Chemical Engineering Process Chemical Engineering Process in Cement Productionin Cement Production

Chemical Engineering Process Chemical Engineering Process in Cement Productionin Cement Production

By:

Eastern Cement Team:

Eng. Ali S. Al-Qahtani

Eng. Sayd Basheer Shafee

Eng. Haridas Nair

By:

Eastern Cement Team:

Eng. Ali S. Al-Qahtani

Eng. Sayd Basheer Shafee

Eng. Haridas Nair

Presented to:SAUDI ARABIAN SECTION OF AMERICAN

INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE)

on Sunday, December 27, 2009at Le Meridien Hotel, Al-Khobar

Presented to:SAUDI ARABIAN SECTION OF AMERICAN

INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE)

on Sunday, December 27, 2009at Le Meridien Hotel, Al-Khobar

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

Saudi Cement Industry

2.46

3.374

2.78

0

0.5

1

1.5

2

2.5

3

3.5

4

2006 2007 2008

DistributedDividend (SRbillions)

Economic ContributionsEconomic Contributions

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.

Our Business

We Produce and Sell ……..We Produce and Sell ……..

Glue ……..Glue ……..forfor construction construction

CementCement

Cement is…..• HydraulicHydraulic BinderBinder

Solidify and gain compressive strength after mixing with Solidify and gain compressive strength after mixing with waterwater

• It binds gravel and sand to form Artificial It binds gravel and sand to form Artificial Rock Sold Material Rock Sold Material

ConcreteConcrete

Limestone

Cement & Concrete technologies

Cement & Concrete technologies

There have been huge developments in the innovation and production of new binder materials in the last 10 years especially in the Epoxy chemicals.

HoweverNon can compete with cement and concrete materials for practicality and economic feasibility of production and construction

Ancient construction Technologies

Ancient construction Technologies

Cement Production Process

Cement Grinding Systems

Pyroprocessing(Chemical Reactions)

Material handling Systems

Material handling Systems

Raw Material GrindingSystems

Cement is Very Old Material….

1812

Research by Louis Vicat on Hydraulic Binders

1824

Invention of Portland Cement by Joseph Aspedin

1838

Invention of chemical Engineering process by Isaac Johnson

1875

Cement Standard by Wilhelm Michaelis

Basic Research and inventions Time Line

Cement Production Technologies

1830’s

Vertical Kilns

1885

Rotary Kilns

1930’s

Long Rotary Kilns

1970’s

Short Rotary Kilns and Preheater Technology

2000’s

• Control and instrumentation

• Gears and bearings

•Cooling and heat transfer

•Material handling systems

•Cyclone and filters

PyroprocessingSystem

Preheater

Rotary Kiln

Cooler

Preheater

What is happning at the Preheater?

• Raw material separation and suspension for heat absorption.

•Moisture Removal

•Decomposition of CaCO3, Decomposition of CaCO3, MgCO3, formation of CA, MgCO3, formation of CA, C2F and C3S begins.C2F and C3S begins.

Formation of CFormation of C1212AA77

Rotary Kiln

•Formation of C3A and C4AF begins, decomposition ofFormation of C3A and C4AF begins, decomposition of CaCO3 completed, free lime reaches maximumCaCO3 completed, free lime reaches maximum

•Formation of C2S reaches maximum, Formation of C2S reaches maximum, C3A and C4AF formation completedC3A and C4AF formation completed

•Formation of liquid phaseFormation of liquid phase

Formation of C3S, gradual decrease Formation of C3S, gradual decrease of free lime content. of free lime content.

Clinker

•Tricalcium silicate (C3S) or Tricalcium silicate (C3S) or alite, dicalcium silicate (C2S) alite, dicalcium silicate (C2S) or belite, tricalcium aluminate or belite, tricalcium aluminate (C3A) and tetracalcium (C3A) and tetracalcium aluminoferrite (C4AF) are the aluminoferrite (C4AF) are the main clinker constituents main clinker constituents

MINERALOGICAL COMPOSITION OF CLINKER

Cooler

Cooler

Final Chemical Process

Addition of GypsumCaSO4.2H2O to control the setting time of cement

Raw Material GrindingSystems

Cement Grinding Systems

Pyroprocessing(Chemical Reactions)

Material handling Systems

Material handling Systems

Cement Chemical Composition

Cement CompoundWeightPercentage

Chemical Formula

Tricalcium silicate 50 % Ca3SiO5 or 3CaO.SiO2

Dicalcium silicate 25 % Ca2SiO4 or 2CaO.SiO2

Tricalcium aluminate 10 % Ca3Al2O6 or 3CaO .Al2O3

Tetracalciumaluminoferrite

10 % Ca4Al2Fe2O10 or

4CaO.Al2O3.Fe2O3

Gypsum 5 % CaSO4.2H2O