Cement Plant Oil & Filtrartion Brochure

KLEENOIL FOR CEMENT INDUSTRY PAKISTAN

Winstar Pvt. Ltd

Manager Business Development

Written by Faisal Ali Shaikh

Pakistan

[email protected]

+92-42-35294861- 3

DYNAMICS OF KLEENOIL TO PROTECT & ENHANCE ADDITIVE OIL PROPERTIES FROM DEPLETION

AT DIFFERENT OIL APPLICATIONS

www.kleenoilpanolin.com

Kleenoil Microfiltration is originally based in Germany, as it was introduced in Europe last 25 years back having more than ten thousand customers. It had also established business in Turkey, Egypt, Far East and Pakistan. Kleenoil Microfiltration produces their own kind of unique filters which can filter upto one micron with moisture removal upto 150 ppm through their simple but versatile, effective Rigs, by-passes applicable on engines, compressors, hydraulics, gear boxes, oil storage sumps/ machines which are not in use. Kleenoil Panolin AG possesses those technologies which can make this difference other than their unbelievable oil range having ten to fourteen years of oil drain interval. The concept behind this technology is to mainly enhance the life of your valuable machineries by thoroughly cleaning the oil as per recommended filtration intervals or continuously through by-pass, so at the end we get fresh oil due to initial extraction of moisture to prevent acid formation and solid contamination removal prevents catalytic reaction, wear tare of parts 60~70% resulting in less downtime, less friction resulting in less power consumption 4~6%, enhancing of oil life around 3 spans or more and finally we achieve greater life of our machines with more production. In cement plant, Kleenoil equipment has its own uniqueness, at one region if it is enhancing the oil life, while on the other region it would be working to give higher production with lower break downs. Simultaneously in third region it would be running to enhance mill bearings and rollers life. All Cement Plants have huge oil consumption both in plant as well as on fleet, it’s how we introduce different equipments at different locations with best application, utility and cost investment in comparison with material and plant life extension.

A project to enhance mineral oil life to minimum double operating hours & lubricating parts life 15% extra...

http://www.kleenoilpanolin.com/

Kiln, Cooler & Cement Mill

(Vertical / Horizantal

Crusher& Coal Mill

(V/H)

Crusher & Raw Mill

(Vertical / Horizontal)

AVERAGE 2- 3 OIL LIFE EXTENSION GRINDING MILL CAN BE SMALL, MEDIUM, LARGE SIZES

(ON BOTH GEAR & HYDRAULICS) (VERTICAL – HORIZONTAL TYPE SET-UP)

KLEENOIL HYD MODEL RIGS UPTO 200 cST. OILS KLEENOIL GEAR RIG CAN BE USED AT

KLEENOIL GEAR MODEL RIGS UPTO 1000 cST. OILS ALL LOCATIONS

With Kleenoil microfiltration oil life can be extended 3 times &

oil only has to be changed when additive depletion occurs as per

periodical lab testing.

New oil always has some contamination

Without microfiltration oil has to be changed when saturation level is reached despite sufficient amount of additive presence.

Saturation

Contimination

3S-700 EDPH-C

4S-700 EDPH-C

CWF 400-1

KLEENOIL APPLICATION ON IMPACT CRUSHER:

Cement plant processing line starts from crusher which is made in different forms to crush limestone, Gipson, clay. For Gipson and clay, belt drive crushers are used in which there is no oil consumption but for line stone we use crushers like impact crusher model which has gear and hydraulic oil consumption. In Chinese model due to bearing failure, there is more oil consumption as compare to

Main gear box: 320 cSt. mineral oil - 250 Ltrs. x Average 8000 hrs oil life Hydraulic system: 46 cSt. mineral oil - 200 Ltrs. x Average 16000 hrs oil life

Av. Production =

160 -1600 tph

Hydraulic oil 46 cSt. Hydraulic oil 46 cSt.

