Location                                 DALAVOI, ARIYALUR (DT), T.N.

Plant Elevation                      +65 mt MSL

Process Technology               DRY PROCESS WITH PRECALCINER

Plant Capacity                       2500 TPD – 1997 (Installed)

                                                3600 TPD – 2001 (Upgraded)

Type of Cement                     OPC – 43, 53 Gr.

Manufactured                       PPC, SRC

Main Plant Supplier              Krupp Polysius – Germany and

                                                Krupp Industries - Pune, India


The Dept. of EIE has arranged an industrial visit to INDIA CEMENTS LIMITED – DALAVOI at Ariyalur District on 19-08-2015. The Students of EIE and Mechatronics visited the company. The staff members Mrs. Saraswathi.K, Mr. T. Sundar, Ms. Janani. R and K. Vinayagamoorthy accompanied the students to visit the Factory

The Senior Vice-President of the Plant Mr. T. Balasubramanian gave the students brief introduction about the working of the Plant.  Mr. Sathyanarayanan, General Manager, Quality Control Department explained clearly the process involved in manufacturing of Cements.  He explained the students clearly the process starting from Limestone Mining – The required limestone is mined from limestone deposit either by using blasting methods or by using surface miner equipment.  The main equipment’s for material handling used in mines are Excavators, Dumpers, Dozers and Front end Loaders.  The mining sequence, methodology and progress is monitored and maintained as per the mining plan.

The Limestone received from Mines is further size reduced by using crushers of different types.  The limestone is crushed to the size of 70 to 80 mm in the case of Vertical Roller mill or 25 to 30 mm in the case of Ball Mill.

In the manufacturing of cement the clinnkerisation is the central part of the main process called Pyro-processing.  The various technologies used for pyro-processing shall be Wet Process, Semi Dry Process, Dry Process and Dry Process with pre-calciner.

The pre calciner raw meal is further fed into equipment called rotary kiln.  When the material is heated further the main objective of clinnkerisation called phase formation is achieved by the combination of main compounds present in raw meal like CaO, SiO2 etc in different matrices and resulting in different phase composition as follows.  These are the main contributing factors for Strength development of any cement.

The clinker produced by Pyro-processing of raw meal is ground to fines with some addition of Gypsum as a setting time retarder.  The grinding of clinker and gypsum is done through various equipment’s.  The general purpose cement produced in varieties called

a)      Ordinary Portland Cement (33, 43 and 53 Grades)

b)      Portland Pozzolana Cement

c)      Sulphate Resisting Cement

The cement manufactured in a continuous process basis and stored in cement silos.  The stored cement is extracted from cement silos and further packed into 50Kgs bags by Rotary Packers.

Apart from the above the total operation of the plant is being done through computerized Control System using DCS with required level of high efficiency field instruments and automation system.



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