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Chemical Engineering Process in Cement Production

المعهد الأمريكي للمهندسين الكيمياْْئين. American Institute of Chemical Engineers. فرع المملكةالعربيةالسعودية. Saudi Arabian Section. Chemical Engineering Process in Cement Production. Presented to: SAUDI ARABIAN SECTION OF AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE)

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Chemical Engineering Process in Cement Production

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  1. المعهد الأمريكي للمهندسين الكيمياْْئين American Institute of Chemical Engineers فرع المملكةالعربيةالسعودية Saudi Arabian Section Chemical Engineering Process in Cement Production Presented to: SAUDI ARABIAN SECTION OF AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE) on Sunday, December 27, 2009 at Le Meridien Hotel, Al-Khobar By: Eastern Cement Team: Eng. Ali S. Al-Qahtani Eng. Sayd Basheer Shafee Eng. Haridas Nair

  2. Who Are we? Our Head Office - Khobar • Our Plant is located at Khrsanih • Three production line of 3.5 mty cement • Joint Stock company listed in Tadawul • 700 employees

  3. Saudi Cement Industry Economic Contributions

  4. Why are we here? • Inform the Chemical Engineering Community about Cement Industry. • Attract Chemical Engineers to start and build carriers in Cement industry. • Attract Local Chemical Engineering Research in Cement Process.

  5. Glue …….. for construction Cement Our Business We Produce and Sell ……..

  6. Cement is….. • HydraulicBinder Solidify and gain compressive strength after mixing with water • It binds gravel and sand to form Artificial Rock Sold Material Concrete

  7. 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. Ancient construction Technologies Cement & Concrete technologies However Non can compete with cement and concrete materials for practicality and economic feasibility of production and construction

  8. Material handling Systems Material handling Systems Pyroprocessing (Chemical Reactions) Raw Material Grinding Systems Cement Production Process Cement Grinding Systems

  9. Cement is Very Old Material…. Basic Research and inventions Time Line Cement Standard by Wilhelm Michaelis Invention of chemical Engineering process by Isaac Johnson Invention of Portland Cement by Joseph Aspedin Research by Louis Vicat on Hydraulic Binders 1875 1838 1812 1824

  10. Cement Production Technologies • Control and instrumentation • Gears and bearings • Cooling and heat transfer • Material handling systems • Cyclone and filters Short Rotary Kilns and Preheater Technology Long Rotary Kilns Vertical Kilns Rotary Kilns 1930’s 1830’s 1885 1970’s 2000’s

  11. PyroprocessingSystem Preheater Rotary Kiln Cooler

  12. Preheater • What is happning at the Preheater? • Raw material separation and suspension for heat absorption. • Moisture Removal • Decomposition of CaCO3, MgCO3, formation of CA, • C2F and C3S begins. • Formation of C12A7

  13. Rotary Kiln • Formation of C3A and C4AF begins, decomposition of • CaCO3 completed, free lime reaches maximum • Formation of C2S reaches maximum, • C3A and C4AF formation completed • Formation of liquid phase • Formation of C3S, gradual decrease of free lime content.

  14. Clinker MINERALOGICAL COMPOSITION OF CLINKER • Tricalcium silicate (C3S) or alite, dicalcium silicate (C2S) or belite, tricalcium aluminate (C3A) and tetracalcium aluminoferrite (C4AF) are the main clinker constituents

  15. Cooler Cooler

  16. Final Chemical Process Material handling Systems Material handling Systems Pyroprocessing (Chemical Reactions) Cement Grinding Systems Raw Material Grinding Systems Addition of Gypsum CaSO4.2H2O to control the setting time of cement

  17. Cement Chemical Composition

  18. Thank You For Your Attention

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