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Cement Chemistry Cement is hydraulic material which develops strength when it reacts with water. It is inorganic material which consists of oxides of calcium,silicon,iron,aluminum. Phases in Cement
C3 S (Alite) C2 S (Belite) C3 A C4 AF
About Cement
Portland cement when mixed with water undergoes the process of Setting & Hardening The initial stiffening or setting of PC pastes appears to be the result of the rapid hydration taking place on the surface of the cement particles. This rapid initial setting is controlled by the presence of calcium sulfate and for this reason a small proportion of gypsum is interground with cement clinker to control the rate of initial setting. Following this the principal reaction is the formation of single calcium silicate hydrate(C-S-H) from the various anhydrous calcium silicates present in the cement particles.
About Cement
C - CaO , H - H2O
About Cement
Process Overview
Additives i.e. Iron ore or Clay
Packaging
Blaine 300-350 m2/kg OR (45) Res. <16% Cement 1) OPC 2) PPC 3) Slag Cement
Final Grinding
Process Overview
Grinding
Grinding
Process Overview
Mining First step in Cement Production Drilling is used to drill deep holes in the soil Blasting is done with the help of drilled holes & explosives Blasted Limestone is excavated with excavator Unearthed Limestone is transported to Crusher
Process Overview
Pre-homogenization of Limestone
Limestone ,excavated from different benches, has different chemical composition.Hence homogenization is needed. In this Crushed limestone is stacked onto stock pile in such a way that inherent CaCO3 Inconsistency is evened out.
Process Overview
Raw Meal Grinding Pre-homogenized Raw Meal in addition with with additives ,e.g. sandstone, iron oxide,clay etc., is ground in Raw Mill.
Types : VRM , Closed Circuit Ball Mill Hot air from Preheater is used for removing moisture in Raw Meal.
Homogenization of powdered Raw Meal is done in blending silo so that Chemical properties of Raw Meal gets equalized w.r.t. time.
Process Overview
Pyroprocessing The homogenous raw meal is preheated in Preheater. The material is then calcined upto 90% in Calciner. The Calicined raw meal is sintered into clinker in a rotary Kiln. Fuel (Coal , Oil) is fired into Kiln to sinter the raw meal. Red hot Clinker is cooled in cooler. The cooled clinker is crushed in Clinker breaker & stored in silo or Gantry for finished grinding.
Process Overview
Finished Grinding
Crushed Clinker is mixed with gypsum & fed into Cement Mill for fine size reduction.
Gypsum is added to control setting time of cement. Circuit Types : Open circuit Ball Mill , Closed circuit Ball Mill , Roller Press with Ball Mill,VRM with Ball Mill
Depending on final Cement requirements Flyash or Slag is added along with Crushed Clinker.
Process Overview
Raw feed fed to kiln contains 30-40% water by weight Raw feed, prepared by either the wet or dry methods according to the nature of the raw materials is formed into pellets or modules, which are fed into the kiln by way of a grate preheater in which the moving bed of nodulized material is dried and brought upto calcining temperature by heat from kiln. Raw Material fed to kiln contains 2-4% water by weight
Dry Process
Raw Meal Crushing Jaw,Impact,Hammer,Gyratory Crusher Raw Meal Grinding Ball Mill , Vertical Roller Mill (VRM) Clinker Crushing Hammer Crusher Final Grinding Ball Mill , VRM , Roller Press, Hybrid
Drying
Grinding Efficiency improves due to moisture removal Better thermal efficiency in kiln
Blending
Raw material with different property get mixed Achieves better homogeneity
Ball Mill
Closed Circuit
Mill Product is Fed to Air Separator & Coarse Material is fed back to mill Material from Mill to Separator is conveyed by Elevator
Air-Swept Operation
Ball Mill
Operational philosophy
Grinding By Impact
Primary size reduction process in first chamber of mill. Large diameter grinding media climbs along the mill lining due to centrifugal force. At the point when the weight of ball exceeds centrifugal force the ball falls down. The impact of the falling grinding charge with Mill lining causes particles entrapped between the charge & lining to fracture and undergo size reduction
Ball Mill
Operational philosophy
Grinding By Attrition
Grinding action in the Fine grinding compartment is generally by abrasion & shearing action Small particles , which are in an agglomerated form before grinding, are sheared off from the surface due to rubbing between multiple large sized aggregates and/or the grinding media.
Air Separator
Operational philosophy The performance of closed circuit mill very much depends upon performance of separator that is used. There are two broad categories of separator. These are
Conventional Type Of separator (mechanical air separator) High Efficiency Separator (static separator)
Both types use Air for separation in which centrifugal force of circulating air separates fines from coarse.
Separation In this type of Separator Due to drag force of air separation of fines from coarse takes place. Fresh feed is fed to distributing plate, which disperse feed into air stream flowing up. Fines get entrained in air stream & coarse hits the wall of separator. After hitting the wall coarse gets collected into cone.
