2021

CEMENT PRODUCTION REPORT

SUBMITTED BY:

Salman Imtiaz (Trainee Engr.)

Muhammad Saad (Trainee
Engr.)
Osama Rehman (Trainee Engr.)
AREA 111 EQUIPMENT:
1) HOPPER: (HO01)
 Cement Hoppers are widely utilized for carrying and transporting large amounts of
cement.
 Its capacity is 200m3

2) APRON FEEDER (AC03):

 The apron feeder is a kind of continuous conveying material machinery.
 Drive type : Single Drive-Left
 Capacity: 1440t/h
 Feeding Size: 1500x1000x1000mm
 Feeding Speed: 0.049-0.146 m/s
 Inclination: 20o
 Motor: MT01 (variable frequency motor) 90Kw

3) HAMMER CRUSHER (HC06):

 Hammer is used to crush the mineral of a hard brittle material. 
 There are 2 discs inside the crusher. Each disc contains 6 shafts and each shaft has 8
hammers on it. In total there are 48 hammers on 1 disc.
 Hammers are changed after crushing 25 to 30 lacs ton of material.
 Capacity: 1200t/h
 Drive Type: Double Drive
 Crushed material is approximately less than 55mm.
 Motors: 800Kw (2)
 The weight of each hammer is 160kg and it gets replaced when it loses 15-20 percent of its
weight.
 After crushing 15 lac tons of material, face of the hammer is changed to the other side for
further working.
 There are manganese lining plates inside the crusher which protects the outer casing of the
crusher itself.

4) BELT CONVEYOR:
 The belt conveyor is mainly used for long-distance transportation of powder and small
block materials.

5) BAG FILTER:
 The bag filters are important equipment in cement factory. In these filters current flow that
includes gas and dust cross through the pores are located in the stuff filter and filtrate by that
remaining on the bag. Afterward, by dust increase on the bag, the filter is shaken until dust
collecting leads to exit hopper.

6) FAN:
 Fans in cement industry are heavy duty and perform two basic functions i.e., supply of air or
removal of exhaust gases and material handling. There are many process fans that find

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 applications in cement industry such as raw mill fans, induced draft fans, cooling fans, raw mill
exhaust fans, coal mill fans and cooler exhaust fans.

7) STACKER (ST13):
 A stacker is a large machine used in bulk material handling. Its function is to pile bulk material
(limestone) on to a stockpile.
 Capacity: 600t/h
 Power: 90Kw

8) MAGNETIC SEPARATOR:
 It is a magnetic separation equipment to extract tramp metal before crushers, grinding circuits
and other sizing equipment.
 Belt Width: 1400mm

9) SLIDE GATE:
 Slide gates are used in the cement industry to shut off silos, bins, containers and
cyclones. A further field of application is their use as a shut-off device beneath
proportioning machines, such as screw conveyors and air slides.

AREA 211:
1) RECLAIMER:
 Reclaiming takes place at the natural angle of slide. A raking harrow is mounted on the bridge
reclaimer which rotates anti clockwise around the central column.
 The sweeping movements of the harrow system cause the material to slide to the base, where
the chain system then conveys it to the centrally placed outlet hopper.
 The material leaves the store by an underground rubber belt conveyor leading either to a
hopper or direct to a cement raw mill.

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REPORT 111

111.The process starts with feeding raw material via Cranes into a hopper of 200m³ capacity. It is then
moved onto an apron feeder (Single drive, 144~1440 t/h capacity, 0.04~ 0.146m/s feed speed and size
BZ 2300x12000mm) driven by a 90kw and 400V motor. The raw material is crushed in a double drive
hammer crusher driven by motors of 800kw each. It contains 6 shafts and each shaft has 8 hammers for
crushing material. The feed moves on to a single drive belt conveyor BC07 (capacity 1200t/h, size
1800x23700mm) driven by a 30kw motor. Material moves on to the next single drive Belt conveyor BC
12 (1200t/h capacity, 2m/s speed, lifting height 13.7m, 1400x200000mm size) driven by 160kw motor.
The feed is then sent to single drive Belt Conveyor BC17 (size 1400x112000 mm, capacity 1200t/h, speed
2m/s, inclination 12° and height of 14m) in case of limestone mix, driven by 160kw motor.

After diverter the other raw materials can be fed to the side stacker through single drive belt conveyor
BC 21 (720 t/h capacity, 1000x120000 mm size, speed 1.6m/s, height 12m) driven by 75kw motor. The
stacker ST22 has a capacity of 1200t/h, a stacking radius of 90m and total power of 259kw. The side
stacker ST13 has a capacity of 600t/h and 90kw power.

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REPORT 211

The stock after being stacked is moved further by Reclaimer RE01 (90m size, capacity 600t/h,) having 6
motors of different ratings.

The material is sent to the belt conveyor BC04

(600t/h ~ 5000m³/h, size 1000x55000mm) via reclaimer, hopper HO02 (25m³) and needle gate NG03
(600x1800mm). It is then moved to another belt conveyor BC05 (600t/h) through a magnetic separator
MS10.

Side Stacker Area 212

The Side stacker stacks piles of Laterite and Limestone each 4000t. A side type Scraper Reclaimer RE10
(200t/h) sends materials via hopper H008(5m) and Needle Gate NG07 (2500x500mm) on to a single
drive belt conveyor BC11 (200t/h, 650x112000mm and 24m lifting height), it is then shifted to a single
drive Belt Conveyor BC18 (200t/h, 16m/s, 3.5m lifting height), moving forward to single drive Belt
Conveyor BC12 (200t/h, 650x112000mm, 1.5m/s). Then comes the belt conveyor BC13 (single drive,
800x10600mm, 2001/h, 1m/s) The feed through 212 moves to2 16h004.

Raw Material Mixing Area 216

Mix limestone is coming from 2118C05 into silo having diameter of 10m and height of 23m. The capacity
of the silo is 1200 ton where the limestone coming from the stacker is stored. Alongside, additives are
coming from the side stacker. Laterite comes from belt conveyor 212B013 into silo containing HO04
hopper having capacity of 350 tons. HG Limestone comes from 212BC13 into silo containing hopper

HO07 Having capacity of 350 tons. Each silo pours material onto its respective weight feeder in
appropriate proportions via needle gates (1000x1000mm). Further, a single driver belt conveyor
2165010 (1000 83000mm, 500t/h/11000mn material lifting Height) carries the poured material to
another single drive belt conveyor 2168C33 (1000-62000mm, 5001/h, 15.7 material lifting height). The
material then enters into raw press area.

Raw Material Grinding Area 216

Material from belt conveyer 216BC3 enters into the V Separator having feed capacity of 1500t/h where
one and coarse material is separated based on their densities, fine material is sucked into dynamic
separator while coarse material falls under the influence of gravity onto the Bucket Elevator 216BE41
which takes the material to the top and pours into the feeding bin 216843. On the way to the feeding
bin, there's a magnetic separator mounted which removes any metal material from the raw material.
The coarse materials then entered into the press rollers via needle gate and pneumatic slide gate. The

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diameter of each roller is 2200mm and width is 1500mm and grinding output capacity is 480 t/h. The
Feed size to the roller is within the range of 55mm to 30min, The material which is grinded to the fine
powder form is sucked into the dynamic separator while the material that remains coarse is put back
into the V Separator via bucket elevator 2168E53 having capacity 1900 t/h This process keeps on
iterating until the material is converted into the powder The material which goes to dynamic separator
is

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