Beruflich Dokumente
Kultur Dokumente
by
RIZWAN IBRAHIM
@)
Signature of Author
Department of Civil Engineering
February 28, 1986
Certified by
Professor Fred Moavenzadeh
Thesis Supervisor
Accepted by
Professor Richard de Neufville
Chairman, Technology and Policy Program
-2-
by
RIZWAN IBRAHIM
ABSTRACT
The purpose of this study is to review the technological options
available for producing cement, to discuss the economics of the various
options, and to assess how the policy framework in the developing countries
influences-the selection of appropriate technology for cement plants.
A review of the technical literature was undertaken to determine the
leading technologies for large and small-scale cement plants. The economics of
the various options is discussed with emphasis on energy and transportation
requirements. A study of the experiences of the World Bank in regard to cement
policy in developing countries is taken to outline the'mportant issues and
policy instruments.
The principal conclusions of the study are that the technology of
cement production is flexible with regard to different raw material and market
conditions. Freight equalization, price controls and other subsidies are often
used to distort markets in the develbping world, thereby leading to selection
of inappropriate technology for cement plants in a country. By exercising a
free market approach and by concentrating research and development funds on
small-scale cement plants, the developing countries together with international
development agencies and the major suppliers of cement plants can improve the
selection of appropriate technology for their cement plants.
Thesis Supervisor: Dr. Fred Moavenzadeh
Title: Professor of Civil Engineering
-3-
ACKNOWLEDGMENTS
-4-
TABLE OF CONTENTS
PAGE:
6
List of Tables...................................................
8
a..............................
List of Figures. .................
CHAPTER 1.0
INTRODUCTION.....................................................
10
1.1 Objective.................................................
13
13
CHAPTER 2.0
AN OVERVIEW OF CEIENT TECHNOLOGY .................................
20
......
20
20
.
Raw Materials ........................................
Processing of Raw Materials in the Kiln ..................
Portland Cement and other Cement End-Products.............
Environmental Issues.................................
24
26
27
33
2.3
2.4
2.5
2.6
CHAPTER 3.0
STATUS OF TECHNOLOGY AND EQUIPMENT IN LARGE-SCALE PLANTS. ......... 38
.
What is Large Scale? ............... ...
.........................
Crushing.......
and
Quarrying
Raw Material Handling and Storage ........................
Raw Mix Grinding...........................................
Homogenization of the Raw Mix..........................
Clinker Production.........................................
3.6.1 Wet Process.........e...............................
3.6.1.1 Semi-Wet Process ............................
...............
3.6.2 Dry Process.........................
Process............................
3.6.2.1 Semi-Dry
.............
..
..
3.6.2.2 Preheaters................
...............
3.6.2.3 Precalciners.................
38
39
42
43
47
51
51
53
53
54
55
58.
... .......
.. .....
3.8 Clinker Grinding................
3.9 Packing and Dispatching ..............................
3.10 Environmental Control ....................................
64
64
66
3.1
3.2
3.3
3.4
3.5
3.6
..62
......
3.7 Clinker Cooing.............6.
CHAPTER 4.0
STATUS OF TECHNOLOGY AND EQUIPMENT IN SMALL-SCALE PLANTS.......... 106
106
s..*.....*.
........
4.1 What is Small Scale?......
4.2 Survey of Available Technologies.......................... 107
107
....................
4.2.1 Vertical Shaft Kiln................
4.2.1.1 Raw Materials and Fuel Preparation .......... 108
4.2.1.2 Kiln Design Packages........................ 111
--;L.
-5-
Table of Contents
PAGE:
4.2.2
4.2.3
4.2.4
4.2.5
120
122
124
125
CHAPTER 5.0
ISSUES IN THE ECONOMICS OF CEMENT PLANT TECHNOLOGY...............
148
164
............................
190
190
190
192
192
194
194
198
200
201
205
208
....
..... ...... .....
............... 214
253
-6-
List of Tables
Chapter 1
1.1
1.2
1.3
1.4
1.5
Chapter 2
2.1 Oxide composition of normal portland cement.
2.2 Principal compounds of portland cement.
2.3 Representative average compound composition for five types of
portland cement.
Chapter 4
4.1
4.2
4.3
Chapter 5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
-7-
List of Tables
Chapter 7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.16
7.17
7.18
7.19
-8-
List of Figures
Chapter 3
3.1 Quarrying and crushing.
3.2 Jaw crusher.
3.3 Toggle jaw crushers.
3.4 Hammer crushers.
3.5 Preblending systems.
3.6 Raw material grinding in the wet process.
3.7 Raw material grinding in the dry process.
3.8 Wet process raw material grinding using the ball mill.
3.9 Dry process raw material grinding using the ball mill.
3.10 Dry process raw material grinding using the rollier mill.
3.11 Roller mill.
3.12 Reclaiming using the scraper.
3.13 Reclaiming using the bucket wheel.
3.14 Schematic of the quadrant blending system.
3.15 Schematic of the Polysius blending system.
3.16 IBAU central chamber blending silo.
3.17 Peters mixing chamber silo.
3.18 Kiln department (Pyroprocessing).
3.19 Flow sheets for the wet and the dry processes.
3.20 Semi-wet process flowsheet.
3.21 Long dry-process kiln system.
3.22 Lepol kiln.
3.23 Dry process 4 stage preheater kiln.
3.24 Polysius Dopol preheater.
3.25 Buhler-Miag raw mix suspension preheater.
3.26 ZAB suspension preheater.
3.27 Krupp counter current preheater.
3.28 IHI preheater.
3.29 MFC preheater with fluid bed reactor.
3.30 RSP preheater.
3.31 Polysius-Rohrbach precalcining process.
3.32 FLS precalciner with separate raw mix preheater.
3.33 FLS prcalciner for low alkali cement.
3.34 FLS integral kiln with precalcining system.
3.35 Humboldt-Wedag pyroclon precalciner.
3.36 KSV precalciner.
3.37 Types of clinker coolers.
3.38 Clinker grinding and cement shipping.
Chapter 4
4.1
4.2
4.3
4.4
4.5
-9-
List of Figures
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
Chapter 5
5.1
5.2
5.3
1.0 INTRODUCTION
Over
the
last
expenditures,
increasingly
replacing
more
annual
well
50%
over
of
rapidly
in
as
of developing
Fixed
Investment).
traditional
well
With rapidly
growing
infrastructure projects,
developing
countries
having
period
averaged about
1950
8% (annually
amounts
of
causes
capacity are
estimated at
$1.2
or
at
least
some
form of
cementing
material, is an
hence
essential to provide
supply
of
cement
a continuing
the
and
infrastructure
more
for development.
of
cement is
Indeed,
the
supply
materials,
expanding
example,
timber,
range
of
alternative
building
Throughout
the
where
developing
half-completed projects
world
to import cement.
foreign exchange
the necessary
of
the availability
countries
is imported,
cement
In
programs.
be finished
which cannot
are
resources
precious
in
wasted
because there is no
fertilizer
supply;
and
consequently self-sufficiency
in
cement
the
1970s,
and now
for over
accounts
8% of world cement
imports
occurred
in the
OPEC
growing
reflecting their
countries,
oil
role
of
trade in cement and the nations most actively involved in it. Table
breakdown
During
of
cement
1970s.
consumption and
Table
1.3
production
provides
in
selected
3000
reported
operating
and
People's
Republic
in communes
of
China,
very
brigades
accounting
U.S.S.R.
led
small cement
for
plants
were
in clinker
than half
of that
production capacity,
followed
by
France, Brazil, Poland, India, the United Kingdom, the Republic of Korea,
Turkey, Romania and Mexico. For comparison, world
clinker
capacity
in
selected
grow
at
of
cement
at
affordable
prices
in
developing
most countries
have
sought
to
achieve
an
facilities,
countries. These
on
factories
range of products
the
model
produce
satisfying
the
of
those
Portland
comparatively
in the industrialized
cement,
and an associated
Organization
International Standards
a more
highly
developed
industrial
sector
the
tendency
been towards
has
given
developing
of
countries
their
are
to
plants
a choice
smaller
of
the
urban,
cement.
in selecting
This
appropriate
available
choices
are:
which
1.1 Objective
The objectives of this
is to
A
study
technological
as
differences
in
the
to
discuss
process,
production
by
plants
cement.
to
discuss
the
policy
framework
in
presents
an
of
introduction
cement
for
technology.
manufacturing
respectively.
The
in :section
technological
in
Sections
cement
1, Section
and
large
packages
small-scale
offered
by
the
plants
leading
cement
over
plants
and
of
are
discussed
plants,
Section
and
the
economics
!t
market
mechanisms
and
of
and
outlines
the
resource constraints.
of
Case studies
taken and
appropriate
the
issues
cement
three
and
typical underdeveloped
options
producing
that
are available
technologies
under
environments are
for
selecting
discussed in Section 7.
Section 8 outlines
the
conclusions
and
recommendations of the
study.
All tables and
chapters.
figures
appear
at
the
end of
the
respective
Table 1.1
W9o01 TRA
1973
tsa coIE.
1970
IortsCoICLfiO
-----------------
Total World
OPECCounlries
Rest of World
23.5
3.5
20.0
;-
589.5
12.8
576.7
CoImT. 1970-1981
;-- --
1981
1979
1976
COesoe i
43.5
18.4
25.1
74.1
36.2
707.9
178.0
71.3
806.7
73.2
33.3
39.9
857.4
53.0
80.4
66.4
21.5
44.9
4.02
27.3Z
3.52
6.72
35.52
3.82
8.32
66.71
4.91
7.72
40.61
5.60
5.82
50.82
3.51
TRAM II 1981
aorts
Esparts
16.34
13.22
9.05
7.82
4.60
4.06
4.08
3.83
3.80
3.35
2.87
2.63
2.30
2.11
2.04
1.30
1.04
0.99
0.96
0.89
0.88
Hloe Kong
Kuwait
Netherlande
India
Bahrain
Siagapore
Germany, Fad. Rep.
Libya
Syria
Veaesueal
Algeria
Nalaysia
Ivory Coast
Tunisia
Yemg
agladeash
Sub-total
56,798
77.59
64,942
88.24
Total World
73,200
100.00
73,600
100.00
gipt
17.08
8.20
6.83
4.91
4.78
4.64
4.37
4.08
2.73
2.73
2.66
2.42
1.78
1.664
1.59
1.37
1.31
1.27
1.14
1.09
1.0
12,026
9,731
6,663
5,757
3.389
3,000
3,000
2.822
2,800
2,465
2,110
1,938
1,691
1.50
1,500
1,000
767
730
707
652
66
12,500
6,000
5,000
3,595
3,500
3,397
3,200
2,90
2,000
2,000
1,930
1,770
1,300
1,200
1,163
1,000
956
930
837
800
756
Saudi Arabia
Iraq
ligeria
U.S.A.
Lo
-*enesoes
726.0
20.3
705.7
34.3
7.2
27.1
Spain
Japan
Gresee
Korea, Rep. of
Turkey
USSR
Bahrain.
freame
alus ia
Canada
Germany, Fed. Rep.
Belgim
Taiwan
Kuwait
Korea, P.D.l. of
Chiea
Yugealavia
Lebmeas
Luembourg
Keyas
Colombia
Table 1.2
World Production. Consumption and International Trade in Cement
(Figures in million metric tons unless othervise specified)
Production
1.
Iports
L71
79
197
191
Exports
19197.9
Apparent
Consumption
Apparent
Per Capita
Consumption
(In Tons)
1981. 1979 1981
Developed Countries
328.4
311.0
15.4
9.9
28.1
23.1
317.6
298.5
.467
.436
Western Europe
North America
154.2
81.5
144.5
75.2
6.6
8.8
6.1
3.8
13.2
4.2
10.3
2.7
146.4
83.5
140.4
74.7
.485
.342
.474
.294
87.2
81.4
10.6
9.7
81.8
77.9
.705
.659
0.1
0.4
5.9
5.5
.326
.314
11.0
7.8
181.4
181.7
.476
.472
29.3
38.0
304.3
353.0
.095
.100
1.0
0.1
0.02
0.5
18.9
2.0
0.1
0.02
0.7
26.2
14.3
6.1
15.4
10.0
68.9
15.4
8.1
18.1
10.2
65.2
.045
.215
.170
.366
.472
.042
.269
.201
.352
.441
Japan
Oceania
3.9 . 6.9
0.01 0.03
Centrally Planned
Countries /a
187.9
187.6
Developing Countries
307.9
360.1
31.9
10.3
6.2
12.4
6.2
86.5
10.5
8.1
13.5
7.2
90.1
9.2
3.2
4.6
1.4
72.2
47.0
79.7
82.0
9.2
0.4
12.0
0.2
3.8
1.1
9.2
1.0
75.8
46.5
79.4
81.1
.062
.049
.054
.080
67.1
76.0
2.9
3.4
3.9
2.2
67.3
76.3
.195
.206
20.4
24.2
13.1
25.5
0.3
4.7
31.3
44.8
.523
.666
844.7
882.9
63.7
73.2
67.8
73.6
834.5
878.0
Sub-Saharan Africa
(excluding South
Africa)
South Africa
North Africa
Middle East
Southern Europe
Asia (excluding
China)
China
Latin America and
Caribbean
Capital Surplus
Oil Exporting
Countries /b
Total World /
3.31
1.62
36.2
9.5
0.03
5.6
4.4
1.3
.192 .190
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a)
the
historical development
commonly used
in
its
describes
effects of
producing
cement.
essentially
naturally
of
alumina.
compounds
Cement
is mainly
made
is why it is also
called hydraulic
cement)
most
from
widely
used
construction
that
in manufacturing
the growth of Portland cement production over the past century and a half.
Initially, in the manufacture of natural and
were
materials
and burned.
placed
Portland
cements,
dry
raw
Disadvantages
of
this
intermittent
invention of
a continuous
introduction of
rotary kiln in
Germany.
In
turn,
the
the
operation at much
in
both
capital
scale of vertical
shaft
kilns has
remained,
in typical situations, to
about 200 tons per day or 60,000 tons per year capacity, major advances in
rotary kiln technology have occurred in the past thirty years. Rotary kiln
technology increased from a limit of 300 tons per day (about 95,000
tons
per year) in the early 1950s to 4500 tons per day (about 1.4 million tons
per year) in the early 1970s. Even more recently, precalcining technology,
developed
in
Japan,
has
opened
the
possibility
of
greatly improved
2-2.5
times
as much
output from the same sized kiln. Kilns as large as 8,000 tons per day (2.5
million tons per year) are in operation.
Accompanying these advances, a shift began from wet process to dry
process rotary kilns, which accelerated in the 1970s in response to rising
energy
costs
costs can be as much as halved by the dry process, although even with this
process, energy custs in efficient
about 40%
investment).
of
the
But
full
the
cost
dry
of
process
new
production
offers
the
(including
returns
on
additional advantage of
reduced volume of exit gases to be cleaned for dust control, thus lowering
the cost of
investments
to
meet
prior to the energy crisis the wet process was still favored for many
plants
because
new
energy
consumption
in
existing
plants
the
by adding
(coal,
for
or
preheaters
to
less
expensive
example,
cement produced was reduced by almost 10% between 1972 and 1980.
believed
to
be
due
This
is
preheaters
of
and
of
in
1972
the
total
to
and
76%;
from 41%
enough, very little progress has yet been made in the United States in the
increased use of additives.
Outside the
United
States, world
cement
industry patterns of
response to higher energy costs seem to have been different. In some cases
the response has been much quicker than the United States,
has
in others
it
barely got underway. Europe and Japan for instance, have consistently
been at the
forefront
of
technical
innovation
for energy.
Energy
by
much greater
energy
and
conversions,
additives, process
been adopted much earlier there than in the United States. In France,
for
example,
the
United
refuse and waste tires, together with coal, as substitutes for higher-cost
forms of energy (gas and fuel oil).
In most
other
steps
aggressively
in others.
Meanwhile,
more
advanced countries.
more
rapidly as in the
the
the
been
has
conversion (very
old
structurally
either
plants,
vertical
kilns)
other
countries,
in need of it
(facilities are, for instance, relatively new, energy is still cheap). The
prolonged world recession has been
sometimes
countries. Necessary
in some
decisions
responsible
during
deferred
the
1970s,
of
for
delayed
investment
structural adjustments
particularly
to
permit
were
in the developing
increases
in the
international prices.
Paralleling the technological advances in cement production, there
have been some cost
saving
innovations
more
important
since
now
easier to ship and store than cement. Moreover, most of the energy cost of
cement manufacture is accounted for
at
grinding
only.
By
the
end
clinker,
in operation
by
switching
to
earlier.
Innovations in shipping and distribution facilities have also been
important in special market
cement
has
now
situations.
scale
bulk
shipping
of
terminals
Large
have made
have
bagging
international
previously it would
have
been
been
built
plants. Likewise
trade
in bulk
in bags,
thereby
floating bagging
cement
feasible where
effects which increased energy prices would otherwise have had on freight
costs.
combination
compounds
which
are
required
(Si02);
sulphur,
in
the
and
alkalies.
The
four
Oxide (Fe203).
A normal raw mix will contain
carbonate
and
12.5
approximately 80
percent
calcium
necessary
of
cement are not pure compounds. Limestone, while being made up primarily of
calcium carbonate,
a quarry, and
high lime
The
impurity will
often
change
rock, depending
on
percentage
the
of
calcium carbonate it
the
oyster
cases,
shells found
contain large
percentages
of
which
have
percentages
high
of
alumina
and
iron
oxide
if the
other
of
the
same
raw mix
design
and 30 percent clay, and another may have 95 percent chalk and 4.5 percent
silica and 0.5 percent iron oxide, in order to arrive at the same chemical
composition in the resulting raw mix. In other words, the
the
different
proportions
of
chemical composition
of
these
same
constituents.
The proportioning or
blending of the raw materials is one of the major steps in the manufacture
of cement. Frequent quality control checks of the raw mix are necessary so
that corrections can be made in the raw materials to maintain a consistent
mix.
