Innovation in Cement Grinding line | The Daily Star
12:00 AM, September 17, 2015 / LAST MODIFIED: 07:06 PM, September 17, 2015

Innovation in Cement Grinding line

Apart from technological innovation, Fresh cement has been sourcing raw materials especially the clinker from CONH, China & TPI, Thailand, the very renowned sources in Asia region as well as the world.

Cement sector is the largest growing sector in Bangladesh. Bangladesh is self-sufficient in fulfilling local market demand for cement. Even so, installed production capacity is higher than local demand.

The major cement manufacturers are importing raw materials from abroad and using grinding technology to produce cement.  Unique cement industries also following this principle. Unique Cement is a unit of Meghna group of industries and is situated at group's Industrial park at Meghnagaht, Sonargaon, Narayanganaj.

As a part of continuous efforts towards becoming the business leader, the Meghna Group Industries (MGI) has been investing in technological innovation since the beginning. Thus the company has set up a latest German Polycom technology from ThyssenkrKruppin 2013 in cement grinding line. The technology is high -pressure grinding mill to produce superior quality cement, in the name of Fresh brand.

The grinding elements of the high-pressure grinding roll are two counter-rotating rolls, between which the material is crushed. The required comminution is transmitted by a hydraulic system. During operation of the PLOYCOM machine it is possible to alter the pressure and thus change the products fineness. The grinding action of a tube mill involves a mixture of compressive and shear forces whereas the POLYCOM imposes virtually pure compressive force on the layer of material between the rolls. The compression stress thus caused in a particle of material is more than five times higher than shear stress would be.

This technology has proven to be extremely effective for the grinding of cement clinker, blast furnace slag, lime stone and other raw materials. ThyssenKrupp Industrial Solutions is the worldwide market leader for this energy efficient technology.

This type of mill offers the benefits: safe process technological design which protects resources and environment; deliver maximum productivity; product that has a higher percentage of fines and least residues ( < 2.5%) than could be achieved in a conventional crusher mill; low operating expenses due to power consumption and costs of wear parts are significantly lower.

Apart from the innovative work, the company is continuously upgrading the existing manufacturing facilities like air classifier, electronic packer and so on.

Fresh cement has started its operation in 2002 with production capacity of 2000 MT per day and grown up gradually according to market demand. Presently it's capacity is 12000 MT/day which is 2nd largest volume in Bangladesh. This progress is identical to the country's economic development. The recent cement consumption per capita in Bangladesh is around 115 kg whereas world average consumption is 525 kg. Bangladesh is continuing to grow up with excellent economic growth rate successively, over a 6 percent, so the country has still has enough space to run with cement sector. Needless to say that huge urbanization and construction of many large infrastructure projects support this observation.

Apart from technological innovation, Fresh cement has been sourcing raw materials especially the clinker from CONH, China &TPI, Thailand, the very renowned sources in Asia region as well as the world. Fresh Cement has excellent backward and forward linkage, say, own mothebr vessel & lighter carrier for raw materials carrying, Power plant for uninterrupted power supply (captive use), Bag plant, , ulk carrier, portable silo, extensive cement distribution system throughout the country. These linkages contribute to make quality assurance plan, uninterrupted delivery and competitive price for a best product which is customer's choice. Currently, multinational cement companies are facing intensive competition with local companies.

Quality division is an extensive process of producing Fresh cement. It is not limited to the quality control activities in state of the art laboratory of plant. It is under quality assurance plan from raw materials sourcing to finished product delivery. Each and every stage is being monitored for a super quality product. The company has separate silos to ensure unmixed product.

Fresh cement has been using in some important projects like 2nd Bhairob Railway project, Moghbazaar-Mouchak Fly over, Shikalbaha power plant, Shahjibazzar power plant and so on. Moreover, Fresh is focusing on upcoming iconic projects in Bangladesh. Finally Fresh Cement consumption has steadily been rising due to growing demand in both the local and foreign markets. The company is producing 3 types of cement for local market complying BSTI/EN standard; Fresh Super (Portland cement, CEM I, 52.5 N which is OPC in ASTM standard) and Fresh Special (Portland Composite cement, PCC, CEM II/A-M, 42.5 N)&Fresh(PCC CEM II/B-M, 42.5 N).And Fresh, Portland Pozzolan Cement (PPC) for export market only.

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Engr. Gopal Kr. Bagchi, General Manager, Technical Support & Business Development, Fresh Cement.

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