1000 Raw Material Preparation Department

ZAVEH TORBAT CEMENT CO.
New Cement Plant 3 500 t/d Clinker Production

A 44.0046.2.001 Rev.1
December 2004
1000 Raw Material Preparation Department
1100 Crushing Plant
Item Description (norm./design)
1111 FH 1 1 Limestone Feed Hopper
1111 AF 1 1 Apron Feeder
1111 SX 1 1 Spillage Conveyor
1111 FH 2 1 Alluvium Feed Hopper
1111 AF 2 1 Apron Feeder
1111 SX 2 1 Spillage Conveyor
1111 SP 1 1 Roller Screen
1112 IM 1 1 Impact Crusher
1115 BC 1 1 Discharge Belt Conveyor
1115 CA 1 1 Maintenance Crane
1117 BF 1 1 Bag Filter Crusher Dedusting
1117 FN 1 1 Bag Filter Fan
1115 BC 2 1 Belt Conveyor
1117 BF 2 1 Bag Filter
1117 FN 2 1 Bag Filter Fan
1115 BW 1 1 Belt Scale
1115 MS 1 1 Magnetic Separator
1
A 44.0046.2.001 Rev.1
December 2004
1115 AN 1 1 Online Analyser
1115 CH 1 1 Two Way Chute
1111 FH 3 1 Iron Ore Feed Hopper
1111 VC1 1 Vibration Feeder
1115 CH2 1 Two Way Chute
2
A 44.0046.2.001 Rev.1
December 2004
General Data:
warranty capacity / Output total: 1 000 t/h
warranty capacity / Output crusher only: 800 t/h
design capacity roller screen: 1 200 t/h
design capacity main apron feeder: 1 200 t/h
design capacity discharge belt conveyor: 1 400 t/h
feed material “A”: alluvium, 200 – 1 000 t/h
feed material “B”: limestone, 50 - 400 t/h
feed material “C”: iron ore, intermittent
feed moisture of alluvium: max. 10 %
feed moisture of limestone: max. 4 %
feed moisture of mixed feed: max. 7 %
bulk density alluvium: approx. 1.5 t/m3
bulk density limestone: approx. 1.5 t/m3
feed size of alluvium: max. 500 mm
feed size of limestone: one edge length max. 1 500 mm
3
A 44.0046.2.001 Rev.1
December 2004
feed size limestone quarried: max. 0.8 m3

acc. to quarry blasting,
run of mine
standard serial blasting
feed size of iron ore: max. 500 mm
total product size

in square mesh DIN 4226: 95 % < 80 mm
99.5 % < 100 mm
4
A 44.0046.2.001 Rev.1
December 2004
1111 FH 1
1 Limestone Feed Hopper
volume: approx. 150 - 200 m3
feeding: dump trucks,
two side feeding
material of construction: concrete,
steel plate wear lining

of the inside walls
sonar level control: 1 piece
5
A 44.0046.2.001 Rev.1
December 2004
1111 AF 1
1 Apron Feeder
capacity nom. / design: 200 - 1 000 / 1 200 t/h
inside width: 2 070 mm
c-t-c distance: 11 600 mm
inclination: approx. 23°
operating speed: 0.09 - 0.20 m/s
motor: 2 x 55 kW FC
speed: 1 500 rpm
Base frame of heavy steel construction.
Tractor chain elastically pre-stressed.
Track rollers mounted on the base frame.
Apron feeder deck of welded steel plates.
Apron plates replaceable by fixing bolts to the two chain strands.
Aprons with special sealing to prevent spillage.
Impact table at the feed point, impact roller supports mounted on rubber blocks.
Drive sprockets with easy replaceable gear rim segments.
Drive shaft with pillow blocs and anti-friction bearings.
Planetary gear reducer with coupling, torque blade, motor support, shrinking disc.
Central automatic grease lubrication for bearings of apron feeder.
Tachometer speed control system.
6
A 44.0046.2.001 Rev.1
December 2004
1111 SX 1
1 Spillage Conveyor
type: trough / scraper bars
location: underneath the apron feeder
gear motor: 5.5 kW
Drive shaft with anti friction bearings.
Chain wheels.
Round link steel chain with scraper bars.
Take-up shaft with anti-friction tension bearings.
Tension spindle with springs.
Steel trough with rails.
Spillage chute steel plate design.
7
A 44.0046.2.001 Rev.1
December 2004
1111 FH 2
1 Alluvium Feed Hopper
volume: approx. 80 m3
feeding: dump trucks,
two side feeding
material of construction: concrete,
steel plate wear lining

