Cement Division

Concrete Base
JMC's Cement Division has proven track record of carrying out process engineering, machine design and manufacturing for 20 cement plants of various sizes.

Engineering & project execution strengths
Today, JMC's Cement Division has highly qualified, experienced cement engineers. They are well equipped with all the modern facilities such as computer aided design software, high speed computer network etc. ensuring timely and accurate supply of engineering information, which is vital for record execution of cement projects.

JMC is proud to have executed cement plants from concept to commissioning, involving all the departments to cement packing.

Manufacturing abilities
The company has one of the largest workshops in India spread over an area of 11,000 sq.ft. well equipped with all the machines required for manufacturing plant and machinery for cement plants upto size of 3000 TPD. This unique strength of having all the facilities under one roof, gives JMC an edge over its competitors. JMC has continuously modernized the shop facilities to maintain its reputation for precision and excellent quality.

JMC is the manufacturer and supplier of ball mills used in cement industry, in India . JMC has manufactured and supplied more than 85 ball mills for grinding raw material, coal and clinker. Process engineering as well the mechanical design of these mills is done with the help of know-how absorbed during long experienced & on hand experience of engineers technocrats & constructors. All the possible designs configurations of grinding systems using ball mills can be offered by JMC. The main systems are :

Ball Mill
The Mill shell is fabricated from IS2062 tested plates. The mill consists, both side end bottoms (material steel casting) Girth gear, Mg. Steel liners bolted with forged bolts & nuts, man holes, feed & discharge hood, torsion shaft, pinion with shaft, Pinion Bearing housing, cooling system etc.

As shown in the flow sheet, the ball mill has two feed points at both the ends and the ground material is discharged centrally. The discharged material is fed on to air separator where the fines of desired size get separated and the grits return to the second chamber through second inlet. Fresh feed is given to the first inlet. A drying chamber can be provided before the first chamber to dry moisture in the material, whenever required. Hot air can be introduced from both the ends. The advantages of this system are –

• High drying capacity : 6% moisture can be dried with preheater gas at 320° C and upto 14% moisture can be dried with hot air furnace. This is possible since large quantity of hot gas can pass through the mill without increase in pressure drop across the mill.
• Optimization : Since grits can be directly introduced in second chamber, grinding media loading in both the grinding chambers can be optimized and over grinding can be avoided.

This mill is 10% more efficient as compared to air swept ball mill, normally used when drying is necessary.

Due to the above advantages this system is recommended for raw material grinding.

Salient Features

• Weigh Feeder
• Ball Mill
• P.G. Conveyor
• Bucket Elevator
• Separator
• Cyclones
• Separator Fan
• Bag Filter
• Grit Separator
• Cyclone
• Fan

Drying chamber can be provided before first chamber. The grinding length of the mill can be suitably divided in two chambers by a control diaphragm which allows fines toriove to the second chamber and large particles get further ground in the first chamber. The grinding media grading can thus be optimized to suit the particle size. Lifting liners are provided in the first chamber. Classifying liners are provided in the second chamber.

This mill can be used in open circuit without separator with larger L/D ratios.

The flow sheet shows the ball mill in close circuit with air separator. The feed is given at one end and the discharge of ground materials is from the other end. The ground material is fed to the air separator. The grits return to the mill inlet and the fines go as the product.

Salient Features

• Weigh Feeder
• Ball Mill
• Bucket Elevator
• Separator
• Cyclone
• Separator Fan
• Bag Filter
• ESP
• Mill Fan
• P.G. Conveyor

This system is ideally suited for grinding low moisture materials to be ground to higher fineness, such as clinker & hence recommended for clinker grinding.

JMC offers all modern feature such as high chrome boltless liners, flow control diaphragms and high efficiency separators with the grinding systems.

The flow sheet shows the ball mill in close circuit with air separator. The feed is given at one end and the discharge of ground materials is from the other end. The ground material is fed to the air separator. The grits return to the mill inlet and the fines go as the product.

The system for using for drying large quantity of moisture and consumes more power than the other systems due to pneumatic handling of the material. Therefore, it is ideally suitable for coal grinding applications in cement plants where drying is the prime requirement and quantity of coal required is relatively small as compared to the other materials ground in a cement plant.

Salient Features

• Raw Coal Hopper
• Table Feeder
• Ball Mill
• Grit Separator
• Cyclones
• Bag Filter
• Fan
• Cyclone
• Hot Air Fan

Material is fed sideways on a spreader disc in the separating chamber. The spread material is divided into grits fines by a re circulating air current created by inbuilt fan fall on the inner cone and fines get separated from recirculating air by cyclonic action. Counter vanes with adjustable length are fitted above the spreader plate to control fineness of the fines. The fan, spreader disc and the counter vanes can be driven by a single drive.

If the fineness is to be varied without stopping the separator, separator fan is driven by a constant speed motor and the spreader disc and counter vanes are driven by a variable speed drive. By varying its speed, fineness can be infinitely adjusted. This separator is still preferred for coarse separation (90 micron size) due to lower specific power consumption, and can be used for raw material grinding applications.

Material is fed at the center of a distribution plate installed on top of a cage rotor. The air flow created by an external fan enters horizontally and flows through a curtain of the material falling from the distribution plate. Heavier particles get separated under the effect of gravity and centrifugal force. Fines get carried away with the air by drag force. The dust laden air leaves separator and fines get separated in cyclones arranged outside the separator. Clean air can be recirculated or dedusted. The cage rotor is driven by a variable speed drive to facilitate on line fineness control.

The separator gives very good control on fines separation and avoids recirculation of fines and hence improves the capacity of grinding system and also helps in improving the product quality due to close particle size distribution.

Salient Features

• External highly efficient fan for air recirculation.
• External, efficient separating cyclones for fines separation.
• Distribution is on the top of the selection zone.
• Cylindrical selection zone gives longer time for fines separation.