An Overview Overview of the Cement Cement Manufacturing Manufacturing Process Dick Bekker (CTL/TT)
The Cement Manufacturing Process O*+ectives of this %resentation ,,,
To %rovie a genera# overview of the cement manufacturing %rocess, To %rovie some s%ecific insights into the main %arts of the %rocess inc#uing. the materia#s invo#ve . the eui%ment use
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Overview . Cement Manufacturing Processes
Raw material supply - Mechanical processes - Thermal process - Chemical process
s e i r a d n u o b t n a l p t n e m e C
Cement
Customer
Concrete & Mortar
Cement Manufacturing Processes Mechanical Processes
0aw Materia#s Ca#careous Argi##aceous &i#ica correctives Iron correctives
Quarrying Crushing Pre-blending Grinding Homogenizing...
Thermal & Chemical Processes
Mechanical Processes
Alernai!e
0aw Mea#
3ue#s $4%sum Minera# Com%onents
Clinker Burning...
Cement Grinding Blending...
Dis%atch
Cement Manufacturing Process . &chematic
A#ternative 3ue#s
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
5uarr4- Limestone an Mar# (C#a4/&ha#e)
Materia#s- 0aw Mi2 Com%onents ,,,
Main "a# Mi$ Com%onens
Calcareous (Ca#cium/Lime) Materia#s .. CaCO6 'imesone(
Argillaceous Materia#s .. &iO'7 A#'O6 ! 3e 'O6 Clay) Marl(
Main Com%onens Chemisry(*
Ca+ , 'ime C
i+/ , ilica
Al/+0 , Alumina A 1e/+0 , 2ron 1
"a# Mi$ Correci!e Maerials
Maerials rich in C) ) A) 1 o correc he ra#mi$
Materia#s- 0aw Mi2 Com%onents ,,,
Limestone
Mar#
0aw Materia# B#asting (Pre%aration)
Explosive Charge emming Primer Carridge
Column Charge
3eonaor or Ca%
Toe Charge
3rilling and blasing
5uarr4 O%eration . B#asting
5uarr4 O%eration7 Loaing ! "au#age
"au#age 8 Tonnes
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
0aw Materia# Crushing ,,, A4er 5uarrying) he maerial is crushed o reduce i 4rom a size o4 6 7.8m o 6 09 - 799mm
Trans%ort to the C#inker Proucing &ite (9)
Trans%ort to the C#inker Proucing &ite (')
0aw Materia# Pre.*#ening
3irecion o4 ra!el during sackingmaking he %ile
"eclaiming is a :9 9 o he direcion o4 sacking
Pre . *#ening- stacking an rec#aiming
&tacking- "ow o 4ou make a :B#ack 3orest; cake<
0ec#aiming- "ow o 4ou eat a :B#ack 3orest; cake<
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
The =ertica# 0o##er Mi## > O%erating %rinci%#e ,,,
0aw Materia# $rining ,,,
Tube mill
;erical mill
Dust Co##ection
(To c#ean gas streams) ...
Bagfi#ter
1#ectrostatic Preci%itator with Conitioning Tower
0aw Mea# "omogenisation ,,, 2n 1iler
1"
The raw mea# is homogenise *4 a com*ination of the wa4 it is ae to / e2tracte from the si#o an the air mi2ing in the si#o,
1"
+u B4%ass
H
G
G<=
Aci!e 2naci!e
$ A&
0aw Mea# "omogenisation ,,,
&tacking- "ow o 4ou make a :B#ack 3orest; cake<
0ec#aiming- "ow o 4ou eat a :B#ack 3orest; cake<
"omogenising- It is no #onger a :B#ack 3orest; cake?
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Main 1ui%ment of a Moern @i#n &4stem
Cooler 3edusing
Air-o-Air Cooler
Process- Preheating/Pre.ca#cination,,, ages 078 89 7
"a# meal 899 $haus gas
078
/ >>9 899
0 ?D8
E
>>9 DD9
8 9
?D8 7999
899 7999 Tem%eraure 9C
C#inker Prouction . @i#n
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
C#inker Manufacture > Conventiona# 3ue#s
"eav4 3ue# Oi#
Pu#verie Coa# ( Bituminous ! Lignite)
atura# $as
Pu#verie Petro#eum Coke
A#ternative 3ue#s an 0aw Materia#s A#ternative fue#s
Dr4 sewage s#uge
O# / orn out t4res
P#astics
se oi#
Disti##ation resiues
aste oo
Anima# mea#7 anima# fat
&o#vents
Pa%er
A#ternative raw materia#s
1arth from oi# s%i##s Aueous s4stems (Oi#4 water)
3ue# Com*ustion ,,, A com%le$ burner is used o mi$ di44eren 4uels #ih air and deli!er hem o he burning zone o4 he kiln 4or combusion
C#inker Manufacture . 3ue#s Coa#7 "eav4 oi#
3#ame
Anima# mea# 3ue#s Drie sewage s#uge
&o#vents
Tires
Ash
C#inker Coo#ing ,,, C#inker at E96F oC enters the coo#er an forms a *e through which air is *#own to coo# it to E9F oC
Coo#ing Princi%#e Ho combusion air o kiln
Ho #ase air o 4iler
Ho clinker in lighly negai!e %ressureF
Grae
Posii!e %ressureF
Cooled clinker ou
Materia#s- 0aw Mea# to C#inker ,,, The *asic seuence of reactions ,,, "eacans "a# Meal >9C(
atura# 1arth Minera#s
Producs E89 - 7E89C(
C C 0 / A3 'i5uidsMel 7E89C(
Cooled Clinker 789C(
&4nthetic 0ock Artificia# Minera#s Alie & Belie A#uminate ! 3errite
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Cement grining ,,, :9I Clinker
Ball mill ote > Com%osie Cemens contain J FH minera# com%onents as a c#inker re%#acement
G FH $4%sum G FH Minera# Com%t
$rining
Porland Cemen
Cement grining
O%eration %rinci%#e of a Tu*e mi##
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Minera# Com%onents (MIC)
Definition Minera# Com%onents are materia#s with *ining %ro%erties which are no erive from the c#inker manufacturing %rocess Minera# Com%onents can *e use
as a#ternative materia#s for c#inker (:c#inker su*stitute;)7 or
for the manufacture of concrete (:cement su*stitute;)
hen ae at the cement mi## or ae to Port#an Cement7 the %rouct is ca##e Com%osite Cement
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Cement grining ,,, :9I Clinker
Ball mill ote > Com%osie Cemens ma4 contain JFH minera# com%onents as a c#inker re%#acement
8I Gy%sum 8I Mineral Com%J
Mi##ing
Porland Cemen
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Cement storage7 %ackaging ! is%atch ,,,
Cemen 4rom he mills
Cement Packaging
Cement Pa##etiing (12am%#e),,, ingle bags in ...
Muli-%ack ou 3irec o load ou) or %lasic #ra%%ed 4irs
Bag Loaing of Trucks
Bu#k Loaing of trucks,,,
Contents
Overview
0aw Materia# 12traction
0aw Materia# Pre%aration
0awmea# Pre%aration
C#inker Manufacture . A#ternative 3ue#s
Cement $rining .
Minera# Com%onents
Packing . Dis%atch . Logistics
Distri*ution / Logistics