A PRESENTATION ON PROCESS DESIGN OF CEMENT

PRODUCTION PLANT

Supervisor

Dr. Ruhul AminAssistant Professor

Chemical Engineering Dept. ,BUET

Prepared bySadiya Afrose(1002040)Pronob Das(0902013)Md. Ishtiak Hossain(0902024)Towfiq Hossain(0902054)

Project definition A cement plant is to be set-up at

Dowarabazar upazila of Sunamganj district in Bangladesh having a capacity of processing 7200 ton per day for an effective operation of 330 streaming days including all auxiliaries, utilities and supporting facilities.

Design basisPlant Location: Dowarabazar, Sunamganj Plant capacity: 7200 ton cement per day

Operating days per year: 330 days

Raw materials: limestone, clay, sand , mill scale

Type of Process: Dry Process

Utilities:

Fuel : Natural gas from Tengratila Gas Field

Power Supply: Grid power line

Water source: On site water reservoir

Climate:

Annual temperature: max 32.7 ˚C & min 8.6 ˚C

Relative humidity: 73.7%

Annual rainfall: 3080 mm

Selection of Process

4 basic types of processes for cement production

Wet processSemi-wet processSemi-dry processDry process

Each process requires a slightly modified approach and use of equipment in the first two of the three manufacturing stages, i.e. the raw grinding and pyroprocessing stages.

The ‘dry’ production process requires less energy and so has lower fuel costs than the wet process and thus is generally favoured where its application is feasible.

Process DescriptionMining- The raw materials are quarried, crushed,

and transported to a nearby cement plant.Kiln feed preparation- Raw materials are

proportioned to the correct chemical composition and ground to a fine consistency.

Clinker production- The finely ground raw meal is fed into large rotary kilns where it is heated to about 1,500°C . This high temperature causes the raw meal to react and form clinker.

Cement milling of clinker- The clinker is cooled and ground with approximately 5%wt. of gypsum and other additives to produce cement.

Process Block Diagram

Process Flow Diagram

List of Auxiliaries, Offsite and Package Units

Air plants Chimneys or stacksCooling towersElectrical generating plantsFlaresIncineratorJettyLaboratoriesMaintenance shopsGarage and vehicular parkingWarehousingPackaging or bagging plantUninterrupted power supply

BuildingChange houseCafeteriaCommunications networkEmergency power systemFire protection systemFuel receiving, blending and storage facilityLandscaping, fencing and site improvementsOffices and auxiliary structuresSecurity systemsSewer linesWater distribution, etc

Process Licensor

A process licensor is an owner of know-how, technical information and patents for the production of a product or products from a certain feed stock using a process scheme.

We will use Larsen &Toubro Limited process licensor for our cement plant design.

List of Major Equipments & Vendors

Conveyor Belt (Zenith, Longyang)Proportioning Equipment (4 hoppers) (Zhengzhou Taihe Materials Co., Ltd)Raw mill (Henan Zhengzhou Mining Machinery Co., Ltd)4 Staged Pre-heater (5 cyclone separators) (Henan Zhengzhou Mining Machinery Co., Ltd)Calciner (A TEC America)Rotary Kiln (Henan Zhengzhou Mining Machinery Co., Ltd)Clinker Cooler (Henan Zhengzhou Mining Machinery Co., Ltd)Clinker Silo (Xinxiang Great Wall Machinery Co., Ltd)Ball Mill & Crusher(Zenith)

Codes and Standards

The common technology which is widely used in our industry from the year 2003 is Portland Composite Cement (PCC) which is made following European Standard Methods (ESM).

Only 65%-80% of clinker is required to produce PCC while 95% of clinker is required to produce OPC.

Engineering Specification for Rotary Kiln