1

Suitable materiel for temp range 1100-120 degree Centigrade and properties of weldable and fabricated also.
Seelam Naveen AISI 321 available in plates, it can used upto degree 1000 C. This stell is weldable Ahmad Nilforoushan Steel 1.4848 & 1.4823 Amit Agarwal HRS grade 7 and grade 9,commonly known asASTM A 297 grade HH and HK material.... muralimohan paladugu hrcs gr 9 and ss 316 Mukesh Doshi HRCS grade 9 is suitable, pl check for area of application also James Kelly With respect, I believe that for an alloy to withstand 1100C, let alone 1200C, it must have over 30% nickel and about 25% chromium. I believe 321 (1.4541 or 1.4878) is useful only to 870C, maybe to 900C for modest life. HRCS Gr 9 and cast HH not much better. HK is the lowest alloy I would suggest. My own experience, since 1974, has been with wrought alloys which may be fabricated. There are a limited number of wrought alloys with the strength and oxidation resistance to survive a cement mill operation 1100 -1200C. One such was 353 MA (1.4854) 25Cr 35Ni 1.5Si, but Outokumpu has chosen to discontinue its production. There are a range of cast alloys available. Two of the best foundries in North America are Kubota Metal Corp, Fahramet Div, in Ontario, Canada www.kubotametal.com, and Duraloy Technologies, Pennsylvania, USA www.duraloy.com. Both have excellent technical
personell, for Duraloy I would suggest Roman Pankiw techmgr@duraloy.com. The French alloy foundry, Manior Industries, is represented on Linked in by Benjamin Fournier. One cast alloy used in the steel heat treating industry is the 28Cr 48Ni 3Co 5W grade, called Super 22H by Duraloy, and KHR48NCo by Kubota. For the highest temperature service one might consider MO-RE 2, 33Cr 50Ni 16W from Duraloy, or KHRSA, 29Cr 49Ni 13W from Kubota Sagar Raysoni SS 310S plates are easily available in the local markets in India and are able to with stand higher temperature upto 1050 deg cen than 321 grade . Also 310S is widely used in cement plants in India because of easy availability and economy as compared to costlier grade such as 353 MA . I have never come across any customer asking for 353 MA here locally . We do have few plants using 30815 instead of 310S here James Kelly I suspect that no customers ask for 353 MA as it was never promoted in India and is no longer made. Until Outokumpu ceased production Rolled Alloys was developing the US market for this grade (I am retired Director of Technology for RA). In cement kilns RA's competition was one or the other high alloy casting as I noted previously. 310S is a decent choice, I have noticed that in Asia 310S is used many places where in Europe and North America we would use one of the higher nickel, higher strength alloys available to us. I am inclined to believe that alloy selection across the globe is based on local availability, and rightly so. Better alloy properties do no good if one cannot buy the material. Should some foundry or alloy stockist decide to promote the higher
alloys, the cement industry in India will eventually find that these expensive grades perform so much better that they pay for themselves. arun rao James, I agree with your comments. On a few ocassions I had recommended using HT or HU grades with a life guarantee. The plants were reluctant to consider. I then proposed ,that they could pay me HK grade price and based on performance,they could pay the rest. The parts outlived their expected life by 2 years.
Investment cost: cement plant excluding land and development, what could be the thumb rule figure for a 1000 and 1500 tpd plant?
Marchal Philippe Dear Mr Pabitra, The cost is around 100.000.000 for 1.000 tpd clinker converted into cement. For 1.500 tpd consider 30% more. Keep in mind the standard economical size is today around 5.000 tpd. We can help you in the conceptual design of your cement plant (raw mix, mass balance, process, layout, flow sheet, cost estimate, operating cost and profitability). Regards Philippe
Pabitra Mukherjee (Mukhopadhyay) Thanks, Marechal, for the info.
Jagat Singh Rathee The investment in terms of capital employed per ton of installed capacity for a brown field integrated cement project of about 10,000 TPD clinker production capacity is in the range of 180 200 USD per ton , with some variation to the tune of 5 - 10%, on account of inflation and currency rate fluctuations. Ben Cardwell I agree with Marechal to a point, we have preformed numerous studies and designed plants around the world for different clients and there are multiple factors to be considered. unfortunately TPY of clinker is not linier and one must consider region and other factors besides economy of scale Zaza Sadunishvili Price for green field from chinese supplier will be 30 % less that from european company. Jagat Singh Rathee Price from Chinese designers / suppliers like Sinoma ,CNBME and others may be even 30 - 40 % cheaper than the European ,Japanese or even the Indian suppliers / designers, but their equipment ,plant and machinery ,including systems & subsystems are yet to be fully established from the very reliability and operational sustainability angle.They also in most of the cases do not follow International Systems / Standards, for parts and spares and even consumables supplies.Other supplier's always cross the rated / guaranteed outputs , by a factor of minimum of 15-20% ,and the cement plant stabilization period is also significantly lower vis-a-vis Chinese plants. The best example is the quality and extreme reliability of FLS ,KHD ,Polysius and Japanese cement plants all over the world,e.g. Holcim integrated cement plant of 12,000 TPD capacity in USA at St.Genevivie ,3X10,000 tpd KHD integrated cement plants of UTCL ,India ,& 2x 10,000 TPD plants of JP Cement ,India ,also from KHD, and the 1x10,000 TPD integrated cement plant from Thyssen Krupp Polysius , of Reliance Cementation ,India.and many more ,in India ,Thailand ,Indonesia ,South
Korea and Japan. Have the true feedback from two 10,000 TPD production lines from Sinoma ,China, for equipment ,machinery and systems reliability and operational sustainability. These plants ha ve yet to be fully stabilized , even after a couple of years of commissioning. You save in the project capital costs initially ,but pay in the long run. These have been the observations of the technocrats involved in such projects from across the globe.
Marchal Philippe I agree with Jagat. Today there is still a lack of reliability of Chinese EPC(turnkey) Cement plant. The first 2 years, the net operating time of the plant is 30% lower and all weak components of the plant are progressively replaced by European parts. This could be acceptable only if the plant doesn't need to run at full capacity the first years according to the business model. Otherwise the profitability of the project will be reduced and the savings on the investment will disappear. For your specific project, several cost simulations according to your business plan can be studied. If needed contact me at philippe.marechal@tcmi.be
Jagat Singh Rathee Even for their own large size ,big capacity cement plants at Anhui Conch and a few others cement manufacturers in ,China , have preferred to go to FLS , Polysius, Loesche ,Christian Pfeiffer , Haever & Boecker,even refractory manufacturers, conveyor belting manufacturers and other European suppliers / designers ( the manufacturing and fabrication shops of these International plant, machinery & equipment suppliers / designers are located within China itself ,owing to the much lower manpower costs in that country, but
the Quality Assurance is strictly under the European Engineers ) ), only from the reliability and uninterrupted sustainability of integrated cement operations. The above example, in my above note example , is of the 2X10,000 tpd Sinoma ,China clinker production lines in KSA ( Kingdom of Saudi Arabia ,at Najaran
Zaza Sadunishvili We have very good experience with Chinese equipment in Georgia. 2007 we installed two Coal mills with coal handling systems and equipment still is working without any problem Guadalupe Rodriguez Standard equipment by FLS or others similars are around 300 MM dlls for a normal 1500 TPD plant The best return of the investment could be a medium size plant as 3000 TPD Chineese equipment is cheaper as first investment, however the cost of maintenance and relibility are very high in the first 2 years Special attention to wear parts as liners and grinding media, usually chineese is not the best quality for this materials Hopefully find this information valuable for you Jagat Singh Rathee Every investor wants to get immediate & quick returns on the capital employed in the cement project .This is possible only ,when the project gets quickly commissioned and gets stabilized it's operations without any interruptions & through the asset sweating. And this is only possible when the quality of equipment ,plant ,machinery ,components and the systems / subsystems are highly reliable / dependable , so as to ensure long campaign life of the plant ,particularly the kiln system. In such a scenario ,the European ,Japanese
and even the Indian equipment suppliers / designers have a definite edge over the Chinese.This is the practical experience of a number of users of technology across the global cement industry. Jean-Marc Ritzenthaler This interesting discussion did so far not address the State garantee that, at least some of, the Chinese builders may have. Any comments or experience? Wilhelm Maier-Krebs dear Sir, we are able to provide a unused Cement production plant, cap. 2200 tp p.day. German brand. can be fired with oil, gas or coal. cement grinding mill and coal mill available.If of serious interest, please contact: info@wmk-cnc.com Ibrahim Munir we are chinese company , we can help you out in this project according to your requirement , if you are intrested please mail me more details at moni@sinopaceic.com. our techical department will give you quick feed back. Concrete Block Making Machine XIAMEN SUNLIGHT XIN MECHANIC EQUIPMENT CO.,LTD,is a leading supplier of building materials machinery and block production plant,which is experienced in manufacturing fully automatic concrete brick making machines, paving brick and Curbstone making machine,hydraulic forming machines.
Regards, Jack Tang Xiamen Sunlight Xin Mechanic Equipment Co.,Ltd Facebook: jacktang618@yahoo.com Gmail: xmsunlight03@gmail.com Skype: xrc.sonny Mob: +86-1885030 6144
Tel:0086 592 5103028 Fax:0086 592 5103029 Web: http://www.xmyg.cn Add: No. H12, North Zorth of Xiamen Gaoqi International Airport, Fujian 361006, China
Dear all experts,is it possible when sieve residue is high the blaine will be high,what are the reasons of this case?
Nohman Mahmud Yes it is possible that although blaine is high & at the same time residue on 90 or 45 micron is also on higher side , this is experienced / encountered normally when weathered clinker is used . The phenomenon occurs due to partial hydration of clinker. Also note that The blaine method determines the fineness of hydraulic cement, using the Blaine air-permeability apparatus, in terms of the specific surface expressed as total surface area in square centimetres per gram, or square metres per kilogram, of cement. While residue analysis determines the size on a particular sieve Munusamy Murugan At normal operation it should be in Reverse ie When Blaine increases ,Residue should drop When material distribution is not even at separator inlet, then both Residue and Blaine will increase,
prabodh singh If seasoned or aged clinker is used for cement grinding ,troumph curve of PSD becomes wider , caused due to superfines generated during grinding, that fills the voids , and makes the cell bed more compacted, , thus there is an increase in time for air flow through the given bed of cement in the Blaine cell,its residue is also found in higher side. It is not a typical case , it often happens , whenever we use aged clinker or particle PSD is not narrow. Cement quality managers do not depend on blaine value only, use of any masking material can give u higher blaine value , cross checking the residue in such case becomes inevitable. some cement industries uses correction factor for blaine value ,based on LOI of cement .
how we can reduce the kcal/kg of clinker in my plant the kcal/kg of clinker is approx. 850kcal/kg of clinker.coal ash is around 20% and moisture is 1.5 %. we are using indian coal how can we decide what is the optimum kcal/kg of clinker.
Marchal Philippe It is necessary to do an audit of the burning line by testing the real major parameters (as O2 measures because false air is very important) and then to design what's necessary to be done to reduce the heat consumption. Examples: - Improvement of the kiln operation by adjusting the settings - Reducing the false air - To optimize the burner settings - To adjust the raw mix
If you need support contact philippe.marechal@tcmi.be Wolfgang Linke It is all relative. If you have a 4-stage preheater kiln with no calciner and an old grate cooler you are world class with 850 kcal/kg. Travel around the world and teach the others! If you have a 6-stage preheater with calciner and an IKN cooler and you experience 850 kcal/kg, there is a lot of room for improvement. The important factors are very low kiln feed variation, steady operation and those factors Marechal Philippe has mentioned. tayyab ihtaysham - Reducing the false air MAX heat recovery in cooler cooling air Nick Sutherland As Wolfgang mentioned, it's all relative and to know where you stand in terms of world class you need to benchmark against other similar kiln plants. I can recommend Michael Clark at Whitehopeleman - see their website for contact details http://www.whitehopleman.com/key_performance
VA.Kerishnan Velayuthan Most main false air , cyclone conditions , raw mix ratio , bunner setting , flame adjustment , raw mix coal adjustment. Jagat Singh Rathee Have the complete heat / energy balance done , for a steady period of 24 hours ,for all the 3 sections of the pyro-processing plant ,covering the preheater ,precalciner strings ,the cement rotary kiln and the clinker cooler system ,so as to exactlypin point the areas where you are losing / wasting the heat / energy during sustained and uninterrupted kiln plant operations.This is extremely important to find out a lasting solution to your problem. Mr.Aditya Srivastava , of JP Cement Satna / Rewa ( M.P.),India ,you have not informed about the number of stages and the number of pre-
heater / precalciner streams for your kiln plants, that is very important to know about the standard range of specific heat consumption ( in terms of kcals /kg clinker ).Other things are supplementry to the issue. Sampathkumar Ponnusamy Aditya, For improvement in the existing running conditions: 1. Stable cooler operation. Maintain constant bed in the cooler. Try to increase the secondary and tertiary air temperature to the optimum level to your plant. 2. Arrest all the false air in the system. Especially in preheater. 3. Reduce the standard deviation of raw meal and optimize the flux Al2O3 and Fe2O3. Jagat Singh Rathee A few most important things to be watched for with care and attention are as under ,inorder to optimize the specific heat consumption in the pyro-processing system : Improve the degree of calcination in the calciner ,smoke chamber to a level of 94-96% , higher the better.I had operated a FLS /L&T kiln plant at about 96-98% degree of calcination ,by maintaining the calciner outlet temp.in the range of 900-915 degrees C , with excellent results w.r.t stability and sustainability of kiln operations ,for a period of about 3 years ,in India. Change the fuel firing ratio from the conventional 60:40 to may be 65:35 in calciner to kiln or even higher ,provided your coal firing system is capable of doing this ,i.e. if there are margins in the fuel firing system's capacity. It is not only better for stabilized kiln operations ,but is quite helpful in improving the kiln BZ lining life ,because of reduced thermal load in the cement rotary kiln . The standard deviation of both the raw meal / kiln feed as well as the pulverized fuel should be as minimum as possible ,so as to have highly consistent quality of coal meal and kiln feed for the pyro system.This is very much possible provided ,you always have enough stocks of kiln
feed in your CF silo ( normal filling level to be +60-65% of design capacity ,for ensuring complete homogenization.Same applies to the solid fuel ( coal ,petcoke or lignite or a combination of all these ) , Operate the kiln at higher speed ( about 5-7% more than the normal speed / rpm ) to have a very high degree of heat exchange by material turning very rapidly , because of faster exposure of the feed inside the rotary kiln,so that the material residence time is reduced in the rotary kiln ,as the meal before entering the kiln inlet has sufficient degree of calcination ,and kiln's job is to transform the calcined meal into clinker compounds / mineral phases. This shall call for further increase in the kiln feed rate to the PH tower, that is an improvement w.r.t. specific throughput from the kiln plant. Maintain kiln inlet O2 maximum around 1.75% ,lower the better ,and PH outlet at about 2.5-2.75 % maximum , lower the better ,this shall call for complete inspection and arresting of any false air in-gressing into the PH / Precalciner strings, including at the kiln inlet seal, and the kiln outlet seal at the clinker cooler beginning. Keep a very close watch on the secondary and tertiary air temperatures ,the have to higher by 10-15 degrees C than your normal range , so as to reduce your specific heat consumption in the pyrosytsem.
What are reasons of coating in cement silo?

