CEMENT INDUSTRIES AND PRODUCTION TECHNOLOGY

GBF stands for Granulated Blast Furnace (pig iron manufacturing process)
GCT Stands for Gas Cooling Tower

Silo –A cylindrical tower used for storing Silage.

A silo (from the Greek σιρός – siros, "pit for holding grain") is a structure for storing bulk materials.
Silos are used in agriculture to store grain (see grain elevators) or fermented feed known as silage.

Three types of silos are in widespread use today: tower silos, bunker silos, and bag silos.

There are different types of cement silos such as the low-level mobile silo and the static upright
cement silo, which are used to hold and discharge cement and other powder materials such as PFA
(Pulverised Fuel Ash).

The low-level silos are fully mobile with capacities from 100 to 750 tons. They are simple to
transport and are easy to set up on site. These mobile silos generally come equipped with an
electronic weighing system with digital display and printer. This allows any quantity of cement or
powder discharged from the silo to be controlled and also provides an accurate indication of what
remains inside the silo.
The static upright silos have capacities from 200 to 800 tons. These are considered a low-
maintenance option for the storage of cement or other powders. Cement silos can be used in
conjunction with bin-fed batching plants.

Problem in silo

 Bridging
 Rat holing
Solution is installation of siperm fluidizing cone.

Blending –the act of blending components together thoroughly

Blend-combine into one/add together different elements e.g.-the color blend well
Clinkers= limestone+ clay+ iron ore+ silica sand heated up to 1500deg Celsius

Definition of Cement
Portland cements are hydraulic cements, meaning they react and harden chemically with the
addition of water. Cement contains limestone, clay , cement rock and iron ore blended and heated
to 1200 to 1500 C°. The resulting product "clinker" is then ground to the consistency of powder.
Gypsum is added to control setting time.
 Cement production process(udayapur )
First Limestone is reduced to less than 100 mm size in the primary crusher.

The Limestone is further reduced to 25 mm size in the secondary crusher. It is then conveyed to
preblending unit for homogenization and storage.

The homogenized Limestone is then conveyed to a Limestone Feed Hopper. Other feed hoppers contain

iron ore, clay and silica sand respectively.

These raw materials are fed in a predetermined proportion into the raw mill for grinding. The finely ground
raw meal is conveyed to the blending and storage silo where through blending of this meal is done by

aeration.

The raw meal from the silo is conveyed to the rotary kiln through preheater tower. Heat transfer takes
place between the kiln exhaust gas and the raw meal in the preheater tower.

When the preheated raw meal is burnt upto the tempreture of 1500oC, clinker is produced.

Burning can be done either by pulverized coal or by furnace oil.

Clinker thus formed is cooled down to about 100oC in the grate cooler and conveyed by bucket elevator
to the clinker storage silo.

Cement is produced when the clinker is mixed with the requisite amount of gypsum and finely ground in
the cement mill.
Cement so produced is collected in the cement storage silo. After that, the cement is conveyed to the
packing plant for packing in jute or polyethylene bag.

It is then finally sent to the market for sale and distribution.

