imento deirmenine ek

Roller Press (Crusher)

High-pressure crushers have two rollers rotating in the opposite direction.

Hydraulic pressure units can create pressures of 50-120 MPa over the last material bed for rolls. In
the cement industry, roller press is widely used as a pre-mill [3]. A roller press system is shown in
FIG.

Walnut Mills (Horomil)

Reliefs used in grinding have a predominance in compressing (compression) and grinding of ball
mills in terms of energy consumption, which is the main interest of the developments in press.

The capacities of such mills vary between 100-300 t / h.

Significant features; less energy consumption compared to ball mills, flexibility in transit between
products, low noise level, compatibility with slag, limestone and other similar minerals in addition
to pheromone and cement [3].

To improve the efficiency of the grinding process, especially chemical mills, which help grinding by
facilitating the flow of material in the ball mills, preventing agglomeration and preventing sticking
/ wrapping on the liner plates with the balls.

As the particle size becomes smaller, the static forces of the particles increase and attract each
other and cause accumulation. this situation is prevented by using chemicals and particles are
obtained in the desired size (10-30 microns). After all; the capacity of the mill increases, the
strength of the product increases, and the settlement of the product increases. The grain size of
the product obtained at the end of grinding in the mills are different from each other. In the
grinding systems, the material from the mill is sent to a grain size sorting and sorting process, and
two rough and thin main cuts are separated. As thin material is sent to the next stage as a product,
the non-fine materials are sent back to the mill to be milled. The equipment that separates the
particles by their size with the aid of air flow is called the Separator. There are two types of
separators

Static Separator

Separation efficiency is low, installation and maintenance costs are low because there are no
moving parts. The mill is used with a filter to de-dust the sweeping air. The distinction is achieved
by the vortical air flow generated by the guide blades. The radial positioning of the fins must be
adjusted for the required fineness. V-type static separator is also available. It realizes the large
contact surface provided by both material and air flows in both the cross and the same direction,
and the efficient heat transfer it provides [3]. The V-type separator is shown in Fig.

Dynamic Separator

These separators are the traditional classifier of the mill product. The material is directed onto a
rotating sweep table, which exposes it to an increased airflow. The coarse grains either fall directly
from gravitational plate or are separated between the auxiliary fan blades and the control valves.
The fine dust moves with the gas to the main fuselage, and the downward flow of the gas allows
the enthalpy to separate from the gas, with the velocity dropping towards the return flaps [3].
Figure 6 shows the dynamic separator structure.

Milling is a surface augmentation process to facilitate the chemical reactions that occur in the
furnace.

Size reduction is the physical change process.

In the process, the material is milled to micron dimensions in cm size. In cement production;

The final stage of raw material production.

Cement making with proper additives from clinker, the basic intermediate

Grinding operations are applied to prepare fuels such as coal, petroleum coke for combustion.

Grinding energy is a low operation for the utilization ball mill, the use rate of the supplied energy is
about 10-15%. Most of the electricity energy given to the system is spread around as heat and
vibration.

The causes of energy losses are: friction between the material particles and the grinding medium,
friction between the materials used as the grinding medium, and the collapsing shrinkage parts
must be brought together again [3].

Tube Millers (Ball)

The material and the grinding elements rotate together in a rotating tube, the material being
milled in this order by friction.

On the rising side of the mill mantle, the material and grinding balls are lifted together and fall
down together according to the speed of rotation of the mill. This intense contact material
crumbles. Steel balls or roller parts are used as grinding elements. The inner surface of the mill
body is covered with steel alloy plates, the functions of which are:

Protecting the milling mantle against wear and tear

Ensure that the material is lifted up

Classify crumbled pieces according to their size

Ball mills can be single or multi-segmented. There is also a grate diaphragm at the exit to prevent
the grinding balls from escaping from the mill.

The view of the ball mill is given in Fig.

Cement factories use mostly coal types and petroleum coke as an oil derivative.

