Cement plant is necessary for cement production, mainly consist of a series of cement equipment apply for preparation of cement raw materials, clinker production, and finished cement production, such as cement mill, cement crusher, rotary kiln, cement roller press, cement dryer, clinker cooler, cement silo, and related cement plant equipment. AGICO CEMENT is a cement plant manufacturer who owns ability to manufacture cement equipment and provide EPC turnkey project for cement plant.
AGICO Cement is a cement plant manufacturer with production capacity of 30,000 tons of equipments and structure parts and 20,000 tons of casting parts.own production equipment of 8m Vertical Lathe, 10m gear rolling machine, 8m Gantry milling machine, 200mm floor-type boring and milling machine,1203200mm bending machine, 150t crane and 40t electric furnace.
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This page and the linked pages below summarize the cement manufacturing process from the perspective of the individual components of a cement plant - the kiln, the cement mill etc..For information on materials, including reactions in the kiln, see the ' Clinker ' pages. For a more detailed account of the cement production process, see the Understanding Cement book.
Cement is typically made from limestone and clay or shale. These raw materials are extracted from the quarry crushed to a very fine powder and then blended in the correct proportions.This blended raw material is called the 'raw feed' or 'kiln feed' and is heated in a rotary kiln where it reaches a temperature of about 1400 C to 1500 C. In its simplest form, the rotary kiln is a tube up to 200 metres long and perhaps 6 metres in diameter, with a long flame at one end. The raw feed enters the kiln at the cool end and gradually passes down to the hot end, then falls out of the kiln and cools down.The material formed in the kiln is described as 'clinker' and is typically composed of rounded nodules between 1mm and 25mm across.After cooling, the clinker may be stored temporarily in a clinker store, or it may pass directly to the cement mill.The cement mill grinds the clinker to a fine powder. A small amount of gypsum - a form of calcium sulfate - is normally ground up with the clinker. The gypsum controls the setting properties of the cement when water is added.
Articles like this one can provide a lot of useful material. However, reading an article or two is perhaps not the best way to get a clear picture of a complex process like cement production. To get a more complete and integrated understanding of how cement is made, do have a look at the Understanding Cement book or ebook. This easy-to-read and concise book also contains much more detail on concrete chemistry and deleterious processes in concrete compared with the website.
Almost everyone interested in cement is also concerned to at least some degree with concrete strength. This ebook describes ten cement-related characteristics of concrete that can potentially cause strengths to be lower than expected. Get the ebook FREE when you sign up to CEMBYTES, our Understanding Cement Newsletter - just click on the ebook image above.
Since our company was founded in 1997, we have never stopped the research in the field of cement production technology and cement equipment design. Over the past 20 years, our engineers and construction team have successfully built hundreds of cement plants for customers around the planet. We are always ready to provide you with the best cement production plan!
The new dry process of cement manufacturing is the latest and most efficient modern cement production technology. It takes suspension preheating and pre decomposition outside the kiln as the core technology, widely applies the latest achievements of modern science and industrial production to the whole process of cement production. The cement plant designed and built according to the new dry process cement production technology has features of high-quality, high-yield, energy-saving, environmental protection, large-scale, and automation at the same time.AGICO has always been the pioneer and practitioner of the new dry process of cement manufacturing. In many years of production experience, we have constantly improved our production equipment and design scheme. At present, the cement plant we built can perfectly meet the production requirements of new dry process cement, making the cement production process of customers more energy-efficient and eco-friendly.
Our professional engineer team will conduct a comprehensive analysis of the factors such as raw materials, production requirements, and geographical location of customers, and design the most perfect cement plant construction plan.
All the equipment in the cement plant will be built in our factory. Small equipment will be directly transported in the form of finished products after assembly, while large equipment will be transported in the form of parts and components, and then assembled on site after arriving at the construction site.
The cement plant construction process will be completed on-site by our professional construction team. With the construction experience of many successful projects, our team is able to achieve the best construction speed and quality of the cement plant.
