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The Cement Process

What is Cement?
A powder of alumina, silica, lime, iron oxide, and
magnesium oxide burned together in a kiln and
finely pulverized and used as an ingredient of
mortar and concrete
The adhesive or Glue that holds concrete together
Concrete: a hard strong building material made by
mixing a cementing material (as portland cement)
and a mineral aggregate (as sand and gravel) with
sufficient water to cause the cement to set and bind
the entire mass
Cement is Part of Concrete
Basic Raw Materials

Limestone Clay Shale

Corrective
Materials

Sand Iron Ore


Limestone Quarry
Limestone Quarry Face
Material Flow In A Cement Plant
Quarry Crushing
Core Raw Materials Primary [Size to ~200 mm]
[Limestone, Shale, Marl] Secondary [Size to ~50 mm]
~1000-4000 mm Stock Piles/
Fuels, Preblending
Fuel Prep, Raw Grinding, Drying
Burning Burners Vertical Roller Mills Classifier
Preheater [Calcination] Silos/ Horizontal Ball Mills
Kiln [Melt, Clinker] Blending Roller Press
Clinker Size ~10-80 mm [Size to ~50-90 microns]

Finish Grinding
Vertical Roller Mills Separator
Clinker Cooler and Breaker Horizontal Ball Mills
Cooling, Transport, Sizing Roller Press
Size to ~25 mm [Size to ~5-30 microns]
Typical Primary Crusher
1 Stage / Single Pass Crushing System
Primary / Secondary Crushing Installation
2 Stage / Single Pass Crushing System
3 Stage Crushing System
Principles of Crushing
Principles of Crushing
Compression. As the name implies,
crushing by compression is done between
two surfaces.

Impact. Refers to the sharp,


instantaneous impingement of one moving
object against another.

Attrition. A term applied to the reduction


of materials by scrubbing it between two
hard surfaces.

Shear. This consists of cleaving action


rather than the rubbing action
Gyratory Crusher

Cone

Input Shaft

Eccentric
Cone Crusher
Jaw Crusher
Roller Crusher
Mill Inlet

Rolls

Mill Outlet
Clay or Mix Crusher
Mix Crusher
ABON Sizers
Hammer Mill Internals
Rotor

Hammers
Impact Zone

Transport Grizzly
Rolls
Hammer Crusher

Grizzly

Input Shaft
Crusher Application Summary
Type of crusher Reduction Typical Feed Material
Ratio
Hammer & Blow Medium to hard,
50:1
Bar Impactor moderate abrasiveness
Hard, tough,
Jaw Crusher 4:1
high abrasiveness
Hard, tough,
Gyratory Crusher 7:1
high abrasiveness
Hard, tough,
Cone Crusher 3:1
high abrasiveness
Medium to soft, high to
Roller Crusher 4:1
moderate abrasiveness
Toothed Roller Soft, sticky, wet (Hard &
4:1
Crusher soft mix for ABON)
Storage Project Criteria
Homogenisation requirement
Raw material properties
Enlargement capability
Lay-out possibilities
Climatic conditions
Open/closed store
Mill feeding method
Storage Types

w/ Homogenizing w/o Homogenizing


Circular Bridge Portal Scraper
Longitudinal Side Scraper
Bridge
Bucket Chain
Excavator
Longitudinal Stacker
Longitudinal Bridge Reclaimer
Longitudinal Bridge Reclaimer & Stacker
Stacking Methods
Homogenizing Stores
Longitudinal stores
Chevron method
Windrow method

Circular stores
Continuous Chevron method

Non - Homogenizing Stores


Cone shell method
Chevron Stacking
Windrow Stacking
Bucket Chain Excavator
Bucket Chain Excavator
Circular Bridge Scraper
Circular Storage
Cone Shell Stacking
Side Scraper
Portal Scraper
Advantages & Disadvantages
Type Function Reclaimer Advantages Disadvantages

L Homogenising Bridge type Store capacity can be Space requirement relatively


o expanded high
n
g
i Composition of the whole Blending in end cones suffers
t pile can be adjusted if end-cone correction
u not applied
d
i Shunting between piles
n
a
l Bucket Handling of sticky Excavator operates only in
Excavator material possible part of pile cross section

Good space utilisation Shunting between piles


Non Homogenising Side scraper Reclaiming possible from Capacity suffers due to too
several piles in same much shunting
Portal scraper
store
C Homogenising Bridge type Limited space requirement Store capacity is fixed
i
r
No end-cone problems Composition of the whole
c
u after initial start-up pile cannot be adjusted
l
a Continuous operation Close control required in case
r of mixing pile
Raw Material Grinding
Raw Mill Feed Systems
Vertical Roller Mill
2 Fan Sytem
3 Fan System
Ball Mill for Raw Grinding
2 Fan System
3 Fan System
FRM MILL
FRM - GRINDING PORTION
The grinding table has a
horizontal grinding track
encircled by
Adjustable dam ring
Adjustable nozzle ring
Air guide cone

