I: OPR :07

Issue(1)

Date : 01/ 0 4/ 2012

Revision: ( 0 )

Date : 01/ 04 / 2012

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) ) quarrying
:

-1
.
-2

-3
.
(2


:
.1 .
.2
.
.3
.

.4
). (Benches

.5
) (Overburden

.

.
Mining system
:
.1 .
.2 .
.3
.4 )
(
.5 .
.6 .
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)Issue(1

I: OPR :07


.7 .

.

.

.

Raw Materials preparation

:
-1 ) ( Crushing & Grinding
Comminution
-2 ) (Raw Mix design
) (COMMINUTION

.
Blake 1858
Jaw crusher
:
.Compression

. Crushing
Grinding

compression or Impact . Friction force

Impact type crusher
Hammer Crusher Impact
crusher Roll crusher

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)Issue(1

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RAW MATERIALS STOCK PILE
- ) (
) .... ( -



. ) (

STAKER

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)Issue(1

I: OPR :07



.
Reclaimer
.

HOMOGENIZATION
) (

) (T
) (
) (Q
:
.

) (
.

)Stacker and
(Reclaimer
) (LHO ) (CHO
.

E Homogenizing
or Blending effect

:
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)Issue(1

I: OPR :07


S x =S / N
: N : S
: S x )
(

:
.1 :

) (CaO

) (CaO

) (CaO

) ( ) (100 =

Z
:
Z = [ ( Y P ) / ( Q P ) ] 100
%96
) (CaO = 4%
) . (CaO = 65% )= CaO
, (40 + 16 = 56 :
Z = 100{ [(0.04 0.65) ( 0.04 0.96)]} = 66.3 kg
) (100
66.3 ) (
= ) 33.7 = (66.3 100 1000
.
:
9
C1000 ~ 00
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CaO
+
CO2
[12 + (2X16)]) + 12 + 40
)(56
+
( 44

(40 + 16) +
66.3

CaCO3
)3X16
) ( ( 100
X

= ) = 56 / ( 100 * 66.3
118.39
2 :
) ( = %10
Clayey Sand & Iron ore
Calcined ore + Ignition loss
% 18.67 +
81.33%
% 100
Y
33.7

100 = ) 41.44 = 81.33 / ( 100 * 33.7
) ( 100 ) ( 118.39
) (41.44
= ) 0.626 = (41.44 +118.39 ) / ( 100

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)Issue(1

I: OPR :07

RAW MEAL
) ( Bins
) ( LSF & SM & AM
) ( Bins ) ( Raw mix
) / ( .

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)Issue(1

I: OPR :07

) ( Raw Meal Grinding

Raw meal
. ) (


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)Issue(1

I: OPR :07



.

.

)(Vertical Roller Mill

) (LSF & SM & AM .
Friction
Pressure - Roller
Table .
Seal Bin Table
Chute
Dam ring
.
Dam ring Nozzle ring
.

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)Issue(1

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) (Vertical Roller Mill

) / (

.


Grindability

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)Issue(1

I: OPR :07



) ( Bins
) (Mechanical recirculation
) (Seal bin .

150
)
( Dust bin CF. Silo ).(Kiln feed

) (Raw Mix Blending

Blending Silo :
:

.
:

.
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)Issue(1

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:
) . (Multi stage
.1
) Continuous
.2

) (Continuous
Controlled Flow

) (
) (
.
%1.5
CaO %0.15

Homogeneous Kiln Feed
:
:Kiln Feed Standard deviation requirements
1.0 % LSF , Or

< S

0.1 % CaO , Or

< S

S < 0.2 % CaCO3 , Or

3.0 % C3S

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< S

Date : 01/ 0 4/ 2012

)Issue(1

I: OPR :07


Kiln Feed System
-
-

.

Pyroprocessing

.1
.2
.3
.4

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Preheater
Calciner
Rotary Kiln
Cooler

Date : 01/ 04 / 2012

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)Issue(1

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PRE-HEATER

), (Co-Current

-

.

