INDUSTRIAL TRAINING PRESENTATION
Presented By:Abhinav verma
Roll No:191043
National institute of Hamirpur
CERTIFICATE
CONTENTS
1. Introduction
2. Objective
3. Raw materials used in manufacturing of cement
4. Processes involved in manufacturing of cement
5. Types of products produced in ACC
6. Findings
7. Strengths
8. Weaknesses
9. Conclusion
10.References
INTRODUCTION
ACC Limited is an Indian cement producer, headquartered in Mumbai. It is a subsidiary of
the Ambuja Cements and became a part of the Adani Group On 1 September 2006, the
name of The Associated Cement Companies Limited was changed to ACC Limited. The
company had been established in Mumbai, Maharashtra on 1 August 1936.
In 1936, eleven cement companies belonging to Tata, Khatau, Killick Nixon and FE
Dinshaw groups merged to form a single entity, The Associated Cement Companies. Sir
Nowroji B Saklatvala was the first chairman of ACC.
The list of companies that were merged:
•The Indian Cement Co. Ltd.
•The Katni Cement and Industrial Co. Ltd.
•Budhi Portland Cement Ltd.
•The Okha Cement Co. Ltd.
•The Gwalior Cement Company Ltd.
•The Punjab Portland Cement
•The United Cement Co. Ltd.
•The Shahabad Cement Co. Ltd.
•The Coimbatore Cement
•The Dewarkhand Cement Co. Ltd.
•The C. P. Cement Co. Ltd.
OBJECTIVES
The main objective of this internship was to study and learn various
processes involved in the production of cement.
Raw materials used in manufacturing of cement-
• Limestone: Limestone is a sedimentary rock composed principally of calcium carbonate
or the double carbonate of calcium and magnesium .
• Iron oxide: Iron oxides are compounds that are basically composed of iron and oxygen
• Sillicon dioxide:Silicon dioxide, also known as silica, is an oxide of silicon with the
chemical formula SiO 2
• Magnesium oxide: Magnesium oxide is an inorganic salt of magnesium formed with ions
of magnesium and oxygen
• Aluminium oxide:Aluminium oxide is a chemical compound of aluminium and oxygen with
the chemical formula Al 2O 3
MANUFACTURING PROCESS OF CEMENT
There are four stages of cement manufacturing-
1. Mixing of raw material
2. Burning
3. Grinding
4. Storage and packaging
1. Mixing of raw material
Calcium, Silicon, Iron and Aluminium are the raw materials used majorly in manufacturing of
cement. There are two methods of mixing. Dry Process and Wet Process.
•Dry Process: The both calcareous and argillaceous raw materials are firstly crushed in the
gyratory crushers to get 2-5cm size pieces separately. The crushed materials are again
grinded to get fine particles into ball or tube mill. After screening this finely grinded
materials are stored in hopper. Then powdered minerals are mixed and dry raw mix is stored
in silos and ready to be sent into rotary kiln.
•Wet Process : In this process first raw materials are crushed and made into powdered
form and stored in silos. Then clay is washed and sticky organic matters are removed. Then
powdered limestone and water washed clay are sent to flow in the channels and transfer to
grinding mills where they are completely mixed and the paste is formed. Then grinding
process is done in a ball or tube mill or even both. Then the slurry is led into collecting basin
where composition can be adjusted. The slurry contains around 38-40% water that is stored
in storage tanks and kept ready for the rotary kiln.
2. Burning of Raw Materials
This process is carried out in rotary kiln while the raw materials are rotated at 1-2rpm at its
longitudinal axis. The raw mix of dry process or corrected slurry of wet process is injected
into the kiln from the upper end. Powdered coal or oil or hot gases are used to be heated up
from the lower end of the kiln so that the long hot flames is produced. The lower part
(clinkering zone) have temperature in between 1500-1700 degree Celsius where lime and clay
reacts to yield calcium aluminates and calcium silicates. This aluminates and silicates of calcium
fuse together to form small and hard stones are known as clinkers. The size of the clinker
varies from 5-10mm. The clinker coming from the burning zone are very hot. To bring down the
temperature of clinkers, air is admitted in counter current direction at the base of the rotary
kiln. The cooled clinkers are collected in small trolleys.
