SRC – Sulphate Resisting Portland Cement

Cement is designed to suit where the ratio of high salts in soil or water is observed and it is
recommended to use it when the cement is in direct contact with the soil which contain high salts or
[Link] high sulfate resistant cement we produce meet the British standards BS EN 197-1 – SR3
and as well as the standards of the American Society for Testing and Materials ASTM C 150 for type V
cement.

OPC – Ordinary Portland Cement

High quality cement suitable for most building purposes. Our Portland cement meets the following
specifications: British standards the European model BS EN 197-1 – CEMI 42.5 N and as well as the
standards of the American Society for Testing and Materials ASTM C 150 for type I cement.

Moderate Sulphate Resisting Portland Cement (MSRC)

It is mainly used in places where cement is in contact with soil containing moderate salts and it
meets the standards of the American Society for Testing and Materials ASTM C 150 for type II
cement.

Clinker

The company sells its surplus clinker production after fulfilling for cement grinding mills within the
country and as well as export to other countries.

Oil Well Cement

Oil Well Cement is made specially for use in the production and exploration of oil and gas in coastal
areas as well as deep groundwater work and offshore wells. It is specially formulated to give the
needed thickening properties that are necessary for pumping into oil wells in which pressures and
temperatures are higher than normal atmospheric conditions.

Ground Granulated Blast Furnace Slag (GGBS)

Cement Company Manufactures Ground Granulated Blast Furnace Slag (GGBS) as per latest
specifications of EN 15167 (supersedes BS: 6699:1992) & ASTM C 989 standards & distributed in bulk
as well as in Jumbo bags.
Key Processes in Cement Production & Packaging

Packaging & Key Standards &

Product Main Production Processes
Distribution Compliance

1. Raw material crushing &

blending (limestone, clay, - Bulk (silos)
- BS EN 197-1
iron ore) - 50kg bags
(SR3)
SRC (Sulphate 2. Kiln burning (high sulfate- - Jumbo bags (1-1.5
- ASTM C 150
Resisting Cement) resistant clinker) tons)
(Type V)
3. Grinding with gypsum - Seawater-resistant
- UAE.S 5:2019
4. Quality testing (sulfate packaging
resistance)

1. Raw material preparation

- BS EN 197-1
2. Clinker production - Bulk
(CEM I 42.5N)
OPC (Ordinary (1450°C) - 25kg/50kg bags
- ASTM C 150
Portland Cement) 3. Fine grinding with gypsum - Jumbo bags
(Type I)
4. Strength & setting time - Truck/rail loading
- UAE.S 1:2018
testing

1. Controlled raw mix (lower

- ASTM C 150
C3A) - Bulk
MSRC (Moderate (Type II)
2. Kiln processing (moderate - 50kg bags
Sulphate Resisting - BS EN 197-1
sulfate resistance) - Export packaging
Cement) (SR2)
3. Grinding & blending (moisture-proof)
- GCC standards
4. Chemical testing

1. Raw meal homogenization - Bulk (shipment)

- ASTM C 595
2. Rotary kiln sintering - Open/closed
- EN 197-1
Clinker (nodule formation) storage
- UAE/GCC export
3. Cooling (air quenching) - Export logistics
regulations
4. Storage & dispatch (moisture control)

1. Special clinker formulation

(low C3A, high C4AF) - Bulk (for offshore - API Spec 10A
2. Controlled grinding rigs) - ASTM C 150
Oil Well Cement
3. Rheology & thickening - Heavy-duty bags (Type IV/V)
time tests - Sealed containers - ISO 10426
4. High-pressure curing tests

GGBS (Ground 1. Slag collection (from steel - Bulk (cementitious - EN 15167

Granulated Blast plants) blends) - ASTM C 989
 Packaging & Key Standards &
Product Main Production Processes
Distribution Compliance

2. Drying & granulation

- Jumbo bags (1-2
(water quenching)
tons) - BS 6699:1992
Furnace Slag) 3. Grinding (to 400-600
- Moisture-proof (superseded)
m²/kg)
packaging
4. Storage & blending

