Cement Manufacturing hrs_eng

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Jesper Kjersgaard Nielsen
Sales Manager
Cement Division, EMEA & APAC
FLSmidth

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  • Præsentation af dagens stof og underviseren
  • These main components must be present in a very exact ratio. Both the ratio between the limestone component and the clay components as well as the ratio between the various clay components must be kept within strict limits to obtain the desired quality of the cement
  • Klassiske FLS oversigt over cement fremstillingsprocessen. 3 naturlige trin i fremstillingen, 2 mellem produkter Rå mel , klinker og slut produktet cement. Indledende 4 lektioner gennemgår vi hele processen så vi starter i bruddet og afstikker omkring kemi når det er nødvendigt.
  • Forudsætningen for at fremstille cement er en godt rå materiale kilde af en størrelse der også fremtidssikre fabrikkens drift i min. 30-40 år. FLS rolle : Ingen involvering i brud undersøgelser, men benytter sig af diverse konsulenter. Flere af dem eks. FLSér
  • Cement rock i Canada Typisk 70-80 % kalksten 10-20 % Ler 0-10 % Additiver som sand og jern.
  • The main constituents in portland cement is calciumoxide, siliciumoxide, aluminumoxide and ironoxide. The typical values of the content of these is shown here. These four constituents are the minerals that are used to control the quality of the clinker.
  • Rundlager Rail diameter 60 to 110 m Stacking cap. max. 2000 m3/h Reclaiming cap. max. 715 m3/h LHO Type range: Rail width 25 to 50 m Reclaiming cap. max. 1000 m3/h (Stacking with ST (Luffing Stacker) cap. max. 1390 m3/h) SS Type range: Jib length 20, 23 and 25 m Reclaiming cap. max. 525 m3/h (Stacking with ST (Luffing Stacker) cap. max. 1390 m3/h)
  • Klassiske FLS oversigt over cement fremstillingsprocessen. 3 naturlige trin i fremstillingen, 2 mellem produkter Rå mel , klinker og slut produktet cement. Indledende 4 lektioner gennemgår vi hele processen så vi starter i bruddet og afstikker omkring kemi når det er nødvendigt.
  • Materialer in i toppen fra lagerne, i bunden ses blå/gule fødeapparater. Størrelsen af siloerne afhænger af det forventede blandingsforhold.
  • Blanding for at op nå før omtalte kemiske sammensætning. Ingen performance garantier men mølle driften afhænger 100 % af dem
  • Kemi
  • Klassiske FLS oversigt over cement fremstillingsprocessen. 3 naturlige trin i fremstillingen, 2 mellem produkter Rå mel , klinker og slut produktet cement. Indledende 4 lektioner gennemgår vi hele processen så vi starter i bruddet og afstikker omkring kemi når det er nødvendigt.
  • The main component, limestone, enters the clinker as calcium oxide CaO But is only present in nature as calcium carbonate
  • The before mentioned crystals are created from these reactions.
  • When the correct amount of each constituent is mix as a raw mix, and burned in the kiln, a chemical reaction will take place. And the following crystals will be created. The percentages is typical values of these in the clinker to obtain the correct strength and properties that are required.
  • Klassiske FLS oversigt over cement fremstillingsprocessen. 3 naturlige trin i fremstillingen, 2 mellem produkter Rå mel , klinker og slut produktet cement. Indledende 4 lektioner gennemgår vi hele processen så vi starter i bruddet og afstikker omkring kemi når det er nødvendigt.
  • Klassiske FLS oversigt over cement fremstillingsprocessen. 3 naturlige trin i fremstillingen, 2 mellem produkter Rå mel , klinker og slut produktet cement. Indledende 4 lektioner gennemgår vi hele processen så vi starter i bruddet og afstikker omkring kemi når det er nødvendigt.
  • Cement Manufacturing hrs_eng

