Cement Process

5/22/2018 Cement Process

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Cement Manufacturing

ProcessBonardo Pangaribuan


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Definisi SemenSemen berasal dari bahasa latin caementum yangberarti bahan perekat.

Dalam pengertian umum, semen diartikan Sebagaibahan perekat yang mempunyai sifat-sifat yangmampu mengikat bahan-bahan padat menjadi satu

kesatuan yang kompak dan kuat


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Definisi SemenSemen Portland adalah :

Semen hidrolisis yang dihasilkan dengan cara

menggiling terak semen portland terutama yang terdiriatas dandigiling bersama-sama dengan bahan tambahanberupa satu atau lebih bentuk kristal senyawa kalsium

sulfat dan boleh ditambah dengan bahan tambahanlain


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Mineral pembentukan Semen


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Sejarah

Sebelum mencapai bentuk seperti sekarang, perekat danpenguat bangunan ini awalnya merupakan hasilpercampuranbatu kapurdan abu vulkanis
http://id.wikipedia.org/wiki/Batu_kapurhttp://id.wikipedia.org/wiki/Batu_kapur


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SejarahBaru pada abad ke-18 (ada jugasumber yang menyebut sekitar tahun1700-an M), -

insinyur asal Inggris - menemukankembali ramuan kuno berkhasiat luarbiasa ini. Dia membuat adonandengan memanfaatkan campuranbatu kapur dan tanah liat saat

membangun menara suarEddystone di lepas pantai Comwall,Inggris.
http://id.wikipedia.org/w/index.php?title=John_Smeaton&action=edit&redlink=1


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Ironisnya, bukan Smeaton yang akhirnyamematenkan proses pembuatan cikalbakal semen ini. Adalah

, juga insinyur berkebangsaanInggris, pada 1824 mengurus hak patenramuan yang kemudian dia sebut semenportland. Dinamai begitu karena warnahasil akhir olahannya mirip tanah

liat , Inggris. Hasilrekayasa Aspdin inilah yang sekarangbanyak dipajang di toko-toko bangunan.

Sejarah
http://id.wikipedia.org/w/index.php?title=Pulau_Portland&action=edit&redlink=1http://id.wikipedia.org/w/index.php?title=Joseph_Aspdin&action=edit&redlink=1http://id.wikipedia.org/w/index.php?title=Joseph_Aspdin&action=edit&redlink=1


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ContentOverview

Raw Material Extraction & Preparation

Raw Meal Preparation

Clinker Manufacture

Cement Grinding

Packing & Dispatch


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ContentOverview



Clinker Manufacture

Cement Grinding

Packing & Dispatch


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Overview

Quarrying

CrushingPre-blending

Grinding

Homogenizing...

Burning...

Grinding

Blending...

Gypsum

Fuels

Mechanical Processes Mechanical ProcessThermal

Process

Mineral

ComponentsClinker

Cement

Dispatch

Raw

Meal

Raw

Materials

Calcareous

ArgillaceousSilica correctives

Iron correctives

Alternative

Chemical

Processes


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Production Flow of Dry-Process Cement


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Stepping Process of Cement

RawMaterialExtraction &Preparation

Raw MealPreparation

ClinkerManufacturing

CementGrinding


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ContentOverview



Clinker Manufacture

Cement Grinding

Packing & Dispatch


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Main RawMix Components

Calcareous(Calcium/Lime) Materials -- CaCO3

(Limestone)bring CaO

ArgillaceousMaterials -- SiO2, Al2O3& Fe2O3 (Clay,

Shale, Marl)

Raw Material


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Limestone, + 82% Clay, + 13.5% Silica, + 3%

Raw Meal

Iron Sand, + 1.5%

Compositions


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Drilling and Blasting


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Haulage and Loading


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Purpose: to crush big rocks

into required small rocks

Maximum feed size

Limestone: 1,500 mm

Shale / silica sand: 500 mm

Product size: max. 75 mm

Crushing ...


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Crusher


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Pre-homogenezation


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Stacker/Reclaimer ConfigurationsSIDE RECLAIMER FRONT RECLAIMER

CONICAL

SHELL

CHEVRON

CHEVCON

WINDROW Not applied


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StackerCircular Storage

Front Acting Reclaimer and Circular

Storage


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Side Acting Reclaimer


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Summary 1st

Step


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ContentOverview



Clinker Manufacture

Cement Grinding

Packing & Dispatch


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Tube mill

Vertical mill

Raw Materrial Grinding ....


