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ISO Team Training CEMENT PROCESS Hon Chong flow chart Raw material preparation Raw meal preparation Clinker producing Cement grinding Coprocessing Coprocessing at HN Plant Rice husk Rubber wastes Liquid wastes Hazardous wastes
ISO Team Training 04-Sept-2007 CEMENT PROCESS CONTENT Hon Chong flow chart Raw material preparation Raw meal preparation Clinker producing Cement grinding Co-processing Hon Chong Flow chart HVL ISO Team Training - Manufacturing Cement Process ppt Cement Production Diagram Production of Cement by the Dry Process Feed Bins Sampling Station Quarry Raw Materials Storage Crushing Plant (s) Corrective Materials and Preblending Electrostatic Precipitator Homogenizing and Storage Silo Cooler Dedusting Coal Raw Meal W ater Air-to-Air Cooler Coal Mill Cyclone Preheater Rotary Kiln Clinker Cooler Conditioning Tower Raw Mill Filter Mineral Gypsum Components Bulk Dispatch Cement Silo Clinker Storage Packing Machine Bag Palletisation Cement Silo Cement Mill Zement-trocken-englisch.dsf Kma 27.4.98 HVL ISO Team Training - Manufacturing Cement Process ppt Cement Production Process _ Steps Mining of limestone drilling or blasting crushing of limestone pre homogenization grinding of raw material homogenization of raw meal pyroprocessing coal grinding, co-processing cement grinding Raw material extraction Raw material preparation Raw meal preparation Clinker production cement storage, packing, and dispatching HVL ISO Team Training - Manufacturing Cement Process ppt Raw Material Preparation-Crusher CRUSHER Type: Impact crusher Size reduction: 1.2 m to 0.1/ 0.05m Using impact forces the size reduction of raw materials from the quarry It is easier to transport smaller material, and spread it along the pre-blending stockpile HVL ISO Team Training - Manufacturing Cement Process ppt Raw Material Preparation-General Reduction ratios: 3:1 to 7:1 by compression To 50:1 by impact and combination of 2-3 stages The type of crushers depends on: The work index of the material Abrasiveness Stickiness Throughput, tons per hour etc Size of feed Power consumption Reduction Ratios needed HVL ISO Team Training - Manufacturing Cement Process ppt RMP_ Crusher type application HVL ISO Team Training - Manufacturing Cement Process ppt RMP_ Pre-blending CHEVRON METHOD ‘To and fro’ stacker movement over the ridge of the pile Chemical uniform in full length due to fast stacker movement Particle and composition segregation in the area of the end-cones The pre-blending efficiency is a function of the number of layers: the higher the number of layers the better the preblending effect Pre-blending will be sufficient with material reclaim in thin slices from the front Pre-blending will be insufficient when material is reclaimed in lateral slices HVL ISO Team Training - Manufacturing Cement Process ppt RMP_ Pre-blending Mixing LS and Clay/sand for reducing impact of sticky clay Sand is silica corrective material Mixing process controlled by PGNAA, and weighing system of sand, clay, and limestone Process control parameters are ratio of clay to limestone, percentage of sand, stockpile volume Quality control parameters: LSF and SR of stockpiles Other quality factors for controlling: MgO, P205, SO3 10 HVL ISO Team Training - Manufacturing Cement Process ppt Normal VRM Roller Operation Vertical roller mill Stable Material bed No Vibrations Feed size OK Max Particle size in feed: 5-8 % of roller diameter Feed size: For a roller of 1m diameter: Max feed size 50-80 mm f (Roller Ø ) HVL ISO Team Training - Manufacturing 67 Cement Process ppt Abnormal VRM Roller Operation / too much feed Vertical roller mill Too High Feedrate Vibrations Roller will start to ‘jump’ VIBRATIONS Feed=> size: f (Roller Ø ) HVL ISO Team Training - Manufacturing 68 Cement Process ppt Abnormal VRM Roller Operation / too low feed Vertical roller mill Too Low Feedrate Material ‘waves’ on rotating table Vibrations Table Roller will start to ‘jump’ => VIBRATIONS Feed size: RISK OF SERIOUS f (Roller ØDAMAGE!!! ) HVL ISO Team Training - Manufacturing 69 Cement Process ppt Modification of setpoints and impact on Process Setpoint Feed Airflow Roller press Sep Speed Water inject Table speed Fineness LOW HIGH LOW HIGH NO NO Drying HIGH HIGH NO NO HIGH NO Impact on Vibration HIGH MEDIUM HIGH LOW HIGH HIGH Pressure drop HIGH MEDIUM NO LOW LOW NO Production HIGH MEDIUM LOW MEDIUM MEDIUM MEDIUM 70 HVL ISO Team Training - Manufacturing Cement Process ppt Cement Grinding_ Quality aspects Ensures to achieve the required chemical and physical properties The product mix and cement quality targets set by marketing and manufacturing Typical quality indicators for the finished product are: Compressive strength at different ages Setting time Fineness (e.g blaine) Consistency Typical quality indicators for process related quality control of ground cement