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   !" #

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I< B+ @1,D

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j -. * , * 1* ]B
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( B5* *  !* .
( B5*   %(* B
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j !* @1* B9 *9
*  *# -  !B
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 1=
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* @1 Q.!*, j J_ V,B
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: 
:j L V9 @17 45 *   %(*j1 B(O B
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? VO!  5  . V5   B55! Bb Q.](* B^ Bb9
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# *# http://upload.wikimedia.org/wikipedia/en/e/e9/KilnBZ.JPG :




  

10

! A4 :9 
 ? POLYSIUS
Kiln Shell Scanner

V9 y ] B9 4 ! Vb B ( y< 

V+5  l I % L, ] # .




  

11

= ' : '9} <   9  ,5,  % ,5,<

  B  ;  %, + ; ,!  -. =b Q*# -.
  @ ,5*b * =b Q( Bq B+  =b S9
#  B Bb 5 .  % ,5,< !  ^+(j1 y
*, @+1  %< yq  B +1    % 4 Q.yq<#
* @9I V  %  . L B<   % +
 . ,!, Q(x @1 O  < 4 V,,5, .
* *   % Planetary *   % =  B#< %
  V ,5,!I % % *H ( % @9( h 1
 ,5,( %,) Bq B+ VO % Lq .  ( .
Planetary cooler

Polysius, Clinker Cooler

!+ ' : '9 V+5 ,5, %

  yH, @q  ,5,
* B9I % ,5, * j1 @1
v9 V9!* (+ @I  .




  

12

") ' : '9 Jb j @1 ,5,

*j1 B9 B !;h J ]5I %
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!  : .=/ @ ! ( O  ,1  !, Db. ` 

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45
 : @ ( B5_ (B5
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") 3
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@1* B9 *9 c 45 V+5
7 % 45 Q.*# J  B9M
-. 4 Q.*# J* *EO
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!* j@ Screw Conveyor

 : U=+  1 5 % *

( BI jH  B9 B745
M (, B+ B,*. ,

13

14

  

! , % }5 r 9 % [

bag !4?! 9! H5I * V+
(ESP) '!++'
=! filter
Electro-Static Precipitator
<B * B* H5 H
B! J -. . V9 LOI B
. * ^ H * % B






  

15

 Z W! !  <!' R / ! #


16

  



 #[ 51

00- Limestone Quarry Crushing

!,  b b b
01- Limestone Stockpile
! ]b]
02- Additives Hopper
1S] * J+
03- Additives Storage
1S] * %j
04- Raw Mill Building
* B5( 5
05- Blending and Storage Silo
Db j B9*
06- Preheater
@q %!
07- Gas Conditioning Tower and
ESP
@,,7  =

08- Kiln
< 
09- Cooler
,5,
10- Deep Bucket Conveyor
@(*
11 , 12- Clinker and Gypsum Storage
Db ,5, j
13- Fuel System
*O* B*l5
14- Cement Mill
457 B5(
15- Cement Storage Silo
457 B9*
16- Packing and Dispatch
%_ B9
17- Central Control Room
j L, !( B1i




!9  "! 


  

17

CENTERLINE Motor Control Centers

BurnerMaster and CombustionMaster

Systems

DODGE Belts, Sheaves, Couplings,

Gear Boxes, Mounted Bearings

Power Transmission

SCADA

Networks (Ethernet, ControlNet,

DeviceNet, Remote I/O, Data
Highway Plus)

Medium Voltage Control (Starters,

SMC Controllers, Medium Voltage Drives)

Industrial Control (Push Buttons,

Pilot Lights, Contactors, Starters,
Terminal Blocks, Switches, Relays)

Reliance Electric Motors

Sensors (Photoswitch)

1998 Rockwell International Corporation. All rights reserved. 8/98

Allen-Bradley Drives, Reliance

Electric Drives and Rockwell
Automation Drive Systems

Motion Control

Motor Protection (SMC, SMP, SMM)

PanelView Terminals (PV900, PV550)

RSView32, RSTools, RSComponents

Software

PLC, SLC, MicroLogix

and ControlLogix Controllers

Hammermill
Crusher

Cement Process

19

  



http://www.cement.org: JO* % *#




  

20

21



  

'!
belt convoyer 1800x14.5 m
outlet chute
mammut crasher
spray chutes
apron feeder type RKF 2600x14.0 m
belt conveyor type 400x10.05
apron feeder RKF 1200x12.0m
superimposed box
bag filter & platform
auxiliary device
contactor & desk
magnetic separator



Sampling station with pneumatic tube system
Sample meal divider
Drum magnet
Chutes
Airjet filter 10000 m3/h
Airjet filter 15000 m3/h
Servie plateform
Dedusting ducts

-./0 13. 567

stacker rails
reclimer rails
belt conveyor 1200x271.76 m
belt conveyor 1000x295.6m A-A
stacker 1000x21
reclimer (Lho 500/35)

22



  

6 EF H.
Belt conveyor 1200x73.8
Belt weigher
Magnet seprator
Riversible belt conveyor 1200*6m
Belt conveyor 1000*42.2
Bag filter 5000 m3/h
Bag filter 10000 m3/h
Dedusting duct & chutes
Riversible belt conveyor 1200*24.75
Belt conveyor 1200* 45.776m
Bag filter 24000 m3/h
Weigh belt
Weigh belt
Weigh belt
Belt conveyor
Belt conveyor
Belt conveyor

