PROJECT TITLE

Design of a Cement Plant for Producing

1.5 MMTPY Clinker, OPC & AND PCC
each
Supervised By : Dr. Iqbal Mahmud

M.G. Toufik Ahmed (1402025)

Shehabul Hassan Mamun (1402040)
Ahosan Habib Rakib (1402047)
Akib Atique Khan Dhrubo (1402053)
PROJECT DEFINITION

A cement plant in Chatak, Sylhet with capacity of

producing 1.5 MMT clinker and 1.5 MMT each of
Portland cement (OPC and PCC) in dry process per
year with 330 working days a year by importing
limestone from Meghalaya, India.
.
Design Basis
Geological Data
Soil Type
• The deposition of three different materials, e.g.
Piedmont Alluvium, Tista Alluvium and Barind
Tract. .
• Clay layer concealed under a thin soil layer less
than one m thick, formed from the weathering of
the red clay.
• Arsenic content is below WHO limit.
Seismic condition
Recent seismic data reveals that the earthquake
magnitude ranges up to 4.8 TO 6.5 Richter Scale
Design Basis
Meteorological Data
Temperature
 Maximum temperature: 380C (April)

 Average annual temperature: 25.60C

 Minimum temperature: 120C

Atmospheric Pressure
• Minimum pressure: 740mm(Hg)

• Design barometric pressure: 760mm(Hg)

Design Basis
Meteorological Data
Rainfall
• Average annual : 2850 mm
• Maximum monthly:235 mm

Humidity
 Average annual relative humidity: 80%
 Average monthly humidity (maximum): 87%
 Average monthly humidity (minimum): 65%
Design Basis
HVAC Condition

• Maximum dry bulb temperature – 36° C

(Summer)
• Minimum dry bulb temperature – 25°C
(Winter)
• Relative Humidity (Maximum) – 84%
(Summer)
• Relative Humidity (Minimum) – 80 %
(Summer)
Design Basis
Raw Materials

• Limestone

• Correcting Materials(Sand,Clay,Bauxite,Laterite)

• Additives(Gypsum, Fly Ash, Slag)

Product-: Clinker Composition
Component Weight percentage (%)
• CLINKER OPC PCC
C2S (2CaO.SiO2) 17.39

C3S (3CaO.SiO2) 50.1

C3A (3CaO.Al2O3) 10

C4AF (4CaO.Al2O3.Fe2O3) 6.6

Inert (unreacted CaO , MgO and other 16

impurities)
Product-: Composition of OPC and PCC
Component OPC PCC
(95% Clinker (80% Clinker +15%
+5%Gypsum) Fly Ash+5% Slag)
SiO2 18.25 23.62
Al2O3 4.89 7.27
Fe2O3 2.05 2.53
CaO 67.96 60.13
MgO 1.28 0.93
Inerts 0.55 0.56
Gypsum 5.00 5.00
Selection of process
chemical and unit operation techniques
better successes achieved using dry process
limestone is preferred as raw material due its availability and high lime
content (around 50%).
The first individual process for cement production was by reaction of
natural rock in a vertical shift kiln
Semi-dry and Semi wet process have been termed as attractive
alternative method to produce cement from Limestone
Most of the industries prefer saling both clinker and cement to achieve
Selected process

Dry Process
80% of world production is obtained by dry process

higher yields and productivity

lower labor costs

Process Description

Industrial production for 330 days per year

5.7 Million ton limestone per year
722 ton limestone per hour
 Mixing and Pyro-processing Packaging
Proportioning
1. Crushing 1.Preheating 1.Separating

2. Mixing 2.Rotary kiln 2.Mixing

reaction
3.Grinding 3.Cooling 3.Grinding

4.Separating 4.Packaging
Process Block Diagram (PBD)
PROCESS FLOW DIAGRAM
Process Description
Unit Input Output

Crusher Limestone, 17338 t/day Crushed limestone, 16471 t/day

Loss(5%), 867 t/day
Deduster Clay and other additives , 3068 t/day Purified additives , 2914 t/day
Loss(5%), 154 t/day

Mixer Crushed limestone, 16471 t/day Raw Mixture, 19385 t/day

Purified additives, 2914 t/day

Grinding Mill Raw Mixture, 19385 t/day Preheater feed, 19288 t/day
Loss in ESP(.5%), 97 t/day

Preheater Preheater feed , 19288 t/day Kiln feed( 600°C), 19288 t/day
Coal+ Air Exhaust Gas
Process Description
Unit Input Output

Rotary Kiln Kiln Feed 19288 t/day Clinker 12136 t/day

Coal+Air Exhaust Gas 7152 t/day
Combustion gases
Separator Clinker 12136 t/day Clinker 4545 t/day
Clinker for OPC (4318 t/day)
Clinker for PCC(3272 t/day)
Clinker Storage Clinker 4545 t/day Clinker 4545 t/day (for sale )

Mixer(Gypsum) Clinker for OPC 4318 t/day OPC 4545 t/day

Gypsum 227 t/day
Mixer (Fly Ash , Slag) Clinker for PCC 3272 t/day PCC 4545 t/day
Fly Ash 818 t/day
Slag 455 t/day
List of Major Equipment

Name of the Equipment Identification no. Number of items

Storage tank F-101, F-201, F-401, F-301 4
Crusher C-101, C-102 2
Grinder C-103, C-201 3
Electrostatic precipitator H-101 1
Compressor 2
Coal Tank
Heater E-101, E-301, E-302 3
Heat Exchanger
Reactor R-201 1
Filter H-201 3
Mixer M-101, M-401, 402 3
Thank You