Very important Notes for Purchasing

Managers in cement Factory

1 Purchasing in the Raw Milling section

2 Purchasing in the Preheater section
3 Purchasing in the kiln section
4 Purchasing in the cooler section
5 Purchasing in the kiln &cooler Filters section
6 Purchasing in the kiln BYPASS section

7 Purchasing in the Gas analyzing

8 Purchasing in the kiln coal mill section

9 Purchasing in the cement grinding section

10 Purchasing in the Weighing Dosing
Raw Best Practice / Specifications Alternatives Operating Not advisable
milling Recommendation target

CHOICE Vertical Mill with Vertical Mill with 2 Tube mills without drying chamber, or without
OF MILL cyclone and fan cyclone and fan compartment Autogenous Mills (only in case of specific appl
SYSTEM with VFD with VFD s closed Roll Press in circuit with V or VSK separator an
separator.
circuit tube
Pregrinding circuit with two- compartments ba
mills with
Air Swept mill Central discharge mill
drying
chambers (if
moisture <
7-8%) or
Tube mills in
combination
with heated
hammer
crushers.
High
efficiency
separator or
Roller Press
with Ball Mill
Modificati Closed circuit mill Closed circuit mill Roll Press in
on of High efficiency High efficiency circuit with V
existing separator separator or VSK
grinding separator
shop and/or
dynamic
separator.
Pregrinding
with two-
compartment
s ball mill
circuit.
Modification
of 1st
generation
separator
Addition of
external
drying drum
New Ball Mill with drying chamber
Equipmen
t
Mill Closed circuit Partial feed Open circuit
Circuit to the
separator
Ball mill 75% critical speed 75 % critical speed <73% or >78% critical speed
speed
Ventilatio Air velocity above Air velocity above
n ball mill ball charge=1,5 to ball charge=1,5 to
2,2 m/s 2,2 m/s
 inside the trunion: VFD fan
22-25 m/s inside
partition:8-14 m/s
0,6 – 0,8 Nm3/kg
raw mix hood <
5m/s
drop out box <
2m/s VFD fan
Mill L/D 1,5 < L/D < 3,2
ratio First compartment
length = 35 45% of
mill total length
Raw Best Practice / Specifications Alternatives Operating Not advisable
milling Recommendation target

Ball mill Moderate lifting Classifying liners in Duo lift Ripple liners
Liners liners for first second
compartment, compartment
classifying liners for
second
compartment
Intermedi Central opening Diaphragms Slots placed radially.
ate adapted to the with material
Partition filling degree. Slots flow control
wall placed concentricly.
– 8 to 12 mm slot
for central partition.
– open area > 50 %
by central opening
Outlet Central opening Slots placed radially.
partition adapted to the
wall filling degree. Slots
placed concentricly.
Partition wall slot
size + 2mm (max
slot = 0,5 min ball
size)
Ball Volume Loading:
charge –
for minimum kWh/t
: 26-28% in C1 and
28-30% in C2
– for max output:
32-34% in C1 and
34-36% in C2
Separator Third Generation Dust load < 1st or 2nd generation separators
High Efficiency 1kg/m3 Qf/Qa <
2.5
Control Fresh feed control Weighing rejects Control mill fresh feed using only one par
to assure constant (belt weigher), rejects flowrate or only elevator power , fo
feed to the measuring elevator
separator. Mill power, mill presure
controled by LUCIE. loss, mill outlet
temperature and
 electronic ear.

