Cement ABC

Cement ABC
by
M.Shyamsundar
FLSmidth 2008 all rights reserved.

So You Want to Make Cement?

And like to know these terms?
• Clinker • CF Silo
• Quarry • Kiln
• Ball Mill • Atox
• Cyclone • Burner
• Calciner • Red river
• Cooler • Crusher
• Raw meal • Storage
• Kiln Feed • Separator

Filter Filter
Crusher
Analyzer
Limestone Clay Sand Iron
1 2 3 4 Raw meal
silo
Storage
Coal mill
1
2
4 3
Raw mill
Clinker
Silo
Separator
Packers
2 3
Cement Cement
silo silo
Cement
silo
Cement mill
Gear unit Ship unloading
Roller press
Ship loading

What is Cement
• A dry powder made from silica, alumina,

lime, iron oxide, and which hardens when
mixed with water; used as an ingredient in
concrete and mortar.

Cement or Concrete?
• Cement is the glue that holds concrete
together
• Cement is to concrete as flour is to bread

Cement is Part of Concrete

What is Mortar ?
A mixture of cement, sand and water
What is Concrete ?
A mixture of cement, sand, gravel and water

Some History
• 3000 BC They used gypsum mortars and
mortar of lime in building the
Egyptians pyramids
• 300 BC - 476 AD Used pozzolana cement from Pozzuoli,

Italy near Mt. Vesuvius to build the
Romans Appian Way, Roman baths, the
Coliseum and Pantheon in Rome

History of Cement
• 1824 Joseph Aspdin of England

invented Portland cement by
burning finely ground chalk
with finely divided clay in a lime
kiln until carbon dioxide was
driven off. The sintered product
was then ground and he called
it Portland cement named after
the high quality building stones
quarried at Portland, England.

History of Cement
Ransome patented the
• 1845 first rotary kiln
• 1882 F. L. Smidth & Co is founded
• 1891 The continuously fed ball mill

was patented

History of Cement
• 1930s Roller mill first applied to cement
manufacture
• 1932 Patent of the cyclone preheater kiln
• 1937 Introduction of the Fuller

grate cooler

History of Cement
Introduction of
• 1950s mechanical separators
• 1973 Introduction of calciner with
tertiary air duct
• 1992 FLSmidth and Fuller introduce the
controlled flow grate cooler

History of Cement
• 1998 Introduction of SF Cross bar cooler
• 2003 Introduction of Hot Disc
• 2004 Introduction of Multimovable cross bar

cooler

Basic Raw Materials
Limestone Clay Shale
Corrective
Materials
Sand Iron Ore

Clinker Production
CaCO3
CO2
Limestone
CaO
1650º F
900º C
Clinker
SiO2 + Al2O3
2650º F
Clay/Sand 1450º C
Iron Ore
Fe2O3

Limestone Quarry

Blast

Dumpers Entering Crusher Building

Feeding the Crusher

Types of Crushers
Hammers and Blow Bar Impactors
Jaw, Gyratory and Cone Crushers
Roller and Toothed Roller Crushers

Apron feeder
Material
from
dumper
Material enters
hammer
crusher

EV Hammer Crusher
Rotor
Hammers
Crushing
zone
Inlet rollers
Outlet grate
General Crusher Type Characteristics
General Crusher Hammer & Blow Bar Gyratory, Jaw and Roller and Toothed
Type Characteristics Impactors Cone Crushers Roller Crushers
Reduction Ratio 50:1 7:1 (Gyratory) 4:1
4:1 (Jaw)
3:1 (Cone)
Wear Resistance Reasonable Excellent Good
Power Consumption Moderate Excellent Good
Max. Lump Size Good with outlet Questionable Questionable

Control grate, questionable
without grate.
Ability to Handle Reasonable Poor Excellent
Sticky Material
Dust Creation High Low Low

Storage
• Cement Production - Continuous operation

• Quarry operations – Day time only
• Storage of crushed feed is needed
• Additives storage is needed
• Conveyors to Grinding System

Longitudinal Bridge Reclaimer

Longitudinal Stacker

Circular Bridge Scraper

Side Scraper

Stacking method - Continuous Chevron
Stacking method - Chevron
Stacking method - Windrow - open pile
Stacking method - Cone shell

Proportioning

Raw Mill Feed hoppers

Proportioning

Raw Mill

Atox Raw Mill
Finished
material
and air
Mill feed
Separator
Grinding Torque arm

rollers
Grinding
table
Tension rod
Mill motor
Gearbox

Mill Interior

Principles of operation

From quarry to raw meal
Size reduction

Raw Meal Blending Silo

CF silo
Inlet
Outlets
Weight
bin

Controlled Flow Concept

CF Silo Bottom

CF Silo Extraction Sequence
Blower Outlet ExtractionOpen part Segment Aeration
fraction of cycle
1 2 3 4 5 6
A 0,137 0,50 1 2 4
1 B 0,192 0,50
3 5 6
1 2 3 4 5 6
C 0,169 0,50 1 2 3 4 5 6
2 G 0,153 0,50
1 2 3 4 5 6
F 0,125 0,33 1 2 3 4 5 6
3 D 0,109 0,33 1 2 3 4 5 6
E 0,115 0,33
t=70 sec
0 60 120 180 240 300 360 420 480 540 600 660 720 sec
2
1 3 1 2 3
B B
3 6 4 1 3 6 4 1
2 4 5 6 2 2 4 5 6 2
G C G C
1 6 5 1 2 3 5 4 3 1 5 1 2 3 5 3
A 6 4
A
4 6 4 6 4 6 4 6
3 5 5 5 1 3 5 5 5 1
F D F D
2 6
4 5 6
4 3 2 2 6 4 5 6 4 3 2
1 1
E E
3 1 3 1
2 2 t=70 sec

Coal Grinding

Typical Fuels
1. Coal
2. Petcoke
3. Oil
4. Natural Gas
Coal

Alternative Fuels
1. Wood Chips
2. Tires
3. Industrial Waste
Wood Chips
Tirax coal mill

Atox Coal Mill

Pyro System

Wet Process System
Fuel Consumption
1400 Kcal/kg Clinker
In the wet process system, drying, preheating,

calcining and burning are all done inside the kiln.

