At Bursa Cement, processes are monitored and measured at every stage, starting from the input products. All activities are carried out in accordance with standards and are constantly improved. The most modern technologies are used with the investments made. Relations with customers are carefully monitored, expectations and satisfaction are measured with customer visits and surveys. Studies are carried out in line with the philosophy of continuous improvement in relations with suppliers.
Participation is encouraged with the Suggestion System implemented in Bursa Cement, which determines "encouraging the creativity and participation of its employees and developing their sense of belonging" as an indispensable mission at every stage of its activities. In the Company, where Quality Management System, Environmental Management System, Occupational Health and Safety Management System, Energy Management System, Customer Satisfaction Management System and Laboratory Accreditation system are implemented, activities are carried out with a focus on continuous improvement in all areas.
Bursa Çimento Fabrikası A.Ş. has a Cement Mixing and Packing Facility established in Kütahya next to the cement factory established in Bursa.
If we briefly summarize these activities;
Raw Materials and Excipients: Bursa Cement Factory supplies the limestone and clay it needs from the quarries and extracts the limestone by blasting. Clay is extracted from the clay fields near the factory to the factory. Auxiliary materials such as gypsum, trass and sand are supplied through suppliers. Fly ash, which is used as an additive in cement, is supplied from our subsidiaries, Ares and Tunçkul.
Raw Material Preparation (Crushing): Raw materials and auxiliary materials (limestone, trass, gypsum) coming from the quarries are crushed in separate crushers and reduced in size and taken to the relevant halls in the stockhold, while clay and sand are stocked in the stockhold for use.
Fuel Preparation: Our main fuel is coal and natural gas is used as auxiliary fuel. In addition to these, solid wastes (contaminated waste, expired tires, etc.) which are called alternative fuels are processed in the ATY Facility (shredding - separation) from the calciner area of the rotary kilns, and liquid wastes (bilge oil, waste oil, etc.) are fed to the system from the rotary kiln flame pipe. . After being homogenized in the Coal Pre-Homogenizing Facility, the coal supplied from the country and abroad is ground in the coal mills and stored in the silos to be burned in the rotary kilns.
Energy Production: Electrical energy is obtained by recovering the waste heat discharged from the rotary kilns. By sending the steam obtained from the PH and AQC boilers to the turbine, the turbine blades rotate and transfer the motion to the generator to produce electrical energy. Through this facility, approximately 20-25% of the electrical energy need of the factory is met from the Waste Heat Energy Production Facility. There will be an annual reduction of approximately 28,000 tons of CO₂ emissions through this investment.
Raw Raw Preparation (Grinding): The feed rates of the limestone, clay and sand used when necessary, which are stored in the relevant halls and in appropriate sizes in the stockhold, are determined by the On-Line Sampling and Analysis Device, POLAB AOT, depending on the content of the raw material, and the materials are fed to the raw meal mills in this context. Drying and grinding processes are carried out in the mills. Raw meal coming out of the mills is first taken to Raw Raw Stock Silos, and then Raw Raw Material to Homogenized Silos.
Clinker Production (Cooking): Raw meal taken from the Raw Homogeneous Silos is cooked at temperatures between ~1.350 °C - ~1.450 °C by burning the main fuel coal, auxiliary fuel natural gas and alternative fuels (waste oil, contaminated waste, etc.) in the preheater Rotary Kilns. When the clinker is poured into the cooler, it is stored chilled to ~ 100 °C in clinker silos or open stock halls.
Cement Production (Grinding): Cement obtained by grinding clinker with some gypsum and various ratios and types of additives or additives (limestone, trass, fly ash) depending on the type of cement to be produced, is transported to cement silos separately according to their types and stored.
Loading: It is sold as bulk, kraft bag, big-bag and sling-bag from silos separated according to cement types.
While carrying out all these activities, Bursa Cement uses the latest technologies and ensures the continuity of the process by effectively implementing all maintenance activities. In our factory, energy efficiency studies are carried out by the Energy Management Unit. Our company; T.R. In recent years, it has won various awards in the Project Competitions for the Efficient Use of Energy in Industrial Facilities organized by the Ministry of Energy and Natural Resources.
POLAB AMT SYSTEM
Bursa Cement bought a new POLAB on line sampling and analysis device for its production lines from Thyssen Krupp Industrial Solutions and commissioned it in August 2015. This system consists of 3 autosamplers and a pneumatic tube system working in connection with the laboratory. The POLAB AMT system in the laboratory prepares samples for analysis and, according to this analysis result, controls the mill feeds by ensuring that raw materials are entered into the mills at appropriate feed rates via a special software (POLAB AQCnet software). The previously existing POLAB AOT system has been replaced by this new version. By means of the adaptive mix controller, the raw material ratios fed to the raw mills are adjusted in order to ensure the desired quality. Thanks to its self-learning feature, the system automatically adjusts the constant material quality according to the changing material properties.
CEM II / A-M (P-L) 42.5 R cement produced in BURSA CEMENT FACTORY is stored in the cement silo of the Kütahya facility. Separate fly ash obtained from fly ash facilities is stored in the facility's ash silo.
The new type of cement obtained by mixing the cement and separate fly ash taken from the silos in the proportions determined by the standards, is taken into the product silos and offered for sale in bulk or bagged form according to the customer's request.
You can reach the current flow chart that summarizes the working system of our factory by clicking the link below.
