1.

Mining Raw Materials

The main raw material used in the manufacture of cement are limestone and clay.
Both raw materials are obtained from mining process in the quarry.
Mining of raw materials is one of the main activities in the overall cement
production process. Planning for mining of raw materials is crucial to the process
- the next process which ultimately boils down to the quality and quantity of
semen. Mining raw material unplanned and well controlled will lead to the failure
of the fulfillment of the target for the next production stage in relation to the
quality and overall production costs may reduce the competitiveness of products
to the same products produced by competitors
Terms of quality limestone and clay in the mining process is as follows:
a. Limestone
52% <Cao <54% and MgO <18%
b. Clay
60% <SiO2 <70% and 14% Al2O3 <17%
Stages of the mining process are as follows:
a. Stripping of overburden (stripping)
b. Drilling and blasting (Drilling and Blasting)
c. Excavation / Loading (Digging / Loading)
d. Transportation (hauling)
e. Solving (crushing)

2. Preparation of Raw Materials

Raw materials such as limestone and clay will be destroyed to reduce the size to
be easy in the milling process. The tools used to crush limestone called Crusher.
And the tools used to break up the clay are called clay cutter.
Crusher is generally used to break up the stones of the size of the diameter (100 -
1500 mm) to a size that is smaller in diameter (5-300 mm) with a breakdown and
suppression system mechanically.
Limestone (800 x 800 mm) 18% H2O sign Wobbler Feeder Hopper pass.
Limestone <90 mm would escape without passing Crusher (700 T / J). Clay (500
x 500 mm) 30% H2O sign Apron Feeder Hopper passes -2 using Clay Crusher
cut to a size of 90 mm 95% qualify. Products from Limestone Crusher and
Crusher Clay mixed in Belt Conveyor and stacked in the Storage Mix.
After the raw material will undergo pre-homogenization process to manufacture
pile mix. The purpose of pre-homogenization of the material is to obtain raw
materials are more homogeneous.

3. Initial Milling
Other raw materials used to make cement are auxiliary raw materials, namely iron
ore and silica sand. Iron sands contribute to the mineral sands Silka Fe2O3 and
contribute to mineral SiO2. Both auxiliary raw materials are mixed with
limestone and clay pile went into the milling process early, which is determined
by the raw mix design.
The main tool used in the process of grinding and drying of raw materials is the
Vertical Roller Mill (VRM). Media Her dryer is hot air coming from suspention-
preheater with a temperature of 300-400 C.
Vertical roller mills are the right equipment for milling and drying the material is
relatively wet. Milling and drying can be carried out efficiently in a single piece
of equipment.
Vertical roller mill running four major functions in one unit of equipment,
namely:
a. Milling (Roller & grinding table)
b. Drying (exhaust gas kiln, cooler, AH1)
c. Separation (Separator)
d. Transportation (Gas dryers ID Fan)
Raw materials into the Vertical Roller Mill (Raw Mill) in the middle (the mill),
while the hot air into the lower part. Material that has been finely will carry out
the raw mill hot air through the top of the tool. The material will be milled on
entry size of about 7.5 cm to max 90m. Milling using centrifugal force at which
the material is fed from the top will be thrown to the side for the round table and
will be eroded by a rotating roller for the round table itself.
Then the material will undergo a process of mixing (Blending) and
homogenization in Blending Silo. The main tool used to mix and homogenize the
raw material is the blending silo, with a stirrer media is air.

