Cpoh6 Contents PDF

6 Cement Plant Operations Handbook – Sixth Edition
Contents
Section A – Process summaries
1. Introduction 10
1. The basics of cement manufacture – 2. History of cement manufacture – 3. Portland cement in today’s world
2. Raw materials 14
1. Raw materials – 2. Raw mix – 3. Reserves – 4. Crushing – 5. Drying – 6. Pre-blending – 7. Storage and handling
3. Raw milling and blending 26

1. Raw milling – 2. Blending – 3. Kiln feed
4. Flames and fuels 34

1. Chemistry of combustion – 2. Fuels – 3. Physics of combustion – 4. Burner design – 5. Cement kiln burners
– 6. Heat transfer – 7. Pollutant formation – 8. Modelling – 9. Fuel storage and firing systems in practice – 10.
Insufflation – 11. Alternative and waste fuels
5. Burning and cooling 60

1. Chemical reactions – 2. Process variants – 3. Kiln burning - 4. Kiln control – 5. Volatiles in the kiln – 6. Kiln bypass
– 7. Kiln startup and shutdown – 8. Kiln refractories – 9. Clinker cooling – 10. Kiln mechanical – 11. Emergency
power – 12. Plant control systems
6. Cement milling 94
1. Storage of clinker and other components – 2. Cement milling – 3. Separators (classifiers) – 4. Ball mill circuit
control – 5. Cement storage – 6. Cement dispatch – 7. Distribution – 8. Quality assurance and customer service
7. Quality control 114

1. Sampling – 2. Chemical analysis – 3. Particle size analysis – 4. Thermal analysis – 5. Microscopy – 6. Virtual
Cement and Concrete Testing Laboratory (VCCTL) - 7. Calorimetry – 8. Burnability – 9. Grindability – 10. Physical
testing – 11. Process control analysis – 12. Chromate passivation – 13. Cement quality – 14. Setting time – 15.
ASTM cement types and specifications – 16. European EN 197 cement specification – 17. Composite cements
(intergrinds) – 18. Supersulphated cement – 19. Calcium aluminate cement (CAC) – 20. Shrinkage-compensating
cements (SCC) – 21. ISO 9001:2000 Quality management system – 22. Concrete problems
8. Maintenance 144
1. Maintenance benefits and costs – 2. Failure modes – 3. Computerised Maintenance Management Systems
(CMMS) – 4. Reliability-Centred Maintenance (RCM) – 5. Maintenance cost management – 6. Maintenance
organisation – 7. Role, planning and control – 8. Mobile equipment maintenance – 9. People and indicators
9. Environment and pollution control 154

1. Dust collection – 2. Pollution control – 3. ISO 14000 – 4. Sustainable development and climate change
Contents 7
10. Hydration of Portland cement 168

1. Initial stage – 2. Induction or dormant stage – 3. Acceleration stage – 4. Deceleration stage
11. Plant reporting 172

1. Definitions – 2. List of reports – 3. Inventories and feeders – 4. Downtime reporting – 5. Miscellaneous reporting
– 6. Typical daily production report – 7. Typical process summary data – 8. Typical equipment downtime report
– 9. Plant manning
12. Accounting 182

1. Cost or management accounting – 2. Investment justification – 3. Capacity increase by process change –
4. Project cost estimation – 5. Financial statements
13. Technical and process audits 194

1. Historical performance – 2. Kiln specific fuel consumption – 3. Cement mill specific power consumption –
4. Other systems – 5. Debottlenecking – 6. Project audit – 7. Risk assessment
14. Plant assessment list 202

1. General – 2. Administration and commercial – 3. Communication with stakeholders – 4. Quarry – 5. Drying – 6.
Raw milling – 7. Blending – 8. Kiln – 9. Fuel – 10. Clinker – 11. Finish mill – 12. Cement – 13. Quality control – 14.
Packing and distribution – 15. Dust collectors – 16. Maintenance – 17. Process – 18. Materials analysis –19. Plant
capacity summary – 20. Storage capacity
15. Cement plant construction and valuation 212