6 EF RST7

Roller mill
Bed plate for drive unit
Upper section of housing
Monting device for pair of rollers
High eficiency separator
Tramp-iron seperator+flap valve
Bucket elevator
Course feed valve D:1400
Troughed belt conveyor
Steel apron feeder
Raw mill bin
Bin weighing device
Magnetic separator
Metal detector (change over flap)

  

23

Single roller belt weigher

Mixture control
Hot gas generator
Chute & duct
Slide valve+shut off flap
Water injection+acc.
Bag Filter 3 Moudoles
Fan
Sampler

[\]^_` 6 EF ab^7

Casing
Stairs - ladders - platforms
Transition
Gas distribution
Collecting electrode & suspension
Discharge electrode & suspension
Collecting plate rapping device
Discharge electrode rapping device
Chain conveyor
Airslide
Cooling tower
Screw conveyor
Screw conveyor
Screw conveyor
Screw conveyor
Screw conveyor
Insulation roof
Exhaust fan
Ducting
Isolating dampers

^ 
g hHi 6 EF k7El
Pneumatic transport by fluidslide
Vertical pneumatic transport
Pneumatic transport by fluidslide
Parallel distributing fluidslide
Dedusting equipment
Original IBAU mixing silo equipment
Pneumatic transport by fluidslide
Mechanical vertical transport



24



  

Pneumatic transport by fluid slide

Weigher feeding station
Feeding system with calbiration device
Pneumatic transport by fluid slide
Sampling equipment
Pneumatic transport by fluid slide
Vertical pneumatic transport
Dedusting equipment

[\
q r6sF
Smoke chamber
Rising duct
Precalciner
Preheater cyclone 5 (C5)
Preheater cyclone 4 (C4)
Preheater cyclone 3 (C3)
Preheater cyclone 2 (C2)
Preheater cyclone 1 (C1)
Firing chimny
Automatic cleaning system
Tertiary air duct
Exhaust fan
Exhaust duct
Preheater doors
Dispersor (with concrete)
Walkways & Access
Shims for cyclons

^ 
g
Roller Station
Tyres
Kiln Shell
Drive
Hydraulic Thrust Roller
Firing Hood
Down Stream Seal
Up Stream Seal
Nosering Fan Comp
Hopper & Supporting Hood

EvE

Fuel & Heating

25



  

^`i`^ q7
Drag chain
Dust hoppers
cooler lower part
Running axle
Center beam
Moving frame
Driving axle
Fixed & movable supports
Hydraulic drive
Cooler upper part
Clinker chute hopper
Clinker breaker
Sealing air piping and pressure
Partition wall cooling
Centralized lubrication
Air piping for mulden plates
Cooling fan
Ventilation ducts
Piping,Elbow,Flanges
Drag chain casing
Hydrulic unit
Piping for hydraulic drive
Driving breaker
Driving drag chain
Platform

[\]^_``^ i`^ q7 ab^7

Casing
Stairs - ladders - platforms
Transition
Gas distribution
Collecting electrode & suspension
Discharge electrode & suspension
Collecting plate rapping device
Discharge electrode rapping device
Screw conveyor
Insulation roof
Exhaust fan
Ducting & Damper

26



  

^`i` H.
Silo super structure
Conveyor bridge
Conveyor bridge
Conveyor bridge
Clincker transport
Clincker transport
Clincker transport
Clincker transport
Rod gates
Motor operated discharge chutes
Manuallyoperated discharge chutes
Magnetic feeder
Telescopic chutes
Silo level indicator
Bag filter 3000 m3/h
Bag filter 12600 m3/h
Bag filter 12600 m3/h
Bag filter 12600 m3/h
Bag filter 12600 m3/h

1q3 s
Apron Feeder
Gypsum Crusher
Belt Conveyor 0.5* 10.42 m
Bucket Elevator
Belt Conveyor 0.5* 18.4 m
Bag Filter &Fan &Damper
Dedusting Ducts
Chutes & Ducts

zFb0 RST7
bin level measuring system
bin level measuring system
shut - off slide valve
shut - off slide valve
proportioning belt weigher
proportioning belt weigher
bag filter 2500 m3/h
radial fan LRMH(S) 315
chutes

27

  

mobile platform and support

metal pipeline
compressed - air reservoir
fitting for compressed air tank
ladder crossing
multichamber tub mill 4.4 *14 (1)
multichamber tub mill 4.4 *14 (2)
gearing - main
auxiliary gearing
erection materials
main motor &auxiliary motor & frame
electrostatic precipitator
fan , centrifugal VRE 800/5021
airslide type BG 250*7 m
radial fan LRH 110
accessories for fan
flexible metal hose
bucket elevator type BG 630
gearing and 2 electromotor
chutes
metal pipeline
water tank and accessories
erection materials
piping system for compressed air
piping system for cooling water
screw conveyor
lifting device for line mill 2
compressed air tank
set of fittings for air tank
airslide GR.400
bucket elevator type BG 1400
gearing and 2 electromotor
airslide GR 400
radial fan LRH 110/1-W
set of accessories for radial fan
flexible metal hose
dynamic classifier separatore ****
pendulum flap gate
airslide Gr.400



