The basic raw material in the production of cement is Limestone. The Limestone ore as obtained from the mines is fed to the raw mills after first crushing it to an acceptable size. Certain additives such as Laterite and Bauxite are also used along with Limestone into the Raw Mills as per requirements. In Raw Mills, the above inputs are reduced to a particular fineness. The output of the Raw Mills, called ‘Raw Meal’ is then burnt in the Kiln and then cooled to produce Clinker.
The Clinker is thereupon fed into the cement mill and pulverized along with Gypsum to yield the Ordinary Portland Cement. A certain proportion of Clinker in the production of cement is replaced by pozzolanic material to produce Portland Pozzolana Cement (PPC).
Some key processes at a glimpse:
Limestone excavated from mines is transported through dumpers and fed to crushers where it is reduced to 25 mm size.
Environment-friendly Over Land Conveyor Belt transports the crushed limestone from the Crusher to the plant site over a distance of 7 km.
Scientifically designed Stackers provide for stacking of the limestone received from the mines in circular/longitudinal stock piles. Use of Reclaimers ensures consistency in quality.
State-of-the-art Vertical Roller Mill grinds limestone feed to powdered form called Raw Meal.
An advanced Coal Mill pulverizes the coal to be injected into Kiln for burning of Raw Meal.
Rotary Kiln provides for Clinkerisation wherein Raw Meal fed from VRM is first burnt to melting point (1400 degree celsius) and then cooled to 100 – 120 degree celsius by means of coolers immediately outside the Kiln to produce Clinker.
Close Circuit Cement Mill ensures high-quality grinding of clinker, gypsum, and pozzolana to yield best possible uniformity of the cement particles.
Centralised control room monitoring the manufacturing process through computers.
Packing Plant is equipped with computer-controlled electronic packers for accurate cement packing. Manual check is also carried out at random to monitor the computer-controlled process and introduce correction as applicable.
Loading of bags in the wagon/trucks is carried out automatically by means of wagon/truck loading machines, equipped with electronic loading counters which accurately keep count of the number of bags being loaded. Efficient logistic and transportation network ensures prompt delivery of materials to the customers.