Cement Plants - VSK & Rotary Kiln Technology
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 turnkey basis.
Salient Features
- Low pressure drop pre-heaters
- Raw mill equipped with high-efficiency separator
- Raw meal blending in CFC silo
- Pre-calciner suitable for alternative fuels
- Inlet & discharge fitted with efficient seals
- Benchmark cooler design
Key Benefits
Near-Zero Maintenance
Energy Efficient
Short Gestation
Low Installed Cost
Cement Manufacturing Process
1. Crushing & Proportioning
Limestone rock is the principal raw material. Primary crushing reduces the rock to about 150 mm, then secondary crushers reduce it to 75 mm or smaller. Material is stacked and reclaimed for homogeneous quality.
2. Raw Milling & Blending
Particles are ground to 90 microns or less in a closed circuit ball mill with high efficiency separator. The fine ground raw meal is sent to CFC silos for homogenization.
3. Pyro Processing
Raw material is heated exceeding 1,450°C in a 5-6 stage pre-heater tower (~110 metres), then through a pre-calciner and into rotary kilns lined with special firebrick.
4. Clinker Cooling & Heat Exchange
Clinker is discharged red-hot and cooled in grate coolers. The heated air is returned to the kilns for fuel savings.
5. Cement Milling, Storage & Packing
Portland cement is produced by adding gypsum in the final grinding process. Lime and silica make up about 85% of the mass.
Rotary Kiln Cement Plant - Project at a Glance
| Plants Offered (TPD) | 600 | 900 | 1200 | 1500 | 2500 | 3000 | 4500 | 5500 | 6500 |
|---|---|---|---|---|---|---|---|---|---|
| Land Area (Sq. M) | 80,000 | 100,000 | 125,000 | 175,000 | 280,000 | 325,000 | 450,000 | 550,000 | 650,000 |
| Captive Power (KW) | 6,000 | 8,500 | 10,000 | 12,500 | 22,500 | 27,500 | 40,500 | 49,500 | 58,500 |
| 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 (~5%) | 30 | 45 | 60 | 75 | 125 | 150 | 225 | 275 | 325 |
| Utilities | |||||||||
| 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 |
Clinker Grinding Plant
We offer Clinker Grinding Plants requiring Clinker, Gypsum, and Additives. Materials are crushed, fed via auto-measuring control systems, and ground fine (3500 Cm²/gm) in a three-chamber Cement Mill. The cement is cooled in aeration silos and packed in 50 Kg bags.