28

  

radial fan LRH 125/1-W

set of accessories for radial fan
flexible metal hose
flowmeter
radial fan VRD 1000
chutes
metal pipeline
landing , platforms,supporting
cooling water line
grinding media filling bocket
airslide BG 250
radial fan LRH 125 W
set of accessories for fan LRH 125
flexible metal hose
sampling device
water seperator
airlift 1250-4000
pneumatic conveying pipeline
separators for airlifts
disk piston blower GMb 16.13
frontal filter with metal filter
wedge - type plate slide valve
bagfilter 2500 m3/h
radial fan LRMH(S) 250
airslide size 250
radial fan LRH 125 W
accessories for fan
flexible metal hose
bag filter
radial fan LRMH - 315
compressed - air reservoir
set of attachments to the tank
chutes
metal pipeline
piping system for comppresd air
airslide supporting
airslide BG 250
radial fan LRH 125/1 W



29



  

set of acessories for radial fan

flexible metal hose

zFb0 k7El
Original IBAU cement silo
Pneumatic transport by fluidslide
Bulk loading equipment
Compressor plant
Dedusting equiomentb 7200 m3/min

{|q.
Elevator 120 m3/h
Niagara Screen
Storage Bin
Gate Valve
Vertical Double Rotary Feeder
Roto - Packer
Empty Bag Table
Empty Bag Chute
Set of guard plate
Complete Spilage Collecting Equipment
Screw Conveyor For Packing Plant
Discharg belt
Bag Trap & Equipment
Inter mediate funnel
Outlet Funnel
Paper Discharge Chute
Belt Conveyor 650 mm x 1.25m
Bag Transfer Chute
Belt Conveyor
Stationary Bag Deflecting Station
Bag Transfer Chute
Truke Loading Conveyor
Bag Filter
Exhaust Fan
Dedusting Duct
Compressor Plant
Compressed air dryer




  

30




  

31

 Z!!!4 [
 "! 

# Q. :




  

32

 u!5
!+ u)+ W  #

 7 B9  @1 ,5,^ * 7: 45
B9  @1 ,5,*
 V9* V ,5,  
< Q 5j*c 9O
 ; @ H1 V9 @1 V9! B5*

Qd = 3000 tonnes day

K1 = 1.6

L = 30 years
Trd = 330days

B9  @1 ,5, Q.< : 5j

Dq = L Trd Qd K1 Dq = 30 330 3000 1.6 = 4.752 107 Tonnes

 %. 9  %, %9 B9 745



  

33

 '!
Qdk = 4500 tonnes

,5, 7 < B9

day

BDLS = 1.2 tonnes

m

K1 = 1.6

  *  ,5, V *V9

CL = 85%
Tcrw = 6 days

457@  1 *# B1?

457@  1 !,* # *! 5

@ ]* *1 !, V  
week

Thd = 12 hours

@ * *1 !, V  

day

%) H t = 15 min utes !, V *  HOr!( @ +O )B5j<

(.r B,

Qcr  '!

@ ]* *1 !, * ] 

RM w = Qdk K1 7 RM w = 5.04 104 tonnes

week

@ ]* *1 !, ! ,* #

LSw = CL RM w LSw = 4.284 104 tonnes

100
week

  

34



+ Q.H *B!@ 1 !,@ 1 !, B9

Qcr =

LS w
Qcr = 595 tonnes
hours
Tcrw Thd
Q!, JO Lb

Hv =

Qcr H t
H v = 123.958m3
BDLS 60



  

35

)w+ .!/
< B+ (9* I + (j @1 !, % B+ * Jb
*# +I V,_ * j*  5 .@  1  q B+ (
. H5@  1 7 Db % B B!

Qdk = 4500 tonnes

,5, <  * B9

day

BDLS = 1.2 tonnes

m

K1 = 1.6

  *  ,5, V *V9

CL = 85%
Qcr = 565 tonnes

457@  1 *# B1?

457@  1 !,* # *! 5

!,@ 1 !, B9
hours

RM d = 7days

* B5( *j 

Qsp ( *% V
V * ( )Jb V B9
Qsp = Qdk K1 RM d Qsp = 5.04 104 tonnes

Qstac ker D, B9

Qcr =

LS w
Qcr = 565 tonnes
hours
Tcrw Thd
Qstac ker = 1.5 Qcr Qstac ker = 847.5 tonnes

hours




  

36

 45  y4)
( %*  @1* % %(* %(* * Q.
@ (* %](* @  % Q(* * H1 JS % B,
<j  5 Q.](* B %I L*  H+ Q.H, <j B
<# <j B B1*<# V](*. B

H<  %( y, <j  !( y@ (B5

h<  %( y, <j   j(B5
Di (+@ (B5
r E# (+@
 C.G j V+, <j V(B5
a<  % j( B5  j V+, <j
 _%



  

37

: B Q.@ 1 4 B5( @( + 

Di = 4 r =

Di
r =2
2

H r
= 6.283radins
r

= 2a cos

: B5(  B!

1r 2 r H r sin 100
2

F=
F = 100%
2
r

24% 28% B1i B5(  B!

26% 32% B+r B5(  B!
26% 32% B+r i B5(  B!




  

38

: 

I <   % 1_ V,q _ V,`* I7 < 

D (+?@ Ic
X @1 (+ *#+
Y @1 (+ 
:
?