Feed Feed size 95%< 50 Precrushing,

mm d80 feed < screening,
20mm, external
drying
Drying Moisture inlet C1 <
compartm 1.5% Specific drying
ent capacity
<300kg/m3
Raw Best Practice / Specifications Alternatives Operating Not advisable
milling Recommendation target

Equipmen VRM
t
Vertical Recirculation of gas Metal detector and Water Gas speeds:
Roller Mill to the mill. Metal extractor in the injection Nozzle ring
detector and feeding line (after facilities in >30 m/s Mill
extractor in the reject’s return) the mill Body: 5 – 7
feeding line (after Bed depth sensor housing m/s
reject’s return) Water injection max Separator: 3
Gas flow 25 kg/t Material – 5 m/s
measurement after External Dust Load:
cyclone or filter Recirculation 600 g/m3 at
Water injection System >30% Fresh mill outlet
system Central mill Feed Capacity
feed. Fan with VFD
HE Separator
Material External
Recirculation
System >30% Fresh
Feed
Capacity
Fan
with VFD
Bed depth sensor
Control Constant mill exit T°
Constant mill gas
flow Mill feed a to
mill deltaP

Preheater Best practice / Specifications Alternatives Operating Not advisable

Recommendation target

Equipmen
t
Cyclones 5 Stage Preheater – No horizonatal inlet 4 Stage For a 5 stage
low moisture < 5% ; no horizontal Preheater – PH, 4.5 to 5.5
raw materials Low surface high kPa
pressure drop moisture (including
 Bottom of cyclone >5% raw kiln)
> 50° height materials
Dip Tube Top (stage 1): 100% Top (stage 1): 100% Hurrivanes –
Length Stage 2/3: 75%min depending
relative to Stage 4/5 : 50%min on geometry
cyclone
inlet
height
Splash Lafarge design >60o below Splash plates
box cleaning devices. At C3
least 55° to 80°
between meal pipe
and
splash box
2 m from flap,
pipe without elbow
60° for kiln feed to
splash box.
Pendulum External knife
flap bearing
Precalcine Vessel + Hot core Residence time > 6 Riser Duct
r preferred Residence sec plus hot core
time > 6 sec for
petcoke, Low-Nox
Tertiary Downward split
air duct design for in-line
calciner Damper
control
Duct velocity 20 to
30 m/s
Process
Gas duct Mini 12 m/s top
velocity at stage with 17 m/s
meal bottom
entrance (intermediate
proportional)
Can install
restriction as
alternative
Riser velocity 16
m/s minimum
Preheater Best practice / Specifications Alternatives Operating Not advisable
Recommendation target

Cyclones Top cyclone Top cyclone

efficiency > 95% efficiency > 95%
Meal Considered if high Lateral
curtain volatile cycles Consider a
expected splitter
Most common on
N-1 stage on kiln
side
Kiln inlet No dead zone
box Smooth design
 (entrance in the
middle)
No turbulances
45°- 50° slope of
inlet
Downcom Cooling by water
er sprays Minimum
evaporation: 4 sec
(for target at 185°C)
No bleed air is
recommended,
except for start up
ID fan VFD drive
preheater Fresh air intake
before the fan (fan
protection)

number 3 Only 2 fans

of fans ID fan, raw mill fan
& baghouse fan
Secondar Burner preferred for
y Fuel Calciner
usage

Kiln Best Practice / Specifications A Operating target Not advisab

Recommendation l
t
e
r
n
a
t
i
v
e
s

Equipmen
t
Burner Lafarge Burner M Position in center line of kiln and
type and A aligned on kiln axis (only if kiln is
position S stable and burner having
sufficient impulse)
b
u
r
n
e
r

i
n

c
 a
s
e

o
f

r
e
g
u
l
a
r

s
o
l
i
d

f
u
e
l

a
n
d

a
l
t
e
r
n
a
t
i
v
e

f
u
e
l

;
Fuel Solid Fuel: 25 – 35 m/s in burner ; >25m/s Solid Fuel: 25 – 35 Alternative Fuel: 25 – 40 m/s in
speed in conveying line m/s in burner ; burner ; >25m/s in conveying
>25m/s in conveying line
line
Total <12% with coal / petcoke < 15% primary air (as low as
primary possible when firing alternative
air fuels)
Liquid > 25 cSt
(main
fuel)
Swirl Design: 0,15
Impulse Design: >2,2

