Limestone/Clay Crushing

IT IS A SINGLE ROTOR
HAMMER CRUSHER, TYPE
MAMMUT – 75/90
SUPPLIED BY M/S. O&K
GERMANY, TWO UNITS
ARE INSTALLED, EACH
HAVING CAPACITY OF
750-820 TONS/ HOUR WITH
A MAXIMUM FEED SIZE
OF 800X1200X1400 MM TO
A PRODUCT SIZE OF 0-30
MM.
IT IS PRIMARILY USED TO
CRUSH THE LIMESTONE
BLASTED FROM THE
QUARRY ALONG WITH
CLAY AS PER THE QUALITY
REQUIREMENT AND FEEDS
THE PRODUCT TO THE
PRE-HOMOGENIZATION
STOCK PILES AFTER
PASSING THROUGH A
SAMPLING STATION.
IT IS A SINGLE ROTOR
HAMMER CRUSHER, TYPE
MAMMUT – 56/75
SUPPLIED BY M/S. O&K
GERMANY, TWO UNITS
ARE INSTALLED, EACH
HAVING CAPACITY OF
100-500 TONS/ HOUR WITH
A MAXIMUM FEED SIZE
OF 800X1200X1400 MM TO
A PRODUCT SIZE OF 0-30
MM
IT IS USED AS A
CORRECTION MATERIAL
FOR THE LIMESTONE AND
CLAY IN CASE OF
INFERIOR CONTENTS OF
Ca O. THE CRUSHED
PRODUCT IS STORED IN
PRE HOMOGENIZATION
STOCKPILES AS WELL AS
IN A CONCRETE SILO.
 Sampling Station

THIS IS AN ON LINE BULK

MATERIAL ANALYZING
SAMPLING STATION CALLED
“POLAB” SUPPLIED BY M/S.
KRUPP POLYSIUS, GERMANY. IT
IS INSTALLED IN BETWEEN THE
LIMESTONE / CLAY CRUSHER
AND PRE-HOMOGENIZATION
PILES

IT COLLECTS PREDETERMINED
QUANTITY OF BULK MATERIALS
– LIMESTONE / CLAY COMING
OUT OF THE CRUSHER ON
CONTINOUS BASIS AND
ANALYSIS OF INDIVIDUAL
COMPONENTS ARE BEING MADE
BY X-RAY ANALYZER. THIS
ENSURES MAKING O
PREHOMOGENISATION PILES AS
PER THE QUALITY
REQUIREMENT WITH DESIRED
SET POINTS. THIS ALSO ACTS AS
A TOOL FOR SECTION
OFDIFFERENT QUARRYING
OPERATION.

Raw Material handling (PREHOMOGENISATION)

EACH LIMESTONE / CLAY
CRUSHER AND HIGH GRADE
LIMESTONE CRUSHER IS
EQUIPPED WITH A BOOM TYPE
STACKER, TYPE –25 SUPPLIED BY
M/S. KRUPP POLYSIUS,
GERMANY, HAVING A CAPACITY
OF 1125 TONS / HOUR.

THE MAIN FUNCTION OF THE

BOOM STACKER IS TO MAKE A
PREHOMOGENISATION PILE OF
40,000 TONS CAPACITY IN MANY
LONGITUDINAL LAYERS AND
THIS KIND OF STOCKPILING IS
CALLED ‘CHEVRON’ TYPE
STOCKPILING.

THERE IS ONLY ONE BOOM

STACKER FOR ALL THE THREE
ADDITIVE MATERIALS VIX.
BAUXITE, IRON ORE AND SAND.

THIS IS ALSO VERY MUCH

SIMILAR TO THE STACKER
MENTIONED ABOVE, TYPE BA-20,
CAPACITY 3000 TONS / HOUR
SUPPLIED BY M/S. KRUPP
POLYSIUS, GERMANY.

