4102

:
( ) 3232 3132

 ()Dedication




.

!
()
, .

(-:)Preface

. .

 ) ) Index

: ()Cement industry
:3 (.......................... )Cement industry

33

3:3 (..... )Cement industry History

33

3:3
(.....)Preface About Cement Production with Dry Process

33

: ()Quarry
:3 ( ............................................... ) Quarry

35

3 :3
( ............................. ) The Quarry And Equipment

35

3 :3
(.. )The Distance Between The Quarry And Factory

35

2 :3
(...... )Storage Of Raw Materials Before Crushing

36

: ()Crusher
:2 (............................................. )crusher

38

3:2 ( ................... ) overview

38

3:2 ( ................ ) Types of Crushers

2:2 (........................)reduction ratio

39
39

: ()Solid Material conveyors

:2 (.....)Solid Material conveyors

33

3:2
(......)Pneumatic Conveying for fine solid material

33

3:2 ( ......... )Bucket Elevator

35

2 :2 (......................... )Belt Conveyor

36

2:2 (...................... )Screw Conveyor

37

5:2 () Drag Chain conveyor

37

6:2 ( ) Deep Bucket Conveyor

38

7:2 (......... )Pan Conveyor

38

8:2 (......................)Apron Feeder

39

9:2 ( .................. )Weight feeders

21

: ()Chemistry of cement Production

:5 ()Chemistry of cement Production

22

3:5
(....... )Chemical Information For Raw Material

22

3:5 (.) Clinker Minerals Main

29

2:5 (..................... )Clinker Modules

21

2:5 ( ) Bogue
(..................................) Clinker Minerals Main

23

: ( ) Material To store
:6 ( .................... ) Material To store

22

3:6 ( ............................................ ) Brief

22

3:6
( ) storages types inside the production process

25

: ()Auxiliary Equipment
: 7 (........... )Auxiliary Equipment

51

3:7 (........................................... ) Fans

51

3:7 (................................ )Dust Collector

52

2:7 ( )separator (..... )classifier

59

7:2 ()Cooling Or Conditioning Tower

67

 5:7 (....................... )Rotary lock

68

: ( )Mills in Cement Industry

:8 ( )Mills in Cement Industry

71

3:8 (.............................. )Ball Mill

73

3:8 (................. )Vertical Mill

77

2:8 (................... )Roller Press

83

2:8 (............................. )Horo Mill

82

: ()Raw Meal Preparation

: 9 ()Raw Meal Preparation

86

: ()Kiln
:31 (........................................... )Kiln

93

3:31 (...................... ) Kiln Types

93

3:31 (........................ )Kiln Feeding

95

2:31 (......... )Clinker Reactions

98

2:31 (.................. )Pre Heater

312

5:31 ()Calciner or Pre-Calciner

318

6 : 31 (....................... )Rotary Kiln

333

7:31 (................... )Rotary Kiln Hood

333

8:31 ()Rotary Kiln Burner

(.......................)Main Burner

332

9:31 (. )Fuel Used in Kiln

332

31:31 (.................. )Clinker Cooler

339

33:31 ()Rotary Kiln

327

32:31
(............ )Information About Kiln Operation

323

 32:31 :
(............. )Kiln Start up Rotary : Warm Up

325

35:31 (.... )Fluidized Bed Kiln

327

: ()Cement
:33 (................................ )Cement

329

3:33 (.............. )Cement Strength

353

3:33 ()Insoluble residue

353

2:33 (.................. )Cement Types

2:33 (....................... )Grinding Aid

353
352

:
: 33 - :
Environmental Pollution in Cement Production and the two reduces: -

356

: ()Packing
:32 (....................................... )Packing

363

: ()refractories Material
:32 (......... )refractories Material

366

: (..)Hydration of Portland Cement

:35 (.372. ..)Hydration of Portland Cement
. : ()Some Outspread InFormation
:36 ()Some Outspread InFormation

