CEMENT MANUFATURING WASTE

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Method of cement manufacturing & during manufacturing different type pollute-net material like as dust ,CO2,SO2,CO occurs. So this PPT helpful to understand type of cement manufacturing like as wet / dry process & maintain environmental conditions by using EPS, wet scrubber ,cyclone separator, gravitational settling chamber on site.

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CEMENT MANUFATURING WASTE

  1. 1. 1
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  3. 3. In civil construction cement is a good bond material . Firstly in 1824 , Joseph Aspdin, a British stone mason, heated a mixture of finely ground limestone and clay in his kitchen stove and ground the mixture into a powder to create a hydraulic cement- one that hardens with the addition of water. 3
  4. 4. 1.Argillaceous materialCao-65%-bond material Silica-17-25% Alumiana-7-8% -providing strength Gypsum-3-5%-to decrease the initial setting time Iron oxide-0-5% Magnesium oxide-0.1-4% Sulphuric oxide-1-2.75% 2.Callcareous materialCalk & limestone 4
  5. 5. DIFFERENT POLLUTANT IN CEMENT PRODUCTION Wet process Major Polluting source Process Inputs Process Outputs Pollution Parameters Impact Crushing Lime stone, silica, clay, shale Crushed raw materials Dust from raw material Air pollution Proportioning and mixing of raw materials & Grinding Water Slurry Noise Workplace Kiln and Clinker cooler Fuel Clinker Water vapour Filter kiln dust Workplace Air Pollution Finish grinding Clinker Gypsum Cement Dust Air Pollution Packaging machine Cement Cement Dust Air Pollution
  6. 6. Limestone65% Argillaceous material Crushing &compacting washing Storage tank water Storage Tank Wet grinding wash mill 6
  7. 7. Slurry Testing of slurry Grind coal Compressed air Slurry calcination (Rotary kiln) clinker Gypsum Clinker grinding ( Ball/Tube mill) Cement storage in silos 7
  8. 8. Weighting & packaging Supply 8
  9. 9. 1.Preparation of slurrygetting row material crushining it 25mm size mix water in raw material store in silos after proper mix slurry 2.Clinker makingslurry placed in rotary kiln by pump. kiln have following temperature Range250-500*C for dry slurry 700-1200*C change in noodles 1500-1700*C done chemical process in clinker of 5to 10 mm size 9
  10. 10. Cooled by cooler and storage in tanks. 3. grindingClinker placed in ball mill for course grinding after then ball for making 90 micron or less size. Mix the 2to 3% gypsum Last grinding cement in 50kg bag by automatic weight recorder. 10
  11. 11. ROTARY KILN JAB CRUSHER TUBE KILN DRUM CRUSHER 11
  12. 12. STORAGE OF CEMENT 12
  13. 13. Dry process Major Polluting Process Inputs source Process Outputs Pollution Parameters Impact Crushing Lime stone, silica, clay, shale Crushed raw materials Dust from raw material Air Pollution Proportioning and mixing of raw materials Crushed raw materials Dust from raw material Air Pollution Grinding Raw material Raw meal Noise Dust Workplace Kiln Fuel Raw material Clinker By-pass kiln dust Air Pollution Clinker cooler Hot clinker Clinker Finish grinding Clinker Gypsum Cement Packaging machine Cement Kiln’s chimney Exhaust gases + Exhaust gases + Particulate particulate particulate Air pollution Dust Noise Air Pollution Cement dust Air pollution Air pollution
  14. 14. Cao limestone Clay Crushing & Compacting Crushing Dry Grinding Calcination (Rotary kiln) Clinker AS SAME WET PROCESS 14
  15. 15. When raw material have hard or slag form, than used dry process. 1.Preparation powder of raw materialstore row material different places as category crushining crushing raw material by jaw crusher in 25 mm hot gasses in kiln used for drying the material mixed the proper proportion of raw material after than grinding in ball or tube mill 2.Clinker makingslurry placed in rotary kiln by pump. kiln have following temperature Range250-500*C for dry slurry 15
  16. 16. 700-1200*C change in noodles 1500-1700*C done chemical process in clinker of 5to 10 mm size Cooled by cooler and storage in tanks. 3. grindingClinker placed in ball mill for course grinding after then ball for making 90 micron or less size. Mix the 2to 3% gypsum Last grinding cement in 50kg bag by automatic weight recorder. 16
  17. 17. Cement waste control Problem Control unit Capture of kiln dust Electrostatic precipitator Bughouse filter,Cyclone Capture of dust from clinker cooler Electrostatic precipitator Bag house filter Control dust from other operations Cover or enclose conveyors, crushers, material transfer points, storage areas Install mechanical dust collectors and/or bag house filters where needed Vacuum sweepers for plant roads Sprinklers for plant roads and storage piles 17
  18. 18. Grit Screening , Grit chamber CO2,CO3 Dissolving in Chimney process SO2,SO3 Wet process
  19. 19. Electrostatic precipitators use high voltage to charge particles in a gas stream. The electrically charged particles are attracted to an oppositely charged plate where they are collected. An electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge . Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device and can easily remove fine particulate matter such as dust and smoke from the air stream. 19
  20. 20. ESP 20
  21. 21. Bag house filterBag house or fabric filtration relies upon a finely woven fabric to separate particles from the air stream as the air passes through the fabric. The design of a bag house is generally dependent upon the air-to-cloth ratio. Wet scrubbingWet scrubbing uses water particles to capture particulate matter in the gas stream. The efficiency of a wet scrubber is generally dependent upon the pressure drop. 21
  22. 22. Cyclone seprator 22
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