Iligan City, hailed as the industrial capital of the Philippines, is home to a myriad of industrial and chemical plants. The industries range from metallurgy to food, caustic soda to pulp and paper, and of course- cement. Here in Iligan City, there are two cement plants, and one of them is Iligan Cement Corporation.
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Figure 1. The arresting cement silos. The first silo is for Type 1, the second for Type 1P and the third for Type P cement.
What is Iligan Cement Corporation?
ICC, as what the corporation is fondly called, started as an expansion program of the Mindanao Portland Cement Corporation (MPCC). Later however, the multinational company Lafarge bought it out. ICC is one of the top ten cement manufacturers in the Philippines. Established on February 19, 1971, ICC Cement plant is the 16th cement processing plant to be established in the country and the only cement plant with an automated loading system for bulk and clinker exports.
ICC is certified for its QUALITY, ENVIRONMENT, HEALTH and SAFETY MANAGEMENT SYSTEMS (ISO 9001, 14001 and OHSAS 18001) - the first in the Lafarge Philippine group.
Note: Lafarge is the largest manufacturer of cement and concrete products in the world. Lafarge is also present in the Philippines. In concrete roof tile, CPAC Monier Inc. In gypsum, Boral Plasterboard.
The Plant
A. Location
The ICC plant is located in Kiwalan, Iligan City, 9.0 kilometers from city proper.
A. Safety
Figure 2. The cumbersome yet necessary PPE, with Jelyn and a fellow trainee.
The plant is known for their strict and tight implementation of health and safety rules and regulations, with their aim of having zero lost-time injuries. As such, the management requires mandatory Personal Protective Equipment (PPE) when working at specific points in the plant particularly in the process line. These are hard hats, safety footwear, high visibility clothing, dust mask and gloves. Also, anyone who enters the plant, whether employee or visitor, is given a safety badge, on which the H and S regulations of the plant is found. The badge will be punched every time a safety regulation is violated, corresponding to a certain sanction.
A. Products
ICC manufactures three types of cement:
1. Ordinary Portland Cement (OPC) or Type 1
2. Portland Plus Cement Type 1P
3. Pozzolan Premium Type P
These are marketed under the brand name Mindanao Cement.
B. The Process Flow.
Quarrying. The ICC quarry is accessed 3-4 km from plant via MPCC road. The 519 hectares of quarry area houses 169.92 million MT of limestone and 25.25 million MT of shale.
Crushing. The crusher is composed of a primary jaw crusher and secondary crusher with a production rate of 310 tons per hour (tph). The feed enters at 800 mm average diameter and exits at 40 mm average diameter.
Drying. The plant utilizes 2 drum dryers with a production rate of 150 tph. The drying medium is heated air through a rectangular furnace heated with ricehulls and hot gas from preheater exhaust. The feed moisture, from 13% becomes 3% for limestone, 26% to 13% for shale and 26% to 13% for pozzolan. The fuel usage is at 90 kCal/kg dried materials and alternative fuels constitute 35% of the fuels used.
Proportioning. After drying of raw materials, proportioning is done before they are feed into the raw mill. The standard proportion is 76% limestone, 20.9% shale, 4% silica sand and 0.1% cinder.
Raw Milling. The mill is a Kawasaki-make ball mill, with a drive of 2200 kW and a production rate of 140 tph. It is operated closed-circuit with bucket elevators. The average power of the mill is 21 kWh per ton of dried materials.
Figure 3. The commanding raw mill silos.
Clinkering. After the raw mill product is homogenized, they will be fed to the kiln which comes in the four-stage suspension preheater type, with a rated capacity of 1580 tons per day. The preheater is composed of 4 cyclones, with the feed reaching different temperatures at each. At 100 degrees Celsius, which is roughly t
he temperature of the first cyclone, water is removed. Next, the chemically combined water is removed at the next cyclone at a temperature of about 500°C. At 900°C, on the other hand, decarbonation and CaO formation occurs at the third stage. Furthermore, the hot meal proc
eeds to the rotary kiln where at 1220°C, C2S. C3A and
C4AF and C3S are formed. Then finally at 1450
°C clinker is formed.
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Figure 4. The towering preheater.
Figure 5. JanMell and the amazing rotary kiln.
Cooling. Since the product from the kiln is extremely hot, this stage is needed. The plant’s cooler is a conventional reciprocating grate type cooler with a rated capacity of 2500 tons per day. It has 6 chambers with beam aeration at first chamber only and there are 8 cooling fans installed.
Proportioning. The proper proportion of clinker and additives dictates the type of cement produced. For Type 1 cement, clinker constitutes 93%, limestone 4% and the remaining 3% is gypsum. For Type P, clinker is 63%, pozzolana is 34% and the 3% is gypsum. The other type, Type 1P Portland Plus composition is not disclosed.
Finish Milling. The plant has two finish mills, one located in the ICC plant (for TP and T1P cement) and the other located at the adjacent MPCC plant (for T1 and T1P cement). They are all ball mills with a production rate of 65 tons per hour, operating closed-circuit and with a drive of 2200 kW.
Packing and Shipping. The packing is accomplished by 2 Roto packers and 1 line packer with capacities of 3500 bags per hour. Each cement bag weighs 40 kg approximately. As evident, there are 3 cement silos corresponding to the three cement types, with each silo having a capacity of 12,000 MT. The dispatching is done in the overland through trucks and offshore through ships.
Iligan Cement Corporation is one of the top cement manufacturers in the Philippines and is one of the contributors of economic boost in Iligan City. Today, Iligan cement’s plant manager and VPO is Mr. Danilo Trugillo, a graduate of Chemical Engineering and Ceramics Engineering. He took up his CerE in MSU- Iligan Institute of Technology. His leadership, collated with the previous and current managers and personnels, contractors, employees and yes, apprentices has made Iligan Cement on top of its game. “For our dreams, trust only Mindanao Cement.”
Working while furnace with safety aspects is the important one there are many rules in India for working the furnace.
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