CEMENT MANUFACTURING PROCESS

QUARRY
The four main raw materials for cement manufacturing are limestone, shale,
silica/pozzolan and iron ore. Limestone and shale materials are readily available at
our adjacent quarry. Limestone comprises 60-80% and shale make up 10-20 % of
our raw material proportion. Our limestone and shale quarries mine life are
estimated to be sufficient for the next 200yrs and 100yrs, respectively. Silica and
iron ore are outsourced from accredited suppliers and completes the mixture,
proportion depending on the raw mix design. (Quarry Operation: Drilling, Blasting,
Hauling)

CRUSHING

Limestone materials from quarry are crushed in the Jaw Crusher and Impact
Crusher to reduce size from 500mm to 19mm after passing through the Vibrating
Screen. Shale and silica / pozzolan materials are passed through the Roll and Fam
Crushers to attain the desired size.
(Shale:300mm to 25mm), (Silica:75mm to 25mm) – Roll Crusher Product
Purity: LST – 90%CaCO3 min, SHL – crushable, SIL – 75%SiO2 min, POZ – 55%SiO2 min
Crushed shale & sil/poz will passed through ROTARY DRYER for moisture reduction
(8-12% product moisture)

RAW MILLING
Raw material proportion are set, proportioned and carried out on weigh feeders,
ground to powder and conveyed to homogenizing silos wherein raw mix will be
tested in conformance with the set quality plan standards and parameters.
Homogenized raw mix are discharged to kiln feed silos for clinker burning.

PYROPROCESSING

Homogenized Rawmix are conveyed to the four stage cyclone preheater to the
rotary kiln wherein gradually heated by contact of hot gases from combustion of
the Kiln fuel, thus chemical reaction takes place as the temperatures of raw mix
rises, inside the kiln a nodules and small lumps called clinker with max. of 25mm
are produced. Sintering zone at the Kiln reaches to as high as 1450oC to 1500oC.
Clinker is quenched at cooler and transported to the clinker silo for storage.

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CEMENT MILLING

Clinker added with certain amount of gypsum to control setting time of cement
and other additives are proportioned, ground with the desired fineness and
conveyed to our 9 cement storage silos ready for withdrawal by our customers.

PACKING OPERATION
We have 7 units Roto Packing Machines with 14 loading bays plus bulk & tonner
bag loading system to serve our customers requirement of up to 300,000 bags
daily cement production. Concrete cement silos have a storage total capacity of
1,000,000 bags plus 2 steel silos with 50,000 bags each.

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