FEASIBILITY STUDY

FOR THE ESTABLISHMENT OF CEMENT PLANT

Contents.

List of Figures……………………………………………………………………………………………………………………………7
List of Table………………………………………………………………………………………………………………………………9
List of Abbreviations……………………………………………………………………………………………………………….10
List of Annexures……………………………………………………………………………………………………………………..15
Executive Summary………………………………………………………………………………………………………………....16
1 INTRODUCTION……………………………………………………………………………………………………………………77
1.1 The Cement Outlook in Pakistan……………………………………………………………………………………..77
1.1.1 Market Structure……………………………………………………………………………………………………78
1.2 Identification of the Proponent……………………………………………………………………………………….80
1.3 Identification of the Consultant……………………………………………………………………………………….87
1.4 Introduction of Cement……………………………………………………………………………………………………91
1.4.1 Non-Hydraulic…………………………………………………………………………………………………………91
1.4.2 Hydraulic……………………………………………………………………………………………………………………….91
1.5 Cement Production Process…………………………………………………………………………………………….91
1.5.1 Quarrying and Crushing…………………………………………………………………………………………………91
1.5.2 Blending & Storage……………………………………………………………………………………………………….92
1.5.3 Raw Milling and Homogenization………………………………………………………………………………….93
1.5.4 Burning ……………………………………………………………………………………………………………………….94
1.5.5 Cement Milling…………………………………………………………………………………………………………….94
1.5.6 Quality Assurance………………………………………………………………………………………………………..95
1.5.7 Cement Dispatch…………………………………………………………………………………………………………95
1.6 Types of Cement………………………………………………………………………………………………………..97
2 CEMENT IN THE GLOBAL & PAKISTAN MARKET CONTEXT………………………………………………100
2.1 Cement in Global Context……………………………………………………………………………………………100
2.1.1 Major Cement producing Countries………………………………………………………………………….100
2.1.2 World Cement Demand…………………………………………………………………………………………..101
2.2 Cement Production in Pakistan,s context…………………………………………………………………….102
2.2.1 Large capacity expansion underway………………………………………………………………………….102
2.2.2 Market share in Pakistan……………………………………………………………………………………………105
2.2.3 Industry high profit margin………………………………………………………………………………………..106
2.2.4 Financing requirements Industry needs FX to finance machinery imports:
107
2.2.5 Prospects of current Expansion phase………………………………………………………………………..107
2.3 Cement Demand projection in Pakistan…………………………………………………………………………109
2.3.1 Public Sector Development Targets…………………………………………………………………………….111
2.3.2 Private Sector Development Targets…………………………………………………………………………..112
2.4 Justification for Global Cement ( Private ) Limited………………………………………………………….112
3 CLINKER BURNING TECHNOLOGY………………………………………………………………………………………113
3.1 Kiln System……………………………………………………………………………………………………………………..113
3.1.1 Long wet-Process Kiln…………………………………………………………………………………………………..113
3.1.2 Short Wet-Process Kiln………………………………………………………………………………………………..113
3.1.3 Semi-Wet Process Kiln…………………………………………………………………………………………………114
3.1.4 Long Dry Process Kiln……………………………………………………………………………………………………114
3.1.5 Dry- Process Kiln with Cyclone Pre-Heater……………………………………………………………………114
3.1.6 Dry Process Pre-Heater…………………………………………………………………………………………………115
3.2 Selection of suitable Process……………………………………………………………………………………………116
3.3 Standard Specifications for Cement…………………………………………………………………………………116
3.3.1 Pakistan Standard Specification PS : 232-1983 (R) ………………………………………………………117
4 PLANT WORKING & EQUIPMENT REQUIREMENT……………………………………………………….118
4.1 Quarry Section………………………………………………………………………………………………………………..118
4.2 Raw Material Crushing and Conveying to Stockpile for plant………………………………………….118
4.3 Mix Pre-Blending System……………………………………………………………………………………………….119
4.4 Additive & Corrective Crushing and Storage………………………………………………………………120
4.5 Raw Material Regulation and Transportation……………………………………………………………..120
4.6 Raw Material Grinding and Exhausted Gas Treatment System……………………………………120
4.7 Raw Meal Homogenizing Silo………………………………………………………………………………………121
4.8 Clinker Burning System……………………………………………………………………………………………….122
4.9 Clinker Storage and Transportation…………………………………………………………………………….122
4.10 Cement Dosing………………………………………………………………………………………………………….122
4.11 Cement Grinding Cement………………………………………………………………………………………….123
4.12 Cement Storage…………………………………………………………………………………………………………123
4.13 Cement Packing and Dispatching Section………………………………………………………………… 123
4.14 Air Compressed Station……………………………………………………………………………………………..124
4.15 Coal handling, Storage & Transport……………………………………………………………………………124
4.16 Coal Grinding……………………………………………………………………………………………………………..124
4.17 Laboratory…………………………………………………………………………………………………………………124
4.18 Electrical System……………………………………………………………………………………………………….124
4.18.1 Power Supply………………………………………………………………………………………………………….124
4.18.2 Distribution System………………………………………………………………………………………………..126
4.18.3 Relay Protection…………………………………………………………………………………………………....128