Retaining 0,6 to 1 m from nosering as single ring, D

rings triangulkar shape o
u
b
l
e

f
l
a
t

b
a
r

M
a
g
g
o
t
e
a
u
x

s
y
s
t
e
m
Kiln slope 3 – 3,5 % 4
%
L/D >10,5 for preca (> 15 is required when
designing for alternaitve fuels)
> 15 for preheater
Tertiary From kiln hood From kiln hood Settling cha
air Take off velocity 5-6 m/s throat and Take off velocity 5-6
tertiary air and 25 m/s in the duct m/s throat and
tertiary air and 25
m/s in the duct
Shell 12 to 18 m/s at shell Supplied
cooling
fans
Kiln Best Practice / Specifications A Operating target Not advisab
Recommendation l
t
e
r
n
a
t
i
v
e
s

Process
Thermal < 5 MW/m² (kiln cross section) < 5 MW/m² < 6.5 MW/m²
load

Kiln hood < 6 m/s

velocity
Kiln load <4,5 t/d/m³
Productio 24 m/s hearth velocity pc kiln <28 m/s
n
Clinker With > 0,025% of Cl input (related to
bypass clinker) consider a bypass
Clinker For off specification clinker, 8 hour
storage separate storage considered

Cooler Best practice / Specifications Alternatives Operating Not advisable

Recommendation target

Equipmen
t
Equipmen Cross Bar or Cross Bar or
t Walking Floor Walking Floor
Selection Design Design
Grate < 45 t/m² d < 45 t/m² d
load
Variable All on 1st grate Variable speed on Fan dampers Flap
speed all on 1st grate (inlet radial)
fans fans. 2nd grate
fans can be with
variable inlet vanes
dampers
Fix inlet 5 to 8 (1.5 – 2.5 m)
rows Max 15 degree
angle Refractory
Horseshoe Air
Cannons
Crusher Roller crusher Hammer
intermediate or at Crusher
the end

Grate 0° 3° maximum
slope
Evacuatio Simple gate and Double gate
n hoppers sensor level mechanically
activated
Process
Air flow Not < 2,1 Nm3/kg > 2.1 Nm³/kg ck
design > 1.7 Nm³/m²/s on
first fans, 2
Nm³/m²/s for KIDS
First fans > 10 kPa (100
pressure mbar) for KIDS
Optimal Lowest
bed stroke
depth permitted
with 20%
reserve on
fans
(6-8 st/min
for properly
designed
cooler)
Air 5 to 7 m/s
velocity
above
clinker
Clinker Min. 1,5 x nominal Min. 1,5 x nominal
transport capacity steel capacity steel
design conveyor conveyor

Process guidelines – Cooler – Page 1 / 1

Kiln filter Best practice / Specifications Alternatives Operating Not advisable
Recommendation target

Equipmen
t
Equipmen Low Pressure Pulse Low Pressure Pulse High Max dP< Off line cleaning is not acceptable due to
t Jet Bag Filter ( 2,5 Jet (LPPJ) Bag Filter Pressure allowed by damage to the bags.
Selection bars) ( 2,5 bars) Pulse Jet fan capacity
(HPPJ) Bag at end of bag
Filter life. Limit
(6bar/100psi) cleaning
, Electrostatic cycles to
precipitator obtain target
bag life.
Equipmen Gross Air to clothe Gross Air to clothe
t Sizing ratio: 1m/min ratio: 1m/min
average average
1.3 m/min max 1.3 m/min max
(upset cond) (upset cond)
Bag Fabric with PTFE Design temperature P84 bags of Adequate Other bag materials that are not proven.
quality membrane and 230°C Peak suitable temperature If using P84 verify the risk of hydrolysis.
fiberglass structure. temperature 260°C construction. control to
Known suppliers: prevent
Gore, BHA, teflon and
 Tetratec SGT
working at evaporation
180°C- 230°C max and bag
damage.
working at
180°C- 230°C
max
Airflow Scale model to
Distributi ensure good airflow
on distribution and
correct fan sizing
before purchase
Compress Air coolers can be Use air dryers Prevent No oil in cleaning air.
ed Air acceptable for LPPJ. (dessicant) moisture
Supply for HPPJ (- condensation
30deg C due in the bag
point). during the
compressed
air pulse.
Exhaust VFD VFD
Fan