D = 4.4m
X = 4.405m
Y = 4.395m
! B  %_ V,q O p

X Y
100 Op = 0.227%
D

= Op




  

39

=b *,  I7  %_ V,q <  !5*#+ 0.2%

( *1 % VI <   @1 (+* 1 % I

 BI .




  

40


:9 !+ 

9<   % L!O  V97 45 + ! B97 % V9

B9 <  % ,5, -. B9 q %q, ;h V9 @1745
!=  B!5 B9 < .

D (+@ <  ) VO(* 9 ( * 

d (+@ <  ) 9 E(* 9 ( * 




  

41

!z :
D = 4.8m

 (+@
4S* <*; < 
(* < @7 
 B< 

w = 200mm
L = 70m

N = 3.5rpm

) B (B* V<

= 35 deg

 < 

= 3%

!*I B <  : Q(O

L
RLD = 14.583
D

= RLD

 (9 <   * * *  @1! B*

kcal
hr

K = 60 106

: -.

w
d = 4.4m
1000

d = D2

K
6 kcal

K
=
3.946

10
TL
d2
m 2 hr

= KTL

Lb<  ) Lb@  J! 4S(* 9  %(




  

42

d2
Vi = L Vi = 1.064103 m3
4
( BO7 B*#+  % ,5,<  * % %I @1 ,5,*
*
:
V9 F1} <   r V9.  J* < ?

<  J! % @q F1 = 3

<  JD,

7.5 F1 = 7

( BO7 l5 <  % @1 ,5,* *

QTH = F1 D3.283 L0.33

day

QTH = 4.903103 t

( BO7 <  % ,5, Lb B!5<

QTH
Vi
t
m3
day

= QSP

QSP = 4.607

@1 %I*   Lb@ <  Lb<   r Bb_V,

+I  %*  B+(* 9  V< -. =b %9Lb
< @++  S .H 9  %9} <   % @1 ,5,*
* .




  

43

) !/= 
' {9: 
))u 
(3
5 <  2 @1 4*I % Bq <  %] 1 ! . 7
  B* V< .x . 7  *HW *O  +1<
5c  % Q.*+ * JS  @  I7 . Q.*+ @ :

< < 
 < 

Wk = 868 MT1
= 2

1- one Metric Tonne = 1 000 kilograms



  

44

: *+ .H %9! b* + Q. B

FTH = Wk cos 90
180

MT

: !=  *+ .@ 1

2
=
= 0.035radian
180
:  !+1]* +

FTH = Wk cos 90 FTH = 30.293

180

MT



  

45


 45 !+
u!5

: (9 Q.H 45 B5( 7 O(

Pr = ?

( *B!@ 1 %I)

Pf = 3200

7 O(

(Blain) !*

Di = 4

() B5( @( +

L = 14

() B5( @,(*

N = 12

( *B+O@ 1 )B5( B

F = 28

(%) B5(  B!

G = 30

% 3000 !*%( B * !

K f = 9.55

V9

: Blain y# V9

Bf

Bf

P f 3000

0.49
1000
=e
B

Pf 3000

0.49
1000
=e

= 1.103
Blain % B Q.H %(

Gf = G Bf
G f = G B f G f = 33.089Kwh / t

 *%( B*

  

46



Grinding media

Di 2 L F
Gm =
4.5
4100

Di 2 L F
Gm =
4.5 Gm = 221.671ton
4100

%I

B5( O

P=

P=

Gm K f Di
1.36

Gm K f Di
1.36

P = 3113kw

*

: ! % B!5 Q.H B5( 7 O(

Pr =
Pr =

P
Pr = 94tph
Gf

P
Gf
B!@ 1 %I




  

 Z[

47

= w+ : 

110

%! B7

105

100

95

10.7 12.10 13.75 15.65

90

85

80

75

70

9.09

7.75

6.52

5.4

4.5

-1# O : ]1  Q 5H  j Sj




  

48

4 : 
 y
 ? ]1  2 % @1 4 . Bq  < VO  <
? .    ? 7 *, . VO Q. v9+ b7 B
< ! B. q
 <
! B* @1<

4.5

3.5

2.5

10

11

12

13

 % B ^  %< * (* < ) (L (O< )@1 (D

]1 @ V9( B+ BI ( L ) B!5! 40 ? . =b ; b
D
! B* @1< ] % 13  -    B  * .

4 
 :9

! B( 5 ]#O <  40 70 @1? ? .
<  5 Q(O  1.5 @1 B+O* ! B(.H B
< ! :

)vl = Dn vl = 3.14 (5100) (1.5 60

vl = 39 cm
sec




  

49

  )  : 

 %j. ! Or* 5  H V<  * :

t = 1.77L F
PDn
@1 Q.(: B
t % B* )(+O
*I L < )(
P < )(
(O D< )(
n < ) @1(B+O
B;j * V<  !=  . B.  V9 745
! 40
V9 F],  Bb * *9 q V< .  V9!  1
@ < +*9 @1 q. H
 r#!( B( Q.H B+ @ :

11.2L

= t = 1.77 L 40 1
PDn
PDn




  

50

!z :
 % B* V< < Q.H(9 :
*I <  75 : (O<  5 :  < 2 :(%2.5) B < 1.5 : @1B+OB+O

11.275
= 56
251.5

=t

 Bb<  Bq, M ?* Bq V<   B*

V< i B*#  B+(5 @1_@ .




