Cement Manufacturing hrs_eng
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Presentation by Jesper Kjersgaard Nielsen Sales Manager Cement Division, EMEA & APAC FLSmidth
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Cement Manufacturing hrs_eng
- 1. Jesper Kjersgaard Nielsen Sales Manager Cement Division, EMEA & APAC F.L.Smidth A/S Vigerslev Allé 77 • DK-2500 Valby • Copenhagen • Denmark Tel +45 36 18 10 00 • Direct line +45 36 18 21 59 Mobile: + 45 30 93 21 59 JeKN@FLSmidth.com
- 2. Cement Production Material 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. 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 – Fe2O3 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
- 4. Romans used concrete 125 AD.
- 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 Packers 2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloading Roller press Ship loading
- 6. Quarry and raw materials
- 8. 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 - 2.8 Alumina ratio (MA) =A/F 1.0 - 1.8
- 9. Portland Cement clinker Typical values for rawmix CaO 63 - 67 % SiO2 20 - 24 % Al2O3 4 - 7 % Fe2O3 2 - 4 %
- 10. 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
- 13. Blasting
- 15. FLS EV knuser • EV 200*300-1 (Diameter/Width/no. of inlet rollers)
- 18. Shear test
- 19. Roller crusher
- 20. Typical guaranty parameters • Production • Lifetime of hammers/teeth • kWh pr. ton crushed material
- 21. Apron Feeder
- 22. Material storage
- 25. Typical guarantee parameters • Stacker/Reclaimer capacity • Homogenization capability • Handling of wet material
- 26. 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 Packers 2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloading Roller press Ship loading
- 28. Feeders
- 29. Atox rawmill • Atox 42.5 (Table diameter ø4,2 m)
- 30. Gas and ground material Material in Separator Rollers Smokegas from kiln
- 32. TUMS ball mill
- 33. Smokegas from kiln Separator Product Material in Rejects return to mill Gas and ground material
- 34. Typical guarantee parameters • Production/Fineness • Lifetime of rollers and table (wear) • kWh pr. ton ground material
- 35. CF silo • Homogenizations factor >8 • LOW or DLD kilnfeed system
- 36. Rawmaterial homogenization Raw meal blending silo CF - Continuous Flow
- 38. 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 Packers 2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloading Roller press Ship loading
- 39. Main machines in a dryprocess kiln system
- 40. PREHEATER
- 41. ROTARY KILN
- 42. COOLER
- 43. MAIN BURNER
- 44. Heating and calcination The main component, limestone, enters the clinker as calcium oxide - CaO But is only present in nature as calcium carbonate– CaCO3 An important part of the process is therefore the calcination of the calcium carbonate CaCO3 → CaO + CO2 occurs at 890 °C CO2 is expelled ”through the chimney” This means that we must use: 1.5-1.6 kg rawmaterial for every kg of cement!
- 45. ILC - In-Line Calciner Rawmeal from CF silo Kiln inlet
- 46. S 2-base kiln 13 x D inside lining 6.8 x D 3.6 x D 2.3 x D Rotary Kiln øD S 3-base kiln 17 x D inside lining 6.4 x D 2xD 1.3 x D 5.3 x D øD
- 47. Rotax 2 Kiln
- 49. Front view Side view
- 50. 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)
- 51. Portland Cement klinker Clinker minerals Ranges Typical C3S45 - 65 % C2S 15 - 30 % C3A 6 - 10 % C4AF 8 - 12 %
- 53. Clinker Porosity C2S Porosity Free CaO C3S
- 54. 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%
- 56. FLS - SF cooler
- 57. SF CROSS-BAR™ CONVEYING SYSTEM
- 58. MFR system
- 59. Typical guarantee parameters • Production (tpd) • kWh pr. ton clinker • Clinker temperature exit cooler
- 60. Clinker silo
- 61. 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 Packers 2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloading Roller press Ship loading
- 62. Clinker grinding
- 63. Grinding of cement Ball mill
- 65. Grinding of cement in OK mill
- 66. Typical guarantee parameters • Production ton/hour • kWh pr. ton cement • Fineness (Blaine or sieve residue) For white cement the colour is guaranteed
- 67. Cement silos
- 69. Ventomatic
- 70. CFI-Silo
- 71. 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 Packers 2 3 Cement Cement silo silo Cement silo Cement mill Gear unit Ship unloading Roller press Ship loading
Editor's Notes
- 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.