Cement Industry Solutions
Heavy Mechanical Equipment & Process Systems for Cement Plants
Industry Overview
The cement industry is one of the most demanding heavy industries, requiring large-scale mechanical equipment, continuous high-temperature operation, and robust material handling systems. Cement plants operate under harsh conditions involving abrasive materials, elevated temperatures, and high mechanical loads, making equipment quality and engineering precision critical.
Mechasol provides custom-engineered cement industry equipment and systems, covering raw material preparation, thermal processing, material handling, and environmental control, with a strong focus on long service life, operational reliability, and maintainability.
Mills & Grinding Equipment
Grinding systems are central to cement production, used for raw meal, clinker, and cement grinding.
Scope & Capabilities
Mechasol designs and manufactures:
Cement mills and mill shells
Mill heads, girth gears, and support structures
Liners and wear-resistant internal components
Grinding equipment is engineered to withstand high impact forces, vibration, and abrasive wear, ensuring stable operation and consistent product fineness.
Rotary Kiln Systems
Rotary Kilns
Rotary kilns are the heart of clinker production, operating at temperatures exceeding 1,400 °C.
Mechasol scope includes:
Rotary kiln shells
Riding rings (tyres)
Support rollers and thrust rollers
Kiln sections and replacement modules
All kiln components are fabricated with strict control of:
Roundness and alignment tolerances
Material selection for thermal expansion resistance
Welding quality and stress control
Rotary Dryers
Rotary dryers are used for raw material drying prior to grinding or processing.
Key Features
Large-diameter, heavy-duty steel shells
Internal lifting flights optimized for material flow
Support rollers and drive assemblies
Mechasol rotary dryers are designed for uniform heat distribution and efficient moisture removal, even with variable feed characteristics.
Tyre & Roller Assemblies
Tyres (riding rings) and roller systems are critical for rotary equipment stability.
Manufacturing Scope
Kiln and dryer tyres
Support rollers
Shafts and bearing housings
Precision machining ensures:
Even load distribution
Reduced shell stress
Extended equipment lifespan
Dust Collecting Cyclone Systems
Cyclones are widely used for primary dust separation in cement plants.
Applications
Raw mill circuits
Kiln exhaust gas cleaning
Material transfer points
Mechasol cyclone systems are engineered to achieve high separation efficiency with minimal pressure loss, supporting downstream filtration systems.
Salt Washing Units
Salt washing units are applied in specific cement and mining processes to remove soluble salts and impurities from raw materials.
System Scope
Washing tanks and reactors
Piping and slurry handling systems
Solid-liquid separation interfaces
These systems contribute to improved product quality and reduced process disruptions.
Mining Filter Press Systems
Filter presses are used for solid-liquid separation in mining and cement-related processes.
Key Capabilities
Heavy-duty filter press frames
Plate and cloth systems
Hydraulic closing units
Mechasol filter presses provide high dewatering efficiency, reducing moisture content and minimizing waste handling costs.
Mining Thickeners
Thickeners are used to concentrate slurries and recover process water.
Design Characteristics
Large-diameter tanks
Central drive mechanisms
Rake arms and underflow systems
Thickener systems are designed for continuous operation and high structural integrity, even under fluctuating feed conditions.
Fabrication & Quality Approach
All cement industry equipment is manufactured under strict quality control procedures, including:
Certified welding processes
Dimensional inspections
Non-destructive testing (NDT)
Trial assembly where required
Mechasol’s fabrication philosophy prioritizes mechanical strength, thermal durability, and ease of installation.
EPC & Integration Capability
Beyond equipment manufacturing, Mechasol supports:
Equipment integration into existing cement plants
Revamp and replacement projects
Mechanical erection supervision
Commissioning support
This allows clients to execute brownfield upgrades and capacity expansions with minimal downtime.
Typical Applications
Mechasol Cement Industry Solutions are applied in:
Integrated cement plants
Clinker production lines
Grinding and packing facilities
Mining and raw material preparation plants
Mechasol Value Proposition for Cement Industry
Proven experience in heavy mechanical fabrication
Capability to manufacture large-diameter, high-weight equipment
Process-aware mechanical engineering approach
Flexible project execution (equipment supply to EPC support)
Long-term reliability and lifecycle focus
Summary
Mechasol Cement Industry Solutions combine heavy-duty mechanical manufacturing expertise with process-oriented engineering, delivering reliable equipment for the most demanding cement plant applications. From mills and rotary kilns to dust collection and solid-liquid separation systems, Mechasol provides robust solutions that support continuous, efficient, and safe cement production.