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PRELIMINARY REPORT
Prepared by:
Engr. KAMRAN RUSTAM
16 April 2011
BLOCK DIAGRAM
Block diagram of 100 tons/day cement manufacturing
Limestone
Crusher Machine
Storage Yard
Operations of
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Kiln
Kiln Motor
Clinker Silo
EP cooler
SILO
Preheater & Porcelain
Coal Mill
Coal Mill Feed Area
Silo
Cement Mill
Packing Plant
POWER PLANT:
For continuous and smooth operations of the plant uninterrupted power supply is very crucial. The company
has its own power generation plant along with WAPDA supply. The Company power plant consists of one
Generators, which is dual nature generators that can be run on GAS as well as on Diesel depends upon
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availability of fuel. In case if any of supporting engine fails to work the company has Turbine Engine of
CATERPILLARS so that there is no load shedding at all. The generator combines produce 1.2MV of energy
RAW MATERIALS
95% of limestone is used for the making of cement at plant. This limestone is extracted by nearby Quarry
and has the highest composition in cement.
Additive Materials
The additive materials that are mixed with limestone at raw mill feed area
areC LA Y,IRO N,BA UX IT ES and SILLICA SAND.
Gypsum
The remaining 5% of material is gypsum which is mixed with
Klinker material at cement mill and be ready for paking plant.
1 Introduction
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Process
Mined limestone is reduced to < 25 mm in size in the crushing section. Crushed raw
materials are then extracted along with fuel and fed to mill in the right proportion.
In the Raw mill these materials are ground to powder and then blended in a
pneumatic blending system. The raw meal powder is then nodulised by spraying
water in a nodulising drum. The nodules are then fed to the kiln and burned to
clinker.
The clinker and Gypsum are stored in a storage yard. Clinker is allowed to naturally
cool for 15 days. Clinker along with a small per cent of Gypsum is ground in to
cement in the Cement mill. The cement is stored in a RCC Silo. As and when required
this cement is extracted from silo and packed in to 50 kgs bags and despatched by
truck or train to the customers
Limestone 11
Crusher 2
Grinder 3
Raw Meal 4
Kiln 5
Additives 7
Klinker 6
Grinder 8
Cement
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Lower capital investment per unit of production without sacrificing the quality
of the product;
Lower gestation period which helps in realizing quicker returns on capital
invested;
Bringing cement manufacture within the financial capacity of the smaller
entrepreneur;
Creating employment opportunities in rural areas;
Setting up a cement industry in locations where movement of heavy machinery
is difficult;
Exploitation of small deposits of limestone as well as limited quantities of
calcareous industrial wastes;
Reducing the average unit cost
of
transporting
cement
through the dispersal of
cement-production facilities.
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SECTION-WISE CAPACITIES
100 tons/day
700 tones/week
168 hours
4.15 tones/h
Raw-mix design
The chemical composition of Portland-cement clinker is made up of several oxide
components of which some are desirable and others are tolerated because they are
unavoidable, though unwanted.
Even in the case of desirable oxides, the relative proportions have to be optimized in
such a way that a trouble-free and smooth operation of the plant is ensured,
production efficiency and fuel economy are maximized, the quality of the product
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satisfies all the requirements and at the same time the cost of production is
minimized.
RAW MILL SECTION
Based on practical experience gained over several decades and also on research
investigations, the relative proportions of major constituent oxides which will
facilitate production and also ensure a reasonable degree of performance have been
defined in modulii values; An increasing silica modulus impairs the burn ability by
reducing the liquid phase content, causes slow setting, hardening and also dusting in
the kiln. The alumina modulus determines the composition of the liquid phase in
clinker. The lower the ratio, the harder is the burning. A higher ratio gives rise to
lumping of clinker, high heat of hydration and fast setting. The preferred values of
LSF are in the range of 0.85 to 0.95. With LSF below the lower limit one can expect a
predominance of dicalcium silicate (belite) with a lower temperature of burning,
while an LSF exceeding the upper limit is expected to require a high burning zone
temperature. Normally used additive materials are Bauxite, Laterite and Sand stone.
Coke breeze is the fuel generally used in SCP plants. Gypsum is ground along with
clinker to produce Ordinary Portland Cement.
The life of a cement plant should be about 30 years for it to be a viable unit.
Therefore, raw materials also should be available nearby for that period. About 80%
of the material used in cement production is Limestone and this should be available
nearby for the life of the plant. Clay also is required for cement production and
usually this material is available closely. Gypsum and fuel are the other
requirements. These are to be brought from reliable sources and kept in stock for
three to four months. While oil or coal can be used as fuel in a rotary kiln plant, fuel
is limited to coke or de-volatilised coal in the case of vertical shaft kilns.
Block Diagram
Cao > 48%
Mgo > 35%
SiO2 > 8%
Fe203
Limestone
Burning
feeder
90micron
< 20mm
Raw Mill
Storage Yard
< 20mm
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Crusher <20mm
Clinker Storage
Cement Mill
Packer
LIMESTONE:
Limestone is a very strong rock and is often cut into large blocks and used in the
construction of buildings and skyscrapers.
Crushed limestone is also used to make cement, plaster and chalk. Limestone fizzes
in vinegar, which means that it reacts to acids. This also means that the outsides of
many of our buildings and monuments are being affected by acid rain. Acid rain
occurs when large companies pollute the air by releasing chemicals like sulphur into
the atmosphere. The sulphur combines with hydrogen and oxygen in the air to form
sulphuric acid! Chalk is also a type of Limestone.