  

51

! 4  : 

VO B V<  ! % @q@ 900 Br 

% V B  =H*B+(5 @1 (1700C 1800C ) O
 B @ O
_@  1350 % 1450 Br .  V,H@ <  %
<*; )( ` E9 [q#, B, @1 B j %
400 Br ; -.  %   q V<  %(*
9  -. V9. 9   V V,H 1@ < %
< V @q, % *  @1 Bq, 7. 45




  

52

 B ! *H ! @1 %<   % %*5! %_ @qB

FLS



!~ y:9 :9+1 

) 
u: 

  

53




  

54




  

55

)9! R!<!  ''9


o)9! !
o!R1W  

o! 
o '!<   # 
#' !+!
o
!+ ! 
o)

o  yw
  )~  




  

56




  

 B < B+(5 @1_@

1500C
1000C

 B x <

! B]!x @1 %b <

57

2%

 @1  ,5,*  B  1200C % ,5, 100C

  @1 ,5,  100C B  2 =9,  2.5
*  V,* i ,5

kcal

   V,*  750 ,5* 
kgClin ker

750

  !5 %I  V,<  %   B @1V

.

@1]1 , * ; < * * <

 +_ 7  V9 45 97 * @1 %I! 5
* 150 *

7 %I  %7 45  60 % 130* i  %*O j4

 9 . ^ *5 7 . 45  B 105* % B
H,. 1

 ( V9 @1 LO 45 f  %q,* , 150 % VO< .
1 B57 @1 457 ] 1 52800 V B. 1

European Cement Association

1-

9*
^g E

B1

! )  
R1W

B1 

1 2stage

4 stage

4 6 stage

SP

SP

PC

300
2800
3.6- 4.5
1.7 2.0
45
150

0.5 1.0
300
4000
3.1 3.5
1.8 2.0
89
150
45 - 65

2000
10000
3.0 3.2
1.8 1.9
89
150

% R]E~^
^g Rb
* {E^ S
E_ h3
O2 % r3s Rqs
** ab^F^  [
*** 
RTH^



  

58

Long

Lepol

BI
Lepol

3- 4 stage

SP PC

Chambers

10 12
300
300
1500
2000
3.5 3.9 3.2 3.6
1.7 1.8 1.9 2.1
45
6 10
200
100
50 - 60

16 21
300
2000
3000
5000
3.6 4.5
3.4 3.6
3.4 4.0
2.1 2.3
12 - 14
8 - 10
100
120 - 150
55 - 65

1- Lepol = Travelling grate preheater kiln

2- SP = Cyclone preheater kiln
3- PC = Cyclone preheater / precalciner kiln
a- t/d @ *1 %I ,5, %  <
- * H Lb

Nm3
kgclidry

* - #$%&' *) +$, ./ 01&2 346, #:,

Gj
ton

** - #1&C0E B/F, GH= $&I0CE#C$,K GE#<, >= .@, # B/

*** - r B != 5 B(+  B

1-

European Cement Association

BI
long

2 stage
PC

28 43
300
2000
3600
5000
5.0 7.5 4.5 5.0
2.2 3.2 2.1 2.3
4-5
5-6
180-220 120 -150
70 - 80



  

59


!
b 457 %   *,5, @q,=
'9'




High Alkali

Low Alkali

M1

M2

M3

CaO

63.5

64.6

64.1

61.1

61.5

Al2O3

5.7

5.0

4.9

4.4

4.3

Fe2O3

2.4

4.0

3.0

3.2

3.1

SiO2

20.4

20.9

20.6

19.3

19.5

MgO

2.4

1.2

1.8

4.2

4.1

SO3

3.3

2.9

2.7

4.1

3.8

Na2O

0.2

0.1

0.13

0.12

K 2O

1.1

0.4

1.51

1.48

Na2Oeq

0.91

0.37

0.42

1.09

1.07

Fineness*

**

**

365

401

583

C 3S

62

64

67

68

69

C 2S

12

11

C 3A

11

C4AF

12

10

m2
400
*95 B J *45c V
kg
m2
,5,  B ^ +**
H* 95*
kg

ASTM : #



  

60

_7  . Rb Eq zFb R

[ ^F
:Q%R<,0S FU<, V) X #RCY4 +L< N0 FP,

RF R^

Rg glEF

_E


F

KRUPP Germany

Rb/r~ 1000 BUE

Impact (Single
Rotor Impactor)

^ ^3 s

KAWASAI Japan %95 eHf 0@I0/#Y4 VP Rb/r~ 400 BUE

V435 )4 +i %95 FF:, 0 V465 )4 +i

Impact (Single
Rotor Impactor)

/ zs s

S

KRUPP Germany )4 +i %95 0@I0/#Y4 VP Rb/r~ 40 BUE

V420

Impact (Single
Rotor Impactor)

