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FGD Gypsum Use in CementFGD Gypsum Use in Cement
Worldwide Cement ProductionWorldwide Cement Production
#1#1 ChinaChina#2#2 IndiaIndia#3#3 United StatesUnited States
US Cement IndustryUS Cement Industry
39 Companies39 Companies118 Cement Plants118 Cement Plants38 States38 States105 MM Metric Tons Consumed105 MM Metric Tons Consumed25 MM Metric Tons Imported25 MM Metric Tons Imported
US Cement IndustryUS Cement Industry
Announced Expansions:Announced Expansions:
–– 20072007 2,430M metric tons2,430M metric tons
–– 20082008 7,400M Metric tons7,400M Metric tons
–– 20092009 2,550M Metric tons2,550M Metric tons
Cement Clinker ChemistryCement Clinker Chemistry
(CaO)(CaO)33..SiOSiO22 and (CaO)and (CaO)22
..SiOSiO22
AlAl22OO33
FeFe22OO33
Raw Feed Components for Raw Feed Components for Cement PlantCement Plant
Calcareous Materials (providing Lime CaO)Calcareous Materials (providing Lime CaO)–– LimestoneLimestone–– Lime Mud (paper industry)Lime Mud (paper industry)
Argillaceous Materials (SiOArgillaceous Materials (SiO22 AlAl22OO33 and Feand Fe22OO33))–– SandSand–– Fly ash (power generation)Fly ash (power generation)–– Bottom ash (power generation)Bottom ash (power generation)–– Iron fines (steel industry)Iron fines (steel industry)–– Sand Blasting Waste (ship building industry)Sand Blasting Waste (ship building industry)–– Spent Catalyst (oil refining)Spent Catalyst (oil refining)
Preheater Precalciner Kiln
•There are five jobs to be done•Drying•Preheating•Calcining•Sintering•Cooling
Dry Process Preheater/Precalciner System
60%Fuel Split
40%
Rotary KilnRotary Kiln
Hot Hot ““ClinkerClinker”” Inside KilnInside Kiln
cement mill
clin
ker
gyps
umgy
psum
addi
tive
Separator
Fines
Finish Grinding Circuit
Rejects
Finish Grinding Mills (Cement Mill)Finish Grinding Mills (Cement Mill)
Ball MillBall MillFirst CompartmentUsed to crush clinker.
Second CompartmentUsed to grind clinker.
GypsumGypsum
Gypsum Added to Control SettingGypsum Added to Control SettingSet Time Increases as Gyp IncreasesSet Time Increases as Gyp IncreasesVarious Cement and Masonry Products Various Cement and Masonry Products Have a Range of SOHave a Range of SO33 ContentContentSOSO33 at 3.5% is a Typical Valueat 3.5% is a Typical Value
GypsumGypsum
““a product composed essentially of a product composed essentially of calcium sulfate in any hydration statecalcium sulfate in any hydration state…”…”CaSOCaSO44
..2H2H22OOCaSOCaSO44
. . ½½HH22OOCaSOCaSO44
Gypsum HandlingGypsum Handling
Natural Gypsum Generally Handles EasilyNatural Gypsum Generally Handles Easily
FGD Gypsum Generally More DifficultFGD Gypsum Generally More Difficult–– Slurry to Filter CakeSlurry to Filter Cake–– MoistureMoisture–– StickySticky
Gypsum HandlingGypsum Handling
Avoid Bucket ElevatorsAvoid Bucket ElevatorsMass Flow Cone Silo BottomsMass Flow Cone Silo BottomsMaterials of ConstructionMaterials of ConstructionReclaim Auger AssembliesReclaim Auger AssembliesReclaim Arm Assemblies Reclaim Arm Assemblies
Marine SilosMarine Silos
Cement BargeCement Barge
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