TABLE OF CONTENTS

1. ACKNOWLEDGEMENT........................................................................................ 3
2. VISION AND MISSON STATEMENT........................................................................4
2.1.VISION STATEMENT..................................................................................... 4
2.2.MISSION STATEMENT................................................................................... 4
3. ABOUT MAPLE LEAF CEMENT FACTORY..............................................................5
3.1.DESCRIPTION............................................................................................... 5
3.2.CAPACITY.................................................................................................... 5
3.3.TECHNOLOGY.............................................................................................. 5
3.4.CORPORATE STRATEGY................................................................................ 5
3.5.CORE VALUES.............................................................................................. 5
3.6.NATURE OF BUSINESS.................................................................................. 6
3.7.OCCUPATIONAL SAFETY, HEALTH AND ENVIRONMENTAL PROTECTION
MEASURES.................................................................................................. 6
3.8.HISTORY...................................................................................................... 7
4. THE PRODUCTION PROCESS................................................................................ 9
4.1.RAW MATERIAL CRUSHING AND STORAGE SECTION......................................9
4.1.1................................................................................................ STACKER
........................................................................................................... 10
4.1.2............................................................................................ RECLAIMER
........................................................................................................... 10
4.2.RAW MATERIAL GRINDING SECTION...........................................................11
4.2.1...........................................................................RAW MILL (ATOX MILL)
........................................................................................................... 11
4.3.RAW MEAL HOMOGENIZATION AND STORAGE SECTION..............................12
4.3.1..........................................................CF SILO (CONTROLLED FEED SILO)
........................................................................................................... 12
4.4.PREHEATING SECTION................................................................................ 13
4.4.1....................................................................CONDITIONING TOWER (CT)
........................................................................................................... 14
4.4.2...............................................................ELECTROSTATIC PRECIPITATOR
........................................................................................................... 14
4.5.COAL (THE FUEL)....................................................................................... 15
4.5.1..........................................................................PFISTER WEIGH FEEDER
........................................................................................................... 15

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4.6.PYROPROCESSING SECTION.......................................................................16
4.6.1.. .DECOMPOSITION OF RAW MATERIALS - REACTIONS AT TEMPERATURES
UP TO ABOUT 1300 C............................................................................. 16
4.6.2........ALITE FORMATION AND OTHER REACTIONS AT 1300 C-1450 C IN THE
BURNING ZONE................................................................................... 18
4.6.3.............................................CLINKER LIQUID AND NODULE FORMATION
........................................................................................................... 18
4.6.4.................................................................................. ALITE FORMATION
........................................................................................................... 18
4.6.5................................................................KILN SPECIFICATIONS (LINE-II)
........................................................................................................... 19
4.7.COOLING SECTION..................................................................................... 19
4.7.1....................................................................................... GRATE COOLER
........................................................................................................... 20
4.7.2...................................................................CROSSBAR COOLER (LINE-II)
........................................................................................................... 21
4.8.CEMENT MILLS SECTION............................................................................ 21
4.8.1.................................................................................. OK MILLS (LINE-II)
........................................................................................................... 22
4.8.2................................................................................. BALL MILL (LINE-I)
........................................................................................................... 22
4.9.CEMENT STORAGE AND PACKING SECTION.................................................23
4.9.1......................................LINE-1 PACKING PLANT CAPACITY AND SYSTEM
........................................................................................................... 24
5. QUALITY MANAGEMNT SYSTEMS.....................................................................24
5.1.LIME SATURATION FACTOR........................................................................25
5.2.ALUMINA RATIO........................................................................................ 26
5.3.SILICA RATIO............................................................................................. 26
6. WASTE HEAT RECOVERY PLANT (WHRP)............................................................26
6.1.ADVANTAGES............................................................................................ 26
6.1.1................................................................................... DIRECT BENEFITS
........................................................................................................... 27
6.1.2................................................................................ INDIRECT BENEFITS
........................................................................................................... 27
6.2.TURBINE................................................................................................... 27
6.2.1...................................................................LIQUID RING VACUUM PUMP
........................................................................................................... 29

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6.3.GENERATOR.............................................................................................. 30
7. SWOT ANALYSIS.............................................................................................. 30
7.1.1............................................................................................ STRENGTHS
........................................................................................................... 30
7.1.2......................................................................................... WEAKNESSES
........................................................................................................... 31
7.1.3...................................................................................... OPPORTUNITIES
........................................................................................................... 31
7.1.4................................................................................................ THREATS
........................................................................................................... 31

ACKNOWLEDGEMENT
We are thankful to almighty Allah who has blessed us with the courage, strength and wisdom
so that we have been able to complete this internship report with His help.
We are greatly thankful to Dr. Asadullah Khan (HOD Department of chemical
engineering, COMSATS Lahore) and Dr. Moinuddin Ghauri (Associate professor,
Department of Chemical Engineering COMSATS Lahore) who kindly provided us
opportunity to check our abilities in such a splendid organization like Maple Leaf Cement
Factory Limited. It was an invaluable experience and an interesting and delightful job.
We are particularly thankful to Mr. Nasir Iqbal (DGM Process, MLCFL) who provided us
with this opportunity to have a practical learning and then test and assess our practical skills.
The guidance and assistance of Engr. Wahab Qureshi, Engr. Mohammad Hamid, Engr.
Asadullah Rajpoot, Engr. Ali Sher, Engr. Rashid Mehmood and all the CCR staff
throughout the internship duration and especially for this internship report has transformed us
into more knowledgeable, hardworking and flexible personalities that can perform better in
the practical life. Sirs, we are thankful to be for injecting such knowledge in our mind and for
the guidance, they have given to us.
We are also thankful to our dear parents who have assisted us financially, mentally and
physically so that today we are proud to call ourselves as educated and an important part of
the society with the knowledge that we have acquired.
Here we must not forget to thank the staff members and workers of MLCFL. Who have
helped us to learn the nature of work being done in the organization and also helped us to
scrutinize what we have learnt in our university from a practical point of view.

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VISION AND MISSON STATEMENT

VISION STATEMENT
The Maple Leaf Cement Factory stated mission is to achieve and then remain as the most
progressive and profitable Company in Pakistan in terms of industry standards and
stakeholders interest.

MISSION STATEMENT
The Company shall achieve its mission through a continuous process of having sourced and
implemented the best leading edge technology, industry best practice, and human resource
and by conducting its business professionally and efficiently with responsibility to all its
stakeholders and community.

ABOUT MAPLE LEAF CEMENT FACTORY

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DESCRIPTION
Maple Leaf Cement is the third largest cement factory in Pakistan. It was set up in 1956 as a
joint collaboration between the West Pakistan Industrial Development Corporation and the
government of Canada. It is strategically located at Daudkhel (District Mianwali) in Northern
Pakistan, which is an area rich in raw materials required for the production of cement.
Kohinoor acquired the ownership and management of Maple Leaf Cement under the
privatization policy of the government of Pakistan in 1992. Presently Kohinoor Textile Mills
is the holding company for Maple Leaf cement.

