Anka Cement Factory

About

Anka Cement Plant was founded by Limak Çimento San. ve Tic. A.Ş. in the province of Ankar, district of Polatlı, within borders of village Babayakup. construction works were started in November 2015 and the plant was commissioned in April 2018.

The plant has a "Positive Environmental Impact Assessment" decision for the plant which came into force after being published in the issue of the Official Gazette dated 17.07.2008 and numbered 26939, as issued according to article 14 of the Regulation on EIA.Limak Anka Çimento Fabrikası, toplam 233.373,61 m2’ lik alanı kapsamaktadır.  Tesiste yılda 1.440.000 ton klinker ve 1.800.000 ton çimento üretimi yapılmaktadır. Proses için gerekli olan kalker ve kil malzemesi Limak Çimento San ve Tic. A.Ş’ ye ait olan ruhsatlı hammadde sahalarından temin edilmektedir. Fabrika için gerekli olan hammaddenin ruhsatlı sahalara yakın olması nedeniyle nakliye mesafeleri kısaltmakta ve nakliye aşamasında oluşabilecek çevresel etki minimum seviyeye inmektedir.

Production at the plant is carried out with pre-heated dry process method. Thus, advantages of the dry process, which is commonly preferred in the world and in our country, are taken due to lower heating energy consumption. Thanks to the development of pre-calcination (preliminary cooking) technology, low NOx emission and maximum fuel raw meal contact time is assured. Increasing the contact period of fuel and raw meal within the pre-calcination cabin above 4 seconds reduces NOx and CO emission.

Release of particulate matter into the atmosphere during the production is controlled by filters with bag and electrostatic precipitator. The rotary kin master stack is fitted with Constant Emission Measurement System and the Ministry of Environment and Urban Planning is able to online monitor that emission limit values are below the legal limits.

Raw materials are stored indoors at Limak Anka Cement Plant and a pre-blending unit whereby preliminary homogenization is carried out has been established. The vertical raw meal mill wherein the energy consumption is minimized has been designed with low NOx emission and low specific thermal consumption in a manner enabling it to reach 95% calcination degree and offer high productivity with low pressure loss, and rotary kiln pre-heater towers and combustion burners with high combustion efficiency, low NOx and low primary air use have been designed.

Thermal consumption and power consumption have been minimized thanks to use of use of the next generation highly productive rotary kiln mirror and cooling, new design versions of Rotary Kiln entry and exit impermeability systems minimizing leakage air.

All material conveyance lines have been designed as closed gallery and a closed clinker stokehold with a capacity of 100,000 tons has been built. Since the electrification and automation structure of the entire system within the plant enables line losses to be minimized, monitored and reported, energy management is made possible.

The plant that has completed all regulatory permits regarding environment management process carries out its operations, thanks to the best techniques available, in a fashion sensitive to the environment with high quality clinker and cement production as well as low energy consumption and low greenhouse gas emission. In 2018 when the plant started the production, an area of 3.950 m² was covered with grass and 750 saplings of varying types were planed in the plant field. Throughout 2019 and 2020, forestation and greening activities in the plant field continued, and 2,980 trees were planted, reaching a total green land of 28.013 m².

Certification studies of the Integrated Management System were completed and the plant became the cement plant to which the first TS ISO 45001:2018 Occupational Health and Safety Management System certificate has been issued within the relevant industry. The other certificates the plant has include TS EN ISO 9001:2015 Quality Management System, TS EN ISO 14001:2015 Environmental Management System and TS EN ISO 50001:2018 Energy Management System certificates.

 

Digital Transformation – (LİMBES)

Limak Anka Cement has established the Limak Document Management System (LİMBES) application / program.

All blue collar and white collar employees are able to log into such program via smart phones, tablets or PCs, using their user name and password, and digitally execute the following practices through effective use of technology in a quick and reliable manner.

Thanks to LİMBES application,

• During the works undertaken at the plant, risk assessment is carried out via te application before the work is commenced and it is ensured that the work is not started before the risk goes down to the acceptable level,

• Risky situations detected by employees and Near Misses that occur are reported via the application, making it possible to ensure that necessary actions are taken. 

• Risky behaviors detected by employees are reported via the application, making it possible to ensure that necessary actions are taken. 

• Issuance and signing of suggestion forms, and recording the same

• Invitation of all visitors and subcontractors entering the plant, recording them and making a controlled entry possible, 

• The visitor invited logs into the application via the link sent by e-mail or smart phone and reads the Law on Protection of Personal Data (LPPD) Visitor Disclosure text, completes details relating to her/him (visitor's name & surname, reason for visit, etc.), watches the Occupational Safety Training Video and, then, enters through the Limak Anka Cement Gate by means of the QR Code so created in the application.

• Owing to the Pandemic Module, during periods of contagious diseases, it is ensured that personnel members with risky health condition are determined and necessary measures are taken before getting on the shuttle bus.