EACH OF THE LIMESTONE / CLAY

CRUSHER AND HIGH GRADE
LIMESTONE CRUSHER UNITS ARE
EQUIPPED WITH BRIDE TYPE
RECLAIMER. TYPE BK – K2
HAVING A CAPACITY OF 500 TONS
/ HOUR EACH, SUPPLIED BY M/S.
KRUPP POLYSIUS, GERMANY.

THE MAIN FUNCTION OF THIS

RECLAIMER IS TO RECLAIM THE
MATERIAL FROM THE
STOCKPILES BY CUTTING IT
VERTICALLY, WHERIN VERY
GOOD HOMOGENISATION OF ALL
INDIVIDUAL LAYERS MADE
 LONGITUDINALLY BY THE
STACKER IS ACHIEVED.

THIS ENSURES HIGH DEGREE OF

UNIFORMITY IN THE MATERIAL
QUALITY BEING RECLAIMED
AND SEND TO RAW MILL.

THERE IS ONLY ONE SCRAPPER

TYPE RECLAIMER FOR ALL THE
THREE ADDTIVIE MATERIASL,
VIZ. BAUXITE, IRON ORE AND
SAND.

THE MAIN FUNCTION OF THIS

RECLAIMER IS SIMILAR TO
ABOVE, THE TYPE IS SK –18 – 200
SUPPLIED BY M/S. KRUPP
POLYSIUS, GERMANY, HAVING A
CAPACITY OF 200 TONS / HOUR.

CRUSHER FOR ADDITIVE MATERIAL

IT IS IMPACT TYPE BAR

CRUSHER, TYPE AP-SME-1313
SUPPLIED BY M/S. HAZEMAG,
GMBH, GERMANY. ONE UNIT IS
INSTALLED, HAVING A CAPACITY
OF 100 TONS/HOUR WITH A FEED
SIZE OF 30-500 MM AND A
PRODUCT SIZE OF 0-40 MM

IT IS PRIMARILY USED TO CRUSH

ALL THE ADDITIVE MATERIALS
REQUIRED LIKE BAUXITE, IRON
ORE AND SAND AFTER BEING
CRUSHED, INDIVIDUAL
 ADDITIVE

CRUSHER FOR ADDITIVE MATERIAL

EACH PRODUCTION LINE IS

EQUIPPED WITH ONE BALL
MILL FOR GRINDING THE
RAW MATERIAL.

IT IS A CLOSED CRICUIT, TWO

CHAMBERS BALL MILL WITH
A SEPARATE DRYING
CHAMBER SUPPLIED BY M/S.
KRUPP POLYSIUS, GERMANY,
IT IS HAVING A CAPACITY OF
360 TONS/ HOUR WITH 5%
RESIDUE ON 90 MICRONS,
DRIVEN BY A GEARLESS
DRIVE MOTOR OF 5900 KW
SUPPLIED BY M/S. A.B.B.
SWITZERLAND.

THE RAW MILL GRINDING SYSTEM IS INDEPENDENT OF KILN

SYSTEM, MEANS NO HOT GASES FROM THE KILN IS BEING USED
TO DRY THE RAW MATERIALS. INSTEAD EACH MILL IS EQUIPPED
WITH AN HOT GAS GENERATOR, CAPABLE FO USING OIL /
GASEOUS FUELS FOR DRYING THE RAW MATERIAL. THE
COMPLETE FIRING INSTALLATIONS WERE SUPPLIED BY M/S.
PILLARD, GMBH – GERMANY.

THE WASTE GASES OF THE RAW MILL GRINDING OPERATION ARE

DEDUSTED IN A TWO CHAMBERS, HIGH EFFICIENCY
ELECTROSTATIC PRECIPITATORS, SUPPLIED BY M/S. LURGI, GMBH
– GERMANY.

IN ORDER TO ACHIEVE HIGH QUALITY, UNIFORM RAW MIX FOR

THE KILN FEED, EACH OF THE RAW MATERIAL GRINDING
INSTALLATION IS EQUIPPED WITH A CONTINUOUS SAMPLING
STATION AND A CLOSE CIRCUIT QUALITY CONTROL SYSTEM
EMPLOYING AN ON-LINE X-RAY ANALYSIS CALLED “POLAB”
SYSTEM SUPPLY BY M/S. KRUPP POLYSIUS, GERMANY.