CAPACITY
At the time of privatization in 1992, the capacity of Maple Leaf to produce Ordinary Portland
Cement (OPC) was 1000 tones per day (tpd). A second plant of 4000 tpd was commissioned
in 1998 and a third plant of 6700 tpd came into production in 2006. It increased the total
capacity to 11,700 tpd. The capacity of White Cement has also increased from 100 tpd to
500tpd with the addition of a new plant. This plant also has provisions for doubling the
capacity to 1000tpd. Presently Maple Leaf cement has 9% of the market share of OPC and is
a leading brand in Pakistan with a diverse customer base. It is also the largest producer of
White Cement in the country with 80% of market share.

TECHNOLOGY
The plants of 4000 tpd, 6700 tpd and of White Cement are state of the art and have been
supplied by FLSmidth in Denmark. In order to ensure the highest efficiency and process
control the plants comprise of equipment with the latest design and technology. To maintain
the highest quality standards a laboratory has also been set up at site for the testing of raw
materials and cement. All Maple Leaf plants comply with National Environment Control
standards.

CORPORATE STRATEGY
We at Maple Leaf Cement Factory Limited manufacture and market different types of
consistently high quality cement, according to the demanding requirements of the
construction industry. Our strategy is to be competitive in the market through quality and
efficient operations. As a responsible member of the community, we are committed to serve
the interest of all our stakeholders and contribute towards the prosperity of the country.

CORE VALUES
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Maple Leaf Cement is committed to run an efficient and profitable business and therefore
aims to employs cutting edge technology to ensure energy efficiency and the optimum use of
natural resources. The visionary and experienced management drives the company to set
goals that position Maple Leaf ahead of the competition and as a key player in the cement
industry.

NATURE OF BUSINESS
Maple Leaf Cement is a part of Kohinoor Maple Leaf Group (KMLG). The group comprises
of companies which are ranked amongst the top companies in the cement and textile sector.
Maple Leaf Cement Factory Limited (MLCFL) is one of the pioneers of cement industry in
Pakistan. Operations of MLCFL are subject to different environmental and labour laws.
Providing Quality cement and ultimately customer satisfaction is our business model.
MLCFL owns two production lines for grey and one for white cement. The plants are located
at Daudkhel District MIanwali. Total annual clinker capacity of the company is recorded at
3,360,000 tons. The company supplies its products in local market and exports as well in
African, Gulf and other Asian countries. The company is fully complying with all applicable
environmental, labout, corporate and other relevant laws.

OCCUPATIONAL SAFETY, HEALTH AND ENVIRONMENTAL

PROTECTION MEASURES
The Company is committed to achieve excellence in Occupational Safety, Health and
Environmental protection. The Company encourages awareness in these areas amongst our
employees, customers, suppliers and all those who are associated with us in our activities.
The Company's goal in respect of safety, health and environment is to minimize all adverse
environmental and health impacts arising out of our operations and to conserve all kinds of
resources and adhere to all legal regulations. Maintenance of health and safety standards at
our plants and offices is our top priority. The Company is committed to actively managing
health and safety risks associated with our business and is actively working towards
improving our procedures to reduce, remove or control the risk of fire, accidents or injuries to
employees and visitors. The Company strives to provide a safe and healthy workplace for its
employees and to act responsibly towards the communities and environment, in which it
operates. It realizes this through the commitment of its leadership, the dedication of its staff,
and application of the highest professional standards of work. Management takes all possible
measures to prevent unsafe activities by its hiring practices and through the implementation
of effective management, human resources and operational policies.

HISTORY
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1956, MLCFL was established by the West Pakistan Industrial Development

Corporation (WPIDC) and incorporated as Maple Leaf Cement Factory Limited.
The capacity of the plant was 300,000 tons clinker per annum.
1967, a company with the name of White Cement Industries Limited (WCIL) was
established with the clinker capacity of 15,000 tons per annum.
1974, under the WPIDC Transfer of Projects and Companies Ordinance, the
management of two companies, namely MLCFL and WCIL were transferred to the
newly established State Cement Corporation of Pakistan (SCCP).
1983, SCCP expanded WCIL's white cement plant by adding another unit of the same
capacity parallel to the existing one; it increased total capacity to 30,000 tons clinker
per annum.
1986, SCCP set up another production unit of grey cement under the name of Pak
Cement Company Limited (PCCL) with a capacity of 180,000 tons per annum.
1992, MLCFL, WCIL and PCCL were privatized and transferred to the KMLG. All
three companies were merged into Maple Leaf Cement Factory Limited on July 01,
1992.
1994, the Company was listed on all Stock Exchanges in Pakistan.
1998, separate production line for grey portland cement of 990,000 tons per annum
clinker capacity based on most modern dry process technology was installed.
2000, Maple Leaf Electric Company Limited (MLEC) a power generation unit was
merged into the Company.
2004, the coal conversion project at new dry process plant was completed.
2005, dry process plant capacity was increased from 3,300 tpd to 4,000 tpd through
debottlenecking and up-gradation of equipment and necessary adjustments in
operational parameters.
2006, a project to convert the existing wet process line to a fuel efficient dry process
white cement line commenced its commercial production. Profit after tax was
reported PKR 1,059 million.
2007, the Company undertook another expansion project of 6,700 tpd grey clinker
capacity which commenced its commercial production on November 01, 2007.
2008, two existing lines of white cement 50 tpd each clinker capacity, converted into
oil well cement plant which started its commercial production.
2011, the Company has successfully started Waste Heat Recovery Boiler Plant.
2012, the Company started earning profit and recorded Rupees 496 million profit after
tax.
2013, the Company has earned the highest ever record profit after tax of Rupees 3,225
million.

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THE PRODUCTION PROCESS

This report covers the following sections of Maple Leaf Cement Factorys Phase-II (GCD):

Raw Material Crushing and Storage Section

Raw Material Grinding Section
Raw Meal Homogenization and Storage Section
Preheating Section
Coal (The Fuel)
Pyroprocessing Section
Cooling Section
Cement Mills Section
Cement Storage and Packing Section

The capacity of the clinker production line is 6700 tons of clinker per day,
corresponding to a production of almost 2,200,000 tons of clinker per year.
The line includes modern technology, which ensures an optimal utilization of the raw
materials, the fuel, the power and the equipment in order to produce cement at the
lowest possible costs.
In the following headings a description is given for each department.

