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MENTO RETM

Bask Tarihi: Mart 2012


Kitap 360 sayfa olup renkli olarak baslmtr.
Kitap ierii:
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Giri
Klinker Hammaddesi
Hammaddenin Krlmas
Hammadde Stoklama ve Harmanlama
Hammadde Hazrlama
Hammadde tme
Yaktlar
Isl lem
Dner Frn
Klinker Soutma
Klinker Bileenleri
Klinker Katklar
Klinker tme
Snflandrclar
Stoklama ve Paketleme
retim Sreci Kontrol
Enerji Tketimi
Ekler
Kaynaklar
Dizin

Kitap Maden Mhendisleri Odasndan temin edilebilir.


http://www.maden.org.tr/yayinlar/kitap_goster.php?kodu=111
MADEN MHENDSLER ODASI
Selanik Caddesi No:19/4 KIZILAY / ANKARA
TEL: (+90) 312 425 10 80 FAKS:(+90) 312 417 52 90
maden@maden.org.tr
www.maden.org.tr

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ERK
1.GR .........................................................................................................................................
1.1 imentonun Tarihi ...................................................................................................................
1.2 imento Frnlarndaki Gelimeler ..........................................................................................
1.3 Trkiyede imento .................................................................................................................
1.4 imento retimi ......................................................................................................................
1.5 Klinker retim Yntemleri .....................................................................................................
1.5.1 Ya Yntemle Klinker retimi ...................................................................................
1.5.2 Yar Kuru Lepol Yatay Izgara-Frn Klinker retim Sreci ..................................
1.5.3 Yar Ya Yntemle Klinker retim Sreci ........................................................
1.5.4 n Istmal Klinker retim Sreci .........................................................................
1.5.5 n Istma Srecinde Kalsinasyon ...............................................................................
1.5.6 Kalsinatr Sistemli Klinker retim Sreci ...............................................................
1.5.7 ki Kalsinatr Hatl Klinker retim Sreci .............................................................

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2. KLNKER HAMMADDELER...................................................................................................
2.1 Klinker Hammaddeleri..............................................................................................................
2.2 Hammaddeler............................................................................................................................
2.2.1 Kalker ...............................................................................................................................
2.2.2 Kalker eitleri..............................................................................................................
2.3 Marn .........................................................................................................................................
2.4 Kil..............................................................................................................................................
2.5 Tebeir.......................................................................................................................................
2.6 Demir Cevheri .........................................................................................................................
2.7 Boksit .......................................................................................................................................
2.8 Dier Hammaddeler .................................................................................................................

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3. HAMMADDENN KIRILMASI ...........................................................................................


3.1 imento Hammaddesinin Krlmasnda Kullanlan Krclar .................................................
3.1.1 Dner Krclar ..............................................................................................................
3.1.2 eneli Krclar ............................................................................................................
3.1.3 Darbeli Krclar ..........................................................................................................
3.1.4 ekili Krclar ...........................................................................................................
3.1.5 Otojen Krclar .............................................................................................................
3.1.6 Konik Krclar .............................................................................................................
3.2 eneli Ve Dner Krclarn Karlatrlmas .......................................................................
3.3 Krlacak Malzemenin zellikleri ......................................................................................
3.4 Krc Seimi ........................................................................................................................
3.5 Los Angeles Anma ndeksi Testi .......................................................................................
3.6 Toz Toplama Sistemleri ........................................................................................................
3.6.1 Toz Siklonlar ............................................................................................................
3.6.2 Kuru Toz Tutucular ....................................................................................................
3.6.3 Ya Toz Tutucular ......................................................................................................
3.6.4 Toz Filtreleri ................................................................................................................
3.6.5 Elektrostatik Toz Tutucular ........................................................................................
3.6.6 Ultrasonik Toz Tutucular ...........................................................................................

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4. HAMMADDE STOKLAMA VE HARMANLAMA ...........................................................


