ZD facilities and equipment kiln for cement

1. Crushing & Proportioning:
Primary crushing involves limestone rock fed through large capacity crushers. This reduces the rock to a maximum size of approximately 150 mm. Secondary crushing further reduces this to 75mm or under. Residule material is stacked and reclaimed with a bridge reclaimer in a cross section so that the homogeneous limestone is fed further in the process. This averages the limestone quality.

2. Raw milling & Blending:
Crushed particles are ground to 90 microns or less in a closed circuit ball mill with high efficiency separator. The raw meal is transferred to continuous blending silos (CFC) for homogenization ,extracted by load cell hopper for feeding to the kiln pre heaters.

3. Pyro processing:
Raw material is heated to over 1,450 °C in a pre-heater tower,then through a pre-calciner and finally to the rotary kiln.

4. Burning :
As the material progresses through the kiln, certain elements are removed in the form of gases. The remaining elements unite to form a new substance (clinker) with new physical and chemical characteristics. Clinker is formed in small marble sized pieces.

5. Cooling:
Clinker is discharged from the kiln and the temperature is reduced in grate coolers. The hot air from the coolers is redirected back to the kiln, this saves fuel and increases burning efficiency.

6 . Milling, Storage & Packing:
Portland cement, the basic ingredient of concrete, is a combination of calcium, silicon, aluminum, iron and small amounts of other ingredients to which gypsum is added in the final grinding process to regulate the setting time of the concrete.