The dam ring and nozzle


ring are designed with
inserts to be easily adjusted
and maintained
Particle Force Balance in a Separator
ATOX MILL
ROTARY SLUICE

Rotary Sluice
Removable side panels allow better
access for maintenance
HEATED ROTARY SLUICE

Heated Rotary Sluice


Hot air is circulated through the rotor walls to reduce sticking
and build up of feed material.
Access and clean out openings for maintenance.
Seal Bin Raw Mill Feed Arrangement
Weighfeeder
Motor Inlet

Outlet Load Cell


Apron Feeder
ATOX Mill, Drying and Grinding Compartment
FULLY AIRSWEPT BALL MILL
AIRSWEPT MILL WITH SEPAX
SEPARATOR
Dust Collection Systems
1. Electrostatic Precipitators
2. Baghouses
Jet Pulse Dust Collector Bag Installation

Tube Sheet Bag Bag Cage


Raw Meal Blending - CF Silo
CF Extraction Sequence
Outlet ExtractionOpen part
Blower
fraction of cycle
Segment Aeration
1 2 3 4 5 6
A 0,137 0,50
1 B 0,192 0,50
1 2 3 4 5 6

1 2 3 4 5 6
C 0,169 0,50
2 G 0,153 0,50
1 2 3 4 5 6

1 2 3 4 5 6
F 0,125 0,33 1 2 3 4 5 6

3 D 0,109 0,33 1 2 3 4 5 6
E 0,115 0,33
t=70 sec
0 60 120 180 240 300 360 420 480 540 600 660 720 sec

2
1 3 1 2 3
B B
3 6 4 1 3 6 4 1
2 4 5 6 2 2 4 5 6 2
G C G C
1 6 5 1 2 3 5 4 3 1 5 1 2 3 5 3
A 6 4
A
4 6 4 6 4 6 4 6
3 5 5 5 1 3 5 5 5 1
F D F D
2 6 4 5 6 4 3 2 2 6 4 3 2
1 1 4 5 6
E E
3 1 3 1
2 2 t=70 sec
Kiln Feed System FLS LOW
FLS-LOW Control Principle

Emptying Period (butterfly valve closed)


Position of flow control gate (Z) regulated based
on differential weight loss in tank (dQ/dt)
Filling Period (butterfly valve open)
Position of flow control gate calculated based on
requested flow rate (Fsp) and tank content (Q)
Z Fsp ( A B Q C Q )2

F - Flow rate [t/h] Z - Flow control gate position [%]


Q - Weight in tank [t] A, B, C - System parameters
Kiln Feed System Pfister
Pfister Feeders
Impact Flow Meter

Material Inlet

Inspection Door

Load Cell

Material Outlet
Impact Flow Internals

Impact
Plate
Processes within the Pyro System as a
Function of Temperature
T
E
M
R
A P
NE
GR
E AT
U
R

I-1N
CE CHARAC
TERI
ST
IC
SPROC
ES
SES T
Y
P
P
R
O E
C
EO
SF
S
10 - 40
0 D
Elr
iy
i
n
mg
i
n,
ae
t
i
ov
a
npo
or
a
f
at
i
o
b
sn
oo
r
bf
e
dr
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waw
t
ea
t
re
r E
En
d
o
n
d
ot
th
e
h
er
rm
i
m
ic
c
40 - 75
0 D
K
D e
a
ec
o
o
l
c
om
i
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mip
o
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p
os

si
t
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fc
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e En
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6
60
0 -
-19
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Dea
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En
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o
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er
rm
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80 -130 r
C
i
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ee
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130 - 13
8
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ao
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ker
mel
tf
ro
mal
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sEn
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oth
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1250-150F o r
m
clinati
o
kermnofA
l
ierai
t
e(C
3S)
t
hep
r
in
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oth
erm
ic
Theoretical Heat of Reaction
kcal/kg
Heat of Reaction Clinker