4.18.4 Control & Monitor…………………………………………………………………………………………………..129
4.18.5 Control Mode………………………………………………………………………………………………………….129
4.18.6 Reactive Compensation…………………………………………………………………………………………..130
4.18.7 Harmonic in Power Distribution………………………………………………………………………………130
4.18.8 Technical Requirements of motor………………………………………………………………………….130
4.18.9 MV Switchboard……………………………………………………………………………………………………..132
4.18.10 MCC………………………………………………………………………………………………………………………133
4.18.11 Illumination…………………………………………………………………………………………………………..133
4.18.12 Cable Selection and layout…………………………………………………………………………………..134
4.18.13 Lightning protection and earthing……………………………………………………………………………135
4.19 Automation in the Production……………………………………………………………………………………….136
4.19.1 Automation and Instruments Description……………………………………………………………………136
4.19.2 Power Supply and Single types……………………………………………………………………………………136
4.19.3 Process Control System (DCS)……………………………………………………………………………………..137
4.19.4 Field Instruments and Equipments………………………………………………………………………………140
4.19.5 Other System, equipments and net in plant……………………………………………………………....142
4.20 Water System ……………………………………………………………………………………………………………..143
4.20.1 Source of water supply……………………………………………………………………………………………143
4.20.2 Water consumption………………………………………………………………………………………………..144
4.20.3 Water quality and pressure quality………………………………………………………………………….144
4.20.4 Water supply system………………………………………………………………………………………………145
4.20.5 Sewage waste water system……………………………………………………………………………………146
4.20.6 Sewage treatment…………………………………………………………………………………………………. 146
4.20.7 Material of Pipe and measurement instrument………………………………………………………146
4.21 Fire-Fighting System……………………………………………………………………………………………………..146
4.21.1 Fire fighting water supply system (Fire hydrant system)…………………………………………146
4.21.2 Other fire fighting system……………………………………………………………………………………..147
4.22 Ventilation and Air conditioning Description…………………………………………………………..147
4.22.1 Design Scope…………………………………………………………………………………………………………….147
4.22.2 Air-Conditioning……………………………………………………………………………………………………….147
4.22.3 Ventilation……………………………………………………………………………………………………………….147
4.23 Project Planning Matrix………………………………………………………………………………………….147
5 RAW MATERIAL INVESTIGATIONS.………………………………………………………………………….149
5.1 Background………………………………………………………………………………………………………………..149
5.2 Area Selection……………………………………………………………………………………………………………….152
5.2.1 Fort Munore Site…………………………………………………………………………………………………………153
5.2.2 Zinda pir……………………………………………………………………………………………………………………….155
5.2.3 Zain ……………………………………………………………………………………………………………………………..159
5.2.4 Zain Region 2……………………………………………………………………………………………………………….162
5.2.5 Mangrotha Region……………………………………………………………………………………………………….165
5.3 Situation Analysis and Area Selection…………………………………………………………………………167
6 ACCESS TO THE PROJECT AND AREA DESCRIPTION…………………………………………………………174
7 MINERALOGY AND GEOLOGY…………………………………………………………………………………………175
7.1 Origin……………………………………………………………………………………………………………………………177
7.2 Classification…………………………………………………………………………………………………………………178
8 OCCURRENCE OF LIMESTONE AND DOLOMITE IN PAKISTAN…………………………………………..179
8.1 Punjab Province…………………………………………………………………………………………………………..179
8.2 Geological Formations…………………………………………………………………………………………………180
8.2.1 Poc- Chiterwata Formation( Paleogene )……………………………………………………………………..180
8.2.2 Pedz- Drazinda Formation (Eocene)……………………………………………………………………………..181
8.2.3 Pep-Pirkoh Formation (Eocene) ……………………………………………………………………………………181
8.2.4 Ped – Domanada Formation (Eocene) ………………………………………………………………………….182
8.2.5 Peh – Habib Rahi Formation (Eocene)………………………………………………………………………….183
8.2.6 Ppd – Dungan Formation (Paleocene)………………………………………………………………………….184
9 QUARRY DEVELOPMENT……………………………………………………………………………………………….187
9.1 Exploration Works…………………………………………………………………………………………………….188
9.2 Cost of Quarry Development…………………………………………………………………………………….188
9.3 Time Schedule…………………………………………………………………………………………………………..189
9.4 Machinery and Equipment Requirement………………………………………………………………….189
9.5 Technical Personnel …………………………………………………………………………………………………190
9.6 Transportation Staff…………………………………………………………………………………………………190
9.7 Maintenance Department………………………………………………………………………………………..190
10 FINANCIAL COMPONENT ………………………………………………………………………………………..191
10.1 Financial Annexures……………………………………………………………………………………………………191
11 Conclusion and Recommendation…………………………………………………………………………..209
ANNEXURES………………………………………………………………………………………………………………………..210
ANNEXURES 1……………………………………………………………………………………………………………………..211
ANNEXURES 2……………………………………………………………………………………………………………………..220
ANNEXURES 3………………………………………………………………………………………………………………………222
ANNEXURES 4………………………………………………………………………………………………………………………228
ANNEXURES 5………………………………………………………………………………………………………………………229
 List of Figures

