KAMYA INDUSTRIES PRIVATE LIMITED

Process Description - The Manufacturing Process

Asbestos Cement (AC) Flat sheets

Raw Material Slurry Preparation
Asbestos Fibre (Wet Milling, Storing & Feeding) - Asbestos Fiber of different grades
are imported mainly from Canada, Russia, Zimbabwe etc, and received in pressure
packed condition in impermeable bags in palletized form. The fibre pallets are
transported to the factory in closed containers through the trailer trucks. These palletized
fiber bags are unloaded in fiber go-downs with the help of forklifts. Fiber bag pallets are
conveyed to the fiber feeding section by means of forklifts. Fibre bags are fed to the
closed Bag Opening Device (BOD) by slant conveyor. Fibre and bags are separated out
in the BOD and taken into a blender along with 35 to 40 % water. While the fibre is
carried to the Blender and finally to the Edge Runner Mill (ERM) from the Blender via
screw conveyor, the empty bags generated are further conveyed to an attached Shredder
unit where bags are torn and shredded to minute pieces before the same joins the fibre
being conveyed to the ERM at screw conveyor. The whole operation of fibre opening,
milling & shredding is carried out under negative pressure by connecting it to the Bag
Filter with the blower. The blended wet fiber along with the shredded bag pieces is fed
into the ER Mill where it is milled for a certain time. From this point onwards the total
process operations involving fibre are carried out in wet condition with no possibility of
dust generation during manufacturing process. The milled wet fiber is conveyed to fiber
silo through a bucket elevator and stored therein.
The milled fiber is weighed in weigh hopper. The pre-requisite quantity of fiber which is
about 8% of the product is mixed with required quantity of water in Wet Opener or fibre
cone where it is re-circulated for about 3 to 4 minutes.
Pulp (Slurry Preparation & Feeding) - Cellulose pulp or waste craft paper is opened
and mixed well in water medium in the Pulper unit which is then stored in a Pulp storage
Tanks, provided with stirrers. The pulp slurry, based on the requirement, is either further
opened, homogenized & refined by re-circulating it through an assembly line of High
Density Cleaner, Magnetic Trap and Refiner or sent directly to the Pulp Storage tank,
provided with a stirrer unit. Pulp slurry is drawn in batches through the Dosing Tank
from this tank.
The above pulp slurry along with solid waste + process sludge, if any, in slurry form
(from sludge recycling tank/Wet Ball Mill) is taken to the Wet Opener (Hydro
Disintegrator) after the requisite circulation time in the Wet Opener.
The combined slurry of pulp & asbestos is then conveyed to the Beater tank.
The Fly ash & Cement (batch draw & slurry preparation) - Pre-requisite quantity of
Special binders - Fly ash (as per consistency requirement) is mixed with water, converted
into slurry and sent to the Storage silos. Measured quantity of this Fly ash slurry is taken
to the Cement + Fly ash Mixing Tank which then is joined by pre-requisite quantity of
cement, conveyed through screw conveyor from the weigh hopper followed by a
specified quantity of water. The weigh hopper receives the cement through screw
conveyor from the silo. The silo has a capacity of storing around more than 100 MT of
cement.
The cement + FA slurry thus prepared in the Mixing tank to the Beater Tank, thus joining
fiber + pulp slurry.
The RM slurry thus prepared is transferred to the Storage Tank where it is under constant
agitation. From here the slurry is taken to the Dilution Tank (or Distribution Tank) and
diluted further using recycled process water.
Lamina Formation
Slurry from the Dilution Tank is taken to the sheet forming machine consisting of an
assembly of 5/6 vats placed in series and with rotating sieve cylinders placed one in each
of vats. The sieve cylinders are fitted at its periphery, with the wire mesh of specific size
(mostly 40 mesh on top surface and 5 mesh on the bottom surface). An end-less felt made
of synthetic woven fabric runs tangentially atop the sieve cylinders. The slurry through
the sieve cylinders gets filtered out. The differential hydrostatic pressure thus created
between the sieve cylinder and Vat causes an asbestos cement film to be formed and
picked up by the sieve cylinder which in turn gets transferred to the moving felt. The
gradually thickening slurry due to filtration is constantly diluted in the vats. The excess
water in film is dehydrated by vacuum system.
AC Flat Sheet Formation
The wet film from the felt is then transferred on to the rotating sheet forming drum of
requisite size.
After the required thickness is achieved the wet sheet is cut by automatic cutter fixed on
the sheet forming drum. The formed sheet is then trimmed widthwise with long cutters to
the required width. The length of the sheet varies as per the market requirement. After
cutting to the required length the sheet is transferred on to the Stacking trolleys by
vacuum sucking.
The formed sheets are stacked in between the hard & flat poly plates of adequate
thickness. These plates do not require oiling (each or four at the maximum, formed sheet
are sandwiched between two poly sheets)
Product Initial Curing & De-stacking
The Flat sheets thus made & stacked in between the Flat Poly sheets are air cured for
about 10 to 12 Hrs. in a closed (Heating) chamber.
After the air curing the sheets are separated out from the poly sheets in De-stacker
machine & then are cleaned and sent back to the Side Conveyor. The sheets then are
inspected on-line, stacked on steel pallets and cured for a week to 10 days before being
finally inspected & tested as per the prescribed specs and then dispatched
 KAMYA INDUSTRIES PRIVATE LIMITED