FLS (IMPACT CRUSHER)

Coal Mining Machine & Coal Crusher Machine

To increase efficiency we crush coal into powder. The coal is transported into coal jaw crusher, coal impact crusher, coal

cone crusher for the primary crusher by belt conveyor. After

first coal crushing process, the coal stone less than 2 inch will be transported into coal grinding mill or coal ball mill for

grinding. The coal above 2 inch will be vibrating and recovery for the second crusher process. The processing will be going

on until the coal stone below 2 inch.

For engine oil, hydraulic oil sump, Kleenoil HDU & SDU-M8 are desired to be installed for increasing oil life with less

down time and greater production efficiency due to active hydraulic movement.

Main Gear oil

320 cSt.

Main gear box

320 cSt.

GYRATORY CRUSHER

Gear oil huge sump

Hydraulic oil

KLEENOIL APPLICATION ON RAW MILL:

Most commonly used raw mills today are vertical raw mills ( roller mill) as compare to horizontal raw mills, based on various contamination types and sizes, Kleenoil rig is compulsory to be used for filtering multiple oil range used for hydraulic and gears. Line filters play a major role in holding larger contaminations down to 30 micron, (average particle grinding size is around 45 micron) which can be considered primary filtration for removal of small granules.

MAJOR OIL CONSUMED IN VARIOUS SECTORS; RAW MILL HYDRAULIC, GEAR, ROLLER UNIT AND OTHER RELATED SECTORS.

MODEL FLS-Denmark (ATOX) 42.5 X 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Main gear box (Maag): 320 cSt. mineral oil - 6900 Ltrs. x Average 8000 hrs oil life

3-Grinding roller: 1000 cSt. synthetic oil - 1200 Ltrs. x Average 8000 hrs oil life

Hydraulic system: 46 cSt. mineral oil - 1500 Ltrs. x Average 12000 hrs oil life

MODEL UBE-Japan (LOESCHE) LM32 X 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Main gear box: 460 cSt. mineral oil - 5000 Ltrs. x Average 8000 hrs oil life

4-Grinding roller : 220 cSt. synthetic oil - 850 Ltrs. x Average 8000 hrs oil life


MODEL FLS-Denmark (ATOX) 52 X 1 UNIT - DG KHAN (CHAKWAL PLANT) ; 600 tph




RAW MILL: IMPROVED NAS CLASS RESULTS THROUGH PARTICLE COUNTER USING KLEENOIL RIG ON ALL LUBE

OILS OF DIFFERENT VISCOSITIES

NAS 8 NAS 3 NAS 11 NAS 2 NAS 5 NAS 2 BEFORE FILTRATION AFTER FILTRATION BEFORE AFTER BEFORE AFTER

Mineral gear oil 320 cSt. used

for 7100 h, total life 8500 hr

Synthetic gear oil 1000 cSt. used

for 9000 h, total life 8500 hrs Mineral HYD oil 46 cSt. used

for 6000 h, total life 9000 hrs

GEAR BOX 320 cSt. oil

ROLLER

1000 cSt. oil

HYDRAULIC 46 cSt. oil

TENSION ROD

ROLLER

MAIN GEAR BOX

OIL 320 cSt.

PULL ROD

RAW MILL

GRINDING ROLLER

OIL 1000 cSt.

HYDRAULIC

OIL 46 cSt.

KLEENOIL MICROFILTRATION

Model 4S series rig is sufficient to filter oil

continuous filtration to enhance oil life from

1 span to 3 spans. The greater the oil gets

contaminated more rapid filtration is required

not only to enhance oil life but also to

enhance equipment or parts life 10 - 20%


Model 4S-700 EDPH is used to filter

hydraulic oils up to 200 cSt.

FLS (ATOX)

range from 20,000 to 30,000 Ltrs. with

KLEENOIL APPLICATION AT COAL MILL FOR KILN: Most commonly used coal mill are vertical coal mills, based on various contaminations types and sizes, Kleenoil rig is necessary to be used for filtering multiple oil range used for hydraulic main gear box & grinding rollers. Line filters play a major role in holding larger contaminations, which can be considered primary filtration for removal of small to larger granules. The concept is same as other vertical mills, normally the capacity is smaller than roller or cement mill.

