KHD-Part-6-Finish Product

Chapter 6
Finish Product
Version 08/2007
KHD Humboldt Wedag GmbH
6 Finish Product
6. 1 Clinker Transport and Storage

6. 2 Finish Product Grinding
6. 3 Cement Types and Quality
6. 4 Cement Shipping
Wednesday, January 28, 2009 2


6. 1. 1 Clinker Transport
The conveying equipment feeding the storage facility must be designed to suit the
maximum possible kiln output, including accidental flooding.
For complete safety, the conveyor subsequent to the cooler is recommended to be

designed for a maximum capacity of 1.5 to 2 times the kiln output.
Reliable conveying equipment for hot, abrasive cement clinker is essential for economic
operation in cement plants.


6. 1. 1 Clinker Transport
Commonly used in clinker transport from clinker cooler to silo or clinker stockpile are:
Deep Drawn Pan Conveyor or Bucket Apron Conveyor
(for slopes up to 28°) (for slopes up to 60°)
Both are suitable for abrasive and hot (up to 700 °C) materials.


6. 1. 2 Clinker Storage
Interim storage of the cement clinker is a

prerequisite for continuous kiln operation
combined with discontinuous clinker grinding and
processing.
A further issue requiring clinker buffer storage is

an unplanned or the scheduled yearly kiln stop.
Recommendation
The clinker storage facilities should be designed
to accept the clinker production of 4 to 6 weeks


6. 1. 3 Recommended Design Data (Data Source: Aumund)
Kiln Output Pan conveyor Storage Capacity
Capacity Pan width
3.000 t/day 250 t/h 1.000 mm 50 – 90.000 t
5.000 t/day 400 t/h 1.200 mm 80 – 150.000 t
7.500 t/day 560 t/h 1.400 mm 100 – 225.000 t
10.000 t/day 750 t/h 1.600 mm 150 – 300.000

Clinker is ground together with Gypsum (3 – 5 %) and / or additives like Puzzolan, Slag,
Limestone…
The optimal temperature range of cement grinding is between 90 to 120 °C.
Injected water into the mill system is used to maintain the above mentioned temperature.
If the temperature is less than 90 °C, than gypsum is insufficiently dehydrated and cement
strength is lost. (CaSO4 • 2 H2O + Heat CaSO4 • ½ H2O).
If the temperature is higher than 120 °C, than the risk of coating formation in the mill system
increases.
To advance the flow properties of the mill charge it is possible to admix grinding aids (e.g.
ethylene glycol based or triethanolamine based to avoid agglomeration).
Another detergent is Fe(II)-sulfate for reducing Chromates in Cement.

Optimum revolution speed of ball mill:
nballmill = 0,73 ~ 0,76 * ncritical
ncritical = 42,3 / √D


Pre-Grinding with Roller Press for higher production capacity

Basic specifications for cement regarding
• possibility to produce concrete and mortar

• sufficient workability
• strength
• deformation behaviour
• durability under ambient conditions
• environmental compability
• harmless to health

Definition of the requirements for cement
Standard Content
EN 196 test and sampling methods
EN 197-1 common cements composition,

specification,
DIN 1164 special cements conformity criteria
EN 197-2 scheme for conformity evaluation

6.3 Cement Types and Quality
27 common cements specified in EN 197-1
5 main cement types
• CEM I (Portland cement)
• CEM II (Portland-composite cement)

• CEM III (Blast-furnace cement)
• CEM IV (Pozzolanic cement)
• CEM V (Composite cement)

• Main constituents of cements specified in EN 197-1 (> 5% of total amount)
main constituent short term

Portland cement clinker K
granulated blastfurnace slag S
natural pozzolana P
natural calcined pozzolana Q
silicious fly ash V
calcareous fly ash W
burnt shale T
limestone with higher TOC L
limestone with lower TOC LL
silica fume D

• Minor constituents of cements specified in EN 197-1 (< 5% of total amount)

Special chosen natural inorganic material or inorganic material resulting from clinker
production (e.g. process dust) not used as main component
→ improving the physical properties of cement
• Sulfate component
Calciumsulfate used as retarder → input limited by permitted total amount of sulfate in

cement
gypsum CaSO4·2 H2O

semi-hydrate CaSO4·0,5 H2O
anhydrate CaSO4

• Additives to cements in terms of EN 197-1

• Special material chosen to improve the production or properties of cement (e.g.
energy savings with grinding process, better flowability and shelf life of cement
in silo)
• Total amount of additives must be < 1% (except pigments)
• Input of organic additives must be < 0,5%

