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    Carthage Cement was founded in 2008 following the split of the company "Les Grandes Carrières du Nord".

    Carthage Cement operates on 3 activities:

    1. Exploitation, production and marketing of aggregates from the Jebel Ressas site.
    2. Production and marketing of ready-to-use concrete.
    3. Manufacturing and marketing of hydraulic binders.
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    Carthage Cement has the most efficient and state-of-the-art production tools, allowing it to meet the needs of the construction materials market with an installed production capacity of:

    Aggregates 12,800 Tons / day

    Cement 6,800 Tons / day

    Ready-to-use concrete 2,600 m3 / day

    • Aggregates
      • Jebel Ressas aggregate quarry
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      • What is Cement
      • The production cycle
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      • Carthage Cement ready-mixed concrete
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    Carthage Cement has taken up the challenge of being a company committed to sustainable development, which is considered one of the main axes of its strategy.

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    • Cement
      • What is Cement
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      • Carthage Cement ready-mixed concrete
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Cement

Cement Carthage

Main navigation ciment

  • What is Cement
  • The production cycle
  • Cutting-edge technology
  • Products
Carthage Cement has high-performance, state-of-the-art production tools, enabling it to meet the needs of the building materials market with an installed production capacity

What is Cement

The cement is a fine mineral powder obtained after a very precise manufacturing process. Mixed with water, this powder forms a pulp that freezes and hardens, even under water. Depending on the composition and fineness of the powder, the properties of the cement are not the same.

The cement is the main component of concrete and lends it a number of properties, including strength. It is a high quality economical building material that is used in construction projects all over the world.

The cement is obtained by grinding and baking a mixture of limestone and clay at 1450 Celsius degrees. Called clinker, this granular material is essentially a combination of lime, silica, alumina and iron oxide.

Carthage Cement manufactures and commercialize various categories of cement, depending on the chemical composition of the raw materials, the possible additions of complementary components at the time of grinding and the fineness of the product.

Each category of products corresponds to specific purpose such as residential constructions, art works construction, underground works or even concretes submitted to aggressive environment.

The cement produced by Carthage Cement meets precise quality criteria and are subjected to regular and thorough controls at each stage of the manufacturing process. This allows it to guarantee the conformity of the end-product to the quality known standards.

Cement
The production cycle

Step 1:

Extracting raw materials

Limestone and clay are extracted from quarries located near cement plants.

Blown off with rocks and boulders, limestone and clay are carried by large trucks to crushers in order to reduce their size and get stones with a diameter less than 10 cm. These raw materials are subject to rigorous selection. Their composition should include lime, silica, alumina and iron oxide in well-defined proportions.

Step 2:

Preparation of the raw materials

Once crushed, the materials undergo a pre-mixing process in the pre-homogenization rooms, which make it possible to obtain a greater regularity of composition.
The materials are then dried and crushed in a grinder (ball or roller mill) in order to reduce their size to a few tens of microns. The crossing of the oven gases into the grinder allows the materials to dry. The fine powder then obtained is called raw meal, hence the expression of raw mill.
Throughout the process, features like sampling, transport and chemical analysis continuously check that the proportions of the material materials correspond to the desired chemical composition.

Step 3:

Cooking

  • The oven

The meal introduced in a powder like form in a preheating tower where it is preliminarily heated by the gases produced in the rotating oven (pre-calcination phase).
Under the influence of the gravity, the flour thus goes down against the flow of the hot oven gases. The tower has several cyclone stages, which makes it possible to increase the temperature of the flour up to 850 Celsius degrees (dry-way process). The flour will then be fed into an inclined rotating oven that is packed with refractory bricks. The oven is supplied with heat thanks to a large capacity burner. The flame temperature reaches over 2000 Celsius degrees.
During this cooking process, there are many complex chemical reactions undergoing. Firstly, the limestone decarbonizes under a heat temperature close to 950 Celsius degrees and then transforms into lime, while the clays decompose into silicates and aluminates. The whole set is then recombined in silicates and aluminates of lime at a temperature of about 1450 Celsius degrees.

  • Clinker

This chemical process leads to the production of a semi-finished product called clinker, which has the hydraulic binder properties.
The clinker is then conveyed through the cooler where it restores a good part of its thermal energy and is cooled by 100 Celsius degrees blowing air.
The chemical composition and homogeneity of the material at the oven entrance, as well as its regularity over time, are fundamental elements in the conduct of the production process. The oven has bag filters that filter dust that ensure limiting discharges to the environment.

Step 4:

Obtaining Cement

The clinker is stored in halls (or silos) and then, in a new grinding stage, passes through ball mills. Its rotation causes, by shocks and crushing, the cut into very fine grains.
The obtained powder is cement.
Gypsum is added to regularize the setting time of the cement. Further additions can be made: limestone filler or flying ashes (issued from coal combustion in the thermal power plants) in order to improve workability and consistency, blast furnace slags (sub-products of steel mills), or even natural or artificial pozzolans to improve hydraulic properties.
The obtained cement is stored in silos of several thousand tons that are sometimes divided into compartments allowing the preservation of several cement qualities.
It is then delivered in bulk or bag.

Cutting-edge technology

Carthage Cement is equipped with state-of-the-art equipment, enabling it to ensure smooth processes, easy handling and a cost-effective production.

1. Crusher

The raw material is fed into a hammer and impact crusher (type EV) through two separate vane distributors in order to bring the two mixtures according to the predetermined set of instructions.

