Cement Manufacturing Process

An Overview of the Cement Manufacturing
Process
Dick Bekker (CTL/TT)

The Cement Manufacturing Process
Objectives of this presentation ...
 To provide a general overview of the cement
manufacturing process.
 To provide some specific insights into the main parts of
the process including:
- the materials involved

- the equipment used
Holcim Group Support Introduction to Cement Concrete & Aggregates August 2006
Contents
 Overview
 Raw Material Extraction
 Raw Material Preparation
 Rawmeal Preparation
 Clinker Manufacture
- Alternative Fuels
 Cement Grinding
- Mineral Components
 Packing - Dispatch - Logistics
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Overview - Cement Manufacturing Processes
Cement plant boundaries

Raw material supply
- Mechanical processes Customer

- Thermal process
- Chemical process
Concrete
Cement & Mortar
Cement Manufacturing Processes
Mechanical Processes Thermal & Mechanical Processes
Chemical
Raw Processes
Materials
Calcareous Alternative
Argillaceous
Silica correctives Raw Fuels
Iron correctives Meal Gypsum
Mineral
Clinker Components
Quarrying
Crushing
Pre-blending Burning...
Grinding Cement
Homogenizing...
Grinding
Dispatch
Blending...
Cement Manufacturing Process - Schematic
Alternative Fuels
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Quarry: Limestone and Marl (Clay/Shale)
Materials: Raw Mix Components ...
 Main Raw Mix Components
 Calcareous (Calcium/Lime) Materials -- CaCO 3 (Limestone)

 Argillaceous Materials -- SiO2, Al2O3 & Fe2O3 (Clay, Marl)
 Main Components (Chemistry):
 CaO = Lime / C SiO2 = Silica / S

 Al2O3 = Alumina / A Fe2O3 = Iron / F
 Raw Mix Corrective Materials
 Materials rich in C, S, A, F to correct the rawmix
Materials: Raw Mix Components ...
Limestone Marl
Raw Material Blasting (Preparation)
Explosive Charge
Stemming
Primer
Cartridge
Column
Charge
Toe
Detonator or Cap
Charge
Drilling and blasting

Quarry Operation - Blasting
Quarry Operation, Loading & Haulage
Haulage
90 Tonnes
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Raw Material Crushing ...
After quarrying, the material is

crushed to reduce it from a
size of ~ 1.5m to ~ 30 - 100mm
Transport to the Clinker Producing Site (1)
Transport to the Clinker Producing Site (2)
Raw Material Pre-blending
Direction of travel during

stacking/making the pile
Reclaiming is at 900 to
the direction of stacking
Pre - blending: stacking and reclaiming
 Stacking: How do you make a “Black Forest” cake?
 Reclaiming: How do you eat a “Black Forest” cake?
Contents
 Overview
- Alternative Fuels
 Cement Grinding
The Vertical Roller Mill – Operating principle ...
Raw Material Grinding ...
Tube mill
Vertical mill
Dust Collection (To clean gas streams) ...
Bagfilter
Electrostatic Precipitator
with Conditioning Tower
Raw Meal Homogenisation ...
In
FR
Filter FR The raw meal is homogenised by
a combination of the way it is
added to / extracted from the silo
and the air mixing in the silo.
Out
HS
Bypass
GKA GKJ
Active Inactive
GAS
Raw Meal Homogenisation ...
 Stacking: How do you make a “Black Forest” cake?
 Reclaiming: How do you eat a “Black Forest” cake?
 Homogenising: It is no longer a “Black Forest” cake!
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Main Equipment of a Modern Kiln System
Dry process kiln (with 5-stage SP and PC

Dry process kiln (with 5-stage SP and PC)
Kiln ID
Fan
Kiln ID
Fan
Filter
Fan
Cooler
Dedusting
Meal Meal
Dosing Dosing
5-stage
5-stage
Precalciner Precalciner Suspension
Fuel Dosing Suspension
Fuel Dosing
Air-to-Air Preheater
Preheater
Cooler
Water
Kiln Fuel
Dosing
Low NOx
Precalciner
Low NOx
Precalciner
Burner
Primary
Air Fan Burner
Cyclone
Conditioning
Preheater
Tower
Cyclone
Preheater
Introduction to CementKiln
Holcim Group SupportBurning Zone Concrete & Aggregates August 2006
Drive
Process: Preheating/Pre-calcination...
Stages
315
50 Raw meal
1
500 Exhaust gas
315
2
660
500
3
785
660
4
880
785
5
1000
0 500 1000
Temperature 0C
Clinker Production - Kiln
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Clinker Manufacture – Conventional Fuels
 Heavy Fuel Oil
 Pulverized Coal ( Bituminous & Lignite)
 Natural Gas
 Pulverized Petroleum Coke
Alternative Fuels and Raw Materials
 Alternative fuels
 Dry sewage sludge
 Plastics
 Old / Worn out tyres
 Used oil
 Animal meal, animal fat
 Solvents  Distillation residues
 Paper  Waste Wood
 Alternative raw materials