Evaporation of combined water 20

Decomposition of clay minerals 35

Decomposition of carbonates 475


Heat of formation of clinker minerals -130
Heat of combustible in raw meal -15

Total heat of reaction 385


Specific Heat Consumption for
Different Kiln Systems
Specific Heat Consumption for Different Kiln Systems Kcal/kg
Clinker
Wet Process Kiln with Internals 1400
Long Dry-Process Kiln with Internals 1100
1-stage cyclone preheater with kiln internals 1000
2-stage cyclone preheater without kiln internals 900
4-stage cyclone preheater without bypass 800
Modern semi-dry process plant with preheater and calciner 1100
Modern 5-stage preheater/calciner system without bypass with satellite or
725
traditional grate cooler for clinker
Modern 5-stage preheater/calciner system without bypass high efficiency
690
(third generation) grate cooler
ILC: In-Line Calciner
Fauji Cement Industry - Pakistan
Cementos Portland, El Alto - Spain
Cimesa - Brazil
Sean Quinn - Ireland
Low NOX ILC Calciner
SLC-D:
Separate Line Calciner - Downdraft
SLC-D-NOX Calciner
Typical Preheater Cyclones
Cast Central Tube
Cast Central Tube
Single Tipping Valve
Double Tipping Valve
Preheater Material Distribution Box
Material Inlet

Dispersion Plate
Dividing Gate
Riser Slide Damper
TAD Hoisting Damper
Rotary Kiln with Two Supports
Rotary Kiln with Three Supports
Conventional Live Ring
Tangential Tyre Suspension
Conventional Kiln Support
Self-Aligning Kiln Support
Kiln Drive with Girth Gear
and Pinion
Kiln Drive Through Rollers
Hydraulic Thrust Roller
Pneumatic Inlet Seal
Kiln Inlet Lamella Seal
Kiln Outlet Lamella Seal
Kiln with Shell Cooling Fans
Kiln Bypass System
Allowable Input of Volatile Components
for Kiln Systems without Bypass
Clinker Coolers
PLANETARY CLINKER COOLER
PLANETARY COOLER
ORIGINALLY DEVELOPED FOR WET PROCESS
KILN SYSTEMS e.g. 2.0 kg air /kg clinker
OPERATES WITHOUT EXCESS AIR
NO EMISSIONS POINT
HIGH CLINKER TEMPERATURE
NO TAD CAPABILITY
COUNTER-FLOW HEAT EXCHANGE (CASCADING)
ROTARY CLINKER COOLER

ITS LIKE HAVING TWO (2) KILNS


ONE FOR BURNING & ONE FOR COOLING

REQUIRES 2 EFFICIENT (kiln) SEALS


ROTARY COOLER
CASCADING ACTION OF CLINKER CAUSES HEAT EXCHANGE
(COUNTER-FLOW HEAT EXCHANGE)
OPERATES WITHOUT EXCESS AIR
NO EMISSIONS POINT
HIGHER INVESTMENT COST
LOWER RADIATION LOSSES, BUT HIGHER CLINKER
TEMPERATURES
SEPARATE DRIVE - HIGHER POWER - 3.5 kWh/MT
YES, TAD POSSIBLE
GRATE CLINKER COOLER CONCEPT
DEVELOPED BY FULLER COMPANY
(F.L.Smidth) IN 1938
THE GRATE COOLER
ADVANTAGES:

HAS THE ABILITY TO HANDLE LARGE


CAPACITIES (> 15,000 TPD)

CAPABLE OF ACHIEVING LOW CLINKER


TEMPERATURES (< 65C + AMBIENT) IF
NEEDED

COMPARABLE HEAT RECUPERATION


(130 kcal/kg)
Clinker Exiting Kiln

Fine Side Coarse Side


EFFECT OF RESISTANCE GRATES

TRADITIONAL COOLER

2nd GENERATION COOLER


CFG AIR BEAM TECHNOLOGY
CIS FIXED INLET
SF COOLER W/ STATIONARY GRATE
LINE
MODULAR DESIGN
Feed End of Crossbar Cooler
Cross-bars Cooler Inlet Refractory
COOLER GRATE WITH MECHANICAL
FLOW REGULATOR (MFR)
AIR DISTRIBUTION W/ MFRS
MFR FLOW CHARACTERISTICS
MMC COOLER
MMC Partial Retrofits
RABBIT EAR FIREHOOD FOR
TERTIARY AIR EXTRACTION
Hammer Breaker at End of Cooler

Vibrating Grizzly Hammers


Hydraulic Roller Breaker at End of Cooler
Air to Air Heat Exchanger
Air-to-Air Heat Exchanger
Coal Types
Coal type Volatile Ash Hygroscopic Age
content moisture
% % %
Anthracite <8 3-5 <2 Old

Semianthracite 5 15 35 26

Quarter rich 15 20 58 26
coal
Bituminous 20 30 8 15 26
coal
Rich coal 30 40 10 20 26