Kiln Burning Fuel: –> Coal - Shed - Local feeding conveyer - Coal mill - Stored in Hooper - Transferred by air process to Kiln

GEAR BOX

OIL 320 cSt.

ROLLER GEAR

OIL 1000 cSt.

HYDRAULIC

OIL 46 cSt.

ROLLER

PULL

ROD

TENSION

ROD

RIG: 4S-700 ED RIG: 3S-700 EDPH-C

FLS (ATOX)


Model 4S-700 EDPH-C-T can filter all kind of oils up to 1000 cSt.,

while in coal mill it is highly recommended to be used. Large pre-filter

will remove excess large and heavily contaminated coal suspended

particles from every oil consumable sector.

MAJOR OIL CONSUMED IN VARIOUS SECTORS; COAL MILL HYDRAULIC, GEAR, ROLLER UNIT AND OTHER RELATED SECTORS. MODEL FLS-Denmark (ATOX) 20 X 1 UNIT - DG KHAN (CHAKWAL PLANT) ; 17 -23 tph




MODEL FLS-Denmark (ATOX) 22.5 X 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)




MODEL UBE-Japan (LOSCHE) LM32 X 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)




CLINKERING DEPARTMENT HAS FOLLOWING SUB-DEPARTMENTS:

(1) KILN (2) Pre-Heater is without any sump (3) Cooler

KLEENOIL APPLICATION AT KILN: Kiln is said to be heart of cement manufacturing where the raw materials are been burned at 1200 – 1400OC to form Clinkers which are in the shape of small rocks. Lot of load is involved in carrying out the rotation of shell/ Kiln, hydraulic system and bearing play a very important role because they are the ones which are rotating and sliding. Kleenoil with its magnified filtration effect clears the oil without depleting additives, enhancing bearing, gears and hydraulic parts life. KILN: MODEL FLS-Denmark ; 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)


3-Supporting roller (4 bearing/ supp. roller): 1000 cSt. synthetic oil - 224 Ltrs. x Average 8000 hrs oil life ( 72 + 80 + 72 = 224 L )

Hydraulic Thrust device: 46 cSt. mineral oil - 200 Ltrs. x Average 12000 hrs oil life

For Gridth gear, Cluber CF Ultra grease is used 270 Kg/ month through spray system and it is not filtered as it is grease.

KILN: MODEL UBE-Japan ; 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Main gear box: 460 cSt. synthetic oil - 1200 Ltrs. x Average 8000 hrs oil life

3-Supporting roller (4 bearing/ supp. roller): 320 cSt. mineral oil - 4700 Ltrs. x Average 8000 hrs oil life (1500 + 1500 + 1700 = 4700 L)

Hydraulic Thrust device: 32 cSt. mineral oil - 200 Ltrs. x Average 12000 hrs oil life

For Gridth gear, Cluber CF Ultra grease is used 5 packing x 180 Kg/ year, through spray system and it is not filtered as it is grease.

KLEENOIL APPLICATION AT CLINKER COOLER: Clinker cooler are mainly of two types, Cross-bar coolers and second one is Horizontal cooler. The hydraulic group of bars bed move to & fro for transferring the clinker material forward through cooler tray. The steel bars are contaminated and impurities are transferred to hydraulic oil, also damaging rotor of hydraulic screw pumps used on hydraulic jacks. There are many small plunger pumps in which mostly the bearing is damaged and also other contacted parts. Kleenoil not only prevents the oil from depleting but also terminates all the metal & impurities catalytic effect by thoroughly filtering the oil.

- Tyre (wheel) on 2 base Kiln are

working on tangential suspension.

- In motor drive station no oil usage

while for hydraulic system, oil is used.

Tyre (wheel) on 3 base Kiln are

mostly floating but tangential

suspension can also be installed on

order depending upon kiln diameter.

Drive station for Girth gear &

pinion for floating suspension.

Self aligning

roller support

Kiln tyre with

tangential suspension

Hydraulic thrust Drive, 46 cSt. HYD

oil used.