RAW MATERIAL CRUSHING AND STORAGE SECTION

The whole process starts from the extraction of different raw materials from earths surface.
The area where this extraction is carried out is known as Quarry. The plants are usually
erected in the vicinity of a quarry so as to cut the costs as much as possible and acquire a
profitable product. Unlike any other cement manufacturing plant MLCF Phase-II is ideally
located and the Raw Material reserves can be vividly seen from the stacking/reclaiming
section of plant. The farthest raw material (clay) that is to be obtained is a mere 4km from
plant.
The 3 primary raw materials for clinker manufacturing are:

Calcium carbonate CaCO3 or limestone

Iron Ore (Bauxite and/or Laterite)
Clay (mainly Silica SiO2)

These are obtained from quarry, where after the removal of overburden, the rock is blasted
and transported into crusher using dump-trucks. The dump-trucks unload themselves in the
hopper of a hammer crusher with the following specifications:

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Hopper capacity: 225 tons (max)

Total number of rotating shafts: 4
Hammers per shaft: 8
Total number of hammers: 32
Weight of each hammer: 90kgs
Outer gate bar allowable size: 125mm (max)
Crushing capacity: 850 tph at normal conditions
Max feed size: 1m3
Main drive motor: 990 KV

The crushed raw material rocks are stacked up in stockpiles, where a carefully monitored
process of stacking and reclaiming across the stockpile is utilized, blending takes place so
that a uniformity in quality of raw material is achieved. Periodic sampling and testing of these
samples ensure effectiveness of the method. There is a two-stockpile system incorporated in
the process, while one stockpile is stacked up, other is being reclaimed. This saves time and
keeps the process running without pauses and breaks.
For line-II there are:

2 x 35000tons Limestone stockpiles

2 x 13000 tons Clay Stockpiles

The limestone stockpiles, without a worry are stored in the open whereas the Clay stockpiles
are kept covered under a shed, as upon rain heavy sludge formation will occur and stockpile
will lose its integrity.

STACKER
For the task of stacking, a stacker is used. A stacker usually moves in two directions:

horizontally along the rail and,

vertically by luffing (raising or lowering) its boom.

Luffing of the boom minimizes dust by reducing the distance that material needs to fall to the
top of the stockpile. The boom is luffed upwards as the height of the stockpile increases.
Stackers are used to stack in different patterns, such as cone stacking and chevron stacking. In
chevron stacking, the stacker travels along the length of the stockpile adding layer upon layer
of material.

RECLAIMER
A reclaimer is a machine used in bulk material handling applications. A reclaimer's function
is to recover bulk material from a stockpile. Reclaimers are rated volumetrically, usually in
m3/h (cubic meters per hour) for capacity, which is often converted to t/h (tons per hour)
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based on the average bulk density of the material being reclaimed. Reclaimers normally
travel on a rail between stockpiles in the stockyard. A bucket wheel reclaimer can typically
move in three directions: horizontally along the rail; vertically by "luffing" its boom and
rotationally by slewing its boom. Reclaimers are generally electrically powered by means of a
trailing cable.
Modern stackers and reclaimers are typically semi-automatic or fully automated, with
parameters remotely set. The control system used is typically a programmable logic
controller, with a human-machine interface for display, connected to a central control system.

A LIMESTONE STACKER MLCFL

Now, from the reclaimer the raw material (reduced in size now) is belt fed to the storage bins.
For the three raw materials there are their respective storage bins. The bins are cylindrical in
shape but conical at the bottom. The percentage of the three raw materials is set by the QC
department in accordance with the quality and composition of the incoming raw material, and
the type of product that is to be produced. Normally following percentages of the three are
used in manufacturing ordinary Portland cement (OPC):

Limestone: 75%
Clay: 23%
Iron Ore: 2%

For manufacturing SRC (Sulfate Resistant Cement) clay supply to raw mill is cut off, instead
Silica is used and iron ores percentage is increased.

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To keep up with the percentages, we actually control them in terms of their mass flow rates.
For the job, weigh feeders are used. These are, in lay mans terms belt drives that take up
material (falling on them from bins outlets) and deliver it on the belt conveyer towards the
Raw Mill. They are equipped with weight sensors so they can adjust their drive motors speed
in order to keep up with the nominated flow rate, hence the materials percentage.

RAW MATERIAL GRINDING SECTION

From the bins via weigh feeders the material is loaded up on the belt conveyer directly
beneath it and is fed to the Raw Mill. A Raw Mill is in practice a Vertical Roller Mill that is
used to grind raw material mix and make a raw meal for the kiln. The raw mill is named so,
because of the material it grinds i.e. raw material mix. The mill used here is FLSs ATOX
roller mill.

RAW MILL (ATOX MILL)

RAW MILL (ATOX MILL)

The ATOX raw mill uses pressure and shear generated between the rollers and the rotating
table to crush and grind raw materials. Feed material is directed onto the grinding table by
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the feed chute. The rotation of the grinding table accelerates the material towards the grinding
track and passes it under the rollers. Partially ground material passes over the dam ring
encircling the grinding table and into the hot gas stream coming from the nozzle ring. The
moisture in the materials evaporates almost immediately, while the finer portion of material is
carried by the gas stream to the separator and the coarser portion deflected directly back to
the table. The separator allows material that has reached the required fineness to leave the
mill, while it rejects oversized material and sends it back to the table for further grinding. The
coarsest fraction of the material that spills over the dam ring may fall through the nozzle ring
and be conveyed back to the feed material inlet by a mechanical recirculation system.
The hot gas stream enters the mill due to the Induced draft caused by System fan (ID fan)
installed on the rear side of preheating towers base. This fan is responsible for the suction
and supplication of hot gas stream from kiln and to preheaters, precalciner, boilers, raw mill,
coal mill, conditioning tower and electrostatic precipitator. The gas stream leaving the mill
with finely ground particles is distributed in four cyclone separators by the mill fan (installed
beside the mill) and there the solid particles are collected at the bottom of the cyclones and
sent to the CF Silo (Controlled Feed Silo) using air slides.

RAW MEAL HOMOGENIZATION AND STORAGE SECTION

From raw mill all the ground product now referred to as raw meal is stored in CF Silo with
the help of air slides. There are 7 air slides which direct the raw meal from the raw mill to the
Lower tank of CF Silo. The interlocking of CF Silo with the feed bins is at when Low tank is
95-97% filled. Low tank has two load cells to load the material and prevent the system from
choking. The rated capacity of the CF Silo is 25,500 tons.

CF SILO (CONTROLLED FLOW SILO)

The CF (Controlled Flow) silo is a continuously operating system for blending and storage of
cement raw meal. Material is extracted simultaneously at different flow rates from a number
of outlets in the silo bottom. The CF system including suitable kiln feed equipment ensures
stable kiln feed composition at minimum power consumption and investment cost. Two
criteria must be met to achieve a high degree of homogeneity in a continuously operating,
through-flow silo where blending is not achieved simply by air agitation:
All the raw meal in the silo must be kept in constant movement towards the outlets.
The raw meal must pass through the silo in flow zones with different residence times.

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CF SILO LINE-II MLCFL

These criteria are met by the CF silo which extracts raw meal at different rates from several
points in the silo bottom and mixes the streams from the various outlets. The silo is in fact
divided into a large number of streams which run parallel at different rates, and this process is
followed by final blending in a small, aerated kiln feed or blending tank. The final result is a
kiln feed of consistent chemical composition. The CF silo's extraction system is governed by
a programmable control unit. This enables selecting optimum flow rate distribution based on
local requirements and conditions.