Ramakrishnan Iyer Moisture in gypsum and probably moisture on account of water spraying inside mill. And also unsealed man-hole doors on silo top. Sergey Perediriy If the coating is at the roof - poor ventilation. If it is on the walls it is a matter whether it is hard or soft. It may be a
combination of many factors^ humidity of air, cement temperature, wall penetration Mohammed Abdo when cement mill outlet temp above 125 ..then most water content in gypsum will dehydrate to form high percentage of in hydrate gypsum thus, this cement will be very edacious to react with water -as humidity in the air - then the cement coat ability will increase inside silo .... then there are other factors will increase the coating as Mrs sergey perediriy said above. Sayed Hassan Reasons of coating at cement silo is atriputed to prehydration of cement caused by dehydration of gypsum which caused by high temp., to overcome this problem you need to decrease the temperature of cement when entering the silo (cooler), another way decrease the quantity of gypsum or add precent of gypsum anhydrite Pradeep kumar If cement temperature is high ie., > 80 deg C , going to the silo and the stock is very high the gypsum gets dehydrated and the moisture moves towards to colder walls and the inner cone. The vapors wet the cement and gets hydrated . If you have alkalies it accelerates the hydration forming syngenite , CasO4.K2SO4.H20 .Hence higher the cement temperature higher is the evaporation.To avoid this make the cement stock alive and reduce the cement temperature. As sergey said that silo must be ventilated with bag filter and if you are in tropical, country moisture passing through the silo aeration blowers can be dried. Imagine if you 10000 tons cement in a silo which has 500tons gypsum ie., 150 tons of water in combined form. May be 50 tons can evaporate assumed and then think what will happen. If it is not possible to cool the cement in your mills then FLS supply powder cooler which has heat exchanger inside. I have an analysis on this and i can share with you which you can help in uploading in the linked-in to share with our all friends. Regards, Pradeep Kumar
Muhammad Usman you are absolutely right Mr. Pradeep because on our plant FLS engineers has installed cooler on cement mills that having heat exchanger. Ashok Sekar Dear Mr. Khurram, I am from FLSmidth and if you need any assistance pls contact me (ashok.sekar@flsmidth.com) and i can forward the same to concerned Sales manager Asif Ali Sheikh Dear Khuram, kindly check the cement temperature ,and the compressed air used for areation could be the reason of moisure and resulting the coating formation. Chelladurai Palaniandy In CEM II production in tropical area i have experienced with high feed moisture in Gypsum , Open yard wet clinker and Wet limestone and overall mill feed moisture is more than 8 % . But we didn't face much problem due to maintain temperate remove as much as moisture in vapor form before going in side silo and maintain silo ventilation , level and method of aeration etc. I think no need of cooler also.
plz i want any one tell me how can i calculate heat balance, clinker factor
Arvind Gopalan Dear Maas, I will try my best to explain to you partly about the Clinker Factor, in other word the Mass Balance(mass in = mass out). There are two ways of ascertaining the clinker factor ie., directly by weighing the clinker using a drop test for a period of about 24 hours which is far more a practical and the most recommended way. The other way is to go in for a Mass Balance based on specific kiln boundaries. In the latter case we have to figure out the type of Dust Recirculation prevalent in the Kiln system ie., whether it is External Dust Circulation
or the Internal Dust Circulation. Considering the Case of External Dust Recirculation the recirculation dust needs to be taken into account(as the Dust goes back to the kiln feed bin) in which case the mass balance will be with the likely inputs of Kiln feed & Coal Ash component( if coal is used as fuel) and the output components which needs to be deducted will be the Recirculation dust and the Bypass dust ( if bypass system is available) to arrive the clinker as they cross the boundary. Likewise in the case of Internal Dust Recirculation the recirculation dust need not be taken into account as they are within the boundary of mass balance(ie the dust comes back to the system after the kiln feed bin). In this case the inputs will be the same as the earlier case but the output will only the Bypass dust( if bypass system is available). As I could not explain to you clearly either by giving an example with the calculations and the pictorial representation of the boundaries , I have made efforts to explain the mass balance in a simple way. If you are further interested to know the mass balance you can mail me to the following id. arvindgopalan@yahoo.com
Regards Arvind. Mohammad Khalessi-P.ENG., PMP Factor for clinker factor from raw material (Raw Mill inlet) is: Clinker=Raw Meal x ((1-LOI)/100) x ((1-H2O)/100)) Factor for clinker factor from Kiln feed is: Clinker= Kiln Feed x((1-LOI)/100) x ((1-H2O)/100) x ((1- Dust
Loss)/100) LOI= Loss of Ignition H2O= Material Humidity(Normally it is 0.5% for Kiln Feed) Dust Loss= Return from ESP and GCT(Between 7-10% depend on the top cyclone efficiency) Heat Balance is just a equation between inputs and outputs I consider the outputs as positive and inputs as negative Outputs 1-Heat loss from main stack from preheater tower and dust loss. 2-Heat loss fro By pass if a system has it. 3-Heat loss from Preheater (Cyclones shell) 4-Heat loss fro Kiln shell 5-Heat required for burning. 6-Evaporation 7-Heat loss in Clinker Cooler 8-Heat loss from output clinker Inputs 1-Heat with Raw Material, Air and Fuel 2-Heat from Ignition Hope that it helps Mustafa Hussein Kindly, could you inform me about all the factors affecting the gates speed of grate cooler Juan Pedro Espern Main factor or parameter to control is the pressure below first gate. It is a good indicator of clinker bed you have inside of grate cooler. Second factor or parmeter to control is the secondary air temperature. It is going to tell you about exchange termic energy between air and clinker.
Mohammad Khalessi-P.ENG., PMP Well that is a complicated question and depends on the process parameters,kiln condition, burning technology and cooler technology but the major points can be: 1-Controlling the teritary air temoerature. 2-Controlling clinker bed thickness and pressure under the clinker bed. 3-Snowman or red river effects
What are the procedure by wich we can decrease the DP level in bag house??
Ramakrishnan Iyer clean bags regularly. What is the temperature of gases passing thru bag house?.If low, water condensation will choke bags. Poor quality bags also will choke the pores of bags. Calibrate all temperatures and pressures in bag house. Atef Ibeid 1st check air press at B,H area is it enough 5-6 bar? 2nd check Poppet valves movement one by one 3rd if every thing is ok ,Cycle burging time ,,,etc ,then investigate ur filter bags by take 3 -5 bags from different compartments & check bags poroosity,may be ur bags is exposed due to high temp,if this is the case,then u ve to check ur bag house inlet temp Protection & to sure if it is activated or not if ur bags loose porosity due to high temp.,then u will ve high Press Dropp DUE TO HIGH RESISTANCE so u need to change ur bags with new one Munusamy Murugan Excess false air leakage at Bag House inlet and through inspection doors will lead to higher DP because of low suction or positive pressure at inlet.So arresting false air will reduce Dp across Bag House
Ashish Ghai You must check the purging sequence, smooth operation of all the solenoid valves, air leakages, Reverse air fan. Then go for bags replacement. Ashish Ghai You must check the purging sequence, smooth operation of all the solenoid valves, air leakages, Reverse air fan. Then go for bags replacement. Ashish Ghai You must check the purging sequence, smooth operation of all the solenoid valves, air leakages, Reverse air fan. Then go for bags replacement.
Kiln Operations Dear Experts, I would like to know that what we are to mainly saw in Kiln and cooler camera in control room ?
carlos barbosa In the kiln you can see: 1- the behavior of the clinker in the kiln. if the material is not going up with the kiln moviment and falling down on the main burner. If so it is a problem. You should see in this area only clinker's balls falling down on the cooler. 2- the temperatura of the flame is not monitored by instrument you can infer it by the flame color. 3- how is the amount of dust in the clinker. In the cooler you can see: 1- the ar distribution in the clinker bed. If there is no a place where there are red river or the air is in excess. 2- snowman
Hassan kiln camera: you can judge the quality of clinker by it is behavior, also you can determine the status of the kiln and burning zone, cooler camera: you can determine the status of the kiln, you can see the formation of snowman and red river, in addition to the clinker bed
Er.aditya Srivastava Mr.Carlos Barbos in my plant we can moniter the flame temprature Ashish Ghai Thank you Mr.Hassan and Mr. Barbosa . Sir, I would like to know about Snow man and Red River. Ashish Ghai Thank you Mr.Hassan and Mr. Barbosa . Sir, I would like to know about Snow man and Red River. Jagat Singh Rathee Dear Ashish Ghai,The red river in the cooler means ,the clinker is not cooled properly while travelling over the cooler area / plates.This is because of the improper cooling air and clinker distribution over the cooler inlet area and in the subsequent zones.Air distribution control , through the cooler bed control mechanism and the cooler fans air control through the control mechanism like fan speed ,damper and the cooler bottom air distribution control valves in the modern coolers, is a must ,so as to arrest the red river formation ,to save / recuperate the heat energy from the clinker, and also to avoid chances of mechanical damage to the cooler structure . Snowman is the formation ( in the form of a small to medium or even occasionally touching the kiln discharge end, just at the cooler beginning ,below the kiln burner pipe ,mostly towards the clinker discharge side ,as the clinker cooler is about 600 - 650 mm off centre from the kiln center line ), is because of excessive liquid phase in the kiln burning zone (
mostly because of soft burning raw mix ) or sometimes excessive fine clinker dust in the clinker being discharged on to the cooler, or due to excessive burning zone temperature, maintained by the operator. These conditions have to arrested by reducing liquid in the range of 27.5 - 29.0 % , in the clinker, and through appropriate flame control mechanism by the operator or use of fuzzy logic ,kiln expert control or the Linkman software for kiln operations , if you do not want to depend too much on the kiln plant operators.Even ,you can play with the kiln speed and cooler to an extent for stabilized and uninterrupted smooth kiln operations. In this exercise ,both your kiln as well as cooler cameras come very handy and are highly useful, for the operators, for flame view ,burning zone view , discharge /cooling zone view and the cooler overall view w.r.t. air distribution ,clinker distribution and the smowman formation ,very clearly
Burners and Flames - FLS , Pillard , KHD , Calculation of Burner Momentum