Unlike large plants which need large quantities
i.e.,
quality,
assured
other
limestone
occurrence
of
comparatively
for small
lower
the
plants,
limestone
and
being
requirements
The
raw materials.
separate
and
extensive
of
mines
mines
will depend
upon the
mode
of
terrains.
plain
The method
of
mining
of
will also depend on the nature of the deposit and the capacity
limestone
of the plant.
is the
most
important operation in
strength
and
clinker produced.
by kiln
output,
and
other
The kiln
is both
a heat exchanger
industry:
and a chemical
vertical
or
shaft
kilns (accounting for only about 5% of world production) and rotary kilns.
Vertical
rotary
kilns
are
cost
efficient
at capacities well
steel
and
200
consist
of
a vertical
cylinder with solid fuel and raw materials fed into the
combustion
and
air
fed into
the
processes,
whereas
vertical kilns are limited to dry process only. Blended dry mix or slurry
enters the upper, or feed end
of
the
slope and rotation to the firing, or discharge end of the kiln. In the wet
process, exit gas temperature is about
slurry
is evaporated
2500C
and
the moisture
in the
one-fourth
the
length of
organic
compounds
flux in the raw mix lowers the temperature required to form clinker.
is produced
by
sulfate
forms
the normal Portland cement appears in Table 2.1. These oxides join to form
compounds. For practical purposes,
composed of
silicate,
four
principal
tricalcium
compounds:
aluminate,
their
Portland
and
tricalcium
silicate,
dicalcium
four compounds
jointly
compose
Portland
dicalcium
silicate
desirable
result in an undesirable
tricalcium aluminate
mentioned above, hydrates rapidly. The implication being that cement paste
sets too quickly for satisfactory molding to be
flash
possible.
To
prevent
weight of cement),
as
gypsum
reacts
of
tricalcium
resistance
of
paste
cement
to
sulfates.
the
faster
rate
liberated. It follows
of
that
Hydration,
exothermic
hydration,
the
the chemical
or
reaction. As
higher the
a general
amount of heat
tricalcium
five
pavements
and
uses
include
masonry units.
attack
is important
and
fur
hydration are
of
concern.
Compared to
lesser amounts
of
tricalcium aluminate
silicate
of
tricalcium
aluminate
and
for
this
reason
has
a greater
2 cement) and
as
is intended for
and
concrete
specifications
Type
cements
include
for
the
three
2A, and
same
uses
as
Types
1, 2, and
3.
they
contain small
are
amounts of air-entraining
air-entrained
and
become
entrained
of
in the
30
The high cost of energy in the production of clinker has also led
the industry
to
production.
Thus
search
for
artificial
suitable additives
waste
have
"stretch"
clinker
additives
to
ashes with
hydraulic
of
additives
only
transportation
new
by
increasing
production
cement
considerations
infrastructure,
of
capacity,
which
raw material
location
and
until
sources,
concentration
ash
then was
access to
of
cement
cement may
and
an intimate and uniform blend of Portland cement and fine granulated blast
furnace slag in which the amount of the slag constituent
and
65%
of
the
total
is between
25Z
-,
b) Portland-Pozzolana
This
Cement:
or
is a uniform blend
Portland-blast
construction, and
Type
by
produced
in
general
The
constituents
in this type of
cement are the same as those for Portland-pozzolan cement, and the methods
of production are the same, however, the amount of pozzolan constituent is
less than 15% of the total weight
of
the blended
cement.
Type
1(PM)
and
uniform
blend
of
constituent
cement
granulated
blast
is for
use
in
combination with
Specialty Cements:
developed
to
seal
fluid
up
to
These cements
must
to
nearly
zero
and
acids,
early
hardening
normally
occur
during
the
hardening
process.
c) Regulated-Set
to
thirty minutes
concrete
and
pipe,
paving
patching,
underwater
patching,
d) Aluminous
Cement:
Sometimes
aluminate
known as
is hydraulic
calcium aluminate
non-Portland cement
same
from
and
magnesia
refractory
cements
are
containing
produced
cement or
to
sulfate
kilns.
e) White Cement:
This
is made
from
silica. Clinker
is
with
burned
the
balls
and liners in grinding mills; recently high-chromium alloys have been used
for
liners
and
and
for
use
in
mortars
for
containing
construction
cement
usually with hydrated lime, limestone, chalk, calcerous shale, talc, slag,
or clay interground for plasticity.
The
grinding
kiln operations
and
emitting oxides
of
ketones.
from
several
clinker
sulfur
cooling
and
also
nitrogen,
cause
dust,
hydrocarbons,
in addition to
aldehydes
and
also cause dust to be generated. The major source of dust in cement plants
is from the kiln.
Water pollution results from water coming in contact with the kiln
dusts. The most significant source of water pollution is from the leaching
operation which is used for
removing
the insoluble portions for reuse as raw materials. Another source of water
34.
of dust
in
the
form
of
slurry. The wet scrubbers used to collect kiln dust from effluent gases is
also a cause of water pollution.
The
supplies of
taken, rainfall runoff can discharge from these piles and carry pollutants
into adjacent waters.
Table 2.1
OXIDE COMPOSITION OF NORMAL PORTLAND CEMENT (TYPE i)
Oxide
Range, Percent
Lime, CaO
60-66
Silica, S10
2
19-25
Alumnina, Al20
3
3- 8
Iron, Fe203
1- 5
Magnesia, MgO
0- 5
1- 3
Source: Reference 17
Table 2.2
Name
Chemical
Composition
Tricalcium silicate
3Ca0- Si0 2
C3S
Dicalcium silicate
2Ca0*Si02
C2S
Tricalcium aluminate
3Ca0*Al 203
C3A
Tetracalcium al umlnoferrite
Source: Reference 17
Abbreviation
C4AF
Table 2.3
Type of
Cement
III
General Description
General purpose
49
46
56
Low heat
Sulfate resistant
Source: Reference 17
38
3.0 STATUS OF TECHNOLOGY AND EQUIPMENT IN LARGE-SCALE PLANTS
This
chapter
of
process.
of cement machinery
for
the
cement
industry:
Chalmers
of
the
U.S.A.,
Fives
Caile
Babcock
of
France
and
and
range
anywhere
from
(about 95,000 tons per year) to as large as 4,500 tons per day (about 1.4
million
tons per year). Kilns as large as 8,000 tons per day (2.5 million
operation and
up
to
million tons per year) are contemplated. The normal size of a large cement
plant being built around the world is around 3000 tons per day
(about
million tons per year). The large cement plants employ the rotary kiln for
both efficiency and economy.
The
(a) straight rotary kiln; (b) rotary kiln with enlarged burning zone; (c)
rotary kiln with enlarged calcining zone; (d) rotary
burning
and
calcining,
calcining
and
burning
zone;
zone
drying,
enlarged drying or preheating zone (long dry process or wet process kiln).
The aim
of
the
zone
enlargement
is the
extension
of the material's
of
the
cement
industry
in
both
equipment
the
used
in various
of which
marbles.
Much
of
the
deposits.
The
for
removing
and
Size reduction
grinding mills. The equipment which breaks up the rock containing the
materials
into
small
pieces,
small
raw
grinding machine, has remained basically the same for many years. Normally
primary and secondary crushers
are
used,
size
kind
impact
and
(c) roll
crushers.
Crushers
for
size
double impeller type) and (b) impact crushers. The selection of the proper
feed openings of gyratory and jaw crushers
crusher
feed
is performed between two crusher jaws; one of them is stationary, and the
other is moved by
toggle
pressure.
Various
design feature have been developed; of these two remain the most
namely
the
cone performs a gyratory motion about a vertical shaft , the lower end
which
is positioned
of
two types: (a) Gates crushers and (b) Symons crushers. The cement industry
employs Gates (Gyratory) crushers mainly
the jaw crusher, the Gates crusher, with the same sizes
of
feed
opening
and discharge slot, has two or three times higher capacity. The Symons (or
cone) crushers are mainly used for secondary crushing.
Cone
crushers
rolls
from each
other. Depending on the kind of crusher feed, the surface of the crushing
rolls can be smooth, ribbed or
toothed.
Subject
the
of
axis
the
rolls.
Hammer
crushers
hard
to
mills work
with
reduction
ratios
1:40;
hammer crushers
of
crushers
are manufactured:
two
types
of
cleavage
low. Crushing by impact is, thus, applicable only for brittle rocks, since
plastic material does not shatter when impacted.
Size
reduction
by
the
impact crusher ensues in three stages: (a) main size reduction carried out
by
striking
(b) impact of the feed against the breaker blades; and (c) by crashing the
material chunks
against
one
another.
size
impact
crusher manufactured
crusher;
by F.L.
and
(c) the
Smidth,
(b) the
Copenhagen, Denmark,
and called
by many
consistency of
is large
and
is
the
raw materials.
In most
cases,
there
is not one
blended
together.
There
are
components
separately
in storage
and
feed
these
to the
by adjusting
the feeders before the grinding by sampling the ground material. This type
of
system
generally
the
various
materials
in
a stockpile
prior
to
the
done
grinding
after
the
grinding.
Preblending systems can range from the two limiting configurations
shown
in
so
that
the
resulting pile is that of the raw mix. The pile is reclaimed and
the
raw mill
in
sent
to
opposing
various
mix component materials are fed from bins directly and simultaneously
The
correct
to
the
the
raw
materials
is to produce a fine
particle-sized material to feed the kiln that will allow proper burning or
clinkerization to take place. The choice of the size reduction or grinding
equipment
and
the
characteristics
process
is
governed
primarily
by
the wet process is generally used and during the grinding water
to
produce
physical
the
is
added
pumpable
is added,
kiln
various
raw
materials
cement,
are
in
all
differential
the
entire
raw
result
necessary to grind
hardest
will
of
the
raw
mix
size
to
for
a
the
point
burning
process.
This
to
grind
the
larger
sizes,
which are
are
cement
basic types: (a)Wet overflow rod mill; (b)wet overflow ball mill;
(c)
wet or dry diaphragm ball mill; (d) airswept mill; (e) double rotator ball
mill; (f) roller mill; and (g) autogenous mill.
The
most
either
feed rate
to
the mill and the material is kept in the mill for a long enough time to be
ground
to the proper fineness. The closed circuit system (Figure 3.8) can
be of several designs
but
essentially
the
mill.
Most
raw
used for
drying
before the mill; (b) combining drying and grinding within the
(c) drying
within the
air
separator.
mill;
and
necessarily
limited
rotary dryer; (b) crusher dryer; (c) flash dryer; and (d) fluid bed dryer.
The equipment for drying and grinding simultaneously within the mill,
generally
be
classed
as
can
3.9),
whether
with
a drying
a single or multicompartment
compartment
to
provide
greater
degree
of
drying
in
the
mill.
In
air
of
this
particular
type of
drawn
mill
mechanical
by
means. In the air-swept mill, the raw material enters with the air through
the
feed
complete
trunnion
material
required,
which
is predried
and
transport
makes
is pneumatic,
possible
the
use
large
of
low
amounts
of
quantities
air are
of
low
both
the
temperature gases.
The
airswept
double
mill
similar to the
rotator
and
the
incorporates
diaphragm
airswept
mill,
mill.
which
the
advantages
of
allows
drying
of
a high initial
moisture content. The raw material is fed, together with hot gas, into the
drying section of the mill. After the material is dried,
through
the
division
it
is
conveyed
exits
of
the
mill into the fine grinding section. A further advantage of the separation
between
ball charge.
Since roller mills are air-swept
and
the
and
grinding
mill
by
an
airlock
type
is
fed
into
(shown in Figure
3.11)
and
is thrown
Ground
outward
material moves
outward
from the
path,
high velocity air passing up through louvers or ports around the periphery
of the table. The classifier at
the
oversize particles from the carrier air. The oversize particles fall
onto
the
grinding
separate out
a dust
remainder
of
the
back
on
material
to
from
collector
the
air.
which separates
the
In Europe, electrostatic
precipitators are used exclusively for roller mill dust collection whereas
glass fabric filters are commonly used
European roller mill systems utilize
in
a precipitator
for both
material
separation and dust collection and are not equipped with cyclones.
As
compared
grinding
than
ball
mills.
However,
accept
somewhat
larger
feed
working
surfaces.
Secondly, a roller
mill
abrasion
exit
gases
sulfur,
and
chlorides
in the
mill,
roller
double
Polysius
(Loesche-mill,
mix
raw
cement
the
past,
fluctuations
plants.
With
increasing
of
in
raw
materials
production
were
capacity
of
processed
the
in
cement
plants,
cement
to
the
of
components
main
sand
and
iron
ore
are
of
the
can
raw
be
divided
material
components
and
(b) segregated
prehomogenization
chemical
composition.
stacking
the
requires
components
balanced
of
stockpile.
Irregular
particle
size
composition
of
the
raw
materials
the most widely used method of preblending in the cement industry. The
particular prehomogenized
components,
after
proportioning
come from the feed bins and weigh feeders, are fed into the
them as they
raw
grinding
mill.
The chemical analysis of the raw mix leaving the mill, supplies the
measures
should
employed:
(a) roof-type
stockpiling
is the
beds
of blending
and
(f) alternate
most widely
employed
stockpiling. Roof
blending bed.
type
To avoid the
selected.
performed
by
Chevron and
Windrow
methods.
The
following
equipment
is usually
blended raw
materials
from
stockpiles
the
used
(a) reclaiming
stockpiles:
then
feed
simultaneously
convey
mounted
bridge
The
bins.
from
the
end,
front
or by
and
along
bed
blending
bucket
wheel
designed
is
to
the
past
production of high
wet
the
quality
process was
cement
the
preferred method
for
Now
pneumatics
has
enabled the cement industry to pneumatically homogenize the dry cement raw
mix.
The
Airmerge
various
system;
raw
(b)
mix
homogenization
Polysius
Homogenization
system;
(c) Moller
Central
system
Chamber Blending
and
Fuller Airmerge
system
supply
volume of the bleuding air directed into the blending quadrant is 75%, and
the air directed into the the three aeration quadrants is 25% of the total
air. Thus an extremely well aerated light density column
of
material
is
created above the blending quadrant. The denser material over the aeration
quadrants
cement
and at
advantageous to supply
air
air
supply
a predetermined length
time,
a nearly
Pulsated
the
raw mix
pulsated
produces
quality
rather than
continuous
blending
air.
air.
3.15
is divided
into
nine
the
system
has
three
processes:
process which is used when there are large input variations in the calcium
carbonate content of the raw mix; (b) an homogenizer with upper
silos
is used
when
the
floor
(c) a throughput
homogenizer
. 50
for
silo
is simultaneously
blending the raw mix simultaneously during silo feeding and discharge,
only
when
material
the
material
entering
the
is discharged
mixing chamber
from
the
or
is subjected
to an intensive,
silos.
The
particular
as
one
discharge, at a
silo wall, irrespective of the silo diameter. Material withdrawal from the
expansion prechamber is also possible. The Peters
homogenizing
silo
reduces high
material composition.
and
continuously
operating
in the raw
Clinker
important
piece
of
a steel tube lined with refractory bricks, an insulation layer between the
front and back housings, a supporting structure and a
and lining,
shell
and a diameter
from
7.5
2 to
of
meters.
The
proportioned and
ground,
homogenized raw materials enter the kiln at its upper feed end, the firing
system is installed at the lower or discharge end. In the rotary kiln, as
lower end, it is exposed to increasing
fusion at
and
calcined,
dried,
about
the
finally
a temperature
2900F,
kiln, the
raw materials
are
is one
of
the
proper
burning
conditions
processes:
(a)wet
process;
feed
the
slurry encounters
shell.
causes these chains to immerse in the slurry and then to receive heat from
the hot combustion gases generated in the burning zone.
transfer
the
heat
The
chains
thus
and
evaporates,
the material
gradually
is converted
to
plastic nodules, which the chains convey further. Slightly beyond the feed
end
chain
system,
and
raises the temperature and drives off combined water in the raw materials.
The calcining zone decarbonates the calcium and magnesium carbonates,
the
burning
and
The fresh clinker then travels through the cooling zone of the rotary kiln
and drops into a clinker cooler. A substantial portion of the heated air
burning
clinker
is eventually
removed
from
the
zone, while
the
reintroduced
into
it may
be
added
of
the
kiln
(a) the
long
wet
process
rotary
kiln with
internal
heat
exchangers
wet process
rotary
kiln without
internal heat
for partial
exchangers, working in
of
drying
the
calcinators);
long
process
wet
filters;
and
(d) the short wet process rotary kiln without internal installations with
mechanical preliminary dewatering of the slurry (the resulting filter cake
is then processed into
nodules
which
are
fed
fuel consumption
implied.
The
raw
materials are washed in water to form a slurry, but then filtered to expel
the
majority
of
content of 18-20%.
the
The
water
cake
content.
is converted
into
exposed to hot kiln gases in some kind of preheater. This removes some
of
the remaining water content before the nodules are fed into the kiln. This
process
theoretically
results
been widely adopted since the procedure for filtering the slurry to form a
cake entails the use of
of
the
water
are either first dried and then ground, or drying and grinding are carried
out simultaneously in a drying circuit mill. Individual components are fed
into the mill by means of
weigh feeders.
homogenized and
fed
into
led
to
the
adoption of
long
suppression systems
kiln, the chain system retains the heat of the hot kiln gases used to
dry
the raw mix. For a dry process the following rotary kiln burning processes
are
applied:
(a) the
long
dry
process
rotary
process
dry
process
refractory
bridges;
(c) the
short
dry
boiler.
raw materials
are
wetted
to
a moisture
content of 12-14% to form a "cake". This cake is then made into pellets or
modules
which are fed onto a travelling grate through which the hot gases
In
this
way
to
half, giving, with the grate, an overall length of about 70% of the
of
the
granules,
the
dust
load
of
the exit gases is very low. Also, the low temperature as well as
vapor make
the
electrostatic precipitation. Figure 3.22 shows a Lepol kiln (as such kilns
are normally called) with a single gas
circuit. When
this
gases penetrate
the
circuit
and
with a double
gas
of
nodules
downward
from where
they are
withdrawn by suction and led to the dust collector. Fresh air is supplied
through
the
inlet
damper
to
the
drying
compartment,
heat losses and in higher exit gas volume. The double gas
improvement
to prevent the
circuit
is an
advantage
is its
The
Lepol
such as
limestone
3.6.2.2 Preheaters
The
revolutionary
innovation
in
the
dry
process
was
the
rotary kiln
for
processing
dry
blended dry meal passes through a special piece of equipment called the
suspension preheater. This is a tall structure in which
number
are
arranged
of cyclones in vertical series. The gases from the kiln are passed
raw
away
by
the
exit
gases.
the
reduce
dust
to
system,
it encounters
progressively
conducted
the
lowest
part
of
the
last
stage and
enters
the kiln
is at
preheaters are
predominantly
the
economy as well as
wet
often added
are
to
the
dry
kiln capacity.
