Internship Report
(From 24-07-19 to 28-07-19)
Submitted to:
Engr. Talib Hussain
Submitted by:
Ahmad Hassan
Konain Faheem
Massab Abrar
Talha Ahmed
DEPARTMENT OF MINING ENGINEERING
UNIVERSITY OF ENGINEERING &
TECHNOLOGY LAHORE
Table of Contents
1. Introduction .........................................................................................................................3
1.1 Vision ...........................................................................................................................3
1.2 Mission .........................................................................................................................3
2. Cement ................................................................................................................................3
3. Surveying ............................................................................................................................4
4. Drilling ................................................................................................................................4
4.1 Drilling patterns ............................................................................................................5
4.2 Data collected from field ...............................................................................................6
4.3 Calculation for per hole material removed .....................................................................6
4.4 Calculations for required number of holes to fulfill per day capacity .............................6
4.5 Formula for Sub drilling and stemming .........................................................................6
4.5.1 Old formulas ..........................................................................................................7
4.6 Specification of drill machines and compressors ...........................................................7
5. Blasting ...............................................................................................................................7
6. Loading and transportation ..................................................................................................8
6.1 Observed cycle time ......................................................................................................8
7. Crushing ..............................................................................................................................8
8. Stacker/Reclamier ...............................................................................................................9
9. Burning ...............................................................................................................................9
10. Cement grinding ...............................................................................................................9
11. Packing .......................................................................................................................... 10
12. Transportation of cement ................................................................................................ 10
13. Export products .............................................................................................................. 10
14. Summary ........................................................................................................................ 10
1. Introduction
Sir Mohammed Anwar Pervez OBE, H Pk is the founder & chairman of Bestway Group including
its subsidiaries Bestway Cement Limited and United Bank Limited in Pakistan, and Batleys
Limited and Bestway Northern Limited in the UK.
Bestway Chakwal plant is working since 2006 with the annual production of about 3.60 million
tonnes.
1.1 Vision
To produce high quality cement at the lowest cost.
1.2 Mission
Consistently produce high quality cement.
Endeavor to be the lowest cost producer.
Achieve 25% of the market share of North Zone in the short term and maintain its position
as the largest cement producer in the country.
Consistently maintain a high standard of customer service.
Continue to invest in human resource through training, development and promotions from
within whenever possible in order to meet future expansion needs.
Continue to set aside adequate funds from net profits for fulfilling its various social
responsibilities particularly in the field of education and health
2. Cement
A cement is a binder, a substance used for construction that sets, hardens, and adheres to other
materials to bind them together. The most common raw rock types used in cement production are:
Limestone (supplies the bulk of the lime) Clay, marl or shale (supplies the bulk of the silica,
alumina and ferric oxide) Other supplementary materials such as sand, fly ash/pulverized fuel ash
(PFA), or ironstone to achieve the desired bulk composition. Following is the list of steps involved
for manufacturing of cement: -
Surveying
Drilling
Blasting
Loading
Transportation
Crushing
Stock pile
Homogenization
Raw milling
Kiln
Chemical process (pre calcination, pyro processing, clinker grinding)
Packing
Loading
3. Surveying
Surveying or land surveying is the technique, profession, art and science of determining the
terrestrial or three-dimensional positions of points and the distances and angles between them. A
land surveying professional is called a land surveyor. Surveying is of vital importance in any
engineering project. During execution of the project of any magnitude is constructed along the
lines and points established by surveying. The measurement of land and the fixation of its
boundaries cannot be done without surveying. The main aspects of surface mining regarding to
surveying are
Deposit calculation
Roads
Direction
Bench Design
Water Flow
4. Drilling
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point.
Drill machines can be classified on the basis of their power source i.e.
Electric
Pneumatic
Hydraulic
There are two basic types of drill machines
DTH A down-the-hole drill, usually called DTH by most professionals, is basically a mini
jackhammer screwed on the bottom of a drill string. The fast hammer action breaks hard
rock into small flakes and dust and is blown clear by the air exhaust from the DTH hammer.
Figure 1 DTH
TH in Top Hammer Drilling the hammer produces a percussive force on the drill rods or
tubes, which is transmitted to the drill bit. The feed device is usually attached with a hinged
boom to a mobile unit. The percussive system strikes the drill rod, for example 2,000-5,000
strikes per minute, and the rotation speed can be, for example, 60-200 rounds per minute.
Together these elements make it possible to drill holes in the hard rock. The excess material
(cuttings) is flushed up from the bottom of the hole by means of pressurized air or water.
Top hammer drills are primarily used in mining, construction and quarrying of rock
material. Top hammer drilling, combined with the “drill and blast” method, makes the
whole excavation process extremely efficient.
Figure 2 Top Hammer
4.1 Drilling patterns
Following figure shows the different types of pattern for drilling
For the best fragmentation result we use staggered pattern.
4.2 Data collected from field
Table 1 Data from 1st drill machine (Tasavar Iqbal was Operator)
B S B.H Drilling Angle Penetration Hole Dai No. of holes Pattern
depth rate
4m 5m 14 m 15m 82º-83º 15m/hour 115mm 7 Single line
Table 2 Data from 2nd drill machine (Azhar was Operator)
B S B.H Drilling Angle Penetration Hole Dai No. of holes Pattern
depth rate
4m 4.5m 9m 10.5m 82º-83º 15m/hour 105mm 9 Single line
4.3 Calculation for per hole material removed
Taking data from table 1
Per hole material removed = 5*4*14*2.6 (S.G)
= 728 tons / hole
Total material removed from 7 holes = 7*728
= 5096 tons
4.4 Calculations for required number of holes to fulfill per day capacity
Capacity = 12000 tons/day
Clinker factor =12000 * 1.6
= 19200 tons /day
85% of limestone is used so
Limestone req. = 19200*85%
= 16320 tons
= 16500 tons (assumed)
No. of holes req.= material req. / Per hole material removed
= 16500/728
͌ 23 holes
4.5 Formula for Sub drilling and stemming
Sub drill length = Explosive Dia *0.0086
Sub drilling = (B.H + sub drilling) / cosθ
Stemming = Explosive dia *0.022
4.5.1 Old formulas
Stemming length = (2/3)B
Sub drilling = (1/3) B
4.6 Specification of drill machines and compressors
Table 3 Drill machine and compressor information
5. Blasting
Blasting is basically use of explosives to break the rock for the mining purpose, the blasted material
then transported to the plant by means of dumpers.