Figure 1-1 Cement Industry Market Share……………………………………………………………………………….78

Figure 1-2 Pakistan cement Industry Location Map…………………………………………………………………79
Figure 1-3 Quarrying and crushing Process in cement quarry………………………………………………….92
Figure 1-4 Bending and storage detail………………………………………………………………………………………93
Figure 1-5 Preparing raw material……………………………………………………………………………………………93
Figure 1-6 Burning process of cement………………………………………………………………………………………94
Figure 1-7 Cement milling process……………………………………………………………………………………………94
Figure 1-8 Loading and dispatch process………………………………………………………………………………….95
Figure 1-9 Cement production process…………………………………………………………………………………….96
Figure 2-1 Major countries in worldwide cement production from 2014 to 2018 ( in million
Metric tons )…………………………………………………………………………………………………………………………100
Figure 2-2 Estimated production of cement by country ( 1998 )……………………………………………101
Figure 2-3 Historical Analysis of cement production capacity & dispatches………………………….103
Figure 2-4 Cement per capita consumption ( 2017 )……………………………………………………………..104
Figure 2-5 Market share to remain unchanged…………………………………………………………………….105
Figure 2-6 Gross profit to sales ratio ( Last 5 year average )…………………………………………………..106
Figure 2-7 Exports by destination ( % of total )………………………………………………………………………109
Figure 4-1 Limestone bearing area on proposed project site…………………………………………………118
Figure 4-2 Segments of the cement plant………………………………………………………………………………143
Figure 4-3 View of canal near to the project………………………………………………………………………….145
Figure 4-4 Project planning matrix…………………………………………………………………………………………148
Figure 5-1 Belt conveyor Installed by DG cement company…………………………………………………..150
Figure 5-2 Sites selected for Investigation…………………………………………………………………………….152
Figure 5-3 Route from dera Ghazi khan………………………………………………………………………………..153
Figure 5-4 Geological formation of the region………………………………………………………………………153
Figure 5-5 Picture of team site visiting the fort Monroe site……………………………………………….154
Figure 5-6 Route to Project site - …………………………………………………………………………………….155
Figure 5-7 Geology of the Project Region……………………………………………………………………………156
Figure 5-8 Pictures of Raw material Resources available at project site………………………………157
Figure 5-9 Locality of CAM Cement Plant Wah ……………………………………………………………………158
Figure 5-10 Route to project site from RWP/ISD…………………………………………………………………159

