1. The cement manufacturing process begins with limestone, the basic raw material used to make cement, is transported by rail to the plant from the limestone quarry
2. The limestone is combined with clay, ground in a crusher and fed into the additive silos. Sand, iron and bottom ash are then combined with the limestone and clay in a carefully controlled mixture which is ground into a fine powder in a 2000 hp roller mill.
3. Next, the fine powder is heated as it passes through the Pre-Heater Tower into a large kiln, which is over half the length of a football field and 4.2 metres in diameter. In the kiln, the powder is heated to 1500 degrees Celsius. This creates a new product, called clinker, which resembles pellets about the size of marbles.
4. The clinker is combined with small amounts of gypsum and limestone and finely ground in a finishing mill. The mill is a large revolving cylinder containing 250 tonnes of steel balls that is driven by a 4000 hp motor. The finished cement is ground so fine that it can pass through a sieve that will hold water.
5. The cement manufacturing process consists of many simultaneous and continuous operations using some of the largest moving machinery in manufacturing. Over 5000 sensors and 50 computers allow the entire operation to be controlled by a single operator from a central control room.
Process of Manufacturing Cement
Crushing Section: -
The raw materials mainly limestone, clay, coke are crushed in the separate crushers and stored automatically into the respective silos.
Storage & Proportioning: -
The different raw materials are extracted from the silos in the desired proportion through table feeders and conveyed to raw mill.
Raw Milling: -
The raw mix is ground into a Ball Mill at desired fineness to produce Raw Meal, and transported for Homogenizing.
Blending & Homogenization: -
The raw meal is homogenized in the blending silos, and is stored automatically into a storage silo for feeding to the kiln.
Palletizing & Burning: -
The nodules are made into a nodulisor and charged into the kiln for burning. The clinker after discharge is stored in the clinker yard through deep Bucket Elevator.
Clinker/gypsum crushing, storage & proportioning: -
Clinker & Gypsum after crushing stored into the hoppers and extracted in the desired proportion with the help of table feeders and transported to the Cement mill Hopper.
Cement Milling: -
The clinker & Gypsum mix is ground in the cement mill to produce cement.
Storage & Packing:
- The cement is stored into the cement silos and aerated, tested and packed for dispatch.
