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Cement Production Technology Insights

The document discusses three ways that cement producers are mobilizing technology to increase production capacity and sustainability: 1) Increasing the final product quantity by blending supplementary cementitious materials like fly ash with portland cement, allowing for higher throughput with less clinker. 2) Using alternative raw materials or additives in the raw meal to improve kiln chemistry and process efficiency. 3) Returning to older mechanical handling technologies to reduce power consumption and allow for higher kiln throughput, which addresses problems caused by pushing newer plants beyond their design capacities.

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miningnova
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Topics covered

  • Plant Energy Consumption,
  • Kiln Chemistry,
  • Maintenance Reduction,
  • Cem II,
  • Silo Management,
  • Inter-Grinding,
  • Homogenisation Mix,
  • Thermal Cracking,
  • Emissions Reduction,
  • Bucket Elevators
299 views7 pages

Cement Production Technology Insights

The document discusses three ways that cement producers are mobilizing technology to increase production capacity and sustainability: 1) Increasing the final product quantity by blending supplementary cementitious materials like fly ash with portland cement, allowing for higher throughput with less clinker. 2) Using alternative raw materials or additives in the raw meal to improve kiln chemistry and process efficiency. 3) Returning to older mechanical handling technologies to reduce power consumption and allow for higher kiln throughput, which addresses problems caused by pushing newer plants beyond their design capacities.

Uploaded by

miningnova
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Topics covered

  • Plant Energy Consumption,
  • Kiln Chemistry,
  • Maintenance Reduction,
  • Cem II,
  • Silo Management,
  • Inter-Grinding,
  • Homogenisation Mix,
  • Thermal Cracking,
  • Emissions Reduction,
  • Bucket Elevators

Mobilizing Technology to

Sustain and Increase


Cement Production
Stewart
Stewart Gater
Gater –
– National
National Engineering
Engineering Projects
Projects Manager
Manager Lafarge
Lafarge Cement
Cement
bulk08
DR Mediatheque Lafarge

bulk08
18
18 April
th
th April 2008
2008

Contents

„ Increasing Quantity of the Final Product


• The blending of supplementary cementitious material with
Portland Cement to increase the capacity of the final
product

„ Opportunities for Alternative Raw Material


• The use of ARM or additive in the raw meal stage to
improve the chemistry in the kiln for improvement to the
overall process

„ Technology – Back to the future


• Using an old technology to overcome industrial problems
that we cause with recent technology

1
Increasing Quantity of the Final Product
„ Cement Types
• Cem I – Portland Cement
• Cem II – Portland Fly-Ash Cement
• Cem III – Portland Limestone Cement
• Cem IV – Blast Furnace Cement

„ Why Industry uses Cem II cements?


• Environmental Benefits
– Reducing emissions and energy consumption

• Improve Performance
– Workability, reducing early risk of thermal cracking, increase
resistance to chemical reactions, etc

• Increase Production of Final Product


– Reducing amount of clinker per tonne of cement

Increasing Quantity of the Final Product


„ What is Cem II
• Inter-Grinding of Portland Cement Clinker with carefully
controlled supplementary cementitious material, usually Fly
Ash
• The post blending of Portland Cement with Fly Ash

„ Blending of Portland Cement and Fly Ash


• Requires
– The correct proportions of each material
– Complete blend for a homogenous mix
„ Equipment
• Mechanical Blenders or Coriolis Flow Meters
– Uses vibration and a paddle wheel
– Measures the mass of material
– The use of mechanical blenders or coriolis flow meters
dramatically reduces the amount of energy used.

2
Increasing Quantity of the Final Product
„ Blending System
Silo

PFA
Cement
Coriolis Flow
Meter

Liquid
Additive

Transport
5

Increasing Quantity of the Final Product


„ Blending System
Silo

PFA C em ent

Mechanical
Blender

Liquid
Additive

Transport
6

3
Opportunities for Alternative Raw Material
„ Reason for the use of ARM and Alternative Fuels
• Key to business strategy
– Commercial advantage, i.e. gate fees

• Extends quarry life

• Environmental benefits
– Landfill, waste, etc
– Emissions

• Improving performance / reliability


– Quality
– Quantity

• Maintenance
– Improved process = less maintenance

Opportunities for Alternative Raw Material


„ Chemistry of the kiln
• Calcium, Silica, Alumina, Iron
• The iron and alumina form a flux which aids the bonding of
calcium and silica
• Chemistry balance or the raw meal is the key to the overall
process
„ Chemistry balance advantages
• Increased throughput
• Reduction in kiln temperature
• Reduction in emissions
• Less wear on cement mills
• Greater variance in range of alternative fuels able to be
used
• The plants energy consumption
• A homogenisation mix raw material in the clinker

4
Opportunities for Alternative Raw Material
„ The need for expansion

Technology – Back to the future


„ Using an old technology to overcome industrial problems
with recent technology
• Problem
– The problem is that kiln throughput are way above their
design criteria.
– This causes industry problems regarding power consumption
on plants.
• The situation
– There is a need for constant upgrading for electrical
capabilities on plants.
– Most plants are close to limited fan situations on kilns
• Aim
– Is to reduce the power consumption within the plant
– Continue to increase kiln throughput
• Possible solution
– Exchange electrical and air equipment in favour of mechanical
equipment – bring back mechanical handling

10

5
Technology – Back to the future
„ Plant section of feed to kiln

Pump Metering Air Lift Pre-heater Kiln


Silo Route Tower
11

Technology – Back to the future


„ Problematic equipment

Air Lift

Pump Metering Air Lift Pre-heater Kiln


Silo Route Tower
12

6
Technology – Back to the future
„ Exchange Equipment – Use of mechanical handling

Bucket
Elevator

Pump Metering Bucket Pre-heater Kiln


Silo Elevator Tower
13

Any questions?
DR Mediatheque Lafarge

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