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Cement Plant Operations Handbook, 5th Edition, Preview

The document is a handbook on cement plant operations containing 17 chapters that cover various aspects of cement production processes and plant management. The chapters discuss topics such as raw materials handling and preparation, kiln burning and cooling processes, cement milling, quality control, maintenance, environmental management, and accounting. It also includes sections with process calculations and technical reference data. The handbook provides a comprehensive guide for cement plant personnel on process operations, process optimization, and plant management.

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emad sabri
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806 views3 pages

Cement Plant Operations Handbook, 5th Edition, Preview

The document is a handbook on cement plant operations containing 17 chapters that cover various aspects of cement production processes and plant management. The chapters discuss topics such as raw materials handling and preparation, kiln burning and cooling processes, cement milling, quality control, maintenance, environmental management, and accounting. It also includes sections with process calculations and technical reference data. The handbook provides a comprehensive guide for cement plant personnel on process operations, process optimization, and plant management.

Uploaded by

emad sabri
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Cement Plant Operations Handbook

5th Edition

Contents
Process Summaries
20

2. Raw Materials

23

1. Introduction

PL

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

SA
M

1. Kiln Burning 2. Control Systems 3. Kiln Control 4. Kiln


Start-up and Shut-down 5. Kiln Refractories 6. Insufation
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
Specications 17. European EN 197 Cement Specication
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

15

Cement Plant Operations Handbook


5th Edition

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

131

PL

9. Combustion and Heat Transfer Processes

1. Dust Collection 2. Pollution Control 3. ISO14000


4. Sustainable Development and Climate Change

1. Chemistry of Combustion 2. Fuels 3. Physics of


Combustion 4. Burner Design 5. Heat Transfer 6. Pollution
Control

155

11. Other Kiln Types

159

SA
M

10. Hydration of Portland Cement

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. Denitions 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 Justication 3. Capacity


Increase by Process Change 4. Project Cost Estimation
5. Financial Statements

14. Technical and Process Audits

187

1. Kiln Specic Fuel Consumption 2. Cement Mill Specic


Power Consumption 3. Other Systems 4. De-bottlenecking
5. Project Audit 6. Risk Assessment

16

Cement Plant Operations Handbook


5th Edition

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

PL

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


Management

17. Statistics

221

SA
M

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
17

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