Cement Manufacturing

Process
Bonardo Pangaribuan
Definisi Semen
Semen berasal dari bahasa latin caementum yang
berarti bahan perekat.

Dalam pengertian umum, semen diartikan Sebagai
bahan perekat yang mempunyai sifat-sifat yang
mampu mengikat bahan-bahan padat menjadi satu
kesatuan yang kompak dan kuat


Definisi Semen
Semen Portland adalah :
Semen hidrolisis yang dihasilkan dengan cara
menggiling terak semen portland terutama yang terdiri
atas dan
digiling bersama-sama dengan bahan tambahan
berupa satu atau lebih bentuk kristal senyawa kalsium
sulfat dan boleh ditambah dengan bahan tambahan
lain
Mineral pembentukan Semen
Sejarah
Sebelum mencapai bentuk seperti sekarang, perekat dan
penguat bangunan ini awalnya merupakan hasil
percampuran batu kapur dan abu vulkanis
Sejarah
Baru pada abad ke-18 (ada juga
sumber yang menyebut sekitar tahun
1700-an M), -
insinyur asal Inggris - menemukan
kembali ramuan kuno berkhasiat luar
biasa ini. Dia membuat adonan
dengan memanfaatkan campuran
batu kapur dan tanah liat saat
membangun menara suar
Eddystone di lepas pantai Comwall,
Inggris.
Ironisnya, bukan Smeaton yang akhirnya
mematenkan proses pembuatan cikal
bakal semen ini. Adalah
, juga insinyur berkebangsaan
Inggris, pada 1824 mengurus hak paten
ramuan yang kemudian dia sebut semen
portland. Dinamai begitu karena warna
hasil akhir olahannya mirip tanah
liat , Inggris. Hasil
rekayasa Aspdin inilah yang sekarang
banyak dipajang di toko-toko bangunan.

Sejarah
Content
Overview
Raw Material Extraction & Preparation
Raw Meal Preparation
Clinker Manufacture
Cement Grinding
Packing & Dispatch
Content
Overview
Raw Material Extraction & Preparation
Raw Meal Preparation
Clinker Manufacture
Cement Grinding
Packing & Dispatch
Overview

Quarrying
Crushing
Pre-blending
Grinding
Homogenizing...
Burning...
Grinding
Blending...
Gypsum
Fuels
Mechanical Processes Mechanical Process Thermal
Process
Mineral
Components
Clinker
Cement
Dispatch
Raw
Meal
Raw
Materials
Calcareous
Argillaceous
Silica correctives
Iron correctives
Alternative
Chemical
Processes
Production Flow of Dry-Process Cement
Stepping Process of Cement
Raw
Material
Extraction &
Preparation
Raw Meal
Preparation
Clinker
Manufacturing
Cement
Grinding
Content
Overview
Raw Material Extraction & Preparation
Raw Meal Preparation
Clinker Manufacture
Cement Grinding
Packing & Dispatch
Main Raw Mix Components
Calcareous (Calcium/Lime) Materials -- CaCO
3
(Limestone) bring CaO


Argillaceous Materials -- SiO
2
, Al
2
O
3
& Fe
2
O
3
(Clay,
Shale, Marl)



