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What is Cement?
A powder of alumina, silica, lime, iron oxide, and
magnesium oxide burned together in a kiln and
finely pulverized and used as an ingredient of
mortar and concrete
The adhesive or Glue that holds concrete together
Concrete: a hard strong building material made by
mixing a cementing material (as portland cement)
and a mineral aggregate (as sand and gravel) with
sufficient water to cause the cement to set and bind
the entire mass
Cement is Part of Concrete
Basic Raw Materials
Corrective
Materials
Finish Grinding
Vertical Roller Mills Separator
Clinker Cooler and Breaker Horizontal Ball Mills
Cooling, Transport, Sizing Roller Press
Size to ~25 mm [Size to ~5-30 microns]
Typical Primary Crusher
1 Stage / Single Pass Crushing System
Primary / Secondary Crushing Installation
2 Stage / Single Pass Crushing System
3 Stage Crushing System
Principles of Crushing
Principles of Crushing
Compression. As the name implies,
crushing by compression is done between
two surfaces.
Cone
Input Shaft
Eccentric
Cone Crusher
Jaw Crusher
Roller Crusher
Mill Inlet
Rolls
Mill Outlet
Clay or Mix Crusher
Mix Crusher
ABON Sizers
Hammer Mill Internals
Rotor
Hammers
Impact Zone
Transport Grizzly
Rolls
Hammer Crusher
Grizzly
Input Shaft
Crusher Application Summary
Type of crusher Reduction Typical Feed Material
Ratio
Hammer & Blow Medium to hard,
50:1
Bar Impactor moderate abrasiveness
Hard, tough,
Jaw Crusher 4:1
high abrasiveness
Hard, tough,
Gyratory Crusher 7:1
high abrasiveness
Hard, tough,
Cone Crusher 3:1
high abrasiveness
Medium to soft, high to
Roller Crusher 4:1
moderate abrasiveness
Toothed Roller Soft, sticky, wet (Hard &
4:1
Crusher soft mix for ABON)
Storage Project Criteria
Homogenisation requirement
Raw material properties
Enlargement capability
Lay-out possibilities
Climatic conditions
Open/closed store
Mill feeding method
Storage Types
Circular stores
Continuous Chevron method
Rotary Sluice
Removable side panels allow better
access for maintenance
HEATED ROTARY SLUICE
1 2 3 4 5 6
C 0,169 0,50
2 G 0,153 0,50
1 2 3 4 5 6
1 2 3 4 5 6
F 0,125 0,33 1 2 3 4 5 6
3 D 0,109 0,33 1 2 3 4 5 6
E 0,115 0,33
t=70 sec
0 60 120 180 240 300 360 420 480 540 600 660 720 sec
2
1 3 1 2 3
B B
3 6 4 1 3 6 4 1
2 4 5 6 2 2 4 5 6 2
G C G C
1 6 5 1 2 3 5 4 3 1 5 1 2 3 5 3
A 6 4
A
4 6 4 6 4 6 4 6
3 5 5 5 1 3 5 5 5 1
F D F D
2 6 4 5 6 4 3 2 2 6 4 3 2
1 1 4 5 6
E E
3 1 3 1
2 2 t=70 sec
Kiln Feed System FLS LOW
FLS-LOW Control Principle
Material Inlet
Inspection Door
Load Cell
Material Outlet
Impact Flow Internals
Impact
Plate
Processes within the Pyro System as a
Function of Temperature
T
E
M
R
A P
NE
GR
E AT
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R
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CE CHARAC
TERI
ST
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SPROC
ES