HYD RIG – 4S-700 ED-C / T (opt.) HYD & GEAR RIG – 4S-700 EDPH-C / T (opt.)

CLINKER COOLER: MODEL UBE-Japan ; 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Heavy Duty Hammer Crusher used (3 shaft having 57 beating hammer on a rotating roller) --- No oil is consumed

SF cross bar cooler: 46 cSt. mineral oil - 2000 Ltrs. x Average 12000 hrs oil life CLINKER COOLER: MODEL FLS-Denmark ; 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Heavy Duty roller breaker: 46 cSt. mineral oil - 1500 Ltrs. x Average 12000 hrs oil life

Multi-movable cross bar cooler: 46 cSt. mineral oil - 2500 Ltrs. x Average 12000 hrs oil life

CLINKER COOLER: MODEL FLS-Denmark ; 1 UNIT - DG KHAN (CHAKWAL PLANT)

The hydraulic 8 jack system makes the bar movement, so clinker can move ahead.

Heavy Duty Hammer Crusher used (1 shaft having 57 beating hammer on a rotating roller) --- No oil is consumed

Cross bar cooler: 46 cSt. mineral oil - 1900 Ltrs. x Average 16000 hrs oil life

Robust “9S-2200 ED-C” or “6S-1500 ED-C” models can be used to filter hydraulic oil where contamination and heat both are critical

factors

KLEENOIL APPLICATION AT CEMENT MILL: Most commonly used cement mills today are vertical cement mills and some manufacturers are also using older models horizontal/ Ball cement mills, based on various micro contamination types and sizes, Kleenoil rig is must to be used for filtering multiple oil range used for hydraulic and gears. Here line filters play a average to below average role in removing larger contaminations because they have filtration efficiency down to 20 - 30 micron, (average grinded cement particle size is 10 micron, like talcum powder). This filtration efficiency can be considered as pre-filtration which can remove unexpected particle sizes while for less than 10 micron particle, there must be something which can extract & hold hard solid contaminations which are continuously entering in the lube oil and destroying system parts, especially the grinding bearing which is huge cost with downtime as compare to Kleenoil filtration plant cost in comparison. Here oil cost can be considered as secondary benefit. CEMENT MILL ARE OF TWO TYPES; (1) Ball Mill / Horizontal Cement Mill (2) Vertical Cement Mill

BALL MILL / Horizontal Cement Mill:

Horizontal set-up is older design which consumes more energy 1.5 times greater than vertical set-up. Metal balls (20-90 mm diameter) or small cylindrical “pebs” are freely rotating in the rotating Ball. In ball mill the most sensitive portion are sliding shoes (pair at both ends to hold the ball weight with desired rotation), having white metal bearing which is lubricated with 680 cSt. oil as it is the most important and expensive part in making the whole process, if any of these parts are damaged, huge amount of cost is going to be invested for reoperation. There is no hydraulic jack system like in Vertical Cement Mill. 320 cSt oil is used in gear box which is rotating the (Ball) Mill and 680 cSt. for sliding shoe bearing which is taking the load of whole ball.

FLS VIDEO - FLSmidth Ball Mill.flv MAJOR OIL CONSUMED IN VARIOUS SECTORS; HORIZONTALCEMENT/BALL MILL HYDRAULIC, GEAR, SLIDE SHOE UNIT AND OTHER RELATED SECTORS ACCORDING TO PLANT PRODUCTION CAPACITY.

Ball Mill / H.C.M: MODEL FLS-Denmark X 2 UNIT - (DERA GHAZI KHAN PLANT)


Main bearing – 2 inlet & outlet: 680 cSt. synthetic oil - 700 Ltrs. x 2 x Average 8000 hrs oil life

( Two Slide trunian bearing )

Small gear boxes - 50: 320 cSt. mineral oil - 400 Ltrs. x Average 8000 hrs oil life

Roller Press gear oil: 320 cSt. mineral oil - 800 Ltrs. x Average 8000 hrs oil life

Roller Press 46 HYD oil is also used but only 15 Ltrs., need not to be filtered.

