Cement Plant

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Cement Plant

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Limestone/Clay Crushing

IT IS A SINGLE ROTOR HAMMER CRUSHER, TYPE MAMMUT 75/90 SUPPLIED BY M/S. O&K GERMANY, TWO UNITS ARE INSTALLED, EACH HAVING CAPACITY OF 750-820 TONS/ HOUR WITH A MAXIMUM FEED SIZE OF 800X1200X1400 MM TO A PRODUCT SIZE OF 0-30 MM. IT IS PRIMARILY USED TO CRUSH THE LIMESTONE BLASTED FROM THE QUARRY ALONG WITH CLAY AS PER THE QUALITY REQUIREMENT AND FEEDS THE PRODUCT TO THE PRE-HOMOGENIZATION STOCK PILES AFTER PASSING THROUGH A SAMPLING STATION. IT IS A SINGLE ROTOR HAMMER CRUSHER, TYPE MAMMUT 56/75 SUPPLIED BY M/S. O&K GERMANY, TWO UNITS ARE INSTALLED, EACH HAVING CAPACITY OF 100-500 TONS/ HOUR WITH A MAXIMUM FEED SIZE OF 800X1200X1400 MM TO A PRODUCT SIZE OF 0-30 MM

IT IS USED AS A CORRECTION MATERIAL FOR THE LIMESTONE AND CLAY IN CASE OF INFERIOR CONTENTS OF Ca O. THE CRUSHED PRODUCT IS STORED IN PRE HOMOGENIZATION STOCKPILES AS WELL AS IN A CONCRETE SILO.

Sampling StationTHIS IS AN ON LINE BULK MATERIAL ANALYZING SAMPLING STATION CALLED POLAB SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY. IT IS INSTALLED IN BETWEEN THE LIMESTONE / CLAY CRUSHER AND PRE-HOMOGENIZATION PILES IT COLLECTS PREDETERMINED QUANTITY OF BULK MATERIALS LIMESTONE / CLAY COMING OUT OF THE CRUSHER ON CONTINOUS BASIS AND ANALYSIS OF INDIVIDUAL COMPONENTS ARE BEING MADE BY X-RAY ANALYZER. THIS ENSURES MAKING O PREHOMOGENISATION PILES AS PER THE QUALITY REQUIREMENT WITH DESIRED SET POINTS. THIS ALSO ACTS AS A TOOL FOR SECTION OFDIFFERENT QUARRYING OPERATION.

Raw Material handling (PREHOMOGENISATION)

EACH LIMESTONE / CLAY CRUSHER AND HIGH GRADE LIMESTONE CRUSHER IS EQUIPPED WITH A BOOM TYPE STACKER, TYPE 25 SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY, HAVING A CAPACITY OF 1125 TONS / HOUR. THE MAIN FUNCTION OF THE BOOM STACKER IS TO MAKE A PREHOMOGENISATION PILE OF 40,000 TONS CAPACITY IN MANY LONGITUDINAL LAYERS AND THIS KIND OF STOCKPILING IS CALLED CHEVRON TYPE STOCKPILING. THERE IS ONLY ONE BOOM STACKER FOR ALL THE THREE ADDITIVE MATERIALS VIX. BAUXITE, IRON ORE AND SAND. THIS IS ALSO VERY MUCH SIMILAR TO THE STACKER MENTIONED ABOVE, TYPE BA-20, CAPACITY 3000 TONS / HOUR SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY. EACH OF THE LIMESTONE / CLAY CRUSHER AND HIGH GRADE LIMESTONE CRUSHER UNITS ARE EQUIPPED WITH BRIDE TYPE RECLAIMER. TYPE BK K2 HAVING A CAPACITY OF 500 TONS / HOUR EACH, SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY. THE MAIN FUNCTION OF THIS RECLAIMER IS TO RECLAIM THE MATERIAL FROM THE STOCKPILES BY CUTTING IT VERTICALLY, WHERIN VERY GOOD HOMOGENISATION OF ALL INDIVIDUAL LAYERS MADE

LONGITUDINALLY BY THE STACKER IS ACHIEVED. THIS ENSURES HIGH DEGREE OF UNIFORMITY IN THE MATERIAL QUALITY BEING RECLAIMED AND SEND TO RAW MILL.

