An integrated facility that prepares the raw mix, feeds it to the pyro-processing system (kiln), and then grinds the clinker from the kiln system into various cement products. Finished cement is stored in large silos on site or bagged for small quantity use. The cement is shipped by truck, rail or barge to customers, or to regional terminals for customer pick-up. Most cement plants have quarries located nearby to supply the limestone and other raw materials.

Types of cement plants !
The Turnkey cement plants have a worldwide reputation. We are well known as complete solution provider having specialization in the field of setting small, medium and large scale cement plants. The types of projects for the different cement plants which this group takes are as follows:

• VSK Cement Plant
• Portland Cement Plant
• Clinker Plant
• Rotary Kiln Plant
• Mini Cement Plant

1. The cement manufacturing process begins when limestone, the basic raw material used to make cement.
2. The limestone is combined with clay, ground in a crusher and fed into the additive silos. Sand, iron and bottom ash are then combined with the limestone and clay in a carefully controlled mixture which is ground into a fine powder in a 2000 hp roller mill.
3. Next, the fine powder is heated as it passes through the Pre-Heater Tower into a large kiln, which is over half the length of a football field and 4.2 metres in diameter. In the kiln, the powder is heated to 1500 degrees Celsius. This creates a new product, called clinker, which resembles pellets about the size of marbles.
4. The clinker is combined with small amounts of gypsum and limestone and finely ground in a finishing mill. The mill is a large revolving cylinder containing 250 tonnes of steel balls that is driven by a 4000 hp motor. The finished cement is ground so fine that it can pass through a sieve that will hold water.
5. The cement manufacturing process consists of many simultaneous and continuous operations using some of the largest moving machinery in manufacturing.

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With an installed capacity of around 157 million tonnes per annum (mtpa) at end-March 2006, large cement plants accounted for 93% of the total installed capacity in India. The installed capacity is distributed over across approximately 129 large cement plants owned by around 54 companies.

The structure of the industry is fragmented, although, the concentration at the top is increasing. The fragmented structure is a result of the low entry barriers in the post decontrol period and the ready availability of technology.

However, cement plants are capital intensive and require a capital investment of over Rs. 3,500 per tonne of cement, which translates into an investment of Rs. 3,500 million for a 1 mtpa plant.

The cement industry has witnessed substantial reorganisation of capacities during the last couple of years. Some examples of the consolidation witnessed during the recent past include:

Multinational cement companies have also initiated the acquisition process in the Indian cement market.