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

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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

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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

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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

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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

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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

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

Management

17. Statistics

221

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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
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