of the inside walls
sonar level control: 1 piece
8
A 44.0046.2.001 Rev.1
December 2004
1111 AF 2
1 Apron Feeder
capacity nom. / design: 50 – 400 / 500 t/h
inside width: 1 600 mm
inclination: approx. 23°
operating speed: 0.09 - 0.20 m/s
motor: 1 x 55 kW FC
speed: 1 500 rpm
Base frame of heavy steel construction.
Tractor chain elastically pre-stressed.
Track rollers mounted on the base frame.
Apron feeder deck of welded steel plates.
Apron plates replaceable by fixing bolts to the two chain strands.
Aprons with special sealing to prevent spillage.
Impact table at the feed point, impact roller supports mounted on rubber blocks.
Drive sprockets with easy replaceable gear rim segments.
Drive shaft with pillow blocs and anti-friction bearings.
Planetary gear reducer with coupling, torque blade, motor support, shrinking disc.
Centralised automatic grease lubrication for bearings of apron feeder.
Tachometer speed control system.
9
A 44.0046.2.001 Rev.1
December 2004
1111 SX 2
1 Spillage Conveyor
type: trough / scraper bars
location: underneath the apron feeder
gear motor: 5.5 kW
Drive shaft with anti friction bearings.
Chain wheels.
Round link steel chain with scraper bars.
Take-up shaft with anti-friction tension bearings.
Tension spindle with springs.
Steel trough with rails.
Spillage chute steel plate design.
10
A 44.0046.2.001 Rev.1
December 2004
1111 SP 1
1 Roller Screen
capacity nom. / design: 1 200 / 1 400 t/h
width: 2 100 mm
length: 5 100 mm
gap size / screening: 80 mm / 0 - 70 mm
overflow: > 70 – 1 300 mm
underflow capacity: 600 - 700 t/h
motor: 2 x 37 kW
Roller screen comprising forged steel shafts.
Double-row roller bearings.
Double seals.
Roller chain connection of shafts with protective guard.
Drive by two motors with couplings, spur gear and chain drive.
Motors pole-reversible.
Cleaning of roller screen by anti-clogging scrapers.
Support structure with wear plates on the side walls.
11
A 44.0046.2.001 Rev.1
December 2004
1112 IM 1
1 Impact Crusher
capacity: 800 t/h
type: single rotor
rotor diameter : 1 800 mm
rotor width : 2 250 mm
rotor speed: 33 m/s
inlet opening: 1 800 x 2 270 mm
motor required: 960 kW
motor speed : 1 000 rpm
Housing, with liners, two parts.
Hydraulic actuated hinged housing.
Disc-type rotor with blow bars.
Shaft, clamping sets, anti-friction bearings.
Impact apron at front and rear side with hydraulic adjustment.
Mechanical locking device.
Hydraulic adjustable grinding path.
Hydraulic cylinders with hydraulic unit.
Rotor speed indicator.
Grease gun for rotor bearings.
Motor pulley, v-belts, flexible coupling, base frame,
Anchor bolts and nuts.
12
A 44.0046.2.001 Rev.1
December 2004
Inlet hood
Steel plate design.
Rubber- and chain curtain.
Crane jib for electrical hoist.
Inlet chute plate.
Crusher discharge box
Designed as surge and buffer hopper.
Level control.
Steel plate design, flanges, bolts, service door.
Dust collecting flange.
13
A 44.0046.2.001 Rev.1
December 2004
1115 BC 1
Discharge Belt Conveyor
capacity nom. / design: 1 000 t/h / 1 400 t/h
width: 1 800 mm
inclination: horizontal
conveying speed: 0.4 - 0.9 m/sec
layer hight: 0.18 – 0.40 m
motor: 45 kW FC
Gear reducer.
Drive pulley and tail pulley carried in anti-friction bearings.
Profile steel framework with standard high support legs.
Top roller station with 30° trough angle.
Standard support idlers and impact idlers.
Multi-layer rubber belt, belt cleaning by means of spring-loaded scraper.
Zero speed, misalignment- and cord switches.
14
A 44.0046.2.001 Rev.1
December 2004
1115 CA 1
1 Maintenance Crane
(-Technical Data-)
lifting capacity: 50 t
1117 BF 1
1 Bag Filter Crusher Dedusting
(-Technical Data-)
capacity: 50 000 m3/h
dedusting: crusher and transfer point
1117 FN 1
1 Bag Filter Fan
(-Technical Data-)
capacity: 50 000 m3/h at 30 mbar
motor : 75 kW / 1 500 rpm
15
A 44.0046.2.001 Rev.1
December 2004
Raw Material Transport:
1115 BC 2
1 Belt Conveyor
( -by Customer- )
type: trough belt conveyor
width: 1 400 mm
c-t-c distance: approx. 105 m
inclination: 20 m
conveying speed: 1.68 m/sec
capacity nom. / design: 1 000 t/h / 1 400 t/h
motor required: 110 kW
Gear reducer.
Drive pulley and tail pulley carried in anti-friction bearings.
Profile steel framework with standard high support legs.
Top roller station with 30° trough angle.
Standard support idlers and impact idlers.
Multi-layer rubber belt, belt cleaning by means of spring-loaded scraper.
Zero speed, misalignment- and cord switches.
16
A 44.0046.2.001 Rev.1
December 2004
1117 BF 2
1 Bag Filter
(-Technical Data-)
dedusting: transfer tower
1117 FN 2
1 Bag Filter Fan
(-Technical Data-)
1115 BW 1
1 Belt Scale
for installation into belt conveyor 1115 BC 2
belt width: 1400 mm
accuracy: 0.5 % in the range of