377

3:36
(....... )Heat Quantity To Product the Clinker

377

3:36
(............................ ) Power Consumption
2:36

377

378

...... ) The Cost Of Cement Production (

379

....................................... )References(

108

........................................... ) Terminology (

 :

Mills in Cement Industry

 :8 ( -: )Mills in Cement Industry

( Raw Meal
) ( )Kiln Feeding ( )Coal ()Fuel
( )Kiln ( )Clinker with the additives
( )Cement % 01 ( . )Electiric Power
( )Cements
( )Balls Mills ( )Horizontal ,
( )Vertical Mill . ( )Roller Press

( )Horo Mill
( )Roler Press ( . )Ball Mill
( ) Blocks (: )0

Mills in Cement industry

Vertical Mill

Ball Mill

Horo Mill

Possible to add

Roller press

Open
circuit

Closed Circuit

Vertical
Roller
Mill

E Mill
or ring
Ball Mill

Aerofall Mill

( ) Blocks ()3

3:8 (-:)Ball Mill

( )Mills ( )Cement
( )Slide ring
( )Slide shoes Bearings
( )Mill , .
( ) Linings ()Metallic Balls
. ( )Chambers
( )diaphragms
( )Metallic Balls
( )Chamber ( )Mill inlet
( )Chamber ()Mill Outlet
( )0-:

Mill inlet

Metallic Balls

Intermediate and
outlet diaphragms

Mill outlet

Linings
()3

( )0 ( ) Slide ring
(-: )Slide shoes Bearings

Slide ring

()3

Slide Shoe

( )Ball Mill ( Raw

)Material ( . )Clinker
( )Clinker ( (Additive ()Cement
5.3 2.3 ( )open circuit 4.3
5.3 ( . )closed circuit ( )open circuit
( )Mill inlet ( )Mill outlet
( )Fineness
( )Chamber ( )closed circuit
) ) separator or classifier ( )Fine
( )Coarse
.
( )Chamber ( Double
)diaphragm with Flow Control ()First Chamber
( )First Chamber
( )diaphragm
.
( ) inlet ( )Outlet
( )Powder
( )Ventilation Fan (Main
) System Fan . ,
( (Suffocation
( )diaphragm .

 (-: )Critical Speed

( )Critical Speed -:
n=76.6/
: D
01% 01 %
( )Critical Speed -:
n=32 /
: D
( )Critical Speed
.
( )Ball .
()Ball
( )Chambers

( )Balls .
( )Ball ( )First Chamber
( )Second Chamber ( )First Chamber
, ( )Second Chamber ( )Ball
( . )First Chamber ( )Classifying Lining
( )Linings ( )Balls
( )Outlet diaphragm ( Intermediate
)diaphragm ( )Second Chamber ( First
)Chamber ( Outlet
. )diaphragm
(-:)Grinding Media
( )Metallic Balls % 43 % 53
( )Grinding Media
% 42 % 54 % 42

 , % 54
. -:
100
]) ) [( 2 (360)) ( 2 + 2
2

( = %

= r
= H
= C = 2 2 + 2
= = h/r = cos1/2

* H D
.

( )Ball Mill ( approximate

) power consumption -:

) Kwt = 7.5 * G * Di ( power consumption

( G = )Grinding Media with ton

) Di = (effective mill with meter

Ball Mill Typical Block Diagram Cement

 (-: )Mill Devlopment

()Roller press
( . )Pre-Grinding
) )diaphragms ( )Chamber
% 2 .%0 ( )0-:
Product
Separator

Feed

Roller press

()3

Ball Mill

) )V- separator
% 53 ( )4 -:

Product

Separator

V-
))separator

()3

Roller press

Ball Mill

Feed

Fresh air
or hot
gas

 (-: )OverView

( )Ball Mill ( Raw

)mill ( )Kiln Feeding ( )Power
( ) Vertical Mill
( )Vertical Mill ( )Clinker
) )Additive ( )Cement .
( )Vertical Mill ( )Clinker Additive
) ) ( )Cement .
( )Aerofall Mill ()Autogenous
0:5 , 0:3
011 051 , ( )Ball % 0 % 04
% 53 % 22
( )Metallurgical
( , )Cement ( ) Raw material
, (. )Vertical Mill
3:8 (-: )Vertical Mill