Because
of
cyclone
Two-stage
existing
to
process,
differ
conditions
(Figure
exhaust
volume
manufacturers
fundamental
that
same
fact
with
achieve
to
was
changes
in the
application of several
(b) Bahler-Miag
a high
raw
degree
separation.
large kiln
very
design
of
of
the
system
for
the
capacities, without
and without
the
current
57
shaft as a fourth stage, with counter current heat exchange. Designing the
fourth stage as a conical
operating
large cross-section of
of
chlorides,
is a considerable
results
advantage
possibility
shaft
preheater
caking
alkalies,
the
sulfates.
In the
ATEINSA
in reducing the
helps
of
large concentration
having
by raw mixes
and
stage
countercurrent
United States,
the Allis
of
shaft stages as well as two cyclone stages located on the top. This
preheater is characterized by
its
high
raw mix.
especially
part
in the
lower
operating
The widely
safety in relation to
spaced
shaft
stages,
counter-current
suspension
preheater
is constructed
stage
most
compartments.
upper
raw mix
the
shaft
into
four
compartment and the cyclone stage. From here the raw mix is carried upward
by the gas stream,
preheated,
separated
the upper most preheater compartment. From here the raw mix descends
from
3.6.2.3 Precalciners
One of the problems with the rotary kiln, both wet and dry, is the
flushing
effect
carbon dioxide on an inclined rotating surface. Some smaller wet kilns and
kilns using the semi-dry
process and
plastic
formation of nodules which eliminate this problem, but in large wet kilns
with
a serious
problem
causing unsteady
operation.
The
precalcinator, by
removing the carbon dioxide outside the rotary kiln, completely eliminates
this problem and is the basis for a much steadier operation.
The industrial development of precalcining occured
West
Germany
in Japan and
during
for
very
large
reduces
life,
alkali
and
sulfate
systems
mix
have
one
entering
common basis:
the
the
degree
of
vessel
which is part of the suspension preheater. Since the rate of heat transfer
is vastly superior in the precalciner than in the rotary kiln, the volume
of the precalciner is very small
in
700C
to
the
precalciner vessel.
raw mix
The
is fed
at
major differences
between configurations is the gas flow and the location of burners and the
geometry of ducts and vessels.
countries
In
the
production
alkali
levels
where
of
necessary, a reduction
low alkali
of
be
must
clinker is
effected. As with
conventional
exit gases. An
bypass
alkali
efficient
volatilization with a low recirculation dust load, i.e., the waste dust is
to have as high a concentration of alkali as possible.
The
bypass
in a
precalciner
Ishikawajima-Harima
main characteristic
of
is that
3.28)
(Figure
process
this
the
SF-suspension
(IHI)
Industries
Heavy
raw mix
the
preheater,
is only
slightly
calcined (about
calcination,
the SF process by
kiln
for
and
which
the
heat
accomplished by suspending the raw mix particles in the kiln gases before
they
enter
the
before
of
the
kiln.
Fuller
Company,
parts
of
increases
the
volume
world.
crisis, Fuller developed a coal dust firing system for the application
of
MFC
60
in
conjunction with
a fluid bed
calciner. The calcining of the raw mix with this process is performed in a
separately
heated
fluid
bed
reactor
located
between
the
suspension
RSP
preheater
is a modification of
Heavy
Industries
Ltd,
the Onoda
both of
Japan.
is calcined
Company
It consists
and
of
Cement
The
suspended
raw
Company manufactures
3.31.
This
gases and air through the rotary kiln's cylinder. It is capable of working
in conjunction with any clinker cooler.
(e) F.L. Smidth (FLS) Precalcining with separate raw mix preheater lines:
This
is shown
air duct which conveys hot combustion air from the grate clinker cooler to
a separate precalciner. The process
control
removal
of
chlorine,
alkalies,
of
90-95Z.
case
the
precalcining
process
This
preheater.
four-stage
the
line
independently of the exit gases from the rotary kiln. The kiln exit
works
is shown in
3.34.
In this process, the kiln exit gases come together with the
of
exit
initiating
gas and
the
exit
gases,
the calcining
place.
preheater,
The
enters
temperature
of
the exit
raw
precalcination,
the precalcining
kiln through
the
1545F. The kiln gases pass the kiln feeding zone, where
takes
Before
mix
this
precalcined
a specially
raw mix
from
designed
pipe. This
blending with
the
of
the
two
raw mix
lines
is very
important.
(h) the Humboldt-Wedag Pyroclon precalciner: This is shown in Figure 3.35.
There
are
two
types
of
precalciners
under
this
name:
Pyroclon "R"
(regular) and Pyroclon "S" (special). The choice between the two types
of
lower
the
in conjunction
rotary kiln
2-2.5
times as
compared
to the
conventional suspension
preheater.
burning
process.
difficult
to
convey
clinker
in
the pyroprocessing
or
is necessary
cooling
and
of
part
because hot
clinker
is
of
clinker coolers: (a) rotary coolers (the cooling drum is located under the
rotary kiln); (b) satellite coolers (the cooling drums are attached to the
circumference of the rotary kiln's discharge end; (c) grate
coolers;
and
rotary
cooler
consists of a revolving
is the
cylinder
type
oldest
into which
of
kiln are emptied. The negative pressure in the rotary kiln induces suction
of cold air through the open end of the rotary cooler and the cooling
passes
the
rotary
air
The satellite cooler consists of several, mostly ten or eleven sheet metal
cylinders arranged wreath-like along
the
circumference
The
satellite
coolers
revolve with the rotary kiln. Openings in the kiln shell allow the clinker
to
enter
the
satellite
combustion
in
rotary kiln, however there are satellite coolers which are capable of
the
conveying
clinker
in
The F.L.
direction.
opposite
the
Smidth
of
grate
clinker
the
generally known as
with air
cooler
was designed
Fuller cooler,
of
effect
detrimental
Compared to
magnesia.
recrystallization of the
expansion which
cement
the
eliminate
is caused
by the
initial
cooling
was
designed
grate cooler
Since
developed for use with rotary kilns equipped with grate preheaters.
a fluidized
bed
creates
the
combine
for
the
cooling
in
the
shaft
all
firms
producing
cement
coolers
machinery
Company, the
Krupp
grate
cooler,
cooler
now manufacture
and
the
cooler
of
the
fineness,
hydration
can
i.e.,
take
to
place
obtain
and
clinker
a specific
concrete
grinding
size
surface so that
is added
to
produce
(b) closed-circuit
grinding;
oversize
returned
to
the
mill
grinding than
in open-circuit grinding.
The
most
commonly
applied
two-compartment mill and an air classifier. The mill and the air-separator
are considered to be an
integrated
end
product)
inlet. A mill
for
a fine
grinding
then
fraction
are stored; the larger sized materials are returned for further
grinding.
dispatch
in 50
kg
sacks is the
transport.
sacks
varies
by
(Spain, Greece,
in others
50Z
in
dispatched
cement
while
Italy),
developing and
in
sacks.
Depending
on
types
sack filling capacity, the machines employed are either of the in-line or
filling
systems.
The
cement
manufacturers
attain an average
(except FLS)
filling
sack
the
about
acceptance
1400
as
sacks
a modern
form of
high
include
of
rate
and
by all
the
FLS
Fluxomatic
rotary
packer.
The
the
in-line
and
Impeller
machines.
Leading
suitable
for
various
types
equipment depends mainly on whether the vehicles are of the covered or the
open type and whether they are loaded from the side, the rear or from the
top. Well
known manufacturers
of
automatic
loaders
available
from
Beumer
and
Boubiela.
system has
Beumer also
vehicles
supplies
advantageous when
dryers;
kilns;
(f) clinker
from
dust; (g) raw gypsum dust; and (h) cement dust. Dust
of
a non-negligible
loss of material.
For
the
control
and
to
gravity settling chambers, further fabric type dust collectors, gravel bed
filters, and finally electrostatic precipitators. When properly designed,
fabric
fiberglass
electrostatic precipitators
and maintained,
operated
installed,
will
preceded by multicyclones
filters
or
adequately
separators
is achieved by centrifugal
air
or
in
locks
to
order
be
treated
prevent infiltration of
tangentially
enter
part
cyclone
tangential entry of the air or gases into the cyclone causes dust
by
thrown out
to
the
discharge
remove
dust
to
be
centrifugal
cyclone
the
at
or with
induced
draught. A large
a positively
charged
consist
collecting
of a negatively charged
plate.
The
dust
particles
electrostatic
dust
precipitators
(or
bag)
filters
crushing
are
operations
and
shovel
dag line
.,
,.,,.
bell conveyor
Lafarge Consultants
Source: Reference 9
Figure
3. 3 Toggle
Jaw Crushers
Source: Reference 9
mi
-U-,.
Sampling
Feed Forward
Raw Materials
INTEGRAL BATOC
IDw Power
Hat
Pyroprocess
PREBLENDING SYSTEM
-~as
r--
TO-
_m~
Raw Milling
Preblending
Pile
~
0-0
Now
Qr):]
C
-----
Saterials
Raw Materials
Raw Milling
Sanpling
Feed Back
High Power
Haro
Pyroprocess
STORAGE HALL
I
water
kin
food
(open circut)
1\
J'qi r s
IIm'k4 Imd
(DSM4-Swm)
-4
-Il
MA
SLURRY
SASI8
RECIRCULATING
Drying
eal Req'd
k, cal I O
Raw Malterl l
-o
Figure 3.9
(ASES
GI
Illeue III
.ijmJim,H
I 6
I'
I
i
~(
'
f
,r
I
~ I
/
I,
'r
'I
I
:.
I
I
Buhler-Miag
Figure 3.13
Source: Reference 9
Figure 3.14
Source: Reference 9
Figure 3.15
Source: Reference 9
82
;SOR
so
Figure 3.16
Source: Reference 9
Figure 3.17
Source: Reference 9
0c
we 514
-Intermediatetake off
for raw and I or ooal drying
-Air rectrculation n cooler
F gur e
Source:
Latarge Consultants
kD
9F
Du4I
m Lowx
cw
Flows
Food
KILN
FEED
PRIPARAnL
OlN
NYWE"
PROCESS
Ovh
DU
tw-1ac
Flev
SOC-r----
PeArwVCkemet
Cws
cO
Lii
FROSHGQ"*#G
Figure 3.19
Wet and dry processes
Source: Reference 16
I..... If
---"
-)- 6101664
I' Iss.e
<
, ,
J
'...
"'"
.. .T
I
I .
14111
6C,
6611011111
jil
.I
118
QUARR
AO CRUSIIIG
SLURY PRIPARAIO
SLURRY PRIPAIAAIIOH
..,/"____
,"
-----L-. -
..
] ....
a,-maaae~
a6ele1ai
CLINKIR SIORACI
IIIISiH GRIIIOIIIG
CItIIll STIORAI
PACKIHG
BULK LOADING
_-crAnUARY
AIR
"
'
AND FUEL
%W*w
H
(ER
Exit gas
vying
Rw mix
feeding
I
I
eying
as paouoge
,,
I--.. .. .
first gOapaosge
. . .
KILN RAW
-%
do
WASTE AEAT
CLINKER
DRY PROCESS
4-STAGE PREHEATER KILN
Polysius Dopol-Preheater
Figure 3.24
Source: Reference 9
Preheater shaft
Figure 3.25
preheater
Source: Reference 9
Raw mix te
Cyclone stages
Shaft stage 1
Shaft stage 2
Shaft stage 3
Gas
Material
Cyclone stage
dfeed
Compartment I
Compartment II
Compartment III
Compartment IV
SF rumn
MmsWI hogw
Go flow
Fue. W%
460
eabi
FPu furnum
SReWyhlM
Prlmuer
*an
ofn--
h
halt
MI
MFC - Burners
burner
-
pipe
cooler
Fluid bed blh
To upper stages
Cyclon
Material
14750-
Calcinat
80-95
row mit
Figure 3.31
Polysius-Rohrbach precalcining
process
Source: Reference 9
Figure 3.32
Source: Reference 9
preheater
__
Notation:
1
2
3
4
5
6
7
8
9
-5
Reference 3. 33
FLS-Precalciner
9 ource:
Reference 9
Notation:
1
2
Figure 3.34
Notation:
Source: Reference 9
1
2
3
4
5
6
Exit gas
Raw mix feed
Cylindrical section with scoops
Rotary kiln
Kiln burner
Planetary coolers
iner
Figure 3.35
Source: Reference 9
ft I% a
Flow of mgteroal
F-low of gas
Cyclone CL
Cyclone C2
0
800- 900 C
- t25mmq.
KSV
I
., inKelrF
oier
Clinker
Figure
3.
36
Source: Reference 9
KSV-precalciner
103
ICIPsar*"-
Sopingl.rate-celer
---
E MI1
9
D -0
o64--A
"&Noon a
Hoeriental.lrate-cooer
104
~F~
COUNTER CURRENT
simeOmk e
Sk***e**kv
STORAGE
addves
-J
0
EQUPMENT
Figure
Source:
3.38
I
I
PALLETRMIG EQUPMENT
BAGOING AND
Lafarae Consultants
----- ,,j
..............
NREHOUSE
106
4.0
chapter
describes
of
technological
which
the
on
leading
technological
a small-scale
is the vertical
packages
all
of
the
periods of time, nevertheless, they reflect the kinds of choices that are
available for small-scale manufacturing under various circumstances.
200-300
to
day and 300 tons per day (6,000 and 90,000 tons per year). Although rotary
kilns have been employed for outputs as low as 150 tons per day, they are
best utilized in larger plants.
Production
of
of
the world.
China, West
Germany,
Italy,
has
been
demonstrated
successfully
used
in
Spain,
application
of
small-scale
spread
all
over
the
country
and
industry. The
distribution
ot
107
cement production in small plants in China is indicated in Table 4.2.
grate
technologies
(e) Lurgi
and
are
sintering
A
below.
described
bed
flame firing
process.
comparison of
sintering
Each of
the
the
different
production of
cement.
Vertical kilns
are
in
internal diameters of 6-9 feet and shaft heights of 24-30 feet for outputs
per day to 200 tons per day. Figure
4.2 shows the flowsheet for a VSK cement plant. The raw meal cannot be fed
to the vertical kiln in the form of a powder. Instead it is mixed with the
fuel in the correct proportions, a suitable quantity of water is added and
the mixture is then agglomerated into round-shaped bodies called nodules.
It is the
requires
the
nodules
that
crushing
of
proportioning of
raw materials,
type
nodulizer.
The successful operation of a shaft kiln depends upon the size of nodules,
their uniformity, porosity, and thermal stability. The nodulizer consists
of an inclined disk or pan
rotating
about
is sprayed.
108
rotating
scraper
continuously
cleans
the
The
drum.
consists
of
a cylindrical
and
the
cooling
zone.
top
and a
into
converted
calcining zone,
the
sintering
nodules and clinker rests on a flat grate rotating slowly at the bottom of
the kiln and mounted on the main shaft. the grate is driven with the help
of a variable speed motor to control the discharge rate
The
taken out
is finally
clinker
of
the
clinker.
the
and
fuel
below.
the processing
is limited
for a vertical
shaft
kiln and
are
Since
differentiated
to
raw
suitable
for
the vertical shaft kiln process, while gas or liquid fuels cannot be used.
The
preferred
fuel
than
20%
volatiles
are
preferred, as well as
is of
minor
importance,
as
coal.
The
ash
109
becomes part of the raw meal, however, excess ash has an adverse effect on
the homogeneity of the burning process.
Pellets made
the pellets
kiln)
the
clog
limestone
shales has
required
sufficient
raw materials
and
pellet
and
should
fuel
and
raw materials
of
up
have high
dust
with excessive
porosity
for uniform
and a non-plastic
moisture
content
of
the nodules
determines their quality and fuel consumption. Nodules with low moisture
are
high
strength nodules
(pelletizer)
for
the
semi-dry
is indispensable for a
process.
The
pan
type
high
quality clinker.
The
pan
whether it be
normal,
black meal
or
coal
slurry.
are
produced
for
direct
into the shaft kiln. The uniformly sized pellets improve gas flow
of
1.5-2.5mm
most
is fed
to the
nodulizer
110
together with
the
raw meal.
approximately
5mm
are
mills can
fed
be
into
used
the
for
this mixture,
the
raw meal
preparation.
is relatively
hard to grind.
black
meal
the
shaft kilns today. In the black meal process, the solid fuel and
all
raw
mix compounds are interground in the raw mill. The roller mill is the most
suitable
for
raw grinding.
of
the
Black Meal
Process
as
proposed by Steven
feed
preparation.
This method
fuel. The
requires the
fuel
method
16-18%) is ground separately in a wet ball mill to make slurry with about
50%
moisture
content. The white meal and the coal slurry are separately
stored in hoppers over the nodulizer platform and are pumped at controlled
rates (through flow meters) into
a double
paddle
water
where
111
of
coal particles before nodulizing, the retention time for the volatile
fuel is increased
component of the
immediately
stage.
the
making
is
the
the
of
technique
into
than
option
This
feeding
based
on
intermixing
rather
of
labor-intensive
output.
and
In
situations
unsophisticated,
where mining
this
maintaining
is likely
flexibility
to
be
a
represents
considerable advance.