Data gathered from the field is given below:
Yield = 6-8kg/ton
Powder factor = 0.4m3/kg
Explosive ratio = High explosive 15%
=Low explosive 85%
Detonator = #8 (plain)
Lahar/Nonel =1-20 N.s
Delay = 25ms
Safety fuse burning rate 120 sec/m
Detonating cord (vod) 7000m/s
Wabox (Nitroglycerine based) (vod) 55000+
Blaster (Water gel) 4500+
Stemming of moist clay
6. Loading and transportation
For the purpose of transportation and load excavators and dumpers are used their details are given
below
Table 4 Loaders and dumpers information
6.1 Observed cycle time
Dumper Driver Cycle time (avg. after five
cycles)
K-10 Iftikhar Shah 13min 25.5 sec
7. Crushing
Operator name: M. Ashraf
Capacity: 1500 ton/hour
Hopper Capacity: 365 tons
RPM: 500
Type: hammer crusher (double rotter)
Hammers: 90
Hammer weight: 120 Kg/hammer
8. Stacker/Reclamier
After crushing, the crushed limestone is piled longitudinally by an equipment called stacker /
reclamier. The stacker deposits limestone longitudinally in the form of a pile. The pile is normally
250 to 300 m long and 8-10 m high. The reclaimer cuts the pile vertically, simultaneously from
top to bottom to ensure homogenization of limestone. The crushed limestone from pile is
transported through belt conveyor to hopper. Similarly, other raw materials like clay, bauxite, iron
ore etc. are also transported by belt conveyor from storage yard to respective hoppers. All raw
materials are proportioned in requisite quantity through weigh feeders. The proportioned raw
materials are transported by belt conveyor to Raw Mill for grinding into powder form. After
grinding, the powdered raw mix, is stored in a raw meal-silo where blending takes place. Blending
is done by injecting compressed air. This powdered material (Raw mix) is fed to the kiln for
burning and Coal also requires homogenization as it contains different ash.
9. Burning
The powdered raw mix is fed into 4 to 6 stage preheater from top by air pressure. The hot gases
from kiln enters preheater from bottom. The powdered raw mix slides down through cyclones and
comes in contact with hot air which travels from top to bottom. In preheater the o o temperature
of raw mix rises to 900 C to 1000 C and nearly 90% Calcination (removal of CO2 from CaCO3)
takes place before entering the kiln. Powdered raw mix enters the kiln at one end and the burner is
situated at the opposite end. The rotary kiln rotates at the speed of 1 to 3 revolution per minute
(RPM). The raw mix in the kiln melts first into liquid form and then transforms into nodules due
to the effect of the rotation of the kiln. There are two zones inside the kiln, namely calcining zone
and burning zone. The zone where raw mix enters into the kiln is called calcining zone. Where
temperature would be 950-1000 C. Burning zone starts after this zone where temperature would
be 1350-1450 C. The hot clinker from kiln discharge is cooled very quickly/ quenched in air with
the help of efficient coolers. The temperature of clinker is brought o o to 80-90 C from 1350 C.
Fast cooling is very essential to get good quality clinker. If cooling is not quick, the compound
stability in clinker will be adversely affected resulting in lower strength of cement after grinding.
Clinker from clinker silo is transported to clinker hopper by belt conveyor. Similarly, gypsum, fly
ash or any other additive are transported to their respective hoppers by belt conveyors.
All operations of feeding of raw meal, coal, burning, temperature control and cooling are automatic
through fuzzy logic / computer control. These operations are controlled from Central Control
Room (CCR) which is the nerve center for any cement plant.
10. Cement grinding
trolled from Central Control Room (CCR) which is the nerve center for any cement plant. The
proportioning of clinker, gypsum and fly ash is done by electronic weigh feeders. In modern plants,
clinker and gypsum are precrushed in a Roller press and subsequently fed into ball mill for fine
grinding. The installation of roller press technology is very beneficial in terms of both quality and
energy conservation. The cement produced from roller press is showing better particle size
distribution in cement (and hence good strength development) and consumes less power. The
resultant product is called cement and stored in a Multi compartment silo. This avoids intermixing
of products.
11. Packing
Cement is packed in HDPE bags having different capacities. Electronically controlled, High
efficiency rotary packers are used for Packing. Packers are highly precise with tolerance of +/-
0.5%. It displays the weight of each bag before discharge.
12. Transportation of cement
Cement is transferred to various locations as per the market requirement and stored in godowns or
the distribution points, this is distributed through trucks and by rail or by cement Bulkers from the
plant.
13. Export products
BESTWAY (Grade 42.5)
BESTWAY (Grade 53.5)
PAKCEM (Grade 52.5)
PAKCEM (Grade 53)
STALLION (Grade 42.5)
LION (Grade 42.5)
LION (Grade 32.5)
14. Summary
During the 14 days internship we have learned major steps involved in cement manufacturing and
our main concern was the mining operations including drilling blasting haulage and transport.