From the limestone quarry to the delivery of the end product, follow every step in the cement manufacturing process. Step 1: Mining. ... Step 2: Crushing, stacking, and reclaiming of raw materials. ... Step 3: Raw meal drying, grinding, and homogenization. ... Step 4: Clinkerization. ... Step 5: Cement grinding and storage. ... Step 6: Packing. 14 Different types of cement :- Ordinary Portland Cement (OPC): This is the most common type of cement which is extensively used. ... Rapid Hardening cement: ... Low heat portland cement: – ... Sulphate Resisting Portland Cement:- ... High alumina Cement:- ... Blast furnace slag cement:- ... Coloured Cement:- ... Pozzolana cement :-

1. 1
Group Members
Muhammad Ahmed ( D-17-CH-71 )
Noman Zia ( D-17-CH-05 )
Zohaib Nadeem ( D-17-CH-45 )
Rao Rayan Abid ( D-17-CH-03 )
Azhar Ali Channa ( D-17-CH-49 )
Zaryab Khan ( D-17-CH-81 )
Umer Farooq ( D-17-CH-77 )
Duration period is 17 DECEMBER 2018 to 29 DECEMBER 2018

2. 2
Context
Acknowledgment
Introduction
Vision
Mission
Quality Control
Products
Mining
Drilling
Blasting
Crusher
Stacker and reclaimer
Raw mill
Pre-heater
Kiln
Cooler
Grinder
Waste Heat Recovery
Packing Plant

3. 3
Acknowledgment
First of all, we are very Thankful to Almighty Allah who gives us Power and
strength to complete our Internship and represent it in such a great way. We
also want to thank our parents who supported us physically mentally as well
as financially.
We are very thankful to all the management of the industry who gave us
chance of internship. They also gave wonderful exposure, advice, clear and
deep criticisms and encouragement aided the Internship tasks.
We also want to pay high regards on behalf of my institution ‘’DAWOOD
UNIVERSITY OF ENGNEERING AND TECHNOLOGY’’ for giving us this
opportunity, and we are very grateful from the depth of our hearts to the
Chairman, teaching staff and Lab Engineers who helped is in the development
of our skills.
Introduction
Lucky cement Limited was founded in 1993 by ABDUR RAZZAK TABBA. The
company started with factories in the PEZU located in LAKKI MARWAT District
of the Khebar Pakhton Khah. It now also owns the factory of Karachi. Lucky
Cement Limited is one of the largest producers and leading exporter of quality
cement in Pakistan with the production capacity of 7.75 million tons per
annum. The company is listed on Karachi, Lahore, Islamabad and London stock
Exchanges. Lucky cement limited has been sponsored by one of the largest
business groups in Pakistan the Yunus brothers Group based in Karachi.

4. 4
VISION
We envision being the leader of the cement industry in
Pakistan, identifying and capitalizing on new
opportunities in the global market, contributing towards
industrial progress and sustainable future, while being
responsible corporate citizens.
MISSION
Our mission is to be a premium cement manufacturer
by building a professional organization, having state-of-
the-art technology, identifying new prospects to reach
globally and maintain service and quality standards to
cater to the international construction needs with an
environment-friendly approach.
Quality Control
The raw materials and the products are tested in different section. In the lucky
cements, many types of tested conducted in the quality control department.
The main test for raw material and the product is following,
Chemical test
1) Loss or Ignition
2) Titration
For chemical testing, there are two method of sampling,
• Press Pallet
• Fuse Beat (More accurate)
Physical test
1) Compressive test
2) Settling time test
3) Expansion test
4) Water Consistency test

5. 5
Many tests are conducted for coal (that is use as a fuel),
1) X-ray Fluorescent Spectrometer test (XFS)
2) Air Dry Base (ADB)
3) As Receiving Base (ARB)
4) Dry Base
5) Dry Ash Free
6) Gross Calorific Value test
Sampling
The collection of samples from the different area is following,
Raw material
Take sample on daily basis
Weight feeder
Take sample per shift
Raw mill outlet
Take sample on hourly basis
Kiln feeder
Take sample on alternate hourly basis
After cooler
Take sample per shift
Products
Lucky Cement (Regular)
Lucky Sulphate Resistant Cement
Lucky Star
Lucky Block Cement
Lucky Gold
Lucky Raj