Process Description - The Manufacturing Process

Fibre (Non Asbestos) Cement (NAC) Flat Sheets

Raw Material Slurry Preparation

Pulp: A combination of either or all of the three varieties of Pulp, namely cellulose pulp or jeans
pulp or waste craft paper is opened and mixed well in water medium in a Pulper unit which is
then stored in Pulp Tanks, provided with stirrers. The pulp slurry is further opened, homogenized
& refined by re-circulating it through an assembly line of High Density Cleaner, Magnetic Trap
and Refiner. The refined pulp is stored in a Refined Pulp Chest, provided with a stirrer unit. Pulp
slurry is drawn in batches through the Dosing Tank from this Chest into the Beater Tank.
Cement: Cement received in bulk tankers or in bags is conveyed pneumatically and stored in the
Storage Silo. From silo it is then drawn through the weigh hopper into the Mixer Tank where a
certain quantity of water enough to convert the cement into slurry of flow able consistency has
already been taken.
Fly ash: Fly ash received in bulk tankers or in bags is conveyed pneumatically and stored in the
Storage Silos. From silos it is drawn into FA weighing & preparation Tank where it is converted
into slurry form. Then it is transferred to FA slurry tanks of adequate capacity, provided with
stirrer. This is then drawn, in batches into the Mixer Tank.
Silica: Silica received in bulk tankers or in bags is conveyed pneumatically and stored in the silo.
From silo it is then drawn through weigh hopper into the Mixer tank where the already batched
cement & fly ash slurry is present.
Ceramic Powder (Aluminum Hydroxide): Aluminum Hydroxide pre-weighed, is taken to
Mixer Tank. In Beater Tank is present the pulp slurry already taken from the refined pulp slurry
chest.
Bentonite – Bentonite received in bags shall be converted into slurry form in batches and shall be
stored in Storage tanks having stirrers. Then it is drawn in batches into the Beater Tank.
Cement, Silica, Fly ash and Aluminum Hydroxide which are in slurry form in Mixer Tank shall
be transferred to Beater Tank through Wet Rotary Sieve to join the mix of Pulp and Bentonite.
The slurry of all the raw materials from this Beater Tank shall be transferred to a Bucket Agitator
which will meet the requirement of main process plant.
Lamina Formation
The raw material slurry from Beater Tank is taken to the Bucket Agitator and thence to the
Dilution Tank where is also added the flocculent material in the appropriate dosage.
From Dilution Tank the slurry is taken to the 5/6 Vat Sheet Forming Machine, consisting of an
assembly of 5/6 vats with rotating sieve cylinders, one in each of 6 vats. The slurry is further
diluted in vats. During this process a film is formed over the periphery of sieve cylinders which
then is transferred on to the felt by couching action. The excess water in film is dehydrated by
vacuum system applied through the felt. The wet film is then transferred on to the sheet forming
drum of the appropriate size. As soon as the product thickness which varies between 3 to 30 mm
as per IS 14862 –2000 is attained, the sheet is cut off automatically from the Sheet Forming
Drum.
The filtered water (returned) from the sheet forming machine is taken to a series of Recuperative
tanks through back water pumps. At this point an anti foaming agent (Structol) in liquid form is
added drop by drop at the back water trench to suppress the foam.
NAC Flat Sheet Formation
The formed sheet is then trimmed widthwise with long cutters to the required width. The length
of the sheet varies as per the market requirement from 1.22 M to 3 M. After cutting to the
required length, the sheet is transferred on to the trolley by vacuum sucking and placed over hard
& flat poly plates of adequate thickness (each or four at the maximum, formed sheet are
sandwiched between two poly sheets). These plates do not require oiling.
Product Initial Curing & De-stacking
Product after an initial curing of 12 – 14 Hrs over trolleys, inside the closed chamber, is separated
from steel templates with the help of the De-stacker unit. Templates are sent back for recycling
after oiling & cleaning.
Product Autoclaving
The product after de-stacking is stacked over special trolleys with interleaves placed after every
120 mm height. The special trolleys with sheets and interleaves are pushed into the Autoclave.
Inside the Autoclave, the Steam pressure is built up by connecting it to a Boiler. After 12 to 14
Hrs of Autoclaving under a specified pressure and temperature, the trolleys carrying the sheets
are pulled out of the Autoclave. The autoclaved sheets and interleaves are separated on a machine
& the finished product is moved to the storage go-down for storage from where the product can
be loaded into trucks after inspection & testing.