List of Abbreviations

AAR Alkali-Aggregate Reaction

AASHTO American Association of state Highway and transportation officials
ACI American Concrete Institute
Aggt. Aggregate
ANN Artificial Neural Network
AP Acrylic Polymer Based
ASR Alkali-silica reactivity
ASTM American society of testing and materials
BEST BIS Bureau of Indian Standards
BSI British Standard Institute
C Cement, Mass of cement, centigrade
C Aggt. Coarse Aggregate
C.I.P Caste-in-place
CA Coarse Aggregate
CA/FA Coarse Aggregate to Fine Aggregate Ratio
CAE Copolymer of carboxylic Acid with Acrylic Easter
CAOH Calcium Hydroxide
CC Conventional Concrete
CD Compact Disk
CEN European committee for Standardization
CH calcium Hydroxide
CLAP Cross Linked Acrylic Polymer
CMDs Conventional mix design methods
CMT Cement comp.st.compressive Strength
CSI Canadian Standards Institute
C-S-H Calcium silicate hydrate
CT Content
CTH Chloride Test, Hardened
CTL Construction Technology Laboratories
DEF Delayed ettringite formation
DIN German Institute for standardization
DOE Department of transportation
RUW Dry Rodded unit weight
F Aggt. Fine Aggregate
FA Fine Aggregate
FHWA Federal Highway Administration
FLA Fly Ash
FM Fineness
GD Good
GGBFS Granulated ground blast furnace slag
GR Grade
H Harsh
HES High early strength
HPC High Performance Concrete
HRM High-Reactivity Metakaolin
HRWR High Range water Reducer
HRWRA High Range Water reducing admixture
HS High strength
HSC High strength Concrete
IC Indian Standard
ISO International Organization for standardization
MAX Maximum
MCE Multicarboxylatethers
MFNN Multilayer Feed-forward Neural Network
MgSO4 Magnesium sulphate
Min Minimum
MOE Modulus of Elasticity
MS Micro Silica
MSA Maximum size of Aggregate
MSC Material Service Corporation
MSCT Micro Silica Content
MXR Mix ratio
N Normal
Na2o Sodium
Na2Oe Total Sodium Oxide equivalent
NaCI Sodium Chloride
NIST National Institute of Standards and Technology
NMSA Normal maximum size of Aggregate
NN Neural Network
NSC Normal Strength Concrete
NSF Napthalenesulfonate
OKGD Okay Good
OM&R Operations, maintenance, repair and rehabilitation
OPC Ordinary Portland Cement
PC Poly Carboxylate Easter
PCE Poly Carboxylatethers
PQC Pavement Quality Concrete
EXECUTIVE SUMMARY

Cement is a strategic commodity, essential for Pakistan's economic security and

infrastructure renewal and expansion. Cement industry is an important economic presence in
communities across Pakistan. The industry is contributing over $269 billion to Pakistan's Gross
Domestic Product. The Pakistan cement industry is comprised of 31 fully operational cement
production plants which consist of gray clinker, Ordinary Portland, Sulphate Resistant, White
Cement, Quick Setting Cement and Low Alkali Ordinary Portland Cement.

