Chemical Engineering Process in Cement Production By: Eastern Cement Team: Eng. Ali S. Al-Qahtani...
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Transcript of Chemical Engineering Process in Cement Production By: Eastern Cement Team: Eng. Ali S. Al-Qahtani...
Chemical Engineering Process Chemical Engineering Process in Cement Productionin Cement Production
Chemical Engineering Process Chemical Engineering Process in Cement Productionin Cement Production
By:
Eastern Cement Team:
Eng. Ali S. Al-Qahtani
Eng. Sayd Basheer Shafee
Eng. Haridas Nair
By:
Eastern Cement Team:
Eng. Ali S. Al-Qahtani
Eng. Sayd Basheer Shafee
Eng. Haridas Nair
Presented to:SAUDI ARABIAN SECTION OF AMERICAN
INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE)
on Sunday, December 27, 2009at Le Meridien Hotel, Al-Khobar
Presented to:SAUDI ARABIAN SECTION OF AMERICAN
INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE)
on Sunday, December 27, 2009at Le Meridien Hotel, Al-Khobar
Who Are we?
Our Head Office - Khobar
• Our Plant is located at Khrsanih
•Three production line of 3.5 mty cement
•Joint Stock company listed in Tadawul
• 700 employees
Saudi Cement Industry
2.46
3.374
2.78
0
0.5
1
1.5
2
2.5
3
3.5
4
2006 2007 2008
DistributedDividend (SRbillions)
Economic ContributionsEconomic Contributions
Why are we here?
• Inform the Chemical Engineering Community about Cement Industry.
• Attract Chemical Engineers to start and build carriers in Cement industry.
• Attract Local Chemical Engineering Research in Cement Process.
Our Business
We Produce and Sell ……..We Produce and Sell ……..
Glue ……..Glue ……..forfor construction construction
CementCement
Cement is…..• HydraulicHydraulic BinderBinder
Solidify and gain compressive strength after mixing with Solidify and gain compressive strength after mixing with waterwater
• It binds gravel and sand to form Artificial It binds gravel and sand to form Artificial Rock Sold Material Rock Sold Material
ConcreteConcrete
Limestone
Cement & Concrete technologies
Cement & Concrete technologies
There have been huge developments in the innovation and production of new binder materials in the last 10 years especially in the Epoxy chemicals.
HoweverNon can compete with cement and concrete materials for practicality and economic feasibility of production and construction
Ancient construction Technologies
Ancient construction Technologies
Cement Production Process
Cement Grinding Systems
Pyroprocessing(Chemical Reactions)
Material handling Systems
Material handling Systems
Raw Material GrindingSystems
Cement is Very Old Material….
1812
Research by Louis Vicat on Hydraulic Binders
1824
Invention of Portland Cement by Joseph Aspedin
1838
Invention of chemical Engineering process by Isaac Johnson
1875
Cement Standard by Wilhelm Michaelis
Basic Research and inventions Time Line
Cement Production Technologies
1830’s
Vertical Kilns
1885
Rotary Kilns
1930’s
Long Rotary Kilns
1970’s
Short Rotary Kilns and Preheater Technology
2000’s
• Control and instrumentation
• Gears and bearings
•Cooling and heat transfer
•Material handling systems
•Cyclone and filters
Preheater
What is happning at the Preheater?
• Raw material separation and suspension for heat absorption.
•Moisture Removal
•Decomposition of CaCO3, Decomposition of CaCO3, MgCO3, formation of CA, MgCO3, formation of CA, C2F and C3S begins.C2F and C3S begins.
Formation of CFormation of C1212AA77
Rotary Kiln
•Formation of C3A and C4AF begins, decomposition ofFormation of C3A and C4AF begins, decomposition of CaCO3 completed, free lime reaches maximumCaCO3 completed, free lime reaches maximum
•Formation of C2S reaches maximum, Formation of C2S reaches maximum, C3A and C4AF formation completedC3A and C4AF formation completed
•Formation of liquid phaseFormation of liquid phase
Formation of C3S, gradual decrease Formation of C3S, gradual decrease of free lime content. of free lime content.
Clinker
•Tricalcium silicate (C3S) or Tricalcium silicate (C3S) or alite, dicalcium silicate (C2S) alite, dicalcium silicate (C2S) or belite, tricalcium aluminate or belite, tricalcium aluminate (C3A) and tetracalcium (C3A) and tetracalcium aluminoferrite (C4AF) are the aluminoferrite (C4AF) are the main clinker constituents main clinker constituents
MINERALOGICAL COMPOSITION OF CLINKER
Final Chemical Process
Addition of GypsumCaSO4.2H2O to control the setting time of cement
Raw Material GrindingSystems
Cement Grinding Systems
Pyroprocessing(Chemical Reactions)
Material handling Systems
Material handling Systems
Cement Chemical Composition
Cement CompoundWeightPercentage
Chemical Formula
Tricalcium silicate 50 % Ca3SiO5 or 3CaO.SiO2
Dicalcium silicate 25 % Ca2SiO4 or 2CaO.SiO2
Tricalcium aluminate 10 % Ca3Al2O6 or 3CaO .Al2O3
Tetracalciumaluminoferrite
10 % Ca4Al2Fe2O10 or
4CaO.Al2O3.Fe2O3
Gypsum 5 % CaSO4.2H2O