By: Muhammad Akmal Qayyum yang handsome gilerr

Quarry Mining Plan

 Limestone Reserves & it’s related challenges.
The main challenges at the limestone reserves is the impurities in the
limestone which mainly consists of Magnesium Oxide (MgO). Due to the
hardness of the MgO in the stone, there will be more wear and tear of the
drilling tools.
Other than that, the limestone reserves used here is from a tin ore mining
remnants, where there’s a lot of wet soil accumulated in these remnants.
The plan design used by Sinoma (equipment manufacturer) is based on
their project in Syria. In Syria, the soil is dry and easier to deal with,
while in Malaysia the soil is wet. Presence of excessive wet soil and clay
often caused the crusher to get blocked. So Crusher had to be clean often
especially during rainy days where this caused the production to be
decrease.
 What are the key quality parameters that influence the stone
excavation process?
The key quality parameters that influence the stone excavation process is
the impurities ratios such as MgO ratio and also other minerals
composition such as clay. These factors are important to ensures the
quality of the raw materials is consistent and within the desired level.
Other than that is the moisture content of the stone as it will affect the
grinding process and the energy required for daily operation.
 How to deal with limestone reserve with high Magnesium Oxide
(MgO) and its adverse effect towards clinker/cement quality?
There are some places that has a higher Magnesium Oxide and some
places that has a lower Magnesium Oxide. So in order to balance the
quantity of the magnesium oxide, saving the cost and to kept the quality
of the materials at the desirable level (3.5% MgO), quarry team will
instruct the contractor to mix the materials together by using excavator,
before discharging it into the crusher.

Crusher
 What type of crushers are used in Hume Cement?
Double Rotor Hammer Crusher
 Detailed specification such as capacity, drive mechanism and output
size?
Crusher Type: TkPC®20D20
 Maximum feed size: 1200x1200x1200mm
Discharge size: 95% under 75mm
Capacity: 1200t/h
Motor power: 2x710kW
Voltage: 6600 v
Dimension (Auxiliary equipment not included): 5670x3850x3570mm
 Sketch & label the critical components of the crusher and describe
the function.

 What are the adjustment to be made to achieve the stone size?

The adjustment that are usually used to achieve the stone size is by
adjusting the gap between the grate and the rotor by using adjusting grate
device. Other than that, regular inspection of the hammer is done to make
sure the crusher can perform at optimum level.
 What is the role of Wobbler Feeder?
The role of wobbler feeder is to discard soil from the stone to avoid
blockages of the crushers due to excessive wet soil content especially
during rainy season. As an example, in the past, the quarry team had to
deal with soil blockage during rainy season which had a downtime of >33
hours and chute cleaning work had to be done for 40 times. This greatly
reduce the productivity of the crusher.
 Describe to common maintenance issues faced in the crusher.
The most common issues faced in the crusher is the hammer, the rotor
and the grate. These are the most critical components in crushers that
required regular maintenance and inspections to make sure it works well.
Hammer wears out a lot due to the high impact force as its primary
function is to crush big limestone boulders into desired size. In this case,
the standard size is between 75mm – 105mm. Often after 6 months of
usage, one side of the hammer will be worn out, so after making the
necessary inspection during shutdown, the shaft that was holding the
hammer will be taken out and the hammer will be reversed to the other
side that is still not worn out yet. After a year, when both side of the
hammer is worn out, the hammer will be replaced with a new one.
Other than that is the rotor. When hammer is totally worn out and unable
to perform effectively to crush the boulders, the rotor will take the
impacts and these can cause cracking and eventually breaking the body of
the rotor. So, hardfacing welding is very necessary to protect the body of
the rotor so that, the rotor can be used for longer period of time.
 List out important inspections to be performed for the internals
Before we list out the important inspections to be performed for the
internals, we need to know their primary and secondary wear. So for rotor
the primary wear is the abrasion from the materials and the secondary
source of wear is the impact which supposedly unlikely to be happened.
While for the hammer, the primary source of wear is the impact from the
limestone boulders, and the secondary source of wear is the abrasion.
So the important inspection for crusher’s internals that need to be
performed is mainly the hammer, rotor, and the grate. The hammer
 Propose an improvement plan to improve the reliability
Using hardfacing diamond shape (1”x1”) 8mm height to protect all the
critical components especially the rotor body. The type of welding rod
preferably to be used is manganese electrode (XALOY52) + hardfacing
electrode Diffusaloy 6180+ EutecTrode® ChromCarb N6006 electrode.
1. XALOY52 (Manganese Electrode):
Application: Used for welding and buildup on manganese steel parts.
Purpose: Provides high-strength welds and is specifically designed for
manganese steel, offering excellent impact resistance and abrasion
resistance.
2. Diffusaloy 6180 (Hardfacing Electrode):
Application: Utilized for hardfacing applications to enhance the wear
resistance of steel components.
 Purpose: Forms a hard, wear-resistant surface on the base metal,
protecting it against abrasion, erosion, and impact. It is often used in
high-stress applications where the component is subjected to severe wear.
3. EutecTrode® ChromCarb N6006 (Anti-Wear Protective Coating
Electrode):
Application: Specifically used for anti-wear protective coating against
combined abrasion, pressure, and impact on steel components, including
low alloy and manganese steel.
Purpose: Forms a protective coating that resists wear caused by abrasion,
pressure, and impact. This coating enhances the durability and lifespan of
steel components, especially in harsh industrial environments.

