Monday, 18 June 2012

Start a Cement Clinker Production Line


(329). Start a Cement Clinker Production Line 

What is cement?
Cement is a fine powder which sets after a few hours when mixed with water, and then hardens in a few days into a solid, strong material. Cement is mainly used to bind fine sand and coarse aggregates together in concrete.  Cement is a hydraulic binder, i.e. it hardens when water is added.
There are 27 types of common cement which can be grouped into 5 general categories and 3 strength classes: ordinary, high and very high.  In addition, some special cements exist like sulphate resisting cement, low heat cement and calcium aluminate cement.

Cement plants are usually located closely either to hot spots in the market or to areas with sufficient quantities of raw materials. The aim is to keep transportation costs low. Basic constituents for cement (limestone and clay) are taken from quarries in these areas.

A two-step process
Basically, cement is produced in two steps: first, clinker is produced from raw materials. In the second step cement is produced from cement clinker. The first step can be a dry, wet, semi-dry or semi-wet process according to the state of the raw material.

Making clinker
The raw materials are delivered in bulk, crushed and homogenised into a mixture which is fed into a rotary kiln. This is an enormous rotating pipe of 60 to 90 m long and up to 6 m in diameter. This huge kiln is heated by a 2000°C flame inside of it. The kiln is slightly inclined to allow for the materials to slowly reach the other end, where it is quickly cooled to 100-200°C. 
Four basic oxides in the correct proportions make cement clinker: calcium oxide (65%), silicon oxide (20%), alumina oxide (10%) and iron oxide (5%). These elements mixed homogeneously (called “raw meal” or slurry) will combine when heated by the flame at a temperature of approximately 1450°C. New compounds are formed: silicates, aluminates and ferrites of calcium. Hydraulic hardening of cement is due to the hydration of these compounds. 
The final product of this phase is called “clinker”. These solid grains are then stored in huge silos. End of phase one.

From clinker to cement
The second phase is handled in a cement grinding mill, which may be located in a different place to the clinker plant. Gypsum (calcium sulphates) and possibly additional cementitious (such as blastfurnace slag, coal fly ash, natural pozzolanas, etc.) or inert materials (limestone) are added to the clinker. All constituents are ground leading to a fine and homogenous powder. End of phase two. The cement is then stored in silos before being dispatched either in bulk or bagged.

The main raw materials used in the cement manufacturing process are limestone, clay, sand, shale and iron ore. Limestone is usually mined on site while the other minor materials may be mined either on site or in nearby quarries. Another source of raw materials is industrial by-products. The use of by-product materials to replace natural raw materials is a key element in achieving sustainable development.
Cement Clinker's Wet Process:
In the wet process, each raw material is proportioned to meet a desired chemical composition and fed to a rotating ball mill with water. The raw materials are ground to a size where the majority of the materials are less than 75 microns. Materials exiting the mill are called "slurry" and have flowability characteristics. This slurry is pumped to blending tanks and homogenized to insure the chemical composition of the slurry is correct. Following the homogenization process, the slurry is stored in tanks until required. 
Cement Clinker's Dry Process:
In the dry process, each raw material is proportioned to meet a desired chemical composition and fed to either a rotating ball mill or vertical roller mill. The raw materials are dried with waste process gases and ground to a size where the majority of the materials are less than 75 microns. The dry materials exiting either type of mill are called "kiln feed". The kiln feed is pneumatically blended to insure the chemical composition of the kiln feed is well homogenized and then stored in silos until required.

Cement Clinker Production Line

The a clinker roller crusher of latest technology was installed in Exxon Machinery.The impact hammer mill of the Tandem drying-grinding plant works in conjunction with a short air-swept tube mill. Instead of a grate, the impact hammer mill is furnished with a solid bottom. The materials leaving the compartment tube mill which is equipped with classifying lining.The mill has installed 3800 kW via central drive system. impact hammer mill and the tube mill are pneumatically conveyed to one common air flow classifier.
Cement Clinker Production Line
Cement Clinker Production Line
Exxon Machinery supply cement clinker production line for cement production.Our cement clinker produciton machines are sold to India, Nigeria, Australia ,Saudi Arabia,Indonesia, Pakistan ,Germany,Bangladesh ,America, ,Iran,Malaysia ,Turkey,Italy, Singpore, Chile,Libya, ,Philippines, Angola, Tajikistan,Dubai,Brazilon,Peru ,Mexico,South Africa,Kenya,Algeria ,Eygpt,Ghana ,Zimbabwe and so on.

Cement Clinker Manufacturing Process

Cement clinker is made by crushing, blending and fine milling of limestone (calcium carbonate) and other materials containing silica, alumina and iron oxides, which are then heated to temperatures as high as 1,450°C in a kiln where the compounds react chemically to form clinker. The clinker is then cooled and ground with small quantities of gypsum and other additives to produce cement.
The heating cement clinker manufacturing process is performed in a rotary kiln, which is inclined at 3 – 4o to the horizontal. The prepared raw mix, now referred to as kiln feed, is fed to the kiln system, directly into the long dry kiln. Long dry kilns are not equipped with preheaters and as a result, the initial heating of the kiln feed occurs in the kiln itself. To ensure sufficient heating for the thermal processes, the kiln is designed to be much longe.

Cement Manufacturing Technology Course

The course content will be suitable for a wide range of personnel within a cement manufacturing company including junior/middle management, technicians, production and control room staff, etc and also for others who wish to gain a comprehensive understanding of the complete cement manufacturing process.

Course Content

  • Module 1 - Objectives of cement manufacturing fundamental requirements of the cement product in application
  • Module 2 - Raw materials for cement manufacture exploration, extraction, processing and mixing of cement raw materials
  • Module 3 - Pyroprocessing 1 - Chemical, physical and mineralogical transformation from raw mix to cement clinker
  • Module 4 - Pyroprocessing 2 - Process and equipment evolution for cement clinker manufacture
  • Module 5 - Cement grinding and dispatch. Finishing the cement manufacturing process and satisfying the end-customer
  • Module 6 - Sustainability in cement manufacture. Meeting corporate, customer, social and environmental obligations in the manufacture of cement

Course Material

The course is open to all in the cement industry and a small fee will be charged for each student. You may also use the course in a classroom situation with multi-student involvement, although certification and course monitoring can only be arranged for the people actually registered for the course.

The course is conducted on-line, allowing students flexibility (within a six-week period) to complete each module and associated assessments at work or home. Students should expect to devote around 5+ hours per week/per module plus some additional time for private reading/study. A computer with internet access (broadband recommended) and email capabilities will be necessary.

Throughout the course the lectures are supplemented with exercises allowing students to relate the course material to their cement factories, or the cement factories of their clients in the case of equipment or service suppliers to the cement industry. Certification is achieved by completing a satisfactory level of exercises, and by end-of -module exams.

The course is complete with downloadable transcripts of the lectures, exercises, and reading material for the training record ..For Further Details -
Machine Manufacturers
Laxmi Engineers
Address:G-588 (B), 2nd Phase, M. I. A., Basni
Jodhpur - 342 005,(INDIA)
Tel : (91)-(291)-2740588 
Fax : (91)-(291)-2741692
Mob : (91)-9829027588

Related equipment that used in the cement clinker processing plant: