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CE

MEN

T INDUST

RY

S

UB BY- A

NSHUL K

UMAR

CI

VIL EN

GINEE

RING

7TH SE

M

HCS

T FARAH M

ATHURA

CEMENT INDUSTRY

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In civil construction cement is a good bond material . Firstly in 1824 , Joseph Aspdin, a British stone mason, heated a mixture of finely ground limestone and clay in his kitchen stove and ground the mixture into a powder to create a hydraulic cement- one that hardens with the addition of water.

CEMENT

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Composition of cement

1.Argillaceous material- Cao-65%-bond material Silica-17-25% Alumiana-7-8% -providing strength Gypsum-3-5%-to decrease the initial setting time Iron oxide-0-5% Magnesium oxide-0.1-4% Sulphuric oxide-1-2.75%2.Callcareous material- Calk & limestone

DIFFERENT POLLUTANT IN CEMENT PRODUCTION

Major Polluting source

Process Inputs

Process Outputs

Pollution Parameters

Impact

Crushing Lime stone, silica, clay, shale

Crushed raw materials

Dust from raw material

Air pollution

Proportioning and mixing of raw materials &Grinding

Water Slurry Noise Workplace

Kiln and Clinker cooler

Fuel Clinker Water vapourFilter kiln dust

WorkplaceAir Pollution

Finish grinding ClinkerGypsum

Cement Dust Air Pollution

Packaging machine Cement Cement Dust Air Pollution

Wet process

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Cement manufacturing wet process

Argillaceous material

washing

Storage Tank

waterLimestone65%

Crushing &compacting

Storage tank

Wet grinding wash mill

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Clinker grinding ( Ball/Tube mill)

Slurry

Testing of slurry

Slurry calcination (Rotary kiln)

Gypsum

clinker

Grind coal

Compressed air

Cement storage in silos

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Weighting & packaging

Supply

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WET PROCESS

1.Preparation of slurry- getting row material crushining it 25mm size mix water in raw material store in silos after proper mix slurry2.Clinker making- slurry placed in rotary kiln by pump. kiln have following temperature Range- 250-500*C for dry slurry 700-1200*C change in noodles 1500-1700*C done chemical process in clinker of 5to 10 mm size

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Cooled by cooler and storage in tanks.3. grinding-Clinker placed in ball mill for course grinding after then ball for making 90 micron or less size.Mix the 2to 3% gypsumLast grinding cement in 50kg bag by automatic weight recorder.

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ROTARY KILNJAB CRUSHER

TUBE KILN

DRUM CRUSHER

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STORAGE OF CEMENT

Major Polluting source

Process Inputs Process Outputs

Pollution Parameters

Impact

Crushing Lime stone, silica, clay, shale

Crushed raw materials

Dust from raw material

Air Pollution

Proportioning and mixing of raw materials

Crushed raw materials

Dust from raw material

Air Pollution

Grinding Raw material Raw meal NoiseDust

Workplace

Kiln Fuel Raw material

Clinker By-pass kiln dust

Air Pollution

Clinker cooler Hot clinker Clinker Air pollutionFinish grinding Clinker

GypsumCement Dust

NoiseAir Pollution

Packaging machine

Cement Cement dust Air pollution

Kiln’s chimney Exhaust gases + particulate

Exhaust gases + particulate

Particulate Air pollution

Dry process

Cement manufacturing Dry process

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Cao limestone Clay

Crushing & Compacting Crushing

Dry Grinding

Calcination (Rotary kiln)

Clinker

AS SAME WET PROCESS

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DRY PROCESS

When raw material have hard or slag form, than used dry process.

1.Preparation powder of raw material- store row material different places as category crushining crushing raw material by jaw crusher in 25 mm hot gasses in kiln used for drying the material mixed the proper proportion of raw material after than grinding in ball or tube mill

2.Clinker making- slurry placed in rotary kiln by pump. kiln have following temperature Range- 250-500*C for dry slurry

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700-1200*C change in noodles 1500-1700*C done chemical process in clinker of 5to 10 mm size Cooled by cooler and storage in tanks.

3. grinding-Clinker placed in ball mill for course grinding after then ball for making 90 micron or less size.Mix the 2to 3% gypsumLast grinding cement in 50kg bag by automatic weight recorder.

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Problem Control unit

Capture of kiln dust Electrostatic precipitator Bughouse filter,Cyclone

Capture of dust from clinker cooler

Electrostatic precipitatorBag house filter

Control dust from other operations

Cover or enclose conveyors, crushers, material transfer points, storage areasInstall mechanical dust collectors and/or bag house filters where neededVacuum sweepers for plant roads Sprinklers for plant roads and storage piles

Cement waste control

Grit Screening , Grit chamber

CO2,CO3 Dissolving in Chimney process

SO2,SO3 Wet process

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METHODS OF AIR POLLUTION CONTROL IN CEMENT INDUSTRY

Electrostatic precipitators use high voltage to charge particles in a gas stream. The electrically charged particles are attracted to an oppositely charged plate where they are collected. An electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge . Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device and can easily remove fine particulate matter such as dust and smoke from the air stream.

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ESP

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Bag house filter-Bag house or fabric filtration relies upon a finely woven fabric to separate particles from the air stream as the air passes through the fabric. The design of a bag house is generally dependent upon the air-to-cloth ratio.

Wet scrubbing- Wet scrubbing uses water particles to capture particulate matter in the gas stream. The efficiency of a wet scrubber is generally dependent upon the pressure drop.

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Cyclone seprator

23 THANK YO

U

24 THANK YO

U