Oman Cement Company

Oman cementumumum Comp any(prenominal)Oman Cement Company (SAOG) was formed in 1978. Rusayl Cement name was completed in 1983 with an annual integrated cement issue galvanising capacity of 624,000 tons, of cement. In 1999 clean bulge outing capacity expanded to a total of 1.2 l in every last(predicate)ygagion tons per yr. The second end product line came on stream in mid 1998. Presently the familiarity is working on expanding the capacity of plant form 1.26 MTS per year to 1.70 MTS per year by upgrading achievement line No. 1 and No. 2.The community facilities be1- Computerized ManufacturingOman cement manufacturing process is fully computerized.This avoids major hazards in manufacturing and needfully less manpower.2- Central LaboratoryThe woodland Control is supported by central laboratory consisting of robotics, X-ray spectrometers, laser particle size analyzers and computerized somatogenic properties examening equipment.3- Quality Management administration and Environmental Management Systemoman cement Quality Management System is in accordance with the Quality Assurance Procedures of ISO 9001 2000 certification.4- Pollution Control.The Oman cement company produces many types of cement which be1- Ordinary Portland CementIt is type I Portland cement. Its uses be reinforced cover buildings, bridges and railway structures. The typical chemical compound compositions of this type are55% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 2.8% MgO, 2.9% (SO3), 1.0% firing loss, and 1.0% extra CaO.2- Sulphate distasteful CementIt is type V, is use where sulfate resistance is important. Its typical compound composition is38% (C3S), 43% (C2S), 4% (C3A), 9% (C4AF), 1.9% MgO, 1.8% (SO3), 0.9% Ignition loss, and 0.8% free CaO.3- Moderate sulphate resistantIt is type II cement. This type of cement can be employ in structures of considerable mass, such as large piers, heavy abutments, and heavy retaining walls. Its use willing reduce temperature grind a way especially when the concrete is subordinate to hot weather. Its typical compounds composition is51% (C3S), 24% (C2S), 6% (C3A), 11% (C4AF), 2.9% MgO, 2.5% (SO3), 0.8% Ignition loss, and 1.0% free CaO.4- Oil tumefy CementOil well cement, use for oil wells grouting, commonly made from Portland cement clear out or from blended hydraulic cements. It is used for cementing work in the drilling of oil wells where they are subject to high temperatures and pressures. Its typical compound composition isMgO 6.0% SO3 3.0% Loss On Ignition 3.0% C3S 48%-65% C3A 3.0% Insoluble Residue 0.75% C4AF+2C3A 24%Production methodsThere are four stages to produce cement that Oman cement using which are1- cookery of the birthday suit material at quarries2- high temperature and cooling to produce clinker3- cooking of the cement4- Cement backpackingProcess description1- Preparation material at quarriesThe dim material contains of limestone (80% of au naturel(p) material), silica, aluminate and i ron ore. The quarries situated around the Oman cement plant. At quarries the raw materials are extracted with heavy equipments. whence the limestones are crushed with mobile crushers connected with long conveyer sing to transport them to storage passing the auto lab to analysis the samples with roentgen ray each two hours. After that the raw material are go to reservoirs. Then they are move with transporter brawl to the raw mill to grind the raw materials. Finally the grinding raw materials are moved to mixture reservoirs to get proper mixture before feed them to kiln.2- Heating and cooling to produce clinkerThe raw materials are moved to channel, where warmth exchange is occurred among these material and the raising hot gases from kiln, then(prenominal) the materials are separated from the gases. After that the material moved to calciner where the limestone is converted to calcium oxide, and then the calcined materials arefed to the kiln where the temperature about 1400 c and then leave from kiln to get clinker. Then the clinker leaves from kiln to air to reduce its temperature to 100 c to be ready to be moved to cement mill.Kiln process3- Preparation of cementThe clinker that came out of the cooler will be transported by the bucket chain conveyor to the silo. The beauty filter on the top of the silo is sized for the feeding by the bucket chain conveyor and thermal air expansion in the storage. The clinker extracted from the silo is transported by charge conveyors to the cement proportioning. The gypsum is added to the clinker. Then the proportioned materials are conveyed via belt conveyor to cement grinding. Materials ground by orb mill are transported separator by bucket elevator. The coarse particles separated return to ball mill for regrinding while the fine product is collected by the bag filter behind the separator and then conveyed to cement silo with an air slither and bucket elevator. Cement silos is used to remembering the cement.Ce ment mill4-Cement packingThe cement from extraction brasss under the cement silo is delivered to the buffer bin by air slide and the bucket elevator and vibrating screen, before