After 1980, it started to be used as fuel in waste (car tires, paper, plastic, sludge, waste oils, etc.).
Coal grinding is very important. The coal burning reaction is finely ground to be exact and fast. The
amount of volatile matter in the car is a basic measure of the degree of grinding. Freshly ground
fine coal is very dangerous; flammable For this reason, the goal is to work with the least amount of
milled coal, which requires almost continuous operation of the coal mill. It is important to feed the
prepared solid fuel furnace regularly. For this purpose weighing devices are used. As it is the most
risky working area, the amount of CO in the gas is constantly monitored, the unit has fire
extinguisher tubes, and explosion caps are placed on the filter / silo to prevent gas jams. Coal
grinding; coal mill outlet temperature, baggy filter outlet temperature, O2 and CO concentrations,
temperature in powder coal silos O2 and CO concentrations are constantly monitored.

The energy required for baking is the chemical energy in the fuels supplied by the furnace flame
tube. It operates continuously for 4-6 months in an environment where the flame temperature is
found at 2050 oC and the mechanical thermal and chemical weathering is at the highest levels, the
coal transport air is 25 m / s, the secondary burning air is 400 m / s and the lateral air velocity is
around 160 m / flame pipe is the most important equipment of the process. To protect it, a
protective refractory sheath (concrete) is built on it, during which the sheath is worn so that there
is a reserve of flame borne in every factory.

imento fabrikalarnda yakt olarak en ok kmr trleri ve bir petrol trevi olan petrokok
kullanlr.

1980 sonrasnda atklarda (oto lastikleri, kt, plastik, amur, atk yalar vb.) yakt olarak
kullanlmaya balanmtr. Kmr tme ilemi ok nemlidir. Kmr yakma tepkimesinin tam ve
hzl olmas iin ok ince tlr. tme inceliinin belirlenmesinde kmrn uucu madde
miktar temel lttr. Taze tlm ince kmr ok tehlikelidir; hzla tutuabilir. Bu nedenle
hedef en az tlm kmr stou ile almaktr, bu da kmr deirmeninin neredeyse srekli
altrlmasn gerektirir. Hazrlanan kat yakt frna dzenli biimde beslemek nemlidir. Bu
amala tartl besleme dzenekleri kullanlmaktadr. En riskli alma alan olduu iin gazlardaki CO
miktar srekli izlenir, nitede yangn sndrme tpleri bulundurulur, gaz skmalarn nlemek
iin filtre/silo zerlerine patlama kapaklar konur. Kmr tmede; kmr deirmeni k
scakl, torbal filtre k scakl, O2 ve CO deriimleri, toz kmr silosundaki scaklk O2 ve CO
deriimleri srekli izlenmektedir.

Piirme iin gereken enerji frna alev borusu ile salanan yaktlarn iindeki kimyasal enerjidir. Alev
scaklnn 2050 oCyi bulduu, mekanik sl ve kimyasal anmann en st dzeylere vard, kmr
tama havasnn 25 m/s, ikincil yakma havasnn 400m/s, yanal hava hznn 160 m/s dolaylarnda
olduu bir ortamda 4-6 ay kesintisiz alan alev borusu srecin en nemli donatsdr. Onu
korumak iin zerine koruyucu bir refrakter klf (beton) yaplr, alma sresince bu klf anr, bu
yzden her fabrikada alev borusunun bir yedei bulunur.
Alternative fuels are non-traditional fuels that have calorific value and can be used as conventional
fuels such as petroleum coke, oil and natural gas in clinker manufacturing. Typically, alternative
fuels are waste or byproducts from industrial, agricultural and other processes.

https://www.intechopen.com/books/alternative-fuel/alternative-fuels-in-cement-manufacturing

Category Fuels

Gaseous
Refinery waste gas, landfill gas, pyrolysis gas, natural gas
fuels

Liquid Tar, chemical wastes, distillation residues, waste solvents, used oils, wax suspensions, petrochemical waste,
fuels asphalt slurry, paint waste, oil sludge

Petroleum coke (petcoke), paper waste, rubber residues, pulp sludge, sewage sludge, used tyres, battery
Solid fuels cases, plastics residues, wood waste, domestic refuse, rice husks, refuse derived fuel, nut shells, oil-bearing
soils, diapers, etc.

