CEMENT PLANT USING CLINKER (CRUSHING PLANT)

[EIRI/EDPR/4010] J.C.: 2140XL

INTRODUCTION

Cement is a material that binds together solid bodies (aggregate) by hardening from a
plastic state. Many materials act as adhesives or cement according to this definition. The
cement referred to above, which is used for civil engineering and the construction
industry, is portland cement. Portland cement is hydraulic and develops strength
primarily by the hydration of the di- and tri-calcium silicates it contains. Hydraulic
means that the paste of cement and water will harden under water. Lime, on the other
hand, will harden due to the reaction with carbon dioxide from the air.

Clinker is a nodular material produced in the kilning stage during the production of
cement and is used as the binder in many cement products. The lumps or nodules of
clinker are usually of diameter 3-25 mm and dark grey in color. It is produced by
heating limestone and clay to the point of liquefaction at about 1400°C-1500°C in the
rotary kiln. Clinker, when added with gypsum (to control the setting properties of
cement and ensure compressive strength) and ground finely, produces cement. Clinker
can be stored for long periods of time in a dry condition without degradation of quality,
hence it is traded internationally and used by cement manufacturers when raw
materials are found to be scarce or unavailable.

Since the cement industry requires high investment capital, high quality (tenor) and
reserves are needed to start the necessary investment in the sector. The chemical
properties of the ore beds used in cement production, as well as their chemical
properties, closeness to the plant, their removability, fragility, grindability and
burnability, low moisture content and homogeneity are the most important factors
affecting the production cost. In addition, the use of alternative raw materials can
further enhance the existing mine life and mineral quality.

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The realization of high quality targets placed on cement in large quantities with a high
potential for substitution and future cement depends on the availability of alternative
raw materials or industrial by products. Turkey stone, cement and ceramics industry,
depending on the demand for primary and secondary raw materials, is expected to
increase until 2030, raw material requirements. The raw materials required for cement
production are limestone, clay and iron ore. In addition, some gypsum is added to the
cement. All these materials are supplied from mines. Energy and fuel are consumed
during production and transportation. Another important issue is the rapid depletion of
resources. In addition to cement raw materials for the reduction of natural resources;
sludge, gypsum, gypsum waste, bleaching waste, sludge waste, casting sand, iron dust,
tufal, gypsum, fly ash, iron slag and excavation soil sludge land etc. materials are used
as an alternative to cement raw materials. These alternative raw materials are added to
the raw mixture of cement at a certain rate to form the composition of the cement.

Mudstone is a fine-grained, degradable sedimentary rock composed of clay and

mud. Shales, also called mudstone or claystone, were formed millions of years ago by
the deposition and accumulation of very small clay particles that broke off from an old
rock mass that had been eroded by rainwater and rivers. Over time, the deposits on the
bottom of the new deposits accumulated on top of the pressure have become a solid
rock. The density of the sludge ore in the land is assumed to be 2.0 g / cm3 on average.
Since the clay mineralization is in a hard structure, production can be carried out by
performing drilling-blasting and size reduction processes in stages during the
production activities by using open operation method in quarries.

In the study area, the thickness of the mudstone ore is around 60 m on average. The
reserve amount was set at approximately 11.987.760 tonnes considering the field work
and the area planned to be studied with ore propagation.

The mudstone consists mostly of shafts (4–62 microns) and clay (4 microns) in size.
Claystone is generally very fine-grained and homogeneous, separated from the shaft
stone (siltstone). Shales are characterized by the ability to separate the leaves along
stratigrafi parallel to the bedding. Many shales are laminal. The mud stones do not
show lamination, and when broken, the crust is broken and massive. Marn is a limy
mud stone.

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 CONTENTS
INTRODUCTION
PROJECT LOCATION
MAP
MIRZAPUR CLIMATE
TRANSPORTATION
HISTORY OF CEMENT
COMPOSITION
BASIC CALCULATION/FORMULATIONS - CHEMICAL SHORTHAND
THE MOST COMMON COMPOUNDS IN CEMENT CHEMISTRY ARE:
A TYPICAL ANALYSIS OF CLINKER IS GIVEN IN THE TABLE BELOW:
CLINKER COMPOSITION
SCIENTIFIC NAME & BOTANICAL DESCRIPTION
AN APPROXIMATE ANALYSIS FOR RAW MIX ON IGNITED BASIS, OR FOR
CLINKER, IS:
MATERIALS, AS MINED, THEREFORE, ARE TYPICALLY PROPORTIONED:
MODULES
THE SILICA MODULUS IS DEFINED AS THE RATIO OF SILICA TO THE SUM
OF ALUMINA AND IRON OXIDE:
THE ALUMINA MODULUS IS DEFINED AS:
THE LSF FORMULA FOR CEMENT IS THEN:
MINERAL COMPOSITION
TYPES OF CEMENT
THE MOST COMMON TYPES OF CEMENT CAN BE DIVIDED INTO THREE
MAIN GROUPS:
ASTM CEMENT TYPES
COMPRESSIVE STRENGTHS – FOR ASTM C109 CUBES
ASTM CEMENT TYPES
AIR CONTENT, FINENESS, SOUNDNESS AND SETTING TIME
TABLES BELOW SHOWS SOME OF THE PHYSICAL REQUIREMENTS
AND CATEGORY DEFINED BY EUROPEAN STANDARD.
TYPES OF CEMENT FOR CONCRETE (BS EN 197-1)
EUROPEAN STANDARD EN 197-1 TYPES OF CEMENT
EUROPEAN STANDARDS FOR STRENGTHS
ASTM CHEMICAL SPECIFICATIONS
COMPOSITION OF CLINKER
THE COMPOSITION OF CLINKER IS EXAMINED BY TWO SEPARATE
APPROACHES:
THE FOUR MAIN COMPONENTS OF CLINKER ARE:
OTHER SUBSTANCES MAY BE PRESENT IN SMALL AMOUNTS:
THERMOCHEMISTRY OF CLINKER
TYPES OF CLINKER