( )Vertical Mill
( )Raw Meal ( E Mill or ring Ball Mill
) ( )Coal
( )Power Station ( ) Vertical Roller Mill
.
( ) Vertical Roller Mill ( Ball
)Mill %21 % 31 0411
% 2 ( Ball
, )Mill 53 011

( ) Vertical Roller Mill .

 ( )4 ( Vertical Roller
-: ) Mill
()3

Fine material product
With Outlet Gases

Material
inlet

Roller

Nozzle
Ring

Hot Gas
inlet

()Mill Main Drive

Coarse
Material
outlet

 ( )4 ( -: ) Vertical Mill
Product

Feeding chute

Separator

Feed

()3

External circuit for

coarse Material

Roller

Nozzle Ring

Hot Gas

Table

Gear Box

Scraper

* ( ) Nozzle Ring ( )Louver Ring .

( ) Tow Roller ,
() ()
. ()Separator

( . )Pressure Drop
( )Separator ( )Separator
. ( ) Nozzle Ring
( )Pressure Drop

 ( ) Mill Fan
( )External Circuit for coarse Material (. )Pressure Drop
(-:)Vertical Roller Mill
( )Feeding Chute ()Rotary lock
( )Triple Gate
( . )False Air
( )Table ( )Table
( )Centrifugal Force ( )Rollers ()Roller
( )Table ( )Hydraulic power
( )Rollers .
( )Raw mill Fan
( )Separator
( )Table . ( )Coarse
( )Nozzle Ring ( )Scraper
( ) External circuit for coarse Material
, ( )Raw mill Fan
( )Cyclone ( )Filter (. )Silos
( )Raw mill Fan

.
( Vertical Roller
)Mill ( )Ball Mill
( )Vertical Roller Mill ( )Cement
( )Clinker ( )Additive (. )Cement
( )Vibration ( )Vertical Roller Mill
( )Ball Mill , ( )Vibration
( )Vibration
.
( )Roller
( )Ball Mill
( )Tow Chamber .

 ( )Gear Box ( )Reducer

( )Table .
( )Raw Mill Feed ( Vertical
) Roller Mill ( Mill
)Main Drive ( )Ball Mill
( )Ball ,
( )Vertical Roller Mill
( )Hydraulically
( )Mill Main Drive .
( )Mill Fan .
)Typical Block Diagram for Vertical Roller Mill (Raw Mill

 2:8 (-: )Roller Press

,
( )hydraulically


, ( )Pre Grinding
(( )Ball Mill ( )Ball Mill
( Vertical Roller
) Mill ,
( )Roller Press . ( )5
(-: )Roller Press

()2

( )5 ( )Roller Press
Product

()2

Separator

V Separator

Roller Press

Feed

 2:8 (-: )Horo Mill

( )Horizontal Roller Mill
) ) Cylindrical Shell ( )Ball Mill ()Roller
( )Roller Press
) ) Cylindrical Shell ( )Roller .
, ( )Ball Mill %51 , % 31
. % 41
,
( )Grindability . ()Ball Mill

( )Lifetime , ( )2
( )Horizontal Roller Mill -:

()2

)(Horo mill
Separator

System Filter

Product

Feeding

Horo Mill

System Fan

 ( -:)Note
.
* ) -: )Circulating Load
511
% % 211 ( )Cement ( )Ball ( Open
)Circuit % 511 %411 ( )Close Circuit
( )Separator %411 % 031 ( )Cement Mills
( )Separator . 011 % 031
031 ( )A
(.)2

Product

Separator

()2

OUT from Mill

Mill

Mill Feed

(= )Circulating Load

* 011

( -:)Note ( Horizontal Roller

)Horo Mill( )Mill . % 331