Ball Mill / H.C.M: MODEL UBE-Japan X 1 UNIT - (DERA GHAZI KHAN PLANT)

Main gear box: 460 cSt. synthetic oil - 4000 Ltrs. x Average 8000 hrs oil life

Main bearing – 2 inlet & outlet: 320 cSt. mineral oil - 1500 Ltrs. x 2 x Average 8000 hrs oil life

( Two Slide trunian bearing )

SHELL / BALL MILL WORKING &

LUBRICATING PARTS DESCRIPTION

Based on different shell sizes used for different purposes and capacities (SAG Mill 12,2 dia, Ball Mill Wet / Dry - 8.23 m dia), various types of gear drives, gear boxes, roller press gears and hydraulic system are also been robust designed to cater the load capacity.

BALL MILL & SLIDE SHOE BEARING LUBE SYSTEM

1

Diameters are 2 to 4.3 meters…

2

3

4

5

6

7

8

FLSmidth MAAG LGD “lateral gear drive” unit with oil lubrication

video and Kleenoil model “4S-700 EDPH-C” best for filtration

http://en.wikipedia.org/wiki/File:LDFMBallMill.jpg

TWIN LINE FILTERS & ONE IN SUCTION (HP) BEFORE BLACK COLOR FOAMING DUE HEAVY FOAMING HAS REDUCED IN 1ST CANNOT FILTER BELOW 60 MICRON TO DIRT/ HEAVY CONTAMINATION FILTRATION WITH CONTIMINATION AS MECHANICAL FOAMING COLOR IS WHITE

Vertical Cement Mill In vertical mill, through main drive motor high quality bearings (SKF through i.e, FLS) in main gear box are rotating the cement grinding bed/ table, the oil used is 320 cSt. In cement grinding bed, the heavy rollers are rotating on grinding table through stationary shaft which is been lubricated with 1000 cSt. oil going in & out after circulating through heavy weight and pressurized rollers grinding the clinker into smaller than 10 micron powder size. The movement of rollers up & down is through hydraulic jack which are been powered by hydraulic cylinders (46 cSt., 140 bar operating pressure) with the support of rocker arm. Damageable parts in bed are casing, rollers and roller supporting cage directly affected by 1000 cSt. oil while if hydraulic 46 cSt. oil is not creating desired/ balanced pressure so there will be improper grinding. In main gear box parts there are seal damages, bearing abrasion, gear damages when 320 cSt oil is having additives depletion, like EP (AW) or antifoam.

MAJOR OIL CONSUMED IN VARIOUS SECTORS; RAW MILL HYDRAULIC, GEAR, ROLLER UNIT AND OTHER RELATED SECTORS ACCORDING TO PLANT PRODUCTION CAPACITY.

V.C.M: MODEL FLS-Denmark (OK) 36 X 2 UNIT - DG KHAN (CHAKWAL PLANT) ; 600 tph




**Different smaller quantities of 320 mineral ; 220 mineral ; 220 synthetic ; 150 mineral are been used for standard gear boxes and belt driven gear boxes. V.C.M: MODEL FLS-Denmark (OK) 39 X 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Main gear box (Maag): 460 cSt. synthetic oil - 7700 Ltrs. x Average 8000 hrs oil life

4-Grinding roller: 1000 cSt. synthetic oil - 2200 x 4 Ltrs. x Average 8000 hrs oil life


**Different smaller quantities of 320 mineral ; 220 mineral ; 220 synthetic ; 150 mineral are been used for standard gear boxes and belt driven gear boxes.

FLSmidth VERTICAL MILL “OK” MODEL USED AT DG KHAN CHAKWAL PLANT-2 AND DERA GHAZI KHAN PLANT-1

OBE VERTICAL MILL

“LOESCHE” MODEL


- With the use of, Model 4S-700 EDPH-C-T or

4S-700 EDPH-C model, it is very important to filter

smaller contaminations which penetrates in

hydraulic pistons during up and down movement.