1q3 s

BEDESCHI Italy

Rb/r~ 1200 BUHS #', #u&f Bv#*

B&,0</ BUE G:H', Rb/r~ 400 )wYC',
r~ 225002

Triangular
Chevron
Longitudinal

EFi [ i6
6

UBE Japan

Rb/r~ 320

UBE-LOESCHE
MILL LM 38.41

6 EF RST7

BMH Germany

47 0uI 18 N0US r~ 10.000 2 BUE

UBE Japan

Q4 +#4 < #$%' E/r~ 3500 BUE

# e&CuI F

UNSP high
efficiency and low
pressure loss

Rsi`

UBE Japan

0.E 3 .0uI 68 #X 4.55 N0US

+&4 B/ Bv&iF,0S 3.5 - 0.3 BX#HS
7E/r~ 4000 BUE 100/4

UBE Dry Kiln

BMH Germany

2 74.84 3C0H4 7E r~ 3500 BUE

Combi Cooler
Grate

^`i^ q7

KAWASAKI
Japan

#C4 13 4.2 #X - / 3300) 2

Rb/r~110 2 BUH,( 0uI

KAWASAKI
Center Drive Ball
Mill with high
efficiency
classifier (O-SEP
A NK2-2500)

zFb RST7

BMH Germany

=, +&<:I 0@/ 4) Rb/1 2400 4 BUE

(F F

Electronic rotary
packer 8-spout

rS R|q R

w&4 2 Rb/r~ 150 2 BUE

Air Slide

zFb FS
a\s

YOKOGAWA
Japan

Continues
RTi/ 13 k7El
Blending System
6 EF
BMH

Digital Control System (DSC)

kF] h`S.

http://www.tcc-sa.com/01html/assetsar.htm *45 B JO* : # -1




  

61

!+ !  ' 2004  '9 2005

9) ~



 745


B9 ,5,

2004

2005

2004

2005

99

99.1

105

106

V

38

39

45

45

%#

934

1000

850

850

#

28

27

35

35

1!

21

20

22

22



32

32

31

31

5H

125

130

150

150

*

36

37

42

42

38

32

33

35

(

38

38

46

46



67

66

76

74

*H B*

53

50

62

62

-!,

35

36

40

40



43

45

65

65

9 !*9

23

24

24

24



46

48

40

40

5

35

40

50

50



38

38

35

35

51

25

27

20

22

 ]

381

392

330

346

*b 7 @9

2130

2220

2100

2120

*; 

# U.S. Geological Survey, Mineral Commodity Summaries, January 2006 :

-1*;  Q; , *,

62



  

1995 ! !  !+

European Cement Association

: #




  

)    4+
!4 

) 5}  Q5*! _5( %

= !+
 !5
 B1b  BI _  B1 _ BI

# European Cement Association :

63




  

64

 yw!+
 '  '9)~ 



Cement and Clinker Production in Arab Countries

Planned and under-construction Expansions in the Arab Countries until 2010

Unit: 1000t
Expected
Expected
Current
Forecast total after
Total
expansion expansion Capacities
expansion
Arab
cement
Clinker
Cement
Clinker
Cement
Clinker
Countries
119.886
109.646
146.813 109.205 266.699
228.851

Planned and under-construction Expansions in GCC Countries

Unit: 1000t
Current
Capacities

Planned and Under-Construction Expansions

Clinker

Cement

The whole Region

Bahrain
346
Oman
2.048
1.950
Qatar
1.500
915
Saudi
25.513
22.733
Arabia
UAE
11.100
6.300

69.166

% of Total
Expansions
in Arab
Countries
56.13

59.581

% of Total
Expansions
in Arab
Countries
52.96

3.270
2.760

4.94
4.17

3.150
2.700

24.619

36.02

38.220

32.42

Area
Cement

Clinker

Forecast total after

expansion
Cement

Clinker

5.54
4.75

5.318
4.260

1.950
3.615

23.611

39.63

50.429

46.344

30.120

27.90

49.320

36.420

Planned and under-construction Expansions in Mashreq Countries

Unit: 1000t
Area

Current
Capacities
Cement Clinker

The whole Region

Egypt
38.200
36.400
Iraq
14.029
13.472
Jordan
4.685
4.037
Sudan
510
480
Syria
50.31
4.592
Yemen
1.275
1.215

Planned and Under-Construction Expansions

Cement

41.275
18.900
4.800

% of Total
Expansions
in Arab
Countries
34.43%
45.79
11.63

3.365
8.960
5.250

8.15
21.71
12.72

Clinker

40.860
18.800
4.800

% of Total
Expansions
in Arab
Countries
37.27%
45.55
11.75

Forecast total after

expansion

Cement
57.100
18.829

Clinker
55.200
18.272

3.300
8.760
5.200

8.08
21.44
12.73

3.875
13.991
6.525

3.780
13.352
6.415

Planned and under-construction Expansions in Maghreb Countries

Unit: 1000t
Current
Capacities

Planned and Under-Construction Expansions

Area
Cement

Clinker

The whole Region

Algeria
13.500
12.209
Libya
6.130
5.806
Morocco
11.100
9.796
Tunisia
7.450
6.340

Cement
9.445
1.575
4.200
3.200
470

% of Total
Expansions
in Arab
Countries
7.88%
16.00
42.66
32.50
4.77

Clinker
9.205
1.500
4.200
2.800
705

% of Total
Expansions
in Arab
Countries
8.40%
16.12
45.14
30.09
7.58

Source: www.iea.org/textbase/work/2006/cement/Al-Rousan.pdf

Forecast total after

expansion
Cement
15.075
10.330
14.300
7.920

Clinker
13.709
10.006
12.596
7.045

IRAQ: STRUCTURE OF THE CEMENT INDUSTRY IN 2004

(Metric tons unless otherwise specified)