THERE IS ONLY ONE SCRAPPER TYPE RECLAIMER FOR ALL THE THREE ADDTIVIE MATERIASL, VIZ. BAUXITE, IRON ORE AND SAND. THE MAIN FUNCTION OF THIS RECLAIMER IS SIMILAR TO ABOVE, THE TYPE IS SK 18 200 SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY, HAVING A CAPACITY OF 200 TONS / HOUR.

CRUSHER FOR ADDITIVE MATERIAL

IT IS IMPACT TYPE BAR CRUSHER, TYPE AP-SME-1313 SUPPLIED BY M/S. HAZEMAG, GMBH, GERMANY. ONE UNIT IS INSTALLED, HAVING A CAPACITY OF 100 TONS/HOUR WITH A FEED SIZE OF 30-500 MM AND A PRODUCT SIZE OF 0-40 MM IT IS PRIMARILY USED TO CRUSH ALL THE ADDITIVE MATERIALS REQUIRED LIKE BAUXITE, IRON ORE AND SAND AFTER BEING CRUSHED, INDIVIDUAL

ADDITIVE

CRUSHER FOR ADDITIVE MATERIAL

EACH PRODUCTION LINE IS EQUIPPED WITH ONE BALL MILL FOR GRINDING THE RAW MATERIAL. IT IS A CLOSED CRICUIT, TWO CHAMBERS BALL MILL WITH A SEPARATE DRYING CHAMBER SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY, IT IS HAVING A CAPACITY OF 360 TONS/ HOUR WITH 5% RESIDUE ON 90 MICRONS, DRIVEN BY A GEARLESS DRIVE MOTOR OF 5900 KW SUPPLIED BY M/S. A.B.B. SWITZERLAND. THE RAW MILL GRINDING SYSTEM IS INDEPENDENT OF KILN SYSTEM, MEANS NO HOT GASES FROM THE KILN IS BEING USED TO DRY THE RAW MATERIALS. INSTEAD EACH MILL IS EQUIPPED WITH AN HOT GAS GENERATOR, CAPABLE FO USING OIL /

GASEOUS FUELS FOR DRYING THE RAW MATERIAL. THE COMPLETE FIRING INSTALLATIONS WERE SUPPLIED BY M/S. PILLARD, GMBH GERMANY. THE WASTE GASES OF THE RAW MILL GRINDING OPERATION ARE DEDUSTED IN A TWO CHAMBERS, HIGH EFFICIENCY ELECTROSTATIC PRECIPITATORS, SUPPLIED BY M/S. LURGI, GMBH GERMANY. IN ORDER TO ACHIEVE HIGH QUALITY, UNIFORM RAW MIX FOR THE KILN FEED, EACH OF THE RAW MATERIAL GRINDING INSTALLATION IS EQUIPPED WITH A CONTINUOUS SAMPLING STATION AND A CLOSE CIRCUIT QUALITY CONTROL SYSTEM EMPLOYING AN ON-LINE X-RAY ANALYSIS CALLED POLAB SYSTEM SUPPLY BY M/S. KRUPP POLYSIUS, GERMANY. IN THIS PREDETERMINED QUANTITY OF RAW MILL PRODUCT IS WITHDRAWN CONTINUOUSLY BY MEANS OF AN AUTO SAMPLER AND THIS SAMPLE IS SENT AUTOMATICALLY TO THE LAB BY PNEUMATICALLY, EVERY 30 MINUTES THE SAMPLE IS ANALYZED FOR ALL CHEMCIAL CONTENTS AND THE OBTAINED RESULTS ARE COMPARED WITH THE SET POINTS. THE DEVIATIONS IN THE SET POINTS OBTAINED ARE CORRECTED AUTOMATICALLY BY A PROCESS COMPUTER, WHICH IN TURN ADJUST THE FEED RATE OF INDIVIDUAL RAW MATERIAL COMPONENTS GOING INTO THE MILL, ENSURING PRECISELY THE DESIRED OUTPUT BEING OBTAINED FROM THE GRINDING MILL.

CRUSHER FOR ADDITIVE MATERIAL

EACH RAW MILL IS PROVIDED WITH 2 NOS. CONCRETE BLENDING SILO EACH HAVING A DIMENSIONS OF 16 MTR. DIAMETER, 24 MTR. HIEGHT WITH A CAPACITY OF 3200 CUBIC METER SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY.