4.1 imento retim Tesislerinde Stoklama ...................................................................................
4.2 Harmanlama Yntemleri .........................................................................................................
4.2.1 Windrow Yntemi ........................................................................................................
4.2.2 Chevron Yntemi ........................................................................................................
4.2.3 Dairesel Yntem .......................................................................................................
4.2.4 Dier Stoklama Yntemleri .....................................................................................
4.3 Besleme Yntemleri ...............................................................................................................

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5.HAMMADDE HAZIRLAMA ................................................................................................
5.1 Malzeme Dengesi .....................................................................................................................
5.2 Kimyasal Modller ...................................................................................................................
5.2.1 Hidrolik Modl .............................................................................................................
5.2.2 Silika Modl ..............................................................................................................
5.2.3 Almina Modl ..........................................................................................................
5.2.4 Kire Doyma Faktr ...................................................................................................
5.2.5 Yaklabilme ndeksi .....................................................................................................
5.3 Klinker Hammaddeleri .............................................................................................................
5.4 Klinker Hammadde Harmannn Hazrlanmas .......................................................................
5.4.1 ki Hammaddeli Harmanlar .........................................................................................
5.4.1.1 CaCO3 Oran le Klinkerdeki C3S Orannn Ayarlanmas .
5.4.1.2 Oranlama le ki Bileenli Hammadde Karmnn Hesaplanmas ....
5.4.1.3 Michealis Forml Kullanarak ki Bileenli Harmann Hazrlanmas
5.4.1.4 CaO Oranna Gre ki Bileenli Harman Hazrlanmas
5.4.1.5 Khl Eitlii Kullanarak ki Bileenli Harman Hazrlanmas
5.4.1.6 ki Hammaddeden Oluan Harman Hazrlanmas .
5.4.1.7 Sabit C3S/C2S Oranna Bal Harman Oluturulmas
5.4.1.8 Harmann Kalker lavesi le Ayarlanmas ....................................................
5.4.1.9 Harmann Kil lavesi le Ayarlanmas .
5.4.1.10 Grafik le ki Bileenli Hammadde Karm Orannn Belirlenmesi ..
5.4.2 Hammaddeli Harmanlar .........................................................................................
5.4.2.1 Hammaddeli Harman Hazrlanmas
5.4.2.2 Harmandan stenilen LSF Ve SAO Deerlerinin Salanmas ..
5.4.2.3 Harmandan stenilen SM Ve HM Deerlerinin Salanmas ..
5.4.2.4 Harmandan stenilen C3S Ve C3A Deerlerinin Salanmas ..
5.4.2.5 Grafik le Bileenli Hammadde Karm Orannn Belirlenmesi .
5.4.3 Drt Hammaddeli Harman Hazrlanmas ....................................................................
5.5 Harmann Kimyasal zelliklerinin Belirlenmesi .......................................................................
5.6 Kmr Klnn Etkisi .............................................................................................................
5.7 Blm Sonucu .................................................... .....................................................................

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6.HAMMADDE TME .......................................................................................................


6.1 Deirmen Tipleri ......................................................................................................................
6.1.1 Otojen Deirmenler .....................................................................................................
6.1.2 Yar Otojen Deirmenler ............................................................................................
6.1.3 Bilyal Deirmenler .....................................................................................................
6.1.3.1 Blmeli Deirmenler .......................................................................................
6.1.3.2 Bilyal Deirmenlerin ektii G..................................................................
6.1.3.3 Kritik Hz ........................................................................................................
6.1.3.4 Kritik Hzn tmeye Etkisi ........................................................................
6.1.3.5 Devreden Yk ..................................................................................................
6.1.3.6 tc Ortamlar .............................................................................................
6.1.3.7 Bilya apnn Hesaplanmas ...........................................................................
6.1.3.8 Bilya Yaps .....................................................................................................
6.1.3.9 Bilya Tketimi ..................................................................................................
6.1.3.10 tc Ortamn Hacmi .................................................................................
6.1.3.11 Deirmen Astarlar ..........................................................................................
6.1.3.11.1 Martensitik Cr-Mo'li Beyaz Dkm .............................................
6.1.3.11.3 Ostenitik 6 Mn - 1 Mo elik Dkm .............................................
6.1.3.11.4 Perlitit Yksek Clu Cr-Mo'lu elik Dkm ................................
6.1.3.12 Astar Anmas .................................................................................................
6.1.3.13 Deirmen Tasarm ........................................................................................
6.1.4 Yksek Basnl tme Rulolar................................................................................
6.1.5 Dier Deirmenler .......................................................................................................
6.2 Kuru tme Devreleri ........................................................................................................
6.3 Ya tme Devreleri ...........................................................................................................
6.4 Hammaddelerin ndekslerinin Belirlenmesi ......................................................................
6.5 tlm Hammaddenin Homojenletirilmesi......................................................................

