Department of Civil Engineering, Dronacharya Group of Institutions, Greater Noida organised an Industrial Visit to Jaypee Cement Grinding Plant, Sikandrabad under the banner of AGI (Association of Geospatial Industries) on 23rd February 2017.  33 students of 2nd Year, Civil Engineering Branch along with Mr. Gyanendra Kumar, Assistant Professor, DGI, Greater Noida visited the site.

Students reached the plant at 10.00 AM and were welcomed by Mr. Tarun Chauhan (Engineering Instrumentation-Jaypee Cement) along with Mr. Adesh Tyagi (DGM, Plant) and Mr. Uttam Singh (Manager, HR).

Mr. Uttam Singh gave a brief about the Plant. He specifically stressed on safety aspects of the project and asked the students to adhere to the rules and regulations. He explained all the aspects of a cement plant including production and CCR (Central Control Room).

Mr. Adesh Tyagi briefed about the technical stages of cement production i.e. Mining, Blasting, Transportation of crushed lime stone to Grinding, Stacker and Reclaimer, Raw Mill, Pre-Heater, Kiln, Cooler House, Cement Mill and Packaging Yard of a standard Cement Plant. He also introduced students to the safety procedure which are followed within the plant.

Students were then taken to the material yard where Clinkers and gypsum were stacked. Best quality Gypsum is being imported from Pakistan which is most important part of the cement. Mr. Tyagi said that Gypsum is used in cement production for enhancing its setting time. Clinker is the main constituent of cement and it is being supplied by Himachal Pradesh Jaypee Cement plant where there are limestone mines.

Mr. Tyagi then accompanied students to the Clinker Hoper from where the clinker is transported to Cement Mill through conveyor belts (covered) where the clinker is grinded in a rotatory cement mill in which different diameters steel balls strikes together for fine grinding of the cement clinker along with gypsum. Cement mill is the most important part of the cement plant where cement is manufactured.

Students also visited Quality Control Lab where samples of the raw material are collected. The students got to know about the physical appearance of the Fly Ash, Clinker and the Steel Balls used in the cement mill.

Mr. Adesh Tyagi explained the plant management and scheduling of the various activities within the Plant i.e. the cycle time of the various activities and monitoring the same for effective management within stipulated time and money. He said that the consumption of power plays an important role in production of cement as the power will decide the production cost of a cement bag.

The students also got to know how the material used for the production is monitored regularly with the help of CCR (Central Control Room) where each process is monitored automatically with the help of computers.

Finally students visited the packaging yard where cement is stored, packed and loaded on trucks. The entire process of packaging is fully automated where the cement is filled in bags and transported to the designated truck for loading. There are enough cement silos where cement is stored when it is in abundance as cement plant runs throughout the year without stoppage. Mr. Tyagi informed that the Plant maintenance done once a year for proper functioning of the machines as it costs a lot to stop and start the production again.

The visit was very informative and full of new information where the students gathered valuable information.