THE PRIMARY FUNCTION OF THE BLENDING SILO IS TO MAKE PERFECT BLEND OF RAW MEAL STORED IN THE SILO ASSURING UNIFORM HOMOGENOUS MATERIAL LEAVING THE SILO. THIS ACHIEVED BY AERATING THE SILO CONTENTS PNEUMATICALLY WITH A CYCLIC AERATION OF VARIOUS SEGMENTS INSIDE THE SILO..

Homogenization Silos

EACH RAW MILL IS PROVIDED WITH 2 NOS. CONCRETE BLENDING SILO EACH HAVING A DIMENSIONS OF 16 MTR. DIAMETER, 24 MTR. HIEGHT WITH A CAPACITY OF 3200 CUBIC METER SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY. THE PRIMARY FUNCTION OF THE BLENDING SILO IS TO MAKE PERFECT BLEND OF RAW MEAL STORED IN THE SILO ASSURING UNIFORM HOMOGENOUS MATERIAL LEAVING THE SILO. THIS ACHIEVED BY AERATING THE SILO CONTENTS PNEUMATICALLY WITH A CYCLIC AERATION OF VARIOUS SEGMENTS

INSIDE THE SILO.

Feeding System

EACH PRODUCTION LINE IS EQUIPPED WITH A KILN FEEDING SYSTEM CALLED POLDOS SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY.

THE MAIN OBJECTIVE OF THIS SYSTEM IS TO FEED THE KILN WITH RAW MEAL PRECISELY CONTROLLED QUANITY FROM THE STORAGE SILOS, WHICH CAN BE CONTROLLED FROM REMOTE. IT MAINLY CONSISTS OF SERIES OF RAW MEAL EXTRACTION APPARATUS, AIRSLIDES, PNEUMATIC CONVEYORS, VERTICAL BUCKET ELEVATORS, A WEIGH BIN SUPPORTED ON LOAD CELLS AND FINALLY A VERTICAL LIFT CONVEYOR TO LIFT THE MEAL UP TO A HEIGHT OF 90 METER AND TO FEED TO THE PREHEATER.

PREHEATER

EACH KILN IS EQUIPPED WITH A 4 STAGE SUSPENSION PREHEATER CALLED DOPOL TYPE 2422 AND ON LINE PRECALCINER CALLED PREPOL AS SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY. THE COMBUSTION AIR FOR THE FUEL SUPLIED IN THE CALCINER IS TAKEN FROM COOLER TAPPED AT KILN HOOD THROUGH A SEPARATE AIR DUCT CALLED TERTIARY AIRDUCT AND THE VOLUME OF THE AIR IS CONTROLLED BY 2 NOS DAMPERS. THE FIRST, THIRD AND FOURTH STAGE IS HAVING 2 NOS. CYCLONES AND THE SECOND STAGE IS HAVING ONE CYCLONE AND THE INDIVIDUAL CYCLONES ARE CONNECTED WITH EACH OTHER BY MEANS OF HOT GAS DUCTS. THE KILN FEED MATERIAL IS FED TO THE TOP STAGE OF THE PREHEATER AND THE KILN HOT GASES ARE SUPPLIED TO THE BOTTOM STAGE OF THE PREHEATER. THE FEED MATERIALS TRAVELS FROM TOP TO BOTTOM AND THE HOT GASES FROM BOTTOM TO TOP AND DURING THIS PROCESS HEAT TRANSFER FROM GASES TO MATERIAL TAKES PLACE. FURTHER AT THE RPECLACINER NEARLY 50-55% OF TH TOTAL HEAT REQURED TO PRODUCE CLINKER IS INTRODUCED BY TWO NOS. BURNERS WHICH CAN USE EITHER GAS OR OIL FUEL. THE FIRING BURNER INSTALLATION WAS SUPPLIED BY M/S. PILLARD GMBH GERMANY. THUS AT THE BOTTOM OF THE PREHEATER THE FEED MATERIALS IS PREHEATED AND PRECLACINED BEFORE ENTERING THE KILN. THE WASTE GASES LEAVING THE RPEHEATER IS PASSED THROUGH

THREE NUMBERS ELECTROSTATIC PRECIPITATOR FOR DUST COLLECTION, SUPPLIED BY M/S. LURGI, GERMANY. THESE FILTERS ARE OF SPECIAL DESIGN CALLED HOT ELECTRO-FILTERS WHICH DOES NOT NEED TO COOL DOWN THE WASTE GASES AND CAN OPERATE WELL UPTO A GAS TEMPERATURE OF 440 DEGREE CENTIGRADE. THE COLLECTED DUST FROM THE FILTER IS FED TO THE PREHEATER ALONG WITH RAW MEAL.