4. Combustion Process
In the combustion process is divided into three stages, namely:
a. Early Warming (Preheating)
After experiencing homogenization in blending silo, the material must first be
accommodated into the kiln feed bin. The main tool used for preheating raw
material process is suspension pre-heater.
Suspension preheater is one of the production equipment to preheat the raw
materials before entering into the rotary kiln. Suspension preheater consisting of
cyclones to separate raw materials from the carrier gas, riser duct which functions
as a warming raw materials (for almost 80% -90% of the heating of dust takes
place here), and kalsiner for systems with a process that begins prekalsinasi in
this SP. At first the raw material heating process occurs with the rest of the gas
flow results in the combustion process suspension preheater kiln through this.
However, with technological development, in suspension preheater heating
process can be continued with calcination process a portion of the raw material,
original equipment coupled with kalsiner suspension preheater which allows the
addition of fuel (and air) to meet the needs of the energy required for the
calcination process. Last appliances are now widely seen to a new factory with
the production capacity is large enough, and called the suspension preheater with
kalsiner.
Suspension pre-heater used consists of two parts, namely the in-line calciner
(ILC) and a separate line calciner (SLC). Material will go first to the cyclone top
to get out of the fifth cyclone. After that, the material will go into the rotary kiln.
The use kalsiner has the following advantages:
Diameter kilns and thermal load is lower, especially for large kilns. In the
suspension preheater systems without kalsiner, 100% of fuel burned in the kiln.
With this kalsiner, compared with kilns that use only the SP alone, then supply
the required heat in the kiln is only 35% - 50%. Typically about 40% of fuel
burned in the kiln, while the rest is burned in kalsiner. As a consequence of a
certain size kiln, with this kalsiner, production capacity can reach nearly twice or
two and a half times higher than when the kiln is used in the suspension preheater
systems without kalsiner. Specific kiln capacity, with the use of this kalsiner,
could reach 4.8 TPD / m3.Di in kalsiner can use fuel with low quality because the
desired temperature in kalsiner relatively low (850-900 C), so the chances of
fuel utilization at a price cheaper, which means the reduction of production costs,
can be obtained. Can reduce the consumption of refractory kiln, especially in the
combustion zone due to thermal load was relatively low and the burden shifted to
kalsiner.Emisi partial combustion NOx is low because the combustion of fuel
occurs at a relatively low temperature. Kiln operation more stable so that it can
extend the life of the compound undergoing refraktori.Masalah circulation (such
as alkaline for example) is relatively easy to overcome.
b. Combustion (Firing)
The main tool used is the rotary kiln or rotary kiln. Inside the kiln calcination
process occurs (up 100%), sintering, and clinkering. The temperature of the
material that goes into the rotary kiln is 800-900 C, while the temperature of the
clinker coming out of the rotary kiln is 1100-1400 oC.
Rotating kiln (rotary kiln) is the main equipment in all units of the cement plant,
because in the kiln will occur all the chemical processes of formation of clinker
raw materials (raw mix). Broadly speaking, in the kiln is divided into three zones,
namely calcination zone, transition zone, and zone sintering (klinkerisasi).
Technological developments resulted partly transferred to the calcination zone
and kalsiner suspension preheater, so that the process that occurs in the kiln is
more effective in terms of heat consumption. The process of heat transfer within
the kiln is largely determined by the radiation process that required a good
insulator to prevent heat flushed out. The insulator is a stone refractory and
coatings formed during the process. Because the function of fireproof stone in
every part of the process, the different types of stone fireproof adapted to its
function. Factors that influence the formation of coatings include:
1. The chemical composition of the raw mix
2. The thermal conductivity of rocks and fire retardant coating
3. The feed temperature when in contact with the coating
4. The temperature of the surface of the coating when in contact with the bait
5. The flame shape and temperature
In the liquid phase sintering zone is necessary, because the reaction takes place
more easily klinkerisasi the liquid phase. But the amount of liquid phase is limited
to 20-30% to facilitate the formation of coating which serves as an insulator kiln.
In kilns without tertiary air almost all the gases of combustion as well as for the
partial burning of the fuel in the calciner through the kiln. Because in high
temperature kilns is necessary to carry out the process klinkerisasi, then the
excess fuel combustion air in the kiln limited to a maximum of about 20-30%,
depending on how the properties of rawmeal ease of burned (burnability of the
rawmix). Thus the maximum fuel burned in in-line calciner is approximately 20-
25%. In general, this type calciner works by burning fuel ranging from 10% to
20% of all fuel requirements, due to combustion in calciner will also result in
temperature of the gas out of the top cyclone higher which means a waste of
energy anyway. Residual fuel ranges between 80% to 90% burned in the kiln. To
assess how the excess combustion air in the kiln in order to obtain a good kiln
operation will be calculated separately. Kilns without tertiary air can be operated
with the type of planetary cooler so the installation becomes simpler and less
power consumption compared with the kiln system that uses the type of grate
cooler.
In the kiln with tertiary air, the fuel being burned in the kiln can be reduced by
about 40% only (even can be up to about 35%), whereas the remaining 60% is
burned in the calciner. Thus the heat load in the kiln suffered reduced to about
300 kcal / kg clinker. Because the dimensions of the kiln is very dependent on the
amount of fuel burned, then theoretically kiln production capacity of a certain
size to be about 2.5 times for the kiln system with tertiary air compared with kilns
without tertiary air. As an example of the capacity of 4000 tons per day (TPD),
tertiary air kiln without the need diameter of about 5.5 m. As for the kiln of the
same size on a system with tertiary air eg SLC system can operate at a maximum
of about 10,000 TPD kapasites. However kiln with tertiary air cooler must work
with the type of grate cooler so that the required additional power of about 5 kWh
/ ton of clinker compared kiln with planetary cooler.
c. Refrigeration (Cooling)
The main tool used for the cooling process is the clinker cooler. Subsequently
sent to a shelter clinker clinker (clinker silo) by using means of transportation,
namely pan conveyor.
The rate of clinker cooling rate determine the final composition of clinker. If
clinker formed during combustion is cooled slowly then some of the reactions
that have occurred in the kiln will turn (reverse), so C3S that has formed in the
kiln will be reduced and dissolved in the liquid clinker which have not been
solidified during the cooling process. By rapidly cooling the liquid phase
solidifies quickly so as to prevent a reduction C3S.
Liquid phase SiO2 content is high and alumino-ferric liquid rich in lime will be
crystallized perfect on rapid cooling. The cooling rate also affects the crystalline
state, the phase reactivity clinker and clinker texture. Rapid clinker cooling effect
on the behavior of the magnesium oxide and also to the soundness of the cement
produced. The faster the process of cooling the periclase crystals formed smaller
arising from the liquid phase crystallization. Klinker by rapid cooling exhibit a
lower specific. This is due to the proportion of the liquid phase is greater and also
the size of the crystals are smaller.