Major operating companies,

major equity owners, and plants
Iraqi Cement Co. (Government, 100%)
Al Tamim Cement Plant
Kubaisa Cement Plant
Al Qaim Cement Plant
Fallujah White Cement Plant
Fallujah Cement Plant
Northern Cement Co. (Government, 100%)
Sinjar Cement Plant
Badoosh III Cement Plant
Badoosh II Cement Plant
Hammam Al Alil II Cement Plant
Hammam Al Alil I Cement Plant
Badoosh I Cement Plant
Southern Cement Co. (Government, 100%)
Karbala Cement Plant
Muthena Cement Plant
Al Najaf Al Ashref Cement Plant
Um Qasr
Al Jinoob Cement Plant
Samawa Cement Plant
Kufa I Cement Plant
Al Sadaa Cement Plant
Tasluja Cement Plant (Kurdistan Regional
Government)
United Cement Co. (Kurdistan Regional
Government)
Total
-- Negligible or no production.

Process type and location of main facilities

2004
operating
capacity

Annual
design
capacity

2 dry process lines at Kirkuk

2 dry process lines at Kubaisa
1 dry process line at Al Qaim
3 dry process lines at Fallujah
2 wet process lines at Fallujah

150,000
150,000
90,000
50,000
--

2,000,000
2,000,000
1,000,000
300,000
200,000

2 dry process lines at Mosul

1 dry process line at Mosul
2 wet process lines at Mosul
1 wet process line at Mosul
2 wet process lines at Mosul
do.

290,000
250,000
130,000
15,000
---

1,200,000
1,000,000
700,000
450,000
200,000
190,000

2 dry process lines at Karbala

2 dry process lines, 37 kilometers from Muthena
4 wet process lines at Kufa
1 dry process line at Um Qasr
1 wet process line at Samawa
do.
1 wet process line at Kufa
2 wet process lines near Sadat Al Hindia
2 dry process lines near Suleimaniyah

90,000
220,000
420,000
60,000
25,000
-145,000
72,000
300,000

2,000,000
2,000,000
1,800,000
500,000
450,000
400,000
200,000
150,000
2,300,000

2 wet process lines at Sarchinar

100,000

250,000

2,557,000

19,290,000

Sources: The European Cement Association, company reports, press articles, and U.S. Department of Commerce.

IRAN CEMEN and CLINKER PRODUCTION (2005-2006)

Name

Abyek (FKCC)
Abadeh
Ardebil
Behbahan
Benvid white
Bohrouk
Bojnourd
Bushehr
Darab
Doroud
Ekbatan
Estahban
Fars
Fars Nov
Qayen
Gharb
Hegmatan
Hormozgan
Ilam
Isfahan
Karoon
Kavir Kashan
Kerman
Khash
Khazar
Khuzestan
Kohkilouyeh
Kordestan
Loshan
Neka
Qeshm
Neyriz white
Saveh white
Sepahan
Shahroud
Shargh
Shomal
Shomal white
Soufian
Tehran
THR 7th U
Uromiyeh
Urmia white
Total

Clinker
Production
Efficiency

Cement
Production

2217643
191710
763391
608334
143511
130317
660697
1053764
909479
857847
154609
260044
639225
73177
671775
567264
454741
1826239
553185
993935
904012
101064
1190456
541180
539800
856918
158975
810323
97290
564340
-138522
312050
1933917
780330
1375580
781661
44202
1382858
1960097
576577
874778
154458
29805265

2538039
207683
856589
691860
130703
9195
716141
1177582
1041633
909173
180411
310122
751426
40970
739501
630139
649331
1804960
592439
1028792
961841
91881
1290015
763750
587118
933524
170084
832485
98750
601012
122438
140784
279753
2526575
834500
1495725
763937
41665
1412056
2013931
605207
903596
166346
32643661

98.56
108.38
110.64
67.59
84.77
12.07
110.12
117.08
101.05
71.67
93.70
83.55
81.17
8.13
101.78
94.54
58.30
101.46
83.82
99.79
100.45
18.87
107.83
90.20
89.97
95.21
68.82
103.89
49.14
94.06
-87.95
99.06
97.67
96.34
98.77
144.22
51.52
96.84
84.31
96.10
100.55
98.07
94.12

Efficiency

108.04
110.02
119.37
73.93
79.79
0.82
114.77
125.81
111.29
73.03
105.13
94.66
91.75
4.38
107.74
100.98
80.05
96.42
86.31
99.33
102.76
16.50
112.35
122.40
94.09
99.74
70.80
102.62
47.96
96.32
42.51
85.95
85.39
122.70
99.06
103.26
97.94
46.69
95.08
83.29
96.99
99.96
101.55
98.26

Source of Data : Dept. of Mine Industry ; Ministry of Industry & Mine




  

68

69

.



.

)
(




  

70

Q. r @1 < * %,^  B+(5 @1_@  H]
]@   V, V9 ,5,* B* B . Q.l5 L*9V
<j Bq , B,@ x  (O ,5,  %< . 9*5
.  S1*9 V r , Q. 5 * V %,
! H+ B y V< * J] * V Bq@1 V
 B* * (* 9 i .
 *9 V@ HS1 V, @(9  %, ,5, v9r
#  B V9b - V,  ,5, V . !(= < @1
!, ( O @1 B9H   . ,5, B  j ,5,
 %<  % ?  %( B . -.*@   BH# * V
] ! B 7 _  % B  j] ! B (H
 *  *= ] G Q.] O % 4< h @ @1
1  . B?*9 B V , r @ 9 *5 *,@
. . S1
 % =9#79 B9 B<  @1 B,<  ] -  B,@ V
< ; !  B, 5 B ** - *I @1 B* -.* 
* @1! * . < Q+*  Bb  B9 =9#+ %9. Q
*@  B] !  B H  @1 % B V_ H,B
7H# . *  B B( _ V,, .H . * .