IN THIS PREDETERMINED QUANTITY OF RAW MILL PRODUCT IS

WITHDRAWN CONTINUOUSLY BY MEANS OF AN AUTO SAMPLER
AND THIS SAMPLE IS SENT AUTOMATICALLY TO THE LAB BY
PNEUMATICALLY, EVERY 30 MINUTES THE SAMPLE IS ANALYZED
FOR ALL CHEMCIAL CONTENTS AND THE OBTAINED RESULTS ARE
COMPARED WITH THE SET POINTS. THE DEVIATIONS IN THE SET
POINTS OBTAINED ARE CORRECTED AUTOMATICALLY BY A
PROCESS COMPUTER, WHICH IN TURN ADJUST THE FEED RATE OF
INDIVIDUAL RAW MATERIAL COMPONENTS GOING INTO THE
MILL, ENSURING PRECISELY THE DESIRED OUTPUT BEING
OBTAINED FROM THE GRINDING MILL.

CRUSHER FOR ADDITIVE MATERIAL

 EACH RAW MILL IS
PROVIDED WITH 2 NOS.
CONCRETE BLENDING SILO
EACH HAVING A DIMENSIONS
OF 16 MTR. DIAMETER, 24
MTR. HIEGHT WITH A
CAPACITY OF 3200 CUBIC
METER SUPPLIED BY M/S.
KRUPP POLYSIUS, GERMANY.

THE PRIMARY FUNCTION OF THE BLENDING SILO IS

TO MAKE PERFECT BLEND OF RAW MEAL STORED
IN THE SILO ASSURING UNIFORM HOMOGENOUS
MATERIAL LEAVING THE SILO. THIS ACHIEVED BY
AERATING THE SILO CONTENTS PNEUMATICALLY
WITH A CYCLIC AERATION OF VARIOUS SEGMENTS
INSIDE THE SILO..

Homogenization Silos

EACH RAW MILL IS

PROVIDED WITH 2 NOS.
CONCRETE BLENDING
SILO EACH HAVING A
DIMENSIONS OF 16 MTR.
DIAMETER, 24 MTR.
HIEGHT WITH A
CAPACITY OF 3200 CUBIC
METER SUPPLIED BY M/S.
KRUPP POLYSIUS,
GERMANY.

THE PRIMARY FUNCTION OF THE BLENDING SILO IS

TO MAKE PERFECT BLEND OF RAW MEAL STORED
IN THE SILO ASSURING UNIFORM HOMOGENOUS
MATERIAL LEAVING THE SILO. THIS ACHIEVED BY
AERATING THE SILO CONTENTS PNEUMATICALLY
WITH A CYCLIC AERATION OF VARIOUS SEGMENTS
INSIDE THE SILO.

Feeding System

EACH PRODUCTION LINE IS

EQUIPPED WITH A KILN
FEEDING SYSTEM CALLED
“POLDOS” SUPPLIED BY M/S.
KRUPP POLYSIUS, GERMANY.

THE MAIN OBJECTIVE OF THIS SYSTEM IS TO FEED

THE KILN WITH RAW MEAL PRECISELY
CONTROLLED QUANITY FROM THE STORAGE SILOS,
WHICH CAN BE CONTROLLED FROM REMOTE.

IT MAINLY CONSISTS OF SERIES OF RAW MEAL

EXTRACTION APPARATUS, AIRSLIDES, PNEUMATIC
CONVEYORS, VERTICAL BUCKET ELEVATORS, A
WEIGH BIN SUPPORTED ON LOAD CELLS AND
FINALLY A VERTICAL LIFT CONVEYOR TO LIFT THE
MEAL UP TO A HEIGHT OF 90 METER AND TO FEED
TO THE PREHEATER.