(a) Loesche
The Loesche Company of West Germany is one of the few (if not
only
one) manufacturers
industrialized
countries.
of
small-scale
Loesche has
cement
continued
t:e
supply turn-key
112
to
The
interground
cement plants
small-scale
Loesche
developed and
the
both
are
the
developing
on
based
the
a disc
type
stationery kiln and the only moving part is the grate which revolves about
four times in one hour. The Loesche
require
dried
together
in
does not
porous
kiln plants
produce
very precise air separators to produce quality cement. The Loesche mill is
an air-swept mill incorporating its
product dust within two minutes after stopping the feed to the
and
India,
are
the technology for small-scale plants. These are: (i) The Cement
Institute
of
India
(CRI);
(ii) Appropriate
Technology
Research
Development
are
material handling,
grinding,
packing
and
113
Therefore, it is the
specific
design package
in
use which
can be
information)
below:
has
CRI's
dissemination
strategy
has
been
to
license
to
machinery
supply
plant
are located
in all the
main regions
of
the
the
originally
"peripherals"
a materials
on
their
own. Movers
Private
Limited,
become
the
market
leader
studies,
and training
of
form
of
personnel.
Under
CRI
licensees,
discussed in detail.
A typical Movers plant consists of
Crushing;
(2) Raw
mill;
the
following
sections:
(1)
(7) Electrical
Figure
114
Typically
in a CRI-VSK cement
in
plant,
dumpers
limestone
of
size not
limestone
is withdrawn from
the
is the
primary
crusher.
Crushed limestone
the
crushed
material
is fed to
the
clay,
coke
breeze
and
additives
the
respective
hopper/storage
fed
to
the
yard
by means
horizontal
of electromagnetic
conveyor
which in turn feeds the raw mill. The raw mill is either a vertical roller
mill or a closed circuit airswept ball mill. Here the mixture is ground to
a fineness of 10% retention on 170 mesh sieve and the material is elevated
to
blending
the
silos,
by
Air
an
merge
air
raw
krom
an air
lift.
silos.
speed
screw feeder
aInd
13% moisture is added to the raw meal in the nodulizer from a water
drying,
115
calcining,
take
burning
sintering, and
of
of a rotary
is extracted
by
block
tube.
a "mole hill"
type
stock pile
ten days
is approximately
clinker. Gypsum
is stored
fed to a horizontal belt conveyor below. From this conveyor, the material
is transferred
cement
mill
to
which
an
inclined
is essentially
a three
compartment
open circuit,
compound tube mill. In the cement mill, the mixture of clinker and
gypsum
is then elevated
to
a cement
packed
in
silo
packing machine.
cement plants
is
taken from a plant currently employing the technique. The plant is located
at
that
Portland
in a vertical
the
intermixing technology, i.e., raw materials and fuel are ground separately
116
and mixed
just
Raw Materials
Marl
Kankar
Limestone
Silica Oxide
8-10%
32-35%
6-8%
Blue dust
Calcium Carbonate
75-85%
50-63%
86-93%
Aluminum Oxide
2.5-3.5%
3-8%
up to 2%
Ferric Oxide
0.8-2.2%
3-4.5%
Magnesium Carbonate up to 4%
up to 4%
8-20%
Water
Gypsum:
90%
Ferric and
Coke Breeze
Fuel
SLV Coal
Steam Coal
6000
4344
4565-5470
30-34%
21-23%
18-20%
3-4%
11-14%
30%
Oxide
(68.9%),
Silica Oxide
(20.2%),
117
ash
used is a 50/50 mixture of coke breeze and SLV coal, with a combined
content of 30%.
The
of
capacities
the
The
raw material
crushing is done using a jaw crusher followed by a hammer mill. The rotary
drier
Due to the variations in the drier feed, the drier discharge quantity also
varies considerably. The
elevator can
bucket
storage
silos
the
homogenizers
mill
ball
by compressed
operated
classifier. Two
cone
air
supplied by Rootes
intermixing
is
used before the raw meal is fed into a rotating pan nodulizer.
The
vertical
has a variable
speed
shaft
hydraulic
drive.
The
cement
grinding section is
similar to the raw meal unit, i.e., has an air swept mill
cone
with a double
part
of
118
(iii) Jorhat Regional Research Laboratory:
This laboratory is located
emphasized
research
on
in
micro-scale
the
province
production
order
of
Assam and
The RRL kilns, which are based upon the CRI-VSK design, have
to
has
been
tested
the
to
kiln
design
the
laboratory
rather
appears
and
by
the
NDRC
has
been
to
have
marketing of its plants, although a few have been sold and are on order in
India.
(iv) Saboo:
The Saboo design for small-scale cement production (20-30 tons per
day) is based upon
literature
of
a refinement
emanating
from
the
a prototype
kiln developed
conducted
handling,
grinding
from
technical
sensitive
to
skills
and
minimizing
rural-based entrepreneurs.
repair
workshops.
the
maintenance
restricted access
of
diverse
119
(c) Miscellaneous designs:
Small-scale
the
by
Pty.
Gorrensen's
the
considerable
companies around
invoked
recently
have
plants
cement
Ltd.
(Australia),
representative of
latest
the
Fur
and Buro
Limited
Company
Engineering
Austrian
Fur Systemtechnik,
Buro
designs
Systemtechnik (West
plant
of
(Austroplan),
which
is
is discussed in more
available,
detail below.
suggested
a design
for a 60,000 to
70,000 tons per year (approximately 200 tons per day) plant. The objective
of this design is to supply a plant to meet
urban
cement needs
on
the
such
as
Ivm-coal and charcoal. Limestone, marl, clay, and other raw materials like
iron oxide and silica are crushed and ground to a grain size
a 10
representing
to a similar fineness.
Both
products
for
are
stored
premixing,
and
then
formed
into
pellets on a dish pelletizer. The pellets are fed into the kiln where tneyv
are
burnt
and air-tight discharge gates. The clinker is stored and then ground
witn
120
and
gypsum
components
other
in
or shipped loose by
and bagged
silos
given
Figures
4.9,
4.10,
burning
plant,
and
is
the plant
the
cement
mill.
The
ground cement
is
it is
grate
design
design
configurations
grate with
(Gottlieb);
and
are:
one
design
feature
extended
The
cone
grate is most suitable for the black meal clinker. Since the clinker
is rather
in
preventing
such
leakage.
but
they
can
kiln
and
(b) short
rotary
121
situation favors the use of gaseous, liquid, solid or mixed fuels of high,
or
medium
low calorific
can be
fired
into
the
and
fuels
low grade
In addition
values.
kiln. The
alkali
dry
the
process,
is sometimes
stable
less
due
to
raw mix
fluctuating
properties.
For the SP-kiln process (Figure 4.14),
preparation
requires
crushing
fed
grinding initially.
and
to
and
fuel
and
Blended
current type, where it is preheated and partially calcined by the kiln hot
gases
passing
in counter
current.
Raw meal
enters
the
kiln
at
is fired
the lower end of the rotary kiln through coal burners. Secondary air
coolers
to
make
raw
materials
escape
in counter
to
of
the
raw
122
mix
developed
bed
typically
consists
a vertical enclosure
of
distribution of
the
solid particles supported by the gas above the grid. The action within the
bed has been compared to a boiling liquid. Fluid beds have been used where
control and uniformity of temperature and large scale continuous operation
are required.
The fluid bed cement kiln shown
cylindrical
in Figure
4.15
consists
of
from
the
both as combustion air and the fluidizing medium, flows from the plenum to
consisting
of
finely
ground
feed
mixture is pneumatically conveyed to the fluidized bed along with fuel and
preheated
The
air.
temperature
of
the
the
fuel
bed. Coarse clinker particles are formed on the fluid bed and when
ground
the
hot
of
the
already
present
clinker particles,
finely
fluidized
tnus
leaves
123
particles
below
2.5mm are
separated
clinker stream by means of a sieve and fed back into the reactor as
clinker.
of
size
The
seed
range and since the amount of clinker that overflows the kiln is constant,
the usual problems of variable kiln discharge and irregular clinker sizes
are avoided. Hot air from the clinker cooler can be used in several ways
to
improve
the
energy
subject to a series
economy
of
heat
of
can be
sufficiently
so
that
used
cooling. In the heat recovery section, air is preheated and the remaining
heat of the kiln gases is used
steam.
to
generate
high pressure
superheated
which
condensate
turbine system
steam
process,
it is claimed,
can
be made completely
self-sufficient.
The specific advantages of the Pyzel
where
there
is:
process
problem
have
claimed
been
(c) a disposal
of kiln dust with high alkali problem; and there is a need to use
fluid
bed
is a stationary
device,
the
operating and
maintenance problems associated with a rotary kiln are avoided because tne
brick lining is not subject to the dynamic stresses of
the
rotary kiln.
124
The
and
is reported
to
have
emerged
from extensive
pilot
studies. The
are
fed
as
pellets
Figure
and
4.16.
the
fuel
In this process,
raw
separately as with the rotary kiln. The principle of the Reba kiln is that
material in the form of
pellets
that
the
combustion gases
through
the
bed
of
of
material
and
grinding in
a roller
mill, and
of raw meal. The nodules produced from the raw meal in the
pelletizer are dried in the preheating shaft and heated in the calcination
zone to about 1100C. The partially
a set of inclined grates (three
granulated
material
sections)
in the sintering
zone.
The
the
top of
the
inclined grate, are subjected to high temperature gases which are produced
in a furnace fired with oil. The flow of gases is in an opposite direction
to the flow of material and thus air used to cool the clinker heats up ind
is used
as
secuondary
air
grate
125
increase
cooler
so
as
to
provided
with
for
clinker
gas
fired and
is
raw
meal
pellets.
the raw meal and the crushed coal are fed into a drum type nodulizer.
The
nodulizer is also fed with 15% burnt clinker and water. The nodules of raw
mix
are
conveyed
iron. A 75mm thick layer of clinker is first spread over this bed and then
fresh nodules fall over the clinker. The sinter bed passes through various
zones and light diesel
oil
is fired
over
various reactions as they pass the various zones and the resulting clinker
is discharged through a rotating type breaker over an open pan
conveyor to
undergo
cooling. The
clinker
horizontal
elevator and then through a series of screens to the clinker yard where it
is ground with gypsum in a grinding mill.
126
The Lurgi
volatility. Fuel oil and gas is also required as additional burning aids.
Table 4.1
COUNTRY
NUMBER OF
ACTIVE KILNS
TOTAL
ANNUAL
CAPACITY
(eonnes 10)
Kenya
India
1
6
6
7
500
56
Iran
na
Australia
Belgium
France
Germany, West
Brazil
Austria
Grece
Italy
Nepal
Poland
Spain
Yugoslavia
1
1
4
4
I
1
1
8
I
1
7
4
2
4
24
31
1
2
2
14
1
6
26
22
110
1100
no
na
80
250
na
na
48
2000
Va
na
* Clinker capacity
na-not available
Source:
Reference 6
Table 4.2
(million
tonnes)
1949
1957
1965
1969
1970
1971
1972
1973
1974
1975
1979
1980
MINI PLANTS
BIG PLANT
PRODUCTION
TOTAL
A-P
Total
Number
Average Size
(tonnes
per annum)
200
25599
15-5
16-9
19"2
19-9
1800
2400
2800
7400
7400
7100
21-6
24.0
24"5
>2800
-3400
3400
> 10100
Source: Reference 6
>40000
Total
(million
tonnes)
% of Total
Production
(million
towIms)
15-0
10-4
13-3
17-7
19"9
28-3
46"00
49-0
40
44
48
50
>50
57
66
66
25-9
30"2
36-9
39-8
41-8
49-6
70-0
73.5
I.
"a
z
01
,---I
,,
|,
<"
Eld~
e 0Sdl
I 6
2,
E-4
,SI".
u .,I _
!'
...
El fjII 111
v"
,,,,
+,,,
+ii
,
""'i t~ " B+
i+I
tI.
gi
iatiji
++'+!
P"
b!.,+ Eb'
!
Ul
"+i+
i +1
,aa~',|
,, +._,.,l t+; _
04
if(51
.. f.+II ,,.0Y
gij_
+Z,..J. i ,.+ ,+ .+
IO+ . .+! uc
rs
ii
-_
8_
0V)
.ss_
~,"
1~iiJ -+
j ''t
xw
+.
.1
130
feeo
gas duct
tc dust cc
pelletiz.ng table
rotat -g
grate
air lock
d.scharoe
blower
clinker conveyor
Figure 4.1
Source: Reference 51
131
CRUSHER
OcIG SmISIE
LIMCOIBEOR EZfa
STORAGE
STORAG
HOPPER
HOPPER
I TARLE
CLAY
FEEDri
Y UM
A I
STORAGE
L
HOPPER
TABLE
FEEDER
STOGE
STORAGE
HOPPER
TABLE
FEEER
HOPPER
TABLE
FEDOER
TABLE
FEEDER
BELT CONVEYOR
BUCKET
ELEVATOR
RAW MIX HOPPER
TABLE
LF3EER
CYCLONE
FAN
RAW MILL
SCREW
BUCKET ELEVATOR
CONVEYOR
LP BSLOWER
LOWER
FiP
-'
SILO
SLENOetG'
RAW MEAL STORAGE
CREW
IONVEYVR
BUCKET ELEVATOR
RAW
MEAL HOPPER
SCREWCONVEYOR
WATER
NOOULISER
EXHAUST
BOOTS
BLOWER
VERTICAL SHAFT
KILN
ilCLINKER
STORAGE
BUCKET
CLINER
ELEVATOR
HOPPER
TABLE
FEEOE
CE~MTNT
OOIG
CEMENT
SILO
A SE
MILL
SUCKET
ELE
PACKING&
132
22 23 24
22 - Blackmeal Conveyor
23 - Blackmeaf Proportioning Be l
24 - Nodulizer
26 - Vertical Kiln
27 - Step Grate with Main Shaft
28 - Main Gear
29 - Kiln Blower
30 - Discharge Gate - Air Lock
-r
Figure 4.3a
1#
L-- 47
x
26
Soul
27
30
49 tj
133
lj4.
Limestone Store
Clay Store
Clay Store
Additives Store
Crushed Limestone Store
Coke Breeze Store
Clinker Store
Gypsum Store
Limestone Hopper
Primary Limestone Crusher
Secondar, Limncstone Crusher
Bucket Ele;ator
Limestone Hopper
Coke Brcczc Hopper
Additive Hopper
Clay Hopper
Mech
Nodulizer Feed Elevator
Nodulizer Feed Hoppers
Nodulizers
Vertical Shaft Kilns
Clinker Elevators
Clinker Store Hopper
Gypsum Storage Hopper
EOT Crane
Rotary Feeders
Bucket Elcvator
Cement Mill
Bucket Elevator
Cement Silo
Centrifugal Type Elevator
Buffer Tanks
Packing Machine
Vehicle Loading
Packed Cement Platform
Gunny Bag Store
Electric Sub-station
Canteen & Rest Hall
Packing Space
Office Building
Stores
Workshop
Gate House
Main Gate
Weighbridge
135
CHIMNEY
-WEEDER
i BLOWER
Figure 4. 5
Source: Reference 6
t'.
JA\..
u-aJ~WMT
ROTAPY R1E
xx4u
L
R~~ MC~)r
rL
(5)
BLXCI-4
W~_____
0'
CEMtIr
Reference 46
137
1. Rawmaterial crushed to minus 1" wth movable breakerplate equipped hammermill, coal minausI" s, gypaim
minus I" size. all enter plan here.
2. Crushed gypaum hopper
3. Crushed coal or coke hopper
hopper
4. LUmestone 'gh"
5. Lmnestone "'low" hopper
6. Clay or hale hopper (opooal)
7. Coal slurry mill and pump
8. Raw mill with automanec mpler and aaalynr
Figure 4.7
Source: Reference 21
138
List of equipment:
(1)
(2)
(3)
(4)
(5)
(6)
List of equipment:
OO
F-1) F-11
W~
. US
Remark:
In
case
the
raw
considerably
material
homogenizing
analysis
is
system
varying
be installed.
mill
Figure 4.10 Schematic presentation of a erying/grinding
Source: Reference: 47
141
List of equipment:
142
O
O
L.J
List of equipment:
(1) Feed hopper for ground fuel
(2) Feed hopper for raw meal
(3) Weighfeeders: Fuel max. 1,6 t/h
Raw meal 16,0 t/h max.
(4) Paddle mixer
(5) Dish pelletizer for a mixture of
16 t/h of raw meal and 1,6 t/h ground fuel
(6) Shaft kiln
(7) Discharge grate ( rollers or plate )
(8) Discharge gate
(9) Apron conveyor
(10) Dust collector
(11) Clinker crusher
Figure 4.12
Schematic presentation of
the burning plant
Source: Reference 47
143
(1)
(2)
(3)
(4)
(5)
(6)
(7)
144
HP 9S0WER
STORAGE
SILO
SUSPENSION
PREMEATER
NE
LOAYING
SAGG0NG &
BRANOING
145
KILN GASES
SIZED RECQ
CLINKER
REFRACTORN
LINING
KER OVERFLOW
CARBON S1
SHELL
FRACTORY
PREHEATED
AIR
NUM
RAW FEED
FUEL
Figure 4.15 Scietific Design Fluidized
Bed Kiln
Source: Reference 31
9wGraneautg
tb40
push "I
H
4.'
Gasflow i Rebaprocess
r-YCL
HmPER
RAWMEAL
148
plants
are
discussed.
and
capital-labor
level
of
The
issue
technology
tradeoff
employed in
cement
plants.
The
costs.
shown
Table
in
Estimates
5.1.
The
countries.
to
in
the different
different
time
periods
The table indicates clearly that the cost per ton of installed
size
of
and
costs
directly
variations
in
of
terms
unit
and
variable cost
items in cement
"average
situation"
of
scale
for
of
the form of index numbers, taking a 250,000 ton per year plant as
100
in
Table 5.3. To get another idea of the economies of scale, one may note the
figures
in
Table 5.4. The economies of scale shown in the table may need
149
to be modified for
developing
countries
to
of
scale
exists
plant
and
distinction
was
made of whether the plant had one kiln or more, whether it was constructed
on an
established
operation or what
site, whether
level and
type
and
only
then scale
economies
can
be put
into
the
proper
perspective.