Lignite 40 - 50 15 30 10 15 Young

Pet Coke < 15 <2 <1 Industrial


Guideline for Fineness of Coal Dust

35

30
% Residue on 90

25

20

15

10

0
0 5 10 15 20 25 30 35 40
% Volatile
Ball Mill System

S y s te m
excess gas

P ro d u c t

F re s h fe e d

Hot gas
s u p p ly
Tirax coal mill
RTKM Separator
FRM MILL
Atox Coal Mill
VRM system

S y s te m
excess gas

P ro d u c t

R e c ir c u la tio n M ill fe e d
gas

Hot gas
s u p p ly
Monitoring for Safety

O 2 CO

G a s A n a ly z e r
T

T
Inertisation System
CO 2

CO 2
CO 2

Inertisation by CO2, alternatively N2


Explosion Relief Valve
Placing of Relief Valves, BM
Placing of Relief Valves, VRM
Duoflex Burner
DUOFLEX BURNER
AXIAL AIR CHANNEL RADIAL AIR CHANNEL COAL CHANNEL
REFRACTORY

IGNITION
GAS
BURNER

BURNER
SET

CENTRAL FUEL DUCT


Duoflex Burner with Extra Channels
for Waste Fuel Firing
Typical Burner Installation
Burner Trolley Primary Air

Firing Hood

Kiln Burner Emergency Primary


Burner Pipe Management Air Fan Air Fan
Panel
Burner Pipe Seal
Coal Pfister
Burner Nozzle
WASTE FUELS
TIRES
Whole, Shredded And Granules CONTAMINATED SOIL
PLASTICS SLURRY
PET, PE, PP ETC.
WOOD SOLVENTS
Shredded, Chipped, Soaked With Pharmaceutical Waste, Paints,
Solvents/Oils Prints
FABRIC
Cloths, Carpets, Car Seats CONTAMINATED WATER
PAINT RESIDUES USED OILS
ANIMAL BONE AND/OR MEAT
MEAL LIQUID AND SOLID
SEWAGE SLUDGE
CHEMICAL WASTE
PAPER, DIAPERS, NEWSPAPERS,
CARDBOARDS
HOUSEHOLD WASTE
PFISTER ROTORWEIGHFEEDER
INSTALLATIONS

SECONDARY FUEL FLUFF


MATERIAL
SECONDARY FUEL -
WOOD CHIPS
HOTDISC
Alternativ
e fuel
Tertiary
Inlet
Air

Raw
Meal
Rotating Burning
Outlet for
Disc Material
Combustion
Gases, Hot Raw
Kiln & Meal & Ashes
HOTDISC
Gases to
Calciner

Kiln Riser
Duct

Kiln Riser
Duct Scraper
Wall
Raw Meal,
Fuel &
Tertiary Air
Inlet
Kiln Heavy
Gases Ashes
HOTDISC INSTALLED ON LOW
NOX ILC CALCINER
Cement Grinding Systems:
Cement Grinding Feed Components

Clinker + Gypsum

+ Additives
Two Fan System
Three Fan System
Ball Mill - General view
Chamber 1 and Diaphragm
Diaphragm - exploded view
OSEPA SEPARATOR

MATERIAL ENTERS
FROM TOP OF
SEPARATOR
AIR ENTERS
TANGENTIALLY
COARSE FRACTION
FALLS OUT THROUGH
THE BOTTOM
PRODUCT LEAVES
THROUGH OUTLET
DUCT WITH AIR TO
BAGHOUSE
SEPAX SEPARATOR
MATERIAL ENTERS FROM A
SINGLE INLET POINT FOR
SIMPLE LAY OUT
AIR ENTERS FROM BOTTOM
COARSE FRACTION FALLS OUT
THROUGH THE REJECT
OUTLET DUCT AND VALVE
PRODUCT LEAVES THROUGH
OUTLET DUCT WITH AIR TO
BAGHOUSE
BROKEN GRINDING MEDIA
FALLS THROUGH THE
TRANSPORT AIR AND ENTERS
THE DISPOSAL CONTAINER
PREGRINDER SYSTEM
HYDRAULIC ROLLER PRESS
SEMI-FINISH GRINDING SYSTEM
Two Stage Separator Product

for
Semi-Finish Grinding

Mill outlet
material

Top separator
reject to ball mill

Roller Press
outlet material

Grit separator reject


to Roller Press
OK Mill

Vertical Roller Mill


for cement and slag
grinding
Developed in the
early 80s by Onoda
and Kobe
FLS license.
OK MILL GRINDING PROCESS
ROLLER SUSPENSION

PRESSURE DISTRIBUTION
BETWEEN ROLLER AND TABLE
OK MILL SYSTEM

P ro d u c t 2

M
1

5
Cement Storage Silos

Dust Collector Transport Line

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