on: February 24, 2013, 11:34:08 AM
Pillard burners and flames ======================================= this lecture is about Know the criteria for burner design Familiarise yourselves with the suppliers and burner types that exist Know the consequences of poor burning, the combustion indicators that confirm this, and the possibilities that exist to correct the situation Encourage your personnel to concentrate efforts on burner optimization ``If it is mixed, it is burnt ============================================================ ======================== Firing Systems + Burners and Flames
Primary Air Rate : 10 12 % Based on stoichiometric combustion air, exc transport Specific Axial Momentum : Gax = 7 10 N/MW Including fuel and transport air Primary air fan Minimum 250 mbar Injection Velocity Coal 30 m/s Petcoke 25 m/s Consider future use of AFR!
Momentum = Velocity * Massflow Quick calculation of specific axial momentum Gax: Gax = %PA * vPA* 1/300 [N/MW] %PA = percentage of primary air [%] Primary air velocity (Bernoulli) : vPA = (2 * pTip / Tip ) [m/s] pTip pressure at burner inlet -5% [Pa] Tip = air density at burner tip T = 50C, p = ambient pressure Example: Amount of primary air: PA = 12%; pBurner Inlet = 200 mbar vPA = 187 m/s Gax = 7.5 N/MW + 1 N/MWfor Coal = 8.5 N/MW ============================================================ ================================
Pillard Rotaflam - Eclpens
250 mbar fan standard Separate adjustment of PA radial and axial Very flexible Extensive experience in Holcim ============================================================ =============================== Unitherm M.A.S Burner - Sigghental
New concept (one single primary air channel) Interesting alternative to conventional burners ============================================================ =========================== FLS Duoflex Ramos Arizpe II
250 mbar fan standard Adjustment on burner tip (only sum of axial and radial air) Little experience in holcim but FLS is reputable supplier ============================================================ ============================ KHD - Pyrojet
Jet air with 1000 mbar axial pressure (blower needed) No cross tip adjustment possible Concept does not foresee amount of primary air (volume) ============================================================ =========================
Burner Adjustment
Typical burner set-up (Rotaflam): 60% axial air, 30% radial air, central air 50mbar ( 10%) ============================================================ =========================== Fuel Oil Atomisation
Why do we atomise? ``To increase the surface area of fuel that is to be mixed to allow rapid burnout. Reaction time of a particle increases approximately with the square of its diameter ============================================================ ============================== Types of Atomisers
Fixed Orifice - Pillard Variable Orifice - FLS Assisted Atomisation ============================================================ ============================= Whats the Ideal Flame ?
Short, Hot and Stable! ============================================================ ================================ Consequences of Poor Burning =============================================
============================================================ ================================ Combustion Indicators ========================================= Clinker Quality Free Lime Liter Weight SO3 in clinker Microscopy Magotteaux test Detects reducing conditions (CO) Coating Formation
Temperature profile Length of fixed coating Stability of coating Ring formation Gas at kiln inlet CO : < 0.05% - good burn out Temperature at kiln inlet As low as possible : > 1100oC Long Flame Short kilns L/D < 12 higher inlet temp acceptable SO3 Volatilisation
============================================================ =============================== Steps to improve combustion - Burner
Carry out Burner Check and Combustion Check
Impulsion Increase shorter flame PA ratio Increase shorter flame Fuel pressure fluctuations Decrease stable flame Fuel velocities Ensure one flame Burner alignment Parallel to kiln axis SAT Increase shorter flame Fuel quality Regulate stable flame Burner Position Kiln outlet - shorter flame ============================================================ ============================= Know the criteria for burner design Familiarise yourselves with the suppliers and burner types that exist Know the consequences of poor burning, the combustion indicators that confirm this, and the possibilities that exist to correct the situation Encourage your personnel to concentrate efforts on burner optimisation
According to you, what are the best 3 innovations of the past 50 yrs in each of the following areas of Portland cement? 1. Manufacturing, handling equipment and storage 2. Raw materials & raw meals 3. Fuels & Energy 4. Process Control 5. Analytical techniques 6. Product Innovation (clinker and finished cement) 7. Grinding Aids 8. Set retardation
Subhash Bhanot I agree with S. Kumar. The Industry has done a lot and still continuing in those 3 innovative areas i.e., Fuels and energy, Process control and Product innovation. The alternate ways of manufacturing cement is taking more attention as the requirement is having lesser carbon foot prints towards mitigating the carbon threat to the universe. Sergey Perediriy Alternative fuels and raw materials S Kumar Fuels & energy, Process control and Product innovation
Dear all, How many hours per day does a reclaimer normally operate? In other words I want to know how can one calculate reclaimer's design capacity? thanks
Wolfgang Linke What reclaimer do you refer to? Limestone, additives, coal? Also it depends on your plant configuration like multiple use of belt conveyors, size of mill feed bins, etc. The design of a modern, well maintained plant keeps the mill feed bin for the mix very small resulting in a contineous operation of the reclaimer. Mill maintenaance day will be also reclaimer maintenance day. Manish Kumar Verma Generally Reclaimer capacity calculated on Raw Mill capacity i.e Raw Mill Capacity x Safety Factor (1.1 to 1.2) x Limestone % in raw mix but mostly people calculates without considering LS %
What we should know about the specifications to improve the life of bags in clinker cooler dust collector? Can any body throw light on different type of bags and spec used in cement industry
Er. Abinash Rath it depends on the type of bag you use , here are different type of material of construction of bags Fabric filter bags (sometimes referred to as envelopes) are oval or round tubes, typically 1530 feet and 5 to 12 inches in diameter, made of woven or felted material.Depending on chemical and/or moisture content of the gas stream, its temperature, and other conditions, bags may be constructed out of cotton, nylon, polyester, fiberglass or other materials. Nonwoven materials are either felted or membrane. Nonwoven materials are attached to a woven backing (scrim). Felted filters contain randomly placed fibers supported by a woven backing material (scrim). In a membrane filter, a thin, porous membrane is bound to the scrim. High energy cleaning techniques such as pulse jet require felted fabrics. Woven filters have a definite repeated pattern. Low energy cleaning methods such as shaking or reverse air allow for woven filters. Various weaving patterns such as plain weave, twill weave, or sateen weave, increase or decrease the amount of space between individual fibers. The size of the space affects the strength and permeability of the fabric. A tighter weave corresponds with low permeability and, therefore, more efficient capture of fine particles. Reverse air bags have anti-collapse rings sewn into them to prevent pancaking when cleaning energy is applied. Pulse jet filter bags are supported by a metal cage, which keeps the fabric taut. To lengthen the life of filter bags, a thin layer of PTFE (teflon) membrane may be adhered to the filtering side of the fabric, keeping dust particles from becoming embedded in the filter media fibers.
Pamarthi S.S.Prasad Number of Fabric Filters available, bag life performance mainly depend upon 1.Air to cloth ratio, 2.Inlet temperature of bag house, 3. Inlet gas flow design, and 4.Bag purging type. We are getting good life of more than 3 years with Nomex bags, air to cloth ration 0.10 to 2.25 m3/m2/minute, temperatures less than 190 deg C.and purging with diff pressure setting.. In another plant we use Glass Fibre bags but inlet dust load is more than the design, inspite of having all other parameters satisfy the design.the bag life is concern to us. Good Filter bags must have all other qualities as mentioned above, then bag life is good and ofcourse the dust emissions too, at the end of the day dust emission matters. best regards
What are effect on quality if high SO3 flyash from power plant is used as gypsum in cement
how to choose Ball mill liner he most important factor for choosing cement mill liner : http://cementforums.com/community/index.php ?topic=9.0
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Ball mill liner how to choose
Of various types of ball mill liner annual consumption of less than 250,000 tons, grinding media (cement industry, said grinding bodies, hereinafter referred to as grinding media) 25% of the annual consumption, the proportion of processing tons of material costs second only to in grinding media, it is the bulk of
consumption items, compared to the liner and grinding media, lining more reflected in economic losses caused by the impact mill operating rate is several times the value of this spare part, more than ten times.
Technical factors affect the consumption of mill liners as many as a dozen, or even more, basically figure out, but several. Throughout China's metallurgical ore processing plant wet milling rough mill is almost 100% metal liner, including high-manganese steel liner. Ordinary highmanganese steel (Mn13) is characterized by shock hardening, to improve its service life, the key is to improve its initial hardness international popular and effective measures to implement the explosion hardening, namely high-manganese steel parts factory before its facilities internal defects of the explosion, one can check the large high-manganese steel pieces, an important part of high manganese steel parts, before the job is excised, so as not to lead to accidents; two through the surface facilities burst of high-manganese steel (special explosives instant impact surface ), high manganese steel parts surface hardness, greatly improving its initial hardness.
Metallurgical ore wet milling grinding ball mill liner, has diversified materials, in addition to the metal liner, rubber liner, polyurethane (PVC) linings, different composite materials magnetic liner came into being.Cement industry and metallurgical ore ball mill job, there are three different points: First, the ball mill low speed former, mostly from 75% to 80% of the critical speed. Secondly, the cement industry slender ball mill, which is short and thick. The third biggest ball diameter of the cement industry head positions, with the latter's largest ball diameter compared to much smaller. , Cement mill liner selection of high-manganese steel real shock hardening properly,
should be vigorously promoted multicomponent alloys of chrome lining.3.5

