CEMENT

MANUFACTURING PROCESS

Mining

The cement manufacturing process starts from the mining of limestone, which is the main raw material for making cement. Limestone is excavated from open cast mines after drilling and blasting and loaded on to dumpers which transport the material and unload into hoppers of the limestone crushers.

Crushing Stacking & Reclaiming of Limestone

The LS Crushers crush the limestone to minus 80 mm size and discharge the material onto a belt conveyor which takes it to the stacker via the Bulk material analyser. The material is stacked in longitudinal stockpiles. Limestone is extracted transversely from the stockpiles by the reclaimers and conveyed to the Raw Mill hoppers for grinding of raw meal.

Crushing Stacking & Reclaiming of Coal

The process of making cement clinker requires heat. Coal is used as the fuel for providing heat. Raw Coal received from the collieries is stored in a coal yard. Raw Coal is dropped on a belt conveyor from a hopper and is taken to and crushed in a crusher. Crushed coal discharged from the Coal Crusher is stored in a longitudinal stockpile from where it is reclaimed by a reclaimer and taken to the coal mill hoppers for grinding of fine coal.

Raw Meal Drying/Grinding & Homogenisation

Reclaimed limestone along with some laterite stored in their respective hoppers is fed to the Raw Mill for fine grinding. The hot gasses coming from the clinkerisation section are used in the raw mill for drying and transport of the ground raw meal to the Electrostatic Precipitator / Bag House, where it is collected and then stored and homogenised in the concrete silo. Raw Meal extracted from the silo (now called Kiln feed) is fed to the top of the Preheater for Pyroprocessing.

Clinkerisation

Cement Clinker is made by pyroprocessing of Kiln feed in the preheater and the rotary kiln. Fine coal is fired as fuel to provide the necessary heat in the kiln and the Precalciner located at the bottom of the 5/6 stage preheater. Hot clinker discharged from the Kiln drops on the grate cooler and gets cooled. The cooler discharges the clinker onto the pan / bucket conveyor and it is transported to the clinker stockpiles / silos. The clinker is taken from the stockpile / silo to the ball mill hoppers for cement grinding.

Cement Grinding & Storage

Clinker and Gypsum (for OPC) and also Pozzolana (for PPC) are extracted from their respective hoppers and fed to the Cement Mills. These Ball Mills grind the feed to a fine powder and the Mill discharge is fed to an elevator, which takes the material to a separator, which separates fine product and the coarse. The latter is sent to the mill inlet for regrinding and the fine product is stored in concrete silos.

Packing

Cement extracted from silos is conveyed to the automatic electronic packers where it is packed in 50 Kgs. Polythene bags and dispatched in trucks.

Electrical Power

or total power requirement of 90 MW we have

• CPP 1 – 25.0 MW
• CPP 2 – 25.0 MW
• CPP 3 – 37.0 MW

Four DG sets provide an emergency backup

TECHNICAL SERVICES

Owning a strong, durable and beautiful home is one of the innate desires of every human being. At RSTCA , the pioneers in the construction of mega Hydroelectric projects and other infrastructure projects, we fully understand that good cement and construction material alone will not ensure strong and lasting structures. Correct construction practices and quality control at the time of construction play an equally important role. Our understanding of the construction practices and related problems has prompted us to extend customized technical services specially tailored for the Individual Home Builders and large projects. We firmly believe that quality construction leads to satisfied customers.

The RSTCA Cement Technical Support Service offerings are:

Technical Service Engineers

Our Area Marketing Offices have a fully functional technical services department aptly supported by qualified Civil Engineers who visit and interact with the customers to asses their needs and accordingly advise them about the best construction practises so that the dream of a strong and durable home is realized. Some of the customer-centric initiatives taken up by the Technical Service Engineers are:

• Customized solutions to the problems of the individual home builder.
• Training the masons and contractors so that they are aware about good construction practices.
• Train the channel partners (Dealers and Retailers) about the product and its correct usage.
• Interact routinely with the professionals (architects and engineers) and share information regarding latest developments in the product and industry.

The services of the Technical Service Engineers can be availed by all users of RSTCA Cement. For more details, please contact nearest RSTCA Cement Area Marketing Office or RSTCA Cement Authorized Dealers.