The
choices of scale and product mix are always key issues in the
cement industry. Scale is itself partly determined by the product mix if,
for example, cement additives are used or
clinker
are
product
quality
export markets
which
require
very
substantially
boost
the
international
also
to
be
industry
usually
an important trade-off between plant size and the risks and costs of
arises
cement,
that
producers and
the
150
the
expected
economies
of
scale
and market
growth rates,
possible
such
scale
decisions
tend
to
be
complicated by special
expansion
project and
is in
justifies
what
is to
simply
is considered
the
most
desirable
scale
for
investment.
in the market by doing so. For development planners, this latter option is
important wherever market growth is reasonably rapid. This is because
investible
resources which would have been required for the smaller plant
earn
satisfactory
earlier
the
along
initial
the
industry's
thrust
to
course
learning
the
curve;
implied
a vital
smaller
initial scale.
The weakest link in the technical performance of cement plants has
been
in
the
pattern
of
Problems
encountered
are
frequently
those
unforeseen
of
stagnant
market
production difficulties
kilns
have
300
per
day
(tpd).
151
$14
The
million.
compares
with
capital
of about $1.7
requirement
million for a 50 tpd VSK plant. Further, the large-scale plants have
found
to
have
most
kilns
rotary
efficient
of
minimum
been
the
return
on
investment
and
has
though the highest rates of efficiency have been found at 50 and 100
plants
need
limestone
5.2 Energy
In an energy-intensive industry like that of
planners
and
investors
cost of energy as
they
alike
do
cement,
development
about
scale
and
of
energy
consumed
than in the value of the fuel used and the reliability of a plant's supply
of electricity.
The
energy
sources
in
other
sources, consisting of waste heat from one phase of the process, which can
be recovered and utilized in another phase of the process.
energy-intensive
phases
in
cement
manufacture
are
The
two
most
pyroprocessing ini
152
mainly
thermal
in the form of
energy
for
raw mill
and
grinding
from
into
before
entering
raw mill and kiln. A small amount of thermal energy may be needed as
kcals/kg
clinker
to
depending
purposes.
clinker normally
tons
.210
upon
the
oil
of
specific
range
about
750
to
2100
used
and
the operating
power
grinding
mills,
fans,
from
about
80
to
160kwh
pumps and
compressors
in the
electrical
consumed typically
(.02
electrical
75%
energy used in a plant and electrical power for the remaining 10% to
Table
5.5
summarizes
the
normal
ranges
of
25%.
(2) semi-wet with grate preheater; (3) semi-dry with grate preheater;
dry
with
long
rotary
.4)
153
with 4-stage preheater and precalciner. The chart in Table 5.6 illustrates
the average operating efficiencies for each type of process.
energy
with
normal
cange
of
1200
consumption
of
Evaporation
in
pyroprocessing
to
kcals/kg).
of between 24-48%)
content
moisture
slurry
average,
35%)
of
the
total
energy
consumption.
In the Semi-wet process (slurry moisture content typically 17-22%)
with grate preheater, the slurry is dewatered in mechanical filter presses
and
resultant
the
preheater
before
filter
entry
cake
into
is
the
then
kiln.
on
dried
a travelling-grate
pyroprocessing energy
Average
10-15%)
with
preheater, the dry feed is mixed with water and formed into pellets
semi-wet
process.
required
However,
for
since
evaporation
the
and
moisture content is
the
average
energy
about
gases.
and
clinker
cooler
and clinker cooler exhaust gases is utilized to preheat and partly calcine
(about 20-30%) the raw mix entering the kiln. As a
source
heat
is
result,
less
primary
154
possible
to
dry
consumes
kiln typically
of
clinker
corresponding
constraints
per
of
kilogram
consumption
by
example)
alkalies, for
Germany
limit
may
the
energy
Japan. However,
the
of
composition
the
and
efficiency
of preheater
the
total
low grade
two-thirds)
fuels
including
industrial
shredded
waste,
in a conventional
system).
The
20-30%
a precalciner
addition of
of
various
similar
the
different
technologies
systems with
preheater
discussed
typical
earlier
energy
are
requirements
Design (SD) Fluid Bed clinkering system. It is shown that the SD fluid bed
process is basically
competitive
with
the
preheater
than
design in overall
the
long
kiln
155
Though
thermal
substantially
lower
energy
than
in
consumption
the
wet
in
process,
the
dry
process
particularly
with the
however,
does,
is
entail
higher consumption of electrical power. A dry raw mill requires more power
then
a wet
consumption
in
power
of
clinker
Average
(range
However,
significant
consumption
several
times
over. Preheater/precalciner
thermal
electrical power
the
electrical
energy
consumption.
dry
kilns
and
therefore
wet
kilns
and
such
kilns.
Power
and the type
grinding
and
crushing
to
tube
economizing on
power
mills
in
large
consumption.
such
mills
The
roller
mill
can
use preheater
exhaust gases to dry raw feed stock, whereas the existing ball mill
needs
additional
distribution and
fuel.
can
often
handle
larger
material
in
in
sizes,
many
a capability that
plants
to
prevent
156
power consumption. Up to 10% savings have been reported through the use of
such organic acids, alcohols, and amines.
Comparison of small and large scale plant energy consumption
The comparison is done
a company
for
with
subsidiaries
in various
countries
Zurich,
engaged in cement
production, owns and operates the 1.27 million ton per year Bamburi cement
plant in Mombasa, Kenya.
This
plant
(Loesche
design) with
operating
Cementia's
six vertical
experience
their Bamburi
for
plant,
6% humidity.
heat
the 750 to 850 kcal achieved with the modern dry process rotary kiln
Power
versus
90-110kwh
95-120Kwh for the wet process and the 4-stage dry process rotary kiln
shaft
dynamic loads and therefore wears out much less than in the
In
well as
an average
and
as
the whole plant of. 950 to 1,000 kcal of clinker with raw
materials containing 5% to
than
shaft
rotary kiln.
the shaft kiln bricks are replaced on an average of every two years in
last
upto
fifteen
while the life of the lining in the rotary kiln does not exceed 1-2 years.
The long life of refractory bricks is the major factor in the high degree
of reliability of the shaft kiln. Fast and easy startups of the plants are
possible
157
up to 6-7 days.
The specifications for coal to
be
used
are significantly different from those for a rotary kiln. The coal
used
for
cement
manufacture
short-flamed
that
coal with
be
the
determines
to
low
volatile matter
kilns
require
the order of 5500 kcal/kg. This calorific value is, however, low
for
use
consumption
the
effect
of
choice
of
process on total energy consumption in the cement industry. The data shown
for
(England,
Pakistan,
consumption
are
Republic
of
Germany
where
the
wet
process
plants
since,
apart
from
type
of
process,
energy
158
consumption
thermal energy
decreased substantially over the last two decades as seen from Figure 5.1,
which shows trends
in
selected
as
taking
wet process kiln, beginning in the late 1950s. The lower energy efficiency
of the cement industry in the United
which
tended
(ii) the
efficiency; and
profitability of
low
generally
slow-growing
many cement
face
of
efficient
energy
of
coal
other
factors
as: extent of competition within its own market including the threat
of imports
at
lower
price
where
existing
growth
respect of exports
of
domestic
will also
cement
the
savings;
influence
energy
rate
program. For
the countries
and
West
consumption
in cement manufacture has tended to increase rather than decrease over toe
159
same period of time, due mainly to the increasing share of the dry process
in
total
shows
5.11
Table
the
in
pyroprocessing
these
improvements
the
be
in
ground
there
efficiency
efficient
been
have
a number
of
specific
Also
of
instead
circumstances,
in
coal
process
plants
the
more
growing
power
lower
in
cement
manufacture
by
As
the
in
developing
began
to
manufacture
cement, they tended to use oil, which was easier to use, and, which at the
prices
prevailing
at
caused
Between
FOB
190u,
and
oil prices increased from $2.7 per barrel to $27 per barreL
from
1973
per
ton
to
prices
incredseI
.L60
coal).
bituminous
outlets,
natural gas increased at about the same rate as oil. The higher
of
and
in
countries
where
systems.
coal-based
industrialized
low cost
to
the
countries,
For
the
and
the
Table
occurred
scope
developing
1974
for
still represents the most significant fuel source, though many conversions
from oil to coal and other fuels have taken place since 1978.
The basic requirement of a kiln fuel is that it must have
enough
calorific
1500-1600C.
In
content
to
produce
a burning
zone
a high
temperature
of
utilize
low
fuel such as oil shale, inferior coal, and under some conditions,
for instance, which would not serve in a conventional kiln where the lower
limit for energy content of fuel is about 4500 kcals/kg. This
of
the
precalciner
becomes
very
important
because
flexibility
deposits of inferior grade fuels which have limited application, and the
precalciner systems allow the cement industry to lower cost by using these
fuels, thereby permitting the scarcer high-grade fuels to be preserved f)r
higher technology applications where their use is more appropriate.
161
oil
of
substituting coal
can yield
5.2.4 Conservation
Some of the more basic energy saving measures which can be readily
implemented in the short-term without major capital expenditures are:
(a) Heat
transfer
100C
in the
exit
of
in slurry moisture:
slurry moisture,
a major factor
use
slurry
from
40%
kcals/kg of clinker.
(c) Improvements in the burning properties of the raw mix: A hard
raw mix
guideline, about 22
kcals/kg
of
clinker
can be
burning
chemical
composition
of
the
mix,
and
by
alterations
improvements
in
in tne
162
(d) Reductions in dust losses: loss of clinker dust implies an energy loss
of about 10 kcals/kg of clinker
use
of
reduce
help
at
the
kiln
air
electrical
energy
mix;
the
the
25%.
In
cement
of the
ball
mill
charge, use
of
segregating
liners,
precrushing of
clinker, and use of grinding aids where cement standards permit them,
yield
important
savings
area.
can
and
The
consumers
compressors
remaining
in the kiln
electrical
systems
and
the
energy is consumed by a
process
conversions:
In
are
converted
to
the
irv
163
semi-dry process, and the raw mill remains wet. The main advantage of full
savings per kilogram of clinker
is, however,
very
capital intensive
include
extremely
needs
the
conversion.
at
type of
high
wet
to
the dry
process.
Such
of certain
raw
raw materials
from
pipeline.
cost/benefit
The
quarries which
require transportation
comparisons
the most
of
popular
of
by
type of
is increased
kilns
yield
even greater energy savings (up to 45% as compared to the wet kiln), while
greatly
expanding
choice
preheater
(dry process)
systems depends upon certain characteristics of the raw materials such as,
for
instance,
on
whether
the
slurry
is easy or
not to handle in a
kiln,
such
conversions
may
164
it possible
to
produce more cement from the same amount of clinker. As a result, the fuel
consumption
per
ton
of
cement will
of
ash, and upto 25% by blast furnace slag, without changing the character of
ordinary Portland cement as a general purpose cement. Such blending is a
well-known and
widely
accepted
permitted an estimated 20 to
40%
practise
products
as
fly ash
and
utilizing
cement
industrial
by
5.2.5 Summary
The incremental efficiency of
energy
85-90 kg
of
fuel
oil)
compares
with
about
800,000-900,000 kilo-calories
of
fuel
1,500,000Kcal
of
fuel and
80Kwh of
process
(or
the
wet
process.
The
use
of
low cost
of
165
substitution
for
fuel
produced
cement
of
oil
(in 1980
locally-available
cheaper
terms),
while
alternatives
(surplus gas, coal, petroleum coke, and even imported coal), could save at
least 2-3 times as much, depending on the available options.
The
other
for
major area
improvements
taken a substantial
toll
in terms
of
of
effects
higher
Energy
intensive
wet process cement plants that began operations around 1960 reportedly had
total energy costs of around $11-12 .per metric ton of cement. Depending on
their size, these plants had capital costs ranging from $80-115 per metric
ton of
capacity.
the
When
price
same
cement.
Had
plants also converted from the wet to the dry process, energy
fuel oil).
effect
of
Therefore,
an important
competitive
production
could
also
help
feasible
prices
166
5.3 Transportation
Transport
decisions
costs
carry
preponderant weight
in all
investment
in the cement industry. This stems from the low value to volume
and weight ratios of the products, and the fact that it takes between 1.65
to
produce one
said
that
the
are
normally
significant
enough
clinker,
to
most
part
of
in 1980
domestic
transport
costs
within
the
developing
location decisions
1980 terms, excluding subsidies) mean, for example, that clinker producing
plants normally have to be located quite close to their
if they
are
to
For
the
source
limestone
same
limestone
are
per
needed
reason, proximity
to
markets
is a decisive
essential
that
will
be
sharpely
167
suitable
limestone
is a
deposit which
(economic) distance from the market than is the port of entry for
shorter
remoteness and small size of many such markets, and the different size and
suitability of the various limestone deposits
countries,
the
scattered
throughout
scale
most
of
greenfield
plants
is that,
other
of
things
reducing
equal
and
infrastructure aside, the unit capital cost per ton of output will rise by
about one-third if the scale is halved. Applying this rule a 250,0UU ton
per year plant, for example which
inland
is 100-200
kilometers
closer
to
an
plant
where
infrastructure
transport
is at
an advanced
the United
stage
of
larger
is its
aggregate
transportation cost.
Savings
on
total delivered
cement
costs
in developing
countries.
In India, tor
and allowances
of
for
the
cement
loss
transport,
excluding
packaging,
168
and distribution costs average $10.31 (Ra. 100) per ton for a distance
about
of
have
$34.18
price averages
cement
been
distorted
because
of
of
much more developed rail network compared to many developing countries for
which the transport costs would be even more significant. China has a much
less well developed
transportation network
centers,
cement
production.
In China,
in
order
to
reach
cement.
Other factors
decisively
in
suitability
of
can,
favor
raw
of
course,
a particular
of
materials
at
to
intervene
location.
different
sites
tip
the
balance
Variations
in the
the
varying
and
of
key
of cement additives can also swing the balance in favor of one location as
against another, although the
option
of
shipping
and
technology
for
the
cement
plants,
When
deciding location,
transportation costs are much more important than investment costs per ton
of finished product. That is to say that economies of scale due to reduced
169
ton of
widely
for
the
increased
distributed
cement
transportation
costs when
costs,
the
in this
energy
intensive
industry,
To
higher
both at the
shipping
of
this
impact of higher energy costs for producers with access to low cost and/or
alternative energy sources. One
consequence
of
distribution
to
cost.
In the
future
energy
sources,
of
cement
to
developing
them
to
charge
While
trend may
protected
weight and
volume
industrial
ratio.
Hence,
scale
commodities
one
be a harbinger of
of
the
most
highly
developing countries
170
analysis
of
the
capital and
investment
in
a cement
plant and quarrying installations together with the cost of the buildings
and storage facilities
provision
of
civil
and
the
cost
facilities).
of
construction
Sometimes
electric
(land clearing,
power
generating
problems
with delivering
requirements
for
requirements of
each of
the
plant
power
these
and
in remote
locations.
items depends
on
the
Investment
upon the
technical
location requirements.
On the
technical level, the prime determinants of plant capacity are the size and
number
of
kilns.
The
capacities
of
the other
including
equipment,
to
those
items
which bulk
large
in investment
costs;
this is due
Local
with regard
conditions
play
to
equipment
a very
in large and
important
role
in
sewers, roads, railway, etc.) are affected by the remoteness of the plant.
The influence of scale operations on total investment costs may be
observed on the basis of that
collected
early 1960s as shown in Figure 5.2. Data for the United States relates
to
171
wet
the
data
elasticity
and
between
size
Soviet
Union
indicate
the
it
existence
of
constant
the
German
data, 0.66 in the Soviet data, to 0.77 in the United States data.
The
costs
developing
(exact
figures
available)
similar
to
that
in
developed
of
freight,
import
profits,
internal
transportation
high
and
and
pollution
control
equipment
with
quality
of
operation
of
cement
production
for
different
size
per unit of output fall sharply as scale increases. Data in Figure 5.3 ini
Table 5.15 shows this is the case for a variety of plants
States,
the
workers
only;
Soviet
Union
allowances
and
must
in
the
Lnited
made
for
administrative personnei.
in
terms
)r
172
man-hours
per ton of cement, are contained in Table 5.16. There are minor
of
the
developed
size
of
the alternative
vary
significantly
of
materials
handling
in the
plant
while a
Table 5.1
Estimations of cost per ton of installed capacity
Capacity in tons
per year
1970
30,000
168
50,000
116
100,000
120
200,000
100
80
250,000
1970 c/
72
60
300,000
60
400,000
83
500,000
80
55
550,000
103
600,000
1,000,000
46
56
42
1,100,000
78
1,200,000
43.2
1,400,000
Source:
1976
Reference
39
Table 5.2
Variations of manufacturing cost with size of cement plant
Cost item
30,000
50,000
100,000
Fuel
4.007
3.58
Electricity (variable)
Production surplus and
maintenance materials
1.45
1.41
2.05
Subtotal
1,000,000
250,000
500,000
3.13
2.70
2.36
2.14
1.27
1.16
1.04
0.94
2.05
2.05
2.05
2.05
2.05
7.57
7.04
6.45
5.91
5.45
5.13
12.13
0.72
2.13
18.48
7.28
0.69
1.28
12.76
4.64
0.64
0.64
8.80
2.32
0.58
0.32
6.60
1.61
0.53
0.26
6.05
1.09
0.49
0.17
14.62
33.46
22.01
114.72
9.82
8.45
6.37
29.05
21.17
15.73
13.90
11.50
2.20
2.00
2.00
1.90
1.90
31.25
23,17
17.73
15.80
13.40
Variable costs
Source:
Reference 39
Table 5.3
Economies of scale in the cement industry
Annual. capacity
of plant (tons)
Variable
cost
Fixed
cost
Total
manufacturing
cost of bagged
cement
30,000
128
340
221
50,000
119
224
176
100,000
109
150
130
250,000
100
100
100
500,000
92
86
89
1,000,000
87
65
76
Source: Reference 39
Table 5.4
Economies of scale
Capacity
(Trmnes per day of
Index of Capital
Cost of Plant
500
1000
2500
44
'57
100
Index of
Unit Cost
cement)
Source: Reference 27
220
142
100
Table 5.5
am
Energy
!by
Znufaturing Stage
REL_rECRICTY
emal Range
Averag
IUr&
NDrmal Range
Avrege
Merae
of
cl/ker
kof
cals/kg
toe/t on
fwh/
hitton
of
toefton
tofe/ton
of clinker
of clinker
of canent
of cement
of cement
of cement
of cement
5-15
10
.0010
2-6
.0010
.0020
20-40
.0075
.0075
15-30
.0055
.1155
CL1rker
Grinding
35-64
.0125
.0125
Misoellarneous
10-16
.0033
.0033
.0298
.1408
Quarrying
s%
share
Raw Material
Grinding &
Preparation
Pyroprocessizg
750-2,100
755-2,115
Total
1,100
1,110
.1100
.1110
82-156
% Share in Total
Notes:
13
119
21
82
2
100
100
Amerages include weighted averages as appropriate. Avemage clinker to cert canversion ratio
assumed, 1.00:1.04.