Bypass System

THE KILN IS EQUIPPED WITH A PROVISION OF BYPASSING A MAXIMUM 20% OF THE HOT GASES FROM THE KILN. THIS IS DUE TO THE HIGH CONCENTRATION OF VOLATILE COMPONENTS LIKE SULFUR ALKALIS AND CHLORINE MAINLY COMING FROM THE RAW MATERIALS ITSELF. THE TAKE OF DUCT IS WELL LOCATED AT THE KILN INLET HOUSING, WHERE THE CONCENTRATIONS OF VOLATILE MATTERS ARE MAXIMUM IN THE FORM OF VAPOR. THE HOT GASES WITHDRAWN FROM THE KILN INLET HOUSING ARE COOLED IN A MIXING CHAMBER BY SUPPLYING ADDITIONAL COOLING AIR FROM OUTSIDE. THE COOLED GAS PASSED THROUGH AN ELECTROSTATIC PRECIPITATOR WHEREIN THE DUST CONTENTS ARE COLLECTED. THE COLLECTED DUST IS STORED IN AS MALL HOPER, FROM WHERE IT IS EXTRACTED BY DUMP TRUCKS AND DISPOSED OFF. THE BYPASS SYSTEM IS DESIGNED AND SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY AND THE ELECTRO STATIC PRECIPITATOR FOR THE BYPASS SYSTEM WAS

SUPPLIED BY M/S. LURGI, GERMANY.

Rotary Kiln

EACH KILN IS HAVING DIMENSION OF 4.6 METER DIAMETER AND 70 METER LENGTH, WITH A PRODUCTION CAPACITY OF 3500 TONS / DAY CLINKER, SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY.

THE KILN TUBE IS INCLINED BY 3.5% SUPPORTED ON 3 NOS TYRE/ROLLER ASSEMBLY AND DRIVEN BY A VARIABLE SPEED MOTOR THROUGH A GIRTHGEAR PINION ASSEMBLY. THE SPEED OF THE KILN CAN RANGE FROM 0.3 TO 3.0 RPM. THE PRE HEATED AND CALCINED MATERIAL FROM THE PREHEATER BOTTOM STAGE CYCLONE ENTERS THE KILN THROUGH A INLET HOUSING AND AFTER PROCESSING AT A PEAK TEMPERATURE OF ABOUT 1400 DEGREE CENTIGRADE, THE CLINKER IS FORMED IN THE KILN WHICH IS TRANSFERRED TO COOLER FOR FURTHER COOLING AND HEAT RECUPERATION. THE KILN IS EQUIPPED WITH A BURNER INSTALLATION WHICH CAN USE EITHER GAS OR OIL OR BOTH AND SUPPLIED BY M/S. PILLARD GERMANY, ABOUT 45- 50% OF THE TOTAL FUEL REQUIREMENT FOR CLINKER PRODUCTION IS SUPPLIED IN THE KILN BURNER.

Clinker Cooler

EACH KILN IS EQUIPPED WITH A CLINKER COOLER FOR COOLING THE CLINKER AND ALSO TO SUPPLY RECUPERATED HOT AIR FOR COMBUSTION IN KILN AS WELL AS IN PRECALCINER.

THE COOLER IS A RECIPROCATING CONTINUOUS INCLINATION 3 GRATE COOLER, EACH GRATE IS DRIVEN BY A VARIABLE SPEED HYDRAULIC DRIVES. THE TOTAL COOLING AREA OF THE COOLER IS 124 METER SQUARE AND COOLING AIR IS SUPPLIED BY 10 NOS. COOLING FANS. AT THE END OF THE COOLER, SINGLE ROTOR HAMMER CRUSHER IS LOCATED TO CRUSH THE BIGGER SIZE CLINKER AND LEAVING UNIFORM SIZE OF CLINKER AHVING SIZE DISTRIBUTION 0-30 MM. THE COMPLETE COOLER INSTALLATION WAS SUPPLEID BY M/S. CLAUDIUS PETERS, GERMANY. THE COOLING AIR PROVIDED IS UTILISED IN COOLING THE HOT CLINKER AND DURING THIS PROCESS THE AIR GAINS SUFFICIENT HEAT, FROM THE HOT ZONES OF THE COOLER. THE RECUPERATED HOT AIR IS TAKEN AS A COMBUSTION AIR FOR KILN AND PRECALCINER. THE ADDITIONAL WASTE GAS OF COOLER IS SENT THROUGH A DEDUSTING UNIT CALLED GRAVEL BED FILTER SUPPLIED BY M/S. LURGI, GERMANY. THE DEDUSTED WASTED AIR IS SENT TO STACK AND COLLECTED CLINKER DUST IS TAKEN TO CLINKER STORAGE.