Characteristics
Design / specifications
Crusher EV 200X300
Production flow 1300 t/h
Alimentation (dim max) 1500 mm
Production (dim) Max 5% +96 mm

2. Raw crushing (ATOX)

For crushing raw materials, a Vertical ATOX vertical mill is used.

The ATOX raw material mill uses the pressure and the generated shear between the rollers and the turntable to crush and pound the raw materials. The feed material is directed onto the grinding table by the feed chute. The rotation of the grinding table accelerates the material towards the grinding track and passes it under the rollers.

The gas passing through the mill reaches the separator (type RAR-LVT) with very high separation performance.

Characteristics
Design / specifications
Broyeur  ATOX 50.0
Séparateur RAR-LVT 52.5
Débit production 455 t/h (sec)
Alimentation

0% >175mm

MAX. 2% >150mm

Min. 30% >25mm

Finesse du Cru Max 12% + 90µm

 

3. Silo homo and Food Oven

Characteristics
Design / specifications
silo  CF 20 x 58
Diamètre du Silo 20 m
Section haute du silo 58 m
Capacité silo (chaque)

22,000 t ~ 2.4 jours consommation

Système alimentation four    Élévateur avec dépoussiéreur

4. Oven and cooler

Characteristics
Design / specifications
Capacité Four     5800 t/j
Préchauffeur    2 lignes 5 étages ILC
Taux de calcination 55-60%
Dimension four

3-base Ø5.0m x 78m

Bruleur Principal    Duoflex pour petcoke et gas
refroidisseur SF 4x6 cross-bar
température clinker 65°C (+ ambiante)
Conception refroidisseur pour    5800 t/d
Débit transport refroidisseur    >5800 t/d
Filtre de Dépoussiérage    A manches
Émissions refroidisseur    Max. 25 mg/Nm^3

5.  Preheater, calciner and oven

Preheater :
The chosen configuration offers an energy-saving solution that takes into account the moisture content of the raw meal as well as the tower dimensions.

Online Calciner:
On-line calciners have lower NOx emissions than in-line calcination furnaces, since all exhaust gases from the furnace must pass through calcination.

Oven with three supports:
The 3-base oven is a high-quality rotary oven with three traditional supports.  

Duoflex burner:
The DUOFLEX ™ burner triggers rotary ovens with pulverized pet-coke, natural gas or any mixture of these fuels.
The DUOFLEX burner is unique. It in fact carries a central duct for gaseous and liquid fuels placed inside an annular coal duct.

6. Clinker cooler. SF Cross-Bar

Characteristics
Design / specifications
type  SF 4 X 6
Degré de chargement    41.8 t/d/m²
Air soufflé 1.96 Nm3 air/kg clinker
Nombre de ventilateurs

9

Inclinaison refroidisseur    4°
Température clinker 65° C (au dessus de l’ambient)

7. Pet-Coke Shredder

For crushing of pet-coke, a TIRAX-type grinding is proposed. It is a fully ventilated system in a closed circuit.

Characteristics
Design / specifications
Broyeur    TM 42x7.25+3.6
Séparateur    RTKM 25
Filter broyeur    Bag filter
Limites alimentation (dim) Max.  5% > 25 mm
Type ppet-coke Pet coke Pet coke High volatile bituminous
Débit de Production   33 t/h (sec) 45 t/h (dry)
Finenesse produit    Max. 3% Max. 12% + 90 um
Humidité alimentation     Max. 8.0% Max. 8.0%
Max. Capacité séchage de 8.0% to 1.0% humidité de 8.0% to 1.0% humidité

 

8. Atelier Crushing Cement

UMS Cement grinder:

Characteristics
Design / specifications
broyeur UMS  50 x 15.0
Séparateur Sepax 425
Débit production 155 t/h
Finesse

320 m² /kg (Blaine)

Product temperature 105°C
Collecteur Filter à manches
Filtre broyeur Filter à manches

Closed circuit:
The circuit includes a very high performance SEPAX 3rd generation separator.

9. Bagging Unit  

Each bagging unit has the following characteristics:

  • Cement is transported through a bucket elevator to a screw conveyor to the bagger.
  • The machine is equipped with 08 rotary nozzles with an automatic or manual applicator.
  • Each filling nozzle is equipped with its own vertical axis propeller and an electronic weighing system including automatic weighing control.
  • Each bagger is connected to two forklift trucks that feed two loaders in parallel so that there’s permanently a truck for loading in order to maintain the line of conditioning with high efficiency.

Products

Ciment Portland au Calcaire : CEM II/A-L 42,5 N
Artificial Hydraulic Lime: CEM II/A-L 42,5 N1.69 MB
Ciment Portland : CEM I 42,5 N
Portland cement: CEM I 42.5 N1.13 MB
Ciment Portland  Résistant aux Sulfates : CEM I-42,5 N-SR3
Portland High Sulfate Resistance Cement: CEM I-42,5 N-SR31.27 MB
Ciment Portland au Calcaire : CEM II/A-L 32,5 N
Portland Cement to Limestone: CEM II / A-L 32.5 N2 MB
Clinker SR
Clinker SR195.54 KB
Clinker OPC
Clinker OPC1.58 MB

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Contact

Block A of the building located in front of the Embassy of the United States of America Lot HSC 1-4-3- Les jardins du lac2- 1053 Tunis

 

Phone: +216 71 19 03 01

Fax: +216 71 19 02 89

Email: info@carthagecement.com.tn

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