Kiln type evolution

Pyro system
Exhaust gas
Raw Meal
Cyclone Tower
Calciner
Riser pipe
Tertiary air
Flame
Cooler
Burner Kiln

Preheater Arrangements
SP ILC SLC
These are some of the many different

configurations of preheaters that have
been installed.
SP Preheater System
Fuel Consumption
800 Kcal/kg Clinker
The SP (Suspension Preheater) system features four

preheater cyclones. Most calcining is done inside the
kiln. Some fuel (15%) may be added in the riser duct.
ILC System
Fuel Consumption
700 Kcal/kg Clinker
The ILC (In Line Calciner) system adds a separate

vessel for calcining. Up to 60% of total fuel may be
added here. Raw meal entering the kiln is 92% calcined.
SLC System
Fuel Consumption
700 Kcal/kg Clinker
The SLC (Separate Line Calciner) system has two

preheater strings, one string attached to the kiln and a
second string with calciner attached to the tertiary air duct.
Preheater Material Distribution
Box
Material Inlet
Dispersion Plate

Diverter Gate

Kiln Terminology
Discharge Tertiary
Hood Air Duct
Rotation1 Inlet Hood
Tire Kiln
Gear Inlet
Shell
Seal
Pier 1 2
Outlet
Seal Kiln Drive
Pier Pier
Pier no. 3 Right
Support Uphill Bearing 3
Roller
1 Rotation, as seen from discharge hood

2 For FLS and Fuller kilns, pier numbering starts at discharge end
3 Bearing right and left a seen from discharge end

Kiln drive station

Rotax-2 Kiln
 State of the art kiln technology

 Two supports
 production rates to 7500 mtpd
 Tangential tire suspension
 Gearless, friction drive
 Self-aligning roller supports
Hydraulic Thrust Roller - HTD

Hydraulic Thrust Roller

Duoflex Burner

Typical Burner Installation
Burner Trolley Primary Air
Firing Hood
Kiln Burner Emergency Primary

Burner Pipe Management Air Fan Air Fan
Panel
Burner Pipe Seal
Coal Pfister
Burner Nozzle

kiln burner
Primary air nozzle
Coal meal nozzle

Why Clinker Cooling ?
• Fix the chemical composition of

clinker minerals
• Protect following transport apparatus
• Ensure low temp in cement mill
• Recuperate heat

Types of Clinker Coolers
• Planetary/Tube Coolers • Rotary Coolers
• Reciprocating Grate • Cross-Bar Coolers

Planetary cooler (Unax)

Reciprocating Grate Cooler
The reciprocating grate cooler was developed in the

1930’s. Clinker falls onto perforated grates. Air blows up
thru the clinker and heats up before entering the kiln.
“Red River”

Grate cooler - CFG
Air beam technology

Controlled Impact Section - CIS

SF Crossbar Cooler

Crossbar Cooler
Cross-bars Refractory

Clinker Breaker

Clinker

Cement Mill

Cement Grinding Feed Components
Clinker + Gypsum
+ Additives
Dehydration of Gypsum
Dihydrate  Hemihydrate  Anhydrite
CaSO4, 2H2O  CaSO4, ½ H2O  CaSO4
• A low degree of dehydration may result in:

– Lower strengths
– Prehydration of silo cement
– Flash setting
• A high degree of dehydration may result in:

– High strengths
– Risk of false set (>75% dehydrated)
– Improved silo storage stability

Cement grinding in UMS mill
Modern two-compartment cement mill with two slide ring supports and central drive

OK Roller Mill
Separator Separator drive
Grinding roller Mill outlet
Rocker arm Mill feed inlet
Gear box Grinding table
Mill stand Hydraulic system

OK Mill - Table and roller design

Cement silos

Packing Plant

Packing on Trucks

Cement ABC

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Cement ABC

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

• A dry powder made from silica, alumina,

FLSmidth 2008 all rights reserved.

• Cement is to concrete as flour is to bread

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

• 300 BC - 476 AD Used pozzolana cement from Pozzuoli,

FLSmidth 2008 all rights reserved.

• 1824 Joseph Aspdin of England

FLSmidth 2008 all rights reserved.

• 1891 The continuously fed ball mill

FLSmidth 2008 all rights reserved.

• 1937 Introduction of the Fuller

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

• 2003 Introduction of Hot Disc

• 2004 Introduction of Multimovable cross bar

FLSmidth 2008 all rights reserved.

Limestone Clay Shale

Sand Iron Ore

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

Hammers and Blow Bar Impactors

Jaw, Gyratory and Cone Crushers

Roller and Toothed Roller Crushers

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

Power Consumption Moderate Excellent Good

Max. Lump Size Good with outlet Questionable Questionable

FLSmidth 2008 all rights reserved.

• Cement Production - Continuous operation

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

Grinding Torque arm

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.

FLSmidth 2008 all rights reserved.