Cement Manufacturing process

1-Mining: The cement manufacturing process starts from the mining of lime stone , which is the main raw material for making cement. Limestone is excavated from open cast mines after drilling and blasting and loaded on to the dumpers which transport the material and unloaded into the hoppers of limestone crusher.

2-Crushing Stacking & Reclaiming of Limestone: The l/s crusher crush the Limestone to minus 80mm size and discharge the material onto a belt conveyer which take it to the stacker via the bulk material analyser. The material is stacked in longitudinal stock piles . Limestone is extract transversely from the stockpiles by the re-claimers and conveyed to the Raw Mill hoppers for grinding of raw meal.

3-Raw Meal Drying/Grinding & Homogen-ization: Reclaimed l/s along with some lat-rite stored in their respective hoppers is fed to the raw mill for fine grinding. The hot gasses coming from the clinkerisations section are used in raw mill for drying and transport of the ground raw meal to the electrostatic precipitator /Bag house, where it is collected and then stored and homogenized in the concrete silo. Raw meal extracted from the silo(ne called kiln feed ) is feed to the top of the pre-heater for pyroprocessing.

4- cooling: Hot clinker discharged from the kiln drops on the cooler and gets cooled. 5-Clinkerisation: Cement clinker is made by pyro processing of kiln feed in the pre-heater and the rotary kiln. Fine coal is fires as fuel to provided the necessary heat in the kiln and the pre-calciner located at the bottom of the 5/6 stage pre-heater. Hot clinker discharged from the kiln drops on the gate cooler and gets cooled. The cooler discharged the clinker onto the pan / bucket conveyer and it is transported to the clinker stockpiles/silo. The clinker is taken from the stockpiles/silo to the ball mill hoppers for cement grinding.

Mining
The major raw material for cement manufacturing is limestone. Limestone is excavated from open cast mines after drilling and blasting and loaded onto the dumper

which is transported the material and unloaded into hopper of the limestone crusher.

Equipment Used in mining:

1. Compressor drilling machine. 2. Shovels/Excavators-for lifting material onto dampers. 3. Dumper- for carrying material.
4. 5.

Built-dozers. Pay-loaders.

Explosive:
1.

Ammonium nitrate(Fuel oil)

2. Nitroglycerine.
3.

Ammonium nitrate and slurry explosive.

Steps of Mining:
1. The first step of mining l/s the l/s has been located. 2. Limestone mining is to remove the mines. 3. The third step is to be taken as drilling. 4. After drilling blasting is done.

Drilling and Blasting:

1. The large hole blasting method is not pre-dominated in quarrying in open pit.

2.

The depth of the wholes are more then 12m and 100150mm dia.

Lime Stone Crusher

Lime stone crusher is the lead role playing equipment in this section. The raw lime stone is carried out from the mines is introduced to the lime stone hopper through whole pack dumper of capacity 32 tons. The feed inside the impact crusher first enters to the crushing chamber with help of apron feed encounters. The impact bars mounted over the rotor &revolving with the circum-frencial velocity of 30-40 m/sec. Material are blown bars and stick on a impact arm. Here materials are initially install to hold these grinding bars. The squire impact arm is install just behind the impact path and having 12 liners. When the material get crushed enough for transportation towards stacker. A bag house is also installed to control the dust loss and pollution control.

Equipment Used in Crushing:

1. Crusher. 2. Apron conveyer for feeding l/s to crusher. 3. Bag filter for collecting dust. 4. Belt conveyer- for transporting crushed material.

This section is worked with following equipment:

1. Impact crusher. 2. Magnetic separator
3. 4. 5. 6.

Limestone stacker& re claimer Bag filter Apron feeder Limestone hopper & late rite hopper

The important mode of transportation in this section is belt conveyer. Main component of impact crusher:

Housing: housing of impact crusher is of studly steel

fabricated and consists of three parts.

Rotor: The rotor in the impact crusher is of s-type

construction secured to the shaft by locking assembly. The blow bar placed in to the rotor from the side and are secured against lateral moment by a suitable locking device at the extreme end. The rotor is dynamically arranged to avoid any undesirable stress on the bearing.

