Cement Plant Operations Handbook

5th Edition

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Process Summaries

1. Introduction 20

2. Raw Materials 23

1. Raw Materials – 2. Reserves – 3. Crushing – 4. Pre-blending

3. Raw Milling and Blending 31

1. Raw Milling – 2. Blending

4. Burning and Cooling 39

1. Kiln Burning – 2. Control Systems – 3. Kiln Control – 4. Kiln Start-up and Shut-down – 5. Kiln Refractories – 6. Insuffl ation– 7. Kiln By-pass – 8. Preheater Cleaning – 9. Fossil Fuels – 10. Waste Fuels – 11. Coal Firing – 12. Clinker Cooling – 13. Kiln Mechanical – 14. Emergency Power

5. Cement Milling 69

1. Clinker Storage – 2. Cement Milling – 3. Separators – 4. Ball Mill Circuit Control – 5. Cement Storage – 6. Cement Dispatch – 7. Quality Assurance and Customer Service

6. Quality Control 83

1. Sampling – 2. Chemical Analysis – 3. Evaluation of Clinker Mineralogy, Microstructure and Clinker Quality – 4. X-ray Diffraction – 5. Particle Size Analysis – 6. Thermal Analysis – 7. Microscopy – 8. The Virtual Cement and Concrete Testing Laboratory – 9. Calorimetry – 10. Burnability – 11. Grindability – 12. Physical Test – 13. Process Control Analysis – 14. Cement Strength – 15. Setting Time – 16. ASTM Cement Types and Specifi cations – 17. European EN 197 Cement Specifi cation – 18. Cement Intergrinds – 19. Supersulphated Cement – 20. Calcium Aluminous Cement – 21. Shrinkage-Compensating Cement – 22. ISO 9001:2000 Quality Management System – 23. Concrete Problems – 24. Domestic Water Treatment

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7. Maintenance 115

1. Failure Modes – 2. Computerised Maintenance Management Systems – 3. Reliability-Centred Maintenance – 4. Maintenance Cost Management – 5. Maintenance Organisation – 6. Role, Planning and Control – 7. Mobile Equipment Maintenance

8. Environment and Pollution Control 123

1. Dust Collection – 2. Pollution Control – 3. ISO14000 – 4. Sustainable Development and Climate Change

9. Combustion and Heat Transfer Processes 131

1. Chemistry of Combustion – 2. Fuels – 3. Physics of Combustion – 4. Burner Design – 5. Heat Transfer – 6. Pollution Control

10. Hydration of Portland Cement 155

11. Other Kiln Types 159

1. Long Wet Kiln – 2. Long Dry Kiln – 3. Lepol (Grate Preheater Kiln) – 4. Vertical Shaft Kilns – 5. Fluidised Bed Kiln – 6. Mini Kilns

12. Plant Reporting 165

1. Defi nitions – 2. List of Reports – 3. Inventories and Feeders – 4. Downtime Reporting – 5. Miscellaneous Reporting – 6. Typical Daily Production Report – 7. Typical Process Summary Data – 8. Typical Equipment Downtime Report – 9. Plant Manning

13. Accounting 175

1. Cost Accounting – 2. Investment Justifi cation – 3. Capacity Increase by Process Change – 4. Project Cost Estimation – 5. Financial Statements

14. Technical and Process Audits 187

1. Kiln Specifi c Fuel Consumption – 2. Cement Mill Specifi c Power Consumption – 3. Other Systems – 4. De-bottlenecking – 5. Project Audit – 6. Risk Assessment

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15. Cement Plant Assessment Data List 195

1. General – 2. Administration and Commercial – 3. Quarry – 4. Drying – 5. Raw Milling – 6. Blending – 7. Kiln – 8. Fuel – 9. Clinker – 10. Finish Mill – 11. Cement – 12. Quality Control – 13. Packing and Distribution – 14. Dust Collectors – 15. Maintenance – 16. Process –17. Materials Analysis – 18. Plant Capacity Summary

16. Cement Plant Valuation and New Plant Construction 205

1. Plant Valuation – 2. New Plant Construction – 3. Project Management

17. Statistics 221

Section B – Process Calculations and Miscellaneous Data

B1. Power 228

B2. Fans and Air Handling 230

B3. Conveying 237

B4. Milling 240

B5. Kilns and Burning 246

B6. Fuels 254

B7. Materials 257

B8. Miscellaneous Data 260

B9. Periodic Table xxx

References xxx

Index xxx

Advertisers’ Index xxx