PREHEATER
 EACH KILN IS EQUIPPED
WITH A 4 STAGE
SUSPENSION PREHEATER
CALLED “DOPOL” TYPE –
2422 AND ON LINE
PRECALCINER CALLED
PREPOL – AS SUPPLIED BY
M/S. KRUPP POLYSIUS,
GERMANY. THE
COMBUSTION AIR FOR
THE FUEL SUPLIED IN
THE CALCINER IS TAKEN
FROM COOLER TAPPED AT
KILN HOOD THROUGH A
SEPARATE AIR DUCT
CALLED TERTIARY
AIRDUCT AND THE
VOLUME OF THE AIR IS
CONTROLLED BY 2 NOS
DAMPERS.
THE FIRST, THIRD AND FOURTH STAGE IS HAVING 2
NOS. CYCLONES AND THE SECOND STAGE IS
HAVING ONE CYCLONE AND THE INDIVIDUAL
CYCLONES ARE CONNECTED WITH EACH OTHER BY
MEANS OF HOT GAS DUCTS.

THE KILN FEED MATERIAL IS FED TO THE TOP

STAGE OF THE PREHEATER AND THE KILN HOT
GASES ARE SUPPLIED TO THE BOTTOM STAGE OF
THE PREHEATER. THE FEED MATERIALS TRAVELS
FROM TOP TO BOTTOM AND THE HOT GASES FROM
BOTTOM TO TOP AND DURING THIS PROCESS HEAT
TRANSFER FROM GASES TO MATERIAL TAKES
PLACE.

FURTHER AT THE RPECLACINER NEARLY 50-55% OF

TH TOTAL HEAT REQURED TO PRODUCE CLINKER IS
INTRODUCED BY TWO NOS. BURNERS WHICH CAN
USE EITHER GAS OR OIL FUEL. THE FIRING BURNER
INSTALLATION WAS SUPPLIED BY M/S. PILLARD
GMBH – GERMANY.

THUS AT THE BOTTOM OF THE PREHEATER THE

FEED MATERIALS IS PREHEATED AND PRECLACINED
BEFORE ENTERING THE KILN. THE WASTE GASES
LEAVING THE RPEHEATER IS PASSED THROUGH
THREE NUMBERS ELECTROSTATIC PRECIPITATOR
FOR DUST COLLECTION, SUPPLIED BY M/S. LURGI,
GERMANY. THESE FILTERS ARE OF SPECIAL DESIGN
CALLED “HOT ELECTRO-FILTERS” WHICH DOES NOT
NEED TO COOL DOWN THE WASTE GASES AND CAN
OPERATE WELL UPTO A GAS TEMPERATURE OF 440
DEGREE CENTIGRADE. THE COLLECTED DUST
FROM THE FILTER IS FED TO THE PREHEATER
ALONG WITH RAW MEAL.

Bypass System

THE KILN IS EQUIPPED WITH

A PROVISION OF BYPASSING
A MAXIMUM 20% OF THE HOT
GASES FROM THE KILN. THIS
IS DUE TO THE HIGH
CONCENTRATION OF
VOLATILE COMPONENTS
LIKE SULFUR ALKALIS AND
CHLORINE MAINLY COMING
FROM THE RAW MATERIALS
ITSELF.

THE TAKE OF DUCT IS WELL LOCATED AT THE KILN

INLET HOUSING, WHERE THE CONCENTRATIONS OF
VOLATILE MATTERS ARE MAXIMUM IN THE FORM
OF VAPOR. THE HOT GASES WITHDRAWN FROM THE
KILN INLET HOUSING ARE COOLED IN A MIXING
CHAMBER BY SUPPLYING ADDITIONAL COOLING
AIR FROM OUTSIDE. THE COOLED GAS PASSED
THROUGH AN ELECTROSTATIC PRECIPITATOR
WHEREIN THE DUST CONTENTS ARE COLLECTED.
THE COLLECTED DUST IS STORED IN AS MALL
HOPER, FROM WHERE IT IS EXTRACTED BY DUMP
TRUCKS AND DISPOSED OFF. THE BYPASS SYSTEM
IS DESIGNED AND SUPPLIED BY M/S. KRUPP
POLYSIUS, GERMANY AND THE ELECTRO STATIC
PRECIPITATOR FOR THE BYPASS SYSTEM WAS
SUPPLIED BY M/S. LURGI, GERMANY.