Blow bar: Blow bar is made from high quality alloys

steel. After the certain period in operation the blow

bar can be taken out from the rotor and turned to other side or exchange.

Wear plates: housing is fitted with the resistance

wear plates which are secured in position by special fastners which can be changed as and required.

Impact Arm: The impact crusher is fitted with the

impact arm. The impact arms are each suspended in the housing parts by means of knock out spindle and can be adjusted the desire gap setting from out side.

Hydraulic system: Impactors are depends on their

size normally supplied with a hydraulic arrangement for setting of gap for grinding path lifting of the rear top housing.

Magnetic Separator:

A magnetic separator is installed just above belt conveyer between crusher and stacker. When the magnetic material are comes along with lime stone .they get se-prated by magnetic separator. In the magnetic separator a permanent magnet and a continually moving belt being fin use. Magnetic materials are attached by magnet due to cont. rotating of belt , material get seprated on removal of magnetic field.

Gamma Matrices:

A gamma matrices analyzer being used for analyze the chemical composition of lime stone. It is also known as cross belt analyzer. In gamma metric analyzer we are using specially gamma rays, the gamma rays are fall on material and return back, according to

absorption rays in to material we can determine the chemical composition of lime stone .

LIME STONE STACKER:A limestone stockpile (closed stock pile) has been proposed at the plant site with stacker re-claimer. The reclaimer will help in feeding a homogenized limestone by mixing rich quality LS with low grade mineral. By installing a re-claimer in the plant, the plant can achieve not only quality raw material input but also the conservation of natural resources by utilizing low-grade raw material.

There are two main methods being used for stacking of lime stone in cement industry. They are..

1.Chevron Method 2.Windrow Method

LIME STONE RECLAIMER

Re-claimer which is used in our industry is bridge type scrapping re-claimer. The bridge on which the racking down device is mounted accommodates a scraper chain conveyer whose blades shift the dislodged material along to collecting belt conveyer that extent along one edge of stack pile. Re-claimer having harrow assembly. Re-claimer moves on a track for fast travel a.c. Motor being used and for slow traveling d.c. motor being used. Harrow is moves to and fro motion on rack car which is driven by a motor. A limit sensor is installed for reverse and forward motion of harrow assembly. According to pile we can adjust the inclination of harrows. When harrows are moves they are scrap the material of each layer of stockpiles and material slides down due to gravity. A scraper chain take out the material and fed to belt conveyor material now get transported forwards limestone hoppers.
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Raw mill:

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Blending Of Raw Meal:

The meal from the mill need storage and blending become different chemical composition of lime stone in different lot. They may vary the quality of lime stone.

Silo:

Silos are huge construction of concrete and iron with aeration units to stone and blend the fine material such as raw material. .Continuous Fluidize Silo: The raw meal is completely fluidized by admission of compressed air through the suitable inlets at the bottom of the silo. The air penetrates the mass of raw meal into the silo and reduces the inter particle friction forces. A circulatory motion is formed and thus homogenization is take place.

Operation of Raw Mill:

When the Limestone feed is started with la-trite rollers get down & the grinding start.The grinded material
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is sucked up through the classifier by the help of hot gases .The reject material from the classifier is sent back to the grinding table by the help of reject group. The remaining fine material is sent to ESP & ESP reject material to silos. So total three types of material is falling on grinding table during running:1)-Mill feed 2)-Classifier reject 3)-Mill reject

SILO
It is the large storage of Raw mill which comes from the Raw Mill. It is made of concrete & can store Raw mill for long time.
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Purpose:Its main purpose is to homogenize the raw mill. One of its main purpose is to also store raw mill for long time.

Construction:It mainly a large structure made of concrete. It contains following devices:1)-Air Compressor 2)-Large Air Ducts 3)-Pneumatic Valves 4)-Exhaust Fans on the top

Preheater Purpose:13

To increase the temperature of rawmill material through the incoming hot air from kiln & transfer air duct.

