P R O C E S S

Mining
The cement manufacturing process starts from the mining of limestone, which is the main raw material for cement. Superior quality limestone is available in UAE at Tawain area, and the same limestone is used for cement manufacturing at Pioneer Cement. Limestone is excavated from mines after drilling and blasting and loaded on to dumpers which transport the material and unload into hoppers of the limestone crushers.

Crushing Stacking & Reclaiming of Limestone:
Crushers crush the limestone to 0-25mm size and transported to the factory site. The limestone is unloaded into the dump hoppers, which discharge the material onto a belt conveyor and takes it to

the stacker. The material is stacked in longitudinal stockpiles. Limestone is extracted transversely from the stockpiles by the reclaimer and conveyed to the Raw Mill hoppers for grinding of raw meal.

Raw Meal Drying/Grinding & Homogenization
Reclaimed limestone along with Shale and Iron ore stored in their respective hoppers is fed to the Raw Mill for fine grinding. The hot gasses coming from the clinkerisation section are used in the raw mill for drying and transport of the ground raw meal to the Blending silo, where it is homogenized. Raw Meal extracted from the silo (now called Kiln feed) is fed to the top of the Pre heater for Pyro processing.

Clinkerisation
Cement Clinker is made by pyro processing of Kiln feed in the preheater and the rotary kiln. Fine coal is fired as fuel to provide the necessary heat in the kiln and the Precalciner is located at the bottom of the 6 stage preheater. Hot clinker discharged from the Kiln drops on the grate cooler and gets cooled. The cooler discharges the clinker onto the pan conveyor and it is transported to the clinker silo. The clinker is taken from the silo to the ball mill hoppers for cement grinding.

Cement Grinding & Storage
Clinker and Gypsum are extracted from their respective hoppers and fed to the Cement Mills. These Ball Mills grind the feed to a fine powder and the Mill discharge is fed to an elevator, which takes the material to a separator, which separates fine product and the coarse. The latter is sent to the mill inlet for regrinding and the fine product is stored in concrete silos.

Packing
Cement extracted from silos is conveyed to the bins for bulk loading and automatic electronic packer where it is packed in 50 Kg Paper bags and dispatched in trucks.