    1. 1. Jesper Kjersgaard NielsenSales ManagerCement Division, EMEA & APACF.L.Smidth A/SVigerslev Allé 77 • DK-2500 Valby • Copenhagen • DenmarkTel +45 36 18 10 00 • Direct line +45 36 18 21 59Mobile: + 45 30 93 21 59JeKN@FLSmidth.com
    2. 2. Cement ProductionMaterial flow in a cement plant dry process. – Rawmaterials for grey cement and white cement – Basic process – Blending, drying and grinding – Preheating and calcining – Burning , clinkerization – Concrete, cement and the hardening proces
    3. 3. What is cement? Clinker (95%) and gypsum (5%) Cement Clinker consist of Calcium-oxide – CaO: (”limestone/chalk”) ~ 75-80% + clay-minerals: Silicium-oxide – SiO2 Aluminium-oxide – Al2O3 ca 20-25% Iron-oxide – Fe2O3These main components must be present in a very exact ratio.Both the ratio between the limestone component and the claycomponents as well as the ratio between the various claycomponents must be kept within strict limits to obtain thedesired quality of the cement
    4. 4. Romans used concrete 125 AD.
    5. 5. Cement Plant Filter Filter Crusher Analyzer Limestone Clay Sand Iron 1 2 3 4 Raw meal silo Storage Coal mill 1 2 4 3 Raw mill Clinker Silo Separator Packers2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloadingRoller press Ship loading
    6. 6. Quarry and raw materials
    7. 7. The 4 main components in clinker:Lime saturation factor (LSF)= 100xC / (2.8xS + 1,18xA + 0,65xF) 93 – 98%Silica ratio (MS)= S/ (A+F) 2.3 - 2.8Alumina ratio (MA)=A/F 1.0 - 1.8
    8. 8. Portland Cement clinker Typical values for rawmix CaO 63 - 67 % SiO2 20 - 24 % Al2O3 4 - 7 % Fe2O3 2 - 4 %
    9. 9. White Cement• Rawmix iron content < 1 %• Low content of Cr, Mn• Reducing conditions in kiln (with oil)• Rapid cooling in cooler (quenching)• Very fine grinding in cement mill
    10. 10. Blasting
    11. 11. FLS EV knuser • EV 200*300-1(Diameter/Width/no. of inlet rollers)
    12. 12. Shear test
    13. 13. Roller crusher
    14. 14. Typical guaranty parameters• Production• Lifetime of hammers/teeth• kWh pr. ton crushed material
    15. 15. Apron Feeder
    16. 16. Material storage
    17. 17. Typical guarantee parameters• Stacker/Reclaimer capacity• Homogenization capability• Handling of wet material
    18. 18. Cement Plant Filter Filter Crusher Analyzer Limestone Clay Sand Iron 1 2 3 4 Raw meal silo Storage Coal mill 1 2 4 3 Raw mill Clinker Silo Separator Packers2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloadingRoller press Ship loading
    19. 19. Rawmaterial siloes Haiphong
    20. 20. Feeders
    21. 21. Atox rawmill • Atox 42.5 (Table diameter ø4,2 m)
    22. 22. Gas and ground material Material in Separator RollersSmokegas from kiln
    23. 23. Grindingtest Atox 3,5
    24. 24. TUMS ball mill
    25. 25. Smokegas from kiln Separator Product Material in Rejects return to mill Gas and ground material
    26. 26. Typical guarantee parameters• Production/Fineness• Lifetime of rollers and table (wear)• kWh pr. ton ground material
    27. 27. CF silo• Homogenizations factor >8• LOW or DLD kilnfeed system
    28. 28. Rawmaterial homogenization Raw meal blending silo CF - Continuous Flow
    29. 29. Cement Plant Filter Filter Crusher Analyzer Limestone Clay Sand Iron 1 2 3 4 Raw meal silo Storage Coal mill 1 2 4 3 Raw mill Clinker Silo Separator Packers2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloadingRoller press Ship loading
    30. 30. Main machines in a dryprocess kiln system
    31. 31. PREHEATER
    32. 32. ROTARY KILN
    33. 33. COOLER
    34. 34. MAIN BURNER
    35. 35. Heating and calcinationThe main component, limestone, enters the clinker ascalcium oxide - CaOBut is only present in nature as calcium carbonate– CaCO3An important part of the process is therefore thecalcination of the calcium carbonate CaCO3 → CaO + CO2 occurs at 890 °CCO2 is expelled ”through the chimney”This means that we must use:1.5-1.6 kg rawmaterial for every kg of cement!
    36. 36. ILC - In-Line Calciner Rawmeal from CF silo Kiln inlet
    37. 37. S 2-base kiln 13 x D inside lining 6.8 x D 3.6 x D 2.3 x D Rotary Kiln øDS 3-base kiln 17 x D inside lining 6.4 x D 2xD 1.3 x D 5.3 x D øD
    38. 38. Rotax 2 Kiln
    39. 39. FLS Duoflex burner
    40. 40. Front view Side view
    41. 41. Portland Cement Clinker Clinker mineral formation 2 CaO + SiO2 → C2S (belite) C2S + CaO → C3S (alite) 3 CaO + Al2O3 → C3A (celit) 4 CaO + Al2O3 + Fe2O3 → C4AF (celit)
    42. 42. Portland Cement klinker Clinker minerals Ranges Typical C3S45 - 65 % C2S 15 - 30 % C3A 6 - 10 % C4AF 8 - 12 %
    43. 43. Clinker PorosityC2S Porosity Free CaOC3S
    44. 44. Typical guarantee parameters for a 5-stage calciner kiln • Production ton per day (tpd) • Heatconsumption kcal/kg klinker (710-730) • kWh pr. ton clinker (20-25) • Maximum free lime CaO <1.5%
    45. 45. FLS - SF cooler
    46. 46. SF CROSS-BAR™ CONVEYING SYSTEM
    47. 47. MFR system
    48. 48. Typical guarantee parameters• Production (tpd)• kWh pr. ton clinker• Clinker temperature exit cooler
    49. 49. Clinker silo
    50. 50. Cement Plant Filter Filter Crusher Analyzer Limestone Clay Sand Iron 1 2 3 4 Raw meal silo Storage Coal mill 1 2 4 3 Raw mill Clinker Silo Separator Packers2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloadingRoller press Ship loading
    51. 51. Clinker grinding
    52. 52. Grinding of cement Ball mill
    53. 53. Grinding of cement in OK mill
    54. 54. Typical guarantee parameters • Production ton/hour • kWh pr. ton cement • Fineness (Blaine or sieve residue) For white cement the colour is guaranteed
    55. 55. Cement silos
    56. 56. Ventomatic
    57. 57. CFI-Silo
    58. 58. Cement Plant Filter Filter Crusher Analyzer Limestone Clay Sand Iron 1 2 3 4 Raw meal silo Storage Coal mill 1 2 4 3 Raw mill Clinker Silo Separator Packers2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloadingRoller press Ship loading

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