Energy equivalents assumed: I kwh - 2,500 kcals (based on energy conversion efficiency in modern
power plants, though, in specific cases, the conversion efficiency may be as low as 3,500 kcals
per kwh);l toe - 107 kcals.
Source:
Reference
16
Table 5.6
Comparative Themnal Energy Consumption in
Various Pyroprocessing Systems
(kcals/kg of clinker)
Waoe Klin
Theorncol
Heat of
Process
Reocton
Dut
o..on
Cooler
Air. Lo.s
1 jTT
:.
Wet
--------I---- -----
230
Semi-Wet
(Grote Preheater)
210
130
125
85
1.400
Energy
Eclency
30)
30
170
70
Semi-Dry
(Graote Preheater)
835
130
87
133
70
Dry
(Long Rotary Kiln)
130
135
70
Note Energy efficency isthe percentage ratio ofthe theoretcal heat ofreoction to the totaol energy consumpion
Reterence
16
43
750-850
49-55
750-850
49-55
80
4-Staoge Preheater/
Precicineir
135
965
160
4-Stoge Preheater
Source:
\\
lolo
Enegy Con-
Table 5.7
Ccmpsrative Features of Different G~ nt Production
lchnoloies
Kiln Process
4 stage
Wet
Evaluation feature
Grate
(pellets)
Grate
(filtercake)
Long
Dry
940-1,060
88D-1,000
Thermal energy
consiapti on
kcal/kg
1,400
800-900
Electric power
conuptLo in ki in
systao
kwah/ton
18-27
18-28
18-28
Mtaxniu percentage
moisture in raw
material which can
be handld by
secondary heat
N/A
4%
N/A
Availability of
econdary heat
Senstitivity to
raw materials
characteristics
( desirable
(
(undestrable
(
high
plasticity
( critical
chain
preheater
( area
system
grate
Source: Reference 16
high rodule
strength
filterality
preheater w.
precalcinr
860-950
750-850
750-850
2-22
22-24
27-31
30-34
10%
9%
7-8
7-F
low alallies
low chloride
aw alkalies
low chloride
prheater
preheater
filter
Table 5.8
Energy requirements of the Fluidized-bed
kiln
Feed Preparation
(quarry, crush,
dry, mix feed)
Clinkerlng
(burn,cool)
Flnlshin
(grind,pack)
Available
Energy Recovery
(steam/power generation, dryer
fuel savings)
Net Energy
Required After
Energy
Recovery
Electrical
Fuel
406,000
286,000
710,000
16,000
5.560.000
5,846,000
710,000
422,000
1,402,000
5.576.000
6,978,000
Electrical
Fuel
534,000
760,000
870,000
315,000
4,600.000
4,915,000
760,000
(320,000)
534,000
336.000
870,000
374,000
3,200,000
3,574,000
760,000
(346,000)
(300.000)
760,000
(646,000)
490,000
310.000
800,000
5.000.000
5,000,000
336.000
Source: Reference
(320.000)
760,000
760,000
(1,400,000)
(180.000)
(1,580,000)
1,609,000
4,616,000
6,225,000
1,322,000
3.236.000
4,558,000
(150,000)
5.130,000
4,980,000
Table 5.9
Energy Consumption in the Cement Industry in
Selectec Developing Couxtries
Annual Energy
Consumption
in Cement
(1012 kcals)
Argentina
Bolivia
Brazil
Cameroon
Caribbean
Chile
Colombia
Ecuador
Ethiopia
Gabon
Indonesia
Malawi
Malaysia
Mali
Morocco
Mozambique
Niger
Nigeria
Pakistan
Panama
Paraguay
Senegal
Sri Lanka
Togo
Tunisia
Uruguay
Source:
9.13
0.81
36.80
0.11
4.00
2.17
10.41
2.02
0.24
0.26
9.18
0.18
3.75
0.10
6.12
1.40
0.06
6.51
6.93
1.05
0.37
0.57
0.83
0.73
3.54
1.33
Reference 16
Percentage
of Commercial
Energy
Consumption
2
5
5
n.a.
4
3
8
5
5
3
3-8
5
7
15
10
4
12
7
8
9
8
7
Percentage
of Energy
as Fuel
Average
Kiln Heat
Consumption
(kcals/kg cl.)
1030
930
1040
1100
1485
1140
1620
1075
1120
1450
970
950
1110
1900
1085
1045
1300
1135
1670
1350
1500
1120
905
830
990
1385
Table 5.10
Energy Consumption in the Cement Industry
in Selected Countries
Year
ICs
- FR of Germany
- UK
- France
DCs
- India
- Turkey
- Portugal
- Tunisia
- Pakistan
- Philippines
1976
1974
1974
1973
1977/78
1978
1977
1981
1979/80
1979
Production
(million tons)
Clinker
68.6
31.0
17.7
27.5
16.5
14.8
3.8
2.1
3.1
3.9
% Share
by Wet
Process
Energy
Consumed
Electricity
(gwh)
11,480c/
3,552
1,818
2,935
ElectriFuel a/ city b/
(kwh)
(toe)
140
0.158
0.090
100
99
0.147
92
0.105
2,400
n.a.
578
264
330
615
Cement
71.2
35.6
18.4
31.9
59
5
69
30
Fuel
(mtoe)
10.9
2.8
2.6
2.9
19.5
15.4
4.4
2.2
3.3
4.1
65
10
30
21
90
27
2.7
1.6
0.5
0.2
0.5
0.5
Source: Reference 16
0.163
0.108
0.132
0.100
0.161
0.128
123
n.a.
131
120
100
150
Table 5.11
Average Electrical Energy Consumption in Cement Manufacture in
Selected Industrialized Countries
(kwh/ton of cement)
1972
Power
Share of
Dry Pro- Consump(%)
cess
France a/
FR of Germany
USA
68
92
28
tion/ton
92
100
137
1976
Power
Share of
Dry Pro- Consumpcess
80
95
41
(%M
tion/ton
95
103
140
1980
Power
Share of
Dry Pro- Consumpcess (%) tion/ton
90
97
48
a/ For France, share of dry process also includes semi-dry and semi-wet
processes.
Source: Reference 16
102
108
142
Table 5.12
Shares of Different Fuels in
Thermal Energy Consumption in Cement ,
(M)
Oil
1974
Coal
Gas
Oil
1978
Coal
34
100
100
83
100
73
100
75
3
17
27
25
97
Gas
Oil
1980
Coal
Gas
ICs
- USA
-
FR of Germany
France
UK
Canada
DCs
-
Argentina
Brazil
Egypt
Indonesia
Morocco
Nigeria
Pakistan
Portugal
Turkey
Philippines
Notes:
63
100
-
For the ICs, the shares are based on the oil-equivalents of the
different energy sources. For the DCs, the figures refer to the
percentage of total cement capacity produced by plants utilizing the
different fuel sources.
Source: Reference 16
Table 5.13
30
40
750
1,500
3,000
8
20
33
14
28
45
Source: Reference 16
23
43
69
27
50
81
32
57
93
36
64
105
40
72
117
44
79
129
120
48
86
141
Wet
Long 2-Stage
Dry Preheater
Grate
4-Stage
Preheater
Preheater/
with
Precalciner Filtration
800
1,050
960
950
1,350
800
1,125
1,080
7-10
12-16
30-40
26-35
o
1,600
1,000
1,920
950
2,700
800
2,250
1,060
15-21
17-23
45-60
41-55
Notes: All capital cost estimates are indicative estimates only of the broad
order of magnitudes involved for the different cases and are not site- or
country-specific. In any given case, the costs could be different from
those indicated on account of factors and circumstances specific to the
case.
Electrical energy conversion ratio assumed:
Source:
Reference 16
187
Table 5.15
Production workers related to plant capacities in
certain countries
(thousand-tons
per year)
100 .........
200 .........
400 .........
500 .........
1,000 .........
flapana
USSR%
USA
1.24
0.82
...
1.55
0.75
-0.48
0.62
0.58
...
.0.93
0.78
0.54
0.32
0.30
0.15
Source: Reference 49
Table 5.16
Average labour productivity in major cement produeing countries
Administrative
and clerical
stal
Total
and related
workers as per.
centage of total
Country
Year
Productionand
related workers
France ..........
Germany (Federal
Republic) ......
1960
1.83
0.50
2.33
77
1958
1959
1960
1956
1960
1958
1959
1960
1960
1958
1959
1960
1960
1958
1959
1960
2.25
1.84
1.76
11.00
2.02
1.79
1.54
1.19
1.34
3.51
3.13
2.86
2.54
1.33
1.22
1.25
0.23
0.34.
0.34
1.9
0.36
0.74
0.72
0.25
0.25
0.62
0.55
0.50
0.63
0.28
0.26
0.28
2.48
2.18
2.10
12.90
2.38
2.53
2.26
1.44
1.59
4.13
3.68
3.36
3.17
1.61
1.48
1.53
91
84
84
85
85
71
68
83
84
85
85
85
80
83
82
82
India ...........
Italy ............
Japan ..........
Netherlands .....
Switzerland ......
USSR ..........
United Kingdom ..
United States ....
Source: Reference 49
Kcols/kg
1.900
1.800
1.700
1.600
1.500
1,400
Cx
00
Oc
1.300
1.200
1.100
1.000
900
800
700
1955
1960
1965
1970
1975
1980
Year
Figure 5.1
Source:
189
TItal ied
i
:nestment
(mi1ion dollars)
(million dollars)
to5
l'.0 I
tan
1
~,~E-~i~%a
I
-I 4T
rt\
Irr
(.O
IrT"e
i
cl
ij
-I
?a
.o
&I
so
S30O
Io
0~-I'.
- --
t =I
r
Scale
ij I
UNITEDSTATES
10
10
-3
i FEDRAL REPUSLII
SOF GERMANY
, li
0- r
-Tii~
-- ]
~~--
jI
IIA
30
5,
I!
4o
20
06
20
to
40
sa
ge
Ie0s
lm
Io
30e7
Plantlcapacit
------
-- Y-
4.Mo
10
inlfthouundtonisperyer
11
l l7.0
5.0
-
4.0-
LO0
-
1.0
0.1
...
0.I - -USS
o.
+411, *,, _ _ %
I-
OA- - -JAPAN
UNITEDSTATES
6.1
ILI
rrr
rr
IIII - I
~rlrrrrrr
Source: Reference 49
190
in
such important
industrial
instruments
environment.
the
affect
Various
governmental
and
institutional
competition and
as cement
facilities
dictate
which
politics
industrial
instruments
affecting
in
competition
ownership,
the cement
(ii) market
segmentation and import controls, and (iii) interest groups. Each of these
issues are discussed below:
6.1.1 Licensing and/or direct state ownership
For
in
involvement
industry.
Such
and,
types
of
in the
these
sometimes,
for
ensuring a competitive
atmosphere
and
191
involve
to
decisions
into government's
sometimes
this
pricing and
of
finance.
other
the
government
scale,
difficulty
of
the
the
of
testing
terrain,
may want
reasons- for
state
Larger
extensiveness
to promote a
involvement.
of
infrastructural
some of
Most African
more
the
countries became
governments
found
it
procedures
which tend to raise the costs and delay project executions, larger
objectives
to
raise
employment
social
skilled
project
differences
or
implementation periods,
employment levels.
192
instruments
state
distribution
of
cement.
The
involved
is substantially
eliminating
competition among
cement
consumers
commonly used
are
give
cement
industry. Duties on cement imports are typically no more than 10%, in view
of
natural
the high
protection
factor. Moreover,
in most developing
simply
by
made
the agency,
often
the
in
firms in the
technology
in
countries.
plants
cement
in the
These
firms
have
been
developing
economies mostly and some industrializing countries. Not only do they also
supply a major
portion
of
developing
country
193
in
producers
the
large-scale
countries
industrializing
cement
technologies,
either
replicate
by virtue
basic
these
of existing,
to
or
they
these
they
also
alternatives.
While
there
is no
reason
in
there appears to be an
to
control
of
the
the
equity
prospective
of
new local
cement
projects,
well as other industries, resulting in higher profit margins. Not only are
investment requirements less at the
distribution
stage,
but
government
price controls also tend to be less damaging than at the factory door. In
any case, existing
cement
incentive to contain
the
manufacturers
entry
of
new,
into
the
and
are
preserved
through interlocking
ownerships,
if not
such
as
local
financial
institutions
projects
are
in developing
in cement
companies.
equity
194
with
relatively
utility-type
assured
equity
on
return
returns. The
with
some
instruments
mostly
used
are:
oil
reflect
shock,
what
to
turned
the
following
governments,
term
be long
to
increases
real
their
in
to
adjust
to
reflect
higher
energy
plants,
of
costs
made
more
task of
the
difficult
than
usual. Restrictiuns on energy price increases, at the same time, made the
choice of process difficult
because
The
experienced
unprecedented
in
controls
of
cement
production
costs
to
pass
on
cost
increases.
price
be
to
of
relaxation
of
195
in
to induce
order
investment
investment
demand
had
profitability and
lack
of
both countries
growth
because of low
in
cement
capacity have
stagnated
more
been
control has
Price
incentives.
In
industry.
the
in
Guatemala, and
in
Colombia
has
substantial export-oriented
begun
to be diverted to serve
domestic markets. Nevertheless Colombia has remained one of the main world
exporters of cement in recent years.
Governments seem to control cement prices in
balance
between
considered to be
price
essential.
The
an
and
stability
use
of
order
to
strike
on
what
would be high. However, in times of slack demand, such a price regime does
not enable the producer to sell all
price
control
acts
only as
a one-way
street
to
an
of slack demand.
In Thailand and
Colombia,
there
may
have
been
a potentially
severity of
past
1970s
of
contrrus
which were announced in early 1982. Because of the relatively high impact
196
of transport costs on
industry,
cement
the
unless
producers
lowest-cost cement
important
natural
price
advantage
is diminished by
output
in domestic
low
of
production in such
cost
to
the
government,
production. Unless
of
markets
the benefits
of
share
reducing the
thereby
counteracted by
offsetting
domestic
consumers
incentive
to expand
and
implementation
timely
operation.
Egypt,
protection, may
cost
responsible
partly
been
have
for
the
inefficiency
1970s
severely
resulted
reduced,
in Turkey
and
sometimes
ability
of
the
investors
It also
to
complete
the
profits
projects
in
the
construction phase.
By
way
of
contrast,
industry and to foster efficiency during times of scarcity. The more rapil
start-up and higher capacity utilization
Indonesia
were
almost
certainly
of
projects
induced by
the
in
Argentina
lucrative
and
market
197
price controls
side
of
cement
consumption. Uneconomic
Reports
are
particularly
common
in
such
the
generally
issue of cement
major
consumers
have
a conflict
prices.
Some
of
cement
in most
countries,
countries,
such
are
the
lowest.
Part
in which
of
cement
prices
paid
by
government into cement manufacture can also stem from desires to minimize
any wider adverse effects of price controls, while simultaneously assuring
availability of cement to meet government policies.
In heavily state controlled environments, like those
Egypt
and
Morocco and
India
India
(the
in Morocco,
in early
1982),
the
extra complication
of paying
the
equitable
fashion which
burden
of
administering
avoids
price
undesirable
risks
control
systems
consequences
further
in an
of the types
which free-market
19B
capacity
of
controlled
quota
can
defining
of the quota in the free market. The system also introduces the concept of
marginal cost pricing since, even
if the
still be
economical
to
increase
output, provided the marginal cost were lower than the marginal revenue of
the additional production.
are
two
major principles
such as
principle
involved
at
first is that of
The
cement.
access
in the allocation of
a similar
The
price.
the higher the price to the producer. The Chinese have generally tended to
use the latter principle which provides a form of
the
small-scale
equalization
used
cement
plants
by
countries
in China.
such
as
On
natural
the
India has
protection
to
these
199
met
regardless
of
throughout
plant locations; their use, hence, calls for extra government vigilance to
avoid costly distortions in the structure of the industry.
The basic objective of the policy of freight
have
equalization
to
freight charge is
built
into
the
free-on-rail
on
all
simply
are
in the sense that they only help to define the average freight
(or
is
to
location
are
subsidized
the extent that actual freight charges per ton exceed (or
freight
policy
encourages
an
inefficient
allocation
of
costs
incurred
overexpansion
result the demand for transport services is higher than if transport costs
were fully payable.
(2) A possibly more important point is that the transportation costs
would
counted
that
benefits
arising
to
from
lower
because
of
given
economic
inadequate
investment.
Consequently,
of
those
200
benefits.
(3) Existing
units
transportation
savings
far
away
eliminated
and
if
producers
to
invest
in exploration of limestone
freight
equalization
consumption areas,
to
nearby.
