Production Cycle
A process that demands rigorous safety, quality and eco-sustainability controls
A virtuous cycle of quality, safety and environmental restoration
Cement production is a complex process that requires rigorous monitoring to guarantee safety, quality and respect for the environment.
Technology and automation facilitate constant and accurate monitoring at every stage. The monitoring
1. Extraction of raw materials
The main raw materials extracted from quarries and mines consist of marl, clay, limestone, and pozzolan.
Marl is a sedimentary rock, of terrigenous type, composed of a clay fraction and a carbonate fraction generally given by calcium carbonate (calcite) CaCO3.
Typical marls have a calcium carbonate content ranging from 35% to 90%.
Extension of the lease: 1100 Ha
Excavated materials 2023: 980.000 ton
Daily production: 9.000 ton
Mine
2. Crushing of raw materials
The quarry-excavated rocks are unsuitable for direct use so they undergo crushing to be transformed into more homogeneous material.
Marl, extracted from the mine, is crushed using a modern hammer mill and ground to a mmax. size of about 80 mm. Crushing and stockpiling contribute to the homogenization of the material.
Production: 700/800 ton/h
Potenza installed power: 630 kWh
Stockpile capacity: 35.000 ton
Mill
3. Flour grinding and sizing
The marl is excavated from the stockpile using scrapers and subsequently analyzed by dual gamma-ray spectrometry to determine the optimal feed composition for the mills producing “raw flour”.
The produced flour is stockpiled in a silo and subjected to further homogenization to attain the requisite chemical and physical properties for quality clinker production in the subsequent firing process.
2 ATOX type FLSmidth vertical mills: from 170 ton/h
Installed power: 1.3 MW h each
2 feeder hoppers: from 1700 ton
2 Gamma-ray analyzers
Flour silo: from 8000 ton
Raw mill
4. Clinker firing
Clinker is produced from “raw flour” which, by burning pet-coke and RDF (Refuse Derived Fuel), is fired in a rotary kiln (at a temperature of 1400-1500 °C), where the chemical and physical reactions take place that allow the transformation of the flour into clinker.
After firing, the cooled clinker consists of dark, glassy granules that are stored in a stockpile. The stockpiling process and subsequent retrieval contributes to its homogenization.
Max capacity: 4500 ton/g
Furnace length: 65×4.5 m
Tower height: 88 m
No. of cyclones: 8
Precalcinator: 36.5×6.9 m
Clinker stockpiling: 45,000 ton
Furnace belt
5. Cement grinding
The clinker is retrieved from the stockpile and sent to the cement mills where it is finely ground with gypsum.
Depending on the type of cement required, limestone, pozzolan and/or blast furnace slag can be added. The specific composition of each cement type imparts unique strength and durability attributes, rendering it appropriate for particular applications.
2 horizontal pipe mills: from 100 ton/h
Installed power: 2.7 MW h each
9 feeder hoppers: from 6750 ton total
8 silos: from 33,000 ton total
Clinker grinder
6. Stockpiling and shipping cement
Cement is stored in silos and can be either loaded directly into bulk cement trucks or packaged into bags on pallets.
The products are sold either in bulk and/or in bags, depending on market requirements.
8 storage silos
Various product types
2 baggers
2 palletisers
2 wrapping machines
7 automatic loading belts
Shipping
7. Environmental restoration
A comprehensive, well-structured, process sustained over time.
Restoration of extraction sites is a complicated process that demands specialized knowledge and continuous effort. Consequently, we engage the expertise of industry professionals and implement comprehensive protocols that encompass various phases.
- Securing the area: The area is decontaminated of any process-related residues and rendered safe to prevent environmental degradation.
- Ground re-profiling: The terrain is regraded to replicate its original topography or one that is ecologically compatible with the surrounding area.
- Fertilization: The soil is enriched with nutrients to promote plant growth.
- Seed sowing and planting: Seeds and seedlings indigenous to the region, well-suited to the local conditions, are planted.
- Monitoring: The area is subject to regular monitoring to track the progress of natural regeneration and make any necessary adjustments.
Replanting
