1-Cement Manufacturing Process and System

CEMENT MANUFACTURING PROCESS
PORTLAND CEMENT COMPONENTS

CEMENT
MANUFACTURING
PROCESS
CEMENT:
Cement is a material which binds together solid bodies (aggregate) by hardening from a
plastic state.
Cement can also be defined as adhesive substance capable of uniting fragments or masses
of solid matter to a compact whole.
Cement functions by forming a plastic paste when mixed with water, develops rigidity (sets)
and then steadily increases in compressive strength (hardens) by reaction with water
(hydration) .
PORTLAND CEMENT COMPONENTS
Name Oxide Formula % of Finished Cement
Tri-calcium Silicate 3 CaO SiO2 (C3S) 50 -70

Di-calcium Silicate 2 CaO SiO2 (C2S) 20 -30
Tri-calcium Aluminate 3 CaO Al2O3 (C3A) 5 -12
Tetracalcium 4 CaO Al2O3 Fe2O3(C4AF) 5 -12
Aluminoferrite
Portland Cement Composition
Components % Contributing Minerals
SiO2 19 - 23 Clay, Shale, Silt Stone, Sand,
Al2O3 3-7 Bauxite,
Fe2O3 1.5 - 4.5 Iron Ore
CaO 63 - 67 Limestone, Chalk,Marl
Free Lime 0.5 - 1.5
MgO
K2O
Na2O
SO3
LOI
IR
RAW MIX - LAFARGE SURMA CEMENT PLANT
Lime Stone Silt Stone Shale Sand Iron Ore

RawMix Clinker
MIX ( % ) 81.8 9.2 8.7 0.3
SiO2 (%) 2.28 83.10 52.60 82.10 1.35 14.11 21.75

Al2O3(%) 1.17 6.88 20.80 7.59 0.24 3.40 5.25
Fe2O3 (%) 0.68 4.39 10.10 3.01 102.70 2.13 3.28
CaO (%) 51.90 0.26 1.23 0.84 0.25 42.58 65.65 FUEL: GAS
MgO (%) 0.98 0.40 1.98 0.66 0.07 1.01 1.56
K2O (%) 0.10 1.15 2.73 3.10 0.04 0.43 0.66
Na2O (%) 0.26 0.32 0.97 0.05 0.05 0.08 CLINKER
SO3 (%) 0.95
C3S - 62.0
LOI (%) 41.90 2.71 7.27 0.89 -5.46 35.14
C2S - 15.59
Cl (%) 0.003 0.003
C3A - 8.36
LSF 632.42 0.11 0.69 0.35 0.35 94.83 94.83
MS 1.23 7.37 1.70 7.75 0.01 2.55 2.55 C4AF - 9.98
MA 1.72 1.57 2.06 2.52 0.00 1.60 1.60
LIME SATURATION FACTOR : (LSF)
LSF = CaO - 0.7 SO3

2.8 SiO2 + 1.2 Al2O3 + 0.65 Fe2O3
(Normal Range : 0.90 - 0.95)
ALUMINA MODULUS : (MA)

AM = Al2O3
Fe2O3
(Normal Range : 1.30 - 1.50)
SILICA MODULUS : (SM)

SM = SiO2
Al2O3 + Fe2O3
(Normal Range : 2.20 - 2.50)
BOGUE’S FORMULAE :
• Used to calculate percentages of clinker phases,

viz. C3S, C2S, C3A, C4AF
• Calculation based on Oxide analysis.
• Gives rough idea of clinker burning, phase
development & cement characteristics.

C3S = 4.07 * CaO - 7.6 SiO2 - 6.72 * Al2O3 -
1.43 * Fe2O3 - 2.85 SO3
C2S = 2.867 * SiO2 - 0.7544 * C3S
C3A = 2.65 Al2O3 - 1.69 Fe2O3
C4AF = 3.043 * Fe2O3
Liquid % (14500C) =
3.00 Al2O3 +2.25 Fe2O3 +MgO+K2O+Na2O

ALLOWABLE INPUT OF VOLATILE COMPONENTS FOR

KILN SYSTEMS WITHOUT BYPASS ON LOI FREE BASIS
COMPONENT NORMAL LIMIT HIGH LIMIT
ILC, SLC & SLC-I
Chlorine as Cl 0.023% 0.029%
Sulphur as SO3 1.25% 1.90%
0.65*K2O+Na2O 1.00% 1.50%

