8/4/2019 Chemical Engineering Process in Cement Production

1/18

Chemical Engineering Process

in Cement Production

By:Eastern Cement Team:

Eng. Ali S. Al-Qahtani

Eng. Sayd Basheer Shafee

Eng. Haridas Nair

Presented to:

SAUDI ARABIAN SECTION OF AMERICANINSTITUTE OF CHEMICAL ENGINEERS

(SAS-AIChE)on Sunday, December 27, 2009at Le Meridien Hotel, Al-Khobar

8/4/2019 Chemical Engineering Process in Cement Production

2/18

Who Are we?

Our HeadOffice -

Khobar

Our Plant is located at Khrsanih

Three production line of 3.5 mtycement

Joint Stock company listed inTadawul

700 employees

8/4/2019 Chemical Engineering Process in Cement Production

3/18

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 Contributions

8/4/2019 Chemical Engineering Process in Cement Production

4/18

Why are we here?

Inform the Chemical EngineeringCommunity about Cement Industry.

Attract Chemical Engineers to start andbuild carriers in Cement industry.

Attract Local Chemical EngineeringResearch in Cement Process.

8/4/2019 Chemical Engineering Process in Cement Production

5/18

Our Business

We Produce and Sell ..

Glue ..

for construction

Cement

8/4/2019 Chemical Engineering Process in Cement Production

6/18

Cement is..

HydraulicBinderSolidify and gain compressive

strength after mixing withwater

It binds gravel and sandto form Artificial RockSold Material

Concrete

8/4/2019 Chemical Engineering Process in Cement Production

7/18

Limestone

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

8/4/2019 Chemical Engineering Process in Cement Production

8/18

Cement Production Process

Cement

GrindingSystemsPyroprocessing(Chemical Reactions)

MaterialhandlingSystems

MaterialhandlingSystems

Raw Material

GrindingSystems

8/4/2019 Chemical Engineering Process in Cement Production

9/18

Cement is Very Old Material.

1812

Research byLouis Vicaton

Hydraulic Binders

1824

Invention ofPortland Cement

by Joseph Aspedin

1838

Invention of chemicalEngineering process

by Isaac Johnson

1875

CementStandard by

WilhelmMichaelis

Basic Research and inventions Time Line

8/4/2019 Chemical Engineering Process in Cement Production

10/18

Cement Production Technologies

1830s

Vertical Kilns

1885

Rotary Kilns

1930s

Long Rotary Kilns

1970s

Short Rotary Kilns and

Preheater Technology

2000s

Control and instrumentation

Gears and bearings

Cooling and heat transfer

Material handling systems

Cyclone and filters

8/4/2019 Chemical Engineering Process in Cement Production

11/18

PyroprocessingSystem

Preheater

Rotary KilnCooler

8/4/2019 Chemical Engineering Process in Cement Production

12/18

Preheater

What is happning at thePreheater?

Raw material separationand suspension for heat

absorption.Moisture Removal

Decomposition of CaCO3,MgCO3, formation of CA,C2F and C3S begins.

Formation of C12A7

8/4/2019 Chemical Engineering Process in Cement Production

13/18

Rotary Kiln

Formation of C3A and C4AF begins, decomposition ofCaCO3 completed, free lime reaches maximum

Formation of C2S reaches maximum,C3A and C4AF formation completed

Formation of liquid phase

Formation of C3S, gradual decreaseof free lime content.

8/4/2019 Chemical Engineering Process in Cement Production

14/18

Clinker

Tricalcium silicate (C3S) oralite, dicalcium silicate (C2S)

or belite, tricalcium aluminate(C3A) and tetracalciumaluminoferrite (C4AF) are themain clinker constituents

MINERALOGICAL COMPOSITION OF CLINKER

8/4/2019 Chemical Engineering Process in Cement Production

15/18

Cooler

Cooler

8/4/2019 Chemical Engineering Process in Cement Production

16/18

Final Chemical Process

Addition of GypsumCaSO4.2H2Oto control the setting time of

cement

Raw Material

GrindingSystems

Cement

GrindingSystems

Pyroprocessing(Chemical Reactions)

MaterialhandlingSystems

MaterialhandlingSystems

8/4/2019 Chemical Engineering Process in Cement Production

17/18

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 or4CaO.Al2O3

.Fe2O3

Gypsum 5 % CaSO4.2H2O

8/4/2019 Chemical Engineering Process in Cement Production

18/18