The structure of a cement plant is complex, which requires workers in different positions to coordinate the operation to smoothly carry out cement production. Our technicians are able to provide customers with free operation training and equipment maintenance guidance to make sure the cement plant is fully functional.
We manufacture and sell various types of cement equipment, and provide transportation and field assembly services. Our cement equipment has a variety of models, which can meet the needs of different scale cement production.
We are always committed to providing customers with the best service in the industry. From design to construction, we devote ourselves to every link. We do our best to bring you the most efficient, energy-saving and environment-friendly cement production scheme.
Our factory is equipped with a series of advanced manufacturing machines such as 8m vertical lathe, 10m gear hobbing machine, 8m gantry milling machine, 150t crane, and 40t automatic electric furnace, which greatly improve our production efficiency and product quality.
During many years construction experience, we have developed a perfect quality management system that strictly supervises every detail of the construction process to ensure the quality of the finished project.
Our projects are not only distributed in 27 provinces of China, but also exported to Brazil, Angola, Russia, Vietnam, Mongolia, and other countries. With professional construction and high product quality, our company has achieved a good reputation among customers.
Kawasaki Heavy Industries, Ltd. has supplied a lot of cement manufacturing equipment worldwide since its first delivery of a rotary kiln in 1932. The cement plant we designed and constructed has attracted the attention of the world's cement manufacturers and specialists due to its advanced performance. Kawasaki large-scale and energy-saving cement plants have so far been supplied around the world and admired by users for the stable running performance.
Our strength lies in our comprehensive technologies including the feasibility study, designing, manufacturing, procurement, construction, test-running, running, operation & maintenance, renovation of cement plants as well as manufacturing machinery for cement plants. We have also applied these technologies to the nonferrous metals processing plant, limestone calcining system. Each system has achieved remarkable results in energy saving and high efficiency.
Following Kawasaki's engineering center in Philippines (KDT), Kawasaki has established in China three joint companies, ACK, CKM and CKE, for engineering, procurement and manufacturing of cement plant equipment. Kawasaki can provide high-performance equipment developed by our prominent technologiesto suit investment needs of customers. Kawasaki has taken over cement plant business of IHI Corporation, and furthermore acquired OK Vertical Roller Mill technologies.
The cement machinery and equipment by Kawasaki leads to superior performance of energy saving, high efficiency and environmental protection. Kawasaki "Low-NOx" KSV (Kawasaki Spouted Bed & Vortex Chamber) In-Line Precalciners have been delivered to major cement companies and contributed denitration and energy saving. October, 2014, 45 units of KSV, ranging 1,700 to 8,500 tons per day have been delivered, and 16 units, 3,500 to 12,000 tons per day, have been secured for immediate delivery. Kawasaki's new generation CK Mills are highly valued for the low power consumption. Kawasaki has secured and/or delivered 97 units of the new generation CK Mills since 2009.
We can provide plants with much higher energy efficiency in response to customers' environment-friendliness by combining our Waste Heat Recovery Power Generation System. This system utilizes the thermal energy of the exhaust gas from SP (NSP) and clinker cooler, and thus generates and covers 30%-40% of electric consumption in a cement plant. Kawasaki is a pioneer in waste heat recovery technologies.
The Zero Emission Eco Town (ZEET) System is an integrated system of cement plant and incineration plant. The ZEET System treats refuse and sludge hygienically, and processes into energy and raw materials for cement manufacturing. This system reduces the fuel consumption for cement manufacturing by obtaining energy from gasified refuse. Since the burned ash is used as raw materials for cement, the final disposal of the ash is no longer required. This system reduces CO2 emissions as compared to disposal by landfill.
