CEMENT MANUFACTURING

From a modest beginning of 2 Lac tonnes capacity per annum, it was gradually increased to 2.2 Million tonnes in the year 2001. Presently both the plants employs the Modern Dry Process Technology. It has most Advanced, Sophisticated, Equipments with centralised control room for process control, the advanced instrumentation with Expert system and elaborate display screen give up-to-the minute information on the production process so that any deviation can be promptly corrected.
Limestone Mines are located at about 3 kms. from the factory. The mines are fully mechanized and has also a terminator for mechanized breaking of individual boulders. The Crusher is located at Mines and crushed limestone is transported by long belt conveyors to factory. The entire quantity of crushed limestone passes through the online cross belt analysers and is stacked at the pile in the factory. Three numbers of separate stacker-reclaimer are available with truck tipplers for proper stacking and

reclaiming of corrective raw materials, fuels and additives. Stacker Reclaimers help to achieve high degree of stacking and ensure maximum level of consistency for the input materials to raw mill, coal mill and cement mill. Pre-stacked limestone of stockpile is ground in the VRM along with corrective materials with required ratios are made to produce raw meal and that is stored in Blending cum Storage Silo. There are separate hoppers with weigh feeders for continuous and regulated addition of each raw material. The mix passes through the cross belt analyser which analyze the mix chemistry and solve the mix ratio every minute to have very good consistency in the raw mix.
Raw meal extracted from silo is fed to the kiln where it is sintered at about 1400o C to clinker. This process is called pyroprocessing which consists of a five stage suspension preheaters with precalciner, the kiln and the clinker cooler. Clinker cooler with CIS and CFG for maximum heat recuperation and the cooled clinker is transported to a storage silo. Finally, grinding is done in OK Vertical Roller Mill for optical particle size distribution and less power consumption with excellent ease of operation for feeding, grinding and classification. To maintain quality of various types/grades of cement, there are separate hoppers with weigh feeders for the addition of fly ash, gypsum, etc. Quality of final product is monitored and controlled every hour by testing samples in the XRF analyser. Final products are stored in cement silos.