being fed into each boxer. The bagged cement can be loaded directly or stored in storehouse temporarily.Machinery and EquipmentsNo. Name office staff1 Limestone Crusher used in stone quarry to crush limestone2 Clay crusher used in stone quarry to crush clay3 Limestone Stacker employ to move limestone to preblending modesty4 Limestone reclaimer apply to take preblended mixture from preblending stockpile5 Coal and iron ore Crusher Used to crush additive materials6 Coal and iron ore Stacker Used to move iron ore to conveyor belt then to proportioning station7 Coal iron ore reclaimer Used for reclaiming all additive materials and coal8 Raw mill used for raw materials grinding and drying9 Raw mill fan Used to plant the mill inlet temperature.10 Preheater fan used to dry the raw materials11 Preheater and p recalciner Preheater used for preheating and partial decarbonation, and precalciner for calcination12 Rotary kiln used to beset raw materials to a high temperature13 Grate cooler Used for quenching14 Cement mill Used to grind cement15 Bag filter Used to collect dust16 Coal mill Used for coal drying17 Bulk dock-walloper for truck Used to load the bulk18 Cement packer Used to pack cement productQuality control systemThe quality control subdivision in the Oman cement company function is to monitor product quality in every stage of production starting with extracting the limestone from the quarry till the stage of cement mills, by victorious samples and analysis them.1- The computer and roentgen ray analysisThe automation lab consists of robot, x-ray spectrometers, laser particle size analyzer and computerized physical properties.The samples will be taken by an automatic sampler from a point between the raw mill and homogenizing silo and then transported manually to the central aut o lab, where it will be semi-automatically prepared and sent to an X-Ray analyzer. The results analyzed will be sent to a proportioning computer. The computer will calculate the ratio of raw materials and send out the set value to constant feeder jibe to the chemical compositions and raw meal module required.2- Physical analysisTo test the fineness, soundness, setting time, strength, specific gravity, heat of hydration and loss on ignition of the cement to achieve the American specifications requirement.Maintenance procedureThe department functions are-Checking all toolry and equipments are work properly.-Scheduling and planning for term of enlistment livelihood, predictive maintenance. Coordinating with all departments for daily problem. Planning, coordinating of preventive and breakdown activities for achieving high plant handiness to meet production target.The procedure that the Oman cement follows in shield of breakdown, preventive and fill updown maintenance are1. Breakd own maintenanceIn case of any breakdown maintenance in the production department, they give study regarding the breakdown to the maintenance department, and maintenance workers are sent to the production plant to fix machine failures.2. Preventive maintenancehere, a team of maintenance workers is sent directly to the production plants to check out whether there is any failure in the machinery or not.3. Shutdown maintenanceWhen the plant is shut down the employees in the production department sent a earn to the maintenance department and successive steps are taken by maintenance department to solve the failures. The plant shutdown occurs every 6 month in March and September.The process of operating and monitoring production lines and machines instantly, so they can watch the failure and damage of the machines and equipments to repair them or replace them.Technical counselingThe technical management responsibility is to supervise all the mechanical, electrical things and maintain the various equipments and everything that related to maintenance procedure, and this management divided in many constituentsa- The machine subdivisionThe responsibility of this section is prepare exigency and planning schedule and do it to all the equipments and treat it to diagnose the unusual failure and fix it. Inspect the machinery, check with drawings and specifications and rectification. It edges with store section to provide the required replacement separate and also contacts with other(a) sections to maintain the equipments at the workshop.At the workshop they fix the equipments in emergency conditions, check the equipments if they work properly and routinely, takes care the equipments and help to clean them.b) The machine operation sectionThe responsibility of this section fabricate the replacement parts, win an order outside the company to get new parts, lathe the machine parts the required the workshops.c) The immediate machine maintenance sectionThe responsibilit y of this section is to check and fix the production lines.d) The electrical sectionThe electricity department is responsible to repair and ensure the continuation of the work of all electrical and electronic equipment and precision instruments on the production line and also supervises contact with other sections to that the electricity working properly.