are joined together depending on the type of bag, for triple ply

bag three layers are joined together. In the next step glue is applied on the sides of papers and then

they are joined together or folded and thus a tube is formed. Then there is a perforation unit from

here the tube goes to separator rollers that consist of two rollers now tube comes in a bag shape.

Then there is a pressing unit from their bags goes to next phase where there base and top is glued

with the bag then the bags are pressed again and send to the drum press after that they are send

forward to the storage area

Paper Mill Flow chart:

Figure 14

Real stand Printer Perforation knife section cross pointing

seam pastingfolding tabletear off unitpacktingpress

turning stationstorage

conveyeralignment

sectionopening unit

paisting top and bottom

unit

folding unitdrum presspacketininginspection

tablestore

33

Chief

Executive

Officer

DGM Works

Group

Director

Director

T&O

Director

Finance Director

Marketing

Electrical

HOD

Chemical

HOD

Civil HOD

HR GM Works GM Admin

Main Store

HOD Mining HOD Mechanical

HOD