Rotary Kiln

EACH KILN IS HAVING

DIMENSION OF 4.6 METER
DIAMETER AND 70 METER
LENGTH, WITH A
PRODUCTION CAPACITY OF
3500 TONS / DAY CLINKER,
SUPPLIED BY M/S. KRUPP
POLYSIUS, GERMANY.

THE KILN TUBE IS INCLINED BY 3.5% SUPPORTED

ON 3 NOS TYRE/ROLLER ASSEMBLY AND DRIVEN BY
A VARIABLE SPEED MOTOR THROUGH A GIRTHGEAR
PINION ASSEMBLY. THE SPEED OF THE KILN CAN
RANGE FROM 0.3 TO 3.0 RPM.

THE PRE HEATED AND CALCINED MATERIAL FROM

THE PREHEATER BOTTOM STAGE CYCLONE ENTERS
THE KILN THROUGH A INLET HOUSING AND AFTER
PROCESSING AT A PEAK TEMPERATURE OF ABOUT
1400 DEGREE CENTIGRADE, THE CLINKER IS
FORMED IN THE KILN WHICH IS TRANSFERRED TO
COOLER FOR FURTHER COOLING AND HEAT
RECUPERATION.

THE KILN IS EQUIPPED WITH A BURNER

INSTALLATION WHICH CAN USE EITHER GAS OR OIL
OR BOTH AND SUPPLIED BY M/S. PILLARD –
GERMANY, ABOUT 45- 50% OF THE TOTAL FUEL
REQUIREMENT FOR CLINKER PRODUCTION IS
SUPPLIED IN THE KILN BURNER.
 Clinker Cooler

EACH KILN IS EQUIPPED

WITH A CLINKER COOLER
FOR COOLING THE CLINKER
AND ALSO TO SUPPLY
RECUPERATED HOT AIR FOR
COMBUSTION IN KILN AS
WELL AS IN PRECALCINER.

THE COOLER IS A RECIPROCATING CONTINUOUS

INCLINATION 3 GRATE COOLER, EACH GRATE IS
DRIVEN BY A VARIABLE SPEED HYDRAULIC DRIVES.
THE TOTAL COOLING AREA OF THE COOLER IS 124
METER SQUARE AND COOLING AIR IS SUPPLIED BY
10 NOS. COOLING FANS. AT THE END OF THE
COOLER, SINGLE ROTOR HAMMER CRUSHER IS
LOCATED TO CRUSH THE BIGGER SIZE CLINKER
AND LEAVING UNIFORM SIZE OF CLINKER AHVING
SIZE DISTRIBUTION 0-30 MM. THE COMPLETE
COOLER INSTALLATION WAS SUPPLEID BY M/S.
CLAUDIUS PETERS, GERMANY.

THE COOLING AIR PROVIDED IS UTILISED IN

COOLING THE HOT CLINKER AND DURING THIS
PROCESS THE AIR GAINS SUFFICIENT HEAT, FROM
THE HOT ZONES OF THE COOLER. THE
RECUPERATED HOT AIR IS TAKEN AS A
COMBUSTION AIR FOR KILN AND PRECALCINER.
THE ADDITIONAL WASTE ‘GAS OF COOLER’ IS SENT
THROUGH A DEDUSTING UNIT CALLED ‘GRAVEL
BED FILTER’ SUPPLIED BY M/S. LURGI, GERMANY.
THE DEDUSTED WASTED AIR IS SENT TO STACK AND
COLLECTED CLINKER DUST IS TAKEN TO CLINKER
STORAGE.
 Clinker Storage

EACH KILN LINE IS

PROVIDED WITH 2 NOS.
CONCRETE STORAGE SILOS.
EACH HAVING A CAPACITY
OF 40,000 METRIC TONS
CLINKER WITH DIMENSIONS
DIAMETER 35.00 METER AND
EFFECTIVE HEIGHT 42.5 MTR.
SUPPLIED BY M/S.KRUPP
POLYSIUS, GERMANY.

