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Production Technology

1. Production Technology Flow chart:

 

2. Production Technology Description:

Limestone is mined at the quarry by drilling and using explosives to blast the rocks. Then it is transported by loading trucks to the receiving hoper of the hammer crusher type LPC-10/700R through apron feeder. The stones are crushed in hammer crusher to the required size ≤ 70 mm, and then transferred to the rubber belt conveyor.

Clinker silo

Limestone is then mixed with clay under a certain rate and transferred to circle storage by a common conveyor.

The clay is taken off by stripping the quarry cover. Transporting truck loads the clay to the clay cutter or warehouse / storage yard to reserve. The clay is crushed, then transferred down to the conveyor to mix with the limestone and they go together into a common conveyor.

Fast PGNAA analyzer is installed on the common conveyor to control the mixing ratio of the mixture of clay + limestone piled up in circle storage with the capacity of 52.000T.

The mixture of limestone and clay stored in the circle storage will be taken by the reclaimer to the center to fall into the conveyor then loaded into the hopper at the dosing place. Additive materials are also loaded to the hoppers in central dosing place by the conveyor. The materials are dosed with appropriate ratios and common conveyor will transport them to the raw mill (Pfeiffer). At there, the materials are crushed into fine powder and loaded in raw meal silo. To ensure that the moisture content of the raw meal is ≤ 1%, the hot air emissed from the kiln with the temperatures of about 220 ° C is used for drying directly in the raw mill.

Raw meal is homogenized by the drawing and mixing system equipped at the bottom of raw meal silo before dosing to feed in the kiln. The raw meal is feed in the preheater in order to increase the heat and decompose carbonate prior burning to clinker in the kiln. Clinker from the kiln will go into the cooler to reduce the clinker temperature from 12000C to 90-100 0C.

Clinker after cooling will be crushed by clinker crusher and then transferred by chain bucket conveyor to clinker storage silo. Drawn system at the bottom of the silo allows drawing clinker for the cement mill or exporting to the customers.

To provide heat and energy for the kiln, coal is purchased from the supplier, then transported, stored and homogenized at the coal storage. Raw coal is handled by the reclaimer and conveyor to load into the coal mill. The coal is pulverized to the required size, dried by hot air taken from the clinker cooler, and then loaded to pulverized coal bin. The weighing systems coal and pump will transport pulverized coal to the kiln’s burning zone and the preheater.

Gypsum and puzzolan are purchased from the supplier to store in additives storage, loaded into the hopper by wheel loader, and then transferred by the conveyor to the storage tanks at the dosing place. Clinker, gypsum, and puzzolan are dosed with appropriate rate. Then the bucket elevator and the conveyor will load the additives into the cement mill. The mixture of materials is finely ground into cement with the required size, and stored in the cement silo separately for each type.

To ensure cement moisture as required, the hot gas from the clinker cooler goes through the pipeline system and transit fan to dry cement in the cement mill.

Cement is sold to the customers as bag and bulk cement. Bulk cement is drawn from cement silo, loaded through transport system to the trucks. Bag cement is drawn from the cement silo and loaded by the bucket elevator for packaging machine. Then those bags are carried through the transport system and loaded on the trucks.

Quality Management

To ensure the quality of the products, quality control department will control the production process as well as the mixing ratio. The laboratory is responsible for testing the quality of raw materials, semi-finished and finished products.

With the goal of achieving top quality, TAFiCO has invested the most modern quality control system. This system including computers and the newest type of radio-spectrum is controlled automatically. The equipments and machines are operated by specialized software controlling raw meal’s quality, allowing analyzing accurately and making reasonable feed rate, ensuring minimal errors, control raw meal manufacturing data, analyzing the composition of raw materials, fuel, clinker and cement accurately.

 

 

1. Quarrying & crushing the materials

2. Storing in the warehouses and blending the materials

3. Dosing the materials

4. Crushing the materials

5. Storing and homogenizing raw meal

6. Preheater and de-carbonating

7. Clinker burning

8. Clinker cooler

9. Clinker silo .

10. Clinker Grinding

11. Storing cement, packing and shipping

 

 

 

 

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