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hamada1984
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Posts: 1 Newbie
Re: how to choose Ball mill liner

Reply #1 on: February 20, 2013, 04:02:54 PM
thank's ...it's good information about mill lining wearing but i want ask question about ... if we charge the mill with over grinding media does it cause rapid wear for mill lining, how the operator can notice there are wear to the lining during operation according to operation parameters
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Administrator Newbie
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Posts: 21
Re: how to choose Ball mill liner

Reply #2 on: February 20, 2013, 07:30:15 PM
Dear hamada thank you for replying : I hope you can make use of this Answer : 1.1.1 Ball Charge Classification Ball chargeclassification works best in small mills. (stphane) 1.1.2 Swelling of charge / Reverse Classification 1.1.2.1 Roberts Experiences: 1. Joliette: 2 different liners used in a monochamber mill. At this point, the ball charge sizedistribution is mixed 2. La Runion. The plant used 2 verysimilar classifying liners of the same dimensions and wear profile. Nonetheless, where the 2 liner types met,there was a strict line defining the loss of the classifying action 3. ?? Cant remember plant: Themounting of the classifying liners was slightly wrong there was a 2 cm gap between liners in the middle of the chamber, which was filled with a ring of 20 mm balls. At this point, as strictdisruption of the classifying effect was observed 4. Many mills: where unground clinker particles get through to the 2ndchamber, they cause localised swelling of the charge. Often, the smaller balls then migrate to themiddle of the chamber leading to swollen mounds in the middle of the chamber. 1.1.2.2 Others Experiences Hanspeter example: Germany? During performance test material fillinglevel was high and ball charge reverse classified. Reduced feed and filling level and after 1day the ball charge was reclassified. -----------------------1.1.2.3 LAFARGE: Reverse classification occurs whenparticles greater than 1/3 the diameter of the void space between balls are NOT crushed immediately. The reasons are:
Feedgranulometry or hardness too much for ball charge In thefirst chamber, inefficient crushing due to ball charge too small or liners too worn Ballcharge too large in the 1st chamber combined with diaphragm slotstoo large large particles get into the 2nd chamber. This problem can be detected by: An overallfilling level more than 3% greater than the calculated filling level o In C1 often the balls are visible but theoverall level is more than 3% above the calculated value. Alternativelythe first part of the C1 might be swollen (especially with high returns load) and the zones behind are empty because the retention is greater in the swollen area. In such cases there may be aninverse classification of the charge (see next point) Reverseclassification in 1st or 2nd chambers. In this case the material is carried bygravity down the slope along the length of the compartment. In addition it is noticed that the balls inthis area migrate down the slope too and they may stop in the middle or the end of the compartment. Often it is theBIGGER BALLS THAT MIGRATE reverse classification in the C1 and C2. Highvariations in power draw at the mill motor 1.2 Residence TIme Open Circuit: >=12 minutes Closed Circuit: >=5 minutes Test usingfluorosceine, mixed in a bag with some clinker, then added to the feed belt. Sample at mill exit every 30seconds for a period of ~25 minutes after adding the clinke+fluorosceine. Need specialised measuring equipment in lab. 1.3 Ball Coating
Ball and liner coating can occur in raw aswell as finish grinding. Ball coatingcan be a result of the following conditions: 1. InadequateGrinding Aid 2. PoorMill Ventilation 3. Mill Overheating 4. TooMuch Moisture Input 5. Mill Overloading Adequate ventilation will help alleviatepersistent problems. Mill ventilationcan serve two purposes to reduce ball coating in mill temperature problem situations. It can take heat away fromthe mill as it is created by the grinding, and it can take water vapor away from introduction with the material or from water sprays which provide additional cooling. The present theory concerning ball coatingis that as the particles of feed shatter under the impact of the ball charge, the surface equilibrium becomes unbalanced. This unbalanced condition causes an attraction between the individualparticles of feed and between the feed particles and balls resulting in ball and liner coating, material agglomeration in the mill and "pack set". Ball and liner coating cushionsthe impact of balls, and in severe cases can affect lift. Material agglomeration affects grinding aswell as separation. Pack set is that condition where bulkcement, after being compacted by vibration, requires considerable mechanical effort to start initial flow. Actually,pack set bears much the same relationship with cement flowability, as starting friction bears to moving friction. Packset, like starting friction, requires more force to start material flow than that required to keep the material flowing. Pack set has become a serious problem in recent years because of thecement industry's use of large diameter mills which causes a higher material surface unbalance and the increased transportation of cement in bulk quantities.
secrets limestone crusher operators don't reveal to you about operations and calculations
I wrote an article about limestone crusher operation procedures and calculation , and I uploaded all function as photos you can save it to your computer , here is the link of the article , please post feedback , and if something you want to ask about the article email me or ask here I will reply http://cementforums.com/community/raw-material-crushing-and-preblending/limestonecrusher-rotor-speed-productivity-motor-power-main-structure/
limestone crusher rotor speed , productivity , Motor power , main structure