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7. YAKITLAR ..............................................................................................................................
7.1 Yaktlarn Kalorifik Deerleri .................................................................................................
7.2 Yakma Sistemleri ....................................................................................................................
7.3 Kmr ......................................................................................................................................
7.4 Kmrn tlebilirlik Testi: Hardgrove Yntemi ...........................................................
7.5 Petrokok ..................................................................................................................................
7.6 Kmrn tlmesi .............................................................................................................
7.7 Kmr Patlamalar .................................................................................................................
7.8 Kmr Kzmas .....................................................................................................................
7.9 Yanma Havas .........................................................................................................................

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8. ISIL LEM ...............................................................................................................................


8.1 imento retimi Ak ............................................................................................................
8.2 Klinker retim Sreci .............................................................................................................
8.3 Klinker retiminde Isl lem Blgeleri ....................................................................................
8.3.1 Kurutma Blgesi ( ~ 450C) ........................................................................................
8.3.2 Kalsinasyon Blgesi(450C-900C) .................................................................................
8.3.3 Gei Blgesi (900-1300C) ......................................................................................
8.3.4 Sinter Blgesi(1.300C-1.550C) .....................................................................................
8.3.5 Soutma Blgesi ...........................................................................................................
8.4 Isl lem Srecinde Kuvars ...................................................................................................
8.5 SiO2-CaO kili Diyagram ......................................................................................................
8.6 CaO-Al2O3 kili Diyagram .....................................................................................................
8.7 Isl lem Srecinde Magnezyum ...............................................................................................
8.8 Uucular ...................................................................................................................................
8.8.1 Isl lem Srecinde Alkali evirimi ...........................................................................
8.8.2 Klorr evirimi .............................................................................................................
8.8.3 Kkrt evirimi ..........................................................................................................
8.8.4 Yan Gei Sistemi ........................................................................................................
8.9 Isl lem Srecindeki Gelimeler ...........................................................................................
8.9.1 Ya Hammaddenin Isl lemi ....................................................................................
8.9.2 n Istma Siklonlar ......................................................................................................
8.9.3 Kalsinasyon Sistemleri ...................................................................................................
8.9.4 Frn k Gazyla Kalsinasyon Sistemi .........................................................................
8.10 Hammaddenin Kimyasal Deiimi ..........................................................................................
8.11 Blm Sonucu ........................................................................................................................

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9.DNER FIRIN ...........................................................................................................................


