Cement Plant

SABOO is known all over the world for manufacturing Cement Plants based on VSK and Rotary Kiln Technology. We offer Small to Medium Size Cement Plants (Capacity varying from : 100 TPD to 1000 TPD ) on turn key basis and have capabilities to undertake all aspects of the project from :- Raw Material Analysis ---Project site Inspection ---- Designing Plants based on Individual requirement ---- Civil Foundation Work ---- Erection and Commissioning of the Plant and Machinery ---Training of the Staff.

  • Salient Features
  • Low pressure drop pre heaters.
  • Raw mill equipped with High efficiency separator.
  • Raw Meal blending in CFC silo.
  • Pre-calciner suitable to work with alternative fuels.
  • Inlet & discharge fitted with Efficient seals.
  • Benchmark cooler design.
  • Benefits
  • Near Zero Maintenance.
  • Operation of Plant is Simple.
  • Gestation period is short.
  • Greater efficiency in Power Consumption.
  • Abundant fuel savings.
  • Low Installed cost.
  • Trusted and proven Trouble free Technology.

Cement Manufacturing Process
1. Crushing & Proportioning:
Limestone rock is the principal raw material, the first step after quarrying in the processes is the primary crushing. Mountains of rock are fed through crushers capable of handling pieces as large as an oil drum. The first crushing reduces the rock to a maximum size of about 150 mm. The rock then goes to secondary crushers or hammer mills for reduction to about 75 mm or smaller. After that the material is stacked with the help of a stacker and reclaimed with the bridge type reclaimer in a cross section so that the homogeneous limestone is fed further in the process, thus averaging the limestone quality.
2. Raw milling & Blending:
The next step in the process is to grind the above particles to a size of 90 microns or less which is done in a raw mill, a closed circuit ball mill equipped with high efficiency separator. After achieving the 90 microns size the fine grinded material also known as raw meal is sent to the continuous blending silos (CFC) for homogenization & extracted by means of load cell hopper for the next step which is feeding to the kiln pre heaters
3. Pyro processing:
The raw material is heated to exceeding 1,450 C (2,700 degrees F) in 5 or 6 stage pre-heater tower (about 110 metres in height) in the suspended form, than through a pre-calciner and finally in a huge cylindrical steel rotary kilns lined with special firebrick. Kilns are frequently as much as 3.7 M (12 pi) in diameter, large enough to accommodate an automobile and longer in many instances than the height of a 40-story building. Kilns are mounted with the axis inclined slightly from the horizontal. The finely ground raw material or the slurry is fed into the higher end. At the lower end is a roaring blast of flame, produced by precisely controlled burning of powdered coal, oil or gas under forced draft.
4.Clinker Cooling and Heat Exchange with Air :
As the material moves through the kiln, certain elements are driven off in the form of gases. The remaining elements unite to form a new substance with new physical and chemical characteristics. The new substance, called clinker, is formed in pieces about the size of marbles. Clinker is discharged red-hot from the lower end of the kiln and generally is brought down to handling temperature in Grate coolers. The heated air from the coolers is returned to the kilns, a process that saves fuel and increases burning efficiency
5. Cement milling, Storage & Packing:
Portland cement, the basic ingredient of concrete, is a closely controlled chemical 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. Lime and silica make up about 85% of the mass. Common among the materials used in its manufacture are limestone, shells, and chalk or marl combined with shale, clay, slate or blast furnace slag, silica sand, and iron ore.

Rotary Kiln Cement Plant Project at a Glance

Plants Offered 600 900 1200 1500 2500 3000 4500 5500 6500
Land area required (Sq. M) 80,000 100,000 125,000 175,000 280,000 325,000 450,000 550,000 650,000
Captive Power Requirements (KW) 6000 8500 10,000 12,500 22,500 27,500 40,500 49,500 58,500
Project Lead time (months) 16 - 18 16 - 18 16 - 18 22-26 22-26 22-26 32-38 32-38 32-38
Raw Material Requirements (Tons Per Day)
Lime Stone 900 1,350 1,800 2,250 3,750 4,500 6,750 8,250 9,750
Clay 90 135 180 225 375 450 675 825 975
Coal (4500 kcal/kg) 120 180 240 300 500 600 900 1,100 1,300
Gypsum (approx. 5%) 30 45 60 75 125 150 225 275 325
Manpower (for 3 shift)
Administrative & Managerial 7 7 10 10 12 15 15 18 18
Technical & Laboratory 15 15 18 20 24 25 25 28 28
Skilled Workers & Front Line     Managers 15 15 18 22 25 28 28 30 32
Unskilled Workers 36 36 44 50 60 65 65 70 70
Power (KWH/T) 100 - 110 100 - 110 100 - 110 90 - 100 80 - 90 80 - 90 80 - 90 80 - 90 80 - 90
Fuel (kcal/kg) 850 - 900 850 - 950 800 - 850 750 - 800 750 - 800 750 - 800 750 - 800 750 - 800 750 - 800
Clicker Grinding Plant
We offer Clinker Grinding Plants which requires the following raw materials:
  1. Clinker
  2. Gypsum
  3. Additives

All the raw materials are crushed with the help of Jaw Crusher if they contain lumps. The feed size for the Cement Mill should be less than 25 mm The raw materials are fed into their respective hoppers with the help of Belt Conveyor Or elevators. The hoppers are fitted with feeding systems which are connected with auto measuring and control system(Weighing Trolley). The measured quantity of raw material is discharged on a weighing Trolley/ conveyor belt. The weighing trolley/ conveyor belt carry the mixed material to the discharge hopper. The material from discharge hopper is taken to the elevator to feed into the Mill feed hopper. The discharge of the feed hopper is controlled by an adjustable speed rotary feeder. The feed of the mill can be varied as per the requirement. The rotary feeder discharge the material in to the Cement Mill. There are three chambers in the Mill. The chambers are filled with grinding Media ( balls & Cylpebs). The material is ground fine ( 3500 Cm2/gm.). The cement is discharged from the mill to the elevator to fill it in the Storage / Aeration Silo. The silo is fitted with compressed air coils. The air cools down the cement in the silo. The cooled Cement is packed with the help of packing machine in 50 Kg. Bags. The final product is tested from the bags for the quality and quantity and other parameters as per the statutory requirements provided by the Government.