on: February 22, 2013, 04:20:22 PM
limestone crusher essential calculation : the following calculation is based on my experience you will not find it any where else for limestone crusher operating parameters if you understood this calculations and applied it you can be in no time limestone crusher operator ============================================================ ============================= let's begin with : 3.2.1 Calculation of the rotor speed of limestone crusher ========================================= of the Hammer crusher rotor speed is calculated at the desired circumferential speed, the peripheral speed of the hammer bit, according to the nature of the material to be broken, and the granularity of the crushed product, the hammer wear and other factors to determine.
Small and medium crusher speed 750-1500 , A peripheral speed of 25 to 70 , The higher the speed, the smaller the particle size of the product. Hammer and lining, the greater the wear of the grate. Power consumption increases. Installation precision machine parts processing increases. Meet the size requirements of the case, the peripheral speed should be low selected. ============================================================ ===============================
3.2.2 productivity computing of limestone crusher =================================== Productivity and specifications of hammer crusher, speed, discharge grate of the gap width, feed particle size, and factors related to the material conditions and the material properties. Commonly used empirical formula:
============================================================ =============================== Motor power calculation of limestone crusher : ================================== The power consumption of the motor depends on the nature of the material, the circumferential speed of the feed. Crushing ratio and productivity. Currently, there is no a complete formula, usually based on practical experience and experimental data, calculated according to the empirical formula:
============================================================ =============================== the crusher main structure parameters design of limestone crusher ================================================ the rotor diameter and length: ======================== Specifications of the hammer crusher with diameter D and length L of the rotor, said rotor diameter D = 800mm, the length of the rotor is L = 800mm. 3.3.2 to the width and length of the discharge port: ==================================== The hammer crusher feed the mouth of the same length and the rotor. The width B 2 .
3.3.3 nesting population size ===================== The size is controlled by the grate of the gap, and the grate of the gap is determined by the size of the particle size of the product. , The average particle size of the product of 1/5 to 1/3 of the gap of the crusher.
Calculation of limestone crusher hammerhead quality: ==================================================== Hammerhead quality is selected too small, hinged on the rotor, so the correct choice hammerhead quality has a significant impact on crushing efficiency and energy consumption, may not meet requirements hammering a material will be broken. Election too big, useless power consumption is too large, the centrifugal force, have an impact on other parts and easily damaged. Would have a hammer blow to take into account the material according to the the momentum theorem hammerhead quality, speed loss, if the loss is too large, it will make partial inverted hammer around itself hanging axial. Reduce productivity and increase the consumption of wasted effort. In order to make the hammer after partial inverted able material quickly restored to the correct working position by centrifugal force when the next broken combat material. Therefore, the rate of loss after the requirements of the hammerhead combat material should not be too large. Generally allow the speed loss of 40% to 60% (based on practical experience):
However, the Just a hammer blow to quality. Actual quality should be based on the rotation order and the rotation of the hammerhead combating quality inertia obtained,
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Can anybody tell me the process instruments used for measuring air flow in bag filter
Joseph Riley The simplest way is to install a hot wire anemometer, either permanently installed or portable insertion style, in the inlet ducting to the filter. You will have to find a location where the gas flow is approximately evenly distributed in the ducting. Depending on your filter design, you may have a hard time finding a good location if you want to find out the gas flow in each compartment. In this case, it is easiest to use the location at the outlet of each compartment, just after the outlet poppet valve, and before the gases join together. Alternately, you could use a pitot tube, but it requires some expertise. Bart Van Roon I allways use a pitot-tube in the duct to the chimney. The electronic versions you have these days calculate directly to m/s airflow. So it it's easy to recalculate to m/hr. Because you take the duct to the chimney (behind the bagfilter) the air is clean and easy to measure. Air in (m/hr) = Air out (m/hr)
Joseph Riley Where you measure is going to be governed by how accurate your want to be with your measurement and the purpose of your measurement. If you try to measure the flow out of the filter, you could be measuring false air intake from the filter hoppers and the outlet ducting. If you need to refer the gas flow measurement back to normalized conditions, in addition to the false air potential, measuring after the filter will also bring the added error of measuring the gases at a different pressure and temperature, which will cause a skew in your gas flow when reported in normal conditions.
Jagat Singh Rathee The stainless steel pitot tubes are available in two configurations ,namely ,L-shaped and the S-shaped .L-shaped pitot tubes are used for the flow measurements through tubes , ducting for clean air ,gases without dust, and the S-shaped pitot tubes are used for the measurement of the dust laden gases / air flow. There are standard coefficients / constants for these stainless steel pitot tubes ,as given by the designers / suppliers, for use during the process measurement calculations.
These pitot tube / instruments are available with the dealers ,dealing in process measurement instruments like anemometer , pressure gauges ,manometers ,portable gas analyzers , thermo-couples etc.etc. including dealers in scientific instruments ,in almost all metropolitan cities.
Er. Abinash Rath actually I am in Qatar so I do not know where to find these . Can you tell me the fluke model or any other company name to find in the site John Kline I think it is appropriate to ask what do you want to use the air flow measurement for. Knowing that you can decide on the best approach to measure it. Without knowing the end use, the instrument choice may not be correct. Pamarthi S.S.Prasad Dear Mr.Abinash Rath Kindly contact this gentleman, may help you in measurement and as well details. Best regards ================================================= Sultan Ahmad Mallick Technical Manager Envirozone LLC PO Box # 39230 Abu Dhabi, UAE Tel : +971 2 5501320 Fax : +971 2 5501321 Mobile : +971 503277547 E-mail : samallick@envirozone.ae <mailto:samallick@nahlamed.ae> Web site: www.envirozone.ae GPS Coordinate - N: 24 19' 16.90'' E: 54 28' 41.66''
Er. Abinash Rath @ pamarth sir I need to check the flow not the oxygen carbon dioxide like that John Kline Assuming that you are measuring on the clean side of the baghouse. I would suggest a clean pitot tube traverse in an area with as straight a duct run as you could find. If you can measure oxygen at the same point, you might double check gas volume versus combustion calculations. Er. Abinash Rath http://www.chevrierinstruments.com/Anglais/Pdf/Cat/F-018.pdf can i use above instrument Daniel Raju Alamanda Yr Question; Can anybody tell me the process instruments used for measuring air flow in bag filter. (I hope you are not talking of which Brand of the measuring instruments...??) For types of instruments: My first advice is to know the total gas flow using "S' type pitot tube at BF inlet. 'L- type would be a disaster as it is high dust laden gas stream. Also get the dust loading= gm/Nm3 using thimble sample train. If there is provision fr dust drop test, pl do it to check the above value. Then if the BF has Air Distributio Grid, then try the Annemometer for correct distribution or adjustment of baffles if any. try at diffrent % of dampers or RPM of fan. Then again at BF outlet you can measure air flow by Pitot tube. Take the actual power drawn by fan & check with calculated theoritical power for measured gas flow, if you know the fan curves. Also take the dust entrained in clean gas by Thimble sample train (mg/Nm3). To measure the moisture content, use cooling rack for flue gases then a moisture absorbant chamber. (potash or silica crystals) wt before & after to get % moisture/Nm3 Finally to get the false air across the bF, use O2 meter. To get the compressed air consumption in BF, note the time to discharge the tank from unloading to loading condition of compressor. You can also determine the dew point at inlet & outlet if your clever enough to use wet bulb/ dry bulb temperatures. can you please check this link can i use this Er. Abinash Rath http://www.chevrierinstruments.com/Anglais/Pdf/Cat/F-018.pdf can you please check this link can i use this
Joseph Riley This instrument has an operating temperature limit of 50 deg C and the pitot tube is only 12" long. If your gas temperature is lower than that, and the duct is less than 24" in diameter, then you
should be able to use it. This instrument is mainly used for HVAC, not for process gas streams. Normally a cement plant has a pitot tube and a vane anemometer in it's toolbox. The pitot tube is used for hot gas streams, such as kiln gas fan, and the vane anemometer is used for clean air, where the fan inlet is accessible, such as in a clinker cooler fan. The pitot tube has to be long enough to penetrate the ducting as close to mid point as possible (sometimes this is not possible due to size of ducting). For the air slide blowers, you would use either a vane anemometer on the intake of the blower and then correct for temperature and pressure to arrive at standard conditions, or you can purchase a permanent insertion flow meter (such as an Annubar) or an thermal anemometer (Sierra Steeltrak or FCI unit). I know that everyone here is pushing pitot tubes for the gases, and you can find several of them out there, however, as I stated previously, if you want a fully bulletproof unit that you don't have to worry about fouling or correcting, you should use a thermal anemometer such as the Kurz insertion flow meter http://kurz-instruments.com/products/2445.htm.
Joseph Riley For permanent installation insertion thermal mass flow meter: http://kurz-instruments.com/products/454FTB.htmhttp://kurz-instruments.com/products/KBAR2000B.htmhttp://www.fluidcomponents.com/Industrial/Products/MassFlowMeters/ProdST98B_AN .asphttp://www.sierrainstruments.com/products/670s.html For permanent installation of the fluidizing air blower piping: http://www.fluidcomponents.com/Industrial/Products/MassFlowMeters/ProdST75.asphttp://www.fluid components.com/Industrial/Products/MassFlowMeters/ProdST50.asphttp://www.sierrainstruments.co m/products/640.htmlhttp://www.sierrainstruments.com/products/quadratherm/640i.html
Wolfgang Linke Can we go back to your original question? Can you please describe what problem you encounter in your plant. Then you will get a wealth of ideas how to solve it.
What is an acceptable loss in strength between the production sample and the dispatch sample A fairly simple question with a rather indepth potential. What is an acceptable loss in strength between the production sample and the dispatch sample of a given cement - particular reference to the 28d strength? Production sample would be from the autosampler after the mill. Dispatch sample would be taken at teh packer / bulk loading point.
gey Perediriy We have the opposite - dispatch sample shows a bit higher strength development and some 100 cm2/g higher Blain Artem Kozinets example from one plant - they loose 2-4 MPa in dispatch vs ex-mill. it is up to management to decide what is acceptable level. the best is not to loose any MPa, but i think 2 MPa is quite acceptable, 5 MPa - not acceptable
Stephen LeSurf It is best if adjust the grind sample SSA to give an acceptable 28 day strength for standards and more importantly customers. There may be a SSA differential from grind to despatch samples because of sampling points, although 100cm2/g seems a little high. However, ultimately the surface area figure is purely arbitrary.
Dear All ! What are the effect of atmospheric conditions on clinker stored in open yard on Loss of ignition , Crystalline structure of Alite , Grindibilty etc
Lime in the clinker gets saturated and the grinding will be easier and the quality of cement reduces with ageing. Usually storage of clinker in open yard is normal practice. No doubt Free Cao reduces with reduction in cement strength made from exposed clinker. It was experienced that Residue of the finish product increases with exposed clinker; moreover, cement mill temperature maintenance is another issue face by the process people. In general long exposure OR Open yard clinker storage be avoided.
Ted Krapkat Hello Muhammad, As others have mentioned;- Free CaO is reduced in clinker stored in the open due to reaction with atmospheric moisture and rain. This water also reacts with the clinker minerals producing additional Ca(OH)2. For example the reaction with C3S is;2(3CaO.SiO2) +7H2O --> 3CaO.2SiO2.4H2O + 3Ca(OH)2 So, as the clinker weathers, its XRD CaO content decreases but it's Free Lime content, as measured by Ethanol/Glycol titration, actually increases. LOI also increases, and is often used as a measure of weathered clinker prehydration But there is a further reaction;- If the clinker is exposed to high humidity for more than a week or two, the Ca(OH)2 which first forms reacts with atmospheric CO2 to form CaCO3, releasing water in the process. ie Ca(OH)2 + CO2 --> CaCO3 + H2O This water can then hydrate more clinker minerals and Free CaO, releasing further Ca(OH)2.... and so on. Once enough water has been absorbed by the clinker these reactions can continue to occur for some time... even if the clinker is later covered, or removed from the elements. There will of course be a large increase in the LOI of the weathered clinker and a corresponding reduction in cement strengths because
of the prehydration of the clinker minerals. However, if you are adding limestone as a filler in your cement, there is a solution to using partially weathered clinker, while experiencing little reduction in mortar strengths, provided that the L.O.I. of the weathered clinker is not greater than the contribution of the normal limestone filler content. For example, if your GP cement normally contains say 5% of pure limestone as mineral filler and 5% gypsum, then your GP cement L.O.I. will be around 3.3%, using fresh clinker. This LOI includes;LOI contribution of fresh clinker = ~0.3% LOI contribution of 5% gypsum = ~0.8% LOI contribution of 5% limestone = ~2.2% If you are already adding CaCO3, in the form of limestone, it is a simple matter to reduce the amount of limestone mineral filler added to the cement, so as to just compensate for the extra CaCO3 in the weathered clinker. At the same time, reducing the amount of limestone filler has the effect of increasing the cement clinker mineral content back to its normal level. But there's a limitation;- In the above example (using 5% limestone filler) it would not be possible to compensate for this extra CaCO3 if the LOI of the weathered clinker is greater than 2.2%. Therefore, it is always best to keep your "outside" clinker covered. But if you are then forced to use it, and you already add limestone as a mineral filler, it is possible to use partially weathered clinker without significant effect on mortar or concrete strengths. But in extreme cases you may have to grind the cement made from weathered clinker slightly finer to expose enough fresh clinker mineral surfaces. You will need to continually test the LOI of the clinker being fed to the cement mill (after first drying it fully) and adjust the limestone feed according to the LOI result obtained. Of course there is a cost penalty since every 1% less limestone added to cement means 1% more clinker consumption for the same amount of cement. Maintaining cement performance when using weathered clinker ALWAYS comes at a price.
Nohman Mahmud Agreed with Mr Ted that whenever clinker is stored in open yard ,its free lime as tested by wet / chemical analysis increases from the free lime content at which clinker was dumped in open yard due to hydration reactions as the method do not distinguish before free CaO and free Ca(OH)2----Refer ASTM C114 , 27 Mohammed Abdo yes the setting time will influence due to C3A reaction with water is great and rapidly more than other mineral's.
that causing to partial attrition of C3A thus the setting time will increase as result of that, there for it will causing to use less amount of gypsum than normal addition . Marchal Philippe Dear Muhammad, It is always possible to store clinker outside but the quality will decrease with the rainfall level. Below 6 months, you will have minor problems. A little bit increase of LOI (up to 2% on weight basis) and an easier grindability that gives fineness in the cement but no compressive strenght according tho the increase of fineness. Usually, to recover an old clinker pile, one can mix old clinker and fresh clinker (20 % fresh and 80% old one) and finally reuse all the stock. We have no experience of wasting old clinker stored outside. Let me know if you need support to solve your problem. Regards Philippe
Mohammed Abdo but how could yard clinker be easier grind ability although the clinker mineral's partially solidify due to react with rain water ??? can you explain further The hydrated clinker is easier to grind because of micro cracks inside the alite crystals partly deteriorated by weathering effect water and CO2. Note the free lime in clinker (around 1%) is usually recarbonated. Jagat Singh Rathee Prolonged storage of clinker in the open has both the advantages and disadvantages Advantages : Clinker becomes easier to grind, cement mill output improves though slightly , which consequently reduces specific power consumption of cement / finish mill circuit, free lime in clinker gets hydrated, easy to handle this clinker etc. Disadvantages : Reduction in cement strength , degree or quantum of decrease ,shall depend upon the duration of outside storing and the condition of storing, if you are making blended cements like PPC or PSC , the additives consumption at the finish grinding stage shall reduce
and consequently ,the manufacturing cost shall increase ,that is detrimental for the company. Material handling cost is an added disadvantage
Dr.MohamedUnfollow Follow Dr.Mohamed
I would like to ask about used oil shale as alternative fuel and raw materials for cement industries? oil shale percent
28 days ago

