02. HCMT Overview Cement Manufacturing-Rev01-18-07-2023

[Audio] Good day everyone. Today, I am excited to talk to you about the overview of cement manufacturing process. This overview provides us with valuable insights on how cement is processed from its raw state to its final form. Through this overview, we gain a better understanding of Hume Cement operations and the processes that are involved in cement production. I hope that this overview offers us a better picture of cement production and how Hume Cement can aid in the development of our company..

[Audio] Hume Cement has continually strived to stay ahead of the game by adopting ground-breaking technology at its integrated cement plant in Gopeng, Malaysia. Operations for Line 1 commenced in 2012 with a capacity of 5000 tons per day and is fully compliant with international standards such as MS ISO 9001 and MS ISO 14001. Following two successful years of operations of Line 1, construction of Line 2 was begun in 2014 and finished in 2016, with a total capacity of 10000 tons per day. Customers benefit from certified cement products, such as Panda Green, Panda Blue, Panda Red and Panda Yellow, that are aligned with MS EN 197 - 1:2014 and MS EN 413 - 1:2012 standards. Hume Cement is proud to be part of the Hong Leong Manufacturing Group, a leader in the cement industry..

[Audio] Hume Cement takes a comprehensive approach to cement manufacturing, utilizing the newest technologies to always yield the finest quality cement with dependable strength. The integrated cement plant is outfitted with a 4th generation cooler developed for the kiln and is capable of producing 3 million tons of clinker, and 5 million tons of cement yearly. This cutting-edge structure enables Hume Cement to constantly turn out 10000 ton per day production lines of cement..

[Audio] At Hume Cement, quarrying and storage of limestone initiates the manufacturing process. The limestone rocks are transported to the crushers with dump trucks, then blasted into smaller pieces. Subsequently, the crushed limestone is transferred to a limestone dome through a conveyor system in preparation for further processing..

[Audio] Hume Cement takes pride in having an efficient cement manufacturing process. The finest limestone is sourced from the 560-acre open cast quarry that is estimated to provide ore reserves for 50 years. A daily requirement of 15000 tons of limestone is guaranteed. Quarrying of limestone started in 2011, which has provided for a continual growth in cement production..

[Audio] At Hume Cement, our limestone quarry operates 10 hours a day for 7 days a week, enabling us to provide a steady supply of raw material which is essential for the cement manufacturing process. Additionally, we make sure to develop 5 benches at a depth of approximately 60 meters to further ensure consistent raw material supply. It is important to note that 80% of the raw materials used by the plant are limestone, thus it is critical to have the plant close proximity to the quarry. Lastly, the kiln operation is 24 hours 7 days to make sure that the process always continues..

[Audio] Hume Cement manufacturing process starts with the delivery of blasted rocks of 1m size. The rocks are then fed into the crusher to reduce the stones to maximum size of 75mm or no larger than a fist size. After that, the crushed stones are transported through a long belt conveyor and kept in a limestone dome which has a capacity of 50000 tons. Finally, the stacker reclaimer is used to stack and reclaim materials from a stockpile..

[Audio] Raw Material Storage. There are several raw materials which require mechanical handling and storage. Therefore, our raw material storage are equipped with stacker reclaimer and conveyor system..

[Audio] At Hume Cement, we aim to ensure the cement production process is efficient and secure. As a corrective measure, all sand, clay and iron rich clay are securely stored in covered storage domes. Then, limestone and clay are mixed to form a calcium silicate clinker. Different types of cement are produced from this process, which is further ground and mixed with gypsum. These steps are taken to guarantee that the cements produced by Hume Cement Sdn Bhd are of premium quality..

[Audio] Hume Cement has an advanced cement manufacturing process that involves raw mill and homogenising silo. The raw mill is used to grind raw materials into a raw mix, while the homogenising silo ensures that the ingredients are evenly blended. The raw mix is then sent to a cement kiln which converts it to clinker. The clinker is then ground to make cement in a cement mill..

[Audio] Our vertical raw mill has a capacity of 400 tons per hour, which enables us to create a fine product with a targeted kiln feed chemistry with a residue of less than 10% on a 90 micron sieve. This is aided by its low specific energy consumption, allowing milling, grinding and classifying processes to take place in a single unit. Additionally, low pressure loss ensures lower power consumption when running. Heat recuperation from the kiln exhaust gases dries raw materials to a moisture content of 0.2%, and the grinding rollers provide enough pressure for individual particles on the bed to fracture. After this, the inlet air lifts the ground material into a high efficiency separator that separates coarse and fine particles...

[Audio] Hume Cement employs a Raw Meal Homogenising Silo in its cement manufacturing process. This enables the uniform mixing of the ground raw meal, thus guaranteeing the even distribution of the ingredients. As seen in the cross section photo, the silo has entry points at the top through which the raw meal is added, and seven extraction points at the bottom. This ensures that the raw meal is homogenised uniformly..

[Audio] Coal storage and coal milling process are indispensable in cement production. The coal dome is used for storing coal until it is ready to be used or transported to the coal mill. At the coal mill, the coal is ground into a fine powder with the help of rollers. This exact process guarantees that particles have the right size for cement production. The coal is fed into the hopper and then crushed by the rollers to make sure the particles have the right size for cement production..