PREHEATING SECTION
From CF Silo the feed is loaded up in bucket elevators using air slides. The bucket elevators
take up the material to the top (at 106.5m) of the preheating tower and drop them in the
preheating cyclones. With Line-I there is a single string preheating mechanism whereas the
Line-II incorporates a double string mechanism for its preheating needs. This allows it to
handle a greater load and hence a greater tonnage per day of clinker is achieved. Simply in a
two-string mechanism there is a pair of preheating towers with a common precalciner.
The raw meal is made to contact the incoming hot gases (due to the suction produced by the
ID fan installed at the rear base of preheating tower) from the bottom in a counter-current
manner in the preheating cyclones. A vortex formation inside the cyclone occurs and this
increases the retention time of the feed in the preheater so as to maximize the heat exchange.
The feed being of high specific gravity falls down through the eye of the cyclone and air
passes upwards. The temperatures range from 300-900 Celsius among the preheating
cyclones. Coolest being on the top and hottest at the bottom.
The feed adopts the following path from the top of the preheating tower till the kiln:
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1.
2.
3.
4.
5.
6.
7.

Cyclone-II
Cyclone-I
Cyclone-III
Cyclone-IV
Precalciner
Cyclone-V
Kiln

At the exit of cyclone-IV there is a diverging gate through which we can control how much of
the feed is to be sent to precalciner and how much to cyclone-V. Usually at MLCF 60% of the
outgoing feed from cyclone-IV is precalcined, rest is being directly fed to the kiln.
In the precalciner ~95% calcination of the feed occurs. The rest of the calcination is carried
out in the calcination zone of the kiln. The use of a precalciner helps in designing a kiln with
a shorter length (as the need for calcination zone is fairly reduced now) and also allows to
achieve the maximum possible calcination so as to achieve a better quality clinker.

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The air on
the other hand
adapts
a
different route.
It is sucked
up
at
the
bottom of
the preheating
tower and
is
passed
through the
preheating
cyclones
where
after
exchanging
heat with the
feed it is
sent to boilers.
One duct
from
one
preheating
string to the
respective
boiler
integrated
with
that
string. The
duct
of
PREHEATING TOWER LINE-I air which is
returning
now a bit
colder is put
MLCFL
back into
the preheating
towers exit duct. Both strings ducts combine at common their System fan. From the system
fan this hot air is sent to Conditioning tower (CT). On its way up to the CT a duct takes up
some of the gases to Raw Mill and another to Coal Mill fulfilling their needs. The returning
ducts again meet the CTs main duct. From CT the gases are passed over to Electrostatic
precipitator (EP). The air is electrically charged but opposite to the charge on the EPs plates.
This charging of air is actually charging of the fines present in air. Due to this method a
greater dust recovery is achieved and the air is cleaned up from any dust and ready to be
stacked up through the chimney by the EP fan, which again is an ID Fan.

CONDITIONING TOWER (CT)

The FLSmidth cooling tower can be used for any cooling of gases such as preheater
exhaust, cooler excess air and kiln bypass systems before they are conveyed to mills and
filters. The hot exhaust gases enter the top section of the vertical, cylindrically shaped and
insulated tower, and are drawn through the cooling tower by a fan. Some of the dust from the
gases is precipitated and collected in the bottom hopper of the conditioning tower and
extracted by a conveyor.
Key benefits:

High water pressure atomization system

Low initial cost
Low power consumption
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Highly reliable

ELECTROSTATIC PRECIPITATOR
The most basic precipitator contains a row of thin vertical wires, and followed by a stack of
large flat metal plates oriented vertically, with the plates typically spaced about 1 cm to 18 cm
apart, depending on the application. The air or gas stream flows horizontally through the
spaces between the wires, and then passes through the stack of plates.
A negative voltage of several thousand volts is applied between wire and plate. If the applied
voltage is high enough, an electric corona discharge ionizes the gas around the electrodes.
Negative ions flow to the plates and charge the gas-flow particles.
The ionized particles, following the negative electric field created by the power supply, move
to the grounded plates. Particles build up on the collection plates and form a layer. The layer
does not collapse, thanks to electrostatic pressure (due to layer resistivity, electric field, and
current flowing in the collected layer).

COAL (THE FUEL)

Meanwhile the raw material is taken up and processed to form raw meal for the kiln, coal is
also being taken up and treated to put to use. The need for coal is as a fuel and is at two
points; first in the kiln and secondly in the precalciner.
In the yard where a bulldozer is piling up the coal respective of its quality in an allocated
space. Maple Leaf Cements is using coal from three different origins:

Indonesian originated coal

South African originated coal
Pet-coke

Just like their stockpiles/stacks there are three different bins where the three types are stored
respectively. A belt conveyer transports them from yard into the bins. According to the
combustion conditions for the kiln and the precalciner the ratio in which the three are going
to be used is decided. Again like the raw material bins weigh feeders there are weigh feeders
installed right beneath the bins and work on the same principle as the aforementioned ones.

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BULLDOZER AT COAL YARD

MLCFL
From the bins via weigh feeders the coal is fed to coal mill. Coal mill actually is a vertical
roller mill provided by FLS under the trade name of Atox Mill. There are two material inlets
and two outlets from this mill. Coal and hot gases are introduced into the mill and just like
raw mill the finely ground coal is ejected from the mill via a separator installed in the mill.
The air carrying finely ground coal is passed through a bag filter and the air passing through
is partially stacked out and some of the filtered air is used to control the temperature of the
incoming hot air from the kiln that is used for grinding of coal.

ATOX COAL MILL

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The separated coal is transported to Pfisters rotary weigh feeders (or simply Pfisters) via a
screw conveyer.

PFISTER WEIGH FEEDER

The Pfister DRW is a Rotor weigh feeder especially designed for dosing pulverized fuels
such as petcoke, lignite, coal dust or oil shale in cement burning processes. Integration of
material extraction, weighing, dosing and material transfer into the pneumatic conveying line
makes it a compact system that provides accuracy and constancy.

At MLCF there are two of these weigh feeders installed on Line-II. These Pfisters are
integrated with blowers in a room adjacent to where they are installed. The blowers make use
of pneumatic air that is the transportation medium of the pulverized coal (our fuel). Here
from Pfisters the coal is transported to Kilns burner and to Precalciner.