SOP Development Considerations

1. Raw Material Handling – SOPs for crushing, blending, and pre-homogenization.

2. Kiln Operations – Temperature control, clinker formation, and cooling.

3. Grinding & Blending – Particle size control, gypsum addition, and additives.

4. Quality Control – Lab testing (chemical, physical, and performance tests).

5. Packaging – Moisture protection, bagging standards, bulk loading.

6. Storage & Logistics – Silos, jumbo bags, export compliance.

1. SRC (Sulphate Resisting Cement)

Production Process:

 Raw Material Preparation:

o Crushing & blending limestone, clay, iron ore (low C3A content).

o Homogenization in pre-blending silos.

 Kiln Processing:

o Preheating in cyclone towers (800–1000°C).

o Clinker formation in rotary kiln (1450°C, low alkali & C3A for sulfate resistance).

o Rapid cooling (air quenching).

 Grinding:

o Clinker + gypsum (3–5%) ground in ball mill to 350–400 m²/kg fineness.

 Quality Control:

o ASTM C 150 (Type V) tests: compressive strength, sulfate expansion (28-day test).

Packaging & Storage:

 Bulk: Loaded into silos for tanker trucks.

 Bags: 50kg HDPE/PP bags (UV/moisture-resistant).

 Jumbo Bags: 1-ton bulk bags for export.

2. OPC (Ordinary Portland Cement)

Production Process:

 Raw Mix: Limestone (80%), clay (15%), gypsum (5%).

 Kiln Process:

o Precalciner reduces energy use.

o Clinker nodules formed at 1450°C.

 Grinding:

o Clinker + gypsum (5%) ground to 300–350 m²/kg.

 QC Tests:

o BS EN 197-1 (CEM I 42.5N): Setting time, strength (3/7/28 days).

Packaging:

 Bulk: Direct pneumatic loading for ready-mix plants.

 Bags: 25kg/50kg paper or woven bags.

3. MSRC (Moderate Sulphate Resisting Cement)

Production Process:

 Raw Mix: Adjusted C3A (5–8%) for moderate sulfate resistance.

 Kiln: Similar to OPC but with controlled cooling.

 Grinding: Finer than OPC (~400 m²/kg).

 QC: ASTM C 150 (Type II) – sulfate immersion tests.

Packaging:

 Bulk or 50kg bags (humidity-controlled storage).

4. Clinker

Production Process:

 Raw Meal: Homogenized in stacker-reclaimer.

 Kiln: Sintered at 1450°C, cooled in grate cooler.

 Storage: Kept dry to prevent pre-hydration.

Export Handling:

 Bulk shipments (10,000–40,000 MT) in sealed vessels.

  Jumbo bags (1 MT) for small buyers.

5. Oil Well Cement

Production Process:

 Clinker: High C4AF, low C3A for high temp/pressure stability.

 Grinding: Coarse grind (200–250 m²/kg) for pumpability.

 QC: API Spec 10A – thickening time, compressive strength under HP/HT.

Packaging:

 Bulk for offshore rigs (pressurized tanks).

 50kg rugged bags for land rigs.

6. GGBS

Production Process:

 Slag Collection: Byproduct from steel plants.

 Granulation: Molten slag water-quenched to glassy granules.

 Grinding: Vertical roller mill to 400–600 m²/kg.

Packaging:

 Bulk for concrete plants.

 Jumbo bags (1–2 MT) with moisture barriers.

Key SOP Focus Areas:

1. Raw Material QC: Reject high-alkali/sulfur inputs.

2. Kiln Optimization: Temperature profiles, NOx/SOx control.

3. Grinding Consistency: Particle size distribution checks.

4. Packaging Integrity: Moisture prevention (especially for GGBS/Oil Well Cement).

5. Lab Testing: Daily samples for compliance (e.g., ASTM C 150 for OPC).

1. Cement Production Value Chain

Stage Key Activities UAE-Specific Considerations

- Limited local quarries → Import

1. Raw Material - Quarrying limestone (70–80% of gypsum/clinker if needed.
Extraction mix), clay, iron ore, sand. - High sulfate content in raw
materials requires pre-testing.

