CEMENT PLANT USING CLINKER (CRUSHING PLANT)
[CODE NO.4010]
It needs to be well understood that cement manufacturing is a highly intensive activity and highly impacts the environment. In the manufacturing process, it is important to save the energy. In the modern cement plants, it is important to check the mix of raw materials before these enter the kiln. It is also important to reduce the energy output when the secondary burning points are installed using the best of alternative fuels.
It is important to understand the benefits of these crushing plants. It significantly reduces the energy costs and accurately controls the kiln processes. It optimizes the burner performance and prevents blockages in the pre-heater cyclones. In the manufacturing process, the portland cement clinker is ground to fine powder and used as a binder in many cement products.
When the clinker is used in dry conditions, it can be kept for several months without appreciable loss of quality. When the cement manufacturers purchase clinker, they usually grind it at the cement plants. In this plant, the gypsum is added to clinker primarily as an additive to prevent the flash settings of the cement.
The cement manufacturing process using the clinker needs to be understood well. The manufacturing process beings with limestone crushing and grinding. The limestone is combined well with clay, sand and iron ore. Thereafter, the fine powder is heated well and passed on through the pre-heater tower into a large kiln. The fine powder is then heated well as it passes through the pre-heater tower into the large kiln and the powder is heated to 1500 degrees. It creates a new product called clinker which resembles the pellets that are about the size of marbles.
The cement grinding technology is adopted by the investors as circuit cement grinding processing. These have the best of advantages such as high manufacturing ability, good production quality, less energy consumption, high automation level, more industry waste using quantity, and others.
The cement manufacturing process of the grinding station has to be adopted well via open circuit manufacturing process. It needs to be noted well that the roller miller is widely used in the grinding system which in turn reduces the feeding size of the ball mill. This greatly increases the production capacity and decreases the grinding energy consumption.
The cement clinker grinding plant acts as a production line in the last period of the cement production process. In the process, the cement clinker is ground well by adding moderate mixing materials which then forms the finished cement. There are various procedures associated with the cement grinding plant – which include the raw material preparation, burning as well as cement making.
We have been able to successfully understand the cement manufacturing process using the clinker. All the needful procedures need to be well understood and executed well for the successful manufacturing of cement. It is important to adopt to the best of technologies for effective cement manufacturing and this is efficiently done by the clinker manufacturing cement plant (crushing plant).
COST ESTIMATION
Plant Capacity 480 MT/Day
Land & Building (8080 sq.mt.) Rs. 6.02 Cr
Plant & Machinery Rs. 8.15 Cr
Working Capital for 1 Month Rs. 4.90 Cr
Total Capital Investment Rs. 19.75 Cr
Rate of Return 40%
Break Even Point 42%
INTRODUCTION
PROJECT LOCATION
MAP
MIRZAPUR CLIMATE
TRANSPORTATION
HISTORY OF CEMENT
COMPOSITION
BASIC CALCULATION/FORMULATIONS - CHEMICAL SHORTHAND
THE MOST COMMON COMPOUNDS IN CEMENT CHEMISTRY ARE:
A TYPICAL ANALYSIS OF CLINKER IS GIVEN IN THE TABLE BELOW:
CLINKER COMPOSITION
SCIENTIFIC NAME & BOTANICAL DESCRIPTION
AN APPROXIMATE ANALYSIS FOR RAW MIX ON IGNITED BASIS, OR FOR
CLINKER, IS:
MATERIALS, AS MINED, THEREFORE, ARE TYPICALLY PROPORTIONED:
MODULES
THE SILICA MODULUS IS DEFINED AS THE RATIO OF SILICA TO THE SUM
OF ALUMINA AND IRON OXIDE:
THE ALUMINA MODULUS IS DEFINED AS:
THE LSF FORMULA FOR CEMENT IS THEN:
MINERAL COMPOSITION
TYPES OF CEMENT
THE MOST COMMON TYPES OF CEMENT CAN BE DIVIDED INTO THREE
MAIN GROUPS:
ASTM CEMENT TYPES
COMPRESSIVE STRENGTHS – FOR ASTM C109 CUBES
ASTM CEMENT TYPES
AIR CONTENT, FINENESS, SOUNDNESS AND SETTING TIME
TABLES BELOW SHOWS SOME OF THE PHYSICAL REQUIREMENTS
AND CATEGORY DEFINED BY EUROPEAN STANDARD.