In addition to total engineering, we manufacture raw mills, kilns, and cement mills which are integral to the quality and energy saving in cement manufacturing. 1) Kiln Product Line -New Suspension Pre-heater -Rotary Kiln / Rotary Dryer 2) Mill Product Line -Tube Mill & Separator -CK Roller Mill -CKP Roller Mill
1997 Indonesia / PT Indocement Tunggal Prakarsa P-10 (3,800tons/day) 1999 Indonesia / PT Indocement Tunggal Prakarsa P-11 (7,500tons/day) 2002 Myanmar Economic Corporation (4,000tons/day) 2003 U.A.E. / Sharjah (3,400tons/day) 2003 Vietnam / VNCC Bimson (3,500tons/day) 2004 Morocco / Lafarge Ciments (2,300tons/day) 2004 Morocco / Holcim (Cement Mill 115tons/hour) 2005 Turkmenistan / GAP Insaat Yatirim Ve Dis Ticaret A.S. (3,000tons/day) 2008 Vietnam Construction Import-Export Corporation (VINACONEX) (6,000tons/day) 2009 "Yemen General Corporation for Cement Industry & Marketing" (3,300tons/day) 2009 Morocco / Lafarge Ciments (2,300tons/day, Expansion project) 2010 Vietnam / VNCC Butson Cement Company (4,000tons/day) 2010 Vietnam / Bimson Cement Joint Stock Company (5,500tons/day)
Powering your potential. Kawasaki is committed to providing customers unique business solutions with our innovative technologies to meet diverse societal needs worldwide. Kawasaki, working as one for the good of the planet.
Ecorporates GmbH has been prominent supplier of key heavy equipment and complete systems for cement manufacturing. We are in partnership with renowned workshops and fabrication facilities in Europe and China for manufacturing of cement plant equipment. Our partner manufacturing facilities are already the OEM for famous European engineering companies. Our customers have benefit of getting the top-quality equipment as per European standards and quality but at competitive price. Our range of equipment and systems for cement manufacturing include:
We also provide ancillary equipment and accessories for silo loading and discharge systems for single and multicompartment silos. The range of components are used for various material handling requirements in cement plant.
Pakistan: Cherat Cements board of directors has approved plans for a US$215m integrated cement plant at Dera Ismail Khan, Khyber Pakthunkhwa. The company has already invested US$8.24m in acquiring land and leases for the plant. When commissioned in mid-2024, it will have a capacity of 11,000t/day.
What is pre-decomposition technology? The core of the new dry process cement plant is suspension preheating technology and pre-decomposition technology. The clinker pre-decomposition technology refers to adding a new heat source, precalciner, between preheater and cement rotary kiln. When the fuel is injected into the precalciner for combustion, the raw material preheated to about 750 by cement preheater is fed into the precalciner at the same time so that the exothermic process of fuel combustion and the endothermic process of carbonate decomposition in the raw meal is carried out rapidly. Generally speaking, the cement raw meal decomposition rate can reach more than 90% before entering the rotary kiln.
What is precalciner? Precalciner, also known as cement calciner, is a kind of high-efficiency direct combustion solid-gas heat exchange cement equipment. It disperses and suspends cement raw meal powder in airflow, making fuel combustion and calcium carbonate decomposition happen in a short time (generally 1.5 ~ 3 seconds). To some extent, it replaces part of the calcining work of a cement rotary kiln. In the calciner, because the fuel combustion and the material endothermic reaction are carried out at the same time, there is no visible flame, but in a state of low-temperature flameless combustion at 820 ~ 900 .
At present, more than a dozen types of precalciners have been put into use. Although each has its advantages, its characteristics and functions are similar. According to the different movement form of airflow, calciner in cement plant can be divided into four types:
The tertiary air with a temperature of 200 ~ 250 is blown into the air chamber of the fluidized bed calciner by a high-pressure fan and then enters the inner chamber through the air cap so that the fuel and raw materials form afluid-bed.