20 - 100 % of nominal capacity
1115 MS 1
1 Magnetic Separator
( -by Customer- )
installation: above belt conveyor 1115 BC 2
type: electro-magnet
operating height: 200 mm
connecting load: 2.2 kW
17
A 44.0046.2.001 Rev.1
December 2004
1115 AN 1
1 Online Analyser
( -included in EE.00: Electrical Control & Automation Equipment- )
Measures the full flow on-line and tracks the current and cumulative pile composition.
In case that the result of the analysis differs from target, signal transmission will
control the speed of the apron feeders to the crushers.
Principle: each element emits gamma rays, when activated by neutrons.
Computer in the CCR (operator´s station):

Operator console is the user interface with the Neutron Analyser.
It communicates using a low capacitance twisted and shielded pair cable, and within
the stacker reclaimer through a field bus.
The measuring quality depends on the specific belt loading, belt speed and material
height.
Due to the analyzer tunnel the idler angle passing through the analyzer should be at
45° (otherwise reflection of gamma rays).
Conveyor belt should have no chlorine content and no steel reinforcement (this would
have an adverse effect on signals for oxides like SO 2, Al2O3 or CaO).
Distance between the belt scale and the analyzer shall be 2 - 5 m in order to
achieve a short time delay.
18
A 44.0046.2.001 Rev.1
December 2004
1115 CH 1
1 Two Way Chute
( -Technical Data- )
location: transfer tower
drive: electric
1111 FH 3
1 Iron Ore Feed Hopper
1111 VC1
1 Vibration Feeder
conveying capacity: 140 t/h
1115 BC 4
1 Belt Conveyor
conveying capacity: 140 t/h iron ore
conveying capacity: 1 400 t/h limestone
19
A 44.0046.2.001 Rev.1
December 2004
1115 CH2
1 Two Way Chute
location: pre bin housing raw mill
drive: electric
1115 BC 5
1 Belt Conveyor
conveying capacity: 140 t/h iron ore
20
A 44.0046.2.001 Rev.1
December 2004
1000 Raw Material Preparation Department
1310 RAW MATERIAL STORAGE
Item Description (norm./design)
1311 BC1 Belt conveyor to stacker
1311 ST1 Stacker
1312 RE1 Bridge reclaimer
1312 BC1 Belt conveyor from reclaimer
1315 BC1 Belt conveyor
1317 BF1 Bag filter
1317 FN1 Fan
Supporting Structure, Operating Platforms
Ductwork, Chutes, Connecting Elements
21
A 44.0046.2.001 Rev.1
December 2004
General Data
Stockyard arrangement: Longitudinal
Stockyard type: pre blending of:

Limestone
Alluvium
Stacking pattern: Chevron
Storage capacity: 2 x 30,000 t (covered)
Pile width (each): approx. 28 m
Pile height (each): approx. 11 m
Pile length (each): approx. 150 m
Bulk density: 1.45 t/m3
Angle of repose: 38°
Grain size: 0 – 80 mm, 5 % >120 mm
Type of stacker: Travelling stacker with

