21-05-2012, 01:16 PM
SHREE DIGVIJAY CEMENT COMPANY LIMITED -COMPANY PROFILE
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Shree Digvijay Cement Company Limited is one of the Pioneer
Cement manufacturers in India manufacturing maximum varieties (8
varieties) of Cement and good brand reputation inland and Abroad.
Shree Digvijay Cement Co Ltd., established in 1949 at Sikka –
Jamnagar and one of the pioneers in the Cement business, is a flagship
Company of Cimpor. A fully computer controlled plant; it has a production capacity of 1.30 million tons per annum. In 2008 Unit was taken over by Cimpor Group.
Its basket of products includes special cements like Oil Well Cement,
Sulphate Resisting Portland Cement and Railway Sleeper Manufacturing
Cement in addition to other varieties of Ordinary Portland Cement etc. Well connected by Road, Rail, Air, and Sea, Digvijay has its own port. Digvijay prolific experience in the domestic and international markets is now further honed with the Cimpor Group’s management skills and technology. The brand name of products of the Company is well known for its superior quality, which matches with the best of in India and also abroad. Having its own Research & Development Department, fully equipped with latest equipment and being controlled by Efficient, Eminent and Professionally qualified & trained personnel, the company has been producing regularly varieties of Cement for special purposes.
The company manufactured Oil Well Cement as per the norms of API
specifications and supplies to ONGC, OIL and Essar Oil Ltd of India. The
manufacturing of this type of cement requires stringent Quality Control
which measures are being carried out by the Quality Assurance
Department of the Company. The Company has made its handsome
contribution in building up Foreign Exchange by exporting substantial
quantity of different types of Cement and Clinker to various countries.
Products:
o Ordinary Portland Cement 53 grade (OPC) as per BIS /
BS / ASTM / SLS standards
o Ordinary Portland Cement 43 grade (OPC)
o Sulphate Resisting Portland Cement (SRPC)
o Railway Sleeper Manufacturing Cement (53-S Grade
OPC)
o Oil Well Cement Class 'G' Grade HSR (as per API
specifications 10A)
o Portland Pozzolana Cement
PRODUCTION DEPARTMENT
I was in production department, I Saw and understood various
processes how clinker is made from raw material like lime-stone,
sand-stone and iron-ore, and further how cement made from clinker.
Main reaction process occurs in kiln at 1400 C to make clinker. To
make cement grinding and rubbing processes take in cement mill.
Main process is done by various machine, those are as follow:
Mining:
Mining process is carried out by surface mining at mining site
which is 90 km away from company. In the mining surface miner is
used to extract the limestone from earth.
Lime-stone from various mines are brought by trucks to factory
premises and unloaded in to the hopper of crusher.
Crusher:
Raw material is feed to crusher by Belt Conveyer, and crusher
crushes it in to small sized piece. In crusher, there are two types of
crushers, primary crusher and secondary crusher.
First material passes through primary crusher, which crushes
the material up to 200 mm size. it having a capacity of 400 THP.
Then material passes through the secondary crusher, which
crush the material up to 50 mm size, and having a capacity of 200
THP.
Raw Mill Grinding:
The desired material is drawn from lime stone reclaimer pile to
the weigh feeder and is fed to the vertical raw mill through belt
conveyor.
Additives (correctives) are added (as per need) by weighed
quantities in lime stone. In raw mill additives materials are sand
stone, morrum, iron ore and High grade lime stone.
UBE LM 36.4 Mill can grind raw materials at 225MT per hour.
The material is dried and transported by the hot kiln exit gases. The
size of the pulverized material is controlled by a dynamic separator,
which separates the oversized particles and sends it back on the
table for further grinding.
Preheating:
Preheating process is done in the preheater string having four
stage LP cyclones. Approximately 40% of the total feed is given to
the pre heater string where it gets preheated by the hot kiln exit
gases and gets calcined up to 30% approximately. The balance 60%
feed is fed to the calciner string where coal is fired in the calciner and
the 30% calcined feed from the pre heater string is also added to the
calciner. Here, about 90% calcinations are achieved. Chemical
formula of this process (at 900 C) is as under:
Kiln Process:
The material comes from preheating is feed into the kiln where
remaining 10% Calcinations process is done. This calcined feed is
transferred to the kiln for the remaining 10 calcinations and sintering
where the flux materials and silica melt and react with lime to form
four clinker constituents. This is achieved by firing coal in the rotary
kiln. Kiln capacity is 2500 TPD and 75 meter long with 3 stations.
Heat is produce by burning of crushed coal. Coal is crushed in
Atox coal mill 17.3. It is vertical closed circuit grinding mill with
Capacity 22 MT/Hr.RM comes in contact with hot gases in various
stages of cyclone and kiln producing hot clinker.
As the material moves through the kiln, certain elements are
driven off in the form of gases. The remaining elements unite to form
a new substance with new physical and chemical characteristics. The
new substance, called clinker, is formed in pieces about the size of
marbles.
Clinker is discharged red-hot from the lower end of the kiln and
generally is brought down to handling temperature in various types of
coolers. The heated air from the coolers is returned to the kilns, a
process that saves fuel and increases burning efficiency