[Audio] Coal milling at Hume Cement has been optimized for efficiency, with a coal mill grinding capacity of up to 40 tons per hour. The coal is ground into a fine powder, which is stored in two 60 ton bunkers, then fired in the kiln and calciner. This is one of the measures taken to guarantee quality and uniformity in the burning process..

[Audio] Hume Cement utilizes highly efficient and automated stacker-reclaimers to consistently supply coal materials. This reduces manual labor and allows for a uniform mixing of the coal materials. The stacker-reclaimers also allow for an orderly storage and reclaiming of coal, thereby optimizing the burning process..

[Audio] Hume Cement decomposes a raw mix of materials into calcium oxide which forms the basis of cement clinker particles at high temperatures with the use of a Kiln and Preheater Tower. The Preheater pre-heats the mix and drives off carbon dioxide and water prior to the mix being fed into the Kiln. This process is essential for producing the cement clinker particles that are the foundation of cement..

[Audio] The process start with preheating of raw mix in stages to achieve 90-95% calcination to facilitate subsequent process of sintering of clinker in the kiln. When raw mix is fed to the kiln where pyro-processing takes place, raw mix is heated at around 1450°C whereby clinker is formed and then rapidly cooled in a high efficiency cooler to produce the marble-sized pellets of clinker..

[Audio] Hume Cement preheaters are equipped with 5 stage cyclone preheater tower. At this stage, heat transfer is made between the hot gases and cold raw meal, accompanied by the evaporation of residual water and the removal of crystal water from the minerals. The process ends with calcination, ensuring the quality of clinker is always of the highest standard..

[Audio] Rotary kiln with preheater towers have three major refractory zones: the calcining zone, the burning zone, and the cooling zone. As the raw mix enters the kiln, a series of chemical reactions takes place as per cross section photo. CO2 is removed from the carbonates and decomposition of clay minerals occurs. This is followed by the formation of C2S (Belite) in a solid state reaction..

[Audio] The process begins with hot clinkers that are emitted from the rotary kiln and dropped onto a grate bed. Then the clinkers are pushed through the cooler by the reciprocating movement of rows of plates. The Secondary air is the air from the grate cooler directly into the kiln , the air flow direction is from cement kiln head to cement kiln tail. Tertiary Air is the air from grate cooler to decomposing furnace through the tertiary pipes. The heat recuperation from hot clinker to minimize fuel consumption for kiln & preheater..

[Audio] Hume Cement is dedicated to environmental responsibility. To reduce our environmental impact, we have installed a de-dusting plant with Bag Filter Type technology. This is a widely-used and effective dust collection system for cement production. Our de-dusting plant has been kept dust emission levels at <20mg/m3, far below the 50mg/m3 limit set by the Department Of Environmental. Real-time monitoring is done through CEMS, overseen by the Department of Environment..

[Audio] Milling cement is an integral part of cement production. To produce fine cement powder, clinker is ground in milling machines like cement ball mills and vertical roller mills. These machines guarantee that our cement products are of superior quality and consistent with industry standards...

[Audio] Hume Cement is devoted to providing superior cement products for its customers. The production of cement starts with the judicious selection of materials, which are then ground and blended to an even consistency in our advanced mills. Our facility houses two ball mills and two vertical cement mills. We guarantee that our procedures for product development are consistent, efficient and cost-effective and our cement is sold under the familiar Panda brand, such as Panda Green (PCC), Panda Blue (OPC), Panda Red (MC) and Panda Yellow (PLC). These products are stored in our nine silos and then shipped to clients..

[Audio] At Hume Cement, we recognize that the production of cement is a delicate process and warrants careful, mindful monitoring throughout. To ensure this, we have drawn up a comprehensive overview of the cement production process. Total output output is 10000 ton, 3000 ton in paper bagged cement and 7000 ton in bulk cement. After milling, the cement is then moved to the rotary cement packer and bagged into 50 kg paper bags before being sent off to the palletizers for stacking and covering with a stretch hood. Monitoring the process is key to guaranteeing that the quality of the product is not compromised. That is why we have taken such stringent measures in the cement production process..

[Audio] Our progressed rotary packers help us accomplish this, permitting us to pack up to 120 tons of cement every hour into 50-kilogram sacks. With the help of these packers, we can give the highest caliber cement to our customers, rapidly and productively..

[Audio] Hume Cement utilises automation and modern technology to improve its palletising process. The company is equipped with two Stretch Hood Palletizers, each capable of processing 120 tonnes per hour, which are used to transfer, arrange and stack cement bags onto 2-tonne pallets. Normally, 40 bags per pallet are covered with a stretch hood. Furthermore, Hume Cement also provides loose-bag packing for customers..

[Audio] Hume Cement uses bulk cement trailers to transport and discharge cement products from the plant to the customers' site. The pressure vessels in the trailers are fitted with loading systems which enable the direct loading of cement products from the silos into the pressure vessels. A weighbridge is used after the trailer leaves the premises, to record the tonnage of the load, thereby ensuring that the correct amount of cement is delivered..

[Audio] Hume Cement has developed a comprehensive overview of the cement manufacturing process. This overview outlines the process from start to completion, and gives a comprehensive look into the production and distribution of cement. We hope that this presentation has provided you with a better understanding of Hume Cement and its operations. We are thankful for your participation in this presentation and your interest in our business..