The feasibility study conducted by the project team indicates that the national demand for
cement products is increasing. This finding is supported by the approval of infrastructure
projects (roads, bridges, and others) as well as the growing need for cement used in housing
developments. The studies, conducted by several sources, indicate that if the production of
cement does not increase, the supply will be insufficient during upcoming years.

CAM Cement plant has initially planned to install one unit producing 6000 tons per day.
The plant land is 2000 kanals with 01 KM distance from CAM mining area. A location map of the
proposed plant site is also incorporated in the report at its appropriate place.

Pakistan is blessed with abundant reserves of limestone, clay and gypsum, the key raw
material used in cement manufacturing. As per the study requisitioned by the Punjab
government, huge deposits of limestone and gypsum are available in the region.
Average utilization of this capacity has stood comfortably above 75% over the last five year with
notable improvement seen in both FY 12 ( +5% ) and FY 13 ( +3% ) respectively. The Local
dispatches are likely to remain on an upward trajectory in upcoming years on the back of higher
PSDP allocations, infrastructural development projects such as dams, motorways, low-cost
housing schemes and power projects etc.
In 1947, there were only four operational cement units in west Pakistan with the total
production capacity of approximately half a million tons per annum. The industry experienced
gradual growth as five plants were set up in the 1950,s with a total capacity of 2.8 million tones
with four more set up in the 1960,s. During the late 60,s the construction industry went
through a boom as demand grew because of an expanding economy and by 1969 the cement
industry of Pakistan had 14 operational cement plants with an annual rated capacity of 3.3
million tones. The cement industry witnessed another major change in the 1990,s as the
industry was privatized, leading to privatization of eight units. Moreover, the government also
announced tax exemption of all industrial units (including cement) in Khyber Phukhtunkhwa
and Baluchistan. Consequently, the private sector also established new plants while tempting
existing units to embark on capacity expansion to reap benefit of growing cement demand.
During the latest decade, the Pakistani cement industry has expanded its production capacity
significantly; while gradually making inroads into the exports markets mainly to India and
Afghnistan. Apart from these two countries , Pakistan cement is also being exported to south
Africa, Iraq, Sri Lanka, Tanzania, Djibouti, Mozambique, Sudan and Kenya. The Cement
production capacity of Pakistan stood 44.8 million tons in FY 13.
Currently, Pakistan is ranked among the top 10 in the world’s cement export. The
industry comprises of 23 companies having 29 plants ( 19 units in the north and 10 units in the
south), with the installed production capacity of 44.09 million tons. The north with installed
production capacity of 35.18 million tons (80%) while the south with installed production
capacity of 8.89 million tons ( 20% ) competes for the domestic market ( Source: PACRA Cement
study February 2014 ).The location of various plants installed in Pakistan is shown in Figure
below.
CAM ONSTRUCTION (PVT) LIMITED PROJECT TEAM Consist of Ch. Abdul Majeed, CEO of CAM
Construction Company, is the sponsor and owner of the CAM Cement plant project. The project
team is shown in the following diagram is given below. The project analyst, construction project
engineer, principal engineer, and contract officer are respectively representative of project
support staff, Civil engineering team, technology engineering team, and contract and
purchasing department. CAM is considered a trusted name in construction sector and as well as
real estate development.

NAME Ch. Abdul Majeed

NATIONALITY Pakistani
E-mail ID
Designation CEO
Contact Detail
Company Address.