1. New plant construction – 2. Project management – 3. Cement plant investment costs – 4. Project phases –
5. Plant valuation
Section B – Process calculations and

miscellaneous data
B1. Power 231

1. Specific power consumption - 2. Power conservation – 3. Three-phase power – 4. Motor power output – 5. Peak
power tariffs – 6. Power generation – 7. Cogeneration
B2. Fans and air handling 233

1. Fan laws – 2. Fan mechanical – 3. Impeller build-up – 4. Gas properties – 5. Plant air distribution – 6. Pitots,
orifices and venturis – 7. False air – 8. Dust loading – 9. Stack draught – 10. Dewpoint of moist air at atmospheric
pressure – 11. Spray cooling of gas – 12. Abrasion resistance
B3. Conveying 238

1. Comparative power consumption for lift – 2. Pneumatic conveying – 3. Bucket elevator power – 4. Belt conveyor
power – 5. Screw conveyor power – 6. Airslide – 7. Drag chain power – 8. Tube belt conveyor – 9. Air-supported belt
conveyor – 10. Sandwich conveyor – 11. Modified belt conveyor – 12. Capsule conveyor – 13. Water pump power
8 Cement Plant Operations Handbook – Sixth Edition
B4. Milling 241

1. Sieve sizes – 2. Circulating load – 3. Classifier recovery – 4. Tromp curve – 5. Mill critical speed - 6. Charge volume
loading – 7. Grace factor and other ball mill parameters – 8. Mill power – 9. Ball weight and surface area – 10.
Maximum ball size required –11. Measurement of wear – 12. Effects of gypsum upon setting time
B5. Kilns and burning 247

1. Cement compounds and ratios – 2. Coating tendency – 3. Burnability factor – 4. Required burning temperature
– 5. Theoretical heat of formation of clinker – 6. Kiln gas velocities – 7. Kiln heat balance – 8. Kiln specific heat
loading (SHL) – 9. Kiln retention time – 10. Kiln volume loading – 11. Kiln capacity vs diameter – 12. Kiln drive
power – 13. Cooler efficiency – 14. Kiln exhaust gas (coal) – 15. Circulation of volatile components –16. Estimation
of kiln bypass –17. Other kiln types
B6. Fuels 259

1. Typical data for solid fuels – 2. Typical data for liquid fuels – 3. Typical data for gaseous fuels
B7. Materials 261

1. Bulk densities of materials for silo storage – 2. Specific gravities and grindabilities – 3. Solubilities of sulphates
– 4. Rates of dissolution of different forms of calcium sulphate at 20°C – 5. Influence of temperature on the
solubilities of various sulphate forms – 6. Chemical formula weights – 7. Coefficients of linear expansion
B8. Statistics 264
B9. Miscellaneous data 269

1. Atmospheric pressure and density vs altitude (0°C) – 2. pH and normality – 3. Laboratory reagents (aqueous
solutions) – 4. Seawater composition – 5. Abundance of elements in earth’s crust – 6. Hardness of materials –
7. Earthquake scales – 8. Beaufort wind scale – 9. World cement production –10. Regional cement consumption
data –11. EU Environmental legislation –12. Ship and truck capacities –13. Patents
B10. Conversion tables 275

1. Length – 2. Volume – 3. Pressure – 4. Weight – 5. Area – 6. Density – 7. Energy – 8. Force – 9. Miscellaneous
References 276
Index 287
Advertisers’ index 290

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6 Cement Plant Operations Handbook – Sixth Edition

3. Raw milling and blending 26

4. Flames and fuels 34

5. Burning and cooling 60

7. Quality control 114

9. Environment and pollution control 154

10. Hydration of Portland cement 168

11. Plant reporting 172

12. Accounting 182

13. Technical and process audits 194

14. Plant assessment list 202

15. Cement plant construction and valuation 212

Section B – Process calculations and

B1. Power 231

B2. Fans and air handling 233

B3. Conveying 238

B4. Milling 241

B5. Kilns and burning 247

B6. Fuels 259

B7. Materials 261

B8. Statistics 264

B9. Miscellaneous data 269

B10. Conversion tables 275

Advertisers’ index 290

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