Working Principle Of Preheater

As the name explains Pre-heater Tower is place to use for preheating the raw material. The material which comes from c.f. silo in other words pre-heater is a device in which heat transfer takes place from hot gases which comes from kiln due to counter current flow of material and hot gases. The raw mill is heated about 850oc before it enter it the kiln pre-heater with calcined system is most economical and hence the length of kiln is reduce preheater in Unit-1 and five stage in unit-2 with separator line calciner. These suspension pre-heaters are work in kiln string & pyro string with pre-calciner string successfully.

Main part of suspension Pre-heater:

1.

Cyclone:

The cyclone is use for separation of raw meal from gas flow. For improving the separating efficiency of cyclones of top most pre-heater stage. We have designed as double separator.

2.

Gas Duct:

The gas ducts is to join the individual cyclone stages to each other. The raw meal coming from next higher stage and in the gas duct
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underneath. The raw meal particles are entering by the upward flowing gas stream and taken to the next cyclone. The heal exchange is achieved by concurrent flow. The gas ducts b/w stage 1 and 2 consist of the cylindrical suction.
3.

These are used for raw meal pipes in pre-heater system the flaps are consists in such a manner that a minimum flow of raw mill is always maintained. The full material causes a upward and downward moment of the pendulum flaps and thus and upward and downward rocking motion of the lever arm with counter weight penetrating the single flaps. The upward and downward forces of flaps is remains constant.

The Double Flow Box:

4.

Raw Material distributor:

It is integral part of raw meal ducts and spits a downward flowing stream of raw meal in to raw meal duct. Basically the distributor has a two fold function.

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Calciner:
The main purpose of the pre-calciner is to let the calcinations process take place out side the rotary kiln. It causes in sufficient reduction of thermal load of the kiln burning as approximately 60% of total fuel is burn in to calciner. This has made possible to increase the production in the given size to about double compared to a conventional dry process kiln with suspension pre-heater. The calciner consists of a vessel lined with heat resistance bricks. Calciner has three inputs and one output.

Input1. Fuel as Pulverized coal.

2. 3.

Preheated material to approx 800oc Hot gases from kiln/coolers at 800oc

OutputHot gases including combustion products and co2 from the calcinations process and material in form of dust carried with the hot gases.

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Rotary kiln:
Purpose:Kiln is cylindrical rotary equipment rotating on supporting rollers at about 3.5 RPM. Discharge in its completing calcinations reaction. Firing is done from kiln outlet with the help of burner pipe.

Construction: Kiln can be divided into :a. Kiln inlet (consist seal, grease pump, lines, cylinders etc) b. Girth gear(Gear, pinion, spray system) c. Thrust roller(Hydraulic cylinder, oil line)
d.

Supporting roller& tyre (Consist of bearing, chair plate, bolts etc) Kiln outlet seal(S.S shims, crown shell, seal)

e.

f. Burner pipe(consist of air pipe, coal pipe, diesel pipe etc)

Kiln inlet:

Kiln inlet is seated by sealing arrangement. Greasing is done by pneumatic pump seal. It consist of
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10-14 segment so it can be mounted and disassembled from kiln inside. A conical section forms an extension of the inlet ring. A brick retaining ring has been mounted at the end of conical section.

Girth Gear:

Kiln is rotating by Gear pinion arrangement. Girth gear is mounted on kiln with the help of spring plates.

Thrust Roller:

The function of thrust roller is to control axial moment of kiln in both upward & downward.

Supporting Roller & Tyre:

Supporting roller are for support of kiln. They are in contact with tyre which are fitted in kiln shell.

Kiln Outlet:
outlet.

There is a sealing arrangement in kiln

Burner Pipe:

It is for firing of fine coal into the kiln. Air is controlled by damper and fine coal by solid flow meter.

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Kiln cooler:
Clinker cooler has two main function to perform. They are:1. To cool the hot clinker quickly.
2.

To provide necessary air for burning of coal in precalciner and kiln.

