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.