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Cement Process Chemistry

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Shambhudayal
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About Cement ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
About Cement ,[object Object],[object Object],[object Object]
About Cement ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
About Cement ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Process Overview Mining & Crushing Raw Mill Grinding Raw Meal Homogenization Pyro Processing Clinkerization Final Grinding Packaging Crushed Limestone Additives i.e. Iron ore or Clay Coal Ash From Coal Fired Fine Raw Meal (120)Res. < 3% Lt. wt 1200-1350 Clinker 1) Gypsum 2) Flyash 3) Pozzolona 4) Slag 1) OPC 2) PPC 3) Slag Cement Blaine 300-350 m 2 /kg OR (45) Res. <16% Cement
Process Overview ,[object Object],[object Object],Heating 1500 o C in Kiln Grinding Grinding
Process Overview ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Process Overview ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Process Overview ,[object Object],[object Object],[object Object],[object Object],[object Object]
Process Overview ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Process Overview ,[object Object],[object Object],[object Object],[object Object],[object Object]
Process Overview ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Size Reduction in Cement Industry ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Grinding in Cement Industry ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Grinding in Cement Industry ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Grinding in Cement Industry ,[object Object],[object Object],[object Object],[object Object]
Ball Mill ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Ball Mill ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Ball Mill ,[object Object],[object Object],[object Object],[object Object]
Air Separator ,[object Object],[object Object],[object Object],[object Object],[object Object]
Mechanical Air Separator ,[object Object],[object Object]
Mechanical Air Separator ,[object Object],[object Object],[object Object],[object Object]
Mechanical Air Separator ,[object Object],[object Object],[object Object],[object Object],[object Object]
High efficiency Static Air Separator ,[object Object],[object Object],[object Object],[object Object]
High efficiency Static Air Separator ,[object Object],[object Object],[object Object],[object Object]
Ball Mill - Dry Grinding Close Circuit ,[object Object],[object Object],[object Object],[object Object],Ball Mill Separator Fresh Feed Rejects Mill Product Final Product TPH Blaine/Residue TPH TPH Accum Mill kW RPM Damper Recirculating Load
Ball Mill - Dry Grinding Close Circuit ,[object Object]
Ball Mill - Dry Grinding Close Circuit ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Ball Mill - Dry Grinding Close Circuit ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Ball Mill - Dry Grinding Close Circuit ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Ball Mill - Dry Grinding Close Circuit ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Ball Mill - Dry Grinding Close Circuit ,[object Object],[object Object],[object Object],[object Object],[object Object]
Ball Mill v/s VRM/Roller press ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Vertical Roller Mill ,[object Object],[object Object],[object Object]
VRM - Typical Raw Mill ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Vertical Roller Mill ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Vertical Roller Mill ,[object Object]
Vertical Roller Mill ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Vertical Roller Mill ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Roller Press ,[object Object],[object Object],[object Object]
Roller Press ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Roller Press ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Modes of Operation ,[object Object],[object Object],[object Object],[object Object]
Clinkerization Overview ,[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],Clinkerization Overview
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Clinkerization Overview
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Clinkerization Overview
[object Object],[object Object],[object Object],Clinkerization Overview
Clinkerization Overview Raw Meal Preheating Removal of Water Calcination Oxide Formation Belite formation Liquid & Phase formation CaO SiO2 Fe2O3 Al2O3 CaCO3 -> CaO + CO2 CaO + SiO2 -> CaO.SiO2 CaO.SiO2 + CaO -> (CaO)2.SiO2 (CaO)2.SiO2 + CaO -> (CaO)3.SiO2 (CaO)3.(Al2O3) ----- C3A (CaO)4.(Al2O3).Fe2O3--- C4AF Clinker Kiln Preheater Raw Meal 30 o C to 100 o C 100 o C to 300 o C 30 o C to 900 o C above 800 o C Above 1200 o C Cooling 1350 o C to 1250 o C Crystalization
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preheater ,[object Object]
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preheater ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kiln ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cooler ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cooler ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cooler ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cooler ,[object Object]
Cooler ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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Cement Process Chemistry

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  • 2.
  • 3.
  • 4.
  • 5. Process Overview Mining & Crushing Raw Mill Grinding Raw Meal Homogenization Pyro Processing Clinkerization Final Grinding Packaging Crushed Limestone Additives i.e. Iron ore or Clay Coal Ash From Coal Fired Fine Raw Meal (120)Res. < 3% Lt. wt 1200-1350 Clinker 1) Gypsum 2) Flyash 3) Pozzolona 4) Slag 1) OPC 2) PPC 3) Slag Cement Blaine 300-350 m 2 /kg OR (45) Res. <16% Cement
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  • 44.
  • 45.
  • 46.
  • 47.
  • 48.
  • 49. Clinkerization Overview Raw Meal Preheating Removal of Water Calcination Oxide Formation Belite formation Liquid & Phase formation CaO SiO2 Fe2O3 Al2O3 CaCO3 -> CaO + CO2 CaO + SiO2 -> CaO.SiO2 CaO.SiO2 + CaO -> (CaO)2.SiO2 (CaO)2.SiO2 + CaO -> (CaO)3.SiO2 (CaO)3.(Al2O3) ----- C3A (CaO)4.(Al2O3).Fe2O3--- C4AF Clinker Kiln Preheater Raw Meal 30 o C to 100 o C 100 o C to 300 o C 30 o C to 900 o C above 800 o C Above 1200 o C Cooling 1350 o C to 1250 o C Crystalization
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