(5) In areas where the economic cost of supplying cement
than
is much
higher
economize on the
use
of
cement
and
to
substitute
for
it other less
obligatory
subsidize
the
different producers.
way
to the
complexity
of
201
government scrutiny of
private
investment
decisions
in
the industry.
if market
forces
tend
to
be
more
readily
promoted;
in the
to
adopt more
industrial ventures
energy-efficient technologies.
from
Moreover, the
the
continued
rise
existence
plants
in
of
the
apparently
Western
profitable
world
and
the
expressed by many
technical
experts
in' the
cement
industry as to the
quality of product from these plants. The efficiency of the shaft kiln has
been considerably improved over the last 25 years, and cement
plants
has
these
plants.
The
improvements
from
kiln
feed
without
excessive
by means
of
moisture using
preblending,
the
pan
type
economy by exact proportioning of fuel and raw mix combined with efficient
insulation of the kiln, minimum
discharge
gates,
air
leakages
using
efficiently
sealed
202
the fire
zone.
Below
the
fire
zone,
solids
are
cooled by incoming
combustion air. In this way substantial heat is recovered from both solids
and gases before they leave the kiln. The problem of
uneven
heating
and
movement through the kiln that plagued the early vertical shaft kilns have
been
largely
overcome
pelletized feed, incorporating the correct amount of fuel into the pellets
of raw meal. With a pelletized
feed
occur.
its
own
correctly
are
to
"hang
eliminated.
fuel, it is said
and
be
necessary
to
use
dioxide
kiln
operation
the
above
points,
there
seems
to
of
producing
cement
applications
this
kiln
is not
be no reason to
personnel,
but
ror
rather
203
should
not
be
used
as
may
smaller plants
not
be
regarded
as
in using, where
possible and
safe,
cements of lower strength than the standard Portland cement. The potential
savings
are
is estimated that
requires
the
only 20
full
Approximately
percent
strength
another
of
of
international
standards.
cement
has uses
such as
mortars, plasters,
foundation
concretes, concrete blocks, soil stabilization for which low grade cements
would be acceptable.
The
use
cement.
some instances, where market size and the quality of raw materials justify
it, a producer can also vary the product mix so as to include higher value
specialty cements. Unfortunately some of
either
consumer reactions
cement
is equally
to
market
prices
as
suitable
systems.
Changing
product standards takes time and can be difficult. Moreover, where product
204
quality
is
diminished
or
building
characteristics.
specifications
product
practises alter
otherwise
can
in
are
tandem
with
changing
cement
builders
of
205
explanations
of
market
the
factors
area
of
failures
of:
an
in
economic/financial
and
engineering
such
contributors to erroneous
economic policies.
below.
(i) Freight equalization
The
freight
cost
equalization system
provides
a complicated
different
of
the process which do not seem to justify the gains received. Nor
seem possible
to
would otherwise face adverse transport costs, since there are more
effective
it
and
does
instruments
direct
far from
to
benefitting
a given
region,
freight
freight
suppliers
of
cement
in
certain
206
remote regions were it not for the larger firms with lower operating costs
reaching those markets without bearing transportation costs.
In order to reduce expensive transportation flows among different
regions of
a country, a gradual
reduction
of
investment.
costs
scope of freight
regional production
pooling
the
be
can
time.
be
The
gradual
reduction
of
freight
countries
provide
influence
true social
the
both
the
signals
which
induce
Since
these
technical
market
change
and
opportunity
costs
are
misrepresented
to
decision makers.
energy,
capital and foreign exchange) has typically favored the large scale plant.
These
for
scale
cement
technology
that
is more
often
desirable
output
than other
is larger
that
larger
than
for
small scale
plant
otier
cement
technologies.
prevent
207
(b) Institutional factors
The
institutional
framework
(licensing,
financed projects,
involving
essentially
over
favors
a large number
local financing.
Lenders
small projects.
project
of
have
proposal
a few
large
smaller projects
difficulties
the large projects are excluded from duties, and companies engaging
large
scale
priority
project
be
are
in
in a
exempted.
the
form
of
the
plants.
Moreover
smaller
plant
required
due
to
technical
diseconomies
choice of
technology
in
assistance
is expensive
of
and
scale,
central
small
for the
training
over by
have
been
adopted
or
the industrialized
countries. Often,
these codes
Portland cement standards for purposes where a lower quality product would
equally satisfy the given performance requirement. More appropriate
based
codes
open the door for lower quality cement as well as inexpensive substitutes
of cement in many sectors like housing, irrigation works, dams,
transport
quality
of
small
plants,
particularly when
run
208
production
the
technologies
for
small
successfully
industry by
the
predominantly
or
completely
private;
in which market
or
periodically
government
relaxed. to
subsidies
(penalties)
general
price controls
are minor
non-existent.
fit
in
mixed
and/or
or
examples which
are
description. Group
are not
zones
and/or
state
is substantially
involved
in
segmentation if it does
not
control distribution
in
a class
of
Egypt
is
209
have tended
to
greater
market
available
to
all
of
these group
of countries in
additives
The
first
cement rather
than
two
alternatives
to
producing
it. Substantial
investments
in
expected
land-based
be
silos
feasible
to
and
be
bagging
hence
stations are
permanent,
exporters
such
as
by
its cement supplier in Greece, making its landed cement prices (bagged, on
the truck at the port) about $55-60/ton. Savings included the avoidance of
higher shipping costs on bagged versus bulk cement, of port demurrage,
3-4%
unloading
losses,
landed
prices
of
up
to
The
fact
neighboring
double
those
East
of
African
Egypt,
region were
indicates
how
210
be
for
realizing
exporters
within
easy
access
for
an economically attractive
option. Whether
it does
so
is primarily a
long-term
shipping
cost
savings
to
increase
the
between the FOB export prices of clinker and cement; for example, a $15-20
the
two
Such a $15-20 per ton FOB difference (as compared to bagged cement) can be
more than doubled
on
a landed
CIF
basis.
This
then
provides ample
utilization
capacity
size necessary to make bulk shipment attractive should also offer greater
of
economies
scale
in the
The
size
of
low-cost
additives
where
raised
by the
raw
materials
are within
easy
regards
capital
cost,
the
reach,
itself
and
becomes
energy is not
economically
inclusion in a project of a
211
less
selective
use
of
expertise has
to be
experienced,
costs
substantial,
can be contained
likely
Where
substantial
partner
local
equity
appears
sponsors
involvement
preferable
have
of
to
help
to
contain
a strong
relying
no cement
costs,
by
the
to be
even be
industry expertise,
foreign sponsor/technical
only on
technical
know-how.
Turnkey
particularly
in
assistance
contracts
cases where
do
not
project
of
reasons,
investment
decisions
in
the
cement
First,
decisions
complicated
by
ingredient,
limestone,
the
fact
are
on where
that
to
deposits
numerous
locate
of
cement
projects
are
and widespread.
Moreover,
the
expensive
weight
ratio;
both cement
the
economies
same
are
For
limestone
significant
and
reasons,
even
though
there
are
exports
tend not
to
be
an atractive
or
freight
212
fragmentation
and
Prospective
for
can
investments
in
small
supported
by
be
institutional investors
in
the
scale cement
cement
industry,
to
and
not
necessarily
accept
to
possible
industries
in developing
are
for
the
small
and have
only
lack of
deposits,
many
countries
operate
grinding plants
limestone
clinker. Apart from Nigeria, typically markets are small and dispersed and
do not permit plants with economies
markets and establish a regional plant. In some countries even that is not
feasible, given their low
plants
individual
technological
has
population
difficulty
developments,
in
keeping
international
for
Thus
density.
the management
itself
industry
of
about
informed
are normally
set
by
the
smuggling
occurs
213
the
parties
concerned
these
problems
about
developing
norms
and
standards
appropriate
for member
214
case
studies
understand
some of
small-scale
plants
in
India.
The
Mali
in
in
an
energy-scarce land-locked
country.
7.1 India
(a) Introduction
Cement
1.2%
of
industrial
production
but
it was
the mid-thirties and during the second world war that the industry
of
1950,
capacity increased
from
30,000 tons to about 3.3 million tons with an actual production in 1950-51
of
2.95 million tons. The annual rate of growth of the installed capacity
during 1971-72 and 1978-79. At the end of 1978-79 the annual capacity
was
22.6 million tons. About 65% of the total capacity was based upon the wet
process, and capacity utilization ranged from 40% to 100%; the average for
the whole industry was 86%. Table
five-yearly
since then. The development of the cement industry from 1970 can be
215
1974-75,
upto
1979. Between 1969-70 and 1974-75 installed capacity increased from nearly
16 million tons per year to over 20 million tons per
rate
of
4.6%.
around 15
Production
million
tons
was
per
period,
growth
an
at
annual
year.
Capacity
year
utilization,
in
the
1960s.
below 80% on
During
the
per
annum
faster
production
growth
rate of 7.0%. In 1978-79, 22.55 million million tons per year of installed
capacity produced 19.42 million tons of cement.
Beginning in 1979-80, there was an acceleration in the increase in
installed
After a
capacity,
decline
the
during
average
the
growth
economically
level
of
29
million
tons
disastrous
(8.6%
in
per
year
annum)
of 1979-80,
reaching
an
tons.
By
has
continuous
and
growing
shortage
of
has
current
cement
availability
in
1979. There are black markets in which prices are at least 25% higher than
official
prices
and
much
higher
three-tiered
second
priority;
and
216
the
remainder
residual
distribution
private users,
most heavily by
but
also
by high
installed
slow growth
in
of existing capacity. The main reasons for the recent deterioration in the
rate of capacity utilization are coal and power shortages.
in India has
the
of
visualized
problems emanating
small-scale
cement
plants was
the
smaller
over the country, and on the other hand to contribute to uplift the
economy
and
local
the
load
in transportation
creating
additional
of
the
cement
employment
burden
of
freight
by
areas.
In India, the small-scale cement industry has been extablished tue
to the pioneering effort of the Cement Research Institute of India
a national
(CKI),
217
to
technology
viable
the
for
small-scale
cement
of
the
production
these
techniques
analysis of
the
efficiency
extent
to which
rationale
for
the
reduced scale is
justified in the Indian cement sector. This section examines the relative
costs
within
the
small-scale
section
has
been
the
cement
sector
large-scale
extracted
from a preliminary
report
on
the
investment
costs
in the
three VSK-based small-scale cement plants. Statistics for the Saboo design
are
based
on quotes
manufacturers).
For
from
Shree
Engineers'
(the designers
and
the
(30, 50, 100 and 200 tons per day) have been provided based upon estimates
by CRI (the licensor)
plant suppliers).
and
Movers
Ltd.
(one
218
in
the
various
sizes
of
This
of
technologies,
investment
919 and 792 respectively, are lower than those for the 30
plant.
economies
Movers/CRI
in operation.
The
The
Movers/CRI
design,
on
the other
hand
and
the
and, hence, the investment costs are also in between the other two.
(ii) Production costs: Available data on the production costs from various
plants employing the respective designs
from Lokapur Cements in Karnataka State are used for the Movers/CRI design
and those from Arif Cements in Jagdishpur (U.P. state) are used
Saboo
design. The
statistics
ATDA
state).
Detailed
breakdown
of
the
the Movers/CRI plants are similar, those for the Saboo plant are
higher.
for
somewhat
7.4, 7.5 and 7.6. Analysis of these tables yields the following features:
-The coal costs at the ATDA plant is higher because it uses steam coal for
the rotary drier.
-Raw material costs are
high for
the
location
of the plant at a distance of 250 kilometers from its raw material source.
Labor
costs
are
219
due
Saboo plant
Sales
realization:
Local
factors
and
affect
different
regions
levels
a price
higher
than that
prevailing
plants
is
given in Table 7.7. The main component of transport costs incurred by the
small-scale plants is that of
fuel,
however
Western
U.P.
state
and with
large-scale cement
plants
companies
private
in
substantially
the
(the
figures
figure
sector).
used
While
plant
averages for 15
material
costs
are
higher for the large-scale plants, power and fuel costs are
the
220
vicinity.
their
techniques
smaller deposits
of
limestone
are
Low labor costs are generally the case in small plants because
the
much
lower
for
the
large sector since this represents the ongoing costs incurred (interest on
outstanding
loans
and
depreciation on
sector,
the
costs of
assumed.
Transport costs for the small-scale plants are given in Table 7.7.
As a comparison the costs for large-scale plants is given
Total
transport
costs
in
Table
7.9.
small plants. The transport savings from small-scale cement plants can
be
ratios
related
is presented
to
the
in Table
sectur,
Movers/CRI
Within
the
221
to
compensate
for distortions
in
the
supply
7.11 using
shadow
prices
for coal,
power, labor and transport of cement. The conversion factors in Table 7.11
constitute
an assessment
of
these production factors within India. An annual cost has been imputed to
capital in Table
productive
7.11
by
employing
a capital recovery
factor.
The
life assumed for the Saboo plant is seven years whereas other
The
30%
less
than the
prices
of
per
cement
in
context,
the
ton in
per
prices
India,
ton. Export
from
some
European
per
ton.
222
7.2 Mali
(a)Introduction
Mali is a landlocked
Sahelian
country
in West
Africa.
It is
semi-arid and among the poorest of countries in Africa and worldwide. Over
80%
of
export
earnings.
population growth was 2.6%, the GNP growth was 4.5% and GNP/capita
2.2%.
This
impoverishment
results
growth
high
population growth.
Large
concessional
aid
was
spent
a large amount
of
foreign
imported cement
insurance and freight) cost because the transport network is very poor and
unreliable. As a result of the growing demand and the very
imports
(due
to
multiple handling
of
the
of
high cost
this
low value
planned a cement plant which was not competitive with imports even at full
capacity utilization.
Industrial development is constrained
land-locked
situation.
The nearest
in Mali
because
of
its
side of the country on which Mali has to rely almost exclusively. Domestic
energy sources are almost non-existent. Small and geographically scattered
223
investments
in
minimum
of
potential
industries
that
the
(GDI)
Gross
DomesLic
Investment
is
40%
compared
with
60%
in
scarce
remote
from
urban
consumption
relatively poor quality making them very costly to exploit for the
industry.
capital,
In
Mali
Bamako,
the
is
Astro
still
deppsit,
under
cement
The
deposit
is
predominate.
The deposit is geologically difficult to exploit and its make up will have
to be carefully studied for its possible use in cement plants.
Gypsum
of
the
country
the
siting
of
an
for
energy
intensive
exploitation
industry
like
and,
cement
production is difficult.
historical
development
7.12.
of
for
224
Mali
Mali remains one of the lowest cement consumers in the world, in line with
neighboring landlocked countries, but
far
the coast or with similar GNP per capita as shown in Table 7.14.
Given the predominance of rural population
level
of
income,
(80%)
and
their
low
the railroad line. The state owned plant (built by the U.S.S.R., employing
the energy intensive wet process) has a capacity of 60,000 tons per
but
it has
year,
not cost competitive with the price of imported cement. Imported cement is
transported by rail from Dakar,
Senegal,
road
are
$1-20/ton higher. Retail prices of cement are almost twice as high as the
CIF
prices
at
the
price at an importing
port
India.
Composition of
retail
imports
and
distribution, and
Since, then imports have been liberalized. Somiex takes a margin of 10% on
top of the delivered price
Mali,
the
distribution
is concentrated
cement
(90%)
around
Bamako.
The
225
be
cautiously
considered
statistical
because
must
of
tightness
the market
Niger,
and
Upper
Volta. A
World Bank report estimates this illegal trade at 500,000 tons per year.
Market projections for demand are usually overly optimistic due to
the
reference
country
cement
are
based on years
Forecasting
cement
demand
for
of
decade
the next
of
these
in Mali is
some
to
GDP
or
to
1990 based upon the past trend of consumption (15 years) and prospects of
economic growth rates
a market
rotary-kiln
large
cemeut
enough
plant.
to
warrant
In Europe,
building
the
that
Mali will
a new large-scale
per year. The market for the region, i.e., Mali, Upper Volta and Niger
about
700,000
tons
per
year
is
located
a strategically located,
suitable and sufficiently large raw material deposit which to date has not
been found; (2) existence of a good transport network among the countries
226
cement
be
easy
considering
project. Due to
the
economic
the
countries'
non-existent. Thus it seems that Mali should not consider any new
for
will
and
location,
project which
project
domestic clinker production. The other solutions that remain are: (1)
(2) import
bulk
cement
and bag
it in the main
distribution center of Bamako; (3) import clinker and grind it in the main
distribution center; and (4) rehabilitate existing plants. The World
conduted
a review
of
Bank
all
and
station
grinding
are
Both alternatives
prices
low
grinding
should
alternative
compared to
the
of
alternative.
The
clinker
be
distribution
in
distribution
supply
sensitive
very
cement
cement,
use
of
this
alternative
local additives
has higher
and
employ
clinker are
usual,
whereas
bagged
cement
is
plant in Mali may be promoted: (1) to avoid the shutdown of the plant and
therefore employment cutback; (2) to
center
and
locally
developed
maintain an
existing
distribution
227
reasons
best
the
main
7.3 Nepal
(a) Introduction
Use
of
Portland
cement
recent and its manufacture is still in the infant stage. Modern buildings
and large construction works mainly use Portland cement.
cost
of
cement
and
the
fact
of
that
the
Due
to
higher
on
the
only
existing plant
around
80%
to
Ltd.
demand.
Pvt.
85%
of
the
total
imports from India, as well as other countries. The nearest plant in India
is 500 kilometers from
the
border. As
India
not
alone
meet
the demand. Imports from other countries take at least three months. Nepal
had
to rely on imports until two projects, i.e., Hetauda Cement Ltd. (750
Cement
Project
228
Cement is also planning the expansion in two phase of its 160 tpd plant to
a 400 tpd plant. The planning calls for Himal Cement to cater to
part
of
the demand in Kathmandu Valley, Hetaudu Cement to supply the Terai region,
where it is located, and to supply the other parts of the country as well.
Udaipur
Cement
limestone
limestone
such as clay,
deposits
shale,
and
are
part
There
the country.
are
soil,
located
suitable deposits can always be found near the limestone deposits. Gypsum,
pozzolana and volcanic materials for manufacture of
not
available
in Nepal.
blended
cements
are
Additives
breeze
at
be
Himal
Cement
is imported from
either
plants in Nepal.
