Cement Plant Operations Handbook,5th Edition,Preview

Cement Plant Operations Handbook 5th Edition

Contents Process Summaries 1. Introduction

20

2. Raw Materials

23

1. Raw Materials – 2. Reserves – 3. Crushing – 4. Pre-blending

3. Raw Milling and Blending

31

1. Raw Milling – 2. Blending

4. Burning and Cooling

39

1. Kiln Burning – 2. Control Systems – 3. Kiln Control – 4. Kiln Start-up and Shut-down – 5. Kiln Refractories – 6. Insufflation – 7. Kiln By-pass – 8. Preheater Cleaning – 9. Fossil Fuels – 10. Waste Fuels – 11. Coal Firing – 12. Clinker Cooling – 13. Kiln Mechanical – 14. Emergency Power

5. Cement Milling

69

1. Clinker Storage – 2. Cement Milling – 3. Separators – 4. Ball Mill Circuit Control – 5. Cement Storage – 6. Cement Dispatch – 7. Quality Assurance and Customer Service

6. Quality Control

83

1. Sampling – 2. Chemical Analysis – 3. Evaluation of Clinker Mineralogy,, Microstructure and Clinker Quality – 4. X-ray Mineralogy Diffraction – 5. Particle Size Analysis – 6. Thermal Analysis – 7. Microscopy – 8. The Virtual Cement and Concrete Testing Laboratory – 9. Calorimetry – 10. Burnability – 11. Grindability – 12. Physical Test – 13. Process Control Analysis – 14. Cement Strength – 15. Setting Time – 16. ASTM Cement Types and Specifications – 17. European EN 197 Cement Specification – 18. Cement Intergrinds – 19. Supersulphated Cement – 20. Calcium Aluminous Cement – 21. Shrinkage-Co Shrinkage-Compensating mpensating Cement – 22. ISO 9001:200 9001:2000 0 Quality Management System – 23. Concrete Problems – 24. Domestic Water Treatment 15

Cement Plant Operations Handbook 5th Edition

7. Maintenance

115

1. Failure Modes – 2. Computerised Maintenance Management Systems – 3. Reliability-Centred Maintenance – 4. Maintenance Cost Management – 5. Maintenance Organisation – 6. Role, Planning and Control – 7. Mobile Equipment Maintenance

8. Environment and Pollution Control

123

1. Dust Collection – 2. Pollution Control – 3. ISO14000 – 4. Sustainable Development and Climate Change

   P    M   A    S 9. Combustion and Heat Transfer Processes

131

1. Chemistry of Combustion – 2. Fuels – 3. Physics of Combustion – 4. Burner Design – 5. Heat Transfer – 6. Pollution Control

10. Hydration of Portland Cement

155

11. Other Kiln Types

159

1. Long Wet Kiln – 2. Long Dry Kiln – 3. Lepol (Grate Preheater Kiln) – 4. Vertical Shaft Kilns – 5. Fluidised Bed Kiln – 6. Mini Kilns

12. Plant Reporting

165

1. Definitions – 2. List of Reports – 3. Inventories and Feeders – 4. Downtime Reporting – 5. Miscellaneous Reporting – 6. Typical Daily Production Report – 7. Typical Process Summary Data – 8. Typical Equipment Downtime Report – 9. Plant Manning

13. Accounting

175

1. Cost Accounting – 2. Investment Justification – 3. Capacity Increase by Process Change – 4. Project Cost Estimation – 5. Financial Statements

14. Technical and Process Audits

187

1. Kiln Specific Fuel Consumption – 2. Cement Mill Specific Power Consumption – 3. Other Systems – 4. De-bottlenecking – 5. Project Audit – 6. Risk Assessment

16

Cement Plant Operations Handbook 5th Edition

15. Cement Plant Assessment Data List

195

1. General – 2. Administration and Commercial – 3. Quarry – 4. Drying – 5. Raw Milling – 6. Blending – 7. Kiln – 8. Fuel – 9. Clinker – 10. Finish Mill – 11. Cement – 12. Quality Control – 13. Packing and Distribution – 14. Dust Collectors – 15. Maintenance – 16. Process –17. Materials Analysis – 18. Plant Capacity Summary

   E    L    P

16. Cement Plant Valuation and New Plant Construction

205

1. Plant Valuation – 2. New Plant Construction – 3. Project Management

17. Statistics

221

Section B – Process Calculations and Miscellaneous Data B1. Power

228

B2. Fans and Air Handling

230

B3. Conveying

237

B4. Milling

240

B5. Kilns and Burning

246

B6. Fuels

254

B7. Materials

257

B8. Miscellaneous Data

260

B9. Periodic Table

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References

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Index

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 Advertisers’ Index

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