BACHELOR OF TECHNOLOGY

IN
CIVIL
ENGINEERING
AT

BUNDELKHAND INSTITUTE OF ENGINEERING AND TECHNOLOGY

JHANSI (2024-25)
REPORT AT

INDUSTRIAL VISIT AT MYCEM HEIDELBERG CEMENT PLANT

SUBMITTED TO:- DEAN ACADEMIC,HOD CIVIL

ABHAI KUMAR VERMA ENGINEERING
SUBMITTED BY:- PRIYANSHU GAUTAM
(23004300000034)
 CONTENT

 ITRODUCTION
 OVERVIEW
 MANUFACTURING PROCESS
 QUALITY CONTROL MEASURES
 ENVIRONMENTAL AND SUSTAINABILITY PRACTICES
 SAFETY AND OPERATIONAL EFFICIENCY
 CONCLUSION
 INTRODUCTION

Introduction On [22FEB 2025], we, a group of students from [BUNDELKHAND INSTITUTE OF

ENGINEERING AND TECHNOLOGY ,JHANSI], had the opportunity to visit the Mycem
Heidelberg Cement Plant located at [JHANSI]. The purpose of the visit was to gain practical insights
into the cement manufacturing process, understand the operational workflow, and explore the
technological advancements in the cement industry.
OVERVIEW OF MYCEM HEIDELBERG CEMENT PLANT

Overview of Heidelberg Cement Heidelberg Cement is one of the leading global cement
manufacturers, known for its sustainable and innovative approaches in the cement and building
materials industry. Mycem Cement, a subsidiary of Heidelberg Cement, operates several plants across
India and is known for producing high-quality cement.
 MANUFACTURING PROCESS

The visit provided an in-depth understanding of the cement production process, which includes the following key
stages:
• Raw Material Extraction and Preparation: Limestone, clay, and other raw materials are extracted from quarries
and crushed into smaller pieces.
• Raw Material Grinding: The crushed materials are ground into a fine powder called raw meal in vertical roller
mills.
• Preheating and Calcination: The raw meal is heated in a preheater and then moved to the rotary kiln,
where it undergoes calcination to form clinker.
• Clinker Cooling and Storage: The clinker is cooled and stored for further processing.
• Cement Grinding: Clinker is mixed with gypsum and other additives and ground to produce cement.
• Packaging and Dispatch: The final product is packed in bags or transported in bulk to distributors and consumers.
 QUALITY CONTROL MEASURE
Quality control of cement is essential to ensure that it meets the required standards for construction. Here are some key
quality control measures:
1. Raw Material Testing
• Limestone & Clay Testing – Chemical composition analysis (CaO, SiO₂, Al₂O₃, Fe₂O₃).
• Gypsum Testing – Purity and sulfate content.
• Fuel Testing – Quality of coal or alternative fuels used in clinker production.
2. Manufacturing Process Control
• Proportioning of Raw Materials – Proper mixing ratio to achieve desired chemical composition.
• Grinding Process – Particle size control to ensure proper fineness.
• Clinker Production – Monitoring temperature in kilns (around 1400-1500°C).
• Addition of Gypsum – Controlled to prevent flash setting.
3. Physical & Chemical Testing of Cement
• Fineness Test – Checked using a sieve or Blaine air permeability method.
• Consistency Test – Vicat apparatus used to determine the water required for normal consistency.
• Setting Time Test – Initial and final setting time measured using Vicat apparatus.
• Soundness Test – Ensures no expansion using Le-Chatelier apparatus.
• Compressive Strength Test – Cube test performed after 3, 7, and 28 days of curing.
• Loss on Ignition (LOI) Test – Determines volatile substances in cement.
• Sulphate and Chloride Content – Ensures cement does not cause reinforcement corrosion.
4. Storage & Packing Quality Control
• Proper Storage – Stored in dry conditions to prevent moisture absorption.
• Packing Strength – Bags should be strong to prevent cement loss.
5. Field Testing (On-site Checks)
• Color Check – Cement should be uniform gray with a greenish tint.
• Feel Test – Should be smooth and not gritty.
• Float Test – Should float for some time before sinking.
• Hand Test – Should feel cool and not warm (indicating proper grinding).
6. Adherence to Standards
• Cement should comply with IS 269:2015 (Ordinary Portland Cement - OPC), IS 1489 (PPC), and IS 455
(PSC) in India.
• Globally, it should meet ASTM C150, EN 197, or BS 12 standards.
ENVIRONMENTAL AND SUSTAINABILITY PRACTICES

The plant follows strict environmental and safety standards. Some of the measures observed include:
• Use of alternative fuels and raw materials to reduce carbon footprint.
• Implementation of dust suppression and emission control systems.
• Regular safety training and protective equipment for workers.
• Water conservation and waste management practices.
 SAFETY AND OPERATIONAL EFFICIENCY
Cement manufacturing involves handling hazardous materials, high temperatures, heavy machinery, and dust exposure.
Key safety measures include:
a) Hazard Identification & Risk Management
• Conduct regular risk assessments for crushing, grinding, kiln operations, and material handling.
• Implement safety training programs for workers and supervisors.
b) Personal Protective Equipment (PPE)
• Enforce the use of helmets, gloves, goggles, hearing protection, and dust masks.
• Ensure compliance with OSHA and local safety regulations.
c) Dust & Air Quality Control
• Install efficient baghouse filters and electrostatic precipitators to reduce dust emissions.
• Provide respiratory protection and improve ventilation systems.
d) Fire & Explosion Prevention
• Use explosion-proof electrical equipment in coal mills.
• Implement thermal monitoring systems for kilns to prevent overheating.
e) Machine Safety & Automation
• Install guardrails, emergency stop systems, and interlocks on conveyors and crushers.
• Use automated monitoring systems to reduce human exposure to dangerous operations.
.

CONCLUSION

The visit to the cement plant provided valuable practical exposure to the cement manufacturing process, safety
measures, and operational efficiency. Observing the real-world application of theoretical concepts helped in
understanding key aspects such as raw material processing, kiln operations, quality control, and sustainability
practices.
One of the most striking takeaways was the level of automation and safety protocols in place to ensure smooth
operations and worker protection. The use of modern technology, such as SCADA, DCS, and AI-driven monitoring
systems, highlights the industry's shift toward efficiency and sustainability. Additionally, waste heat recovery,
alternative fuels, and emission control measures emphasize the cement sector's commitment to reducing environmental
impact.
Overall, the visit was an eye-opening experience that reinforced classroom learning with hands-on insights. It also
highlighted the importance of engineering, safety, and sustainability in large-scale industrial operations. The
knowledge gained from this visit will be invaluable for future studies and career prospects in the cement and construction
industry.