During the period of 1998 to 2014, Pakistan cement industry grew at a commendable rate
and now total annual production of cement is quadruple of what it was in 1998. Besides making
a direct contribution of 7.5 % to large scale manufacturing, the industry influences growth in
the allied segments ( e.g steel, chemicals, wood etc). At present, there are 24 manufacturing
units operating in the country with a total installed annual capacity of 49.4 million tons. The
industry operates in two separate zones – North and South – with Northern zone representing
around 80 % of the total production capacity and sales. The manufacturers in the south zone
have more room for revenue diversification as they can tap several export markets ( via sea ).
The export potential for manufacturers in the Northern zone, however, is limited to
Afghanistan and India only.
 COMPANY EXPANSION/mln/tons US $/mln COMPLETION
LUCKY CEMENT LTD 2.3 200 FY 18-FY 21
ATTOCK CEMENT PAKISTAN LTD 1.1 120 FY 18-FY 21
CHERAT CEMENT COMPANY LTD 4.6 315 FY 17-FY 19
DG KHAN CEMENT COMPANY LTD 2.6 200 FY 18-FY 21
FECTO CEMENT LTD 1.0 100 FY 18-FY 20
GHARIBWAL CEMENT LTD 2.4 200 FY 18-FY 21
BESTWAY CEMENT PAKISTAN 1.7 190 FY 19-FY 20
POINEER CEMENT LTD 2.3 225 FY 19
POWER CEMENT LTD 2.1 235 FY 18-FY 19
MAPLE LEAF CEMENT LTD 2.3 225 FY 19
KOHAT CEMENT COMPANY LTD 1.0 110 FY19-FY 21
TOTAL 23.4 2120

The plant will need a level area measuring about 100 acres for its installation. In addition, an
area of another 100 acres approximately will be needed for construction of a residential colony
for housing the essentially needed staff for the plant. The cement plant will comprise of various
sections. Before making a specific reference to site selection the consultant has considered
appropriate to give background on the raw material resources available in Pakistan. The
Principal focus is on limestone resources.
Pakistan is amongst the few countries which are rich in industrial minerals. In exhaustive
reserves of limestone, clay and gypsum are available which the raw material for the cement
manufacturing are. The 32 installed units in the country seem to be over ( 16 million ) capacity
compared to the indigenous demand of cement ( around 10 million ). The cement
manufacturer, therefore, developed a cartel to utilize their capacity as per agreement to avoid
over supply to the market which otherwise would have reduced the cost. The rehabilitation
program of Afghanistan has opened new avenues in the region as a result there is a sudden rise
in the demand. The production of cement has therefore to follow the demand curve. New units
are under installation in salt range to meet the growing demand of cement in the domestic and
international market.

QUERRY SECTION :
 The main raw materials, limestone and clay, will be obtained from the leased areas
situated near the plant. The quarries will normally be operated during the daytime general shift
hours only and for six days in a week. They will be developed in accordance with a well thought
out plan for meeting the daily requirements of the factory. About 11000 tones of limestone and
2700 tones of clay will be extracted per day and will then be transported to the feed-hoppers of
the crusher. A development plan for the quarry has been given in the following pages.
Raw material crushing and conveying to stockpile for plant. The limestone will be supplied from
mines through dump trucks and will be fed into the apron feeder underneath the feed hopper,
then be crushed in the impact crusher. The feeding size of limestone will be below
1500x1200x1200 mm, crusher with capacity of 1200tph is adopted. The product size shall be
95% below 75mm.
The clay will be fed into the apron feeder underneath the feed hopper by dump trucks,
then be crushed in the double roller crusher. The feeding size of clay will be below 500 mm,
crusher with capacity of 400tph is adopted. The product size shall be 95% below 75mm. The
crushed limestone and clay will be fed into the storage pile via common belt conveyor.