6. 6
Mining
This is the very first step in cement production, in this process the main raw
material for production i.e. limestone and clay is obtained. The quarry area
was about 11.5 km divided into 7 phases. Each phase contains different
composition of limestone. This process consists of three major parts:
Drilling
Blasting
Drilling
It is the first step in cement manufacturing. Mining is done in quarry. First of
all, drilling is done using the rotary driller which uses 3.09 m drilling rod having
black diamond at its end in gutch formation. There are two terms related to
drilling depending on their relative positions: Spacing and burden. Spacing is of
4.5 m and burden is of 4 m. Bench height is of 20m and in order to prevent
towing; sub drilling of 1.5 m is done.
The abundance of required materials present in quarry is as follows:
CaO: 45-50%, SiO2: 4-6%, Mg: 1.5-4.5%
Blasting
After drilling, holes are filled with explosives for blasting. Two types of
explosives are used: High explosive and low explosive.
High explosive is used 20% and low explosive is used 80%.
All the explosives are connected to a red wire which is filled with gun
powder. The rate of burning of red wire is 4000-5000m/min.
The red wire is then connected to a black fuse wire of 2m for detonation.
The rate of burning of fuse wire is 1m/55sec.
Fuse wire is lighted with a matchstick and the quarry area is evacuated.
Blasting is done at lunch time for safety purposes.
After drilling and blasting boulders of limestone and clay are transported to
crushers in dumper trucks.

7. 7
Crusher
CRUSHING is the 2nd
step in the cement production. The raw materials
obtained is in form of large rocks which is then crushed into coarse particles.
The raw material transported from the mining area is deposited into the chute
attached to the crushing machine. The feed is of 1.5m dropped on the APRON
CONVEYER, which carry feed to the crusher head. The feed from the apron
conveyer is dropped on the FEED ROLLER, where the feed is reduced to the
size of 1m, then the feed falls down to HAMMER ROLLER, which consists of 5
axles, each axle contains 9 hammers. Each hammer weighs approx. 120kg. The
material is crushed to a size of 70-80mm which is dropped into the chute,
which is below the crusher connected to delivery tunnel. It consists of long belt
and a magnetic separator. Any metallic particles present in the feed is
removed.
All the crushers work generally on the same operation and 3 principle
laws of crushing
Whole Crushing operation is consisting of the following:
1) Feed Roller
2) Rotary Hammer (connected to a 1000KW Motor)
3) Apron Conveyer (connected to a 37 KW Motor)
4) Discharge conveyer (connected to a 45 KW Motor)
5) Magnet Separator
There are 2 limestone crushers (each of 1000-ton
capacity)
There are 2 coal/clay crushers (each of 400-ton capacity)
One gypsum crusher of capacity 700 ton/h.

8. 8
Stacker and reclaimer
STACKING and RECLAIMING is the 3rd
and an important step in the cement
production. In STACKING the feed from the Delivery tunnel is transported to
the LONG BELT, which then further carries the feed to the STACKING MACHINE
or STACKER, the stacker makes piles of the feeds. Then the feed is store in the
ware house.
RAW MILL
Vertical Roller Mill (VRM)
Vertical roller mill is a type of grinder used to grind materials into extremely
fine powder. It is driven by an electric motor of the power 2240 kw. It has the
following main parts, the description of each is given below with its name.
Grinding Table
Grinding table is supported and driven by gear box. It mainly consists of wear
plates which are held in place with the help of retainer ring. The feed is piled
on the surface of the table. While it has a dam ring over which the excessive
or rejected material can be flows down.
Rollers
There are four vertical rollers of weight 28 tons each, which are free to be
rotated. They are supported by the frame of the mill. The grinding bed is
crushed as it passes beneath the stationary rollers.
Classifier
The classifier is housed above the rollers which separates the fine particle and
throws back the rejected coarse particles again on the grinding table.
The percentage of each of the constituent material is set up and sent through
reclaimers. Then the constituent that are limestone, clay, silica sand, iron ore
are allowed to fall on the conveyor belts and then they fall on the single belt
to move and enter the rotary feeder. The purpose of the rotary feeder is to
prevent the air from entering. The rotary feeder allows the incoming feed
from the hopper to pass smoothly and continously to the mill. It maintains a
constant air pressure or vacuum difference between the Inlet and Outlet

