Oman Cement Company
Oman Cement Company ( SAOG ) was formed in 1978. Rusayl Cement works was completed in 1983 with an one-year incorporate cement production capacity of 624,000 dozenss, of cement. In 1999 clinkering capacity expanded to a sum of 1.2 million dozenss per twelvemonth. The 2nd production line came on watercourse in mid 1998. Presently the company is working on spread outing the capacity of works signifier 1.26 MTS per twelvemonth to 1.70 MTS per twelvemonth by upgrading production line No. 1 and No. 2.
The company installations are:
Computerized Fabrication
Oman cement fabrication procedure is to the full computerized.
This avoids major jeopardies in fabrication and needs less work force.
Central Laboratory
The Quality Control is supported by cardinal research lab consisting of robotics, X-ray spectrometers, optical maser atom size analysers and computerized physical belongingss proving equipment.
Quality Management System and Environmental Management System
oman cement Quality Management System is in conformity with the Quality Assurance Procedures of ISO 9001: 2000 enfranchisement.
Pollution Control.
The Oman cement company produces many types of cement which are:
- Ordinary Portland Cement:
It is type I Portland cement. Its utilizations are strengthened concrete edifices, Bridgess and railroad constructions. The typical compound composings of this type are:
55 % ( C3S ) , 19 % ( C2S ) , 10 % ( C3A ) , 7 % ( C4AF ) , 2.8 % MgO, 2.9 % ( SO3 ) , 1.0 % Ignition loss, and 1.0 % free CaO.
- Sulphate Resistant Cement:
It is type V, is used where sulfate opposition is of import. Its typical compound composing is:
38 % ( C3S ) , 43 % ( C2S ) , 4 % ( C3A ) , 9 % ( C4AF ) , 1.9 % MgO, 1.8 % ( SO3 ) , 0.9 % Ignition loss, and 0.8 % free CaO.
- Moderate sulfate resistant:
It is type II cement. This type of cement can be used in constructions of considerable mass, such as big wharfs, heavy abutments, and heavy retaining walls. Its usage will cut down temperature rise particularly when the concrete is capable to hot conditions. Its typical compounds composing is:
51 % ( C3S ) , 24 % ( C2S ) , 6 % ( C3A ) , 11 % ( C4AF ) , 2.9 % MgO, 2.5 % ( SO3 ) , 0.8 % Ignition loss, and 1.0 % free CaO.
- Oil Well Cement
Oil good cement, used for oil Wellss grouting, normally made from Portland cement cinder or from blended hydraulic cements. It is used for cementing work in the boring of oil Wellss where they are capable to high temperatures and force per unit areas. Its typical compound composing is:
MgO: 6.0 % SO3: 3.0 % Loss On Ignition: 3.0 % C3S: 48 % -65 % C3A: 3.0 % Insoluble Residue: 0.75 % C4AF+2C3A: 24 %
Production methods
There are four phases to bring forth cement that Oman cement utilizing which are:
- Preparation of the natural stuff at preies
- Heating and chilling to bring forth cinder
- Preparation of the cement
- Cement wadding
Procedure description
- Preparation stuff at preies
The natural stuff contains of limestone ( 80 % of natural stuff ) , silica, aluminate and Fe ore. The preies located around the Oman cement works. At preies the natural stuffs are extracted with heavy equipments. Then the limestones are crushed with nomadic crushers connected with long conveyor belt to transport them to storage go throughing the car lab to analysis the samples with x-ray each two hours. After that the natural stuff are moved to reservoirs. Then they are moved with conveyer belt to the altogether factory to crunch the natural stuffs. Finally the crunching natural stuffs are moved to mixture reservoirs to acquire proper mixture before fed them to kiln.
- Heating and chilling to bring forth cinder
The natural stuffs are moved to impart, where heat exchange is occurred between these stuff and the raising hot gases from kiln, so the stuffs are separated from the gases. After that the stuff moved to calciner where the limestone is converted to calcium oxide, and so the calcined stuffs arefed to the kiln where the temperature about 1400 degree Celsius and so go forth from kiln to acquire cinder. Then the cinder leaves from kiln to air to cut down its temperature to 100 degree Celsiuss to be ready to be moved to cement factory.
- Preparation of cement
The cinder that came out of the ice chest will be transported by the pail concatenation conveyer to the silo. The bag filter on the top of the silo is sized for the eating by the pail concatenation conveyer and thermic air enlargement in the storage. The cinder extracted from the silo is transported by belt conveyers to the cement proportioning. The gypsum is added to the cinder. Then the proportioned stuffs are conveyed via belt conveyer to cement crunching. Materials land by ball factory are transported centrifuge by pail lift. The harsh atoms separated return to ball factory for regrinding while the all right merchandise is collected by the bag filter behind the centrifuge and so conveyed to cement silo with an air slide and pail lift. Cement silos is used to hive away the cement.