PYROPROCESSING SECTION
Kiln is the part of the cement plant where the only unit processing is happening, everywhere
else its operations that are being carried out. The chemical transformations taking place are
the reason for the production of clinker and hence cement. It may be safely said that kiln is
the heart of a cement plant.
Pyro-processing of the raw meal is carried out at this stage. In pyro-processing calcium
carbonate reacts with silica bearing minerals in the feed to form compound of calcium
silicates. Over a billion tons of cement is made a year. The clinker producing capacity of the
kiln defines the plants capacity. As the main energy consuming and greenhouse effect
causing section of the cement industry, kiln efficiency holds a vital position in the design and
maintenance departments sight.
The kiln is made of a steel casing lined with refractory bricks. There are many different types
of refractory brick and they have to withstand not only the high temperatures in the kiln but
reactions with the meal and gases in the kiln, abrasion and mechanical stresses induced by
deformation of the kiln shell as it rotates.
Bricks in the burning zone are in a more aggressive environment compared with those at the
cooler end of the kiln (the 'back end'), so different parts of the kiln are lined with different
types of brick.
Periodically, the brick lining, or part of it, has to be replaced. Refractory life is reduced by
severe changes in temperature, such as occur if the kiln has to be stopped. As the cost of
refractories is a major expense in operating a cement plant, kiln stoppages are avoided as far
as possible.

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DECOMPOSITION OF RAW MATERIALS

TEMPERATURES UP TO ABOUT 1300 C

REACTIONS AT

This includes:
i.

Water evaporation in the raw feed, if any.

ii.

Loss of carbon dioxide from the limestone (ie: calcining).

iii.

Decomposition of the siliceous and aluminosilicate fractions of the feed.

iv.

Formation of a sulfate melt phase.

The decomposition products react with lime to form intermediate compounds which in turn
form other compounds as clinkering proceeds.

WATER EVAPORATION
In wet-process kilns, and their derivatives, water must first be driven off. In a wet-process
kiln, calcining takes place after the water has been driven off, about a third of the way down
the kiln. In the more modern pre-calciner kilns, the feed is calcined prior to entering the kiln.

CALCINING
In isolation, decarbonation of calcium carbonate at 1 atmosphere takes place at 894 C. This
temperature is reduced to 500 C-600 C if the reaction takes place in contact with quartz or the
decomposition products of clay minerals, which react with the calcium oxide as it forms.
In a wet-process or preheater system without a pre-calciner, most of the calcination takes
place in the rotary kiln within a moving mass of feed. This situation is not ideal for
calcination because heat transfer has to take place through a large mass of material and CO2
has to escape outwards as heat moves inwards.
A pre-calciner calcines the raw material much more efficiently than a wet-process kiln. Raw
meal is dispersed in the hot gas and calcination takes place in seconds, rather than the half an
hour or so inside a kiln at the same temperature.

FORMATION OF EARLY AND INTERMEDIATE COMPOUNDS

During calcination, the lime produced starts to react with other components of the raw feed.
The initial silicate product is belite. Some calcium aluminate and ferrite phases also start to
form.
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A number of phases are formed in the clinker feed before the burning zone proper is reached.
These intermediate phases dissociate in the burning zone and are not therefore found in
clinker but assist in forming the final clinker minerals.

SULFATE MELT PHASE

At intermediate temperatures, sulfates combined with calcium and alkalis form a liquid
phase. This is separate from the aluminate and aluminoferrite-based liquid formed in the
burning zone - the two liquids are immiscible.
As with the main liquid phase, the sulfate liquid phase contributes to ion mobility and
promotes combination.

ALITE FORMATION AND OTHER REACTIONS AT 1300 C-1450 C

IN THE BURNING ZONE
In the burning zone, above about 1300 C, reactions take place quickly. The clinker is in the
burning zone for perhaps 10-20 minutes but in this time a lot happens:
i.

The proportion of clinker liquid increases and nodules form.

ii.

Intermediate phases dissociate to form liquid and belite.

iii.

Belite reacts with free lime to form alite.

iv.

Some volatile phases evaporate.

CLINKER LIQUID AND NODULE FORMATION

Above about 1300 C the proportion of liquid starts to increase - by 1450 C, perhaps 20-30%
of the mix is liquid. The liquid forms from melting ferrite and aluminate phases and some
belite. The liquid content is more than the sum of the aluminate and ferrite phases in the
cooled clinker because of the dissolved lime and silica.
The additional liquid causes coalescence of clinker particles, leading to the formation of
nodules.

DISSOCIATION OF INTERMEDIATE PHASES

The intermediate phases dissociate to form mainly aluminate phase, which then becomes part
of the liquid, and belite.

ALITE FORMATION
Alite forms by the transition of some of the belite to alite and also directly from free lime and
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silica to alite. These reactions occur rapidly once the clinker temperature is above about 1400
Celsius.
EVAPORATION OF VOLATILES
Volatile phases in the cement kiln are principally alkali sulfates, with a much smaller
proportion of alkali chlorides. As the part-burned feed approaches the burning zone, these
volatile phases are in liquid form and a proportion volatilizes, the remainder passing out of
the kiln in the clinker as inclusions within the pores.
The volatilized material passes back down the kiln, where it condenses on the relatively cool
incoming feed. It again becomes part of the sulfate melt phase, promoting reactions, and is
once again carried within the clinker towards the burning zone.
This recirculating load of alkali and sulfate can occasionally become excessively high. Large
quantities of condensing volatiles can then cause blockages in the kiln or in the preheater as
the condensed liquid sticks feed particles together, forming accretions.

KILN LINE-II MLCFL

KILN SPECIFICATIONS (LINE-II)

Number of rotors: 2
Drive: friction drive
Diameter: 5.5m
Length: 66m
Inclination: 3.5
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Kiln capacity: 6700 TPD

From the kiln the clinker comes out and is immediately cooled down in the cooler section.
There are two different types of coolers for the two lines. For line-I there is grate cooler and
for line-II there is crossbar cooler.

COOLING SECTION
As the meal passes through the burning zone, it reaches clinkering temperatures of about
1400 C - 1500 C. Nodules form 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
over the 'nose ring' at the end of the kiln and drops out into the cooler.
The purpose of a cooler is, obviously, to cool the clinker. This is important for a several
reasons:

From an engineering viewpoint, cooling is necessary to prevent damage to clinker

handling equipment such as conveyors.

From both a process and chemical viewpoint, it is beneficial to minimise clinker

temperature as it enters the clinker mill. The clinker gets hot in the mill and excessive
mill temperatures are undesirable. It is clearly helpful, therefore, if the clinker is cool
as it enters the mill.

From an environmental and a cost viewpoint, the cooler reduces energy consumption
by extracting heat from the clinker, enabling it to be used to heat the raw materials.

From a cement performance viewpoint, faster cooling of the clinker enhances silicate
reactivity.

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, so that
deliveries to customers can be maintained when the kiln is not operating.

Fast cooling of clinker is advantageous - it makes for more hydraulically-reactive silicates

and lots of small, intergrown, aluminate and ferrite crystals. Slow cooling gives less
hydraulically-reactive silicates and produces coarse crystals of aluminate and ferrite - overlarge aluminate crystals can lead to erratic cement setting characteristics. Very slow cooling
allows alite to decompose to belite and free lime.
The air in the cooler is blown using mechanical flow regulators. They control the amount of
air entering the cooler necessary to fulfill the need. The air then passes out of the cooler
through cooler fans suction. One duct carry the air to the boiler so that steam is generated for
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WHRP and the other take it to the cooler side EP for dust collection. Collection of dust is
equally important as any other factor to increase the efficiency of the plant. After the dust is
collected from the EP the air is stacked through the chimney via EP fan.
There are two different types of coolers for the two lines. For Line-I there is grate cooler and
for Line-II there is crossbar cooler.