False Air Direct < 30%

Preheater
Gases
Compound <
50%
Preheater
Gases
Kiln filter Best practice / Specifications Alternatives Operating Not advisable
Recommendation target

COOLER
FILTER
Equipmen Air to air heat Air to air heat Common Exhaust Gas flow in BH hopper must not cause ab
t exchanger to get exchanger to get baghouse for system bags due ro high velocities.
Selection 130°C at exit 130°C at exit RM/kiln and capacity to
cooler handle
ESP when all normal
cooler gas operation
used for raw and to
materials provide
drying sufficient
capacity for
push
conditions
for the full
length of the
bag life.
Exhaust gas flow Gas velocity at heat Water injection in the exhaust pipe
from the cooler exchanger’s inlet in
straight entry and normal conditions:
 oriented <10 m/s
downwards
through heat
exchanger
Cooling fan are VFD
speed
Exhaust VFD VFD
Fan

System Design upset Design upset

Sizing conditions 450 C conditions 450 C
exhaust gas exhaust gas
temp. Design temp. Design
flow 1.7 nm3/kg flow 1.7 nm3/kg
clinker clinker
Kiln By-pass system Best Specifications Alternatives Operating Not advisable
practic target
e/
Recom
menda
tion

Equipment
Dedusting Bag ESP
filters
(240°C)

Dust transport As Air transport

short if Cl < 10%
as
possibl
e
Mecha
nical
Storage As Direct dust intermediate storage
small addition to
as cooler filter
possibl or heat
e, with exchanger
mecha
nical
extracti
on

Process
Location take-off On top
of the
smoke
box, on
the kiln
side
Distant
 from
C3
dischar
ge to
avoid
dust
mixing
Level of chlorine in Dilutio Cl control
dust n with using cyclone
kiln system with
feed if bypass
> 10% (Taiheyo)
Cl
Quenching Air Air to air
quench cooler as
ing as second
close cooling step
as to minimize
possibl the gas
e to quantity
the
take
out,
either
directly
to
200°C
or at
least to
400°C
Exhaust air To Raw mill or Separate stack
cooler main stack if
fans to SO2 is
avoid acceptable,
SO2/Di dioxins still a
oxins threat.
Detached
plume also a
potential
issue if
organics in
raw mix
Dust management Cemen Clinker Dust wasting
t (limiting
(limitin factor for Cl)
g Dust
factor Washing with
forCl heavy metal
as recovery, for
allowe low limit of
d by Cl in cement
local
standar
d)
Target level of chlorine 1,00% Higher
in kiln back-end mat concentratio
n acceptable
if possible for
build- ups

Process guidelines – Kiln By-pass system – Page 1 / 1

Gas analyser Best Specifications Alternatives Operating Not advisable
practic target
e/
Recom
menda
tion

Kiln inlet
Kiln inlet
Probe Probe Oil cooled In-
long situ
enoug
h to
enter
the
kiln,
retract
able,
motori
sed
Dry
probe
require
d
Water
cooled
jacket
Same
probe
for all
gases
Back
flush
(clean,
dry air)
CO Manda
tory
Type:
IR
Scale:
0-
20000
ppm
NOx Manda
tory
Type IR
No
NO2
conver
 ter
neede
d
Scale:
0-
20000
ppm
O2 Manda
tory
Type:
Param
agnetic
0-10%
SO2 Requir IR (on
ed if separated
Total line)
SO3
input >
1.2%
on
clinker
basis
or S/A
ratio >
1.2
Type
UV
Quartz
cells 0-
20000p
pm
Gas treatment Heated
line
(>180°
C)
2
cooler
dryer 1
for
SO2
and 1
for
other
gases
For
other
gases
H2O2
injectio
n
Suspension preheater kiln – no
PC
Exit of preheater tower Manda
tory
for O2
 and
CO
Exit of Precalciner
Precalciner
Probe Probe
at
Bottom
cyclon
e exit
retract
able,
Dry
probe
require
d
Water
cooled
jacket
Same
probe
for all
gases
Back
flush
(clean,
dry air)
Gas analyser Best Specifications Alternatives Operating Not advisable
practic target
e/
Recom
menda
tion

