Chemical Engineering Process in Cement Production

Presented to: SAUDI ARABIAN SECTION OF AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE) on Sunday, December 27, 2009 at Le Meridien Hotel, Al-Khobar

By: Eastern Cement Team: Eng. Ali S. Al-Qahtani Eng. Sayd Basheer Shafee Eng. Haridas Nair

Who Are we?

Our Head Office Khobar

Our Plant is located at Khrsanih

Three production line of 3.5 mty cement

Joint Stock company listed in Tadawul

700 employees

Saudi Cement Industry

Economic Contributions

4 3.5 3 2.5 2 1.5 1 0.5 0 2006 2007 2008 2.46 Distributed Dividend (SR billions) 3.374 2.78

Why are we here?

Inform the Chemical Engineering Community about Cement Industry. Attract Chemical Engineers to start and build carriers in Cement industry.

Attract Local Chemical Engineering Research in Cement Process.

Our Business
We Produce and Sell ..

Glue .. for construction

Cement

Cement is..
Hydraulic Binder
Solidify and gain compressive strength after mixing with water

It binds gravel and sand to form Artificial Rock Sold Material

Concrete

There have been huge developments in the innovation and production of new binder materials in the last 10 years especially in the Epoxy chemicals.

Limestone

However
Non can compete with cement and concrete materials for practicality and economic feasibility of production and construction

Cement Production Process

Material handling Systems

Material handling Systems

Raw Material Grinding Systems

Pyroprocessing (Chemical Reactions)

Cement Grinding Systems

Cement is Very Old Material.

Basic Research and inventions Time Line

Research by Louis Vicat on Hydraulic Binders

Invention of Portland Cement by Joseph Aspedin

Invention of chemical Engineering process by Isaac Johnson

Cement Standard by Wilhelm Michaelis

1812

1824

1838

1875

Cement Production Technologies

Control and instrumentation Gears and bearings Cooling and heat transfer Material handling systems Cyclone and filters

Vertical Kilns

Rotary Kilns

Long Rotary Kilns

Short Rotary Kilns and Preheater Technology

1830s

1885

1930s

1970s

2000s

Pyroprocessing System
Preheater

Rotary Kiln
Cooler

Preheater
What is happning at the Preheater? Raw material separation and suspension for heat absorption.

Moisture Removal
Decomposition of CaCO3, MgCO3, formation of CA, C2F and C3S begins.

Formation of C12A7

Rotary Kiln

Formation of C3A and C4AF begins, decomposition of CaCO3 completed, free lime reaches maximum

Formation of C2S reaches maximum, C3A and C4AF formation completed Formation of liquid phase
Formation

of C3S, gradual decrease of free lime content.

Clinker
MINERALOGICAL COMPOSITION OF CLINKER Tricalcium silicate (C3S) or alite, dicalcium silicate (C2S) or belite, tricalcium aluminate (C3A) and tetracalcium aluminoferrite (C4AF) are the main clinker constituents

Cooler

Cooler

Final Chemical Process

Material handling Systems

Material handling Systems

Raw Material Grinding Systems

Pyroprocessing (Chemical Reactions)

Cement Grinding Systems

Addition of Gypsum CaSO4.2H2O to control the setting time of cement

Cement Chemical Composition

Cement Compound Tricalcium silicate Dicalcium silicate Tricalcium aluminate Tetracalcium aluminoferrite Gypsum Weight Percentage 50 % 25 % 10 % Chemical Formula Ca3SiO5 or 3CaO.SiO2 Ca2SiO4 or 2CaO.SiO2 Ca3Al2O6 or 3CaO .Al2O3 Ca4Al2Fe2O10 or 4CaO.Al2O3.Fe2O3 CaSO4.2H2O

10 %
5%