PRACTICAL TRAINING

PRESENTATION
1

VENUE KAMDHENU CEMENTS,

JAMMU

12/09/2021
 PRESENTED BY

SUMIT DIGRA
Enroll No 404/07
Roll No 26
Semester 8th
Branch Chemical

Chemical Engineering Department

N a t i o n a l I n s t i t u t e O f Te c h n o l o g y S r i n a g a r

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 Different Sections Of Cement Plant
3

Coal Section

Precalciner and Preheater

Rotary Kiln

Clinker Yard

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Block Diagram Of Different Sections Of
Cement Plant
 Coal Section

5
About 94% of the thermal energy utilised in the cement
plant is met by coal. For every 4 kg of clinker produced,1 kg
of coal is used.
The fine coal is supplied as fuel to the kiln and calciner

The coal is grinded in a ball mill having 7m length and

2.6m diameter.
The mill has capacity of about 10 tons per hour.

It produces product of which 12% is retained on 90 micron

mesh.
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Block Diagram Of Coal Section

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 Precalciner And Preheater

Calcining involves the decomposition of CaCO3 to CaO and firing at 1400-1500oc to

promote compound formation.
 Pre-calcination of raw meal is carried out in five stage cyclone suspension pre-heaters.
 90% of the calcinations of raw meal occur before it enters the rotary kiln.
The waste gases (hot gases from the kiln) are made to flow countercurrent to raw meal
in the pre heater and precalciner (DDF).
The gas flow rate temperature and pressure at different points in the pre heater section
is different.
 The material acquires a temperature of about 1000oc before entering the kiln.

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 Rotary Kiln
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The rotary kiln used in the plant is massive, with raw meal intake
capacity of 40 tons per hour (TPH) and driven by the motor of 400 Kw
capacity.
The kiln has 45m length, 3m diameter, with maximum rpm of about 3.1
and inclined at a small angle(2.5o) .
 The high temperature of about 1400oc inside the kiln is responsible for
conversion of preheated/precalcined raw meal to clinker.
The hot gases from the kiln are re-circulated to pre heater.
Output from the kiln is the clinker (of the size of golf ball or less than
that) at the rate of 25 tons per hour
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 Different Zones Of Kiln

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•CalciningZone (900 ºc)
•Heating Zone (1330 ºc)
•Liquid Zone (1350 ºc)

•Max Temperature Zone (1400-1500 ºc)

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 Reactions In Different Zones Of Kiln
TEMPERATURE (ºC) PROCESS CHEMICAL TRANSFORMATION

< 100 Drying/elimination of free water H2O(l) H2O(g).

Al4(OH)8Si4O10
100 to 400 Elimination of absorbed moisture. 2(Al2O3.2SiO2)+4 H2O.
H2O

400 to 750 Decomposition of clay with clay Al2O3.2SiO2

formation of metakolinite
Al2O3.2SiO2 Al2O3
600 to 900 Decomposition of metakolinite to a +2SiO2
mixture of free reaction oxides
CaCO3 CaO+CO2
600 to 1000 Decomposition of limestone and CaO +SiO2+ Al2O3
formation of CS and CA
CaO.SiO2+CaO.Al2O3;
2 CaO + SiO2 2CaO.SiO2;
800 to 1300 Binding of lime by CS and CA with CaO.Al O +2 CaO 3CaO. Al O ;
2 3 2 3
formation of C2 S, C3 A, and C4 AF CaO.Al O +3CaO+Fe O
2 3 2 3.

4CaO.Al2O3.Fe2O3

1250 to 1450 Further binding of lime by C2 S to 2CaO.SiO2+CaO 3CaO.SiO2.

form C3 S.
Cement clinkers
 Clinker Cooling and Storage

13

The clinker discharged from kiln at around 1000 oC temperature is

cooled in a grate cooler installed with five cooling fans.
The clinker temperature is reduced to about 110-120 oC.
The grate cooler pours its material (clinker) on to the deep bucket
inclined chain conveyer which conveys it to the tripper belt
conveyer.
The ESP connected to the grate also discharges the collected
material (dust) onto this conveyor.
The tripper belt carries the clinker to the storage shed

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KLINKER COOLING
AND STORING
CLINKER COOLING AND STORING

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 15

Thank you

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