CO Manda
tory
Type:
IR
Scale:
0-
20000
ppm
NOx Manda
tory
Type IR
No
NO2
conver
ter
neede
d
Scale:
0-
20000
ppm
O2 Manda
 tory
Type:
Param
agnetic
0-10%
Gas treatment Heated
line
(>180°
C)
2
cooler
dryer 1
for
SO2
and 1
for
other
gases
For
other
gases
H2O2
injectio
n3
other
in line
O2 last
CEM (stack)
Location Follow
local
regulat
ion
Dust Scatter
ed
light
system
O2 In-situ
system
(Zircon
)
0-10%
H2O Optical
in-situ
system
IR
0-10%
CO Optical Extractive
in-situ with heated
system probe
IR and line
0-2000 (>180°C) +
mg/N FTIR
m3
NOx SO2 Optical Extractive
HCl in-situ with heated
COV system probe
-UV and line
0-2000 (>180°C) +
mg/N FTIR
m3
Optical Extractive
in-situ with heated
system probe
-UV and line
0-500 (>180°C) +
mg/N FTIR
m3
Optical Extractive
in-situ with heated
system probe
-IR and line
0- (>180°C) +
100mg FTIR
/Nm3
Extracti
ve FID
0-
200mg
/Nm3
CO Protection with
ESP
Precalciner Kiln Use
precalc
iner
exit CO
with
prehea
ter exit
CO as
back
up
Suspension preheater Use
kiln kiln
exit CO
with
prehea
ter exit
CO as
back
up
Coal Mill Best practice / Specifications Alternatives Operating Not advisable
Recommendation target

Equipmen
t
Equipmen Vertical mill Vertical mill Ball mill , Central discharge mills “deep bowl” mills
t Ring roller
Selection mills
 Pendulum
mills

Process Hot gas from pre Hot gas from pre Direct or semi direct firing
Gas heater with de heater with de
dusting dusting
Sensors CO analysers:
– Raw Coal Bin
– Mill Filter Exit
– Each Pulverised
Fuel Bin
O2 analysers:
– Preheater Exit
– Before Mill
– Mill Filter Exit
Temperature Differential
sensors temperature
– Raw coal across
hopper/silo separator for
– Before mill ball mill
– After mill
– Hot gas duct
– Filter bottom
– Coal dust after
filter
– PF silo bottom
( In banks of four
around cone)
– Differential
temperature across
filter
Load Cells
– Raw Coal Bin
– Pulverised Coal
Bins
Pressure indication
– Before mill
– After mill
– Mill differential
pressure
– Filter differential
pressure
Dust monitor
– Coal bag filter
main stack
Coal Mill Best practice / Specifications Alternatives Operating Not advisable
Recommendation target

Fire Bulk system C02 2Kg/m3 of volume Bottle

suppressi of the system coal CO2 systems
on system mill, filter, silos and can be
 ducts and enough considered if
for 2 complete local
discharges (X3 for conditions or
remote locations) regulations
do not allow
bulk or if
delivery time
is excessive.
Safety for See Safety See Safety
mill and Equipment in Equipment in
feeding Model Plant Model Plant
system

Pet coke Install a dynamic Open circuit

grinding 3rd generation
separator
According to
Combustion BP the
fineness should be
less 0.1
% rejects on 200µ
Cement Best practice / Specifications Alternatives Operating Not advisable
Grinding Recommendation target