5. Milling end.
Raw material cement manufacturing process consists of:
1. The main raw material, namely slag / clinker.
2. Raw materials corrective / auxiliary namely gypsum
3. Raw materials additives are trass, fly ash, slag, and others.
Finish Mill / end milling is a process of grinding along the slag with 3% - 5%
gypsum natural or synthetic (for control setting called retarder) and some type of
additive (pozzolan, slag, and limestone), written in a certain amount, for meet
quality and specification of cement required.
Slag grinding process is broadly divided into a milling system open circuit and
closed circuit grinding system. The figure below shows the image "a" closed
circuit and image "b" open circuit. Open circuit in shell length of about 4-5 times
the diameter to obtain the desired fineness. While in closed circuit shell length of
about 3 times the diameter or less to accelerate product passing. Separator works
as well as the separator cooling cement products.
Horizontal Tube Mill / Ball Mill is a milling equipment that is often found in
different types of cement, although now beginning encountered vertical slag mill
for grinding into cement.
Material that has undergone milling then transported by bucket elevator to the
separator. Separator serves to separate the cement whose size has been fairly
smooth with a size that is less smooth. Cement smooth enough to be taken of air
through the cyclone, then captured by the filter bag which will then be transferred
into a cement silo.

6. Packaging.
Packaging of cement is divided into two, namely by using zak packaging (kraft
and woven) and packaging in bulk form. In the form of sacks of cement will be
distributed to the shops buildings and end users. While the cement in bulk form
will be distributed to projects.
Stages of the packaging process by using zak are as follows:
Cement silo storage products are equipped with aeration system to prevent
clotting / coagulation of cement that can be caused by water from the outside, and
a patron of the ambient air that has high humidity. After the cement from the silo
removed using pressurized air (discharge) from the cement silo bin and taken to
temporary shelters before entering the machine packer or loading into trucks.