Presented By Uttam Kumar Ghorai

Materials Science ( 3rd sem)

Roll No-24

Brief Introduction of Cement Manufacturing process. Fuel for cement manufacturing process. Mechanisms for the formation of build up . Analysis and Prevention of build up. Evaluation of Cement Quality. Cost Comparison. Indian Scenario. References.

Temperature 1300-13900c

+Gypsum

Cement

Inlet to mid zone Acidic refractories. Mid zone to outlet zone Basic refractories.

Properties of Coal

Properties of Pet Coke

Properties
%Ash 25.0 %Fixed Carbon 48.0

Properties
%Ash %Fixed Carbon Calorific Value (Kcal/Kg) % Sulfur
C + O2

Calorific Value (Kcal/Kg) % Sulfur

3400
1.5

0.57 89.2 7905 5.6

CO2 + Heat

Ref: Calorific value was determined by using : Bomb Calorimeter (20027) ; Advanced Research Instrument company, INDIA

Volatile elements are

CaCO3 S+ O2 CaO + CO2 SO2

Sulfur ( S)
Potassium (K) Sodium (Na) Chlorine ( Cl)

Pet- Coke
Raw Materials

Na2O +SO2 +1/2 O2 K2O + SO2 +1/2 O2

Na2SO4 K2SO4

Remaining SO2 + 1/2 O2 + CaO

CaSO4 ( build-up/ Coating)

This excess SO3 & Chlorine also damage the Kiln refractories.

1.Analysis of different coatings

Composition (%) Coating at riser Soft ring at 40m distance Uneven hard coating

SO3
Na2O K2O

4.40
0.27 2..20

3.27
0.35 1.84

0.41
0.24 0.52

Coating

Ref: Alkali was determined by using Flame Photometer - 042 (Photo electric instrument Pvt. Ltd Jodhpur)

2. Molar Sulfur/ alkali ratio of Final out put ( Clinker)

% Na2O % K2O % SO3

0.27 0.63 1.32

SO3

SO3 = Alkali
K2O 94

80

+ 0.5 *

Na2O 62

The optimum ratio should be 1.1 If the ratio exceeds 1.1, it is concluded that an excess sulphur is present in the kiln material which is not balanced by alkalis & excess Sulfur will form CaSO4.

= 1.85

Ref :- Project Work at Lakheri QC lab, ACC Ltd.

3. Sulfur Volatility :-

cHM

cCli

Volatility :Volatility < 0.7 > 0.7 > 0.9

SO3Cli SO 3 1 SO3HM
Criteria OK Build up problem Serious build up problem

Ref :- Project Work at Lakheri QC lab, ACC Ltd.

4. O2 atmosphere in the kiln

K2SO4

O2 excess

K2O + SO2 + O2

K2SO4

O2 deficiency

K2O + SO2 + O2

The equilibrium of the above equation is shifted to the left favoring the formation of Alk- SO4 with increasing O2 & SO2 partial pressure which indicates that enough oxygen should be present in the kiln atmosphere. It is observed that with increasing oxygen content up to approximately 2%, volatility of sulphur should be progressively reduced.

5. Excess Chlorine & By pass system

Chlorine limit

290
Chlorine

< 250 - 290 g Cl / t cli

Fuels Materials

Kiln system
Clinker
Ref- Madukkarai cement works, Acc Ltd.

OLD

NEW

LS SM AM

= 95.5 = 2.21 = 1.28

LS SM AM

= 94.0 = 2.09 = 1.25

very high alite(C3S) content (75 80 %)

lower alite (C3S) content (64 %)

Ref:- experiment was done by R & D section , at Thane , Mumbai. Acc Ltd

(C3S)

(C2S) (C4AF)

Ref:- experiment was done by R & D section , at Thane , Mumbai . Acc Ltd.

Cement cost / 5o kg bag- when Coal as a Fuel

Different Cost Weight (in Kg) Cost in Rs.

Cement cost / 5o kg bag- when 20% pet-Coke as a Fuel

Different Cost Weight (in Kg) Cost in Rs.

Clinker

32

60

Clinker Fly Ash

33.1 15

41 9 7 153

Fly Ash

15

9
11 150

Gypsum 3 Others Total 50

Gypsum 1.9 Others Total 50

230

210

Ref: Project work at Lakheri QC lab ACC Ltd Rajasthan.

Pet-coke has high fixed carbon content & due to this reason by using small amount of pet-coke large amount of energy wiil be obtained. Pet-coke has low ash content .So better quality of cement will be produced. Due to high sulfur content more SO3 will be generated at combustion time. Which causes the formation of build ups. To remove excess SO3, from the kiln system by pass system is necessary or addition of certain compounds (Na2CO3/K2CO3) which can balance the excess SO3. Using the by product ( Pet- Coke ) , the ultimate cost of the cement will be reduced.

No. of Cement plants having used Petcoke

37

No. of Cement plants regularly using Petcoke

13

No. of Cement plants regularly using > 70 8 % Petcoke No. of Cement plants regularly using 50 to 70 % Petcoke 9

90 80 70 60 50 40 30 20 10 0 Supplies to Major Cement Plants, % of Total 2000-01 2001-02 2002-03 2003-04 2004-05 2005-2006 2006-2007

1.Aditya cement, Shambhupura, Rajasthan . 2. Birla cement , Chittorgarh, Rajasthan . 3. J.K. Cement, Nimbahera, Rajasthan. 4. J.K. Cement, Mangrol, Rajasthan. 5. Lakshmi Cement, Sirohi, Rajasthan. 6. Shree Cement , Beawar, Rajasthan 7.Gujarat Sidhee Cement, veraval, Gujarat. 8.Saurastra Cement, Ranavav, Gujarat. 9. Shree Digvijay Cement Co . Ltd. , Gujarat. 10. Diamond cement i& ii , Damoh, MP. 11. J.P Cement , Rewa, MP. 12. Vikram Cement ,Khor,MP 13. ACC Cement Ltd. Gagal and Lakheri Cement works.

Duda -Cement Data Book (2nd edition); 1998 Chemistry of Cement & Concrete by F.M.Lee .(3rd edition);2005 Advances in Cement Technology by S.N.Ghosh. ( 2nd edition);2002 Training programme on Physico-Chemical Process in Cement Manufacturing in July2006 at ACC Ltd. Jamul Cement Works, Chhattisgarh. Project Work ( Alternative Fuel : Petcoke Its use in Cement industry) from December to February2006 at ACC Ltd. Lakheri Cement Works , Rajasthan. www.

wikipedia.org

www .google.com