Lump formation in

cement silos
Lumps formed in
cement silo
 Reasons for Lump formation in cement silo

Entry of humid
Temperature of
Air through aeration
cement
Blowers and lack of
venting

surface conditions
Of cone and the Entry of moisture
Side walls Along with
cement

SO3 and Alkalis Storage time of

In the cement in the cement
 Temperature of cement

Cement temperature must be less than 80 Deg C when

conveyed into silo. If it is more than 80 deg C the crystalline water
from Gypsum gets dehydrated and moisture moves to the colder
part ie center cone and the walls .This moisture Hydrates the fine
cement and causes cake formation. Presence of alkalis
acclerates prehydration.In our clinker K2O+ Na2O is 0.8. In
cement 0.63 (PPC) and SO3 is 1.8 %.The coating formed is
Called Syngenite( K2SO4.CaSO4.H2O)
 Intensity of coating formation as a function
Of cement temperature stored in cement silo
100
Percentage of heaviest coating

80 SO3=2.7 %
260 M2/kg

60

40

20

0
60 80 100 120 140
Cement temperature Deg C , stored
 Effect of surface on lump formation

If surface of the inner cone and side walls are rough cement
make dead layer and over a period of time they get hydrated
And dislodged causing blockage.

To have a glassy surface, the walls and floor are coated with
epoxy Or materials which can form fine surface which
facilitates smooth out flow flow of material
 Storage time
High storage time and high cement temperature, both can
aid cake formation.

Our cement in silo 4 and 5 is more than 12 days In silo 3 it is 2 to 3

days.
 Effect of gypsum content on cake formation
Higher gypsum addition or higher SO3 in cement accelerates the hydration
of cement In silo. Anhydrate gypsum reduces coating formation ie., Caso4

Our cement
 Addition of anhydrate
(Gypsum without water)
Can reduce lump
Formation in silo.

Ratio of anhydrate/gypsum(CaSO4.2H2O) ratio

 Ultimate solution

1. Reduce the cement temperature from 90 deg C to 70

step by step

2. Reduce the storage time present 10 days to 6 days

3. Silo venting must be on when cement is extracted and

aeration is done. When RH is high It can accelerate
the hydration
Thanks for your kind attention

K.P.PRADEEP KUMAR
Sr G M Operation
Chettinad cements Ltd
Karikkali works