ACC factory consists of 2 identical and fully equipped clinker lines of 2.1 Million tons capacity each. All the equipment is based on the state of the art and latest technology and system design, yet enjoying process simplicity and adaptability to local conditions. The plant machinery is of the most advanced proven design, supplied by world’s leading equipment manufacturers.

 

ACC limestone quarry is located 2.8 KM from the plant site. Nearby, the raw material crusher receives the limestone together with the outsourced clay; and, after crushing, the raw mix is transported via belt conveyor to the storage inside the factory. The limestone-clay mixture is automatically controlled by a gamma ray cross belt analyzer.

 

Other materials needed for clinker and cement production, in much less quantities, are directly delivered inside the plant by truck.

 

Prior to the pyro-process, the raw mix, together with minor additions of sand and iron ore, is ground into vertical mills (2 ATOX 45) capable to grind up to 500 t/h at the required fineness.

 

The 5 stage ILC Preheater/Kiln/Cooler systems, which are the core of the pyro-process, are so far the biggest capacity ever built in Egypt, designed for 6000 t/day each line. It can produce up to 6700 t/d steadily and comfortably. The clinker freshly produced is stored in 35,000 tons clinker silos. Each clinker line is equipped with 2 horizontal ball mills capable to grind 200 t/h, making a total installed capacity of 800 t/h cement production. To store the different types of cement, 4 silos of 15,000 tons capacity each are available. All silos have truck loaders underneath and feeding systems to the packing plants.

 

Both packing plants consist of 3 packing machines of 120 t/h each and 1 palletizer with a capacity of 210 t/h. Each packer can either feed the palletizer, or two manual truck loading points, which allows them to run continuously over the 24 hours of the day. This way, 720 t/h can be loaded at any time but also, in peak times, our forklifts can load more cement from the 2 storages of 2,000 tons each, where freshly produced palletized cement is stored.

 

All processes are monitored and controlled by PLC centralized in the Control Room, and the quality of each production step is controlled by fully equipped laboratory and personnel 24 hours per day 7 days per week.