3. Grinding of clinkers
The cooled clinkers are received from the cooling pans and sent into mills. The clinkers
are grinded finely into powder in ball mill or tube mill. Powdered gypsum is added around
2-3% as retarding agent during final grinding.
The final obtained product is cement
that does not settle quickly when
comes in contact with water. After the
initial setting time of the cement, the
cement becomes stiff and the gypsum
retards the dissolution of tri-calcium
aluminates by forming
tricalciumsulfoaluminate which is
insoluble and prevents too early
further reactions of setting and
hardening.
4. Storage and packaging
The grinded cement is stored in silos, from which it is marketed either in container
load or 50kg bags.
TYPES OF CEMENT PRODUCED IN ACC-
1. Portland cement
43 Grade Cement (OPC 43 Grade)
ACC Cement is the most commonly used cement in all constructions including plain and
reinforced cement concrete, brick and stone masonry, floors and plastering. It is also used
in the finishing of all types of buildings, bridges, culverts, roads, water retaining
structures, etc.ACC Cement is marketed in specially designed 50 kg bags.( IS 8112)
53 Grade Cement
This is an Ordinary Portland Cement which surpasses the requirements of IS: 12269-53
Grade. It is produced from high quality clinker ground with high purity gypsum. ACC 53
Grade OPC provides high strength and durability to structures because of its optimum
particle size distribution, superior crystalline structure and balanced phase composition. It
is available in specially designed 50-kg bags.
2.Blended Cements
Fly-ash based Portland Pozzolana Cement (IS 3812)
This is a special blended cement, produced by inter-grinding higher strength Ordinary Portland
Cement clinker with high quality processed fly ash - based on norms set by the company's R&D
division. This unique, value-added product has hydraulic binding properties not found in ordinary
cements.It is available in specially designed 50-kg bags
Portland Slag Cement (IS 455)
This is a slag-based blended cement that imparts strength and durability to all structures. It is
manufactured by blending and inter-grinding OPC clinker and granulated slag in suitable
proportions as per our norms of consistent quality. PSC has many superior performance
characteristics which give it certain extra advantages when compared to Ordinary Portland
Cement.It is available in specially designed 50-kg bags.
FINDINGS
• Out of the ranking given by the customers the most important rating given by all of them
was for company ‘s name , timely delivery of the product , regular supply , dealer supply
and discipline.
• A few of the dealers are not satisfied by the sales force support and the discount facilities
given by the company.
• All of the dealers are highly satisfied with the product quality which is provided by the
company.
STRENGTHS
• Efficient workforce of around 10000 employees.
• Vast network and uninterrupted supply chain managed by
an energetic sales force from an extensive spread of sales
offices spanning India.
• Products assures quality and they are acknowledged for their
superior quality and durability.
• Manufacturing excellence and their strive to retain their position
as India’s foremost manufacturer of cement .
WEAKNESS
• ACC has the highest sensitivity to cement prices and its fragmented capacity results in
not being able to influence the price in any significant manner.
• ACC is a price follower despite being the the largest cement manufacturer in the country.
It’s sensitivity to price ensures that it can never lower prices to gain market share without
hurting itself more than the competitor.
• The decrease in the cost of production does not show much impact in ACC’s cost structure
This is basically due to high power and fuel cost.
CONCLUSION
• The company should focus more on the sales force support which they provide to their
dealers.
• The company make sure that their top management visits the respective dealers so that
the dealers would have the feeling that the company is always trying to keep touch with
them.
• The company should also ensure that they provide proper training to their dealers with
regard to the proper use of commodity.
REFERENCES
• www.acclimited.com
• www.Wikipedia.org
• www.indiainfo.net
• www.dnb.com