Gypsum Crushing

IT IS A IMPACT TYPE, SINGLE

ROTOR CRUSHER HAVING A
CAPACITY OF 100 TON / HOUR,
SUPPLIED BY M/S. HAZEMAG,
GERMANY. IT CAN FEED UP
TO A SIZE OF 40-500 MM WITH
A PRODUCT SIZE OF 0-40 MM.
THIS IS USED TO CRUSH GYPSUM TO BE USED
ALONG WITH CLINKER IN CEMENT MILL.

THE CRUSHED GYPSUM IS STORED IN TOW NOS.

STOCKPILE.

IT IS A SCRAPER TYPE RECLAIMER, HAVING A

CAPACITY OF 200 TONS / HOUR, SUPPLIED BY M/S.
KRUPP POLYSIUS, GERMANY.

IT IS USED TO RECLAIM GYPSUM FROM THE

CRUSHED STOCKPILE AND FEED TO CEMENT MILL
HOPPERS.

Cement Grinding System

IN ALL FOUR BALL MILLS

ARE INSTALLED FOR
GRINDING CLINKER AND
GYPSUM TO PRODUCE
CEMENT.
IT IS A OPEN CIRCUIT, TWO CHAMBER BALL MILL
SUPPLIED BY M/S. KRUPP POLYSIUS, GERMANY,
HAVING A CAPACITY OF APPROXIMATELY 105 TONS /
HOUR EACH AT A FINENESS OF 3200 BLAINE, DRIVEN
BY A GEARLESS VARIABLE SPEED DRIVE MOTOR OF
5250 KW EACH, SUPPLIED BY ABB, SWITZERLAND.

THE GROUND CEMENT IS PASSED THROUGH A

CONTINUOUS AUTO SAMPLER WHERE THE QUALITY
OF CEMENT IS MONITORED BEFORE IT GOES TO THE
STORAGE SILO.

EACH MILL IS PROVIDED WITH A CLINKER AND

GYPSUM HOPPER AND PREDETERMINED RATIOS
ARE SET FOR FEEDING.

Cement Silos
 FOUR CONCRETE CEMENT
SILOS WITH A TOTALE
STORAGE CAPACITY OF 40000
TONS EACH SILO IS EQUIPED
WITH MULTIPLE
EXTRACTION DEVICES TO
CATER THE NEED FOR
DIFFERENT SALES
REQUIRMENTS.

Cement Bulk-Loading

EACH CEMENT STORAGE

SILOS ARE PROVIDED
WITH ONE CEMENT BULK
LOADING TERMINAL,
CONSISTING OF A
VIBRATORY FEEDER,
TELESCOPIC CHUTE AND
WEIGHING STATION.
EACH ONE OF THE UNIT
IS HAVING A LOADING
CAPACITY OF 200
TONS/HOUR, SUPPLIED
BY M/S. KRUPP POLYSIUS,
GERMANY.

Packing Plant
 CEMENT FROM THE
INDIVIDUAL CEMENT
STORAGE SILOS ARE
EXTRACTED VIA-SERIES
OF EXTRACTION UNITS,
SCREW CONVEYORS AND
BUCKET ELEVATORS AND
TAKEN TO A SMALL
BUFFER BINS IN THE
PACKING PLANT.

FROM HERE THE CEMENT IS BAGGED BY 4 NOS.

ROTARY PACKERS AND 4 NOS. AUTOPACKERS TO
LOAD ON TRUCKS.

THE ROTOPACKERS ARE OF TYPE 6023 – 6RC,

SUPPLIED BY M/S. HAVER AND BOECKER, GERMANY
AND EACH IS HAVING A CAPACITY OF 100
TONS/HOUR.

THE AUTOPACKERS ARE SUPPLIED BY M/S.

BEUMER, GERMANY AND EACH IS HAVING A
CAPACITY OF 100 TONS/HOUR.