The main advantages of using Alternative Fuels in the Cement Industry are economic and
environmental.

Cement producers strive to reduce their production costs. Fuel accounts for 20 to 25% of the
production cost of cement and one viable option is the use of alternative fuels at a much lower
cost than conventional fossil fuels.

The use of waste fuels reduces the carbon footprint that results from using fossil fuels and
therefore the overall environmental impact of cement manufacturing operations. It also extends
the supply of fossil fuels and is a safe way of absorbing waste which otherwise would present a
waste disposal problem.

The use of alternative fuels in cement kilns helps eliminate air pollution problems by removing
additional emissions from combustion plants.

http://pecconsultinggroup.com/use-of-alternative-fuels-in-the-cement-industry

For economical and sustainable operation Denizli Cementos preferred preheater calciner and main
burner to run alternative fuels and raw materials.

This project has two bucket band providing the fuel delivery. Fuel and raw materials are
transported without dust-free and energy-saving. There are 4 collection sites for shredding and
mixing waste. the wastes are separated to be sent to the head or transfer part of the rotary kiln.
There are alternative fuels bunkers in rotary kiln 1 and rotary kiln 2. Alternative fuels is weighed in
the shenck and it is given to the rotary kiln. On the rotary kiln; the heavier and dense material
should be burned, but less than 30 mm in the flame tube. PVC, food and beverage, brick, and
concrete can not be burned.

There are some criteria for the use of alternative fuels.

Alternative fuels have high calorie.

The chlorine rate should be kept low. If the Cl ratio is high, it damages the furnace.
It will not be heavy metal in the alternative fuel.
The humidity should be between 10% and 15%.
 The maximum mercury content is 10 ppm.
The total amount of sulfur should be above 1%.
ABSTRACT
This research paper contains the results of an investigation about cement
production, types, effects of environment and the economical anlaysis for not only in
Turkey and the other countries in the world.
Today, cement is the basic building material that is in powdered form and
takes a hard form when it gives a reaction with water. The most popular type of
cement is Portland cement because of its strength and resistance to water. Although
Portland cement is the main cement used in concrete, there are other types of
cement. The three types that are often mentioned are Portland, blended, and non-
hydraulic. All Portland and blended cements are actually hydraulic cement. Different
types of portland cements are created based on the use and chemical and physical
properties desired.

Cement is a manufactured product made by blending different raw materials and

firing them at high temperature in order to achieve precise chemical proportions of
lime ,silica,alumina and iron in the finished product known as cement clinker. Cement
is therefore essentially a mixture of calcium silicates and smaller amounts of calcium
aluminates that react with water. I will explain these composites in the properties
section.
Cement manufacturing consists of raw meal grinding, blending, pre-calcining, clinker
burning and cement grinding. In short, limestone and other materials containing
calcium, silicon, aluminium and iron oxides are crushed and milled into a raw meal.
This raw meal is blended and then heated in the pre-heating system (cyclones) to
start the dissociation of calcium carbonate to oxide. The meal goes further into the
kiln for heating and reaction between calcium oxide and other elements to form
calcium silicates and aluminates at a temperature up to 1450 0C: so-called clinker
burning. The cyclone system is attached to the rotary kiln by a riser duct. Secondary
fuel is fed to the riser duct, the main fuel mixture, coal/petcoke, fires the kiln. Reaction
products leave the kiln as a nodular material called clinker. The clinker will be
interground with gypsum and other materials to cement.You will see the
manufacturing process have some steps and report gives these step by step with
details in the manufacturing parts.
Cement is the single most commonly used building material in the world today. World
cement production increased as in previous years continued in 2009, production
reached 3.0 billion tons. China, India, America, Japan, Turkey are among the major
producers of cement industry in the world. Today, since production capacity of Turkey
has been increased day by day, in the production of cement Turkey has been the first
country in Europe and fifth country in the world today.You will see these informations
with some figures,tables about statistical data.
Also, I mentioned the environmental problems of cement in the other section. Cement
is everywhere, and the building material makes a huge impacts on the environment.
Such as, energy consumption, some atmospheris gases emissions etc.
After that all steps; I hope you will find your questions answered about tire
manufacturing process in this report.