Raw Material
Limestone, + 82% Clay, + 13.5% Silica, + 3%
Raw Meal
Iron Sand, + 1.5%
Compositions
Drilling and Blasting
Haulage and Loading
Purpose: to crush big rocks
into required small rocks
Maximum feed size
Limestone: 1,500 mm
Shale / silica sand: 500 mm
Product size: max. 75 mm
Crushing ...
Crusher
Pre-homogenezation
Stacker/Reclaimer Configurations
SIDE RECLAIMER FRONT RECLAIMER
CONICAL
SHELL
CHEVRON
CHEVCON
WINDROW Not applied
Stacker Circular Storage
Front Acting Reclaimer and Circular
Storage
Side Acting Reclaimer
Summary 1
st
Step
Content
Overview
Raw Material Extraction & Preparation
Raw Meal Preparation
Clinker Manufacture
Cement Grinding
Packing & Dispatch
Tube mill
Vertical mill
Raw Materrial Grinding ....
Bin bin Raw Material
Purpose: to temporary
storange and weighting
raw material
Proportion raw material
LS, Clay, Iron ore, Sand
Main purposes
To grind, and
To dry raw materials
- Using exhaust gases
from the kiln
Product (Raw Meal)
Fine powder
Maximum size 90
micron
Moisture of 1%
Vertical Roller Mill
Vertical Roller Mill
Processes inside .....
Grinding
The material is trapped
between the rollers and the
table
Drying
When the hot gas contact the
material leaving the table
Transport
From the table to the separator
and filter by the gases
Separating
The fine product from the
coarses
Process : Grinding
View from top
View from side
Gas & Product Material
Feed Material
Separator Rejects
Internal Circulation
Large Material falls through to scraper
Internal gas
flow
Material & Gas
Material
Gas
Separator:
removes fine material
rejects coarse material
VRM Process Inside
Product is Raw meal
10 cm
90 m
VRM - Some Common Mill Configurations
G.Pfeiffer Loesche FLS Atox Polysius
The raw meal is homogenised by a
combination of the way it is added
to/extracted from the silo and the air mixing in
the silo.
Active Inactive
Bypass
G AS
G KA G KJ
HS
FR
Filter FR
Out
In
Raw Meal Homogenisation ...
Summary 2
nd
Step
Content
Overview
Raw Material Extraction & Preparation
Raw Meal Preparation
Clinker Manufacture
Cement Grinding
Packing & Dispatch
Process:Preheating/Pre-calcination...
0 500 1000
Stages
Raw meal
Exhaust gas
880
785
660
500
315
785
660
500
315
50
1000
5
4
3
2
1
Temperature
0
C
Process:Preheating/Pre-calcination...
Process:Preheating/Pre-calcination...
The preheating and precalcining processes are done in
the preheater tower. In just a few seconds the raw
meals is heated from 50
o
C up to 870
o
C and calcined up
to 95% (CO
2
dissociated)
Temperature Type of reaction
20 100 Evaporation of free water
100 300 Loss of physically adsorbed H2O
600 900 Dissociation of carbonates (CO2)
> 800 Formation of C2S, C3A and C4AF
Kiln
Process:Burning inside the Kiln
a rotating steel tube
40 230 m long
2.5 7.5 m diameter
Protected by refractory
materials (resistant to heat)
Slope ~2 3
o
Sinters material to clinker
Process:Burning inside the Kiln
Temperature Type of reaction
> 1250 Liquid phase of C3A and C4AF forms
~ 1450 Complete of reactions and crystallizations of C3S and C2S
1300 - 1250 Crystallizations of liquid phase mainly aluminates and ferrite
Heavy Fuel Oil
Pulverized Coal ( Sub-Bituminous &
Lignite)
Natural Gas
Pulverized Petroleum Coke











Fuel
A complex burner is used to mix different
fuels with air and deliver them to the burning
zone of the kiln for combustion
Fuel
Process: Clinker Cooling ...
The cooling occurs
Inside the kiln (cooling zone)
- From 1,450 to 1,100
o
C
In the Cooler
- From 1,100 until about 100-
200
o
C
Purposes
Heat recuperation
Safety for transport system and
storage
Clinker Quality
Kiln
Cooler
Clinker
Process: Clinker Cooling ...
Product is Clinker
Quality of Meal (Formula)
LSF =
(2.8S + 1.1A + 0.7F)
(100C)
90 105
SM =
(A + F)
(S)
2.1 2.5
(F)
AM =
(A)
1. 2 2.0
Sequences of chemical reactions
Proportion CaO SiO2 Al2O3 Fe2O3
Limestone 82.2% 51.6 3.8 1.4 0.4
Sand 2.9% 1.7 85.8 5.2 2.1
Clay 13.5% 2.6 55.7 16.2 6.1
Iron ore 1.4% 5.3 18.6 4.8 60.6
100%
42.9 13.4 3.6 2.1
LSF = 100 SM = 2.3 AM = 1.7
Primary
ingredients in kiln
feed (raw meal)




These supplay

CaO


CaO


SiO
2


SiO
2


CaO


CaO

1450
o
C

CaO


SiO
2


Al
2
O
3


Fe
2
O
3


CaO


CaO


CaO

SiO
2

Sequences of chemical reactions
Chemical reactions
Composition of Clinker
Clinker Phase Content
C
3
S Alite ~ 60 %
C
2
S Belite ~ 20 %
C
3
A Aluminate ~ 10 %
C
4
AF Ferrite ~ 10 %
Free lime (CaO
free
)
Periclase (MgO)
Alkali sulphates (Na
2
SO
4
, K
2
SO
4
)
In minor amounts :
Product is Clinker Minerals (under Microscope)
alite
Summary 3
rd
Step
Content
Overview
Raw Material Extraction & Preparation
Raw Meal Preparation
Clinker Manufacture
Cement Grinding
Packing & Dispatch
Compositions
Cement
MIC, Clinker, Gypsum,
Cement Grinding....
Operation principle
of a Tube mill
Cement Grinding....
Cement Grinding...
Cataracting motion
for coarse feed
Cascading for fine
material
Purpose
To store cement
How to Discharge
For bag cement, through
- Rotary packer
For bulk cement, through
- Loading spout
Cement Grinding...
Product is Cement
Summary 4
th
Step
Content
Overview
Raw Material Extraction & Preparation
Raw Meal Preparation
Clinker Manufacture
Cement Grinding
Packing & Dispatch
Layout of dispatch / shipping station
Cement
Silo
Cement
Silo
Storage
Dispatch/Transport
Packing & Loading
Cement from the mills
Cement Storage, Packaging & Dispatch
Cement Packaging
Cement Palletizing
Bag Loading of Trucks



Bulk Loading of Trucks