Gément Industry Cement Plant Map - Key 00. Limestone Quarry and Crushing plant 01. Limestone Stockpile 02. Additives Hopper 03, Additives Storage 04, Rew Mill Building 05. Blending and Storage Silo 06. Preheater 07. Gas Conditioning Tower and ESP 08. Kain 08. Cooler 10. Deep Bucket Conveyor 11/12. Clinker/Gypsum Storage 13. Coal Mil Building 14. Cement Mill and Bag House 15. Cement Storage Silo 16. Packing & Dispatch 17. Central Control Room 00 jestone Quarry and Crushing Plant ‘The major raw material for cement production is limestone. The limestone most suitable for cement production must have some ingredients in specified quantities ie., calcium carbonates, silica, alumina, iron, etc. Typically, cement plants locations are based upon the availabilty of good quality limestone in the vicinity. The quarrying operations are done by the cement producer using the open cast mining process. Quartying is done through dling and subsequently, using heavy earth moving equipment such as bulldozers, payloaders and dumpers. The quarried raw material is then transported to the cement plant, using mechanical conveying equipment such as ropeways or belt conveyors, or by vehicles ike wagons and trucks. The quarried limestone is normally in the form of big boulders, ranging from a few inches to meters in size, These varying sizes of limestone need to be crushed to a size of about 10 mim in order to be prepared for fiish-grinding.There ate mainly two types of crushers available for this purpose- compression type or impact type crushers. There are many types of compression type crushers such as jaw crusher, gyratory crusher, cone crusher, roll crusher. The impact technology is used in hammer crusher/impact crusher.Crushing is done either in two stages or ina single stage. In the two stage crushing system, a compression type crusher is used in the frst stage for raw crushing, followed by impact/hammer crusher in the second stage. In single stage crushing, an impact type crusher ig used. The selection of the crusher depends mainly on the characteristics of the raw materials. This selection is further guided by the panticiesie distribution requirements~of the down-stream equipment such as raw mills and lastly by financial considerations,__cimestone Stock Pile The raw materia is stored at either the quarry of at the plant. Typically, circular or longitudinal stock piles are used to store the materialA number of layers are stacked in circular or longitudinal piles and are reclaimed in transverse, cross-sectional slices. The stock piles consist of separate layers/piles of different kinds of raw material. This is used in segregating the raw material quaiity-wise, The required quantity of the various raw materials is thus easily extracted for use. The extraction of different ualites of raw material is monitored and controlled in order to maintain the desired composition of raw meal, suitable for feeding into the Win. 02 & 03 Additives Storage Hopper In order fo get the required composition of raw material, certain additives such as iron ore, bauxite, laterite, quartzite and flourspar are added in required quantities, These additives are stored at the plant in separate hoppers and are extracted using belt conveyors in conjunetion with belt-weighing equipment. This ensures that only the required quantities are extracted and added to the raw material 04 Raw Mii Building The raw material is finish-graund before being fed into the kiln for clinkering. This grinding Is done using either ball mills or vertical roller mills (VRM). The raw material is Simultaneously dried Ball mills use impact with attrition principles for grinding the raw material. Inside the ball mills, various sizes of balls are used and classifying liners are used to maintain the position of different sizes of balls. The larger sized balls are utilized for impact grinding and the smaller balls for attrition. VRM uses the ‘compressian principle to grind the raw material, The choice between a ball mill and VRM is gavemed by many factors such as the moisture content of the raw material, the size of the plant, the abrasiveness of the material, the energy consumption levels, reliability, and finally financial consideratians, Ball mills are suitable for low and medium moisture content in the range of five to six per cent and are preferred for abrasive material. The main advantage of VRM is higher grinding efficiency and ability to accept material with higher moisture content Normally the energy consumption level in VRM is 10 to 20 percent lower than in ball mils. 05 Blending and Storage Silo Normally there are various sources of limestone, each with different qualities, which are added with various additives to get the required composition of raw mix. AS there are various sources of raw materials, it becomes necessary to blend and homogenize these different materials efficiently to counteract fluctuation in the chemical composition of the raw meal. The variations in the ‘composition of kiln feed have very adverse impacts on the efficiency of the kiln. It results in undesired coating and ring formation inside the kiln, In order to blend and homogenize the caw materials properly, continuous blending silos are used. 08 Preheater The most important activity in cement manufacturing is clinkering (or burning) of raw material. Clinkering takes place in the kiln and the preheater system.Preheater systems offer heat transfer from the hot kiln gases. 