Chemical Engineering Process

in Cement Production

Presented to:
SAUDI ARABIAN SECTION OF AMERICAN
INSTITUTE OF CHEMICAL ENGINEERS
(SAS-AIChE)
on Sunday, December 27, 2009
at Le Meridien Hotel, Al-Khobar
By:
By:
Eastern
Eastern Cement
Cement Team:
Team:
Eng.
Eng. Ali
Ali S.
S. Al-Qahtani
Al-Qahtani
Eng.
Eng. Sayd
Sayd Basheer
Basheer Shafee
Shafee
Eng.
Eng. Haridas
Haridas Nair
Nair
 Who Are we?

• Our Plant is located at Khrsanih Our Head

Office -
•Three production line of 3.5 mty Khobar
cement
•Joint Stock company listed in
Tadawul
• 700 employees
Saudi Cement Industry
Economic Contributions

4
3.374
3.5
3 2.78
2.46
2.5
Distributed
2 Dividend (SR
1.5 billions)

1
0.5
0
2006 2007 2008
 Why are we here?
• Inform the Chemical Engineering
Community about Cement Industry.

• Attract Chemical Engineers to start and

build carriers in Cement industry.

• Attract Local Chemical Engineering

Research in Cement Process.
Our Business
We Produce and Sell ……..

Glue ……..
for construction

Cement
 Cement is…..
• Hydraulic Binder
Solidify and gain compressive strength after mixing with
water

• It binds gravel and sand to form Artificial

Rock Sold Material

Concrete
There have been huge developments in the
innovation and production of new binder
materials in the last 10 years especially in
the Epoxy chemicals.

gies
Technolo
t c o ns truction
Ancien
Limestone

Cem
e nt
&C
o nc
rete
tech
nolo
g i es

However
Non can compete with cement and concrete
materials for practicality and economic
feasibility of production and construction
 Cement Production Process

Material Material
handling handling
Systems Systems

Cement
Raw Material Pyroprocessing Grinding
Grinding
Systems
(Chemical Reactions) Systems
Cement is Very Old Material….
Basic Research and inventions Time Line

Research by Invention of Invention of chemical Cement

Louis Vicat on Portland Cement Engineering process Standard by
Hydraulic Binders by Joseph Aspedin by Isaac Johnson Wilhelm
Michaelis

1812 1824 1838 1875

Cement Production Technologies
• Control and instrumentation
• Gears and bearings
•Cooling and heat transfer
•Material handling systems
•Cyclone and filters

Short Rotary Kilns and

Vertical Kilns Rotary Kilns Long Rotary Kilns Preheater Technology

1830’s 1885 1930’s 1970’s 2000’s

Pyroprocessing
System

Preheater

Rotary Kiln
Cooler
Preheater
What is happning at the
Preheater?
• Raw material separation
and suspension for heat
absorption.
•Moisture Removal
•Decomposition of CaCO3,
MgCO3, formation of CA,
C2F and C3S begins.

 Formation of C12A7
 Rotary Kiln

•Formation of C3A and C4AF begins, decomposition of

CaCO3 completed, free lime reaches maximum

•Formation of C2S reaches maximum,

C3A and C4AF formation completed

•Formation of liquid phase

Formation of C3S, gradual decrease

of free lime content.
Clinker
MINERALOGICAL COMPOSITION OF
CLINKER
•Tricalcium silicate (C3S) or
alite, dicalcium silicate (C2S)
or belite, tricalcium aluminate
(C3A) and tetracalcium
aluminoferrite (C4AF) are the
main clinker constituents
Cooler

Cooler
 Final Chemical Process

Material Material
handling handling
Systems Systems

Cement
Raw Material Pyroprocessing Grinding
Grinding
Systems
(Chemical Reactions) Systems

Addition of Gypsum
CaSO4.2H2O
to control the setting time of
cement
Cement Chemical Composition
Weight
Cement Compound Chemical Formula
Percentage

Tricalcium silicate 50 % Ca3SiO5 or 3CaO.SiO2

Dicalcium silicate 25 % Ca2SiO4 or 2CaO.SiO2

Tricalcium aluminate 10 % Ca3Al2O6 or 3CaO .Al2O3

Tetracalcium Ca4Al2Fe2O10 or
10 %
aluminoferrite 4CaO.Al2O3.Fe2O3

Gypsum 5% CaSO4.2H2O