The preheated cement raw meal (temperature is about 820 ~ 860, not exceeding 860), a certain amount of fuel, and hot air (kiln tail flue gas or tertiary hot air) are fed into precalciner at the same time. After entering the calciner, the fuel and raw meals are dispersed by high-speed airflow and in a suspension state at about 900. The fuel is flameless combustion in the calciner, and the heat released by it makes the calcium carbonate in the raw meal decompose at a high speed through a convection heat transfer and radiation heat transfer. Generally, this decomposition process can be completed in a few seconds, and the decomposition rate of the whole raw meal is as high as 85% ~ 95%, forming an efficient operation mode of combustion, exothermic, endothermic, and decomposition at the same time.
Precalciner forms the clinker calcining system in the new dry process cement plant together with cement preheater, rotary kiln, and cement cooler. In addition to cement calciner, AGICO also provides other high-quality clinker calcination equipment, such as cyclone preheater, cement rotary kiln, grate cooler, rotary cooler, etc.
AGICO Group is an integrative enterprise group. It is a Chinese company that specialized in manufacturing and exporting cement plants and cement equipment, providing the turnkey project from project design, equipment installation and equipment commissioning to equipment maintenance.
Sweden: Cementa says that the decision by the Supreme Land and Environmental Court to reject its renewal application to continue mining limestone at its quarries in Gotland will create a crisis for consumers in the autumn of 2021. The quarries supply its integrated Slite cement plant. The producer said that the majority of Swedish cement production could cease in November 2021 following the expiry of the current licence in October 2021.
We are seriously concerned but also surprised by the court's ruling today, said Magnus Ohlsson, the chief executive officer of Cementa. Limestone has been mined in Slite for over 100 years, which has built up a huge knowledge bank about how the business affects the surrounding environment. Our application is solid and clearly shows that it is possible to conduct a continued sustainable limestone mining in the area. We must go through the decision carefully and then set up the strategy for how we will handle the situation, He added, For Sweden, our customers and for us and our employees, it is important that political decision-makers and authorities quickly draw up new guidelines for how the supply of critical building materials such as cement and concrete should work.
The subsidiary of Germany-based HeidebergCement originally received clearance in 2020 to renew its mining operations at the site until 2041. However, this was subsequently challenged. The current decision by the Supreme Land and Environmental Court was reached as they said they had insufficient evidence to assess the environmental impact of the application.
India: JK Cement has targeted a 10% year-on-year sales growth in its 2022 financial year, which ends on 31 March 2022. The Economic Times has reported that the company foresees sales growth due to the on-going government infrastructure investment push, minimal monsoon disruptions and pent-up cement demand following Covid-19-led disruptions. Cement chief operating officer Rajnish Kapur said that growth momentum from the end of the 2021 financial year will likely continue throughout the coming nine months, despite a Covid-19 led sales drop in the first quarter of the 2021 financial year.
The cement producer also expects that its new cement plant project at Panna in Madhya Pradesh is likely to be completed in the 2023 financial year due to Covid-19 related delays. The plant will bring its total cement production capacity to around 20Mt/yr from nearly 15Mt/yr at present once it is finished. The company is also considering acquisitions to further increase its capacity to 25Mt/yr by the mid-2020s.
Uruguay: The Administacin Nacional de Combustibles, Alcohol y Portland (ANCAP) and the Administracin de Ferrocarriles del Estado (AFE) have signed an agreement to exchange logistics services, materials and real estate. Under the deal ANCAP estimates that 380,000tt/yr of fuel and 390,000t/yr of cement and limestone can be transported by rail. The arrangement also includes: offering preferential transport rates to ANCAP; moving cement and limestone between ANCAPs plants and quarries; conducting restorative work at ANCAPs Queguay limestone quarry and its integrated Paysand cement plant; and supplying rail ballast to AFE.