- Cement wadding
The cement from extraction systems under the cement silo is delivered to the buffer bin by air slide and the pail lift and vibrating screen, before being fed into each bagger. The bagged cement can be loaded straight or stored in depot temporarily.
Machinery and Equipments
- Limestone Crusher used in rock prey to oppress limestone
- Clay crusher used in rock prey to oppress clay
- Limestone Stacker Used to travel limestone to preblending reserve
- Limestone reclaimer Used to take preblended mixture from preblending reserve
- Coal and Fe ore Crusher Used to oppress linear stuffs
- Coal and Fe ore Stacker Used to travel Fe ore to conveyor belt so to proportioning station
- Coal & Fe ore reclaimer Used for repossessing all linear stuffs and coal
- Raw factory used for natural stuffs crunching and drying
- Raw factory fan Used to set the factory recess temperature.
- Preheater fan used to dry the natural stuffs
- Preheater and precalciner Preheater used for preheating and partial decarbonation, and precalciner for calcination
- Rotary kiln used to raise natural stuffs to a high temperature
- Grate ice chest Used for slaking
- Cement factory Used to crunch cement
- Bag filter Used to roll up dust
- Coal factory Used for coal drying
- Bulk stevedore for truck Used to lade the majority
- Cement bagger Used to pack cement merchandise
Quality control system
The quality control section in the Oman cement company map is to supervise merchandise quality in every phase of production get downing with pull outing the limestone from the prey till the phase of cement Millss, by taking samples and analysis them.
- The computing machine and x-ray analysis:
The mechanization lab consists of automaton, x-ray spectrometers, optical maser atom size analyser and computerized physical belongingss.
The samples will be taken by an automatic sampling station from a point between the altogether factory and homogenising silo and so transported manually to the cardinal car lab, where it will be semi-automatically prepared and sent to an X-Ray analyser. The consequences analyzed will be sent to a proportioning computing machine. The computing machine will cipher the ratio of natural stuffs and direct out the set value to constant feeder harmonizing to the chemical composings and natural repast faculty required.
- Physical analysis:
To prove the choiceness, soundness, puting clip, strength, specific gravitation, heat of hydration and loss on ignition of the cement to accomplish the American specifications demand.
- Care process:
The section maps are:
- Checking all machinery and equipments are work decently.
- Scheduling and be aftering for preventative care, prognostic care.
- Coordinating with all sections for day-to-day job.
- Planning, organizing of preventative and breakdown activities for accomplishing high works handiness to run into production mark.
The process that the Oman cement follows in instance of dislocation, preventative and shutdown care are:
- Breakdown care
In instance of any breakdown care in the production section, they give information sing the dislocation to the care section, and care workers are sent to the production works to repair machine failures.
- Preventive care
here, a squad of care workers is sent straight to the production workss to look into out whether there is any failure in the machinery or non.
- Shutdown care
When the works is shut down the employees in the production section sent a missive to the care section and consecutive stairss are taken by care section to work out the failures. The works closure occurs every 6 month in March and September.
The procedure of operating and monitoring production lines and machines immediately, so they can watch the failure and harm of the machines and equipments to mend them or replace them.
Technical direction
The proficient direction duty is to oversee all the mechanical, electrical things and keep the assorted equipments and everything that related to maintenance process, and this direction divided in many subdivisions:
The machine subdivision
The duty of this subdivision is prepare exigency and planning agenda and make it to all the equipments and describe it to name the unusual failure and hole it. Inspect the machinery, cheque with drawings and specifications and rectification. It contacts with shop subdivision to supply the needed replacing parts and besides contacts with other subdivisions to keep the equipments at the workshop.
At the workshop they fix the equipments in exigency conditions, look into the equipments if they work decently and routinely, takes care the equipments and aid to clean them.
The machine operation subdivision
The duty of this subdivision manufacture the replacing parts, make an order outside the company to acquire new parts, lathe the machine parts the required the workshops.
The immediate machine care subdivision
The duty of this subdivision is to look into and repair the production lines.
The electrical subdivision
The electricity section is responsible to mend and guarantee the continuance of the work of all electrical and electronic equipment and preciseness instruments on the production line and besides supervises contact with other subdivisions to that the electricity working decently.