.

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)Issue(1

I: OPR :07




-:
)

( .

.
.

-:
,
:
,

.
.

,
,
.
) (Head ,
). (Flap gate

) / ( :
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)Issue(1

I: OPR :07


,
.
) / ( , -:
) ( ) (

.
) (

.

-:
.1
.
)
.2
( ). (CO
.3 .
) (False air .
.4

ROTARY KILN

1450

-

) (
) (
.
.

..


.
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)Issue(1

I: OPR :07

-:
.1 ) 20 (
.
.2 ) 5 ( .
)
.3
300 400 ( .
.4 ) ( 1/8

.

.5
) 300 ( .
) 880 920 (
.6
). (% 90 - %80

) 400 ( .

*
) %6 - %2
(
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)Issue(1

I: OPR :07


) . ( % 4 - % 2.5
.
*
) (
. ) (% 17 - %5
-:

*


) 24.3 / (
) 45.6 / ( .
:

) ( ) K Cal /
(m2 .hr ) 300.000
/ . 3 ( .
:

) . (K Cal / hr
3200 ~ 2270 = : /

.
= 765 ~ 543 /

) ( Free water



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)Issue(1

I: OPR :07




). (SO2
) (C2S ) , (C3A )( C4AF
) (% 35 20
) (C3S
)(Solid-state reaction

) (C3A) (C4AF
.

.
-:
.1 .

.2
) 300 (
.
.3

-1 ) : ( Free Lime CaO
. ) ( % 1.5
:
) (

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)Issue(1

I: OPR :07


) ( LSF

.
-2 ) : ( Liter weigh
.
) (CaO . ) 1300 ~ 1200
/ ( ) 1200 / (
) ( 1300 .

.1

) : ( O2

-:

.
.

-2 ) : ( CO
.

.
) ( O2& CO
.
-3 ) : ( CO2 .

-:
. Burnability
.1
Secondary air .
.2
Excess air
.3
.
False air .
.4
) . ( Coating / Lining
.5
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)Issue(1

I: OPR :07



.6
.

Clinker cooling
,
,
) . (Liquid phase
) ( -:
) 550 ~ 900 (
.1
: ) ( Powder
( Liquid phase ( C3A + C4AF ) ( C2S
. % 27 ) ( C2S ) ( C3S ) C2S +
( Free lime ) ( Free lime
150 .
-:
.2
) ( grain )
(Hydration Liquid phase Glass
phase
) ( C3A
. ) ( Dust Elite
( (C3S . ( ( Belite C2S

) ( Grate cooler

:



.
-:
.

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)Issue(1

I: OPR :07

.

.

( % ) AVERAGE

( % ) RANGE

OXIDES

65

69 ~ 60

CaO

21

24 ~ 18

SiO2

8 ~ 4

Al2O3

8 ~ 1

Fe2O3

5 ~ 3

MgO

2 ~ 1

K2O + Na2O

2 ~ 1

SO3

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)Issue(1

I: OPR :07

) (

) ( C3A
C3A -:
: 60

10 60
) . ( C3A )
( C3A
Expansion .

-:
) (C3A
.1
) ( SO3
.2

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)Issue(1

I: OPR :07

ball mill
: E
: F ) (
: G
: A
: B
: C
: D

Tube mill in closed circuit, Rotor type separator

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)Issue(1

I: OPR :07


) 2 (

packing

% kg 2 50

.

. :
) : (Minor component & MgO & Na2O
.1
K2O & SO3
) : ( Trace component TiO2 , P2O5 ,
.2
Cr2O3 , F , Mn2O3 , CL
.3
) ( Minor component
1 ) : ( MgO
) ( MgO )CaCO3 .
(MgCO3 - -
). (MgO
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)Issue(1

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) (MgO ) %2 (
) ( MgO
. Mg(OH)2
, Mg(OH)2
MgO
) ( .
) (MgO ) %2
( , ) %4 (
.
2 ) (Na2O ) : (K2O
, Alkalis
.
,

,
.