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UtpalUnfollow Follow Utpal Utpal Sengupta Dear Dr. Mohamed, Yes oil shale can be used in cement industry. But only we have to see how it has to be handled and its storage system. SENGUPTA. 27 days ago Unlike Like
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Dr.MohamedUnfollow Follow Dr.Mohamed Dr.Mohamed Shabaan Thanks so much Mr. Utpal if you have any papers or data please send me by my Email. mowhhoob@yahoo.com 26 days ago Unlike Like

Syed IftikharUnfollow Follow Syed Iftikhar Syed Iftikhar Hussain we can offer you Used Tires scrap from UAE to use as fuel in Cement industry as we are currently supplying the same to India and Pakistan cement industry pls write me for more detail as nexlines@gmail.com 21 days ago Unlike Like

DougUnfollow Follow Doug Doug Clark As I recall there was at least one factory managed by Blue Circle that was doing this back in the 1980's. The shale was fed direct to the precalciner so that the oil did not evaporate in the top stages of the preheater and cause high Hydrocarbon emissions. I do not remember the factory name now but I think there were some papers written about it so you can probably find some information about it. 20 days ago Unlike Like

rajeshUnfollow Follow rajesh rajesh sharma I agree with Mr Clark. It can be used in PC 19 days ago Unlike Like

JohnUnfollow Follow John John Kline There are a couple of plants that use oil contaminated raw materials. I believe the plant in Malaysia was the Rawang plant, but if that is not correct it is one of the Lafarge (former Blue Circle) plants there. In this case the oil is in the shale and therefore the minor component in the cement raw mix. Therefore adding to the precalciner works almost as well as a normal preheater system. That is heat from the oil shale rlease makes up for loss of specific heat consumption due to some of the raw mix bypassing the preheater.
There is a plant operating in the US (Cemex - Lyons, CO) that uses an oil impregnated limestone (naturally occurring). The limestone is too oil rich to add to the preheater, so the raw mix is fed directly to the precalciner without a preheater. Here again the oil in the raw material makes up for some of the heat lost due to the lack of a preheater. In the case of Rawang, the mix chemistry is a bit more difficult to control. 19 days ago Unlike Like

StuartUnfollow Follow Stuart Stuart Elliot Try these links: http://www.easac.eu/fileadmin/PDF_s/reports_statements/Study.pdf 'Oil shale is used for cement production by Kunda Nordic Cement in Estonia, by Holcim in Germany, and by Fushun cement factory in China' http://en.wikipedia.org/wiki/Oil_shale_industry @There are a few good examples. Holcim cement plant in Dotternhausen, Germany, and PanMalaysia Cement are using oil shale with low oil yield directly in the clinker manufacturing process as a raw material and as a secondary fuel. Kunda Nordic Cement in Kunda, Estonia, and Holcim Dotternhausen cement plant are using burnt shale as a cement component' http://www.thefreelibrary.com/Oil+shale+cement-ecology+and+economy%3a+there+is+forest+behind+the...-a0199121940 This is a paper about Dotternhausen http://www.eap.ee/public/oilshale/8_hilger_2003_3s.pdf 18 days ago Unlike Like

JohnUnfollow Follow John John Kline Stuart, very good information, thanks. Is KHD involved in the oil shale business in Europe or China ? So in summary there are several ways in which oil shale / limestone can be used in cement manufacture. Shale can be added to the calciner directly. Limestone can be added to the calciner, but then no preheater. Spent shale from processing can be used as a raw material or as a cement replacement. In the case of a cement replacement it will have to have pozzolanic or hydraulic properties. 18 days ago Unlike Like

StuartUnfollow Follow Stuart Stuart Elliot I am not aware of any KHD involvement in Oil Shale burning at present. 18 days ago Unlike Like

Dr.MohamedUnfollow Follow Dr.Mohamed Dr.Mohamed Shabaan Thanks so much for all 17 days ago Unlike Like
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BabarUnfollow Follow Babar Babar Siddique Muhammad Dear Dr. Mohammed, while using oil shale as a cement raw mix component OR as fuel. Complete redesigning of Raw Mix is required. Ash content is usually 50% plus. Oil shale ash Usually contains SiO2 more than 60%. The main hurdle is its sticky nature and point of inclusion in system. However; in my opinion if Bracquet formation with certain material is possible it will result in ease in its use. 16 days ago Unlike Like

TedUnfollow Follow Ted Ted Krapkat Although the use of oil shale represents a cost saving in thermal energy input to the kiln, there are a couple of quality issues with adding shale to the precalciner. Firstly, since the shale is added after the raw mill, the raw meal chemistry must be formulated to allow for the shale chemistry. (ie higher LSF) This means that to control clinker quality (particularly free lime) in the event that shale feed to the kiln is suddenly lost, or otherwise unavailable for some reason, one or more of the following options needs to be available;1. A redundant dosing system for delivering the shale to the precalciner. ie duplication of key delivery system equipment. 2. The ability to quickly begin addition of another material with very similar chemistry (eg. flyash) in place of the shale.
In addition, the shale dosing system needs to be able to be adjusted accurately, to enable fine control of the clinker quality. Regards, Ted. 16 days ago Unlike Like

Dr.MohamedUnfollow Follow Dr.Mohamed Dr.Mohamed Shabaan Thanks Ted Krapkat and every body for your information 16 days ago Unlike Like

MarchalUnfollow Follow Marchal Marchal Philippe Dear Mohammed, It is possible to use oil shale at the main burner as a mix with coal to get a maximum of 35% ashes in the mix to keep a high temperature of the sintering zone of the kiln.In a good precalciner (calciner design is extremely important), it is possible to use ground oil shale up to 45 % ashes in the mix fuel shale + some solid fuel. Note solid fuel can be replaced by natural gas or oil according to local availabilities. We can help with process design based on practical experience. Regards Philippe
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what is the contribution of CBM in equipment reliability in Cement Industry
CarlitoUnfollow Follow Carlito Carlito Tolentino CBM (Condition Base Monitoring) is a one of the important maintenance philosophy where you can prevent your equipments from emergengency breakdowns that leads to costly repairs you can use CMMS to make your CBM programs effectively. A combination of Preventive and Predictive Maintenance can spell an edge in improving your Maintenance KPI's OEE, MTTR , MTBFand etc. 9 days ago Unlike Like

KosmasUnfollow Follow Kosmas Kosmas Konstantas CBM , on top of all the above mentioned profits, because of its systemic approach, usually decreases long term maintenance costs. 8 days ago Unlike Like

Jagat SinghUnfollow Follow Jagat Singh Jagat Singh Rathee This is a basic requirement ( CBM :Condition Based Monitoring ) now a days for the modern day state-of-the-art ,technologically advance super sized cement plants ( +10,000 TPD to +12,000 - 13,000 TPD clinker production capacity ) ,across the globe , to improve and sustain the long campaign life of the pyro-processing plant in particular.This reduces the maintenance costs drastically in the long run, as it is right tool for predictive & preventive maintenance of all disciplines viz.mechanical ,electrical ,process ( refractory lining life improvements ) ,mining ( HEMM & Crushers ) and the instrumentation ( Control & Automation systems ), by using quality spares from global suppliers. Those plants who are not used to CBM systems ,are more prone to not only break downs ,but their maintenance costs are also on the rise, over a period of time. So it is in the overall interest of the plant health in the long term ,to ensure the use of these modern day condition based monitory systems. 8 days ago Unlike Like