Equipmen
t
Equipmen Vertical Mill Vertical Mill Roller Press Ring roller mills, central discharge mills
t Pregrinding
Selection circuit with
two-
compartment
ball mill
circuit.CKP
with 2
compartment
mill,
Ball mill
Ball Mill Closed circuit mill
Circuit with separate filter
for mill ventilation
and separator
Ball mill Single
compartment with
lifting and
classifying liners*
2,8 < L / D <3,2
* 27% <Length first
Compartment<
 35% mill effective
length.
1st comp: 8 – 10
kWh/t
Ball mill 75% of the critical 75% of the critical <73% Critical speed >78%
speed speed speed
Separator 3rd generation high Basket variable tip Static 1st generation separators, De dusting by
efficiency speed 10 to 30 m/s, separator for
separators, radial process air pregrinding
de dusting by filters velocity 3 to 5 circuits,
m/s, fines to
separator
By-pass 5 to 10 %
Imperfecti < 0.30
on
Acuity <= 15 µm

Ventilatio Air velocity above >1.5% moisture at mill inlet(Pozzolanic m

n ball mill ball charge:1.4 – 2.2 be dried before feeding)
m/s
Inside the trunion:
< 22m/s Inside
partition:<12m/s
VFD fan
Cement Best practice / Specifications Alternatives Operating Not advisable
Grinding Recommendation target

Ventilatio Separator Qf/Qa:1.8 Separator Qf/Qa:1.8 Separator

n kg/m³, VFD fan for kg/m³, VFD fan for Qf/Qa
separator HES, HES, range: 1.8-
The circulating load The circulating load 2.5
200% 200% kg/m3(200%
C.L), Cement
temp 90-110
deg ,
VFD for fan
Ball mill Reverse step liners Reverse step liners Duo lift Ripple liners
internals for first in first
compartment, compartment with
classifying liners for lifting ht range: 70-
second 75mm. Classifying
compartment liners in second
compartment
Intermedi central opening * 6 to 8 mm slot Single plate, slots on rever
ate adapted to the * Central screen diaphragm liners
Partition filling degree open area 60
wall *Material transport % minimum
capacity 500t/m2/h *Provision of Flow
control gates to
regulate material
flow
Outlet central opening Intermediate
partition adapted to the partition wall slot
wall filling degree size+2mm,
*Material transport
capacity 500t/m2/h
Ball Nominal ball >32% ball charge
charge charge loading 28-
30% for both
compartments,
(installed power on
32% filling)

Process
Control Pre requisites for Belt weigher for Elevator
Lucie – Fresh feed rejects power
variation through
weighing of
separator rejects,
feed accuracy with
in +/- 1%,
electronic ear to
detect filling of first
compartment.
Feed Feed size passing Precrushing,
on 100% <30mm, drying of wet
95% < 25mm additives
Temperat Cement temp Cement
ure range: 90-110 deg cooler
control C
Weighing Best Practice / Specifications Alternatives Operating Not advisable
Dosing Recommendation target

Pulverised
Coal
Equipmen Small bins close to Small bins close to Pfister New systems of Pfister and Coriolis > 50 m
t the burning point the burning point
Selection <50 m <50 m
on cells for on cells for
calibration Schenck calibration Schenck
Coriolis, Coriolis,
Variation < 0,5 % Variation < 0,5 %
(short term) (short term)

Velocity Minimum number Minimum number

of elbows velocity of elbows velocity
>= 25 m/s >= 25 m/s
Solid 4-6 kg/nm3 4-6 kg/nm3 > 7 kg/nm3
concentra
tion
Raw meal
Equipmen Schenk Coriolis Pfister Weigh
t Feeder

Effective Variation < 0,5 % Variation < 0,5 % Accuracy <

weighing (short term) (short term) 0,5 % (short
term)
Transport Elevator Elevator Air-lift