SES T
Y
P
P
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SF
S
10 - 40
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Theoretical Heat of Reaction
kcal/kg
Heat of Reaction Clinker
Dispersion Plate
Dividing Gate
Riser Slide Damper
TAD Hoisting Damper
Rotary Kiln with Two Supports
Rotary Kiln with Three Supports
Conventional Live Ring
Tangential Tyre Suspension
Conventional Kiln Support
Self-Aligning Kiln Support
Kiln Drive with Girth Gear
and Pinion
Kiln Drive Through Rollers
Hydraulic Thrust Roller
Pneumatic Inlet Seal
Kiln Inlet Lamella Seal
Kiln Outlet Lamella Seal
Kiln with Shell Cooling Fans
Kiln Bypass System
Allowable Input of Volatile Components
for Kiln Systems without Bypass
Clinker Coolers
PLANETARY CLINKER COOLER
PLANETARY COOLER
ORIGINALLY DEVELOPED FOR WET PROCESS
KILN SYSTEMS e.g. 2.0 kg air /kg clinker
OPERATES WITHOUT EXCESS AIR
NO EMISSIONS POINT
HIGH CLINKER TEMPERATURE
NO TAD CAPABILITY
COUNTER-FLOW HEAT EXCHANGE (CASCADING)
ROTARY CLINKER COOLER
TRADITIONAL COOLER
Semianthracite 5 15 35 26
Quarter rich 15 20 58 26
coal
Bituminous 20 30 8 15 26
coal
Rich coal 30 40 10 20 26
Lignite 40 - 50 15 30 10 15 Young
35
30
% Residue on 90
25
20
15
10
0
0 5 10 15 20 25 30 35 40
% Volatile
Ball Mill System
S y s te m
excess gas
P ro d u c t
F re s h fe e d
Hot gas
s u p p ly
Tirax coal mill
RTKM Separator
FRM MILL
Atox Coal Mill
VRM system
S y s te m
excess gas
P ro d u c t
R e c ir c u la tio n M ill fe e d
gas
Hot gas
s u p p ly
Monitoring for Safety
O 2 CO
G a s A n a ly z e r
T
T
Inertisation System
CO 2
CO 2
CO 2
IGNITION
GAS
BURNER
BURNER
SET
Firing Hood
Raw
Meal
Rotating Burning
Outlet for
Disc Material
Combustion
Gases, Hot Raw
Kiln & Meal & Ashes
HOTDISC
Gases to
Calciner
Kiln Riser
Duct
Kiln Riser
Duct Scraper
Wall
Raw Meal,
Fuel &
Tertiary Air
Inlet
Kiln Heavy
Gases Ashes
HOTDISC INSTALLED ON LOW
NOX ILC CALCINER
Cement Grinding Systems:
Cement Grinding Feed Components
Clinker + Gypsum
+ Additives
Two Fan System
Three Fan System
Ball Mill - General view
Chamber 1 and Diaphragm
Diaphragm - exploded view
OSEPA SEPARATOR
MATERIAL ENTERS
FROM TOP OF
SEPARATOR
AIR ENTERS
TANGENTIALLY
COARSE FRACTION
FALLS OUT THROUGH
THE BOTTOM
PRODUCT LEAVES
THROUGH OUTLET
DUCT WITH AIR TO
BAGHOUSE
SEPAX SEPARATOR
MATERIAL ENTERS FROM A
SINGLE INLET POINT FOR
SIMPLE LAY OUT
AIR ENTERS FROM BOTTOM
COARSE FRACTION FALLS OUT
THROUGH THE REJECT
OUTLET DUCT AND VALVE
PRODUCT LEAVES THROUGH
OUTLET DUCT WITH AIR TO
BAGHOUSE
BROKEN GRINDING MEDIA
FALLS THROUGH THE
TRANSPORT AIR AND ENTERS
THE DISPOSAL CONTAINER
PREGRINDER SYSTEM
HYDRAULIC ROLLER PRESS
SEMI-FINISH GRINDING SYSTEM
Two Stage Separator Product
for
Semi-Finish Grinding
Mill outlet
material
Top separator
reject to ball mill
Roller Press
outlet material
PRESSURE DISTRIBUTION
BETWEEN ROLLER AND TABLE
OK MILL SYSTEM
P ro d u c t 2
M
1
5
Cement Storage Silos