AhmadUnfollow Follow Ahmad Ahmad Nilforoushan CBM is effective method of predictive maintenance for monitoring of equipment's condition & diagnosis. It has different methods such as: * Vibration analysis for rotary machines (Electrical motor, gearbox, bearing & ...) (by vibration analyzer and different analyzing method like: FFT (Fast Fourier transform), BCU (Bearing condition unit) & ... * Thermal analysis for mechanical & electrical equipments (by Infrared thermography camera) * Oil analysis for lubrication systems (it can check wearing in journal bearing,efficiency of sealing & ...) They are latest CM methods, but there are another methods like noise analysis too. in PM process, you have maintenance based on predefined time, but in CM process, you will
have maintenance based on condition of machine. You can check different photo & more information on www.payaparseh.com 7 days ago Unlike Like

Dear experts, What is the specific heat capacity of raw meal at 50(C) and 800(C)?
Ted Krapkat Hello Azin, This link should help you;http://www.cementengineer.com/cementfriends/file/download/2256 (see Chapter 4, page 24)
Volatilisation of SO3? OK, we all know the volatile cycle and the effects of SO3 in the kiln system, but my question is this. Why does the level of SO3 volatilisation increase under reducing conditions? Does the point at which SO3 evaporates change in a reducing atmosphere, or is there some other chemical process going on here?
Satesh More CaSO4 gets converted to CaO+SO2+1/2O2 under reducing conditions. 29 days ago Unlike Like

MohammedUnfollow Follow Mohammed
Mohammed Abdo increase oxygen (excess air) in the rotary kiln tends to oxidize sulfur to a solid sulfate that is retained in the clinker or expelled from the system with the CKD. 29 days ago Unlike Like

AlanUnfollow Follow Alan Alan Gee @1200 deg, and 0% O2, sulfur is 100% volatile. Depending on the partial pressure in the system (O2) level) volatilization changes. It is not a linear curve, but I have seen some published data showing the volatilization vs PPO2 (volatilization increases as PP O2 decreases). Yes, SO3 evaporation changes in reducing conditions. 28 days ago Unlike Like

TedUnfollow Follow Ted Ted Krapkat Hello Kevin, It's not the formation of CaSO4 that is important, as some responders have indicated. Sulphur volatility is largely dependent on a chemical reaction between SO2, alkalis and oxygen to form low volatility alkali sulphates. These are far more thermally stable than CaSO4. This is also why the molar alkali/sulphur balance is a critical factor in reducing buildups. High temperatures, high chloride concentrations and lack of O2 can push this reaction in reverse, resulting in sulphur & alkali-rich buildups.
See the following thread for more info.... http://lnkd.in/ADBB6y Regards, Ted. 28 days ago Unlike Like

mohan.mUnfollow Follow mohan.m mohan.m madayi I follow Ted Krapkot comments regularly and always likes his comments on the subject 27 days ago Unlike Like

MuhammadUnfollow Follow Muhammad Muhammad Sajjad Is there any quick fix for Clorine ? We have 0.8 % in hot meal coming from Poultry waste. Percentage will increase when RDF will be used in near future. 23 days ago Unlike Like

KenUnfollow Follow Ken Ken Postle The quick fix is a by-pass, does not have to be large if only for chlorine, it is possible to route the waste gas stream through the clinker cooler dust collector. 23 days ago Unlike Like

KevinUnfollow Follow Kevin Kevin McAdam There is only one option for high levels of Chlorine, as Ken says, fit a by pass. But I was involved in a commissioning project where there was a high level of chlorine in the raw materials but we had no problems with alkali chloride buildup in the preheater? From what I understand if the chlorine bonds with Na2O to form sodium chloride, this compound is relatively stable in the kiln so tends to come out in the clinker, pottasium chloride is the most volatile. Check the levels of chlorine in the clinker. Basically, if you are having operational issues with chlorine, fit a bypass, if not then there is obviously no need. 23 days ago Unlike Like

TedUnfollow Follow Ted Ted Krapkat Hello Kevin, Yes, I have noticed the same thing with regard to sodium volatility in the kiln. In the presence of excess potassium, sodium does not seem to be very volatile at all. However, I don't think it has to do with a difference in volatility due to the boiling points of KCl and NaCl. Both alkali chlorides have very close boiling points (KCl = 1413 and NaCl = 1407 degC) I believe it has more to do with their relative affinities for chloride. This idea is supported by the enthalpy of formation of KCl compared with NaCl. (KCl = -436kJ/mole while NaCl = 411.2kJ/mole.) So, if KCl is thermodynamically more stable than NaCl, then it follows that potassium will be more likely to combine with chloride. If this is the case, and potassium is also in excess, then it is quite possible that all or most of the chloride will be "used up" by the potassium, leaving sodium to combine with sulphur. (or at least be more statistically likely to do so) In addition, since Na2SO4 is far less volatile than KCl, sodium is effectively removed from the volatile cycle quicker, further lessening the chances of NaCl formation in the gas phase.
Regards. Ted. 10 days ago Unlike Like

IBRAHIMUnfollow Follow IBRAHIM IBRAHIM ABU AWWAD But what is the residual percent of chloride that will be preserved in the produced clinker, is it could be still below 0.1 % as required in the international standards. 9 days ago Unlike Like

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SunilUnfollow Follow Sunil Sunil Nair by pass duct is connected with kiln inlet rider duct. how to evaluate whether by pass is for Cl, alkalies or for SO3. which factor determines the driver and what should be the base of operation. 9 days ago Unlike Like

PradeepUnfollow Follow Pradeep Pradeep kumar Dear Kevin, The reason is CO is converted into CO2 taking O2 from SO3. CaSO4+CO = CO2+ CaSO3 sodium sufite K2SO4+CO= CO2+ K2SO3 potassium sulfite Actually the SO2 level increases and the recycling starts. Under Oxidised conditions 2SO2+2O2 =2SO3 which is reversible reaction The temperature, the concentration of O2, etc will shift the eqilibrium. K= (SO3)++ / (SO2)++ ( O2)++ ( sorry i could not write in this column) O2 will shift towards to SO3 The sulfides are thermally unstable and they evaporate easily and leaves the burning or transition zones as vapors. If you form SO3 , under oxidised conditions ,they form sulfates like CaSO4, or CASO4.K2SO4 ( calcium langeibenite) which are thermally very stable. Hence what recycling is not SO3 but SO2. Usually SO3 ( from Coal)never comes out of preaheater when kiln is running as it is aborbed by CaO or K2O in the raw meal. If you have pyrite in lime stone (raw meal)and it burns in the top stage SO2 escapes because you have less O2 . Moreover it combines with CaO or K2O at more
than 1000 -1100 degC which is inside the kiln.
What about reactions between Clorine , alkalis and sulphates in kiln ? What compound cause coating at smoke chamber / calciner and feed pipes ?
Ted Krapkat Hello Muhammad,
The compounds which cause build-ups in the smoke box/calciner and feed pipes will be different depending on the following factors;(a) The chemical balance of chlorides, alkalis and sulphur in the hot meal. (b) Oxygen content in the gases at the kiln inlet. (c) Burning zone and calciner temperature.
Chlorides: Alkalis (particularly potassium) preferentially react with chloride to form KCl and NaCl. Any left over alkalis then react with SO2 and oxygen to form alkali sulphates. Chlorides are far more volatile in burning zone than alkali sulphates and will substantially evaporate and recirculate to the back end of the kiln where they will be deposited on incoming meal. Some chloride will however escape with the clinker, and if this amount is equal to the amount of fresh chlorides entering the kiln with the raw meal, a balance will be maintained and few buildups will occur. However, if the chloride input changes or the burning zone temperature increases these factors will upset the balance and buildups will occur more frequently.
Sulphates and Oxygen: As mentioned before if akalis are in molar excess of chloride they will react with SO2 and oxygen to form alkali sulphates according to the following equation;K2O + 2 SO2 + O2 --> 2 K2SO4 If insufficient oxygen is present in the kiln inlet gases, the reaction above will not occur and very little alkalis or sulphur will exit the kiln in the clinker. Instead, K2O and SO2 levels in the back end of the kiln will increase rapidly causing the hotmeal to become sticky and heavily coat the walls and other surfaces of the smokebox/calciner/meal pipes, causing buildups. The solution is
to have the residual alkalis and sulphur in molar balance AND to ensure at least 2-3% O2 at the kiln inlet. If sulphur is in large molar excess of alkalis, sulphate spurrite build-ups can form higher up in the preheater by reaction of C2S, CaO and SO3 ie;CaO.SiO2 + CaO + SO3 --> 3 CaO.SiO2.SO3 Sulphate spurrite is stable at temperatures between 900 -1200 degC and causes buildups which are very hard and difficult to remove.
Temperature: If the temperature in the burning zone is excessive, not only will more alkalis/sulphur and chloride be evaporated from the clinker charge, but the kiln inlet temperaure is likely to be too hot as well. This can make the hot meal even stickier (due to the low melting point of alkali/sulphate/chlorides eutectic mixtures (mp 500-600 degC) that occur in the hot meal. The result will be an increased tendency to form buildups. Regards, Ted.
1 month ago Unlike Like

IBRAHIMUnfollow Follow IBRAHIM IBRAHIM ABU AWWAD But what is the residual percent of chloride that will be preserved in the produced clinker in this case, is it could be still below than 0.1 % as required in the international standards.

TedUnfollow Follow Ted Ted Krapkat Hello Ibrahim, Each kiln system is unique.... Without a bypass, the amount of chloride retained in the clinker depends largely on the total input of chloride from the raw materials, AFRs and fuels... after accounting for any chloride leaving the stack(s). Some kilns may at times exhibit a so-called "detached plume" on the stack. This is caused by ammonium chloride leaving the kiln system in gaseous form and condensing as solid particles in the cooler ambient air. This can represent a significant amount of chloride leaving the system, which can potentially pose a serious environmental problem.
With a bypass installed, the chloride in the clinker is determined by the amount of kiln gases bypassed and the quantity of chloride contained in them.
Regards, Ted.