9.1 Dner Frnlarn zellikleri ......................................................................................................
9.2 Frnn Ana Bileenleri ............................................................................................................
9.2.1 Tama Rulo ve Ringleri ...............................................................................................
9.2.2 Ovalleme ......................................................................................................................
9.2.3 Tama Ring Balantlar ............................................................................................
9.2.4 Destek Rulolar ...........................................................................................................
9.2.5 Frn Hareket Sistemleri ...................................................................................................
9.2.6 Pinyon Ve Ana Dili Ayarlar .......................................................................................
9.2.7 Frn Giri Ve k Azlar .......................................................................................
9.3 Frnn letmecilii .................................................................................................................
9.3.1 Frnda Kabuk Oluumu ...................................................................................................
9.3.2 Frn Tayc Rulo Yataklarnn Isnmas .................................................................
9.3.3 Frn Gvdesinin Kzarmas ..........................................................................................
9.3.4 Frnn Istlmas ........................................................................................................
9.3.5 Frnn Durdurulmas ...................................................................................................
9.4 Frn Tulalar ..........................................................................................................................
9.4.1 Bazik Tulalar ..............................................................................................................
9.4.2 Yksek Alminal Tulalar ........................................................................................
9.4.3 Ate Kili Tulalar ......................................................................................................
9.4.4 zel Tulalar ...............................................................................................................
9.5 Tula rlmesi ........................................................................................................................
9.5.1 Tula Says .................................................................................................................
9.6 Malzemenin Frnda Kal Sresi .............................................................................................

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10. KLNKER SOUTMA .........................................................................................................
10.1 Klinkerin Soutulmas ............................................................................................................
10.2 Klinker Soutucular ...............................................................................................................
10.2.1 Dikey Soutucular .....................................................................................................
10.2.2 Hareketli Izgara Soutma Sistemi ..............................................................................
10.2.3 Dner Soutucular ......................................................................................................
10.2.4 Dairesel Soutucular .................................................................................................
10.2.5 Izgaral Soutucu Sonras Dikey Soutucular ...........................................................
10.2.6 Planet Soutucular ......................................................................................................
10.2.7 Izgaral Soutucular ....................................................................................................
10.2.8 Izgara-Bar Soutucular ...............................................................................................
10.2.9 Pendulum Soutucular ...............................................................................................
10.3 Soutucu Giri ve k ........................................................................................................
10.4 Soutucu Etkinlii ..................................................................................................................

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11. KLNKER BLEENLER .......................................................................................................


11.1 Klinkerin zellikleri .............................................................................................................
11.2 Klinkerin Bileenleri .............................................................................................................
11.2.1 Trikalsiyum Silikat (C3S) ..........................................................................................
11.2.2 Dikalsiyum Silikat (C2S) ...........................................................................................
11.2.3 Trikalsiyum Alminat (C3A) ....................................................................................
11.2.4 Tetrakalsium Aluminoferrit (C4AF) ..........................................................................
11.3 imentonun Yaps ................................................................................................................
11.4 Bogue Formlleri....................................................................................................................
11.5 Bogue Formlnn Uygulanmas ............................................................................................

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12.KLNKER KATKILARI ...........................................................................................................


12.1 Puzolanik Maddeler .............................................................................................................
12.1.1 Doal Puzolanik Mineraller .......................................................................................
12.1.2 Kalsine Edilmi Doal Puzolanlar ............................................................................
12.1.3 Pomza ve Perlit ...........................................................................................................
12.2 Yksek Frn Crufu .............................................................................................................
12.3 Uucu Kller ..........................................................................................................................
12.4 Alta (CaSO4.2H2O) .........................................................................................................
12.5 Silis Duman ........................................................................................................................
12.6 Pimi ist ...............................................................................................................................

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13.KLNKER TME ...........................................................................................................


