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How optimize your cement operation

Updated: Jul 27, 2020

In the competitive cement production market, technology improvement is vital to increase production and revenue. While you face the significant challenges of globalization and increasingly stringent environmental regulations, you must ensure exacting quality standards. You want to avoid downtime and wasted energy.

Raw Material Transfer from Quarry to Different Silos

Cement industries typically produce Portland cement. Most of the raw materials used are extracted from the earth through mining and quarrying. Those are lime (calcareous), silica (siliceous), alumina (argillaceous), and iron (ferriferous). As limestone is the prime constituent of cement, the major cement plants are located near the good quality limestone quarry. At first lime stones and quarry, clays are fed to primary crusher house for raw crushing. Then the materials are transferred to the secondary crusher house. After that, the crushed materials are fed to the stockpile. Inside the stockpile, there is a stacker/reclaimer which segregates the raw material quality-wise into different stacks. The stacking and reclaiming systems operate independently. There are also four additives- iron ore, bauxite, laterite, and fluorspar into the stack pile to get the required composition of cement. The additives are brought to the stack pile by conveyor C4. Then according to the requirement limestone, iron ore, bauxite, laterite, and fluorspar are transferred to different silos by their respective conveyors.

Puranova automates this process fully using a PLC, which takes real-time decision depending upon the various field level input signals from various sensors placed in different critical points (e.g. push buttons, upper-level detectors) and sends the decision to the output devices (e.g. conveyors, primary & secondary crushers, stacker & reclaimer S/R system.

Additionally, Puranova can automate the following processes within a cement plant operation:

  • Raw Material Transfer from Different Silos to Homogeneous Silo

  • Bucket elevator automation

  • Screen vibrator automation

  • ESP (Electrostatic Precipitator) & ID Fan Control

  • Pyroprocessing & finish milling automation

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