Manufacturing Process(other)
1. Crushing and Proportioning
Limestone rock is the principal raw material, the first step after quarrying in the processes is the
primary crushing. Mountains of rock are fed through crushers capable of handling pieces as large
as an oil drum. The first crushing reduces the rock to a maximum size of about 15 cm (6 po). The
rock then goes to secondary crushers or hammer mills for reduction to about 7.5 cm or smaller.
2. Raw milling & Blending
The next step in the process is to grind the above particles to asize of 90 microns or less which is
done in a raw mill, a closedcircuit ball mill equipped with high efficiency separator. Afterachieving
the 90 microns size the fine grinded material alsoknown as raw meal is sent to the continuous
blending silos(CFC) for homogenization & extracted by means of load cellhopper for the next step
which is feeding to the kiln pre heaters.
3. Pyro processing
The raw material is heated to exceeding 1,450 °C (2,700 degreesF) in huge cylindrical steel rotary
kilns lined with specialfirebrick. Kilns are frequently as much as 3.7 M (12 pi) indiameter, large
enough to accommodate an automobile andlonger in many instances than the height of a 40-story
building.Kilns are mounted with the axis inclined slightly from thehorizontal. The finely ground raw
material or the slurry is fedinto the higher end. At the lower end is a roaring blast of
flame,produced by precisely controlled burning of powdered coal, oilor gas under forced draft.
4. Burning and cooling
As the material moves through the kiln, certain elements aredriven off in the form of gases.
Theremaining elements unite toform a new substance with new physical and chemical
characteristics. The new substance, called clinker, is formed inpieces about the size of marbles.
Clinker is discharged red-hot from the lower end of the kiln andgenerally is brought down to
handling temperature in varioustypes of coolers. The heated air from the coolers is returned to
the kilns, a process that saves fuel and increases burningefficiency.
5. Cement milling, Storage & Packing
Portland cement, the basic ingredient of concrete, is a closelycontrolled chemical combination of
calcium, silicon, aluminum,iron and small amounts of other ingredients to which gypsum is
added in the final grinding process to regulate the setting time ofthe concrete. Lime and silica make
up about 85% of the mass.Common among the materials used in its manufacture arelimestone,
shells, and chalk or marl combined with shale, clay,slate or blast furnace slag, silica sand, and iron
ore. The abovemixture

Layout

limestone primary & secondary crusher lime stone feed hopper +iron ore feed hopper + silica sand
feed hopper+ clay feed hopper raw mill(for grinding) heat 1500deg C clinkers

gypsum add

cement
TYPES OF CEMENT:

1. Ordinary Portland Cement

2. Rapid Hardening Cement (or) High Early Strength cement
3. Extra Rapid Hardening Cement
4. Sulphate Resisting Cement
5. Quick Setting Cement
6. Low Heat Cement
7. Portland Pozzolana Cement
8. Portland Slag Cement
9. High Alumina Cement
10. Air Entraining Cement
11. Supersulphated Cement
12. Masonry Cement
13. Expansive Cement
14. Colored Cement
15. White Cement

Chemical Composition of cement is:

1. Lime 63%
2. Silica 22%
3. Alumina 06%
4. Iron oxide 03%
5. Gypsum 01 to 04%
Basic Chemical Components of Portland Cement:
– Calcium (Ca)
– Silicon (Si)
– Aluminum (Al)
– Iron (Fe)

Typical Raw Materials:

– Limestone (CaCO3)
– silica Sand (SiO2)
– Shale, Clay (SiO2, Al2O3, Fe2O3)
– Iron Ore/Mill Scale (Fe2O3)
-Gypsum

Functions of Cement Manufacturing Constituents

I. Lime (CaO):
1. Lime forms nearly two-third (2/3) of the cement. Therefore sufficient quantity of the lime
must be in the raw materials for the manufacturing of cement.
2 . Its proportion has an important effect on the cement. Sufficient quantity of lime forms
dicalcium silicate and tri-calcium silicate in the manufacturing of cement.
3. Lime in excess, causes the cement to expand and disintegrate.
 II. Silica (SiO2):
1. The quantity of silica should be enough to form di-calcium silicate and tri-calcium
silicate in the manufacturing of cement.
2. Silica gives strength to the cement.
3. Silica in excess causes the cement to set slowly.
III. (iiAlumina (Al2O3):
1. Alumina supports to set quickly to the cement.
2. Lowers the clinkering temperature.
3. Alumina in excess, reduces the strength of the cement.
IV. (iv) Iron Oxide (Fe2O3):
1. Iron oxide gives colour to the cement.
V. Magnesia (MgO):
1. It also helps in giving colour to the cement.
2. Magnesium in excess makes the cement unsound
(vi) Calcium Sulphate (or) Gypsum (Ca SO4) :
1. At the final stage of manufacturing, gypsum is added to increase the setting of cement.

Cement is a pulverized material that develops binding

forces due to a reaction with water.
􀁸 Hydraulic Cement - Stable under water
􀁸 Nonhydraulic Cement 􀁸-Products of hydration are not resistant to water (i.e. limestone)

Flow sheet diagram

 Short notes on:
1. GBF SYSTEM
 Ground-granulated blast-furnace slag (GGBS or GGBFS) is obtained by
quenching molten iron slag (a by-product of iron and steel-making) from a blast
furnacein water or steam, to produce a glassy, granular product that is then dried
and ground into a fine powder. The main components of blast furnace slag are CaO
(30-50%), SiO2 (28-38%), Al2O3 (8-24%), and MgO (1-18%).

