Raw Material Receiving & Storage |
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Limestone: Limestone from quarry is fed by dump truck to single rotor crusher having a capacity of 1000 t/h. Crushed limestone is transported by belt conveyors up to the limestone storage yard having a storage capacity of 22.500 tons X2 piles or transported to limestone hopper directly. |
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| Limestone stocked in storage yard is extracted by reclaimer and transported to raw material mixing hopper. | |
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Schist: Schist from quarry is fed by truck to single rotor type crusher having capacity of 400 t/h. Crushed schist is transported by belt conveyors up to schist hopper directly or schist open yard stock. |
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Iron Ore: Iron ore from storage is crushed with the crushing capacity of 150 t/h and transported by using the same line for schist crusing with time sharing operation and transported iron ore hopper or to iron ore open yard storage. |
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Sand: Free sand is stocked at sand storage yard after transportation by trucks. Sand is fed by wheel loader to sand receiving hopper on the belt conveyor then transported by the belt conveyor up tot he sand hopper. |
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Gypsum: Gypsum is fed by dump truck to the single rotor type crusher having a capacity of 40 t/h crushed. Gypsum is transported by belt conveyors and bucket elevators up to Gypsum bin. |
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Raw Material Mixing & Grinding |
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The Grinding Process: Weigh feeders are provided under Mixing Hoppers. Weigh feeders extract and feed required quantity of limestone, shist, iron ore, and sand to the Raw Mill through belt conveyors, for material grinding and according to raw material specifications, a vertical roller mill of 340 tph capacity is provided due to its very low power consumption. |
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The Mixing Process: The Mixing system comprises a multi feeding system and 2 continuous mixing silos, capacity of each is 10000 tons. |
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Thermal Processing |
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Clinker Burning: Homogenized raw meal is sent to kiln feeding system via air slides and bucket elevators. UNSP preheater comprises of five-stages preheater, two strings with UNSP precalciner. The size of our rotary kiln is 68m X 4.55m supported by three sets of roller tyres. Kiln by-pass dust treatment system (up to 30%) is provided to prevent harmful materials coating on the transition point betweensuspension preheater and rotary kiln. |
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| The system includes dust palletizing facilities, which converts the by-pass dust to pellets and enables simplified disposal, without generating dust during transportation. Heavy fuel oil (Bunker - C) is used as fuel for Pyroprocessing system. | |
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Clinker Cooling: Clinker is cooled down with a 4000 tons capacity cooler, area of which is 72.8m2. The cooled clinker is 80 degrees hot. |
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Final Processing: |
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Clinker Transport & Storage: Clinker from the cooler is transported to two clinker silos 15000 tons capacity each or to unburnt clinker bin, by a system of pan conveyors. Clinker Grinding and Cement Storage: Two set of ball mills are provided in close circuit grinding systems (2 X 110 TPH) with high efficiency separator (O-SEPA). Cement Mill #1 upgraded to produce 180 tph during the year using roller press technology. The finished cement is transported to four cement silos, of 10.000 tons capacity each by Air slides, conveyors, and bucket elevators. |
Packing & Dispatch |
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Bagged Cement Loading: 4 sets of Rotary Packer having capacity of 2.400 bags/h are provided. 4 sets of Automatic Bag Loader and one Manual Bag Loader for loading onto trucks. Bagged cement is loaded onto trucks by workers through manual loader. |
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Bulk Cement Loading: 3 sets of Bulk Loaders having a capacity of (2 * 150 tph), (1 * 170 tph) each are provided, with their allocated weigh bridges. |
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