luffing movement
Stacking capacity actual / design: 1,200 / 1,400 t/h
Type of reclaimer: Bridge type
Reclaiming capacity: 500 t/h / 700 t/h
22
A 44.0046.2.001 Rev.1
December 2004
1311 BC1
Belt conveyor to stacker
Belt width: 1,400 mm
c-t-c- Length: approx. 350 m
Inclination: 10 m
Conveying speed: 1.68 m/s
Material flow (design): 1,400 t/h
Material to be conveyed: mixed material
Temperature: ambient
23
A 44.0046.2.001 Rev.1
December 2004
1311 ST1
Stacker
Boom Conveyor
Conveying capacity (design): 1,400 t/h
Belt speed: 2.09 m/s
Tripper
Rails
Control House incl. Operator’s Panel
Switch gears
Cables
24
A 44.0046.2.001 Rev.1
December 2004
1312 RE1
Bridge reclaimer
Handling capacity: 500 t/h
based on a density of: 1.45 t/m3
Length of horizontal portion of chain 28.0 m
Electrical Equipment
Control
Type of control PLC unit
Control House
 control house, suitable sized to contain all required electrical control and power
switch gears
Switchgears
Power supply and signal exchange
Safety devices
Cables
Rails for Reclaimer
Rail length: 315 m
Type of rail: A 100 or equal
25
A 44.0046.2.001 Rev.1
December 2004
1312 BC1
Belt conveyor from reclaimer
Material flow (norm/design): 500 t/h / 700 t/h
1315 BC1
Belt conveyor
Material flow (norm / design): 500 t/h / 700 t/h
26
A 44.0046.2.001 Rev.1
December 2004
1317 BF1
Bag filter
Capacity: 15,000 m3/h
Dedusting: transfer points
1317 FN1
Fan
Capacity: 15,000 m3/h at 30 mbar
Supporting Structure, Operating Platforms
For access to maintenance openings and inspection areas of the relevant equipment.
Fabricated of rolled steel profiles with gratings, railings and stairs or ladder.
Ductwork, Chutes, Connecting Elements
Dedusting ductwork in steel plate design, flanges, seals, mechanical damper at every
dedusting point.
Chutes designed for technological demands, inspection opening.
Connecting elements at flanges and supports as screws, washers, nuts.
27

1000 Raw Material Preparation Department

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ZAVEH TORBAT CEMENT CO.

New Cement Plant 3 500 t/d Clinker Production

1000 Raw Material Preparation Department

1100 Crushing Plant

Item Description (norm./design)

1111 FH 1 1 Limestone Feed Hopper

1111 AF 1 1 Apron Feeder

1111 SX 1 1 Spillage Conveyor

1111 FH 2 1 Alluvium Feed Hopper

1111 AF 2 1 Apron Feeder

1111 SX 2 1 Spillage Conveyor

1111 SP 1 1 Roller Screen

1112 IM 1 1 Impact Crusher

1115 BC 1 1 Discharge Belt Conveyor

1115 CA 1 1 Maintenance Crane

1117 BF 1 1 Bag Filter Crusher Dedusting

1117 FN 1 1 Bag Filter Fan

1115 BC 2 1 Belt Conveyor

1117 BF 2 1 Bag Filter

1117 FN 2 1 Bag Filter Fan

1115 BW 1 1 Belt Scale

1115 MS 1 1 Magnetic Separator

1115 AN 1 1 Online Analyser

1115 CH 1 1 Two Way Chute

1111 FH 3 1 Iron Ore Feed Hopper

1111 VC1 1 Vibration Feeder

1115 BC 4 1 Belt Conveyor

1115 CH2 1 Two Way Chute

1115 BC 5 1 Belt Conveyor

warranty capacity / Output total: 1 000 t/h

warranty capacity / Output crusher only: 800 t/h

design capacity roller screen: 1 200 t/h

design capacity main apron feeder: 1 200 t/h

design capacity discharge belt conveyor: 1 400 t/h

feed material “A”: alluvium, 200 – 1 000 t/h

feed material “B”: limestone, 50 - 400 t/h

feed material “C”: iron ore, intermittent

feed moisture of alluvium: max. 10 %

feed moisture of limestone: max. 4 %

feed moisture of mixed feed: max. 7 %

bulk density alluvium: approx. 1.5 t/m3

bulk density limestone: approx. 1.5 t/m3

feed size of alluvium: max. 500 mm

feed size of limestone: one edge length max. 1 500 mm

feed size limestone quarried: max. 0.8 m3

feed size of iron ore: max. 500 mm

total product size

1 Limestone Feed Hopper

volume: approx. 150 - 200 m3

feeding: dump trucks,

two side feeding

material of construction: concrete,

steel plate wear lining

sonar level control: 1 piece

capacity nom. / design: 200 - 1 000 / 1 200 t/h

inside width: 2 070 mm

c-t-c distance: 11 600 mm

inclination: approx. 23°

operating speed: 0.09 - 0.20 m/s

speed: 1 500 rpm

Base frame of heavy steel construction.

Tractor chain elastically pre-stressed.