Eulogio “Amang” Rodriguez Institute of Science and Technology
College of Engineering
Nagtahan, Sampaloc Manila
STEEL STRUCTURES IN
CEMENT PLANT PROCESS
FLOW
LEADER: Eugenio, Alejandro D.
Members:
Arguelles, Glezy G. Parane, Jose Jr. C.
Austral, Earah Sofia V. Patalita, Bernie G.
Barde, Jean Camille B. Pascual, Aljhun A.
Bautista, Edwin V. Reyna, Christian Dave
Castaneda, Aaron James P. Santos, Ma. Angela C.
Espiritu, Kim Bernard C. Sayago, Juliet O.
Legada, Rigor Louise M.
CEMENT PLANT PROCESS FLOW REQUIREMENTS
GENERAL REQUIREMENTS:
- Factory should be located as far as possible on limestone deposits
- Load Bearing Capacity of Soil
- Seismic Zone of the Location
- Wind Directions and Velocity at different Height
CIVIL ENGINEERING DESIGNS AND CONSTRUCTIONS:
- Development Plant
- Planning and Layout of Roads
- Drainage of Plant and Colony
- Periodically Laying of Refactory in Kiln
- Design and Installation of Main Water Supply Scheme, Underground and Overhead
Water Tank and Water Pipes.
- Non-Factory Building, Admin Office and Colony Factory Building and Machinery
Foundations.
- Single Mills (400 Tons per Hour)
- Pre-heater Tower (Tallest Structure)
o Chimneys
4 - 6 Stages (80 – 90 meters)
- Storages Silos
o 15,000 – 20,000 Tons Capacity
o 16 – 20 meters Diameters
- Clinker
o 60 – 80 meters Diameter
PARAMETERS NEEDED FOR CIVIL DESIGNS:
- Dimensions of Buildings
- Locations of Machinery
- Sizes and Spaced occupied by Machinery
o Floor Plans, Front, Rear and Sides Elevations
- Dead Loads and Dynamic Loads
- Expansion Tolerance
- Entry and Discharge Points
- Layout of Ducts in the Departments with their Dimensions and Orientations.
- Opening in Floor Sized and Locations
- Access Flatform to be Provided
- Staircases and Ladders and Landings for Access between Floors
- Locations for Lifts when Provided
- Walkways for Inspections and Corresponding Lappers and Flatforms
BUILDING DESIGN:
- Column spacing has a direct Influence on non-depths of beams
- Depths of Beams and Sizes of Columns Determine clear space for Machinery
- Different Floor have their own Network of Secondary beams to support the
Machinery Transferred to main beams.
VERTICAL MILLS
- Dead Weight
- Vibrates
MATERIAL HANDLING:
- Conveying Crush and Uncrushed Limestone
- Transport of Clinkers from Mills
- Adequate Lengths for Conveyors Belts
o Mechanical Conveying to Pneumatic Conveying to save Power
STORAGES
- Blending Materials
- Oil / Diesel / Coal
- Clinker
- Circular Silos (60m – 80m Diameter)
LOCATION OF CRUSHING PLANT
- Quarries are close
o Crushing Place are Inside the Main Plant
- Stone Brought in by Dumpers
o Plant would have to have a long ramp for reaching a suitable height for
unloading run off mine stone in the crusher hopper
INCOME POWER PLANT
WATER SUPPLY
- Plant required water for:
o Cooling of Machines
o Treating exhaust gases
o Consumption as Drinking Water
CONTOURS
- Should be used to advantages in locating the various sections of the Plant
DRAINAGE
- Poor drainage can cause flooding
DEVELOPING THE LAYOUTS
- Site and Infrastructural Conditions.
- Contour Map
- Wind Velocity
- Geological Surveys
- Power Line Routes
- Locations of Substations
- Location of River / Streams / Reservoir
- State Roads and Highways
ROADS
- Is good to provide for a “Ring Road”
- Main road from the Main Entrance Should be a Two-way Four Lane
PARKING AND GARAGES
- Company’s and Owners
- Vans
- Cars etc.
- Dump, Backhoe etc.
- Provide Service Station for Petrol and Diesel and For Garages for Routine Service
Stations.