- Main gear box must be thoroughly cleaned for high

speed production.

- Roller oil must be periodically filtered out to

prevent from depleting and saving expensive

bearing life.

ROLLER GEAR

OIL 1000 cSt.

HYDRAULIC

OIL 46 cSt.

MAIN GEAR

OIL 320 cSt.

http://en.wikipedia.org/wiki/File:LDRMRollerMillDiag.jpg

KLEENOIL FILTRATION CYCLES CONVERTING NAS CLASS-13 TO NAS CLASS-6 AFTER 4 CYCLES AND AFTER 2 MORE

CYCLES THE OIL IS EQUAL TO NAS CLASS-4, TOTAL 6 FILTRATION CYCLES GIVEN TO “SYNTHETIC GEAR OIL 1000 cSt.”

V.C.M: MODEL FLS-Denmark (OK) 39 X 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Magnification - 10X Magnification - 60X Magnification - 60X

BEFORE FILTRATION : OIL STATUS HAVING METAL PARTILCES 15 – 50 MICRON

INCLUDING SILICA AND MOISTURE BUBBLE

AFTER FILTRATION : FOUR CYCLES

`

AFTER FILTRATION : TWO MORE CYCLES = TOTAL SIX CYCLES

-Synthetic gear oil 1000 cSt.

-Current oil NAS Class – 13

-Used for more than 9000 hrs.,

oil has completed total life but it

was recovered because additive

have not been depleted despite

the oil was changed and stacked

in drums for 15 days before

filtration.

-Huge contaminations of clay,

sand, metallic particles are seen,

the main reason of oil change.

-Further used after 6 - 7 months

this oil has been quiet dangerous

for the system.

-NAS Class – 4 highly improved

from NAS Class – 6 after 2 more

cycles.

-Improved from NAS Class – 13

to NAS Class – 6 after 4 cycles.

KLEENOIL AFTER 6 FILTRATION CYCLES CONVERTING “SYNTHETIC GEAR OIL 680 cSt.” NAS CLASS-10 TO

NAS CLASS-4


Magnification - 10X Magnification - 60X

BEFORE FILTRATION : OIL STATUS HAVING CONCENTRATED PARTILCES 15 – 35 MICRON

AFTER FILTRATION : SIX CYCLES

-Synthetic gear oil 680 cSt.



oil has completed total life but it


have not been depleted.

-Concentrated contaminations

of clay, sand and ore particles

are seen, the main reason of oil

change required.

-Oil is no good for further use if

main bearing life needs to be

protected.


to NAS Class – 4 after 6 cycles.

NAS Class – 10

KLEENOIL AFTER 6 FILTRATION CYCLES CONVERTING “MINERAL GEAR OIL 320 cSt.” NAS CLASS-09 TO

NAS CLASS-04


Magnification - 10X Magnification - 60X Magnification - 60X

BEFORE FILTRATION : OIL STATUS HAVING PARTILCES 10 – 40 MICRON

AFTER FILTRATION : SIX CYCLES

-Mineral gear oil 320 cSt.



oil has completed 70% life but it


have not been depleted.

-Concentrated contaminations

of clay, sand and ore particles

are seen but filtration will give

better life to main gear box

parts and the oil film will have

sufficient covering to protect

edges.


to NAS Class – 04 after 6

cycles.

KLEENOIL AFTER 5 FILTRATION CYCLES CONVERTING “MINERAL HYDRAULIC OIL46 cSt.” NAS CLASS-09 TO

NAS CLASS-03 TO O4

V.C.M: MODEL FLS-Denmark (OK) 39 X 1 UNIT - DG KHAN (DERA GHAZI KHAN PLANT)

Magnification - 60X Magnification - 60X

-Mineral Hydraulic oil 46 cSt.



oil has completed more than

80% life but after filtration the

hydraulic system is now more

protected against from any seal

leakage due to cracking,

moisture introduction or

pressure pipe breakdown due to

oil acidification.

