Where Innovation Takes Shape
Our Manufacturing Process
1) RAW MATERIALS RECEVING & STORAGE:
- Receiving of Raw Materials through well-equipped Weigh Bridge system where material delivery, documentation check, inspection & weighing.
- Piling up different type of Raw Materials in desired storage locations (by LUFFING BOOM STACKER) and reclaiming (by BRIDGE TYPE & PYLON TYPE RECLAIMER) with the capacity of 50,000 MT.
2) RAW MATERIALS TRANSPORTATION & FEEDING:
- Transporting the raw materials through Conveyor Systems (BELT CONVEYORS) from the reclaiming station and feeding into desired Feeding hoppers (LIMESTONE / SHALE / IRON ORE/ SILICA SAND).
- Raw materials are transported on a belt that is weighed continuously (WEIGH FEEDERS) to the Raw Grinding Mill (BALLMILLS). The belt runs through a set of load cells, and the speed is controlled to ensure quality with accurate feeding.
3) RAW MATERIAL GRINDING & STORAGE:
- The Grinding capacity of each mill as designed (2 Identical BALL MILLS) is 100 Tons Per Hour (TPH). With the process optimisation C modifications, we have upgraded the production efficiency increment of 50 % up-to 150 TPH and along with the reduction of specific power by 15 %.
- Using wide range of Alternative raw materials to substitute the main raw materials which are consumed in Raw grinding for cost efficiency.
- In the Raw meal storage silo we frequently monitored the material distribution of Kiln feed (Raw meal) for Clinkerization process to maintain the clinker
4) PRE-HEATING & CLINKERIZATION:
- Preheater Tower (Energy Efficiency / Faster Reactions & Uniformity) – is a vertical, multi- stage (6 STAGES WITH ILC PC) structure with stages of pre-heating cyclones used to pre-heat the raw meal before it enters the rotary kiln for Clinkerization process.
- Clinkerization process with a Rotary Kiln of different type of zones (Pre-heating / Calcining / Transition / Sintering & Cooling). Rotary kiln with a capacity of (3500 TPD & drawn with 4100 TPD as maximum production), a rotating cylindrical furnace in which the raw meal undergoes chemical transformation to form The kiln operates at extremely high temperatures, typically between 1400°C and 1500°C
- With proper controlling and process optimizing we produce the good quality of clinker to ensure the unwanted interruptions in final product (cement) quality.
- Revamping the Natural Gas firing system during the unavailability of coal and succeed with optimum Kiln operation.
- Using wide range of Alternative fuels to substitute the main fuel (Coal/Gas) which are consumed in Kiln operation for cost efficiency.
5) COAL GRINDING & FIRING:
- The Grinding capacity of mill as designed (BALL MILL) is 20 Tons Per Hour (TPH). With the process optimisation C modifications, we have upgraded the production efficiency increment of 30 % up-to 26 Along with usage of Alternative fuels with mail fuel to produce fine fuel for firing in Kiln operation.
- Using Multi-channel Burner in main firing which have in the reduction of Nox and maintaining the flame stabilization.
6) CEMENT GRINDING & STORAGE:
- The Grinding capacity of each mill as designed (2 Identical BALL MILLS) is 110 Tons Per Hour (TPH). With the process optimisation C modifications, we have upgraded the production efficiency increment of 10 % up-to 120 TPH for low cements and along with the reduction of specific power by 10 %.
- Using wide range of Alternative raw materials to substitute the main raw materials which are consumed in Cement grinding for cost efficiency.
7) PACKING & DESPATCH:
- The Packing capacity of each packer as designed (2 Identical packers) is 120 Tons Per Hour (TPH).
- Now we have installed Jumbo bags loading system (1.5 MT) with in-house arrangements.
Innovative Quality Assurance for Superior Cement Performance
Pioneer Cement Industries has well-equipped laboratory ensures quality control, regulatory compliance, and process optimization in cement manufacturing, leading to high-performance cement products of different types.
In Pioneer Cement Industries, we are producing following different types of cement to meet customer requirement in local and international market.
Our Products Details
| Product Type | Details | Loading Facility |
|---|---|---|
| OPC 42.5 | Ordinary Portland Cement CEM I – 42.5 N | Bulk, Jumbo bags & 50 kg Bags |
| OPC 52.5 | Ordinary Portland Cement CEM I – 52.5 N | Bulk & Jumbo bags |
| SRC | Sulphate Resisting Portland Cement 42.5 N | Bulk, Jumbo bags & 50 kg Bags |
| MSRC | Moderate Sulphate Resisting Portland Cement | Bulk |
| PLC 32.5 | Portland Limestone Cement 32.5 N | Bulk & 50 kg Bags |
| CEM II 42.5 R | CEM II Portland Limestone Cement 42.5 R | Bulk |
| MC 22.5 | Masonry Cement 22.5 N | 50 kg Bags |
| MC 12.5X | Masonry Cement 12.5 X | 50 kg Bags |
| GGBFS | Ground Granulated Blast Furnace Slag | Bulk & Jumbo bags |
Our testing Laboratories
In Pioneer Cement Industries, laboratory plays a crucial role in ensuring the quality and consistency of cement.
We have four state of art laboratories, fully equipped with standard analytical instruments:
- Physical Laboratory
- Conducts tests on raw materials, clinker, and cement to ensure compliance with standards.
- Key tests include fineness (Blaine test), setting time, compressive strength, soundness, and consistency.
- Monitors physical properties to optimize grinding, setting behaviour, and durability of cement.
- Chemical Laboratory
- Analyses the chemical composition of raw materials, clinker, and final cement products.
- Uses wet chemical methods such as titration and gravimetric analysis to determine major oxides like SiO₂, Al₂O₃, Fe₂O₃, CaO, and MgO.
- Ensures the proper balance of compounds required for quality cement production.
- XRF (X-ray Fluorescence) Laboratory
- Equipped with XRF spectrometers for rapid and accurate elemental analysis.
- Provides real-time monitoring of raw mix composition, clinker, and cement to maintain product consistency.
- Helps in process control by optimizing raw mix design and fuel usage.
- Concrete Testing Laboratory
- To check slump and flow of concrete with different mix design and different aggregates
- Compressive strength of concrete to meet project specifications.
Management System Certification
We have implemented the following Management systems certification for Pioneer Cement Industries:
Quality Management System as per IS/ISO 9001:2015
Environment Management System as per IS/ISO 14001:2015
Occupational Health & Safety Management System as per OH&S 45001:2018
There are more than 20 no. cement manufacturing plants in UAE, out of that Pioneer Cement Industries is in top 5 to get these following Product Conformity Certificates
Product Conformity Certificate demonstrates the compliance of products and manufacturing facility as per International/National standards.
- DCL (Dubai Central Laboratory) Product Certification – Most important requirement for supplying cement to well established Ready-mix customers and Builders in Dubai.
- ADQCC (Abu Dhabi Quality and Conformity Council) – Very important certificate to sell cement in Abu Dhabi market.
- Fujairah Municipality Product Conformity Certificate – This certificate is required to supply cement in any construction project working in Fujairah Emirates.