SERVICE BUILDINGS
- Factory Buildings
- Production Department
- Sectional Laboratories
- Engineering and Design Offices
- Office for executives
o Administrative Office
o Stores
o Workshops
NAME PLATE SHOULD SHOW
- Name of the Project
- Name of the Company
- Size / Capacity of the Plant
CEMENT PLANT PROCESS FLOWS
PHASE 1: RAW MATERIALS EXTRACTION
CEMENT USES RAW MATERIALS SUCH AS LIMESTONE, CLAY AND SAND. GENERALLY,
CEMENT PLANT ARE FIXED WHERE THE QUARRY IS NEAR BYE TO SAVES THE EXTRA FUEL
COST AND MAKES CEMENT SOMEHOW ECONOMICAL.
BEFORE TRANSPORTATION OF RAW MATERIALS TO THE CEMENT PLANT, LARGE SIZE OF
ROCKS ARE CRUSHED INTO SMALLER SIZE WITH THE HELP OF PRIMARY AND SECONDARY
CRUSHER
PRIMARY CRUSHER – ROUGH LIMESTONE INTO 5 – 8 INCHES
PRIMARY CRUSHER – FINE LIMESTONE INTO ¾ - 1 INCH.
PHASE 2: PROPORTIONING, BLENDING AND GRINDING
THE RAW MATERIALS WHERE ANALYZED AND PROPER PROPORTIONING OF LIMESTONE
AND CLAY BEFORE GRINDING. GENERALLY, LIMESTONE IS 80% AND CLAY IS 20%.
THEY GRIND THE RAW MIX WITH THE HELP OF HEAVY WHEEL TYPE ROLLERS AND ROTATING
TABLE. ROTATING TABLE RORATES CONTINUOUSLY UNDER THE ROLLER AND BROUGHT THE
RAW MIX IN CONTACT WITH THE ROLLER. ROLLER CRUSHES THE MATERIALS TO A FINE
POWDER AND FINISHES THE JOB.
PHASE 3: PRE-HEATING RAW MATERIALS
AFTER GRINDING, THE RAW MATERIALS IS READY TO FACE THE PRE-HEATING CHAMBER.
PRE-HEATER CHAMBER CONSIST OF SERIES OF VERTICAL CYCLONE FROM WHERE THE RAW
MATERIALS PASSES BEFORE FACING THE KILN. PRE-HEATING OF THE MATERIALS SAVES THE
ENERGY AND MAKE PLANT ENVIRONMENTAL FRIENDLY.
PHASE 4: KILN PHASE
KILN IS A HUGE ROTATING FURNACE CALLED THE HEART OF CEMENT MAKING PROCESS.
THE RAW MATERIAL IS HEATED UP TO 1450 CELCIUS THIS TEMPERATURE BEGINS A
CHEMICAL REACTION CALLED DECARBONATION
PHASE 5: COOLING AND FINAL GRINDING
AFTER PASSING OUT FROM THE KILN, CLINKERS ARE COOLED BY MEAN OF FORCED AIR.
CLINKER RELEASED THE ABSORB HEAT AND COOL DOWN TO LOWER TEMPERATURE.
RELEASED HEAR BY CLINKER IS REUSED BY CIRCULATING IT BACK TO THE KILN TO SAVES
ENERGY.
THE STEEL BALLS TUMBLE AND CRUSH THE CLINKER INTO VERY FINE POWDER. THIS FINE
POWDER IS CONSIDRED AS CAMENT. DURING THE FINAL GRINDING GYPSUM IS ALSO
ADDED TO THE MIX IN SMALL PERCENTAGE THAT CONTROL THE SETTING OF CEMENT.
PHASE 6: PACKING AND SHIPPING
MATERIALS IS DIRECTLY CONVEYED TO THE SILOS FROM THE GRINDING MILL. SILOS ARE
THE LARGE STORAGE TANKS OF CEMENT IT IS PACKED TO ABOUT 20-40kb BAGS. THE
REMAINING CEMENT IS SHIPPED IN BULK QUANTITIESBY MEAN OF TRUCK, RAILES OR SHIPS.
MACHINES NEEDED:
- Primary Crusher
- Secondary Crusher
- Storages Silos
- Vertical Roller Mills
- Dust Collector
- Pneumatic Pump
- Dry Mixing and Blending Silos
- Ground Raw Materials Storages Silos
- Rotary Kiln (4 Stages)
- Clinker Cooler (Coal, Oil or Gas Fuel)
- Storages Silos for Clinkers and Gypsum Proportioning
- Final Grinding Mills
- Dust Collector
- Cement Pumps
- Bulk Storage (Cement)
- Bulk Truck, Car or Box Car