India: Wonder Cement has ordered its eighth vertical roller mill from Germany-based Gebr. Pfeiffer. A MPS 3070 BK type mill has been selected for grinding petroleum coke and coal. The throughput rate for pure petcoke grinding will be 40t/hr with a product fineness of 2% R 90m. The mill will be equipped with an SLS 2900 BK type classifier. Due to the high abrasiveness of Indian coal, the mill and classifier will be designed with a correspondingly robust wear protection. The new mill will support the fourth 8000t/day production line at the producers plant at Tehsil Nimbahera, Chittorgarh in Rajasthan.
Most of the components of the coal mill will be manufactured by Gebr. Pfeiffer India including the housing and foundation parts, the grinding bowl and a large part of the force-transmitting parts. Delivery of the mill is scheduled for the end of 2021. Commissioning of the entire kiln line with the new grinding plant is scheduled for spring 2022.
Cameroon: Luc Magloire, the Minister of Commerce, has written to Cimenteries du Cameroun (CIMENCAM) threatening to close its production facilities if it raises its prices without approval. In the letter the minister accused the subsidiary of LafargeHolcim of increasing its wholesale prices and of preparing to do so again without consent, according to the Ecofin Agency. Prices have reportedly risen by up to 8% in some places.
Friction occurred between the government and CIMENCAM in 2020 when LafargeHolcim renewed the term of Benot Galichet as the chief executive officer of its local subsidiary. The government, a large minority shareholder of the company, opposed the decision. The government and the cement producer have also disagreed previously over the price of cement.
Fernando A Gonzlez and Cemex took to the virtual airways this week with Cemex Day 2021. The investors update comprised the usual greatest hits package explaining how well everything is going: earnings growth and leverage levels about to hit desired targets, selective investments and divestments on the way, new production capacity round the corner and punchy sustainability goals turning up earlier than expected. Or at least thats the way that chief executive officer Gonzlez and the team told it.
To be fair to Cemex, it seems to be in a good place right now. It weathered 2020 well and now its first quarter results in 2021 compared to the same period in 2019, before coronavirus hit, are looking rosy with cement sales volumes growth of 9%. How much of that is attributable to pent up demand from 2020 remains to be seen though. Its strategy of focusing on markets in North America and Europe appears to have paid off in recent years with its competitors copying it as they have retreated from riskier climes and concentrated on core territories. Its obsession with righting the ratio between its debts and earnings is closer than ever to being realised, with a 4.07x net leverage ratio in 2020 and a target of 3x or lower planned for 2023. That last target is crucial both materially and psychologically for the company as it starts to put it back in the same financial field as its Western multinational competitors and opens up new investment opportunities.
From a production angle, the big news from the event was a 10Mt/yr cement production expansion project between now and 2023. This wasnt quite as promising as it sounded, as just under half of this was attributed to legacy projects in Mexico, Colombia and the Philippines and some of the new projects had already been announced, but it does bookmark a move from divesting plants to upgrading and building new ones.
The new projects comprise an additional 5.7Mt/yr capacity from on-going debottlenecking, new integrated plants, new grinding plants and reopening idle or mothballed plants. During the event Jos Antonio Gonzlez, the Executive Vice President of Strategic Planning & Business Development broke it down into 3.5Mt in Mexico, consisting of 1.5Mt additional grinding capacity at the integrated Tepeaca plant, a 0.5Mt/yr expansion at the integrated Huichapan plant and 1.5Mt/yr from bringing both idled lines back into production at the CPN Hermosilla plant in Senora to support the US market. That last one notably was partly announced in February 2021. In Europe and the US the group plans to add 1.2Mt/yr including expanding grinding capacity at two plants in Europe with details to be announced later. Finally, the company plans to add 1Mt/yr of additional capacity in South American including restarting an idled 0.5Mt/yr kiln at a plant in the Dominican Republic and building a new 0.5Mt/yr grinding mill in Guatemala.