 Earth from oil spills
 Aqueous systems (Oily water)
Fuel Combustion ...
A complex burner is used
to mix different fuels with
air and deliver them to the
burning zone of the kiln for
combustion
Clinker Manufacture - Fuels
Coal, Heavy oil
Flame
Animal meal
Fuels
Ash
Dried sewage sludge
Solvents
Tires
Clinker Cooling ...
Clinker at ~1350oC enters
the cooler and forms a bed
through which air is blown to
cool it to ~150oC
Cooling Principle
Hot combustion air to kiln Hot waste air to filter
Hot clinker in
Slightly negative pressure!
Grate
Positive pressure!
Cooled
clinker out
Materials: Raw Meal to Clinker ...
The basic sequence of reactions ...
Reactants + C S+ C S
3 2 Cooled
Raw Meal AND
Products Clinker
(60°C) Liquids/Melt
(150°C)
(450 - 1450°C) (1450°C)
Natural Synthetic Rock

Earth Artificial Minerals
Minerals Alite & Belite
Aluminate & Ferrite
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Cement grinding ...
+ 5% Gypsum Portland
90% Clinker Grinding
+ 5% Mineral Comp’t Cement
Ball mill
Note – Composite
Cements contain > 5%
mineral components as
a clinker replacement
Cement grinding
Operation principle
of a Tube mill
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Mineral Components (MIC)
 Definition
 Mineral Components are materials with binding

properties which are not derived from the clinker
manufacturing process
 Mineral Components can be used:
 as alternative materials for clinker (“clinker substitute”), or
 for the manufacture of concrete (“cement substitute”)
 When added at the cement mill or added to Portland

Cement, the product is called Composite Cement
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Cement grinding ...
+ 5% Gypsum Portland
90% Clinker Milling
+ 5% Mineral Comp’t Cement
Ball mill
Note – Composite
Cements may
contain >5% mineral
components as a
clinker replacement
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Cement storage, packaging & dispatch ...
Cement from the mills
Cement Packaging
Cement Palletizing (Example)...
Single
bags in ...
Multi-pack out
Direct to load
out, or plastic
wrapped first
Bag Loading of Trucks
Bulk Loading of trucks...
Contents
 Overview
- Alternative Fuels
 Cement Grinding
Distribution / Logistics
Technical Data (Typical Example) ...
5 days/week
8 hours/day Note: 3000 t/d ~ 1 Mio. t/y
6720 tonnes/day 1.4 7 d/w
840 tonnes/hour 22 h/d
Quarrying & Raw 4800 t/d Factor 1.6 7 d/w
material preparation
220 t/h 24 h/d
3000 t/d 7 d/w
Raw meal preparation
125 t/h 16 h/d
3300 t/d 5 d/w
Clinker burning process
140 t/h 8 h/d
4600 t/d
Cement grinding
600 t/h
Storing/Dispatching
5 kWh/t
30 kWh/t
30 kWh/t
40 kWh/t
Total cement plant ~3500 MJ/t clinker 2 kWh/t
(ie. 120 kg coal/t ); and ~100 kWh/t cement 3 kWh/t
Auxiliaries

Cement Manufacturing Process

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Cement Manufacturing Process

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An Overview of the Cement Manufacturing

Dick Bekker (CTL/TT)

- the materials involved

 Packing - Dispatch - Logistics

 Packing - Dispatch - Logistics

Cement plant boundaries

- Mechanical processes Customer

 Packing - Dispatch - Logistics

 Calcareous (Calcium/Lime) Materials -- CaCO 3 (Limestone)

 Main Components (Chemistry):

 CaO = Lime / C SiO2 = Silica / S

 Raw Mix Corrective Materials

 Materials rich in C, S, A, F to correct the rawmix

Drilling and blasting

 Packing - Dispatch - Logistics

After quarrying, the material is

Direction of travel during

 Reclaiming: How do you eat a “Black Forest” cake?

 Packing - Dispatch - Logistics

 Reclaiming: How do you eat a “Black Forest” cake?

 Homogenising: It is no longer a “Black Forest” cake!

 Packing - Dispatch - Logistics

Dry process kiln (with 5-stage SP and PC

 Packing - Dispatch - Logistics

 Heavy Fuel Oil

 Pulverized Coal ( Bituminous & Lignite)

 Pulverized Petroleum Coke

 Alternative raw materials

Coal, Heavy oil

Slightly negative pressure!

The basic sequence of reactions ...

Natural Synthetic Rock

 Packing - Dispatch - Logistics

 Packing - Dispatch - Logistics

 Mineral Components are materials with binding

 When added at the cement mill or added to Portland

 Packing - Dispatch - Logistics

 Packing - Dispatch - Logistics

Cement from the mills

 Packing - Dispatch - Logistics

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