are: Fineness (blaine, sieve residues, particle size distributation) SO3 for gypsum dosage Cement temperature for dehydration of gypsum Selected elements or components for mineral component dosage (e.g CaCO3 for limestone dosage) 71 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing Burning of alternative fuels (AF) offers unique advantages from an environmental point of view They are fired at high temperatures, without releasing residues and reducing the overall CO2 emission that would be produced when destroying them They can also contribute to keeping our manufacturing costs low 72 HVL ISO Team Training - Manufacturing Cement Process ppt Coprocessing_ Solid handling system 73 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing_ Liquid Handling System 74 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing_ Impacts 75 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing_ Examples of installation diagram At Eclepens 76 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing_ Examples of installation diagram At Joliette 77 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing_ Examples of installation diagram At Altkirch 78 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing_ Examples of installation diagram At Seattle Plant 79 HVL ISO Team Training - Manufacturing Cement Process ppt Co-processing at HN Plant Rice husk Rubber wastes Liquid wastes Hazardous wastes Target is TSR of >18% from 2010 Contributing to reduce net CO2 emission 80 HVL ISO Team Training - Manufacturing Cement Process ppt Last one 81 HVL ISO Team Training - Manufacturing Cement Process ppt [...]... guarantee proper: Material handling Too wet material => build up, transport and maintenance problems Grinding Too high moisture contents strongly reduce mill capacity Product quality Excessive moisture in the cement leads to undesirable cement hydration HVL ISO Team Training - Manufacturing 15 Cement Process ppt Raw Meal Preparation- VRM and grinding process Grinding Feed material consisting... Manufacturing Cement Process ppt Argillaceous Components While calcination is taking place, the argillaceous components are breaking down, making Al2O3, Fe2O3 and SiO2 available 23 HVL ISO Team Training - Manufacturing Cement Process ppt Lime & Silica Reaction At elevated temperatures of the process, lime will react readily with silica to form C2S belite 24 HVL ISO Team Training - Manufacturing Cement Process. .. of the raw material to enable transport of the raw meal 12 HVL ISO Team Training - Manufacturing Cement Process ppt Raw Meal Preparation- Fineness R90 R200 Fineness targets: R90: 10-15% R200 1.5 % could result in cement unsoundness ISO Team Training - Manufacturing 32 Cement Process ppt Clinker manufacturing process 33 HVL ISO Team Training - Manufacturing Cement Process ppt Preheater cyclones Design features of preheater cyclones Co-current heat exchange cyclone Low pressure drop by... point, C3A and C4AF cool to form to solids HVL ISO Team Training - Manufacturing 29 Cement Process ppt What Makes Good Clinker ? 1 Chemistry Burnability 2 Meal Fineness 3 Correct Burning Conditions: temperature time atmosphere (oxidizing) cooling 30 HVL ISO Team Training - Manufacturing Cement Process ppt Influences of Major and Minor Phases on Cement Properties Major Phases C3S C2S C3A...RMP_ key concerns Wet and sticky materials in raining season PGNAA operation and maintenance Quarry master and mixing muck-piles at quarry Accuracy of weigh feeders Limestone size control for OPC LS mixing in cement Cement quality impact of MgO, P205 Kiln process impact of SO3 11 HVL ISO Team Training - Manufacturing Cement Process ppt Raw Meal Preparation- Function Purposes... Aluminum & Iron C3A At elevated temperatures of the process lime will also react readily with aluminum and Iron to form a number of intermediate products The resulting synthetic minerals C3A and C4AF are key components not only in cement but as precursors to the liquid phase of the sintering process 25 HVL ISO Team Training - Manufacturing Cement Process ppt C2S formation C2S will continue to form... feed fineness is R90 µm = 15 % 26 HVL ISO Team Training - Manufacturing Cement Process ppt Liquid Phase Upon completion of C2S formation at approximately 1250 °C, the Calcium salts of Aluminum and Iron reach a point where they become a LIQUID In the heart of the BZ, 20 – 30 % of the clinker will be a liquid 27 HVL ISO Team Training - Manufacturing Cement Process ppt C2S, Free Lime → C3S In that liquid,... up to 2.5:1 Spec power cons system: 0.1-0.2 kWh/t 19 HVL ISO Team Training - Manufacturing Cement Process ppt Clinker Manufacturing- Basis reaction sequence Raw mixture (20°C) reactants + products + intermediate products (450 - 1300°C) alite + belite + melt (1450°C) cooled clinker 20 HVL ISO Team Training - Manufacturing Cement Process ppt Sequence of Reactions Occurring in a Rotary Kiln Heating