OCL INDIA LIMITED
OCL INDIA LIMITED, formerly “Orissa Cement Limited” and better known as “OCL” was established in the year 1949 is a Public Limited Company having its registered office and works at Rajgangpur, in the state of Orissa. Late Sri Jaidayalji Dalmia, was the founder and plant started producing cement by using wet process technology supplied by M/s F.L. Smith, Denmark and successfully despatched the first consignment of cement on December 31, 1951, under the brand name of “Konark”.
Keeping a steady progress with time and technology, the plant was modernized to fully automated dry process plant in 1988. OCL was the first Indian cement company to installed Vertical Mill for grinding cement The mill was supplied by M/s Loesche, Germany in 1997.The annual cement installed capacity increased up to 6.70 million tonnes after commissioning of its new Clinkerization unit no 2 at Rajgangpur,Odisha & Cement grinding units at Kapilas Cement Works (KCW), near Cuttack (Odisha). & OCL Bengal Cement Works (BCW) at Medinapur.
MANUFACTURING OF KONARK CEMENT:-
Conventional mining using Drilling & blasting system is used for mining alongwith the Primary rockbreaker.The mined out limestone is transported to crusher by using dumpers. The limestone is crushed upto 75mm and is stacked in the circular pile of 52000 MT capacity.The crushed limestone is then transported to the factory at Rajgangpur Cement works by 13km long CCBC (Cross country) Belt conveyor. The limestone from mines is either directly fed to the Raw mill or stacked in the longitudinal pile in the plant using the stacker. T
As per requirement,blended limestone is reclaimed with the help of reclaimer & transported to VRM hopper. This limestone along with additives (morrum, Fly ash, cinder etc.) as required is taken into the Vertical Roller Mill (VRM) for grinding through weigh feeders at definite proportions. In VRM, the mixture is ground to a fineness of about Residue-17% on 90 micron known as raw meal and is fed and stored in the blending silo.
ESP and Reverse Air bag house is used for controlling the dust emissions t while the Gas Conditioning tower is used for conditioning the hot gases to improve the ESP efficiency and control the emissions.
§ Make:- KHD
§ Type:- Rotary Kiln with inline calciner & 5 stage double string preheater
§ Capacity:-3000 TPD
§ Dimension:- 3.8 m Dia x 56 m Length
§ Inclination:- 3.50
The raw mill from the silom is fed to the by using the kiln feed circuit which has airslides and bucket elevator. 92% calcinations occurs in preheater before it is fed to the kiln. Fuel is fired in the calciner and kiln.
The kiln is driven by electric drive & shell is supported by rollers. Also thrust rollers arrangement is provided to compensate the floating of rotary kiln during rotation.
Line-2 Clinkerisation unit is commissioned in 2009 with modern & latest technology which is highly energy efficient & environmental friendly.
§ Make:- KHD
§ Type:- Rotary Kiln with inline Calciner.
§ Capacity:-4000 TPD
§ Dimension:- 4.2 m Dia x 64 m Length
GRATE COOLER (Both line):-
Clinker produced in the rotary kiln(both line) is cooled in the Grate Cooler upto 110 deg centigrade The Humboldt Wedag Grate Cooler is a reciprocating grate cooler with a continuous grate.
Clinker cooled in Grate cooler is stored in Closed circuit in Line-1 & also in Line-2 it is stored in Clinker Silo.
CEMENT GRINDING SECTION
After Clinkerisation, clinker fed to the CVRM (3 Vertical mills) & cement mills (4 ball mills) alongwith Gypsum & other materials like slag etc. This is the single largest Cement grinding units of 7 Mills (3 VRM+4 BALLMILL) in single location. The first Loesche clinker/slag mill in India, an LM 46.2+2, was commissioned at Rajgangpur plant in 1997.
In CVRM, Slag and Clinker with Gypsum are ground separately and stored in separate compartments silos from where OPC or PSC & PPC (by inter mixing by means of a paddle mixer) is obtained.
1) Cement Ball Mills (4 Nos)
2) Cement Vertical Roller Mills (CVRM)-3 Nos.
The ground material from all Grinding Mills is passed through Bag filter & filled to compartment silos. Latest Pulse jet bag filters are installed in all Grinding Mills. The dust laden gas enters the bags from the Mill& the cleaned gas vent to the stack.
Cement and Clinker despatch
It is the final process of our cement factory where finished product i.e. cements is packed in bags, subsequently despatched through wagons or trucks. There are 17 Nos. of cement silos in which cement is stored and thereafter it is conveyed to the packing machine hoppers through air slide and elevators via vibrating screen for packing purpose. There are 6 Nos. of Rotopacker M/C in our packing house. The packed bags are conveyed to the points of loading by means of belt conveyor arranged in respective routes from where they are loaded to the wagons or trucks by wagon loaders or truck loaders respectively.
Clinker is also loaded in to the railway wagons and despatched to our grinding units at Kapilash and Medinipur.
Page 7 of 7