GRATE COOLER
The essential characteristic of a grate cooler is a layer of clinker spread on a more-or-less
horizontal perforated grate, through which cold air is blown. The grate is made of steel, and
the cold air keeps it sufficiently cool to avoid melting or burning. The clinker progresses
through the cooler by moving more-or-less horizontally along the grate, and so the direction
of the cooling air is roughly at right angles to the direction of movement of the clinker, and
the cooler functions as a cross-current heat exchanger. This mechanism is inherently less
efficient than a counter-current heat exchanger such as a rotary or planetary cooler, but there
are distinct advantages:

The hot clinker at the inlet is treated with cold air rather than partially heated air, so
that a rapid quenching effect is possible, improving clinker quality by preserving
reactive high-temperature silicate polymorphs.

By using air in excess of that needed for combustion, the clinker can readily be cooled
below 200C.

It is easy to tap off exhaust hot air streams in desired temperature ranges for use in
other processes - e.g. calciner tertiary air or drying air for fuel or raw materials.

It is fascinating to read the Fuller cooler patent of 1937: in distinct contrast to discussions of
modern coolers, the preamble of the patent focusses almost exclusively on the benefits of the
cooler to clinker quality.
The types of grate cooler are differentiated according to the method whereby the clinker is
moved along the grate, and are treated in chronological order of their introduction.

CROSSBAR COOLER (LINE-II)

The FLSmidth Cross-Bar cooler features:

A stationary grate line with no undergrate spillage or conveying system

Separation of the conveying and cooling systems

Air distribution plates with mechanical flow regulators

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Modular construction

Bars that all are movable and reciprocate so as to optimise transport efficiency and
enable horizontal installation

Quick and easy to install, the FLSmidth Cross-Bar cooler ensures maximum availability with
minimum maintenance. And with a completely new size and structure of its modules, it
makes for an ideal new cooler or upgrade.
The clinker size determines the opening and closing of mechanical flow regulator. If the
clinker size is large then the regulator will close decreasing the area and increasing the
pressure, and if the size is small converse behavior is observed.

CEMENT MILLS SECTION

As soon as the feed is cooled down, an apron conveyer transports it to the clinker silo. There
are two clinker silos; one for each line. Each of them has a rated capacity of 40000tons. The
silos are setup in such a way that if one line is shut down for maintenance or due to some
other reason, its clinker silo can feed the cement mill(s) of the other line too. Moreover the
silos have a dump point, that when the silos are filled up the clinker pours out of it and is
manually piled up near the silos using a belt conveyer and/or dump-trucks.
There are six bins installed in a pair of three manner. Out of one pair, three bins store three
different materials to feed a mill. The three materials for the mill are

Clinker
Gypsum
Additive(s)

The Additive is manually fed using a belt conveyer, whereas the clinker is automatically
taken up from the silos. A nearby gypsum crusher (a hammer crusher) crusher gypsum and
using a belt conveyer fills up the gypsum bins. The sole reason for the addition of gypsum is
to adjust the settling time of cement.
For line-I theres a ball mill for the cement grinding task, and for line-II there are two OK
Mills. OK mills are nothing but vertical roller mills for cement grinding that can produce a
cement of equal or greater fineness at lesser energy expense.

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CEMENT MILLS SECTION MLCFL

OK MILLS (LINE-II)
The OK Mill combines the drying, grinding and separation process into just one unit, which
requires less space and reduces complexity in 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. Compared to ball mill, the OK Mill can produce equal
or even better quality cement. The key benefits of OK Mills are:

OK vertical roller mills use 30-50% less energy than ball mill systems
Simple layout and fewer machines in the mill circuit ensure high run-factor and low
maintenance costs
Excellent drying capability when grinding blast furnace slag or blended cements with
wet components
Roller and table profile improve operating stability and reliability
Consistent cement quality with easy to adjust quality parameters
Special design features for iron removal during slag grinding minimize wear
Optimal wear-protection on all internal surfaces
Space-saving design reduces civil construction costs
Flexibility to operate with two or four rollers guarantees long term availability

The mill arrangement is very simple and operation is correspondingly flexible and reliable.
To maintain the appropriate temperature in the mill circuit-for example to ensure adequate
dehydration of the gypsum when grinding cement-the layout is prepared with provisons for
recirculation of hot gases to the mill inlet. In case the mill feed is wet slag or includes a
significant portion of wet additives, additional heat must be provided, for instance from a heat
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generator. Otherwise, if the mill feed is very hot, the mill exit temperature controls a damper
for cold air intake.

OK MILL

BALL MILL (LINE-I)

For Line-I theres a ball mill installed by FLS. This ball mill has following specifications:

Diameter: 5m
Length: 13m
Media: High density chromium steel balls
Compartment 1: 3.9m
Compartment 2: 9.1m
Media size in compartment 1: 90, 80, 70, 60mm
Media size in compartment 2: 25, 20, 17, 15mm
Capacity: 190 TPH

The FLSmidth ball mill grinds cement clinker, gypsum and similar materials of moderate
moisture content in a one-compartment or two-compartment system. As the crushing
compartments rotate, the balls inside them grind the clinker. Ball size determines the degree
of product fineness.

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BALL MILL LINE-I MLCFL

The FLSmidth ball mill can operate in an open or closed circuit and has a corrugated lining in
the grinding compartment for added effectiveness. The ball mill consists of standard modules
that can be configured for capacity, plant layout and end-product specifications. The drive can
be fitted as a side or central drive upon request, and mills can be fitted with pre-grinders to
achieve maximum grinding efficiency for any specified end-product quality. When fitted with
the Hydraulic Roller Press (HRP) as a pre-grinder, for example, the power consumption of
the whole mill system can be reduced by up to 30%.
The FLSmidth ball mill is easy to operate and maintain, ensuring production efficiency and
high mill run time. A large through-flow area facilitates the flow of venting air, which in turn
ensures a low pressure drop across the mill and thus lower energy consumption.

CEMENT STORAGE AND PACKING SECTION

The ground cement output from the mills is transported using air slides and bucket elevators
and finally filled in the cement silos. From the cement silos this ground cement is taken up
and sent to packing plant where its packed and sent to customer.
There are a total of 5 cement silos

For Line-I: 2 x 10000tons (OPC)

For Line-II 2 x 20000tons (OPC)
1 for SRC

Packing mechanism is almost same for both the lines except for the capacity and number of
packers. Line-I has 4 packers and Line-II has 6.
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Cement is stored in the silos, from the bottom of the silo air is blown and cement is made to
blow with the rising air. Then using air slides the cement is transported to the bottom of the
packing plant towards the bucket elevator. The governor of the air slides are used to
determine which packer is to be used. Bucket elevator takes the cement to the top and drops it
on the vibrating screen. Vibrating screen has filtering function which filters the cement from
any other impurity and directs the waste to the wasting duct and transfers the fine cement to
the Packer Hopper. From here cement comes into packer and bags are filled. Each bag weighs
50kg.

