An Overview of The Cement Manufacturing Process: Dick Bekker (CTL/TT)

An Overview of the Cement Manufacturing
Process
Dick Bekker (CTL/TT)
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
Holcim Group Support
Introduction to Cement
August
Contents
Overview
Raw Material Extraction
Raw Material Preparation
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
Packing - Dispatch - Logistics
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Raw material supply

- Mechanical processes
- Thermal process
- Chemical process
Cement plant boundaries
Overview - Cement Manufacturing Processes
Customer
Cement
Concrete
& Mortar
August
Cement Manufacturing Processes

Mechanical Processes
Raw
Materials
Calcareous
Argillaceous
Silica correctives
Iron correctives
Quarrying
Crushing
Pre-blending
Grinding
Homogenizing...
Thermal &
Chemical
Processes
Mechanical Processes
Alternative
Raw
Meal
Fuels
Gypsum
Mineral
Components
Clinker
Burning...
Cement
Grinding
Blending...
Dispatch
August
Cement Manufacturing Process - Schematic
Alternative Fuels
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Quarry: Limestone and Marl (Clay/Shale)
August
Materials: Raw Mix Components ...

Main Raw Mix Components
Calcareous (Calcium/Lime) Materials -- CaCO 3 (Limestone)
Argillaceous Materials -- SiO 2, Al2O3 & Fe2O3 (Clay, Marl)
Main Components (Chemistry):
CaO = Lime / C
SiO2 = Silica / S
Al2O3 = Alumina / A Fe2O3 = Iron / F
Raw Mix Corrective Materials
Materials rich in C, S, A, F to correct the rawmix
August
Materials: Raw Mix Components ...
Limestone
Marl
August
Raw Material Blasting (Preparation)
Explosive Charge
Stemming
Primer
Cartridge
Column
Charge
Detonator or Cap
Toe
Charge
Drilling and blasting

August
Quarry Operation - Blasting
August
Quarry Operation, Loading & Haulage
August
Haulage
90 Tonnes
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Raw Material Crushing ...

After quarrying, the material is
crushed to reduce it from a
size of ~ 1.5m to ~ 30 - 100mm
August
Transport to the Clinker Producing Site (1)
August
Transport to the Clinker Producing Site (2)
August
Raw Material Pre-blending
Direction of travel during

stacking/making the pile
Reclaiming is at 900 to
the direction of stacking
August
Pre - blending: stacking and reclaiming

Stacking: How do you make a Black Forest cake?
Reclaiming: How do you eat a Black Forest cake?
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
The Vertical Roller Mill Operating principle ...
August
Raw Material Grinding ...
Tube mill
Vertical mill
August
Dust Collection (To clean gas streams) ...

Bagfilter
Electrostatic Precipitator
with Conditioning Tower
August
Raw Meal Homogenisation ...

In
Filter
FR
The raw meal is homogenised by

a combination of the way it is
added to / extracted from the silo
and the air mixing in the silo.
FR
Out
Bypass
HS
GKA
GKJ
Active Inactive
GAS
August
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!
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Main Equipment of a Modern Kiln System
Dry process kiln (with 5-stage SP and PC

Dry process kiln (with 5-stage SP and PC)
Kiln ID
Kiln ID
Fan
Fan
Filter
Fan
Cooler
Dedusting
Meal
Dosing
Precalciner
Fuel Dosing
Air-to-Air
Meal
Dosing
5-stage
5-stage
Suspension
Suspension
Preheater
Precalciner
Fuel Dosing
Preheater
Cooler
Water
Kiln Fuel
Dosing
Low NOx
Precalciner
Low
NOx
Burner
Precalciner
Primary
Burner
Air Fan
Cyclone
Preheater
Cyclone
Preheater
Holcim Group SupportBurning Zone
Kiln Drive
Conditioning
Tower
August
Process: Preheating/Pre-calcination...
Stages
315
50
2
3
4
5
0
315
Raw meal
500 Exhaust gas
500
660
660
785
785
880
1000
500
1000
Temperature 0C
August
Clinker Production - Kiln
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Clinker Manufacture Conventional Fuels
Heavy Fuel Oil

Pulverized Coal ( Bituminous & Lignite)
Natural Gas
Pulverized Petroleum Coke
August
Alternative Fuels and Raw Materials

Alternative fuels
Dry sewage sludge
Plastics
Old / Worn out tyres
Used oil
Animal meal, animal fat

Solvents
Distillation residues
Paper
Waste Wood
Alternative raw materials

Earth from oil spills
Aqueous systems (Oily water)
August
Fuel Combustion ...

A complex burner is used
to mix different fuels with
air and deliver them to the
burning zone of the kiln for
combustion
August
Clinker Manufacture - Fuels

Coal, Heavy oil
Flame
Animal meal
Fuels
Dried sewage sludge
Ash
Solvents
Tires
August
Clinker Cooling ...