Determination of free lime (with a conductivity device)

The ratio of the free lime (Free CaO) to the conductivity device is determined in the
sample.
Samples should be milled so that it passes completely out of the 125 micron sieve.
1 gram sample is placed into a beaker containing 80 milliliters of ethylene glycol.
put on the magnetic stirrer.
The conductivity measurement device probe touched to the beaker base.
When the temperature reaches 80 C, the unit is turned off and the value is saved.

fineness analysis
The tact of each material is determined.
Vacuum in the vacuum screening machine is adjusted to 25 megabits.
Weigh 25 grams of sample, pour all over the sieve.
if the material adheres to the cover of the device, it is lightly struck with a hammer on the
cover.
When the sieving is finished, the material on the sieve is weighed. (R1)
new measurement is made with a new sample. (R2)
The cement residues (R), R1 and R2 are averaged.

Liter weight analysis

This analysis is made of clinker.
the clinker sample is sieved between two sieves.
Then, from a certain height, it is filled into the well known container of 1 lt volume.
it is spatulated and weighed. (M)

moisture analysis
the humidity of limestone, gypsum, clay, trass, iron ore, bauxite, coal is determined.
The material passed from the crusher is reduced.
The sample is weighed by quatration method. (M)
The first weight of the sample and ceiling is recorded. (M2)
The sample is left in the oven until the difference between the last two weighings is 0.1.
weighed at room temperature. (M1)
The oven temperature for gypsum is 45 degrees.

preparation of perl in melter

Perl should be prepared in the melting apparatus for chemical analysis of the sample in the
XRF instrument.
The loss of heat of the sample is determined.
The amount of the substance is calculated by adding a heat loss.
NH4I is prepared by dissolving in pure water.
flux is weighed in the specified quantities.
Flux is added to the sachet.
4 drops of NH4I are added.
The crucible is inserted into the device and the melting process is started.
Kimya
Analysis of calories in coal
the coal sample is weighed in the metal crucible. Weighing is recorded. The calorimeter is
placed on the device.
glow loss
glow loss
The specimens should be such that the 125 micron mesh can be replaced.
1 gram sample is weighed (m1) at 950 degrees Celsius and placed in a tightly closed almond
basket.
The fixed mass is determined after cooling to room temperature in the desiccator. (M2)

ash in coal
The dry coal is passed through a 200 micron sieve. 1 gram is weighed and poured into a
container. (M1)
It is kept on the heater until it becomes ashed at 130 degrees.
it is removed from the frying pail and mixed with the platinum rod.
Cool and weigh in the desiccator.

combustible sulfur
the amount of combustible sulfur in dry coal is determined.
The calorimeter bomb is closed for 15 minutes.
Then the mouth of the bomb is opened slowly and the gas in the bomb is evacuated.
the inside of the cover, the crucible and the inside of the bomb are washed away.
The beaker is boiled well, the Co2 is evaporated.
The white band is filtered through the strainer paper.
After boiling on the permeate heater, barium chloride solution is added.
the blue band is filtered through filter paper.
The sample is burned in the oven and cooled in a desiccator.
weighing is done. (M1)

limestone cement
1 gram sample is weighed and waited for 30 minutes at 550 degrees.
The sample is cooled and stored.