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SULFATE RESISTANT CLINKER
LOW HEAT CLINKER
WHITE CLINKER
LOW-ALKALI CLINKER
BELITE CALCIUMSULFOALUMINATE TERNESITE (BCT)
CEMENT QUALITY - MAIN FACTORS
ADVANTAGE OF CEMENT PLANT USINGCLINKER
GLOBAL PRODUCTION AND ENVIRONMENTAL IMPACTS
FIGURE : GLOBAL CEMENT PRODUCTION IN 2017
TABLE. SUMMARY OF GASES EMISSION DURING CEMENT MANUFACTURING
PROCESSES EXPRESSED IN G/KG * CEMENT AND G/KG ** CLINKER
TABLE. SPECIFIC THERMAL ENERGY CONSUMPTION IN A CLINKER
MANUFACTURING PROCESS
USE OF CLINKER: CONVERSION TO CEMENT
MARKET SURVEY
MARKET SIZE
INVESTMENTS
GOVERNMENT INITIATIVES
INDIAN CEMENT INDUSTRY ANALYSIS
GEOGRAPHICAL DISTRIBUTION OF CEMENT INDUSTRY IN INDIA
REGIONWISE CEMENT PRODUCTION IN INDIA
CEMENT PRODUCTION CAPACITY OF INDIA BETWEEN FY 2018
AND FY 2021(IN MILLION METRIC TONS)
NORTHERN REGION
EASTERN REGION
SOUTHERN REGION
WESTERN REGION
CENTRAL REGION
CONSUMPTION VOLUME OF CEMENT IN INDIA FROM FINANCIAL
YEAR 2009 TO 2018 WITH AN ESTIMATE FOR FINANCIAL YEAR 2019
(IN MILLION METRIC TONS)
TOP KEY MANUFACTURERS IN WORLDWIDE CEMENT CLINKER MARKET ARE:
ABOUT CEMENT CLINKER MARKET:
CEMENT CLINKER MARKET SEGMENTATION ANALYSIS:
CEMENT CLINKER MARKET SEGMENTS BY TYPES:
CEMENT CLINKER MARKET SEGMENTS BY APPLICATION:
GEOGRAPHICAL SEGMENTATION:
EXPORT AND IMPORT OF CEMENT
INSTALLED CAPACITY AND KEY MARKETS IN EACH OF THE GEOGRAPHIC
REGIONS
RECENT STRATEGIES
SUCCESSFUL USE OF ALTERNATE FUELS IN CEMENT PRODUCTION
GROWTH DRIVERS AND OPPORTUNITIES
HOUSING AND REAL ESTATE

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PUBLIC INFRASTRUCTURE
INDUSTRIAL DEVELOPMENT
CEMENT CLINKER MANUFACTURING PROCESS
EXTRACTION AND PREPARATION OF RAW MATERIALS
HOMOGENIZATION
PRE-HEATING
KILN PHASE
COOLING AND STORING
CEMENT CLINKER GRINDING
FLOW CHART OF BALL MILL FOR CEMENT CLINKER GRINDING:
PHYSICAL CONTROL AND COMPOSITION OF RAW MIX
BURNABILITY OF RAW MIX
INFLUENCE OF THE RAW MIX ON CLINKER FORMATION AND BURNABILITY
TYPES OF KILN
TYPES OF KILNS - WET, DRY & SEMI-DRY
WET KILN
DRY KILN
LONG DRY KILN
ASH ABSORPTION
VOLATILE MATTER
CIRCULATION OF VOLATILE IN SIMPLE KILN SYSTEM
MELTING AND BOILING POINTS OF ALKALI SALTS
MAIN FEATURES DURING BURNING
CHEMICAL CONTROL DURING OPERATION OF THE KILN SYSTEM IS
DIVIDED INTO THE FOLLOWING:
FUEL
TYPES OF FUEL
COAL
TYPICAL PETROLEUM COKES
PROXIMATE ANALYSIS OF COAL:
ULTIMATE ANALYSIS OF COAL:
CHEMICAL ANALYSIS:
HEAT VALUE:
FUEL OIL
TYPICAL ANALYSIS FOR OIL IS:
GAS
WASTE FUELS
COMBUSTION
COAL & OIL
FINENESS OF COAL
DRYING OF COAL
ASH CONTENT
GAS CONTENT
MINOR COMPONENTS

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REQUIREMENT FOR AIR
PROCESS GAS
PROCESS FLOW DIAGRAM
MACHINERY SUPPLIERS
MACHINERY PHOTOGRAPHS
CYCLONE PRE-HEATER IN CEMENT PLANT
CEMENT PACKING MACHINE
CEMENT ROTARY KILN
HEAVY WHEEL TYPE ROLLERS AND ROTATING TABLE
5-STAGE VERTICAL CYCLONE PREHEATER IN CEMENT ROTARY KILN
CALCINING PROCESS
ROTARY KILN
ROTATING BALL MILL
SILOS
RAW MATERIALPHOTOGRAPHS
COAL
GYPSUM
SLUDGE
SLAG
PRODUCT PHOTOGRAPHS

APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 480 MT/Day

Land & Building (8080 sq.mt.) Rs. 6.02 Cr
Plant & Machinery Rs. 8.15 Cr
Working Capital for 1 Month Rs. 4.90 Cr
Total Capital Investment Rs. 19.75 Cr
Rate of Return 40%
Break Even Point 42%

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