CEMENT PROCESS - FLOW SCHEME

PROCESSES IN CEMENT MANUFACTURE

Limestone Additives
Quarrying Quarrying
Crushing Crushing
RAW MATERIAL
STACKING / RECLAIMING
/ MIXING
FUEL GRINDING RAW MATERIAL GRINDING HOMOGENISING
Burning to
FUEL FIRING produce Clinker
3 - 5% Gypsum
CLINKER GRINDING CEMENT
Geo statistical techniques for quarry evaluation
Variogram
Krigging Techniques
Limestone Quarrying
Drilling
Blasting
Transport
Mining
LIMESTONE TRANSPORT
Crushing
Limestone from mines lump size up to 1 -2 m
Crusher
Product Size : - 25 mm for Ball mills

60 - 100 mm for VRM
(Based on mill size)
HAZEMAG CRUSHER
Quality Check:
Product size Granulomtery
CRUSHER
Pre-Homogenising of Materials
Objective:
- Homogenising of Raw Materials
- Raw Material Storage
Type of Storage / Stock Piles

- Longitudinal store with Bridge Reclaimer/ Portal Scraprer
- Circular Storage
Operation:
- Raw Material Stacking
- Raw Material Reclaiming
Stacker / Reclaimer
PORTAL SCRAPER BRIDGE SCRAPER
Quality Check:
Chemical Composition
Standard Deviation of CaO / LSF
Raw Material Grinding:
RAW MIX FEED

Feed Size 60 - 100 mm
Vertical Roller Mill
Raw Meal Product

12% R90  sieve
RAW MILL: 8
1. Main Motor
5
2. Gear Box
3. Grinding Table
10
4. Roller 6
5. Separator 11
4
6. Material feed
7. Hot gas inlet 3
8. Gas + Material outlet

7
9. Accumulators
9
10. Material reject cone
2 1
11. Seal air
RAW MILL: OPERATING PRINCIPLE

100 %
Recirculation 10-
25%
New Feed
100%
1500 –
3000 %
Nozzle Ring
45 – 60 m/s
10 – 25%
RAR - LVT SEPARATOR
ATOX RAW MILL INTERNALS

HOT GASES FROM

PH FAN EXIT
GAS CONDITIONING TOWER

ELECTROSTATIC PRECIPITATOR
Homogenising Kiln Feed
Objective:
- Store of finished ground raw mix

- Providing homogeneity to kiln feed
ILC Preheater
LP CYCLONES
First Second Middle Lower

In Line Calciner 70 - 85% material
180 dgr bend for
improved mixing
Oxidizing zone
Restriction for
Tertiary air improved mixing
Reduction
zone
Fuel 15 - 30% material
Degree of Calcination
Clinker Manufacture:
Kiln feed undergoes a combination of physical / chemical
process
Drying of raw mix, removal of water of crystalization,

calcining of raw mix (expulsion of CO2). Formation of
compounds, C2S, C3A, C4AF, Formation of C3S,
nodulisation and cooling.
CHEMICAL TRANSFORMATIONS
Temp Process Chemical

(Deg C ) Transformation
< 100 Drying, removal of H 2O (l) → H 2O (g)
water
Decomposition of Al 2(OH) 8Si 4O 10
100-400 clay with formation → 2(Al 2O 3. 2SiO 2)
of kaolinite +4H 2O
Decomposition of Al 2O 3. 2SiO 2 → Al 2O 3. +
600-900 metakaolinite to a +2SiO 2
mixture of free
reactive oxides
600- 1000 Decomposition of CaCO 3 → CaO +CO 2