Fineness Control
Circulating Air Volume in Separator is only MV that can control Fineness. The less is the volume more is Fineness. Auxiliary fan in separator can very the circulating air volume. As Auxiliary fan rpm increases circulating air volume decreases which intern decrease material dragged by air to fines of separator. Thus Fineness can be increased. Sp. Power requirement for such separator is around 6 kWh/ton.
Limitations
High Fineness of product is difficult or can be achieved with high circulating load.
Separation
The Mill discharge material is fed on dispersion plate. The material then cascade down to separating (classifying zone) where tangential inlet air suspends feed particles against the opposing centrifugal force of the rotor.
Intense shearing force breaks apart the particle agglomerates for highly efficient classification.
Product size particles, controlled by rotor speed, pass through the rotor blades to the cyclone. Rejects fall down to the collection hopper & fed back to mill. An externally located fan sucks the fine. Air is again recirculated to the separator. Small amount of recirculated air is vented off.
Fineness Control
Fineness can be controlled by rotor speed & air volume in separator. By increasing rotor speed feed material requires more turn & energy against centrifugal force to get through rotor blades. Due to this fineness of product increases.
Process Fresh feed is fed to ball mill with Separator rejects. Ball mill product goes to Separator for separation Rejects is fed back to mill
Rejects
Recirculating Load
Ball Mill
Fresh Feed
TPH Accum Mill kW
Separator
Mill Product
TPH RPM Damper
Final Product
TPH Blaine/Residue
MV-CV relation
Cause :
Feed Size increase Moisture increase in feed Hardness of Feed increase
Control:
Cut the fresh Feed
Separator Resonance
Cause :
Mechanical structure natural frequency matches with Separator at certain RPM
Control:
Prohibit RPM for resonance range
Malfunctions
Cause :
Feed hardness & size Worn out Mill charge Blocked diaphragm High moisture content Fractured diaphragm
Malfunctions
Cause :
Increased feed hardness Grinding media too large Too few grinding media Diaphragm slots worn out Mill feed overloading Malfunction of separator Mill fan damper jammed
Malfunctions
Cause :
Low mill draught Excessive wet feed
VRM/Roller Press
Grinding-Compressive stress Greater Fines Lower kWh/ton Flexible for different products Requires High skills
Operational philosophy
Process VRM is widely used for Raw Meal Grinding. Raw Material is fed to table . Raw Material get grounded between table & roller. Hot air with re-circulation air enters from bottom of the mill through perforated plates. Air carries ground material to separator inlet which is integral part of Mill. Separator reject falls back to grinding table & fines are carried by air to cyclone.
Mill Vibration Bed Layer Thickness Mill DP Fan Power Mill Outlet Temp. Residue/Blaine
: : : : : :
Health of Mill Stability Stability Air Volume Feed Moisture Drying Quality
MV - CV relation
Vibration High
Cause :
Imbalance between Material DP & Air DP
Control:
Cut/Increase Feed Increase Water Spray
Cause :
Inlet Material Property changes e.g. Moisture , Grindability High Feed rate
Control:
Cut Feed
Roller Press
Operational philosophy
Roller Press
Process Roller Press is widely used for Finished Grinding in hybrid mode of operation. Raw Material is fed to overhead silo . Material bed is always maintained above roller press. Ground material is fed to separator by elevator. Separator reject is fed to roller press & fines are carried by air to cyclone. Sometime ground material doesnt goto Separator. Only divider divides ground product ,one part of which goes back to Roller Press.
Roller Press
Roller Gap - Health of mill Back Pressure - Good grinding Over head Silo level - Choke feed Residue/Blaine Returns Mill Power
Modes of Operation
Roller press & Ball mill for finished grinding can work in following modes
Clinkerization Overview
Main Aim of this section is to produce Clinker from Raw meal in energy efficient manner
Kiln Operation can be in following mode
Wet Process : Kiln Feed Water 30 - 40% Semi Dry/Wet process Dry Process : Kiln Feed Water 2 - 3%
Clinkerization Overview
The choice of the process to be used depends upon a complex combination of different factors This includes:
The nature of the raw materials. The thermal efficiency of the different processes and their variations fuel and other energy prices
Clinkerization Overview
Kiln :
Cooler :
Heat Recovery from Hot Clinker Cooling Clinker rapidly to form reactive clinker
Clinkerization Overview
Evaporation of Water
400 - 900
Removal of structural water and OH group from clay minerals Clacination
above 800
above 1250
Formation of liquid phase (aluminate & Ferrite melt) Crystalization of Alite ,Belite I.e Completion of phase formation
Clinkerization Overview
Clinkerization Overview
Raw Meal
Preheater
Raw Meal Preheating 30oC to 100oC Removal of Water 100oC to 300oC
30oC to 900oC
(CaO)2.SiO2 + CaO -> (CaO)3.SiO2 Cooling Crystalization 1350oC to 1250oC Liquid & Phase formation
above 800oC
Belite formation Above 1200oC CaO + SiO2 -> CaO.SiO2 CaO.SiO2 + CaO -> (CaO)2.SiO2
Kiln
Clinker
Different Type of Preheater System 4 , 5 , 6 stage ,One string - With or Without Calciner 4 , 5 stage ,Two String - Calciner String , Kiln String 4, 5 stage ,Two string - Both Calciner String
Preheater
More Stages gets added in Preheater String More Heat Recovery from Waste Heat Gas More Capital Cost Less Temperature For Raw Mill Grinding
Preheater
Aim Maximum Heat Recovery from waste heat gas Maximum Calcination without melting raw meal Operational Philosophy Heat exchange between Waste Heat Gas & Raw Meal takes place through Direct Heat Exchange in Riser Duct Separation of Raw Meal Solid from Gas is carried out in Cyclone at each stage. Maximum Calcination is carried out in Pre-Calciner by burning Coal.