2. GCT(GAS COOLING TOWER) SYSTEM

 The purpose of a GCT is to cool the flow and optimize the uniformity of the gas and its
temperature, in order to make the air filtration device more effective at extracting the
dust.
 GCT have two models, based on different water injection systems: a Spillback Injection
System, based on spillback nozzles, and a Dual-Media Injection System, in which water
is atomized by water pressure and compressed air.

WHY CHOOSE OUR GAS CONDITIONING TOWERS?

 Unparalleled efficiency. We use model tests and CFD simulations to calculate the ideal timing and
gas distribution parameters.
 Even mixing. We have mastered our Gas Distribution System (GDS) to ensure even gas/water
mixing, avoiding the creation of mud.
 Reduced energy costs. Our optional Dual-Nozzle System allows you to reduce the number of
nozzles in operation when operating with lower gas volumes.
 Smaller tower size. Our special nozzles, coupled with our GDS, increase evaporation, reducing the
gas retention time in the tower and thus the tower’s size. Our GDS can even be applied as a retrofit
to improve our competitors’ installations.
 Optimized control system. Our Temperature Control System is designed to optimize reaction
times, allowing you to cope with new process conditions at the tower inlet rapidly to ensure
continued efficiency.
 3. ESP - An electrostatic precipitator (ESP) is a filtration device that removes fine
particles, like dust and smoke, from a flowing gas using the force of an
induced electrostatic charge minimally impeding the flow of gases through the
unit.

Advantages of electrostatic precipitator

 This is more effective to remove very small particles like smoke, mist and fly ash. Its range
of dust removal is sufficiently large (0.01 micron to 1.00 micron). The small dust particles
below 10 microns cannot be removed with the help of mechanical separators and wet
scrubbers cannot be used if sufficient water is now available. Under these circumstances,
this type is very effective.
 This is also most effective for high dust loaded gas (as high as 100 grams per cu. meter)
 The draught loss of this system is the least of all forms(1 cm of water)
 It provides ease of operation.
 The dust is collected in dry form and can be removed either dry or wet.

Disadvantages of a electrostatic precipitator

  The direct current is not available with the modern plants, therefore considerable electrical
equipment is necessary to convert low voltage (400 V) A.C to high voltage (60000 V) D.C.
This increases the capital cost of the equipment as high as 40 to 60 cents per 1000 kg of
rated installed steam generating capacity.
 The running charges are also considerably high as the amount of power required for
charging is considerably large.
 The space required is larger than the wet system.
 The efficiency of the collector is not maintained if the gas velocity exceeds that for which the
plant is designed. The dust carried with the gases increases with an increase of gas velocity.
 Because of closeness of the charged plates and high potential used, it is necessary to protect
the entire collector from sparking by providing a fine mesh before the ionizing chamber.
This is necessary because even a smallest piece of paper might cause sparking when it
would be carried across adjacent plates or wires.

Factor affecting efficiency of ESP

a. Gas temperature,humidity,flow rate
b. Particle resistance
c. Fly ash composition
d. Plate length
e. Surface area

4. Stationary and rotary type packing system

Main features of 8-Spout Automatic Rotary Cement Packing Machine:

a. Computer-aided design, mechanical and electrical integration, automatic measurement,
stable performance;
b. Simple structure, very few wearing parts, greatly reducing equipment investment and
maintenance costs;
c, Auto-complete press bags, filling out the bag, the closing function;
d., The whole sealed tight, easy maintenance, no blocking, no card, no leakage;
e, Weighing accuracy, stable performance, simple operation;
f, The seal is good, reasonable structure, durable;
g, Small size, light weight, easy to adjust maintenance.

5. Kiln burner-
---A cement kiln is a huge inclined rotating furnace .As the raw materials of
limestone ,clay, and shale tumble towards the 3400deg F(187100deg C)
flame ,a chemical reaction transforms them into clinker which is ground
together with gypsum to form portland cement .