Cemex has also stepped up its target reduction in CO2 emissions to below 475kg CO2/t of cementitious material, an approximately 40% reduction in CO2 emissions compared to 1990 levels, by 2030. The previous target for 2030 of 520 kg CO2 has been brought forward to 2025. This compares to LafargeHolcims similar target of 475kg CO2/t by 2030, HeidelbergCements target of 500kg CO2/t by 2030 and CRHs target of 530kg CO2/t by 2030. The group is planning to spend US$60m/yr on its decarbonisation projects. This compares to a spend of around US$140m/yr on its 10Mt/yr cement production capacity expansion drive over the next three years. Or to put it another way, the group is spending more on growing than sustainability.
Unfortunately, it wasnt all good public relations for Cemex this week with the news in the Colombian press that one of its former executives is set to be investigated by the authorities over his alleged involvement in the ongoing Maceo cement plant corruption case. The background to this one is that in 2016 Cemex fired several senior staff members, and the local subsidiarys chief executive resigned, in relation to the building of a new integrated plant at Maceo. This followed an internal audit and investigation into payments worth around US$20m made to a non-governmental third party in connection with the acquisition of the land, mining rights and benefits of the tax free zone for the project. Legal proceedings followed in Colombia and the US. Many large companies have legacy problems to deal with. Just take LafargeHolcims continued connection to Lafarge Syrias conduct in the early 2010s. At the time of writing the Maceo plant is still yet to start operation and is likely to be one of the ongoing projects mentioned above.
Cemexs second quarter results are due to arrive towards the end of July 2021 but the group is presenting an upbeat image. Sales are up, debts are down, divestments are out and expansions are in. Confidence is important for a multinational trying to convince the rating agencies to give it back its investment grade, so whether this is strictly true or not it certainly knows how to talk the talk. One question going forward at least is how strictly Cemex will want to stick to its core markets if the good times really have returned?
Spain: Votorantim Cimentos has agreed to buy Cementos Balboa from US-based investment company KKR for an undisclosed sum. The producer operates a 1.6Mt/yr integrated plant at Alconera in Badajoz, Extremadura that started production in 2005. The purchase is subject to regulatory approval in Spain.
This transaction exemplifies our strategy for growth and positioning in Spain and reinforces our presence in the country, says Marcelo Castelli, global chief executive officer of Votorantim Cimentos. The Brazilian-based company has been present in Spain since 2012 and currently operates four integrated cement plants, two grinding plants, a mortar plant and several concrete and aggregates plants, operating in the regions of Andalusia, the Canary Islands, Castile and Len, Extremadura and Galicia .
Spain: Cementos Molins has completed the acquisition of a white cement terminal in the Port of Alicante from Turkey-based imsa. The unit includes a 10,000t silo and it will be able to supply over 50,000t/yr from the site. The producer also plans to use the terminal to bolster exports from its 0.7Mt/yr integrated white cement plant at Kairaouan in Tunisia, which is operated by subsidiary Socit Tuniso-Andalouse de Ciment Blanc (SOTACIB). It distributes products from this plant to over 15 countries.
Pakistan: Bestway Cement and Reon Energy have commissioned a 14.3MW captive solar power unit at the formers integrated cement plant at Farooqia, Khyber Pakhtunkhwa. The unit is part of a 50MW project deal that is planned to install solar units at the cement producers plant at Farooqia, Chakwal, Kallar Kahar and Hattar, according to the Pakistan Observer newspaper. Energy generated at the new solar plant at Farooqia is expected to reduce energy costs and reduce reliance on the national electricity grid.
Germany: Two studies looking at how to prepare investments for the conversion to an oxyfuel process have been completed at Hocims Germanys Lgerdorf cement plant. The projects were running with technology partners ThyssenKrupp Industrial Solutions and Linde. Project Oxyfuel100, part of the Westkste100 initiative, was finalised in mid-April 2021. In addition to the oxyfuel process, the technical and economic feasibility of the downstream CO2 extraction, processing and forwarding was examined. The results of the feasibility study were reported as being extremely positive.