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.

Sejarah
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.

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
Mechanical Processes
Raw
Materials
Calcareous
Argillaceous
Silica correctives
Iron correctives

Quarrying
Crushing
Pre-blending
Grinding
Homogenizing...

Thermal
Process

Mechanical Process

Alternative

Raw
Meal

Fuels

Gypsum

Clinker
Burning...
Chemical
Processes

Mineral
Components

Cement
Grinding
Blending...

Dispatch

Production Flow of Dry-Process Cement

Stepping Process of Cement

Cement
Grinding
Clinker
Manufacturing
Raw Meal
Preparation

Raw
Material
Extraction &
Preparation

Content
Overview

Raw Material Extraction & Preparation

Raw Meal Preparation

Clinker Manufacture
Cement Grinding
Packing & Dispatch

Raw Material
Main Raw Mix Components

Calcareous (Calcium/Lime) Materials -- CaCO3

(Limestone) bring CaO

Argillaceous Materials -- SiO2, Al2O3 & Fe2O3 (Clay,

Shale, Marl)

Compositions

Limestone, + 82%

Clay, + 13.5%

Silica, + 3%

Raw Meal

Iron Sand, + 1.5%

Drilling and Blasting

Haulage and Loading

Crushing ...
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

Crusher

Pre-homogenezation

Stacker/Reclaimer Configurations
SIDE RECLAIMER
CONICAL
SHELL

CHEVRON
CHEVCON

WINDROW

Not applied

FRONT RECLAIMER

Front Acting Reclaimer and Circular

Storage
Stacker Circular Storage

Side Acting Reclaimer

Summary 1st Step

Content
Overview

Raw Material Extraction & Preparation

Raw Meal Preparation

Clinker Manufacture
Cement Grinding
Packing & Dispatch

Raw Materrial Grinding ....

Tube mill
Vertical mill

Bin bin Raw Material

Purpose: to temporary

storange and weighting

raw material
Proportion raw material

LS, Clay, Iron ore, Sand

Vertical Roller Mill

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

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 side

View from top

VRM Process Inside

Gas & Product Material
Feed Material

Separator:
removes fine material
rejects coarse material

Internal gas
flow

Separator Rejects
Internal Circulation
Large Material falls through to scraper

Material

Material & Gas

Gas

Product is Raw meal

10 cm

90 m

VRM - Some Common Mill Configurations

G.Pfeiffer

Loesche

FLS Atox

Polysius

Raw Meal Homogenisation ...

In
Filter

FR

FR

Out
Bypass

HS
GKA

GKJ

Active Inactive

GAS

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.

Summary 2nd Step

Content
Overview

Raw Material Extraction & Preparation

Raw Meal Preparation

Clinker Manufacture
Cement Grinding
Packing & Dispatch

Process:Preheating/Pre-calcination...

Process:Preheating/Pre-calcination...
Stages
1

315

50

Raw meal
Exhaust gas

500
315
2

660

500
3
785
660

880
785
5
1000
0

500
Temperature 0C

1000

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 50oC up to 870oC and calcined up
to 95% (CO2 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 3o
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

Fuel
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

Process: Clinker Cooling ...

Process: Clinker Cooling ...

The cooling occurs

Kiln
Clinker

Inside the kiln (cooling zone)

- From 1,450 to 1,100oC
In the Cooler
- From 1,100 until about 100200oC
Purposes
Heat recuperation
Safety for transport system and
storage
Clinker Quality

Cooler

Product is Clinker

Quality of Meal (Formula)

LSF =

(100C)
(2.8S + 1.1A + 0.7F)
90 105

(S)
SM =
(A + F)
2.1 2.5

(A)
AM =
(F)

1. 2 2.0

Sequences of chemical reactions

Proportion

CaO

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

1.4%

5.3

18.6

4.8

60.6

100%

42.9

13.4

3.6

2.1

Limestone

Iron ore

LSF = 100
Primary
ingredients in kiln
feed (raw meal)

SiO2 supplay
Al2O3
These

SM = 2.3

Fe2O3

AM = 1.7

Sequences of chemical reactions

CaO
CaO
CaO
CaO
CaO
SiO2
SiO2
SiO2

CaO

CaO
SiO2
1450oC

CaO

Al2O3
Fe2O3

Chemical reactions

Composition of Clinker
Clinker Phase

Content

C3S

Alite

~ 60 %

C2S

Belite

~ 20 %

C3A

Aluminate

~ 10 %

C4AF

Ferrite

~ 10 %

In minor amounts :

Free lime (CaOfree)

Periclase (MgO)
Alkali sulphates (Na2SO4, K2SO4)

Product is Clinker Minerals

alite

(under Microscope)

Summary 3rd Step

Content
Overview

Raw Material Extraction & Preparation

Raw Meal Preparation

Clinker Manufacture
Cement Grinding
Packing & Dispatch

Compositions

Clinker,

Gypsum,

Cement

MIC,

Cement Grinding....

Cement Grinding....

Operation principle
of a Tube mill

Cement Grinding...

Cataracting motion
for coarse feed
Cascading for fine
material

Cement Grinding...
Purpose

To store cement

How to Discharge

For bag cement, through

- Rotary packer

For bulk cement, through

- Loading spout

Product is Cement

Summary 4th Step

Content
Overview

Raw Material Extraction & Preparation

Raw Meal Preparation

Clinker Manufacture
Cement Grinding
Packing & Dispatch

Cement Storage, Packaging & Dispatch

Layout of dispatch / shipping station
Cement from the mills
Storage
Cement
Silo

Cement
Silo

Dispatch/Transport
Packing & Loading

Cement Packaging

Cement Palletizing

Bag Loading of Trucks

Bulk Loading of Trucks