After introducing of red hot clinker into the cooler, mechanically driven gates moves it to the rear end of cooler. Three pair of gates are installed inside the cooler. A single pair consist of fixed gate and movable gate. Too and fro moment of movable gate pressurized which cools it quickly. Clinker cools down gradually as it moves, due to the air blow by the fans which is taken from the atmosphere. Air falling over clinker is highly pressurized which cools it quickly. Clinker escaping out of the cooler is fed to a hammer crusher, since lumpy material requires crushing. Crushed material is transported to clinker silo through deep bucket
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conveyor. Temperature of clinker escaping out of cooler is about 208oc.

Grate Cooler operation:

The grate cooler operates with a cross current principle in which the clinker is moved across the grate while cooling air blow in from below through the grate and clinker layer. The hot clinker falls from kiln and forms clinker bed on he grate and transported through the cooler over alternatively fixed and reciprocating grates. At the inlet of first great clinker is quenched and spread evently across the cooler width by the increased cooling air. The grate is fabricated to be as possible to obtained a thick clinker layer and a uniform distribution of air through the clinker bed in the interest of heat recovery. During the clinker transport from the cooler a part of dust and small size clinker is falls from the grates and collected into hoppers under the grates. The drag chain and rotary air lock system fed these clinker and dust in clinker transport system. A dust collection ESP is also installed beside the cooler known as cooler ESP. Exhaust gases from collection is fed to the ESP for dust collection.

Grate cooler consist of: Cooling grate Plates Standard Plates Cooling housing

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 Drive unit

Grate aeration system

Clinker crusher Conveying unit(DBC) Cooling fan

Coal Mill:

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The coal mill works for producing the pulverized coal for burning to increase the temperature of kiln, pre-heater, raw mill .It works as same as raw mill for lime-stone & latrite mixture {Raw mill} grinding, & the coal mill grind & transfer the coal to the furnace for burning. The raw mill is grounded dried swept away by fan through the separator to bag filter or ESP. finally it is stored in to the fine coal bin hot air for coal mill is supplied by cooler exhaust hot gases or pre-heater outlet gases before GTC circulation. The function of coal mill is to ground suitable grate coal and for feeding the same in to the kiln and calciner in fluidized form. Coal from stock yard is fed for stacking and reclaiming in to the stacker and re-claimer. Pre-homogenized raw coal is feed in to the coal mill hopper
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with the help of belt conveyer. The raw is then fed to the coal mill VRM via weigh feeder, drag chain and screw conveyer.

Important Parameters Of Coal:

Residue on 90 micron=18-20% Residue on 212micron=0.4-1% Moisture Volatile Matter Ash content =1.5% =20-30% =28-32%

Coal Mill:Coal Mill is an important integral part of cement plant. Here large size of approx size 600mm, is ground fine to the size of 90 micron. Coal from coal mill is used to feed kiln and calciner. Outlet tem of coal from coal mill is different in different seasons. It is 70-750c in dry season and 80-840c in rainy season. Coal from mines is initially crushed at crusher site. Coal is then sent to stacking making mixture homogenized. Reclaimer picks up the coal and coal is fed to the coal mill hopper through belt conveyer. Coal taken out from hopper is feed inside VRM with the help of a screw conveyer which is

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mounted just below the hopper. Coal inside VRM is grounded between roller and table. Hot air from cooler ESP fan is taken inside VRM and is used for drying of coal. Fine coal from VRM moves to the cyclone, where most of the coal is separated from air and the coal which does not get collected due to ultra fine size is separated with the help of ESP. LV separator is for separating coarse and fine particles. Now, coal is fed to screw conveyer through rotary lock, which transport it to the FK pumps. Two FK pump delivers material to the storage bins.

There are two Storage bins, They are:1.Kiln Bin

2.

Pre-calciner Bin

Fine Coal is then transported to the kiln and pre-calciner by kiln firing FK pump and pre-calciner FK pump respectively.

Classifier:
A classifier is the top most rotary part of the vertical roller Mill . Here classification of materials occurs .Fine particles pass through classifier and course

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particles are rejecter and recycled for regrinding. According to the fineness required speed of the classifier rotor can be adjusted.

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