Cement Process Overview

The Siam Cement Industry Co.,Ltd.

Cement Manufacturing Process

Raw
Raw Material
Material Preparation
Preparation
Raw
Raw Material
Material Grinding
Grinding
Burning
Burning Process
Process
Cement
Cement Grinding
Grinding
Cement
Cement Storage
Storage&&Dispatching
Dispatching
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The Siam Cement Industry Co.,Ltd.

Cement Manufacturing Process

O
O
O
O
O

Raw Material Preparation

Raw Material Grinding
Burning Process
Cement Grinding
Cement Storage & Dispatching

The Siam Cement Industry Co.,Ltd.

Raw Material Preparation

Purpose
O To reduce the size of material by crushing.
O To reduce the quality variation by preblending.

The Siam Cement Industry Co.,Ltd.

Raw Material Preparation

X
X
X
X

Raw Material
Quarrying
Crushing
Pre-blending

The Siam Cement Industry Co.,Ltd.

Raw Materials for Cement Industry

Calcareous (CaCO3)
O Argillaceous (SiO2,Al2O3)
O Corrective materials
O Additive materials
O

The Siam Cement Industry Co.,Ltd.

Raw Material
X Four major chemical components in OPC
(CaO)
59-67 %
O Calcium oxide
(SiO2)
14-26 %
O Silica oxide
(Al2O3)
4-8 %
O Alumina oxide
(Fe2O3)
2-5 %
O Iron oxide

The Siam Cement Industry Co.,Ltd.

Quarrying
O
O
O
O

Removing overburden
Drilling
Blasting
Excavating and Hauling

The Siam Cement Industry Co.,Ltd.

Quarrying

The Siam Cement Industry Co.,Ltd.

Quarrying

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The Siam Cement Industry Co.,Ltd.

Quarrying

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The Siam Cement Industry Co.,Ltd.

Quarrying

12

The Siam Cement Industry Co.,Ltd.

Crushing
X Four principles of material breakage
O
O
O
O

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Impact
Attrition
Shearing
Compression

The Siam Cement Industry Co.,Ltd.

Type of Crusher
X Main types of crushers for ordinary use in
cement plant
O Swing hammer mill
O Blow bar impactors
O Jaw crushers
O Cone crusher

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The Siam Cement Industry Co.,Ltd.

Type of Crusher
O
O
O

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Roller jaw crushers

Roller crushers
Cutting rollers

The Siam Cement Industry Co.,Ltd.

Hammer Crusher with Grate Bar

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The Siam Cement Industry Co.,Ltd.

Pre - blending
Stacking Methods
O Longitudinal stores
- Chevron method
- Windrow method
O Circular stores

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The Siam Cement Industry Co.,Ltd.

Pre - blending
Reclaiming Methods
O Bridge scraper
O Side scraper
etc.

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The Siam Cement Industry Co.,Ltd.

Stacking Method

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The Siam Cement Industry Co.,Ltd.

Reclaiming Method

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The Siam Cement Industry Co.,Ltd.

Raw Material Grinding

Purpose
X To produce a homogenous raw meal
which can give good burning conditions
in the kiln , in sufficient quantity.

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The Siam Cement Industry Co.,Ltd.

Raw Material Grinding

X Type
O
O
O

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of mill
Tube mill
Vertical mill
Roller press

The Siam Cement Industry Co.,Ltd.

Vertical Roller Mill

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The Siam Cement Industry Co.,Ltd.

Vertical Roller Mill

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The Siam Cement Industry Co.,Ltd.

Burning Process
Purpose
X To convert raw meal into clinker which
is a chemical process that take places at
temperature up to 1450 o C

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The Siam Cement Industry Co.,Ltd.

Burning Process
Type of reaction and temperature development
X

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Heating up
oC
O 20-100
o
O 100-300 C
oC
O >500

Evaporation of free water

Loss of physical adsorbed water
Structural changes in silicate minerals

The Siam Cement Industry Co.,Ltd.

Burning Process
O
O
O

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600-900 o C
>1250 o C
~1450 o C

Cooling
oC
O 1300-1240

CaCO3
CaO+CO2
Formation of liquid phase
Completion of reaction
Crystallization of liquid phase

The Siam Cement Industry Co.,Ltd.

Burning Process
O
O
O
O

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Raw meal
Tricalcium silicate
Dicalcium silicate
Tricalcium aluminate
Tetracalcium aluminoferite

Clinker
( C3S )
( C2S )
( C3A )
(C4AF )

The Siam Cement Industry Co.,Ltd.

Burning Process

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The Siam Cement Industry Co.,Ltd.

Burning Process
O

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Type of Process
- Wet process
- Semi wet process
- Semi Dry process
- Dry process

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Burning Process
O

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Type of Kiln
- Long kiln
- Suspension pre-heater kiln
- Pre-calciner kiln

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Kiln

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The Siam Cement Industry Co.,Ltd.

Burning Process
O

33

Type of Cooler
- Rotary cooler
- Planetary cooler
- Grate cooler

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Cooler

34

The Siam Cement Industry Co.,Ltd.

Fuel in Burning Process

O
O
O
O
O

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Heavy fuel oil

Lignite / Coal
Petroleum coke
Natural gas
Secondary fuel (Used
oil/tyre,Industrial waste)

The Siam Cement Industry Co.,Ltd.

Cement Grinding
Purpose
O To grind the clinker from the kiln ,
approximately mixed with 4-5 %
gypsum and other possible additive
material , into the final product ,
cement.

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The Siam Cement Industry Co.,Ltd.

Cement Grinding
Grinding system
O

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Tube mill
- Opened circuit
- Closed circuit
Tube mill with pre-grinding unit
- Roller press
- Vertical shaft impact crusher
- Vertical roller mill

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The Siam Cement Industry Co.,Ltd.

Cement Grinding
O

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Finish grinding system

- Roller press
- Vertical roller mill

The Siam Cement Industry Co.,Ltd.

Cement Grinding

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The Siam Cement Industry Co.,Ltd.

Cement Grinding
Type of cement
O Portland cement
O Mixed cement
Possible additive for mixed cement :
fly ash , pozzolana , blast furnace slag ,
limestone etc.

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The Siam Cement Industry Co.,Ltd.

Cement Storage & Dispatching

Purpose
O To store and separate different type of
cement and prepare for dispatching in
bulk or bag.

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The Siam Cement Industry Co.,Ltd.

Cement Storage & Dispatching

O

Dispatch in Bag
- Bag / Big Bag

- Palletizer
O

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Bulk loading

The Siam Cement Industry Co.,Ltd.

Cement Storage & Dispatching

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The Siam Cement Industry Co.,Ltd.

Cement Storage & Dispatching

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The Siam Cement Industry Co.,Ltd.

THE END

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The Siam Cement Industry Co.,Ltd.