Kiln Process Control

• Critical Parameters: Fuel, Feed, Kiln Speed, Gas Flow

• Kiln Temperatures - Burning Zone
• Kiln Stability
• Chemistry
• Instrumentation

Fuel can be any combustible hydrocarbon like-coal,coke,natural gas,used motor

oil,wood,tire,cellulose other

Why Burn Wastes?

A cement kiln is a proven technology for
recycling by beneficial REUSE of solid and
hazardous wastes.
The benefits are:
– energy recovery
– material recovery
– economics
– environmental preservation

6. Working principle of bag filter/bag house

 A baghouse (BH, B/H), bag filter (BF) or fabric filter (FF) is an air
pollution control device that removes particulates out of air or gas
released from commercial processes or combustion for electricity
generation.
  Unlike electrostatic precipitators, where performance may vary
significantly depending on process and electrical conditions,
functioning baghouses typically have a particulate collection
efficiency of 99% or better, even when particle size is very small.
 Baghouses are very efficient particulate collectors because of the
dust cake formed on the surface of the bags. The fabric provides a
surface on which dust collects through the following four
mechanisms:

 Inertial collection - Dust particles strike the fibers placed perpendicular to the gas-flow
direction instead of changing direction with the gas stream.
 Interception - Particles that do not cross the fluid streamlines come in contact with
fibers because of the fiber size.
 Brownian movement - Submicrometre particles are diffused, increasing the probability
of contact between the particles and collecting surfaces.
 Electrostatic forces - The presence of an electrostatic charge on the particles and the
filter can increase dust capture.
A combination of these mechanisms results in formation of the dust cake on the filter, which
eventually increases the resistance to gas flow. The filter must be cleaned periodically.
Baghouse types - Cleaning methods

 Mechanical shakers
 Reverse air (R/A)
 Pulse jet (aka Reverse Jet)

Fig. Mechanical Shaker Baghouse Fig. Reverse Air Baghouse

 Fig. Reverse Jet Baghouse

Reclaimer
 Reclaimer A reclaimer is a large machine used in bulk material
handling applications. A reclaimer's function is to recover bulk material such as ores
and cereals from a stockpile. A stacker is used to stack the material.
 Reclaimers are volumetric machines and are rated in m 3/h (cubic meters per hour)
for capacity, which is often converted to t/h (tonnes per hour) based on the average
bulk density of the material being reclaimed.
 A bucket wheel reclaimer can typically move in three directions: horizontally along
the rail; vertically by "luffing" its boom and rotationally by slewing its boom
 Reclaimer type
Reclaimers are named according to this type, such as "Bridge reclaimer"

 Bucket wheel reclaimers use "bucket wheels" for removing material from the
pile they are reclaiming.
 Scraper reclaimers use a series of scrapers on a chain to reclaim the
material.
 Portal reclaimers
STACKER

 A stacker is a large machine used in bulk material handling. Its function is to pile
bulk material such as limestone, ores and cereals on to a stockpile. A reclaimer can
be used to recover the material.
 Stackers are used to stack in different patterns, such as cone stacking and chevron
stacking.
 A stacker can usually move in at least two directions: horizontally along the rail and
vertically by luffing (raising and lowering) its boom
 Fig..Combined reclaimer and stacker

Mill
CEMENT MILL- Cement mill is mainly used in grinding of cement finished products and
materials,also to the metallurgical,chemical,electricity and other industrial and mining
enterprises and other grinding various ore materials.

BALL MILL- This series of ball mill is suitable for ore dressing, chemical, coal, cement and
refractory sectors to operate fine grinding.

Mill may refer to:

 Mill (grinding)

Industrial tool for size reduction (comminution) and/or filtration:

 Roller mill, a mill using rollers

 Ball mill, a mill using balls to crush the material ,etc

Grinding is the second step of mineral processing and the last stage of the comminution process.
The product from a crushing unit is fed to a mill in order to decrease the particle size (sometimes
even to 10 microns) for subsequent processing. The reduction ratio is usually large (8 to 25:1
sometimes 500:1)
PRINCIPLES OF GRINDING

Grinding is performed in a rotating cylindrical steel vessel which contains crushed ore with a
grinding medium free to move inside the mill, lifted by the rotation of the drum, to break the ore to
produce a specified product. The grinding medium can be the ore itself, natural or manufactured
non-metallic media or manufactured steel e.g. steel rods, steel or iron balls.