07 Gas Conditioning Tower and ESP The conditioning tower is used to reduce the temperature and to increase the moisture level of the dusty exhaust gas from the kiln, Before itis passed through the bag house and ESPs. It is called a conditioning tower because it conditions the hot gas, thus making it more suitable for the ESP and bag house to extract dust from it The Electrostatic Preciptators are used in cement plants particularly for removal of dust from the exit gases of cement kilns and, trom the exhaust air discharged by dryers, Combined grinding and drying plants, finishing mils and raw mills through water injection Through ESPs, the dustladen gas is ‘made fo flow through a chamber usually horzontally, during which it passes through one or more high votage electric fields formed by altemate discharge electrodes ans plate type collecting electrodes By the action of electric fied, the dust particles, which have become elecreally charged by negative gas ‘ons which are formed at the discharge electrodes and attach themselves fo the particles, fy o the collecting electrodes and are deposted there. The dust is dislodged from these electrodes by rapping and thus falls info the receiving hopper at the base of the precipitator casing 08 Kitn A. kiln is the heart of any cement plant. It is basically @ long cylindricai-shaped pipe, and rotates in a horizontal position. Its intemal surface is lined by refractory bricks, Limestone and additives are calcined in this. The output of the kiln is called clinker 09 Cooler ‘The clinker coming out of the kiln is hot. It is cooled in a set-up called a cooler, In the cooler, cold air is blown to effect heat exchange between hot clinker and cold air.Jeep Bucket Conveyor The deep bucket conveyor is essentially an equipment to lit material vertically. 11/12 Clinker/Gypsum Storage ‘The output of the kiln is stored before itis fed to the cement mill for conversion to cement. This storage is called clinker storage, if itis used for clinker storage purpose, If the storage space is used fer gypsum storage, itis called gypsum storage. The storage may be of silo type or covered stacker reclaimer type or simply a gantry type. Silo type clinker storage has the advantage that there is no dust pollution and spillage of clinker. Same advantage can be achieved through stacker reciaimer type as well However, there is 2 ittle bit of dust generated. Gantry type is not used in modem cement plants because of its environmental unfriendly nature. 12 Gypsum Storage The output of the kiln is stored before it is fed to the cement mill for corversion to into cement. This storage is called clinker storage, if'it is used for clinker storage purpose. If the storage space is used for gypsum storage, itis called gypsum storage. The storage may be of silo type or covered stacker reclaimer type or simply a gantry type. Silo type clinker storage has the advantage that there is no dust pollution and spillage of clinker. Same advantage can be achieved through stacker reciaimer type as well However, there is a litle bit of dust generated. Gantry type is not used in madern cement plants because of its environmental unfriendly nature Limestone coming out of quarry is crushed in multiple stages in a sizing plant before it is put in limestone stockpile, Crusher are mainly of two fypes viz. Jaw crusher and Hammer crusher. Jaw crusher is basically a simple mechanism having two plates one fixed and another moving. This is also called primary crusher. Hammer crusher has got metallic hammer mounted on the axes and the sizing achieved by the impact of the hammer. 13 Coal Mitt Building The coal mil building houses the mill for grinding lumpy coals. This fine ground coal is used for burning in the kiln.The mills used for coal grinding and drying are either trumbling mills (tube mills) or roller mils 14 Cement Mill and Bag House Clinker, along with additives, is ground in a cement mill, The output of a cement mill is the final product viz. Cement. In a cement mil, there is a cylindrical shell lying horizontal which contains metalic balls and as it rotates, the crushing action of the balls helps in grinding the clinker to fine powder. The term bag house is applied to large filters containing a number of tubular bags mounted in a usually rectangular casing. The dust laden air is drawn through them by suction. The bag house is used to remove usty particles from discharge of different equipment such as cement mill, coal mill and kiln, In a bag house system discharge {gas containing dusty particles is passed through a series of bags made of strong fabrics. 415 Cement Storage Silo The cement storage silo is used for storing the finished product - cement, 416 Packing and Dispatch ‘The cement is packed with the help of a rotary packer and finally dispatched to the market 17 Central Control Room It is the nerve center of the cement plant since all equipment is controlled from this place. It is the place from where ail the process parameters are controled.PROCESS FLOW SHEET “UMESTONE CRUSHOMO PLANT sous am sxe aso | ae ote | fe |—) ase [ ag ‘eat nia ‘acwon Soe Aerio reson sae como 04 Pe : saxon (erin) “wes stot secene £7 rea annie ee [sae = a, le a swe ra — nana Reference ‘WebSite hitp:/www.acclimited.com/newsite/frame,aso Back