PACKING PLANT MLCFL

LINE-1 PACKING PLANT CAPACITY AND SYSTEM

Silo capacity: 10000tons

Air Slides: 120 tons/hr
Bucket Elevator: 130 tons/hr
Vibrating Screen: 150 tons/hr
Packer Hopper: 2 tons
Nozzle Operating system: 6 Bar
Aeration per packer: 0.6 Bar
Packer Nozle system: VENTO Digital System
Packer type: Rotary Packer
Blower Pressure per aeration of silo: 0.6 - 0.7 Bar

For Line-I there are 8 sprout packers and 8 are there for Line-II as well. In the packer of lineI the worker manually attach the bag in the packer and the bag is filled and sealed but in
Line-II the same task is done by a machine.
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After the bag is packed, it is passed over the VENTO check machine which checks for its
weight to the set point. If the bag is not meeting up with the set point it is sent to the cutter
where the bag is wasted and cement is again transported the packer. One packer can drive a
maximum of 2 belt conveyers but one at a time. It cant operate both belts parallel. At the end
of the line there are trucks that are loaded up with the bags till their allocated weight is
achieved and hence the product is finally dispatched.

QUALITY MANAGEMNT SYSTEMS

The Company is ISO-9001:2008 certified and truly implements Quality Management System.
The Company manufactures cement through the plant based on state of the art technology of
world renowned FL Smidth Automation Denmark. Quality is assured through systematic and
effective adoption, implementation, monitoring and continuous enhancement of quality
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control systems using latest methods of analysis. All stages of the production process right
from the selection of raw materials, processing of materials and the finished product are
subjected to rigorous testing to ensure that each bag of cement is of the highest quality. The
quality check parameters during each level of the process are monitored and controlled by the
latest version of technology & equipment connected on-line with Central Control Room
through PLC system. The frequency of sampling and testing along with control parameters is
defined. Apart from the usual quality control equipment, Maple Leaf's Quality Control
Department is equipped with state-of-theart technologies such as:

X-ray Fluorescent Analyzers and Diffract meter to analyze chemical components;

Sample preparation tools such as a jaw crusher, Sample dividers, disk grinding mill
and mixer mill;
Precision Electronic Balances;
Drying Ovens & Furnaces;
Lab glassware;
PC Based Automatic Calorimeter and Sulfur Determinator to analyze fuels.

All the Lab equipment are calibrated to ensure accurate & precise test results. That is
why; each brand of the Company is internationally certified.

LIME SATURATION FACTOR

The LSF is a ratio of CaO to the other three main oxides. Applied to clinker, it is calculated
as:

LSF = CaO*100/(2.8 SiO2 + 1.18 Al2O3 + 0.65 Fe2O3)

0.66 > LSF < 1.2
=
=
The LSF controls the ratio of alite to belite in the clinker. A clinker with a higher LSF will
have a higher proportion of alite to belite than will a clinker with a low LSF.
Typical LSF values in modern clinkers are 0.92-0.98, or 92%-98%.
Values above 1.0 indicate that free lime is likely to be present in the clinker. This is because,
in principle, at LSF=1.0 all the free lime should have combined with belite to form alite. If
the LSF is higher than 1.0, the surplus free lime has nothing with which to combine and will
remain as free lime.
In practice, the mixing of raw materials is never perfect and there are always regions within
the clinker where the LSF is locally a little above, or a little below, the target for the clinker
as a whole. This means that there is almost always some residual free lime, even where the
LSF is considerably below 1.0. It also means that to convert virtually all the belite to alite, an
LSF slightly above 1.0 is needed.
The LSF calculation can also be applied to Portland cement containing clinker and gypsum if
(0.7 x SO3) is subtracted from the CaO content. (NB: This calculation (ie: 0.7 x SO3) does not
account for sulfate present as clinker sulfate in the form of potassium and sodium sulfates)
and this will introduce a slight error. More particularly, it does not account for fine limestone
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or other material such as slag or fly ash in the cement. If these materials are present,
calculation of the original clinker LSF becomes more complex. Limestone can be quantified
by measuring the CO2 content and the formula adjusted accordingly, but if slag or fly ash are
present, calculation of the original clinker LSF may not be conveniently practicable.)

ALUMINA RATIO
Alumina Ratio is ratio of aluminum oxide to Iron(III) oxide. This determines the potential
relative proportions of aluminate and ferrite phase in the clinker.
An increase in clinker AR (also sometimes written as A/F) means there will be proportionally
more aluminate and less ferrite in the clinker. In ordinary Portland cement clinker, the AR is
usually between 1 and 4.
The above three parameters are those most commonly used. A fourth, the 'Lime Combination
Factor' (LCF) is the same as the LSF parameter, but with the clinker free lime content
subtracted from the total CaO content. With an LCF=1.0, therefore, the maximum amount of
silica is present as C3S.

AR = Al2O3 / Fe2O3
1.5 > AR < 2.5
=
=
AR <1.5 is called Ferro cement.
AR = 0.637 is called Ferrari cement.

SILICA RATIO
The silica ratio (also known as the Silica Modulus) is defined as:
SR = SiO2/(Al2O3 + Fe2O3)
A high silica ratio means that more calcium silicates are present in the clinker and less
aluminate and ferrite. SR is typically between 2.0 and 3.0. The silica ratio is sometimes called
the silica modulus.

WASTE HEAT RECOVERY PLANT (WHRP)

Waste heat recovery plant is now installed in almost every cement industry. It has now
become a compulsion from environmental department. This plant mainly utilizes the waste
heat from clinker cooler and the preheater waste heat to generate steam and the steam is

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further used to drive the turbine. The turbine is then coupled with generator to produce
electricity.

ADVANTAGES
The waste heat recovery system can benefit us both directly and indirectly

DIRECT BENEFITS

The recovery process will add to the efficiency of the process and thus decrease the
cost of fuel and energy consumption needed.

INDIRECT BENEFITS

Reduction in pollution: thermal and air pollution will be drastically decreased since
less flue gases of high temperatures are emitted from the plant and most of the eergy
is being recycled.
Reduction in equipment sizes: As fuel consumption reduces so the control and
security equipment for handling the fuel decreases. Also, filtering equipment for the
gas is no longer needed in large sizes.
Reduction in auxillary energy consumption: Reduction in equipment sizes mean
another reduction in the energy fed to those systems like pumps, filters, fans etc.