Stacker & Reclaimer.

 Identify what type stacking of the beds. – longitudinal or circular,
Chevron or Windrow?
The type of stacking of the beds is Endless Circular Chevron Stacking.
 Method of reclaiming – scraper, bucket or disc?
Scraper and Bucket reclaiming method. Where the
 Common maintenance issues
Most common maintenance issues are Bucket Reclaimer loose and
dislodged.
 Why stacking and reclaiming is referred as pre-homogenization
process?
During the stacking process, raw materials, including limestone, are
arranged in layers. The circular chevron stacking method, create stable
piles that minimize segregation and maintain material consistency.
Bucket reclaimers can handle and adapt to various material
characteristics, this ensure that the material extracted from the stockpile
remains consistent in composition.
 How does this process influence the clinker chemistry?
The process of pre-homogenization on the clinker chemistry caused the
chemical composition to be uniformed leading to predictable chemical
reactions during clinker formation. Variations can cause fluctuations in
clinker composition, affecting the quality of the final product. It also
reduces unwanted impurities which it will allows removal or blending of
impurities like MgO or S in limestone. Controlled impurity levels will
avoid issues like expansion or delayed setting in cement, ensuring clinker
quality. Lastly it maintains the consistency ratio of Limestone-Raw Mix
 which affects formation of clinker phases, directly influencing cement
properties.

My Info
1. Pre-Homogenization: process in which the raw materials used in the
manufacturing of cement are mixed to ensure that the composition of the
mixture is consistent from one batch to another. This process aims to reduce
the chemical and mineralogical variations in the raw materials, creating a
uniform mix that can be used in the production of high-quality cement.
The raw materials for cement production, such as limestone, clay, shale, silica,
and iron ore, often have natural variations in their composition. These variations
can affect the quality of the final cement product. Pre-homogenization involves
blending these raw materials in a controlled manner to achieve a consistent
mixture before they are fed into the kiln for the clinker-making process.
There are several methods of pre-homogenization, including the use of stackers
and reclaimers. Stackers are used to stack the different types of raw materials
in layers, ensuring a homogeneous mix. Reclaimers are used to reclaim and
blend the stacked materials, further homogenizing the mixture. This pre-blended
material is then transported to the raw mill for grinding, where it is converted
into a fine powder. This powder, after grinding, is known as raw meal and is
used in the production of cement clinker through the kiln process.
By ensuring a consistent composition of raw materials through pre-
homogenization, cement manufacturers can produce cement with predictable
and desirable properties, leading to a high-quality end product. Consistency in
raw material composition is crucial for the chemical reactions that occur in the
kiln during the cement-making process, ultimately influencing the strength,
setting time, and other properties of the cement.
Operational team – production, maintenance, quarry, quality process departments.

Support Team – Human Resources, Finance, Procurement, Health & Safety, IT.