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Our system consists of the below process;
- Quarrying: Primary raw materials (limestone and
clay) are taken from quarries and secondary raw material
(sand) are brought from elsewhere to the factory.
- Crushing: Limestone, gypsum, trass are crushed for
decreasing of their dimension.
- Raw material preparation: The raw materials which
are controlled proportions are ground and dried in the
raw mills to get raw meal for the dry kiln process.
After that, the ground materials (raw meal) are
homogenised to achieve the required chemical uniformity.
- Fuel preparation: Main fuel is the coal (lignite).
Besides, natural gas is used and alternative fuels are
used to substitute in part for the main fuels. Drying
and grinding together take place for solid fuel (coal)
preparation in the coal mill.
- Clinker burning (Kiln Operation): The raw meal
is fed to the kiln system to produce clinker. Our kiln
system is dry process. Our kiln systems have precalciner
and preheater towers. During the kiln operation, the raw
meal is dried-preheated-calcined-sintered successively.
The sintered clinker is cooled fast by cooler fans. Then
the clinker is stored in the closed concrete clinker
silo.
- Cement grinding: Portland cement is produced by
intergrinding clinker and gypsum. In blended cements
(composite cements) there are other constituents such as
trass, fly ash. Grinding is realised in the cement
mills. Moreover, Roller press unit (high pressure
grinding roll) is used to comminute the clinker so this
method of high pressure interparticle comminution
produces compacted cakes of clinker. Besides, trass
dryer unit also is used to dry and crush of trass
material. The different cements which are produced in
the cement mills are stored in cement silos.
- Packing and dispatch: Cement may be shipped as
bulk cement or packed into bags for dispatch. Cement
which is stored in cement silos are packed via rotary
packing. Bulk loading land carriers are pneumatic cement
trucks so it is used in bulk loading. Besides, the
cement can be shipped in bulk 1.5 mt of big bags and 50
kg craft paper sacks packed in sling bags.
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Bursa Cement uses the most modern technologies. Some of
these are;
- Bursa Cement Factory has 3 POLAB AOT systems for
online analysis of the raw meal downstream of the raw
material grinding system. This system was installed
directly downstream of the raw meal so POLAB AOT takes
raw meal samples at short intervals, fine- grinds them,
analysis them with its energy dispersive X-ray
fluorescence analyser and controls the raw material
composition and mill feeding. With the online
instrumentation the analysis is carried out site every
15 minutes, and the corrections to the mix can be done
automatically. As a result of using this system, stable
raw mix with the right concentration of each of the main
component is provided for the stability of the kiln
operation.
- Bursa Cement Factory has 2 Rotaflam Rotary Kiln Burner
for firing of liquid, solid, gaseous fuels. This burner
makes the use of up to 100% secondary fuel possible.
- All of the equipments are controlled in the Central
Control Room via PCS7 CEMAT Automation System.
- Bursa Cement Factory also has Absorption Chiller Unit
(Broad IX Two Stage Steam Chiller) which is the most
efficient system by means of converting energy. The
Absorption Chiller is the most versatile, dependable,
effective and environmentally friendly air conditioning
and
 process cooling technology. The waste hot gas which
is taken from the clinker cooler unit is sent to
recuperation system for getting steam. A part of steam
which is obtained in recuperator is used to supply hot
water and heating purpose. The other part of the steam
is sent to Absorbtion Chiller Unit for supplying cool
water which is used for the purpose of cooling of MCC - PLC and the other
rooms.
- Circular Mixing Bed for Coal was put into operation in
2008. The Chevron stacking method is used for circular
blending bed stockpiles. Preblending stores are used for
improving the chemical consistency of either a single
component or a multiple component. As a result of this
system, standard deviations of the chemical parameters
in coal are minimized and the stable flame in the kiln
burner is observed so, these results have a positive
effect on the cost of fuel and energy.
- Big bag packing and storage unit was put into
operation in 2008. The cement is filled into big bags of
1.5 tons each.
- Bursa Cement Factory laboratories have been equipped
with latest technology. Some of these are;
• ARL 9900 XRF-XRD Instrument: Elemental and quantative
phase analysis can be done by ARL. It was put into
operation in 2009.
• Malvern Mastersizer 2000 Automated Particle Size
Distribution Measurement Instrument: It’s particle size
analyser. It was put into operation in 2008.
• Eltra Carbon Sulphur Detarminator: It is used for coal
analysis. It was put into operation in 2008.
• Thermo Gravimetric Analyser: Volatile matter,
humidity, ash analyses for coal can be done by this
instrument. It was put into operation in 2008.
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