.


:


.


. ) . (% 0.6
3 ) : ( SO3
, .
%3.5 ) ( .
) (SO3
) (% 3 2 ) ( %1
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)Issue(1

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) (SO3
-:
) (SO3 ) (SO2

,
.
- -

-1 ) : (Alkalis Equivalent

(A.E. = Na2O + 0.659 K2O

(USUAL : < 0.6%

-2 ) : (Sulphate Modulus

M.SO3 = (0.85K + 1.29N 1.13CL) / SO3

)( USUAL : 0.83 < MSO3 < 1.00

-3 ) : ( Alkalis / Sulphate

) A.S.R = SO3 / ( K + 0.5 N

< (USUAL 0.6 < A.S.R

(1.4
) ( Trace elements
1 ) : ( TiO2
%1 :
) (C3S ) (C2S ). (Free Lime

-2 ) : (P2O5
, %2 :
) (C3S ) (C2S .

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)Issue(1

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3 ) : ( Cr2O3
, :
: ) Early & increase the

(compressive strength : ,
. EKSEMA

-4 ) : (CL

,
.
) ( .
.
) . ( % 0.1
5 ) : ( F
) (CaF2 ,
:
) (Dusting ) (B-C2S ). (-C2S

) (C3S ) (C2S .

-6 ) : (Mno3
) (C3S ) (C2S

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)Issue(1

I: OPR :07




.
, -:
) ( HM
.1
( Lime Saturation Factor ( LSF
.2
( Silica Modules ( SM
.3
( Alumina Modules ( AM
.4
) ( IL
.5
) ( BI
.6
) ( BF
.7
) ( PL
.8
- 1 ) :( HM
) ( CaO -:
HM = CaO/ SiO2 + Al2O3 + Fe2O3
1.7 ~ 2.3
- 2 ( Lime Saturation Factor ( LSF
) SiO2
. ( + Al2O3 + Fe2O3 ) (CaO


-:
(LSF = CaO /2.8( SiO2) +1.18( Al2O3) +0.65( Fe2O3
102 ~ 66
) ( SiO2
) ( CaO ) ( C3S ) ( Fe2O3
) ( C4AF )
. ( C3A -:
) ( CaO
LSF = 100
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)Issue(1

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) ( LSF ) ( Compressive strength
) (LSF ) ( Free lime )
(C2S ) ( C3S
) (Free lime ) (C2S ) ( LSF

: ) (LSF ) ( 66 )= C3S
( 0
- 3
3.6

~ 1.8

) SM )Silica Modules

SM = SiO2 / Al2O3 + Fe2O3

) ( SM ) ( C3S ) (C2S
) ( C3S Free lime
.
.
- 4 ) AM ) Alumina Modules
1 ~ 2

AM = Al2O3 / Fe2O3

) ( AM

) ( AM Liquid phase ) ( C3S

Dust
) IL ) Ignition Loss

-:
IL = 0.44 ( CaCO3 ) + 0.524 ( MgCO3 ) + + ( H2O )COM + ( MO )OR
)( Burning Index ( BI
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)Issue(1

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) (
:
2.6 4.5

BI = C3S / C3A + C4AF

) BF ) Burning Factor
) (kiln operator

:
( BF = (LSF ) + 10 (SM ) + 3 ( MgO + Alkalis
)USUAL : 100 < B.F. < 120 , best = 108
( Liquid phase ( PL
1450 :
( PL = 1.13 ( C3A ) + 1.35 ( C4AF ) + ( MgO + Alkalis
( % Usually : ( 23 % ~ 28

)Hydration of portland cement
) : ( Hydration ,

.

) :( Normal setting
.1
) ( Initial setting 45
) ( Final setting 10
. 2 ) : ( Flash setting

) ( SO3 )
( C3A.3CS.31H ) ( C3A .
. 3 ) : ( False setting
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)Issue(1

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.

) 140 (

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)Issue(1

I: OPR :07