| Process I: Quarries Managing all forms of raw material quarrying, such as limestone and clay, but mainly optimizing the usage of the different quarries, assuring the ease and efficiency in all quarrying steps. Assuring the proper raw mix proportioning, by sorting all kind of raw materials and piling them according to the best chemical composition to form the proper raw mix for the second production process. Many manufacturing tools are used during that process to assure the blasting and crushing of 11 million tons of cement raw material per year, mainly limestone and clay. Process II : Raw Milling & Clinker Manufacturing Raw material, mainly limestone and clay, is being crushed to uniform size using two types of sophisticated crushers. The final outcome, the Raw Mix, is analyzed by gamma rays minute by minute to assure its proper blending. Raw Mix is measured and carefully fed into ball mills grinder, and result a fine powder called the Raw Meal, which is stored in silos and mixed thoroughly to ensure the homogeneity of raw meal and proper kiln efficiency. Raw meal is fed into the pre-heater tower. As it cascades down, it reaches a temperature of 1440 C’. The clinker occurs in this burning zone. The clinker coming out of the kilns drops into in a cooler, and conveyor belts pull them to a circular storage. Main de-dusting filters are used to clean the gas before leaving the kiln using natural gas. Process III : Cement Grinding and Packing The clinker produced in the previous process is transported to cement mills by conveyor belts. Horizontal steel tube filled with steel balls is the concept of those grinding mills that grind the clinker into the first form of what is to be named Portland cement. A fine grey powder is formed to be mixed with certain amounts of gypsum and other additives in several other grinding steps to reach the desired fineness and standard mix. This process also manages to determine particles sizes by many high efficient separators assuring proper grading and uniformity of the cement particles. Now, cement is moved to storages silos, and depending on market demand, it is loaded in bulk or bagged. Process IV : Quality, Environment and Safety Consistency is the keyword for quality. Analyses during the process, and at the final stage of each process, result in a product with the desired quality meeting required worldwide standards. Many high tech equipment is used to assure the required quality analysis details, especially during the mixing process. As a result, ECC exceeded by far all the world known standards. Environment is a major concern in ECC daily operation. All international measurements are applied physically in all production processes setting an example to many other plants. Employees’ safety is another major concern and the major responsibility. Thus, the company conducts periodic trainings to increase the awareness about safety rules and procedures. Process V: Engineering It’s another main support function to all the above processes, responsible for studying all technical and engineering new projects related to production, including modification and upgrades. Process V is also in control of maintaining all plant infrastructure such as roads and lighting, in addition to managing the water treatment station located in the plant. Process VI: Maintenance and Material Planning Another support function that consists of two teams: the Maintenance, Planning and Preparation team (accountable for the maintenance management activities) and the Planning team (to assure provision of materials necessary during all production action), showing expertise in material inventory management. ECC does not provide services to local market only but is also an exporter extending services to the international market, including GCC, Mashreq countries, north & east Africa, Europe & US. Contact Information: Egyptian Cement Company (ECC) Head Office: Nile City Towers, the South Tower, Corniche El Nil, Cairo, Egypt. Telephone: (+20-2) 2461- 2400 – Fax: (+20-2) 2461- 1995/ 90 Plant: 93 km, The Old Katamia Road, Sokhna, Suez, Egypt. Telephone: (+20-12) 399 3301 - 6 Web Site: www.egyptiancement.com |