Clinker Storage

EACH KILN LINE IS PROVIDED WITH 2 NOS. CONCRETE STORAGE SILOS. EACH HAVING A CAPACITY OF 40,000 METRIC TONS CLINKER WITH DIMENSIONS DIAMETER 35.00 METER AND EFFECTIVE HEIGHT 42.5 MTR. SUPPLIED BY M/S.KRUPP POLYSIUS, GERMANY.

Gypsum CrushingIT IS A IMPACT TYPE, SINGLE ROTOR CRUSHER HAVING A CAPACITY OF 100 TON / HOUR, SUPPLIED BY M/S. HAZEMAG, GERMANY. IT CAN FEED UP TO A SIZE OF 40-500 MM WITH A PRODUCT SIZE OF 0-40 MM. THIS IS USED TO CRUSH GYPSUM TO BE USED ALONG WITH CLINKER IN CEMENT MILL. THE CRUSHED GYPSUM IS STORED IN TOW NOS. STOCKPILE. IT IS A SCRAPER TYPE RECLAIMER, HAVING A CAPACITY OF 200 TONS / HOUR, SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY. IT IS USED TO RECLAIM GYPSUM FROM THE CRUSHED STOCKPILE AND FEED TO CEMENT MILL

HOPPERS.

Cement Grinding System

IN ALL FOUR BALL MILLS ARE INSTALLED FOR GRINDING CLINKER AND GYPSUM TO PRODUCE CEMENT. IT IS A OPEN CIRCUIT, TWO CHAMBER BALL MILL SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY, HAVING A CAPACITY OF APPROXIMATELY 105 TONS / HOUR EACH AT A FINENESS OF 3200 BLAINE, DRIVEN BY A GEARLESS VARIABLE SPEED DRIVE MOTOR OF 5250 KW EACH, SUPPLIED BY ABB, SWITZERLAND. THE GROUND CEMENT IS PASSED THROUGH A CONTINUOUS AUTO SAMPLER WHERE THE QUALITY OF CEMENT IS MONITORED BEFORE IT GOES TO THE STORAGE SILO. EACH MILL IS PROVIDED WITH A CLINKER AND GYPSUM HOPPER AND PREDETERMINED RATIOS ARE SET FOR FEEDING.

Cement Silos

FOUR CONCRETE CEMENT SILOS WITH A TOTALE STORAGE CAPACITY OF 40000 TONS EACH SILO IS EQUIPED WITH MULTIPLE EXTRACTION DEVICES TO CATER THE NEED FOR DIFFERENT SALES REQUIRMENTS.

Cement Bulk-LoadingEACH CEMENT STORAGE SILOS ARE PROVIDED WITH ONE CEMENT BULK LOADING TERMINAL, CONSISTING OF A VIBRATORY FEEDER, TELESCOPIC CHUTE AND WEIGHING STATION. EACH ONE OF THE UNIT IS HAVING A LOADING CAPACITY OF 200 TONS/HOUR, SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY.

Packing Plant

CEMENT FROM THE INDIVIDUAL CEMENT STORAGE SILOS ARE EXTRACTED VIA-SERIES OF EXTRACTION UNITS, SCREW CONVEYORS AND BUCKET ELEVATORS AND TAKEN TO A SMALL BUFFER BINS IN THE PACKING PLANT. FROM HERE THE CEMENT IS BAGGED BY 4 NOS. ROTARY PACKERS AND 4 NOS. AUTOPACKERS TO LOAD ON TRUCKS. THE ROTOPACKERS ARE OF TYPE 6023 6RC, SUPPLIED BY M/S. HAVER AND BOECKER, GERMANY AND EACH IS HAVING A CAPACITY OF 100 TONS/HOUR. THE AUTOPACKERS ARE SUPPLIED BY M/S. BEUMER, GERMANY AND EACH IS HAVING A CAPACITY OF 100 TONS/HOUR.