Cement Manufacturing Process

An Overview of the Cement Manufacturing Process

Dick Bekker (CTL/TT)

Holcim Group Support

The Cement Manufacturing Process

Objectives of this presentation ...To provide a general overview of the cement manufacturing process.To provide some specific insights into the main parts of the process including:

the materials involved the equipment used


ContentsOverviewRaw Material ExtractionRaw Material PreparationRawmeal PreparationClinker ManufactureAlternative FuelsCement GrindingMineral Components Packing - Dispatch - Logistics




Overview - Cement Manufacturing ProcessesCementRaw material supply Mechanical processes Thermal process Chemical processCement plant boundaries


Cement Manufacturing Processes

QuarryingCrushingPre-blendingGrindingHomogenizing...Burning...GrindingBlending...GypsumFuelsMechanical ProcessesMechanical ProcessesThermal &Chemical ProcessesMineral ComponentsClinkerCementDispatchRaw MealRaw MaterialsCalcareousArgillaceousSilica correctivesIron correctivesAlternative


Cement Manufacturing Process - SchematicAlternative Fuels




Quarry: Limestone and Marl (Clay/Shale)


Main Raw Mix ComponentsCalcareous (Calcium/Lime) Materials -- CaCO3 (Limestone) Argillaceous Materials -- SiO2, Al2O3 & Fe2O3 (Clay, Marl)

Main Components (Chemistry):CaO = Lime / CSiO2 = Silica / SAl2O3 = Alumina / AFe2O3 = Iron / F

Raw Mix Corrective MaterialsMaterials rich in C, S, A, F to correct the rawmix

Materials: Raw Mix Components ...


Materials: Raw Mix Components ...MarlLimestone


Drilling and blastingRaw Material Blasting (Preparation)


Quarry Operation - Blasting


Quarry Operation, Loading & Haulage


Haulage




Raw Material Crushing ...After quarrying, the material is crushed to reduce it from a size of ~ 1.5m to ~ 30 - 100mm


Transport to the Clinker Producing Site (1)


Transport to the Clinker Producing Site (2)


Direction of travel during stacking/making the pileReclaiming is at 900 to the direction of stackingRaw Material Pre-blending


Pre - blending: stacking and reclaimingStacking: How do you make a Black Forest cake?Reclaiming: How do you eat a Black Forest cake?




The Vertical Roller Mill Operating principle ...


Tube millRaw Material Grinding ...Vertical mill


BagfilterDust Collection (To clean gas streams) ...


Raw Meal Homogenisation ...


Raw Meal Homogenisation ...Stacking: How do you make a Black Forest cake?Reclaiming: How do you eat a Black Forest cake?Homogenising: It is no longer a Black Forest cake!




Main Equipment of a Modern Kiln System


Process: Preheating/Pre-calcination...


Clinker Production - Kiln




Clinker Manufacture Conventional FuelsHeavy Fuel OilPulverized Coal ( Bituminous & Lignite)Natural GasPulverized Petroleum Coke


Alternative Fuels and Raw MaterialsAlternative fuelsDry sewage sludgeOld / Worn out tyresAnimal meal, animal fatSolventsPaper

PlasticsUsed oilDistillation residuesWaste Wood


Fuel Combustion ...


Clinker Manufacture - FuelsCoal, Heavy oilAnimal meal Dried sewage sludgeSolventsTires


Clinker Cooling ...


Cooling PrinciplePositive pressure!Hot combustion air to kilnSlightly negative pressure!Hot waste air to filterHot clinker inCooled clinker outGrate


Materials: Raw Meal to Clinker ...C3S + C2SANDLiquids/Melt(1450C)Reactants +Products(450 - 1450C)Raw Meal(60C)CooledClinker(150C)The basic sequence of reactions ...Synthetic RockArtificial MineralsAlite & BeliteAluminate & FerriteNatural EarthMinerals




Cement grinding ...Ball mill90% Clinker GrindingPortlandCement+ 5% Gypsum+ 5% Mineral ComptNote Composite Cements contain > 5% mineral components as a clinker replacement


Operation principleof a Tube millCement grinding




DefinitionMineral Components are materials with binding properties which are not derived from the clinker manufacturing processMineral Components can be used:as alternative materials for clinker (clinker substitute), orfor the manufacture of concrete (cement substitute)

When added at the cement mill or added to Portland Cement, the product is called Composite Cement Mineral Components (MIC)




Cement grinding ...Ball millNote Composite Cements may contain >5% mineral components as a clinker replacement




Cement storage, packaging & dispatch ...


Cement Packaging


Single bags in ...Multi-pack outDirect to load out, or plastic wrapped firstCement Palletizing (Example)...


Bag Loading of Trucks


Bulk Loading of trucks...




Distribution / Logistics


Technical Data (Typical Example) ...4800 t/d 7 d/w 24 h/d3000 t/d 125 t/h 5 days/week 8 hours/day6720 tonnes/day 840 tonnes/hour 7 d/w 22 h/d 220 t/h 7 d/w 16 h/d3300 t/d 140 t/h 5 d/w 8 h/d4600 t/d 600 t/h5 kWh/t30 kWh/t30 kWh/tTotal cement plant ~3500 MJ/t clinker (ie. 120 kg coal/t ); and ~100 kWh/t cement40 kWh/t2 kWh/t3 kWh/tAuxiliaries1.4Factor 1.6Note: 3000 t/d ~ 1 Mio. t/y

This mission is a draft !

You might add new issues or relevant points to be considered

Cement Manufacturing Process

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