  

     & %  # "!

71



&   &1)0 . )  +

'()  ) 7 4 5
.5 : =>0 ; )0 4  ?.. @A
& ;=  C ". )  ) ' );+ F# 
4
%4 " G+ +5 AJ' G5  &I) ; 4 . :>? A
 P4 ?# NA 4 ". M &I  )'0 4)  &'
) 4& ;= Q;  C) ' F#  C=; &!' G5I
V!4A ( TA +5 U5#) )+ # ! A TA G
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U5## ) \  G5   ;= C I   )
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);+ !() )0 . .
4 ?;5A ; ;`) ;:U 4 &+5 )`# A#0
%+  +  NA;`) )  G5 A ') P5 ' P
A   :      .




  

72

) # #'? {9 5u' '9!1  : 

 :
w

)


'

(O ,5,  %< 

*I < 

(O<  ) (+@(

 B* @1< 

 %j. r @1 B* V<

 < @1 %j

 B < )*^  B _@(

 V9* B* B

 V9j ,5

 <  %]1

T 1

MLT 31
ML1T 1
 ; B H

* ]  Q.H, @ :

)5  L' M 9+*i  T 4 r
=, Q.,  H Br#  * V, @1 B<#+: B




  

73

-1

-3

-1

-1

-1

Q. ; B, -. H 9 HS1 %, ;9

 r x @1 Q.!B

n=9

 * x r = 4
 , , @1 V ; 9 * m = r = 4 . -.! B
 BO*<# <# B< H * @1. _: V,

-1

-3

-1

-1

-1

 *b  9) B]  9 (B@ n r = 9 4 = 5 :

  

74



: @ B! Q.@ 1 B9] 

a4

a8

1 = dD 1 k 2 3
2 = lD 5 k 6 7
a

a12

a16

a20

3 = mD 9 k 10 11

4 = D 13 k 14 15

5 = D 17 k 18 19

: *# Q.H V9  9 ; 1 y# f a4 a3 a2 a1 V9 %9

L : 1 +1 a1 +1 a2 1 a3 + 0 a4 = 0

M : 0 + 0 a1 +1 a2 +1 a3 + 0 a4 = 0

T : 0 + 0 a1 3 a2 1 a3 1 a4 = 0

: 0 + 0 a1 1 a2 + 0 a3 + 0 a4 = 0

:  V#; 9 B*b Q. V %

a1 = 1

a = 0
2

a3 = 0

a = 0
4




  

d
9  9 1: y#
D

75

= 1 V9 Q.H*#  %9 q V9 :

d
D

= 1

l
D

= 2

m
D

= 3

4 =

k 2
5 = 2
D
6 =

` E9  9 .  Q.]

 B@ ^ Q.]  9 B@ :

) 1 = f ( 2 , 3, 4 , 5, 6

d
l m

k 2
= f( ,
) ,, 2 ,
D
D D
D
(O ,5,*  % B<  ! % }5 Q.(: B




  

76

l m

k 2
d = D f ( ,
) , , 2 ,
D D
D
 % Q.( B _  %, ! B , ,5,  %B
*9 V  V9@ x  (O . H5 V1 %, ,1 _ V,,
! B< . f_ V. _ % V_ 5H@ !5 @,
_1 @,5 5H@  %, ,5, B ! B* * W5B(+
 B(+ %, ,5, B ! . B % -.5 B!5 ; B, %,L,
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77

l m

k 2
f( ,
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m
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k 2
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D2
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 Ll9 Q9  h * *. @,5
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78

l m

k 2
d = D f ( ,?O B*  % %,
9, , 2 , ) : B
D D
D
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prototype 9  9

*5 ) r# 5< ( *# mod el  _  V %.%
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prototype = mod el
! %9?  + 50 B<#_  %. %*5: 1%
*I <  75 : (O<  5 :  < 2 :(%2.5) B < 1.5 : @1B+O % B* V<

B+O

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251.5

=t

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79

(O< 4S S1*  5(* 9 ( B+,5, B_ B,
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el
D
D

75
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= 17.85
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D prototype

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) prototype = 86

  

80



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Vtheory = L = 75
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2
2

V = 13%1039 = 135m3
1

< V * ,5, B( *B1?,

= 1500 kg3
m

M = V = 1500 135 = 202500kg

%I 200 < V * B
B( CaO, FeO, SiO, Fe2O3) Q.H <V * Bj
: 2 r B 1700  1500

= 0.004Pa.Sec = 0.004

kg
m.s
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(210 )(1.560)
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mod
el
D
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= 109
D prototype

1- http://www.simetric.co.uk/si_materials.htm
2- http://www.springerlink.com/content/u97150755p027632



  

81
1

  *  O = f % <V *

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( 4.2 )

0.004

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prototype

= 80029.5

= 80029.5
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:

d)
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D mod el D prototype
1- http://www.springerlink.com/content/u97150755p027632




  

82

0.5 d
50
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4200
4200

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