Preheater
Process Gas enters from bottom cyclone Raw meal enters from top cyclone Gas is sucked by induced draft fan from kiln Fan is placed at Preheater Outlet From Last but One cyclone raw meal goes to PreCalciner where coal is fired Tertiary air is sucked in Calciner from cooler After Pre-Calciner Raw meal is carried to last cyclone by air & Separated raw meal from this cyclone goes to Kiln
Preheater
: Heat Recovery : ESP security, Oxygen Shortage : Completion of Calcination : Material Fusion Temp : Excess Air , Leakage : Cyclone Jamming
Calciner Outlet Temp Kiln inlet Material Temp PHOutlet Draft / O2 Cyclone Cone Draft Handles PHOutlet Fan Damper /RPM : Air Quantity Calciner Coal : Heat Quantity
Preheater
MV-CV Relation
Preheater
Cause:
Less Oxygen for Coal Combustion High Calciner Coal Feed rate
Control:
Cut Calciner Coal Increase PHFan RPM or Damper
Preheater
Cause :
High Calciner Coal Feed rate Less Raw Meal Rate Secondary Burning of Coal in preheater
Control:
Cut Calciner Coal
Preheater
Cause :
High Calciner Coal Feed rate Less Raw Meal Rate
Control:
Cut Calciner Coal
Preheater
Cause :
Less Air Coating in cyclone Brick lining failure , Flap damper Malfunction
Control:
Cut Raw Meal Feed Rate
Kiln
Aim Maintain Clinker Quality Minimize Heat Consumption Operational Philosophy Heat is generated by Coal combustion High residence time i.e. 20 min High Temp 1500oC Maximum Contact area of Hot air & Material by circulatory motion (4 rpm)
Process Kiln is cylindrical rotating furnace (60 m length) & installed slightly slant (3-4degree) to carry the material to lower end when rotating. At Lower end is the burner where coal is fired through using primary air for conveying. Cooler Secondary air is sucked into Kiln which is at high temp ( Due to heat recuperation from hot clinker ). Secondary Air from Cooler & Primary Air gets heated by combustion of coal. This air travels opposite to material flow & Heat Exchange between air & material takes place
Kiln
Kiln
Major Operating Parameter Kiln Torque Burning Zone Temp. Clinker Lt..wt. & Free Lime Kiln Hood Draft Kiln inlet CO or O2 Handles Kiln Feed Kiln RPM Kiln Coal
: : : : :
Clinker Quality Good Heat Content Clinker Quality Safety & Maintenance Oxygen Availability
Kiln
:Rapid Contribution to strength : Slow Contribution to strength : Rapid Contribution to strength : V. Slow Contribution to strnth
Clinker Quality
Kiln
Affecting Parameters
Degree of Kiln feed mixing Kiln Feed Granulometry Burnability of kiln feed Degree of heating Retention time Clinker Cooling Rate
Kiln
MV-CV Relation
Kiln
Cause :
Less Air More Kiln Coal
Control:
Cut Kiln Coal Increase PH fan RPM / Open Damper
Kiln
Cause :
Less Heat Content in Kiln High Kiln filling
Control:
Reduce Kiln RPM & Increase Kiln Coal Decrease Kiln Feed
Kiln
Red Spot
Cause :
Coating Deformation Brick dislodging
Control:
Reduce Kiln RPM Stop Kiln
Aim Recuperate Maximum Heat from Clinker Maintain Clinker Quality Minimize Clinker Temperature
Cooler
Operational Philosophy Maximum Heat Recuperation in first few compartments is achieved by keeping high bed height of Clinker Lower Clinker temperature is achieved in last few compartments by Low Clinker bed height & High Air volume
Cooler
IKN Cooler
Grates Doesnt move. Forward motion for clinker is created by Horizontal Air Jet with very high velocity. Air with very high velocity flows parallel to Clinker flow & then moves vertically up.
Major Operating Parameter Under-Grate Pressure Grate Drive Amps Clinker Temperature Secondary Air Temp. Hood Draft Cooler Vent Temperature Handles Air Volume / Fan Damper / Grate Drive Speed Vent fan Damper / RPM
Cooler
: : : : : : Clinker Bed Clinker Bed Clinker property , Safety Recuperation Safety Heat Loss
Fan RPM
Cooler
MV-CV Relation
Cooler
Cause :
High Clinker Bed Height Lumps
Control:
Increase Grate Speed