CEMENT DIVISION, TATA CHEMICALS LIMITED

Manufacturing Process Of Cement

F.L.Smidth a world leader for cement Process Technology has

supplied Dry Process cement Manufacturing Technology for TATA
Chemicals Limited, Mithapur.
The Cement Manufacturing Process requires following various
types of Raw Materials to produce cement.

Main raw materials:

1. Limestone (Chemical grade as well as cement grade)

2. Clay (obtained from mines located in nearby villages)
3. Blue dust (Fe2O3 containig material)
4. Laterite (substitute for laetrile)
5. Bauxite.
6. Sandstone (substitute for clay)
7. Fly ash from captive power plant
8. Dry cake recovered in ESF from Soda ash effluent
9. Bag filter dust from Soda ash plant
10. Coal
11. Fly ash (in PPC only)
12. Marine Gypsum from Salt plant
13. Bottom Ash From Power Plant.

CEMENT DIVISION, TATA CHEMICALS LIMITED

CEMENT DIVISION, TATA CHEMICALS LIMITED

MANUFACTURING PROCESS OF CEMENT

1.0 Raw Materials Handling

The raw materials for manufacture of cement are limestone, blue dust,
clay, sandstone (as a substitute for clay), laterite (as a substitute for blue
dust), dry cake (recovered from Soda Ash effluent in Effluent Solid
Filtration plant), gypsum, coal, fly ash and waste lime grit (process waste)
from Soda Ash Plant dumped at our Malara site.

The undersize limestone separated in soda ash plant is reduced to desired

size in the crusher and stacked in a 15000 tones homogenizing storage
area. The blended limestone is reclaimed from the storage area via a
scraper reclaimer and conveyed to the raw mill storage bin area. Other raw
materials like blue dust and clay are trucked into the plant and conveyed to
individual storage bins in the raw mill area through belt conveyer.

2.0 Process in Raw Mill:

Individual weigh feeders underneath the storage bins proportion the

individual raw material components to the grinding mill (raw mill) for fine
grinding. The raw mill is a two-chamber ball mill with closed circuit grinding
and is equipped with 1630 KW main drive motor and SEPAX 2S-355-air
separator. The grinding media charge is Hichrome type balls.

CEMENT DIVISION, TATA CHEMICALS LIMITED

CEMENT DIVISION, TATA CHEMICALS LIMITED

The raw mill is capable of producing 130 TPH of raw meal at a final product
fineness of 15% retained on 90-micron sieve & 1.5% retained on 212-
micron sieve. The coarse material is recycled back to mill for further
grinding. The mill utilizes the available preheater exhaust gases and cooler
excess air for drying the raw materials from 6-10% moisture down to a final
product of moisture of 0.5%. The resultant product of the raw mill, called
raw meal, is mixed with dry cake from ESF plant, 1% fly ash and bag filter
lime dust from Soda ash plant and conveyed via air slides and bucket
elevator to a 8,000 T CF Silo (16.0 m diameter X 38 m tall) for blending and
storage. The blended mix extracted from the CF Silo through seven gates
provided at the bottom, called kiln feed, and conveyed to the preheater and
precalciner via airlift system.

3.0 Preparation of Clinker (Pyro processing)

The kiln feed in requisite quantities is then transferred to rotary kiln via kiln
feed bins, air lift vessels, preheaters and precalciner. The preheater
consists of a six stage cyclone, and a precalciner with four stage cyclones,
from where kiln feed passes. The kiln feed is preheated in preheater by
means of kiln hot gases and precalcined in precalciner by applying
secondary coal firing in precalciner vessel before it is admitted into the
rotary kiln. The heat exchange between the material and the hot exhaust
gases from kiln is done in cyclones in which both the material and the gas
are in suspension. Alkalis present in kiln feed is removed by bypassing a
part of the kiln hot gases to gas condensing tower (Alkali bypass system)
before kiln feed enters the rotary kiln. The alkali waste collected in this

CEMENT DIVISION, TATA CHEMICALS LIMITED

CEMENT DIVISION, TATA CHEMICALS LIMITED

tower is dumped within the factory premises and gases are vented after
dedusting in ESP.

The 90 % calcined material that leaves the calciner enters a kiln for
final calcining and clinkering. The kiln has dimensions of 3.95 m diameter
by 64.3 m long and 3.5 % inclination and is driven by the inlet pair of the
supporting roller. The drive power is 450 kw. The calcined material passes
further down the rotating kiln and by applying heat energy clinker is formed.
The coal is used as fuel for rotating kiln. Coal stored in the raw coal hopper
is fed to the coal mills for pulverization and then stored in fine coal bins
prior to being pneumatically conveyed to the calciner and the kiln Swirlex
burner as fuel to rotary kiln. The hot exhaust gases from the kiln are used
in the preheater / precalciner as well as in raw mill/coal mill for drying the
raw materials/coal and for carbonation of Soda ash effluent and drying of
wet cake in ESF plant. The exhaust dust laden gases are led to a high
efficiency ESP, provided for both the kiln and raw material where solid
particles are recovered and recycled while dust free gases are vented.

The clinker exits the kiln at approximately 1450 deg centigrade into a
Coolax grate cooler where ambient air is blown by various cooler fans for
cooling to a final product temperature of 65 0C above ambient. The grate
area is 53.5 m2 (CFG area 22.77m2).The discharge of the cooler is
equipped with the latest design of the hammer crusher of 52 tph capacity.

A part of the hot air from the cooler is vented after dedusting in ESP
by a cooler exhaust fan and rest of the hot air is used in kiln. The final
product clinker is conveyed to a) old clinker silo of for further manufacture

CEMENT DIVISION, TATA CHEMICALS LIMITED

CEMENT DIVISION, TATA CHEMICALS LIMITED

of cement, b) reject clinker silo, which is for waste clinker of inferior

quality ,& c) new clinker silo for sale as such on loose condition.

4.0 Preparation of Cement:

Grinding Media Charge: 59 Tons 1st chamber & 104 Tons 2nd chamber
From old clinker silo, clinker is fed to cement mill, wherein clinker along
with fly ash and gypsum, in required proportion, is ground to form cement.
The types of cement manufactured are PPC (Pozzolana Portland Cement)
and OPC (Ordinary Portland Cement) of Grade 43 & 53. For manufacture
of OPC clinker is mixed with gypsum in desired proportion and for
manufacture of PPC clinker is mixed with gypsum and fly ash in desired
proportion. The resultant cement is packed in the PP bags of 50 kg for its
dispatch.

CEMENT DIVISION, TATA CHEMICALS LIMITED