The WHRP in MLCFL has a total of 5 boilers integrated to it. These are water tube boilers.
The advantage of using this tyoe if boilers is that they are most safe, less prone to explosions
and provide excellent quality steam. The effective heat transfer surface area can be increased.
The boiler capacity is increased by:

AQC 1 (installed at grate bar cooler Line-I)

AQC 2 (installed at cross bar cooler Line-II)
EG (installed at exhaust of engine generator)
PH 1 (installed at 4th stage of single string preheater, Line-I)
PH 2 (installed at 5th stage of double string preheater, Line-II)

The PH 2 has its two units having the common steam drum.
These are actually nor boilers but instead they are steam generators because boilers only
generate steam that have a dryness factor of 1 then this steam is heated in super heaters but
boilers which have built in super heaters are called steam generators.

TURBINE

Capacity : 16 MW
Main steam pressure before #1 MSV : 1.486 MpaG
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Main steam pressure after #1 MSV 1.497 MpaG

#1 Governor position : 51.9 mm
Main steam Temperature after #1 governor : 319.4 Celsius
Main Steam Pressure after #1 Governor : 1.177 MpaG
#2 Governor Position : 41.5mm
Main steam Temperature after #2 governor : 315.4 Celsius
Main steam Pressure after #2 governor 1.77 MpaG
Inside wall Temperature of #2 MSV : 302.5 Celsius
Outside Wall temperature of #2 MSV : 310.3 Celsius
#2 MSV Displacement : 120.5 mm
Main steam press= before #2 MSV : 1.480 MpaG
Main steam pressure after #2 MSV : 1.502 MpaG
Condensor Vacuum : -0.0871 MpaG
Mixed Steam temperature before admission valve : 131.3 Celsius
Mixed steam temperature after admission valve : 123.5 Celsius
Mixed steam pressure before admission valve :0.288 MpaG
Mixed steam pressure after admission valve : 0.071Mpa
Admission steam control valve position : 6.8%
Turbine Speed : 2995 - 3000 RPM
Generator Active power : 16.130 MW

Condenser again converts low quality vapor into its liquid phase and then water is directed to
the feed pumps which continue the Rankine Cycle to generate power.
The vibration is very much important in turbine system, thus the vibration measuring sensors
are calibrated in micro scale so that they can precisely measure vibrations in micrometers.
The RPM sensor is also installed. Temperature and Pressure sensors are present afrer and
before every equipment, even valves.
Mostly, valves are pneumatic controlled i.e. operated by air pressure. Air acts as a breathing
unit for the whole WHRP as well as PGP. The compressors are present that suddenly blast the
air into the lines, the range of this pressure is 6 8 bars atmost. These systems are called IP
systems whose input is in the form of current in milli amperes and output is the calibrated
pressure.
There are two major expenses of the plant

Water treatment
Cooling tower fans

The water and steam lost in the steam traps is re-stabilized by the addition of some measured
quantity of treated water. This water is treated to prevent the boilers from sooting and turbine
blades from rusting. For this treated water a separate department and qualified staff is present
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which chemically dose the water and controls pH and make it suitable for entering in the
power cycle.
The cooling tower has two main fans which are used to cool the showering water coming
from the condenser. The cooling water capacity is calculated and required amount of the
cooling water is made to enter the condenser. The condenser vacuum is generated by the
Liquid Ring Vacuum Pump.

LIQUID RING VACUUM PUMP

A liquid ring vacuum pump is a rotating positive displacement pump. They are typically used
as a vacuum pump but can also be used as a gas compressor. The function of a liquid ring
pump is similar to a rotary pump, with the difference being that the vanes are an integral part
of the rotor and churn a rotating ring of liquid to form the compression chamber seal. They
are inherently low friction design, with the rotor being the only moving part. Sliding friction
is limited to the shaft seals. Liquid ring pumps are usually powered by an induction motor.
The specifications of the liquid ring pump installed are:

Type: 25W 4203-OEK4

Motor Power: 37KW
Capacity: 7-18.5
Pump Speed: 980RPM
Inlet Pressure: 33-1013 hPa
Outlet Pressure: 1013 hPa
Operating Liquid: 20-5.5 m3/hr
Pump weight: 410 kgs

Feed water pumps are used to force the water again towards boilers to continue the cycle. As
the boilers are stationed at long distances so the feed water pump should be powerful or 2 or
more pumps in series should be used to perform the task efficiently.

The feed water pump is installation is at the bank of river Indus, 10km away from the plant.
The specifications of the Pump-I are:

Manufacturer: Toshiba
Motor: 3-Phase Induction Motor
Rated voltage: 400V
Rated Current: 246A
Rated Frequency: 50Hz
Speed: 2970RPM
Max ambient temperature: 50oC

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The steam flow data shows that approximately 4 tons of steam is required in order to produce
1 MW of the electricity but it varies and depends on the degree of superheat of the steam.
When all the boilers are in running condition then plant produces 16MW. The generator is
coupled to the turbine. The turbine RPM is therefore kept constant whether it is running for
16MW or 2MW. The reason for this is that the plant is synchronized with WAPDAs grid and
frequency depends upon the RPM of turbine. So the RPM is kept constant at 3000.

GENERATOR
The generator specifications are:

Rated power: 18MW

Rated voltage: 6.3KV
Rated current: 2062A
Rated output: 2.5 MVA
Power factor: 0.8
Exciting current: 355.2A
Connection: Y
Weight: 54.38 tons

SWOT ANALYSIS
SWOT analysis is being used at Maple Leaf Cement as a strategy formulation tool, in order to
match our strengths with perceived opportunities and minimize our weaknesses to avoid
market and other threats. Management at Maple Leaf considers the following factors of
SWOT analysis relevant to us:-

STRENGTHS

Single largest cement producing site in Pakistan.

State of the Art FL Smidth plants.
Higher EBITDA %.
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Excellent logistic management.

Fully diversified Cement Producer.
Strong Local and International branding
Offering over 330 days/year production.
Well diversified fuel mix and efficient operation.
Well developed and refined human resource.
Lowest Energy cost per ton of clinker.

WEAKNESSES

Cyclical industry.
High transport cost.
Highly regionalized and localized market.
High electricity cost.
Energy load shedding.
High taxation.

OPPORTUNITIES

Focus on cost optimization

Huge govt. expenditure in infrastructure development.
Availability of housing loan from financial institutions.
Rising population works as a catalyst for housing boom.
Low per capita consumption.
Research to develop new products
Long term growth at the rate of 7% to 8%

THREATS

Rising input cost of coal.

Rising cost of logistics.
Rising cost of power and fuel.
High interest rates.
Currency devaluation risk.
New entrant threats due to high potential market.
High incidence of taxes.

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BIBLIOGRAPHY

On site information and handouts provided by the assigned in charges and engineers.
Cement Engineers Handbook by Otto Labahn
The Cement Plant Operations Handbook by Philip A. Alsop
www.kmlg.com
www.flsmidth.com
http://www.understanding-cement.com
www.wikipedia.org

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