The process is divided in 3 parts:Raw Materials- Raw Mill Section
- Kiln Section
- Clinker Grinding Section
1. Raw Mill Section :All the raw materials should be of less than 25 mm size. If the
size of the raw material is bigger than 25 mm, It has to be crushed
through a crusher and Hammer Mill. All the materials are crushed
stored in the storage yards through belt conveyors.
Now, the raw materials are taken as per their required percentage
with the help of a weigh belts( Control by PLC ).The measured
materials is went to feed belt conveyor and after that shifted to a
feed hopper through elevator .The feed of material is controlled
with the help if ratchet Feeder/Table feeder.
2. Kiln Section :From Surge silo the mixed raw materials are taken to Nodulizer with
the help of a screw conveyor.Then water is sprayed on the mix (10%)
to make nodules with the help of nodulizer. These nodules are fed
into the Kiln through feed chute for burning and Fusion. The
temperature goes up to 1350OC in the burning zone. The material
travels very slowly in the Kiln. All the material get fused here.
After passing through the burning zone the material starts cooling
slowly. The Clinkerisation starts and the clinker finally comes out
of the Kiln.
3. Clinker Grinding Section :The clinker so obtained is crushed to make its size less than 25
mm. The crushers/Roller crusher are used to crush the clinker. The
Gypsum is used as an additive. Both material crushed together and
went into feed hoppers through elevator. They are collected through
the feeders provided below the feed hoppers. The clinker and gypsum
are mixed in certain ratios (5%). So, the weigh belt is used to
weigh the ingredients for mixing. A modern electronic weighing
& control system may also be used to weigh and measure the
ingredients The ratchet/Tables feeder is used to control the feed
in the mill and control the fineness of the Cement.
The ground Cement is taken to the aeration and storage silo with
the help of elevator or air lift.The aerated Cement is filled in
50Kg bags with the help of packing machine. The product is stored
in the godown through belt conveyor and stacking/dispatched as per
requirements. The pollution control equipments are necessary as
there may be dusting in the plant.