13.1 Klinker Bileenleri ...............................................................................................................
13.2 imento tme Boyutlar .................................................................................................
13.3 imento tme Deirmenleri ...........................................................................................
13.3.1 Sarka Rulolu Deirmeler .........................................................................................
13.3.2 Loesche Deirmenler ................................................................................................
13.3.3 Atox Deirmenler.......................................................................................................
13.3.4 Dikey Rulolu Deirmenler .........................................................................................
13.3.5 Bilyal Dik Deirmenler ...........................................................................................
13.3.6 Konik Yatakl Rulolu Deirmeler ...........................................................................
13.3.7 Yatay Valsli Deirmenler .......................................................................................
13.3.8 Bilyal Deirmenlerle imento tme ....................................................................
13.4 tmede Kullanlan Katk Maddeleri ...............................................................................
13.5 tmede Aa kan Isnn Hesaplanmas .......................................................................
13.6 Bilyal Deirmenlerde imento tme Sresi ................................................................
13.7 tc Bilya Ve Silpepsler ..............................................................................................
13.8 Bilyal Deirmenlerle Hareket Sistemleri ............................................................................
13.9 Deirmen Kapasiteleri .........................................................................................................
13.10 Klinker tme Devreleri ....................................................................................................
13.11 tme Devrelerinde Devreden Yk ...................................................................................
13.12 Bilyal Deirmen Boyutlandrlmas in Saysal rnekler ................................................
13.12.1 Kuru tme Faktr, EF1 ...................................................................................
13.12.2 Ak Devre tme Faktr, EF2 ..............................................................................
13.12.3 Deirmen ap Faktr, EF3 .....................................................................................

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13.12.4 ri Boyut Faktr, EF4 .............................................................................................
13.12.5 nce Boyut Faktr, EF5 .............................................................................................
13.12.6 ubuklu Deirmen Kltme Faktr, EF6 ...............................................................
13.12.7 Bilyal deirmen Kltme Faktr, EF7 ..................................................................
13.12.8 ubuklu Deirmen Faktr, EF8 ...............................................................................
13.12.9 Deirmenlerin Boyutlandrlmas .............................................................................
13.12.10 Deirmenler in Gereken tc Miktarnn Hesaplanmas ..............................
13.12.11 Bilya apnn Hesaplanmas ...................................................................................
13.12.12 Bilya Dalmnn Belirlenmesi .............................................................................
13.12.13 Blmeli Bilyal Deirmen Boyutlandrlmas .........................................................

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14.SINIFLANDIRICILAR ..........................................................................................................
14.1 Snflandrc eitleri ...........................................................................................................
14.2 tme-Snflandrma Devreleri .............................................................................................
14.3 Snflandrc Etkinlii ............................................................................................................
14.4 Devreden Yk ........................................................................................................................

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15. STOKLAMA VE PAKETLEME ........................................................................................


15.1 Stoklama .................................................................................................................................
15.2 Paketleme ................................................................................................................................
15.3 Malzemenin Tanmas ..........................................................................................................
15.3.1 Havayla Tama Sistemleri ......................................................................................
15.3.2 Bantl Tayclar ........................................................................................................
15.3.3 Basnl Havayla Tama ..........................................................................................
15.3.4 Dikey Tayclar ........................................................................................................
15.3.5 Vidal Tayclar ......................................................................................................
15.4 Dozlama sistemleri ................................................................................................................

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16. RETM SREC KONTROL ............................................................................................


16.1 retim Sreci Kontrolnn Gereklilii ...............................................................................
16.2 retim Sreci Kontrol Sistemleri ........................................................................................
16.3 retim Sreci Kontrol Dngleri .........................................................................................
16.4 imento retim Tesislerinde retim Sreci Kontrol ..........................................................
16.5 Kitleme Sistemleri .................................................................................................................

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17.ENERJ TKETM.................................................................................................................
17.1 Hammadde Tketimi ..............................................................................................................
17.2 Enerji Tketimi ................................... ...................................................................................

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18.EKLER ................................ ....................................................................................................


Ek 18.1 TS EN 197-1 Standardna Gre imento Snflandrmas ..............................................
Ek 18.2 imentolar Basma Dayanm .................. ............................. .......................................
Ek 18.3 Grafik katlar ............... ...............................................................................................
Ek 18.4 Elek Serileri ..................... ............................ .................................................................
Ek 18.5 Klinker retim Tesislerinde rnek Ekipman Listesi ... ..................................................
Ek 18.6 l evirim izelgeleri .................... .......................................................................
Ek 18.7 imento Sektrnde Kullanlmas nerilen Baz Szck Ve fadeler ...........................

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19. KAYNAKLAR.............................................................................................................................

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20. DZN ........................................................................................................................................... 353

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