Details on the vertical shaft kiln employed in
plant
the
Himal
Cement
are shown in Table 7.19. In the Himal plant the fuel consumption is
in the range
of
930-960
kcal/kg
clinker
for
is arouni
229
supply
very
of power supply. At
intermissions
and
power
efficiency.
c) Poor
maintenance
due
to
shortage
of
the
public
sector
control,
with
in
of
terms
low
of
grade
are
and
ample
labor
landlocked
supplies
at numerous
fuel-scarce
countries,
there is an acute undersupply of fuels to run these plants. The use of low
grade
fuel
in
vertical
shaft
Nepal which does not have to expend valuable foreign exchange on importing
oil for firing itb cement plants.
Manufacture of blended cements using slag, pozzolanas, and fly i.s
could contribute to
energy
consumption.
So
too
230
used
and
imports
of
231
Table 7.1
Cement Factories and Production in India
Yeze
Number of recto.ries
1914
1934
260
7T
950
Annual Growth
Rate Duzng
13.8
1944
17
1,600,1
5.3
1954
25
4,3001/
10.4
19(4
36
9,690
8.4
1989
42
13,576
7.0
s0
14,263
1.0
56
18,2381
5.1
1974
1979
1983
8.6
1984
77
29,1424
Source: Reference 10
Ceutia
ptez.
Exscudirng prdud
tta
ta
f~re
.aame.ent plantf.
15.0
Coi
parative
Investmrent
Table 7.2
Costb of VAm plants in
India
ATLA
Saboo
'25tpd
20tpd
30tpd
50tpd,
100tpd
200tpd
0,80
1.00
1.00
1.00
1.00
1.50
18.47
16.31
18.50
21.71
28.72
.47.46
Land
Building
Movers CRI'
Movers2
ClIi
Movers
15.60
7.00
18.35
23.86
42.13
8.05
5.00
14.56
15.56
33.11
8.15
4.00
15.07
24,07
31.24
8.00
2.00
Miscella-neous
10.00
11.76
18.53
Total
49 80
20.96
66.51
6.77
5.00
9.00
75.84
52.27
95.01
792
960
Dust Collectors,
Elevators & Conveyors
Pre-,operative Expenses
TOTAL FIXED CAPITAL
j/
Wsurce: ieference 10
CR.I
2-P.-/
30.52
95.20
94.01
44.54
134.28 151.02
16.32
13.59
131.50 130 31
797
790
180.32 19 .06
546
597
250.04
26.16
334 16
506
Table 7.3
Couparative Production Costs of VS.I plants in India
(W/t cei,,ant)
Arii
RRL4/
70.35
187.42
90.06
183.68
157.50
144.00
121.55
122.97
122.00
94.15
75.00
62.12.
26.36
98.38
11.57
158.08
154.47
156.00
120.08
Interest
104.99/
Item
_ATR
Lokanu 1_
Raw Materials
69.74
Coal
Power
Labout
Depreciation
78.677-/
780.25
5
74.8Y
10 .005'
95.276
76.00J
44.27-2
63.137Y/
863 95
663.66
557, 60_
_ _
1J
7500 tpa
2/ 90 tpd 6 330 Jo,-king days p.a.
/ 20 tpd @ 300 working days dad 90', efficiency.
5/ 18% on working Capital, 12A on fixed Capital.
7/ 5% on
3
6/
52300 tpa
20:, and 15.
Source: Reference 10
TaLle 7.4
Raw .laterials cad Fuel Rgquirements
Cost 1R/tonne
4A.
Raw Material
Lokapur
Arif
-_
'Roquirement/t Cement
ATOA
Lokapur
Ari f
1.20
140
45
Limestone
1.19
3.
0.03
Kankar
Clay (Red
0.21
Burning)
BLue Dust
Total Raw Meal
279
Gypsum
280
330
1.60
1.41
0.06
0.04
1.42
0.05
53.00
57.15
173.42
16.74
13,20
_ 14,00
69.74
70.35
0r
187.42
74.88
,157.50
144.00
183.68
157.50
144.00
112.00
9+.15
800
0.04r,
36.00
S.L.V,
Coal
700
0.104
72.80
Cake Breeze
720
0.104
150
P,)wer (Kwh)
Wo)urcet: klferteilCC
10
3.30
12.80
Steam Coal
720
3,15
3,52
Coal
750
166.60
20
0.22
0.iC
320
Arif
54.00
0.011
320
Laterite
Lokapur
ATOA
37.00
1.40
Marl
0.21
125
0.20
90
12.
97
Table 7.5
eber requireents
lHumber
Type
Administrative
Average pay/employee/month
Lokapur
ATDA
Loklapur
Arif
ATDA
11
591
1139
933
453
Arif
Total
ATDA
Lokapur
Ar i f
714
78w0
123.0
60.0
673
771
73.2
130.0
780
060
47.0
3;.0
46.8
52.0
12/day
500
12/dayv
12".1
360.0
119.0
O/day
4-11
8/day
156.0
180.1
132.0
465.91
783.1
493.0
Technical
(a) Plant
(b)
Laboratory
Production
Semi-skilled
(.)
(b) Unskilled
Total
122
I/II I
le
7500
62.12
117
29700
26.36
16
5000
98.38
~_I_
P. '','(()
Source: Reference 10
Table 7.6
Other Production Costs
Estitmated Cost/yeac
Item
DA
Cost/t (Ai
Loka;our
Arif
Loiapur
ATDA
Ar it
Office overheads
90.0
341J.1
60.0
12.00
11.72
12.00
Packing material
750,0
2673.0
500.0
100.00
90.00
100.00
6.76
50.7
Lubricants
Repairs,. Maintenance
and Consumables
Insurance
224.3
1353.7
70.6
213.0
11 85w6
45327.3
175.0O1/
29.91
45.0
780.0
7.17
9.00
158.08
151.47
156.00
____
Source: Reference 10
Includes cost of lubricj-nts
Auminj
3/
33,%
fixAed
wat,,
pCCre1 Ty rePorted
,n tihWe
co&L
35.00
9.41
__
1/
45.5R-/
of ki.
62.
Table 7.7
Costs/t
.4anspo
Mt
Limestone/Marl
Lokapur
Ari._
10.00
110.00
Cemont
Lokapur
12.00
7.40
Arif
130.90
Coal
Steam
153.00
6.89
SLV
324.00
33.70
Coke Breeze
30.00
360.00
380.00
39.52
75.60
.76.00
182.31
2 2 4 .1
183.00
10.97
8.99
9.15
98,48
96.59
216.05
12,6
1'.6
Gypsum
Total Raw
t
3-1/
aterials
Transport Cost as
of Production Cost
/
19.202
Cement
30.00
22.003
117.68
126.59
S.5
Source: Reference 10
1/
/
j
Inoludes 1b.
E;LLhoI.
195.50 by rail
ud from 50Y
Lutimated fluii
I aJz
1 .Ald ald
25.0
local
Lo
sale 4 f 25 t
J:'%,07/0,3)fe in
tliere.
locally aL Jaglshpiur
@ I.
13.33/L.
238.05
19.2
--
Table 7.8
Ccaparison of cost data for small and large scale plants
Installed Capacity
20 tpd _25
792.00
91 9.27
645,45
1035.00
9)5.00
939.70
Investment Cost
Sales Realisation
Cost
Production Costs
100 tpd
tpd
Cost
_-
Raw Material
187.42
21. /
69.74
8.9
Coal
144.00
16.7
103.68
23.5
Power
94.15
10.9
122.97
15.8
Labout
98.38
11.4
62.12
3wr0
Cost
A_
70.35
0.S
190.62
21.8 )
147.38
20.6
122.00 18.2
80.56
9.2 )
3.9
86.67
9.9
26.36
154.47 23.1
Interest
108.00
12.5
104.99
13.5
74,85 11.2
10. 1
63.13 .%4
100.0
___
16.5V
171.05
Net Profit
780 .25
100.0
214.75
21.
_ ~_
__~_~_
_____
668.66 10,o.
271.04 20.82/
__ __ _
C,,t
A#
, I
r ,,I I ta.
cuolii),IIies in
L,)ilv i lant.
94.013
13.1
161.53 18.5
201.15
26.1
99.95
11.5
29.02
4.3
166.67
19.1
47.01
7.0
872.81 100.0
711.87
100.0
5.1 32
106.13
13.0
47.03
____
Source: Reference 10
Average
0ost
157.50 23.6
2o.3
863.95
]__
Co!;t
818.00
27.0
158.t0
78.67
919.89
1450.002/
193.28
18.1
k-.8b
1154.18
9.9
156.00
76.00
1-450 tpd1/
86.81
Other ProductimCosts
Depreciation
165 tpd
(_/t1450ent)
239
Table 7.9
Large scale plants: Transportation costs
Iteam
Avergae Tz:nsport
costs (toinne)
Rawv!at-rials
26ij
Limestone
Coal
200235/
Gypsum
12(00-1500 - /
200-2355-
1.25-1 .30
15.00-15.60
0.23-0.32
50.40-57.60
0.05
10.00-11.75
80.20
Transport costs as
a o of Production
Costs
11.3
650 (nail)
Cement
200 (Road)
165.60)
195,78
1(.3
Source: Reference 10
1/ Estimated from
INCAER,
1979
/ ;.GR, 1984.
/ Estimate based on location of gypsunm produLcers
115.5&/1
240
Table 7. 10
Proauctivity
Capital-Output! /
Capital-Labour
('000ooo :)
Output-Labour
Tonnes,
Person
Aift
1.3
54.7
58.5
47.2
ATDA
1 .7
69.3
73.3
61 .5
Lokapur
1.0
212.9
337.6
253.3
ARC
4.0
204.1
132.8
118.0
Large Scale
3.2
265.4
332.2
337.3
Source: Reference 10
241
Table 7.11l
Ecorxnwc valuation of cement production and distribution
Conversion Factors
Coal
1,33
1.50
Labout
0.30
Transport (Cement)
Ari (20)
ATDA(25)
679.95
596.59
530.68
606.19
635.34
22.00
19.20
30.00
55.00
115.58
701.95
15..79
560.63
661.19
751 .+
Production cost
Transport (Cement;
Total
1.30
(Rs./t cement)
2/
Lokapur(1 00))
ARC(165)
Large
4i
Cqst Incr3ase/Decrease :
Coal
47.52
60.61
53.50
62.90)
Power
47.08
61.49
61 .00
40.28)
(-) 17.33
Labour
4.40
3.64
6.00
99.00
t25.94
120.50
Transport(Cement)
Net Increase
Annu_ i;Capital
Co st 1
58.96
229.374/
134.,359
1030.32
376.32
17.6
25.5
94.70/
11.00
60
I s..L7
I 15 4 . 50 Z/
1ce.
Total c.onomic
Cost
Internal Rate of
Return (06)
775.38
34.2
912.54
18.1
/15
Source: Reference 10
10C8.8
7.6
242
Table 7.12
Apparent Cement Consumption (tons)
Mali
1965
1970
1975
1977
1979
1980
34,000
40,000
71,000
63,000
90,000
85,000
Table 7.13
Selected Cement Consumption Indicators
Malli
1970
1980
Cement/capita (kg)
7.5
12.2
46.4
60.4
11.2
23.8
Construction Output
US$)
Cement/Million US$ GDI
(tons)
Cement/Million US$
Construction (tons)
0.86
1.4
3.6
3.6
Table 7.14
6,129
5,465
4,862
5,597
5,240
2,350
10,634
7,463
631,726
31,512
5,154
GNP/capita
(US$)
120
140
190
150
380
280
370
770
160
140
480
Cement/capita
(kg)
13
12
10
17
62
92
55
126
29
7
27
GDI
(US$ million)
103
172
213
'179
327
215
783
1,759
21 ,651
595
759
Table 7.15
Composition of prices (retail) in
US $ per ton
Source
Dakar
Mali
Abidjan
80.0
80.0
40.0
52.0
120.0
132.0
Taxes, Duties
29.0
20.0
11.6
18.0
8.6
18.0
178.6
178.6
Total Cost
Retail Prices
a/
1981
Table 7.16
Estimated profitability of various
cement supply alternatives (IRR %)
Alternative
Diamou rehabilitation
Diamou conversion
Malbaza expansion
Integrated plant
Clinker Grinding
Cc:-cnt bagging
Distribution center
Capacity
(tons cement)
60,000
185,000
120,000
300,000
185,000
185,000
185,000
185,000
Mali
15.0
13.0
-
1.2
-0.7
22.9
19.5
25.8
Table 7.17
Consumption of Cement in Nepal
Fiscal Year
Im
Import from
Overseas
Countries
Production
from Himal
Cement Co.
(Unit: Tons)
Total Corrected
Consumption
1962/63
3,035
32,230
36,265
1963/64
14,036
25,532
39,568
1964/65
23,959
37,380
61,339
1965/66
32,760
41,389
74,149
1966/67
15,585
19,417
38,002
1967/68
33,329
29,846
63,175
1968/69
54,401
17,162
71,563
1969/70
69,967
27,232
97,199
1970/71
65,245
23,088
88,333
1971/72
61,185
69,107
130,292
1972/73
59,000
78,581
137,581
1973/74
45,000
154,078
199,078
1974/75
56,080
163,321
14,000
233,401
1975/76
56,636
90,142
29,565
176,343
1976/77
127,470
77,071
42,036
246,577
Source:
Reference
Table 7.18
Fiscal
Year
Asian
Development
Bank
Holtec
Engineers
Engineers
Pvt. Ltd.
Indi
230
251
252
1981/82
253
276
278
1982/83
278
304
305
256
1983/84
306
334
336
279
1984/85
336
370
304
1985/86
370
331
1986/87
407
361
1987/88
448
394
1988/89
493
429
1989/90
542
Source:
Reference 2
1,000 Tons)
Engineering
Cg
Consulting
Co., Ltd.
Japan
Engineering
India, Ltd.
India, Ltd.
India
United
Consultn
ants
Nepal
300
216
1980/81
1994/95
(Unit:
Onoda
..
235
407
391
372
468
627
549
460
721
964
770
Table 7.19
Comparison of shaft kilns
Himal Plant
(Nepal)
Black Meal Process
CRI
India
Deggan Plant
(Austria)
Black Meal Process
Units
(Kenya)
2.9
2.8
1.77
2.9
2.4
2.5/2.6
1.18
2.6
Total height
8.25
8.0
8.2
8.55
1.35
1.2
2.1
1.7
Nodule diameter
mm
10-30
10-15
8-10
10-15
15-18
12-13
12-13
14
200-220
220
150
200
mm
3
Air volume
m /h
30,000
10,000
4,800
Air pressure
mm WG
1,200
1,300-1,800
600-800
*C
70-95
80-100
150
75-85
Clinker temperature
390
80-200
60-100
80-150
Coke Breeze
(India)
Coke Breeze
(India)
Anthracite Coal
(Swaziland)
Type of fuel
Kcal/Kg
Calorific value
6,400
Volatile matter
12,000
1,500
5,200
5,200
1-3
1-3
6,800
Kcal/Kg
20.5
970
950-1,050
1,050
960
Normal output
t/h
7.40
6.7
1.25
7.7
Maximum output
t/h
8.60
7.5
1.3
8.8
83.3 Co
80 L
70 L
Ash content
Heat consumption
28-35
27
70 L
16.0 S
10 Cl
22 CL
Coal addition or
interground
9.2-10.0
9-10
8.0
.)ut
k -. lerence
249
Conclusions
This study clearly shows that there is a great deal of flexibility
in the technology of cement production for developing countries. There are
a variety of choices in the equipment and options available for selecting
the type and level of
technology.
Large-scale
density
sources
and
density markets
exist
in addition
to
poor
where
infrastructure
for
transportation.
Developing countries are primarily
small-scale cement
because
of
the
plant
technologies
conditions
and
have
in
their
prevailing
lower
abor
shown
the
initiative
is not
technically
efficient
and
technology
and
to
its
rotary
thrust
has
development
in the
area
of
small-scale cement production. The developed countries have not shown much
interest
in developing
small-scale
cement
plants,
usually
high
density
of
demand
and
scale
well
in t:e
developed
250
in the developed countries, favor larger plants with the smallest possible
labor force.
There are doubts as to whether large-scale cement plant technology
is appropriate in all circumstances, on account of the large capital input
required, the long time-lag before plants can
limited
number
of
points
and
deposits
of
of
the
come
raw materials
of
high average
consumption
most
of
the
of
operation, the
in low
density markets.
into
stages
of
However,
development
for
encouragement
exploiting
has
not
small-scale
the
been
There
markets.
smaller
given
on
an
exists
technologies
a great deal of
but
adequate
international basis
to the
are doubts as to the quality of product available from such plants and the
quality of the plants themselves.
Under Indian conditions the small-scale vertical shaft kiln cement
plant does represent a viable alternative to the large-scale
plant
rotary
kiln
large sector, the less sophisticated Saboo design offers competition under
stringent condition that quality
monitored
by
of
the
cement
produced is carefully
251
of
the
per day.
The Indian case
that
study shows
transport burden in cost terms from 16% of the selling price to under 10%.
In a country with an overburdened transport infrastructure, this has to be
that
cement
of
deposits
small
there are
in very
production
product
local
is dispersed,
"status
the
in
the
supply
of
cement
plant
in the
machinery
inherent
the
cement
a political
projects.
Many
bias
in
favor of
capital
intensive
because only such plants are supplied and in some cases subsidized by the
established developed country manufacturers.
Recommendations
A research and development effort
developers
major
of
small-scale
international
cement
development
for
plant
should
be
undertaken
by
the
organizations
to
such investments,
ascertain
to
identify
which
the
252
between
the
The
the
interest
quality
of
the
of
machinery
established
must
available
machinery
for
smaller
suppliers in such
technologies
for
cement production
in developing
influence
conditions arising
to
subsidies
and
responsibilities in project
selection
should
constraints
do
without
not
technologies. Since
due
eliminate
there
from
price controls.
be
to
ensure
One
of the
that
is flexibility
in the
technology of cement
such
the
253
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