Clinker at ~1350oC enters
the cooler and forms a bed
through which air is blown to
cool it to ~150oC
August
Cooling Principle
Hot combustion air to kiln
Hot waste air to filter
Hot clinker in
Slightly negative pressure!
Grate
Positive pressure!
Cooled
clinker out
August
Materials: Raw Meal to Clinker ...

The basic sequence of reactions ...
Reactants +
Raw Meal
(60C)
Natural
Earth
Minerals
Products
(450 - 1450C)
C S+ C S
3
2
AND
Liquids/Melt
(1450C)
Cooled
Clinker
(150C)
Synthetic Rock
Artificial Minerals
Alite & Belite
Aluminate & Ferrite
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Cement grinding ...

90% Clinker
+ 5% Gypsum
+ 5% Mineral Compt
Grinding
Portland
Cement
Ball mill
Note Composite
Cements contain > 5%
mineral components as
a clinker replacement
August
Cement grinding
Operation principle
of a Tube mill
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Mineral Components (MIC)

Definition
Mineral Components are materials with binding
properties which are not derived from the clinker

manufacturing process
Mineral Components can be used:
as alternative materials for clinker (clinker substitute), or
for the manufacture of concrete (cement substitute)
When added at the cement mill or added to Portland
Cement, the product is called Composite Cement
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Cement grinding ...

90% Clinker
+ 5% Gypsum
+ 5% Mineral Compt
Milling
Portland
Cement
Ball mill
Note Composite
Cements may
contain >5% mineral
components as a
clinker replacement
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Cement storage, packaging & dispatch ...
Cement from the mills
August
Cement Packaging
August
Cement Palletizing (Example)...

Single
bags in ...
Multi-pack out
Direct to load
out, or plastic
wrapped first
August
Bag Loading of Trucks
August
Bulk Loading of trucks...
August
Contents
Overview
Rawmeal Preparation
Clinker Manufacture
-
Cement Grinding
-
Alternative Fuels
Mineral Components
August
Distribution / Logistics
August
Technical Data (Typical Example) ...

5
8
6720
840
days/week
hours/day
tonnes/day 1.4 7
22
tonnes/hour
Quarrying & Raw
4800
material preparation
220
d/w
h/d
t/d Factor 1.6
t/h
Raw meal preparation
Note: 3000 t/d ~ 1 Mio. t/y

7
24
3000
125
d/w
h/d
t/d
t/h
Clinker burning process
7
16
3300
140
d/w
h/d
t/d
t/h
Cement grinding
5
8
4600
600
d/w
h/d
t/d
t/h
Storing/Dispatching
5 kWh/t
30 kWh/t
30 kWh/t
40 kWh/t
Total cement plant ~3500 MJ/t clinker

(ie. 120 kg coal/t ); and ~100 kWh/t cement
2 kWh/t
3 kWh/t
Auxiliaries
August

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An Overview of the Cement Manufacturing

The Cement Manufacturing Process

the process including:

Holcim Group Support

Raw Material Extraction

Raw Material Preparation

Packing - Dispatch - Logistics

Holcim Group Support

Raw Material Extraction

Raw Material Preparation

Packing - Dispatch - Logistics

Holcim Group Support

Raw material supply

Cement plant boundaries

Overview - Cement Manufacturing Processes

Holcim Group Support

Cement Manufacturing Processes

Holcim Group Support

Cement Manufacturing Process - Schematic

Holcim Group Support

Raw Material Extraction

Raw Material Preparation

Packing - Dispatch - Logistics

Holcim Group Support

Quarry: Limestone and Marl (Clay/Shale)

Holcim Group Support

Materials: Raw Mix Components ...

Calcareous (Calcium/Lime) Materials -- CaCO 3 (Limestone)

Argillaceous Materials -- SiO 2, Al2O3 & Fe2O3 (Clay, Marl)

Main Components (Chemistry):

Al2O3 = Alumina / A Fe2O3 = Iron / F

Raw Mix Corrective Materials

Materials rich in C, S, A, F to correct the rawmix

Holcim Group Support

Materials: Raw Mix Components ...

Holcim Group Support

Raw Material Blasting (Preparation)

Drilling and blasting

Quarry Operation - Blasting

Holcim Group Support

Quarry Operation, Loading & Haulage

Holcim Group Support

Holcim Group Support

Raw Material Extraction

Raw Material Preparation

Packing - Dispatch - Logistics

Holcim Group Support

Raw Material Crushing ...

Holcim Group Support

Transport to the Clinker Producing Site (1)

Holcim Group Support

Transport to the Clinker Producing Site (2)

Holcim Group Support

Raw Material Pre-blending

Direction of travel during

Holcim Group Support

Pre - blending: stacking and reclaiming