DIFFERENT TYPES OF MILLS

1. Tumbling mills
2. Stirred mills
3. Vibrating mills

Tumbling mills: In this mill, the mill shell is rotated and motion is imparted to the charge via the
mill shell. The grinding medium may be steel rods, balls, or rock itself. Tumbling mills are typically
employed in the mineral industry for coarse-grinding processes, in which particles between 5 and
250 mm are reduced in size to between 40 and 300 microns.

Figure : Mechanism of grinding in tumbling mills

Different Types of Tumbling Mills

 Rod Mills: Mills loaded with rods as the grinding media are used for primary grinding of
rocks and minerals. The rods fall from a height and roll down the mill so the rods impart
an impact force as well as an abrasive action. The product size from a rod mill is much
coarser. Hence a rod mill generally precedes a ball mill in a grinding circuit especially
where a fine size product is required.
 Ball Mills: The final stages of comminution are performed in tumbling mills using steel balls
as the grinding medium and so designated "ball mills." Since balls have a greater surface
area per unit weight than rods, they are better suited for fine finishing.
 Autogenous (AG) Mills: Autogenous mills are so-called due to the self-grinding of the ore: a
rotating drum throws larger rocks of ore in a cascading motion which causes impact
breakage of larger rocks and compressive grinding of finer particles.
 Semi-Autogenous (SAG) Mills: SAG mill is similar to AG mills, but utilizes grinding balls to
aid grinding just like ball mills. It uses a ball charge of approx. 6 - 15%. SAG mills are
characterized by their large diameter and short length as compared to ball mills. SAG mills
are primarily used in the gold, copper and platinum industries with applications also in the
lead, zinc, silver, alumina and nickel industries.

Stirred mills: The mill shell with either a horizontal or a vertical orientation is stationary and
motion is imparted to the charge by the movement of an internal stirrer. Fine grinding media inside
the mill are agitated or rotated by a stirrer, which typically comprises a central shaft to which is
attached pins or discs of various designs. Stirred mills find application in fine (15-40 microns) and
ultra-fine (<15 microns) grinding.

Most common stirred mills are:

 Tower mills (VertiMill): In a tower mill, steel balls or pebbles are placed in a vertical
grinding chamber in which an internal screw flight provides medium agitation. Product
sizes may be 1-100 microns at capacities of 100t/h or more.
 IsaMills (horizontal): IsaMill uses small grinding media and high stirrer velocity to impart
energy to the media, which increases the breakage rate of fine particles caused by
attrition/abrasion at relatively low power consumption. It is claimed that the IsaMill can
efficiently grind minerals to below 10 microns. The grinding media that can be used
include granulated slag, river sand, or a sized portion of the ore itself.

Vibrating mills: The motion is imparted to the charge by the vibratory motion imparted to the
shell. The vibration can be generated by springs, electromagnets, air cushions or unbalanced mass.
These mills also have application in fine (45 microns) grinding.

High-energy vibration mills can grind materials to surface areas of around 500m2/g, a degree of
fineness, which is impossible in a conventional mill (Russell, 1989). Vibration mills are made with
capacities up to 15t/h, although units of greater capacity than about 5t/h involve considerable
engineering problems.
 Calcination
 defines it as 'heating to high temperatures in air or oxygen.
 calcination is also used to mean a thermal treatment process in the absence or limited
supply of air or oxygen applied to ores and other solid materials to bring about a thermal
decomposition.
 A calciner is a steel cylinder that rotates inside a heated furnace and performs indirect
high-temperature processing (550–1150 °C, or 1000–2100 °F) within a controlled
atmosphere

Fig . An oven for calcination of limestone

For example, in limestone calcination, a decomposition process, the chemical reaction is

CaCO3 → CaO + CO2(g)
The standard Gibbs free energy of reaction is approximated as ΔG°r = 177,100 −
158 T (J/mol).[4] The standard free energy of reaction is 0 in this case when the
temperature, T, is equal to 1121 K, or 848 °C.