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Binbin Raw Material

Purpose: to temporary

storange and weighting

raw material

Proportion raw material

LS, Clay, Iron ore, Sand


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Main purposes

To grind, and

To dry raw materials- Using exhaust gases

from the kiln

Product (Raw Meal)

Fine powder

Maximum size 90micron

Moisture of 1%

Vertical Roller Mill


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Vertical Roller Mill


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Processes inside ..... Grinding

The material is trappedbetween the rollers and thetable

Drying When the hot gas contact the

material leaving the table

Transport

From the table to the separatorand filter by the gases

Separating The fine product from the

coarses


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Process : Grinding

View from top

View from side


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Gas & Product Material

Feed Material

Separator Rejects

Internal Circulation

Large Material falls through to scraper

Internal gas

flow

Material & Gas

Material

Gas

Separator:

removes fine material

rejects coarse material

VRM

Process Inside


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Product is Raw meal

10 cm

90 m


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VRM - Some Common Mill Configurations

G.Pfeiffer Loesche FLS Atox Polysius


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The raw meal is homogenised by a

combination of the way it is added

to/extracted from the silo and the air mixing in

the silo.Active Inactive

Bypass

GAS

GKA GKJ

HS

FRFilter FR

Out

InRaw Meal Homogenisation ...


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Summary 2nd

Step


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ContentOverview



Clinker Manufacture

Cement Grinding

Packing & Dispatch


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Process:Preheating/Pre-calcination...


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0 500 1000

Stages

Raw meal

Exhaust gas

880

785

660

500

315

785

660

500

315

50

10005

4

3

2

1

Temperature 0C

Process:Preheating/Pre-calcination...


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Process:Preheating/Pre-calcination...The preheating and precalcining processes are done inthe preheater tower. In just a few seconds the rawmeals is heated from 50oC up to 870oC and calcined upto 95% (CO2dissociated)

Temperature Type of reaction

20 100 Evaporation of free water

100

300 Loss of physically adsorbed H2O600 900 Dissociation of carbonates (CO2)

> 800 Formation of C2S, C3A and C4AF


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Kiln


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Process:Burning inside the Kiln

a rotating steel tube

40 230 m long

2.5 7.5 m diameter

Protected by refractorymaterials (resistant to heat)

Slope ~2 3o

Sinters material to clinker


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Process:Burning inside the Kiln

Temperature Type of reaction

> 1250 Liquid phase of C3A and C4AF forms~ 1450 Complete of reactions and crystallizations of C3S and C2S

1300 - 1250 Crystallizations of liquid phase mainly aluminates and ferrite


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Heavy Fuel Oil

Pulverized Coal ( Sub-Bituminous &

Lignite)

Natural Gas

Pulverized Petroleum Coke

Fuel


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A complex burner is used to mix different

fuels with air and deliver them to the burning

zone of the kiln for combustion

Fuel


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Process: Clinker Cooling ...


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The cooling occurs

Inside the kiln (cooling zone)

- From 1,450 to 1,100oC

In the Cooler

- From 1,100 until about 100-200oC

Purposes

Heat recuperation Safety for transport system and

storage Clinker Quality

Kiln

Cooler

Clinker

Process: Clinker Cooling ...


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Product is Clinker


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Quality of Meal (Formula)

LSF =(2.8S + 1.1A + 0.7F)

(100C)

90105

SM =(A + F)

(S)

2.12.5(F)

AM =(A)

1. 22.0


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Sequences of chemical reactionsProportion CaO SiO2 Al2O3 Fe2O3Limestone 82.2% 51.6 3.8 1.4 0.4

Sand 2.9% 1.7 85.8 5.2 2.1

Clay 13.5% 2.6 55.7 16.2 6.1

Iron ore 1.4% 5.3 18.6 4.8 60.6

100% 42.9 13.4 3.6 2.1

LSF = 100 SM = 2.3 AM = 1.7Primary

ingredients in kiln

feed (raw meal)

These supplay


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CaO

CaO

SiO2

SiO2

CaOCaO

1450oC

CaO

SiO2Al2O3

Fe2O3

CaO

CaO CaO

SiO2

Sequences of chemical reactions


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Chemical reactions


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Composition of ClinkerClinker Phase Content

C3S Alite ~ 60 %

C2S Belite ~ 20 %

C3A Aluminate ~ 10 %

C4AF Ferrite ~ 10 %

Free lime (CaOfree)

Periclase (MgO)

Alkali sulphates (Na2SO4, K2SO4)

In minor amounts :


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Product is Clinker Minerals (under Microscope)

alite


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Summary 3rdStep


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Content

Overview



Clinker Manufacture

Cement Grinding

Packing & Dispatch


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Compositions

Cement

MIC,Clinker, Gypsum,


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Cement Grinding....


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Operation principle

of a Tube mill

Cement Grinding....


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Cement Grinding...

Cataracting motionfor coarse feed

Cascading for fine

material


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Purpose

To store cement

How to Discharge

For bag cement, through

- Rotary packer

For bulk cement, through

- Loading spout

Cement Grinding...


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Product is Cement


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Summary 4thStep


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Content

Overview



Clinker Manufacture

Cement Grinding

Packing & Dispatch


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Layout of dispatch / shipping station

CementSilo

CementSilo

Storage

Dispatch/TransportPacking & Loading

Cement from the mills

Cement Storage, Packaging & Dispatch


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Cement Packaging


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Cement Palletizing


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Bag Loading of Trucks


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Bulk Loading of Trucks


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Cement Process

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