limestone and 3CaO+ 2SiO 2 +2Al 2O 3
formation of CS → 2( CaO.SiO z) +
and CA CaO.Al 2O 3
800-1300 Decomposition of
limestone and 2CaO +SiO 2
formation of C 2S, → 2CaO.SiO 2
C 3A and C 4AF CaO.Al 2O 3 +2CaO
→ 3CaO.Al 2O 3
CaO.Al 2O 3 +3CaO
+Fe 2O 3 →
4CaO.Al 2O 3.Fe zO 3
1250- Further binding of 2CaO 2.SiO 2 CaO →
1450 lime by C 2S to form 3CaO.SiO 2
C 3S
CHEMICAL TRANSFORMATIONS
MgCO3 : MgCO3 - > MgO +CO2
Organic Carbon : C + O2 -> CO2
Sulfur as pyrites : 2 FeS2 + 6 1/2 O2 +
2 CaCo3 -> Fe2O3 +
2 SO2+2CaSO4 +2 CO2
Sulfur in fuel : 2S + 3 O2 -> 2SO3
CaO + SO3 -> CaSO4
Recarbonation : CO2 + CaO - > CaCO3 + heat
CAPACITY : 3600 TPD TEMP / PRESSURE PROFILE

Pressure Temp.
(mmWG ) DP ( Deg C)
Fan Inlet 453 367
Stage 1 408 78 381
Stage 2 330 54 599
Stage 3 275 64 781
Stage 4 212 52 890
Calciner Exit 160 900
The Rotax-2 suport rotary kiln

The Rotax-2 rotary kiln

MODERN FIRING SYSTEMS
FOR CEMENT KILN
GAS FIRING - ROTARY KILNS

Natural gas used for firing in kiln contain following hydrocarbons
Heat Value Heat Value
kCal/kg kCal/m3
Methane (CH4) 11890 8581
Ethane (C2H6) 11110 14000
Propane (C3H8) 10960 20608
Methane is dominant component in natural gas (80 -95%)
Natural gas at 20 - 25kg/cm2 passes through reducing valves / station to
reduce pressure to approx. 7 kg/cm2.
Reducing stations at kiln / calciner further reduce the pressure as needed
for process.
- Robust Design
- Low Primary Air
Consumption
- Adjustable Swirl
- Adjustable Air Nozzle Area
- Central Fuel Injection
- Suitable for Alternative
Fuels
- Environmentally optimized
DUOFLEX BURNER - main features

DUOFLEX BURNER
GAS
DUOFLEX Burner
CLINKER COOLING:
OBJECTIVE:
- Recuperate as much heat as possible from clinker to improve heat economy.
- To cool the clinker to a temperature acceptable to subsequent conveying
devices and storage to ~ 100 C.
CLINKER COOLERS:
Planetary Cooler
Grate Cooler
Rotary Cooler
Planetary Cooler
GRATE COOLER
FOLAX COOLER
GRATE COOLER
COOLAX COOLER
CIS/MFR FIXED INLET

COOLER - CFG
GRATE COOLER
CLINKER PHASE COUNTING (PHASE %) BY IMAGE ANALYSIS TECHNIQUE

REFRACTORY:
Clinker burning in kiln is high temperature process
Parts exposed to high temperatures in pre-heater / kiln / cooler are
lined with refractory to protect the shell.
Selection of refractory material could be from the following:
Basic Bricks
High Alumina Bricks
Castable
Refractory material selection / installation and optimal operation
ensures long life.
Some refractory properties critical for good refractory performance
are:
Resistance to high temperature
Spalling resistance
Resistance to chemical attack
Abrasion resistance
Coatability
Refractory lining details

COOLING ZONE
TIP CASTING
INLET CAL. S. U.T. BURNING L.T.

CONE ZONE ZONE ZONE ZONE ZONE OUTLET
CLINKER STORAGE:
• Clinker abosrbs water & hyrates.

• Premature hydration of clinker
results in cement loosing strength
on grinding.
• Hydrate clinker does not exhibit
proportionality between strength
and fineness.
CLINKER SILO
Lime Stone
Separator
Clinker
E-Crane for Unloading

Cement Silo
Gypsum
Slag Ball Mill Packer
Fly Ash
Fly Ash Unloading
Truck Loader Bulk Loader Barge Loader
Raw material Unloading Crane Pneumatic Raw material Unloading (Fly ash)
E-Crane from Belgium – World best hydraulic crane
Clinker Grinding:
Clinker (94 - 97%) and Gypsum ( 3 -6%) is ground together to get

Ordinary Portland Cement (OPC)
Why Gypsum Addition ?
- Delay the setting time of cement so as to allow time to
work with concrete before it hardens.
- It increases cement strength
- Mineral C3A is extremely reactive. Gypsum reacts with C3A to form
ettringite which is deposited on surface of C3A particles thus impeding
the direct C3A reaction with water
Cement (Ball) Mill

IMPACT
ATTRITION
Ist Chamber Lining
2nd Chamber Lining

Insert OSEPA Fines
Material Feed
❖ Fuller O-SEPA Secondary

Air
Primary
Air
Rejects
O - SEPA
Fast Track Block 2 - Week 1 - 1999 / Separators - Finish Grinding / Institut Cimentier / 19
SEPARATOR
INTERNAL WATER COOLING IN A BALL MILL

CFI SILO
PACKER
PACKING PLANT
% ENERGY CONSUMPTION PER TE OF CEMENT

MISCELL.
2%
PACKING LS CRUSHER RAW
2% 2% GRINDING
23%
CEMENT
GRINDING COAL
40% GRINDING
3%
KILN
28%
BALL MILL WITH OPEN SEPAX CIRCUIT
PROCESS FLOW
CENTRAL CONTROL ROOM

Raw Mix / Kiln Feed Composition for Clinker
• Limestone ( 78 - 82 %)
• Clay (15 – 17 %)
• Sand ( 2- 3 %)
• Iron Ore ( 0.5 – 1 %)

1-Cement Manufacturing Process and System

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CEMENT MANUFACTURING PROCESS

PORTLAND CEMENT COMPONENTS

PORTLAND CEMENT COMPONENTS

Name Oxide Formula % of Finished Cement

Tri-calcium Silicate 3 CaO SiO2 (C3S) 50 -70

RAW MIX - LAFARGE SURMA CEMENT PLANT

Lime Stone Silt Stone Shale Sand Iron Ore

SiO2 (%) 2.28 83.10 52.60 82.10 1.35 14.11 21.75

LIME SATURATION FACTOR : (LSF)

LSF = CaO - 0.7 SO3

ALUMINA MODULUS : (MA)

SILICA MODULUS : (SM)

• Used to calculate percentages of clinker phases,

• Calculation based on Oxide analysis.

• Gives rough idea of clinker burning, phase

development & cement characteristics.

C3S = 4.07 * CaO - 7.6 SiO2 - 6.72 * Al2O3 -

1.43 * Fe2O3 - 2.85 SO3

C2S = 2.867 * SiO2 - 0.7544 * C3S

C3A = 2.65 Al2O3 - 1.69 Fe2O3

C4AF = 3.043 * Fe2O3

3.00 Al2O3 +2.25 Fe2O3 +MgO+K2O+Na2O

ALLOWABLE INPUT OF VOLATILE COMPONENTS FOR

Sulphur as SO3 1.25% 1.90%

0.65*K2O+Na2O 1.00% 1.50%

CEMENT PROCESS - FLOW SCHEME

PROCESSES IN CEMENT MANUFACTURE

FUEL GRINDING RAW MATERIAL GRINDING HOMOGENISING

Geo statistical techniques for quarry evaluation

Limestone from mines lump size up to 1 -2 m

Product Size : - 25 mm for Ball mills

Type of Storage / Stock Piles

PORTAL SCRAPER BRIDGE SCRAPER

Raw Material Grinding:

RAW MIX FEED

Vertical Roller Mill

Raw Meal Product

8. Gas + Material outlet

RAW MILL: OPERATING PRINCIPLE

RAR - LVT SEPARATOR

ATOX RAW MILL INTERNALS

HOT GASES FROM

GAS CONDITIONING TOWER

Homogenising Kiln Feed

- Store of finished ground raw mix

First Second Middle Lower

Fuel 15 - 30% material

Drying of raw mix, removal of water of crystalization,

Temp Process Chemical

600- 1000 Decomposition of CaCO 3 → CaO +CO 2

CAPACITY : 3600 TPD TEMP / PRESSURE PROFILE

The Rotax-2 suport rotary kiln

The Rotax-2 rotary kiln

GAS FIRING - ROTARY KILNS

DUOFLEX BURNER - main features

CIS/MFR FIXED INLET

CLINKER PHASE COUNTING (PHASE %) BY IMAGE ANALYSIS TECHNIQUE

Refractory lining details

INLET CAL. S. U.T. BURNING L.T.

• Clinker abosrbs water & hyrates.

E-Crane for Unloading

Slag Ball Mill Packer