NO. WORKSHOP MAIN EQUIPMENT PARAMETERS QUANTITY

1 Limestone Heavy Size: B2200x11600mm 1
Crushing Apran Capacity:180~1800t/h
Feeder Feeding size: 1500x1000x
1000mm
Installing angle:23*
Motor Power:
~2x 45kw (Frequency
Controlled)
Impact Crusher Capacity: 1200t/h(wet basis ) 1
Feeding size: 1500x 1200x
1200mm
Size of output: 95%<75mm
Motor Power:1700kw
2 Clay Heavy Size: B1400x8000m
Crushing Apron Capacity: 100~500t/h
Feeder Feeding size : 500x 500x
500mm
Installing angle: 15*
22kw (Frequency Controlled)

Double Capacity : 400t/h(wet basis) 1

Roller Feeding size: 500x 500x
 Crusher 500mm ( max )
Size of output: 95%<75mm
Motor power : 2x160kw

Mix Pre-Blending System:

A rectangle pre-blending stockpile with the capacity of 2x40000t will be set up to store
mix and the capacity of 5000t will be stored high grade limestone. In pre-blending shed, mix
and H.G limestone will be stacked continuously by a bridge-type scraper with capacity of
800t/h. After being blended, they will be conveyed into proportioning bins of raw meal grinding
system by belt conveyors.
Additive & Corrective Crushing and storage

The crushed material, Iron ore and sand shall be transport to corrective & additive
pre-blending building through belt conveyor and side type stacker with capacity of 400t/h. One
rectangular building has been considered to store different corrective/ additives required for
the plant.
Storage capacity for different materials shall be as follows.

 Sand: 4500 t:
 Iron Ore: 4500 t
 Additive: 5000 t,
 Gypsum: 5000 t

Corrective & additive shall be pre-blended in the storage, then being extracted by two side
scrapers with capacity of 200 t/h, the materials will be transported to dosing station before raw
mill or cement mill via belt conveyors.

Clinker Burning System

Clinker burning system is mainly composed of a rotary kiln of Dia.5.0x74m length, a

double-string five-stage cyclone pre-heater and a precalciner of CDC type. The capacity of this
system is designed to be 6000 tons of clinker per day.
Clinker Storage and Transportation
 One set silo dia.40m are used for clinker storing with capacity of 45,000t.
Clinker out of cooler will be sent into the silos through pan conveyor. Arc valves are installed
under the silos to extract the clinker to belt conveyors and then clinker will be sent to the
proportion bins of cement mill by belt conveyors. An unburned clinker silo with a set of bulk
loading system is set beside the clinker silo, storage capacity is 1000t.

Cement Dosing
Three bins are set in the cement proportioning station respectively for clinker gypsum
and additive. The cement mill bins are steel construction, equipped with load cells. All materials
be extracted and proportioned by weigh belt feeders. Weigh belt feeders feed the material on a
belt conveyor and bucket elevator, which shall feed the material either to cement mill or to
reject bin.

Cement Grinding System

There is a VRM be set. Cement mill capacity is 350tph based on OPC (Blain
3200cm2/gm).
The mixture after proportioning will be conveyed into the cement mill by belt conveyors and
bucket elevator. In the mill, materials after grinding will be forced to fly upwards by rising air.
Going through the separator at the top of the mill, cement powder with air will flow out of the
mill and enter the bag house. Collected cement from bag house will be conveyed to cement
silos by air slides and bucket elevator.
The exterior circulating mill system can save power electrical and enlarge output. The exterior
circulating material, through belt conveyor and elevator, will be conveyed into the mill for re-
grinding.
Hot air will be provided from an auxiliary diesel fired hot air generator as required.
Cement Storage
As for cement storage, two cement silos of capacity 2x20,000t shall be set. At the
bottom of the silos, the aeration units are set up with the compressed air being supplied by the
root’s blowers. There is also a discharging installation under the silos, which consists of
distributing device, valves, pneumatic switch and electrical flow rate valve. Cement will be
unloaded from the silo bottom by the discharging installation and sent to packing section and
bulk cement station. Under each silo, there is a cement bulk loading for trucks with weigh
bridges and dispatch with capacity of 225tph.
Cement Packing and Dispatching Section