LIMESTONE REQUIREMENT
Daily requirement :
Monthly requirement
80 tones/day
2400 tones/month
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10
CLAY
The interaction of cement with clay or clay with cement and
the stability of both materials is of special interest in many
cases of environmental concern. Possible interactions of
these materials happen in waste deposits of various kinds.
Clay-cement suspensions are used in slurry walls for
remediation of hazardous waste sites. Here the high pH may
cause a destabilization of certain clay minerals and also a
decrease in the clay-concrete strength compared to clayfree concretes.
The setting of the cement has been showed to be strongly influenced by the kind of clay
used in the suspension. The interaction of settled cement and clay is of interest in cases
where for example a clay barrier is built in connection with existing concrete constructions
in a waste disposal. For a better understanding of the clay cement reactions compacted
mixtures of setted finely grinded cement or calcium hydroxide were examined after being
allowed to swell under constant volume condition at elevated temperatures for 4 to 16
weeks. The interface of setted cement and Na- and Ca-bentonite was investigated in
relevance to changes in mineralogy and microstructure.
CLAY REQUIREMENT
Daily requirement :
Monthly requirement :
17.5 tones/day
525 tones/month
The most obvious reaction is the replacement of exchangeable sodium ions in the Nabentonite with calcium ions from the cement pore water. However, results also indicate a
beginning structural alteration of the Montmorillonite. In this case leaching of alumina from
the octahedral sheet produces a silica-rich residual phase (possibly Cristobalite) and a tetracalcium-alumina-hydrate (4CaO Al2O3 13H2O)
COKE BREEZE
Raw meal interground with fuel (called black meal) is fed in the form of nodules. Because of this, there
is an inherent limitation on the maximum volatile matter of the fuel. The volatile matter should not
exceed 10 per cent, otherwise during burning the intranodule pressure may increase due to the release of
the volatile matter. Consequently the nodules may break. Coke-breeze, a waste product from the steel
industry, has so far been used as fuel in VSK cement plants. The preferable specification of coke-breeze or
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11
17.5 tones/day
525 tones/month
: 25-25 per cent
: below 10 per cent
: 4500 kcal/kg or more
GYPSUM
Gypsum is a very soft mineral composed of calcium sulfate dihydrate, with the chemical formula
CaSO42H2O
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DAILY REQUIREMENT
Daily requirement
Monthly requirement
No. of VSKs :
Capacity of each VSK :
5 tones/day
150 tones/month
1 nos.
100 tones/day of clinker
2.5 tones/day
75 tones/month
STORAGE REQUIRMENT
Clinker stock :
Gypsum stock :
1500 tones
450 tones
BLENDING
Capacity of one blending silo
No. of blending silos
Storage capacity
Silo diameter
No. of storage silos
52.5 tones
1 nos
148.6 cu.m
same as cement silo
1 no.
CRUSHING SECTION
Weekly Limestone
requirements :
Weekly requirement
Working hours
Capacity of packer
STOCK
Tons/hour
945
735 tones/week
49 hours/week
15 tones/h
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13
Tons
Limestone stock
Clay stock
Coke breeze stock
Additive stock
4050
525
1575
450
POWER
In a SCP, daily power requirements are relatively less compared to the large cement plant. A
one million tones/annum plant will consume about 3.3 million units of electricity a day
compared to that of 100,000 tones/annum SCP at 0.033 million units/day.
Power
KWH/ton
Units/tone (avg)
1200
Units reqd /year
438,000
WATER SUPPLY
Water is required in a cement plant for human consumption, cleaning purposes, cooling of
equipment and for nodulising in SCP plants. Taking an average of 250 litres/tone of cement
produced, we need about 75,000 litres of water/day for a 100,000 tpa cement unit. This is
far less than the 350,000 litres needed for a one million tones/annum plant.
Water
Litre
For Process
For human Consumption
Mill cooling & make-up
26,000
5000
9000
40,000
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unsatisfactory burning in the kiln during initial stages which will subside once the
operators get more experience in the burning techniques. Dust generation, though
negligible, is inherent in the burning process and better burning techniques reduce
the emission levels considerably. In the following paragraphs of this report, we give
the dust generation sources, their characteristics and the methods presently
employed to limit dust emission are detailed.
3 Dust Generation sources and characteristics
3.1 Mining
Manual mining is employed in SCP cement plants and dust generation is low. However,
sometimes free dust is generated while drilling and this is suppressed using water
sprays.
3.2 Crushing
Main dust generation source is the Secondary Crusher and a Bag filter system is
provided to collect and remove this dust.
3.3 Raw Mill
While grinding the raw materials in the Ball mill, some dust is produced. This is
collected in Cyclones and bag Filters.
3.4 Blending & Storing
Dust generated during this process is collected in Bag filters and fed back in to the
storage silo.
3.5 Kiln section
The kiln feed is in the form of moist nodules and do not generate dust. This bed
ensures that dust entrained in the lower portions of the kiln is filtered during its
upward movement.
Kiln chimneys operate under natural drafts and do not generate any dust emission.
The low velocity of gas in the c himney allows the dust to settle. Movers (India) have
provided a Wet Scrubber at the chimney which ensures further that whatever dust
generated in the kiln is entrapped in the water spray of the scrubber. The slurry
formed is fed back in to the Noduliser.
3.6 Cement grinding
Cement mill is provided with bag filter to collect the dust generated during grinding.
3.7 Storage and Packing
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15
For the storage silo as well as the packer, bag filter is provided to collect the dust
generated.
DUST GENERATION
Measured/Calculated Quantity
Exhaust
gases
CO
SO2
Dust content
Dust