Mechanical requirements of cement specified in EN 197-1
compression [MPa]
strength
early strength standard strength
classes
2 days 7 days 28 days
32,5 N - ≥ 16,0
≥ 32,5 ≤ 52,5
32,5 R ≥ 10,0 -
42,5 N ≥ 10,0 -
≥ 42,5 ≤ 62,5
42,5 R ≥ 20,0 -
52,5 N ≥ 20,0 -
≥ 52,5 -
52,5 R ≥ 30,0 -

Pysical requirements of cement specified in EN 197-1
strength classes start of setting [min] soundness [mm]
32,5 N
≥ 75
32,5 R
42,5 N
≥ 60 ≤ 10
42,5 R
52,5 N
≥ 45
52,5 R

Chemical requirements for cement according to EN 197-1
property test method acc. to cement type strength class limits a

CEM I
loss on ignition EN 196-2 all ≤ 5,0 %
CEM III
CEM I
insoluble residue EN 196-2 b all ≤ 5,0 %
CEM III
32,5 N
CEM I 32,5 R ≤ 3,5 %
CEM II c 42,5 N
Sulfate as SO3 EN 196-2 CEM IV 42,5 R
CEM V 52,5 N ≤ 4,0 %
52,5 R
CEM III d all
Chlorides EN 196-21 all e all ≤ 0,1 % f
pozzolanity EN 196-5 CEM IV all meet standard
a weight-%, b c d e f special requirements for some cement types see EN 197-1

Cement checking to be executed by cement producer according to EN 197-1
property cement test method acc. to testing frequency

early strength
all EN 196-1 2/week
standard strength
start of setting all EN 196-3 2/week
soundness all EN 196-3 1/week
CEM I
loss on ignition EN 196-2 2/month a
CEM III
CEM I
insoluble residue EN 196-2 2/month a
CEM III
Sulfate all EN 196-2 2/week
Chloride all EN 196-21 2/month a
pozzolanity CEM IV EN 196-5 2/month
a 1/month if no test value is > 50% of characteristic value





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Chapter 6

6. 1 Clinker Transport and Storage

Wednesday, January 28, 2009 2

6. 1 Clinker Transport and Storage

For complete safety, the conveyor subsequent to the cooler is recommended to be

Wednesday, January 28, 2009 3

6. 1 Clinker Transport and Storage

Wednesday, January 28, 2009 4

6. 1 Clinker Transport and Storage

Interim storage of the cement clinker is a

A further issue requiring clinker buffer storage is

Wednesday, January 28, 2009 5

6. 1 Clinker Transport and Storage

Kiln Output Pan conveyor Storage Capacity

Capacity Pan width

3.000 t/day 250 t/h 1.000 mm 50 – 90.000 t

5.000 t/day 400 t/h 1.200 mm 80 – 150.000 t

7.500 t/day 560 t/h 1.400 mm 100 – 225.000 t

10.000 t/day 750 t/h 1.600 mm 150 – 300.000

Wednesday, January 28, 2009 6

6. 2 Finish Product Grinding

The optimal temperature range of cement grinding is between 90 to 120 °C.

Another detergent is Fe(II)-sulfate for reducing Chromates in Cement.

Wednesday, January 28, 2009 7

6. 2 Finish Product Grinding

Optimum revolution speed of ball mill:

nballmill = 0,73 ~ 0,76 * ncritical

Wednesday, January 28, 2009 8

6. 2 Finish Product Grinding

Wednesday, January 28, 2009 9

6. 2 Finish Product Grinding

Pre-Grinding with Roller Press for higher production capacity

Wednesday, January 28, 2009 10

6. 3 Cement Types and Quality

Basic specifications for cement regarding

• possibility to produce concrete and mortar

Wednesday, January 28, 2009 11

6. 3 Cement Types and Quality

Definition of the requirements for cement

EN 196 test and sampling methods

EN 197-1 common cements composition,

EN 197-2 scheme for conformity evaluation

Wednesday, January 28, 2009 12

6.3 Cement Types and Quality

27 common cements specified in EN 197-1

5 main cement types

• CEM I (Portland cement)

• CEM II (Portland-composite cement)

Wednesday, January 28, 2009 13

6. 3 Cement Types and Quality

• Main constituents of cements specified in EN 197-1 (> 5% of total amount)

main constituent short term

Wednesday, January 28, 2009 14

6. 3 Cement Types and Quality

• Minor constituents of cements specified in EN 197-1 (< 5% of total amount)

Calciumsulfate used as retarder → input limited by permitted total amount of sulfate in

gypsum CaSO4·2 H2O

Wednesday, January 28, 2009 15

6. 3 Cement Types and Quality

• Additives to cements in terms of EN 197-1

Wednesday, January 28, 2009 16

6. 3 Cement Types and Quality

Mechanical requirements of cement specified in EN 197-1

Wednesday, January 28, 2009 17