Mobilizing Technology to

Sustain and Increase

Cement Production
Stewart
Stewart Gater
Gater –
– National
National Engineering
Engineering Projects
Projects Manager
Manager Lafarge
Lafarge Cement
Cement
bulk08
DR Mediatheque Lafarge

bulk08
18
18 April
th
th April 2008
2008

Contents

„ Increasing Quantity of the Final Product

• The blending of supplementary cementitious material with
Portland Cement to increase the capacity of the final
product

„ Opportunities for Alternative Raw Material

• The use of ARM or additive in the raw meal stage to
improve the chemistry in the kiln for improvement to the
overall process

„ Technology – Back to the future

• Using an old technology to overcome industrial problems
that we cause with recent technology

1
 Increasing Quantity of the Final Product
„ Cement Types
• Cem I – Portland Cement
• Cem II – Portland Fly-Ash Cement
• Cem III – Portland Limestone Cement
• Cem IV – Blast Furnace Cement

„ Why Industry uses Cem II cements?

• Environmental Benefits
– Reducing emissions and energy consumption

• Improve Performance
– Workability, reducing early risk of thermal cracking, increase
resistance to chemical reactions, etc

• Increase Production of Final Product

– Reducing amount of clinker per tonne of cement

Increasing Quantity of the Final Product

„ What is Cem II
• Inter-Grinding of Portland Cement Clinker with carefully
controlled supplementary cementitious material, usually Fly
Ash
• The post blending of Portland Cement with Fly Ash

„ Blending of Portland Cement and Fly Ash

• Requires
– The correct proportions of each material
– Complete blend for a homogenous mix
„ Equipment
• Mechanical Blenders or Coriolis Flow Meters
– Uses vibration and a paddle wheel
– Measures the mass of material
– The use of mechanical blenders or coriolis flow meters
dramatically reduces the amount of energy used.

2
 Increasing Quantity of the Final Product
„ Blending System
Silo

PFA
Cement
Coriolis Flow
Meter

Liquid
Additive

Transport
5

Increasing Quantity of the Final Product

„ Blending System
Silo

PFA C em ent

Mechanical
Blender

Liquid
Additive

Transport
6

3
 Opportunities for Alternative Raw Material
„ Reason for the use of ARM and Alternative Fuels
• Key to business strategy
– Commercial advantage, i.e. gate fees

• Extends quarry life

• Environmental benefits
– Landfill, waste, etc
– Emissions

• Improving performance / reliability

– Quality
– Quantity

• Maintenance
– Improved process = less maintenance

Opportunities for Alternative Raw Material

„ Chemistry of the kiln
• Calcium, Silica, Alumina, Iron
• The iron and alumina form a flux which aids the bonding of
calcium and silica
• Chemistry balance or the raw meal is the key to the overall
process
„ Chemistry balance advantages
• Increased throughput
• Reduction in kiln temperature
• Reduction in emissions
• Less wear on cement mills
• Greater variance in range of alternative fuels able to be
used
• The plants energy consumption
• A homogenisation mix raw material in the clinker

4
 Opportunities for Alternative Raw Material
„ The need for expansion

Technology – Back to the future

„ Using an old technology to overcome industrial problems
with recent technology
• Problem
– The problem is that kiln throughput are way above their
design criteria.
– This causes industry problems regarding power consumption
on plants.
• The situation
– There is a need for constant upgrading for electrical
capabilities on plants.
– Most plants are close to limited fan situations on kilns
• Aim
– Is to reduce the power consumption within the plant
– Continue to increase kiln throughput
• Possible solution
– Exchange electrical and air equipment in favour of mechanical
equipment – bring back mechanical handling

10

5
 Technology – Back to the future
„ Plant section of feed to kiln

Pump Metering Air Lift Pre-heater Kiln

Silo Route Tower
11

Technology – Back to the future

„ Problematic equipment

Air Lift

Pump Metering Air Lift Pre-heater Kiln

Silo Route Tower
12

6
 Technology – Back to the future
„ Exchange Equipment – Use of mechanical handling

Bucket
Elevator

Pump Metering Bucket Pre-heater Kiln

Silo Elevator Tower
13

Any questions?
DR Mediatheque Lafarge