- Additives like laterite (for iron)

2. Raw Meal - Crushing, blending, and may be imported.
Preparation homogenization (raw mix silos). - Dust control critical in arid
climates.

- Energy-intensive → Use waste

heat recovery (UAE mandates
3. Clinker - Preheating (cyclones), calcination
efficiency).
Production (900°C), kiln burning (1450°C), cooling.
- Alternative fuels (tires, biomass)
to reduce costs.

- High-power consumption →
- Clinker + gypsum (+ slag/fly ash for
4. Cement Optimize grinding aids.
blended cement) ground in ball/VRM
Grinding - Export-focused plants prioritize
mills.
finer grinding.

- Export hubs (Jebel Ali, Fujairah)

5. Packaging & - Bulk (silos/tankers), bags (25–50kg), require strict moisture control.
Logistics jumbo bags (1–2 tons). - Sulfate-resistant packaging for
marine exposure.

2. Major Manufacturing Processes

A. Raw Material Processing

1. Quarrying:

o Drill/blast limestone (UAE’s Hajar Mountains).

o Crushers reduce rocks to <25mm.

2. Blending:

o Corrective mixes (e.g., high-alumina clay for SRC).

o Online XRF analyzers ensure chemical consistency.

B. Pyroprocessing (Clinker Production)

 1. Preheater Tower:

o Raw meal heated to 800°C (calcination: CO₂ release).

2. Rotary Kiln:

o Fuel (coal, petcoke, or alternative fuels) burns at 1450°C.

o Key phases: C2S → C3S (clinker nodules form).

3. Cooler:

o Grate cooler reduces clinker temp to 100°C (recycled hot air saves energy).

C. Cement Grinding

1. Ball Mill/Vertical Roller Mill (VRM):

o Clinker + 5% gypsum ground to 300–400 m²/kg (finer for OPC, coarser for oil-well
cement).

2. Additives:

o GGBS (for slag cement), fly ash (for PPC), or limestone (for CEM II).

D. Quality Control

 Lab Tests:

o Chemical: XRF (SiO₂, Al₂O₃, Fe₂O₃ ratios).

o Physical: Blaine fineness, setting time, compressive strength (3/7/28 days).

o Special: ASTM C 452 (sulfate expansion for SRC).

E. Packaging & Dispatch

 Bulk: 95% of UAE exports (ships, tankers).

 Bags: Polypropylene with UV protection (for GCC heat).

3. UAE-Specific Challenges & Solutions

Challenge Solution

High energy costs Waste heat recovery (WHR) systems, solar preheating trials.

Sulfate-rich environment Strict C3A control (<5% for SRC), ASTM C 150 Type V compliance.

Dust emissions Bag filters, enclosed conveyors (meets UAE EPA standards).

Export logistics Moisture-proof silos, jumbo bags with desiccants for sea transport.
Challenge Solution

4. Key Equipment

 Crushers: Jaw, gyratory (for raw materials).

 Kiln: 60–150m long, 3–5 RPM (UAE plants use 5-stage preheaters).

 Grinding Mills: VRMs (energy-efficient) or ball mills (for finer cement).

 Packing Machines: Rotary packers (120–240 bags/min).

5. Regional Standards

 UAE.S 1:2018 (OPC), UAE.S 5:2019 (SRC).

 GSO/FDHS 9:2013 (GCC cement testing).

 ASTM C 150 (Type I/V) for exports to Africa/Asia.

6. Process Flow Summary

1. Limestone → Crusher → Raw Mill → Homogenization Silo.

2. Preheater → Kiln → Cooler → Clinker Silo.

3. Clinker + Gypsum → Grinding Mill → Cement Silo.

4. Packing Plant → Dispatch (Truck/Ship).

Actionable Insight

To optimize a UAE plant:

 Prioritize energy efficiency (WHR, alternative fuels).

 Focus on SRC/Oil Well Cement (high demand in Gulf/MENA).

 Automate QC with AI-based XRF/predictive maintenance.