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Sagar Raysoni likes this comment by James Kelly Suitable materiel for temp range 1100-120 degree Centigrade and properties of weldable and fabricated also.: I suspect that no customers ask for 353 MA as it was never promoted in India and is no longer made. Until Outokumpu ceased production...
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Sagar Raysoni likes this comment by arun rao Suitable materiel for temp range 1100-120 degree Centigrade and properties of weldable and fabricated also.: James, I agree with your comments. On a few ocassions I had recommended using HT or HU grades with a life guarantee. The plants were...
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Cement spare parts management

Cement spare parts management is an important aspect of the the cement enterprise asset management, many companies are often included in the spare partsERP system (or a financial plus for purchasing, selling and storing) management, but the result is the inventory remains high, amounting to less than the information technology benefits. The problem is that the spare parts equipment based, not associated with equipment, separate management would be meaningless. Causality is concerned, the initiator of spare parts demand in the repair, maintenance in turn depends on the operational status of equipment, equipment, maintenance, spare parts, three are integrated, interrelated and indivisible, leave the device alone pipe spare parts become a river without water, without trees. Generalized spare parts also include rotables itself can be used as assets (equipment), but is a part of the equipment, repairable and then, typically as motor. An annual production capacity of 200 tons of cement enterprise, its spare parts inventory may reach 20 million yuan to 25 million yuan, the annual procurement of spare parts in about 10 million yuan. Group cement companies, the production capacity of 20 million tons calculation should be more than a dozen cement plants, spare parts inventory decreased by 20%, and that at least 50 million yuan of funds out of the province, and The Group integrated management of spare parts inventory may be reduced by about 40%, can save money reach billion. This article is from the spare parts management objectives, key points about, spare parts management integration problems to explore with industry peers. A device management objectives Cement enterprises, especially modern dry process cement production enterprises is typical asset-intensive enterprises, the operational quality of the equipment, maintenance level is directly related to the completion of the production plan, when the equipment due to malfunction or shut down after the accident, the timely supply of spare parts for is particularly important to reduce downtime quickly resume production. From the point of view of cost control, you can use as little as possible to spend the cost of spare parts to reduce corporate funds used. Spare parts management appears to be simple, but it will have a direct impact on cost control and operation of the equipment is very important. Implement scientific spare parts management is very complicated and delicate work, takes a lot of work.
Has a special significance for the management of the cement companies, the one from the craft. Line of 2500 tons and 5000 tons of line equipment is basically the same, only different models, specifications, etc., corresponding spare parts is also very much the same, the definition of a line of equipment, spare parts, can be extended to the rest of the production line. Early larger workload, do a lot of basic work late progress much faster; Second, determine the spare parts of different kiln-shaped, linear, and build a new line can directly request using prescribed equipment within the Group, spare parts standards; annual demand increase in procurement three can effectively reduce procurement costs, but also makes the inventory reduction.
Cement spare parts management include basic management, purchasing, inventory, contract management, management objectives are: 1.Optimization:
First of all, in the usual sense"Zero inventory" does not apply in the modern dry process cement production enterprises, even standard parts should not be this storage strategy, which is determined by high continuity of cement production of spare parts guaranteed. We emphasize that the optimization, including:
1) Inventory optimization:
Inventory management is a balance to make the two opposing goals, namely upcoming maintenance spare parts availability maximum maintenance work; (2) reduce the excessive inventory balances and related transportation costs. That is, to find the best inventory balances, and ensure minimum inventory under the premise of ensuring the safe operation of equipment. Inventory optimization: pressThe ABC classification as well as the spare parts to determine the stock of consumption history; Dispersed storage optimization: multi-warehouse management or internal warehouse allocation, or the internal supply the scattered warehouses unified management, in order to ensure a reasonable distribution of spare parts reserves; The optimization of the state of the spare parts: including the allowance, the amount of expired amount of safety stock, economic order quantity to determine the re-order point, in order to reduce human factors; Inventory cost optimization: dynamically monitor the cost of spare parts, the most reasonable inventory costs; Encoding method optimization: coding easy to remember, easy to use, do not need to have a specific meaning.
2) Procurement optimization:
From the initiation of the procurement requirements to final** Settlement, as much as possible to reduce the links, each node has a clear division of responsibilities, operate efficiently, and be able to effectively track, audit, and control.
3) Business process optimization:

Procurement process, warehousing processes, billing processes need to be optimized by the best business model, a highly efficient, the flow of business processes.
4) Supplier structure optimization:

Through the establishment of the the main supplier system based supplier catalogs, supplier structure optimization.
2. Timely supply:
The reserve position of the spare parts of to decide downtime length of the important factors in the shutdown case. Spare parts management and maintenance management should consider unification. A maintenance plan spares requirements planning, warehouse available is allocated to the maintenance program, do not start the procurement process; Another situation is when the failure or accident to find spare parts, spare parts emergency procurement. The better way is to establish a corresponding mathematical model, and by calculation and analysis of historical consumption data, security, economic, spare parts inventory program, as much as possible to reduce emergency procurement.
3.Controllability:
Either cement spare parts procurement process, inventory management process, any point can be comprehensive tracking, such as a spare parts warehouse in which there are several available quantities, there are several reserved, set aside the plan to which alternatives, Which to buy, which contracts, which batch procurement needs who proposed, in which purchase orders, the price is how much, how the price of purchasing history, who acceptance in previous years quantity, etc. can all be tracked and controlled.
4.Comprehensive analysis:
Procurement of spare parts out of storage,The ABC classification suppliers conduct a comprehensive analysis and decision-making through these analyzes spare parts. These analyzes can not only real-time refresh, but also intuitive graphical unfolded. For example: you can keep abreast of which spare parts storage warehouse in which the number is reserved to the maintenance program, how much is available, how much the day before the spare parts within the next month, how long it will take to buy spare parts money can chart real-time view. Cement Group, directly from the headquarters perspective to each plant, each line, each device, each spare parts, each warehouse achieve dynamic control group.
And spare parts management points Spare parts inventory optimization and reduce, or reduce the cost and supply of timely and effective is to maximize the protection of the normal production line running based, spare parts management, in addition to be considered together with the maintenance and management, but also in conjunction with the device management planning So the gist of the spare parts management include:
1 associated with the device:

That each device on which spare parts, a spare parts can be used on which devices, only this correspondence is established may reduce stock. In addition to the general sense of the spare parts, versatility again fan, reducers, valves, air compressors, bearings, motors, pumps, roller and gear wheel and other equipment as common as rotables management.
2.Timely supply of spare parts:

Safety stock, re-order point,ABC classification, the procurement lead time, resource sharing, and a variety of methods to ensure timely supply of spare parts.
3.Spare parts inventory control:

In addition to recording the information of all the spare parts, in real-time understanding of their status and payment history, re-ordering, inventory, and the corresponding drawings, documentation, also includes the track out of storage conditions, and to optimize the management of spare parts, and eliminate redundant or sluggish inventory, thereby reduce costs. Through inventory optimization and reasonable plan, establish reasonable inventory levels to meet the maintenance requirements, and that is in the right place with the right spare parts, spare parts so that the maximum share.
4.Suppliers directory management:

Main supplier system is determined based on quality, price, delivery time, payment terms for spare parts suppliers. Determined outside the main suppliersThree or more suppliers, through regular analysis of the changes. The main purpose is possible to eliminate costly off-contract procurement, from the most reputable suppliers order to ensure the quality of spare parts. On this basis, establish a directory of suppliers, in order to protect production equipment to maximize the safe operation and high-quality operation, to reduce the failure rate. Large-scale group purchasing to get lower prices from suppliers. Directory of suppliers can better control the quality of spare parts, and improve equipment reliability.
5.Procurement process management:
By determining the procurement process, to help complete the procurement. Procurement staff to keep abreast of relevant information, such as purchase requisitions, quotations, inquiry, suppliers, orders and contracts. At the same time as part of the spare parts logistics supply chain, according to the maintenance plan and inventory status automatically procurement, to determine the correct spare parts procurement at the right time. Group enterprises can achieve a multi-site, multi-organization national (or globalization) procurement to improve procurement efficiency and reduce procurement costs.
6. Spare parts drawings document management:

Many enterprises to pay attention to the management of drawing files, pay little attention to spare parts drawings document management, actually in the repair process, according to the correlation structure of the equipment parts (spare parts), you can quickly query the spare parts needed to save the time to find spare parts to ensure find the right spare parts, maintenance work more quickly and high quality. Non-standard parts need Waixiejiagong, special pieces, complete drawings documentation enables to shorten the processing cycle is large, the quality is also more reliable. Spare parts drawings document detailed sound basic requirements, the digitized drawings document database management.
7.Revitalize and swap:

Some spare parts may be kept for several years has been no access to the technological transformation equipment change some pieces of no use but has been in Curry, certain pieces to buy or buy moreThe ... these precipitation assets ", make an inventory of the the precipitation assets is one aspect of the spare parts management, usually corporate history the longer, more precipitation can be an effective means to revitalize this part of the assets. Cement companies in addition to revitalize the outside of the plant, also can mutually adjust, in accordance with Group Planning Differences in storage, transfer between the sharing of resources. "
Dear experts, I would like to ask about pozzolanic ash in raw meal to achieve the ideal module value (LSF, SR,AR) thanks
16 days ago

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TedUnfollow Follow Ted Ted Krapkat Hello Antonio, Normally you would only use this type of material in your raw mix if your limestone deposit was deficient in the appropriate types of clays. Do you know the chemical or mineralogical composition of the ash? Is this ash natural in origin (ie. volcanic) or man-made (eg. fly ash) Regards, Ted. 14 days ago Unlike Like

JohnUnfollow Follow John John Kline Pozzolanic ash is often high in silica and can be used to add silica to the raw mix. Depending on the age and type of ash, it may be hard to grind and cause some burnability issues. High grade natural pozzolans make a great cement additive, which should be kept in mind as well. 11 days ago Unlike Like

IBRAHIMUnfollow Follow IBRAHIM IBRAHIM ABU AWWAD First you should identify exactly what are you going to modify, then you could decided wither the Pozzolanic ash is useful or NOT 10 days ago Unlike Like

Daniel RajuUnfollow Follow Daniel Raju
Daniel Raju Alamanda Ash segregation in mills is a problem in case of fly ash. other are ok, but limited use. also see the reactivity. 10 days ago Unlike Like

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Suitable materiel for temp range 1100-120 degree Centigrade and properties of weldable and fabricated also.

Pabitra Mukherjee (Mukhopadhyay) Thanks, Marechal, for the info.

What are reasons of coating in cement silo?

Burners and Flames - FLS , Pillard , KHD , Calculation of Burner Momentum

Pillard Rotaflam - Eclpens

============================================================ =============================== Steps to improve combustion - Burner

Carry out Burner Check and Combustion Check

Ball mill liner how to choose

should be vigorously promoted multicomponent alloys of chrome lining.3.5

Re: how to choose Ball mill liner

Re: how to choose Ball mill liner

limestone crusher rotor speed , productivity , Motor power , main structure

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7 days ago Unlike Like

what is the contribution of CBM in equipment reliability in Cement Industry

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Regards. Ted. 10 days ago Unlike Like

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than 1000 -1100 degC which is inside the kiln.

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Cement spare parts management

3) Business process optimization:

4) Supplier structure optimization:

1 associated with the device:

2.Timely supply of spare parts:

3.Spare parts inventory control:

4.Suppliers directory management:

5.Procurement process management: