Cement manufacturing Process. Details of Machinery, Production Rate. Case Study of Zeal Pak Cement Industry at Hyderabad, Sindh. Special zoninf for cement industry

1. CEMENT INDUSTRY
PROGRAM DEVELOPMENT
NAME: RANA AHTISHAM
ROLL NO. CE15AR35

2. BACKGROUND:
1947, 4 cement factories (located at Karachi, Rohri, Dandot and
WAH.) 470,000 tones capacity 1956 two plants were established at
Daudkel and Hyderabad (Zeal Pak Cement Factory). 1972 State Cement
Corporation of Pakistan (SCCP) was established Economic Reforms
Order. acute shortage of cement in late 70s and early 80s. This gap was
filled by the import of cement
1991, 7 new plants were installed in private sector. Government of
Pakistan, has privatized 8 cement plants since 1992. The units
established in the private sector are new, efficient and use “dry process”.
At present there are more than 29 cement plants in Pakistan with
installed capacity of over 19.5 million tones per annum.
Reference
www.ravimaxine.com

3. TYPES OF PROCESS:
• Wet Process
• Dry Process
• Pre-heater/ Pre-claimer process
Process
Current
Production
Remarks
Wet Process 5% Old Process
Dry Process 74%
Most
Common
Process
Pre-
Heater/Pre-
Claimer
Process
15-20 %
Newest
Process

7. Major spaces & MACHINES USED IN MANUFACTURING of cement:
• Lime Quarry Machinery
• Stacker & Reclaimer
• Limestone Bunker
• Raw/Ball Mill
• Silos
• Coal Mill
• Pre-heater
• Rotary Kiln
• Kiln Cooler
• Cement Mill
• Packing Plant Machinery

8. LIME QUARRY MACHINE:
In Quarrying the Limestone, heavy earth equipments
are used.
• Quarry Machine
• Bulldozer
• Pay loader
• Dumper

9. STACKER & RECLAIMER:
Stacker is a large machine used in bulk material
handling. Its function is to pile bulk material such as
Limestone, ores, etc, on to a stockpile.
A Stacker normally travel on rail between
stockpile in the stockyard. A stacker can usually
move in at least two directions: horizontally along
with rail & vertically by luffing (raising & lowering
its bottom).
A Reclaimer can be used to recover the material.
What we should do…
• Need a large space with high ceilings.
• Needs 10% covered area of manufacturing parts.

10. LIMESTONE BUNKER:
It is used for the storage of crushed Limestone.
The material is fed into Bunker from reclaimer
followed by belt conveyor.
What we should do…
• It is a silo structure (recommended).
• Needs 20% of total storage.

11. RAW/BALL MILL:
Raw/Ball mill contains 3 chambers : Dry, Coarse,
Fine. The material is fed to the ball mill in the inlet
side & the gas from pre-heater outlet is also fed in
the inlet of ball mill. Once the material is moved
through all 3 chambers.
What we should do…
• A House Mill is made separately.
• Needs 15% of total covered area.

12. SILOS:
It’s a large storage of Raw meal which comes
from Raw mill. It made up of concrete & can store
Raw meal for long time.
What we should do…
• Depends upon production.

13. VERTICAL COAL MILL:
Vertical coal mill is typically designed to process materials in medium hardness,
like soft coal or bituminous coal, and it is mainly used in positive pressure
pulverizing system of soft coal.
It is an ideal device that integrates crushing, drying, grinding, and grading
conveying all together.
What we should do…
• It can be place within the Cement Mill.
• Because of its vertical structure, it do not need
a larger space.

14. PRE-HEATER:
The purpose of Pre-heater to increase the
temperature of Raw mill material through the
incoming hot air from kiln and transfer air duct.
What we should do…
• Provide a space along with horizontal kiln to
place Pre-heater Machine

15. ROTARY KILN WITH COOLER:
It’s a cylindrical rotary equipment rotating on
rotating rollers. Due to inclination of cylinder and
slow rotation of material, the material roll in hoop
direction.
It is used to convert Raw material into Clinker.
After cooling of the clinkers, either it moves to Silo
(as clinkers also sale out in market) or to Cement
Mill.
What we should do…
• Provide a huge space for multiple kilns.
• Almost 30-40% of manufacturing part, is used for
kilns and its supporting mechanism.

16. CEMENT MILL:
A cement mill (or finish mill in North American usage) is the equipment used to grind the hard,
nodular clinker from the cement kiln into the fine grey powder that is cement. Most cement is
currently ground in ball mills and also vertical roller mills which are more effective than ball mills.

17. ROTARY KILN WITH COOLER:
It’s a cylindrical rotary equipment rotating on
rotating rollers. Due to inclination of cylinder and
slow rotation of material, the material roll in hoop
direction.
It is used to convert Raw material into Clinker.
Sloping of kiln is 3-4% of total length.
What we should do…
• Provide a huge space for multiple kilns.
• Almost 30-40% of manufacturing part, is used for
kilns and its supporting mechanism.

18. Pneumatic Bag Packing Machine
• Capacity : 3 - 10 ton per hour
Mobile Bag Packing
Machine
Capacity : 3 - 10 ton per hour

19. CONVEYORs:
• Belt Conveyor
• Capacity : 3 - 40 ton per hour Frame Height: 51mm (2”)
• Widths: 48mm—650mm (1.8” - 25.6”)
• Lengths: 610mm — 12192mm (2 - 40 ft)
• Speeds: Up to 400 FPM
• Screw Conveyor
• Sub-drive throughWorm ReductionGear Box.
• Capacity : 3 - 20 ton per hour
• Bucket Conveyor
• Capacity : 3 - 3 ton per hour

20. crusher:
• Jaw Crusher
• Feed size>500 mm
• Product size < 5 mm
• Capacity : 3 - 30 ton per hour
• Roller Crusher
• Feed size > 500 mm
• Product size < 5 mm
• Capacity : 3 - 25 ton per hour
• Hammer Crusher

21. Dry process cementproductionline （25-200t/d）Configuration

22. Global
Production
of Cement

24. In all the cement production processes there are hazards that can
be classed in:
Safe behavior
Environment,Work and PassageAreas
• Routine and general hazards such as: Safety labeling & Personal
Protective Equipment (PPE)
• Special hazards during the cement production phases such as:
Quarrying, Crushing, Clinker production, Milling processes at raw mill,
cement milling and coal milling, Material transport, Storage o Use of
hazardous material o Isolation
• Special hazards as a result of the work environment: Dust, Noise,
Fire, Emergency response
Workers’ Safety

25. BUBBLE DIAGRAMS:
• Quarrying
• Stackers & Reclaimer
Step 1: Crushing
• Adding water in Ball
Mill
• Without water in Ball
Mill
Step 2: Mixing
• Kiln used to burn
material & to convert
it into Clinkers
through cooling.
Step 3: Burning
• Clinkers either store in
silos or go to packing
plant.
• After packing cement
is ready for shipping
Step 4: Packing

31. ZEAL PAK CEMENT FACTORY, HYDERABAD