Our Process
Our cement production process is designed to produce the highest quality cement, backed by state-of-the-art technology and rigorous quality control. At East African Portland Cement PLC, we are committed to being the top choice for our customers by delivering reliable, consistent, and high-performance cement products.
Limestone Mining at Kibini, Kunkur, and Bissil-Mulage
- Mining Operations: Our process begins at our quarries in Kibini, Kunkur, and Bissil-Mulage, where high-quality limestone is extracted. Using advanced mining techniques, we ensure efficient extraction while minimizing environmental impact.
- Primary Crushing: The mined limestone is fed into a jaw crusher to reduce it to smaller, manageable sizes, making it easier for subsequent processing.
2. Transportation to the Factory
Road Transportation: The crushed limestone is transported by road from the mining sites to our factory, where the production process continues.
3. Secondary Crushing and Raw Material Preparation
- Secondary Crushing: Upon arrival at the factory, the limestone undergoes further crushing to achieve the desired size for milling.
- Raw Meal Preparation in the ATOX Mill: The crushed limestone is fed into an ATOX mill, where it is ground along with other essential materials like clay and iron ore to form a fine powder known as raw meal.
4. Raw Meal Transport and Preheating
- Pneumatic Conveyor Transport: The finely ground raw meal is transported via pneumatic conveyors to the preheater tower.
- Preheating: In the preheater, the raw meal is heated using exhaust gases from the kiln. This step reduces the energy required for the subsequent clinkerization process.
5. Clinker Production in the Kiln
Calcination and Clinkerization: The preheated raw meal enters the kiln, where it undergoes calcination and clinkerization at temperatures up to 1450°C. This high-temperature process results in the formation of clinker, the primary component of cement.
6. Clinker Cooling and Transport
- Clinker Cooling: The hot clinker is quickly cooled to preserve its chemical properties.
- Pan Conveyor Transport: The cooled clinker is then transported by pan conveyors to the milling section, where the final cement product is prepared.
7. Cement Grinding and Blending
- Milling Section: In the milling section, the clinker is ground together with fine Kunkur, pozzolana, and gypsum to achieve the desired cement composition. This stage is crucial in determining the final properties of the cement.
- Quality Control: Throughout the milling process, our stringent quality control measures ensure that the cement meets the highest industry standards.
8. Cement Storage and Packaging
- Cement Storage in Silos: The finely ground cement is stored in large silos, where it is kept ready for packaging and distribution.
- Packaging: The cement is packed into 50kg bags or stored in bulk, depending on customer requirements.
9. Distribution to Clients
- Distribution: Finally, the packaged cement is distributed to our network of distributors and other clients, ensuring timely delivery and customer satisfaction.