5. Process Overview Mining & Crushing Raw Mill Grinding Raw Meal Homogenization Pyro Processing Clinkerization Final Grinding Packaging Crushed Limestone Additives i.e. Iron ore or Clay Coal Ash From Coal Fired Fine Raw Meal (120)Res. < 3% Lt. wt 1200-1350 Clinker 1) Gypsum 2) Flyash 3) Pozzolona 4) Slag 1) OPC 2) PPC 3) Slag Cement Blaine 300-350 m 2 /kg OR (45) Res. <16% Cement
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49. Clinkerization Overview Raw Meal Preheating Removal of Water Calcination Oxide Formation Belite formation Liquid & Phase formation CaO SiO2 Fe2O3 Al2O3 CaCO3 -> CaO + CO2 CaO + SiO2 -> CaO.SiO2 CaO.SiO2 + CaO -> (CaO)2.SiO2 (CaO)2.SiO2 + CaO -> (CaO)3.SiO2 (CaO)3.(Al2O3) ----- C3A (CaO)4.(Al2O3).Fe2O3--- C4AF Clinker Kiln Preheater Raw Meal 30 o C to 100 o C 100 o C to 300 o C 30 o C to 900 o C above 800 o C Above 1200 o C Cooling 1350 o C to 1250 o C Crystalization