TYPES OF CEMENT FOR CONCRETE (BS EN 197-1)
EUROPEAN STANDARD EN 197-1 TYPES OF CEMENT
EUROPEAN STANDARDS FOR STRENGTHS
ASTM CHEMICAL SPECIFICATIONS
COMPOSITION OF CLINKER
THE COMPOSITION OF CLINKER IS EXAMINED BY TWO SEPARATE
APPROACHES:
THE FOUR MAIN COMPONENTS OF CLINKER ARE:
OTHER SUBSTANCES MAY BE PRESENT IN SMALL AMOUNTS:
THERMOCHEMISTRY OF CLINKER
TYPES OF CLINKER
SULFATE RESISTANT CLINKER
LOW HEAT CLINKER
WHITE CLINKER
LOW-ALKALI CLINKER
BELITE CALCIUMSULFOALUMINATE TERNESITE (BCT)
CEMENT QUALITY - MAIN FACTORS
ADVANTAGE OF CEMENT PLANT USINGCLINKER
GLOBAL PRODUCTION AND ENVIRONMENTAL IMPACTS
FIGURE : GLOBAL CEMENT PRODUCTION IN 2017
TABLE. SUMMARY OF GASES EMISSION DURING CEMENT MANUFACTURING PROCESSES EXPRESSED IN G/KG * CEMENT AND G/KG ** CLINKER
TABLE. SPECIFIC THERMAL ENERGY CONSUMPTION IN A CLINKER MANUFACTURING PROCESS
USE OF CLINKER: CONVERSION TO CEMENT
MARKET SURVEY
MARKET SIZE
INVESTMENTS
GOVERNMENT INITIATIVES
INDIAN CEMENT INDUSTRY ANALYSIS
GEOGRAPHICAL DISTRIBUTION OF CEMENT INDUSTRY IN INDIA
REGIONWISE CEMENT PRODUCTION IN INDIA
CEMENT PRODUCTION CAPACITY OF INDIA BETWEEN FY 2018
AND FY 2021(IN MILLION METRIC TONS)
NORTHERN REGION
EASTERN REGION
SOUTHERN REGION
WESTERN REGION
CENTRAL REGION
CONSUMPTION VOLUME OF CEMENT IN INDIA FROM FINANCIAL
YEAR 2009 TO 2018 WITH AN ESTIMATE FOR FINANCIAL YEAR 2019
(IN MILLION METRIC TONS)
TOP KEY MANUFACTURERS IN WORLDWIDE CEMENT CLINKER MARKET ARE:
ABOUT CEMENT CLINKER MARKET:
CEMENT CLINKER MARKET SEGMENTATION ANALYSIS:
CEMENT CLINKER MARKET SEGMENTS BY TYPES:
CEMENT CLINKER MARKET SEGMENTS BY APPLICATION:
GEOGRAPHICAL SEGMENTATION:
EXPORT AND IMPORT OF CEMENT
INSTALLED CAPACITY AND KEY MARKETS IN EACH OF THE GEOGRAPHIC
REGIONS
RECENT STRATEGIES
SUCCESSFUL USE OF ALTERNATE FUELS IN CEMENT PRODUCTION
GROWTH DRIVERS AND OPPORTUNITIES
HOUSING AND REAL ESTATE
PUBLIC INFRASTRUCTURE
INDUSTRIAL DEVELOPMENT
CEMENT CLINKER MANUFACTURING PROCESS
EXTRACTION AND PREPARATION OF RAW MATERIALS
HOMOGENIZATION
PRE-HEATING
KILN PHASE
COOLING AND STORING
CEMENT CLINKER GRINDING
FLOW CHART OF BALL MILL FOR CEMENT CLINKER GRINDING:
PHYSICAL CONTROL AND COMPOSITION OF RAW MIX
BURNABILITY OF RAW MIX
INFLUENCE OF THE RAW MIX ON CLINKER FORMATION AND BURNABILITY
TYPES OF KILN
TYPES OF KILNS - WET, DRY & SEMI-DRY
WET KILN
DRY KILN
LONG DRY KILN
ASH ABSORPTION
VOLATILE MATTER
CIRCULATION OF VOLATILE IN SIMPLE KILN SYSTEM
MELTING AND BOILING POINTS OF ALKALI SALTS
MAIN FEATURES DURING BURNING
CHEMICAL CONTROL DURING OPERATION OF THE KILN SYSTEM IS
DIVIDED INTO THE FOLLOWING:
FUEL
TYPES OF FUEL
COAL
TYPICAL PETROLEUM COKES
PROXIMATE ANALYSIS OF COAL:
ULTIMATE ANALYSIS OF COAL:
CHEMICAL ANALYSIS:
HEAT VALUE:
FUEL OIL
TYPICAL ANALYSIS FOR OIL IS:
GAS
WASTE FUELS
COMBUSTION
COAL & OIL
FINENESS OF COAL
DRYING OF COAL
ASH CONTENT
GAS CONTENT
MINOR COMPONENTS
REQUIREMENT FOR AIR
PROCESS GAS
PROCESS FLOW DIAGRAM
MACHINERY SUPPLIERS
MACHINERY PHOTOGRAPHS
CYCLONE PRE-HEATER IN CEMENT PLANT
CEMENT PACKING MACHINE
CEMENT ROTARY KILN
HEAVY WHEEL TYPE ROLLERS AND ROTATING TABLE
5-STAGE VERTICAL CYCLONE PREHEATER IN CEMENT ROTARY KILN
CALCINING PROCESS
ROTARY KILN
ROTATING BALL MILL
SILOS
RAW MATERIALPHOTOGRAPHS
COAL
GYPSUM
SLUDGE
SLAG
PRODUCT PHOTOGRAPHS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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