Concentrated contaminations of

dust particles are seen mainly in

small sizes which are needed to

be removed through periodical

filtration.

BEGORE FILTRATION

OIL STATUS: NAS Class – 09

BEGORE FILTRATION

OIL STATUS: NAS Class – 03 TO 04

KLEENOIL BY-PASS TECHNOLOGY INSTALLED ON FLEETS FOR LESS DOWN TIME, LONGER

OIL CHANGE INTERVAL, LESS BREAKDOWN IN HYDRAULIC SYSTEMS ( IN PIPING, SEALS).

HYD - SDU-H350 ON VOLVO WHEEL LOADER ENGINE - CAT BULLDOZER D8R

SDU-H350 RK-TWIN for hydraulic oil SDU by-passes installed for

LIEBHERR Crawler Excavator 974 different applications on TEREX

HYDRAULIC OIL

MOTOR OIL

FUEL

VOLVO FM12 DUMPER - ENGINE

Cement Plant and it various contamination forms from quarry to packing

Best application of KLEENOIL equipments at various cement sectors

Quarry - Store - Reclaimer - Belt - Raw Mill - R.M Silos - Kiln - C.Cooler - Clinker Silos - Cement Mill - C.M Silos - Packing

CaSO4.2H2O

White color

(SiO2, Al2O3, Fe2O3 and CaO)

(CEMENT MILL)

a) Black stone shape

b) 3 -4 type materials

are mixed.

c) Settling time is

also increased.

(Shale)

Kiln

1200 - 1400OC

Air quench cooler reducing

temp to 50 - 100OC

Types :

Cross bar Cooler

**Horizontal Cooler

(RAW MILL)

Proportioning

equipment &

Coal grinding

mill

Coal

Clinker

Raw Mixes for Cement: 1) Lime stone, clay, shale (sand)

CaO ; SiO2 ; Al2O3 ; Fe2O3

Most imp. oxide is lime, CaO

2) Gypsum

CaSO4.2H2O

Clinker has 4 compounds:

1) Alite Ca3SiO5

2) Belite Ca2SiO4 - larnite

3) Aluminate Ca3Al2O6

4) Ferrite Ca2AlFeO5

Concrete: is mixture of

- Sand, water, gravel, cement.

- 4 compounds are formed.

1) Alite Ca3SiO5

2) Belite Ca2SiO4 - larnite

3) Aluminate Ca3Al2O6

4) Ferrite Ca2AlFeO5

TYPE OF CEMENTS:

1) Mix 1: General-purpose

88.0% gray limestone, 8.9%

clay, 2.2% sand & 0.9%

millscale.

2) Mix 2: Sulfate-resisting

87.6% gray limestone, 5.2%

clay, 5.0% sand & 2.2%

millscale.

3) Mix 3: White cement 2.3% white limestone, 6.8%

kaolin & 10.9% sand.

http://en.wikipedia.org/wiki/White_Portland_cement

PAKISTAN REFERENCE CUSTOMERS:

DG KHAN CEMENT, CHAKWAL (ONE CEMENT PLANT INSTALLED)

DG KHAN CEMENT, DERA GHAZI KHAN (TWO CEMENT PLANT INSTALLED)

BESTWAY CEMENT, HATTAR (ONE CEMENT PLANT INSTALLED)

BESTWAY CEMENT, CHAKWAL (TWO CEMENT PLANT INSTALLED)

LUCKY CEMENT, HUB (ONE CEMENT PLANT INSTALLED)

ATTOCK CEMENT, KARACHI (ONE CEMENT PLANT INSTALLED)

Raw Mill, MGB Big chunks, Lump of carbon, Suspended H2O Gear & Hyd. oil

metal ions Silica Bubble filtered & cont..

100X magnify. 100X magnify. ISO 4406: 1999 ISO 4406: 1999 Green balls

Contamination microfiltered oil = 23/21/18 = 14/12/9 are additives

on filter paper on filter paper NAS 1638=12 NAS 1638=3 never filtered

THE END

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Cement Plant Oil & Filtrartion Brochure