9. 9
ports efficiently. The material from the feed mouth fells into the center of the
grinding table which is then moved to the edges by the application of
centrifugal force and is ground by the rollers. There are hydraulic systems
outside the roller for the sake to move them up and down to adjust the bed of
material. The raw mill uses pressure and shear produced between the rollers
and the rotating table to crush and grind raw materials. The rotation of the
grinding table pushes the material towards the grinding track and passes it
under the rollers. Coarse material and bigger lumps drop through the nozzle
ring and is ultimately recirculated into the feed material inlet. Hot gases are
used to lift the material that is finely grinded because its lifting power is more,
and to remove moisture from the material. The lifted material is then allowed
to pass through the classifier which after rejecting the coarse particles sends
the fine powder to the cyclone, where the filtration of flue gases takes place.
Cyclone
Cyclone is a Structure without moving parts having Inlet velocity of gas
stream changed into a narrowed vortex or twisting flow downward between
walls of gas discharge outlet and body of cyclone or main vortex wherein
centrifugal force created which tends to drive particles to the wall of cyclone.
The fine powder leaving the mill enters the cyclone separator and here
the filtration of flue gases takes place. It almost filters 95% percent of the gases
while remaining 5% is done through the bag filter section. The gas leaving the
upper duct of the cyclone is carried towards the bag filter section for further
separation of the ultra-fine particles.
Bag house
The grinded material which is sucked by the system fan which passes
through a classifer where the fine particles are futher moved to the
cyclone and the remaining feed goes to the bag house
The bag house bag filter or fabric air filter is an air pollution control
device that removes particulates out of air or gas
The main function of bag house is suction and purging
There are 20 chambers in which each chamber contains 114 bags
There is also bag filter which suck the air from the environment and
clean the dust form the grinded material.

10. 10
SILO
After the material is grinded the fine particles moves from the bag
house to the silo by drag belt and elevator.
The capacity of silo is 6000 ton
The height of silo is 60 meter.
Pre-heater
It has five cyclones. Frist is two in one cyclone and four are high
efficiency cyclones and a pre calciner to prepare the feed for kiln, as
the feed enters the pre-heater section it is heated by flue gases.
Feed inlet temperature is 300 C and the outlet temperature is 900 C.
Flue gas from the kiln is then transferred to cyclone C5, any
clinker dust is collected in C5 and returned to
the Kiln, the flue gas at 900 carries the feed
falling from C3 and takes to C4, the flue gas at
around 700 degC carries the feed falling from
C2 and takes to C3, the flue gas at around 600
degC from C3 takes the feed falling form C1A
and C1B and transfers to C2, the flue gas from
C2 at around 500 degC is mixed with feed coming
from raw storage silo going to twin cyclone which
from the riser is transferred.

11. 11
Kiln
Rotary kiln is the main equipment of
cement production host. Cement
rotary kiln mainly use for calcining
cement clinker, mainly include the
kiln cylinder, driving device,
supporting device, thruster device,
kiln head seal device, kiln tail seal
device, kiln hood and other parts.
Kiln cylinder is rotary kiln’s body is
rolled and welded by steel plate. Kiln
body is made of high-quality carbon
steel or alloy steel plate.
The property of Kiln used at Lucky cement plant is,
64 meter in length,
Rotation of kiln is 4-5 rpm
total diameter of kiln is 4.3 meter and inner diameter is 3.9 meter.
Slop of kiln is 3.5 %.
Temperature (deg C) Reaction Heat Change
100 Evaporation of free
water
Endothermic
500 and above Evaporation of combine
water,
endothermic
900 and above evaluation of CO2 from
lime, main reaction
between clay and lime
Exothermic
900-1200 Liquid formation endothermic
1200 and above Further formation of
liquid
endothermic

12. 12
The clinker consists of following compounds,
Dicalcuim silicate (C2S)
Tricalcium silicate (C3S)
Tricalcium aluminate (C3A)
Tetracalcium aluminoferrite (C4AF)
Magnesium oxide in free state (M)
Cooler
Clinker from kiln goes to hood from where it is dropped to cooler where its
temperature is reduced from 1400C to 200C. This consists of a perforated grate
through which cold air is blown, enclosed in a rectangular chamber. Then
clinker is transfered to 6000 ton silo.
Grinding
Cement mill is the area where finally cement is manufactured by the addition
of second stage raw materials (Slag, Gypsum and clinker).
Waste Heat Recovery
Lucky Cement Limited is now in the process of installing a waste heat recovery
system which will utilize the waste heat generated during clinker production
into electrical power with zero emission of carbon and without consuming any
fuel. This effort of producing 25 MW electricity.
Packing Plant
Lucky cement also exports loose
cement by loading it into through
bunker. It exports tons per day. Loose
cement storage and ship loading
terminal at berth -25 west wharf
Karachi port.

13. 13
Our suggestions
We suggest that the company make a proper plan for safety control,
firstly inform the visitor or internees about the emergency exit gate
and assembly points.
We noticed that the company maintains low safety level. We saw that
the labor work in dusty place and without PPEs, also it is not
environment friendly.
We suggest the company to reduce CO2 emission from their industry
We suggest that the company sales their products in a reasonable price
as compere to chinese companies.
We suggest that they provide cleaner and healthy environment.
We saw that the instruments are very congested and closed together.
We felt unsafe and uncomfortable for traveling from one place to
another.