WO2012038859A1 - A method for adjusting the cement clinker chemistry - Google Patents
A method for adjusting the cement clinker chemistry Download PDFInfo
- Publication number
- WO2012038859A1 WO2012038859A1 PCT/IB2011/054006 IB2011054006W WO2012038859A1 WO 2012038859 A1 WO2012038859 A1 WO 2012038859A1 IB 2011054006 W IB2011054006 W IB 2011054006W WO 2012038859 A1 WO2012038859 A1 WO 2012038859A1
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- WIPO (PCT)
- Prior art keywords
- cement raw
- raw materials
- grinding machine
- cement
- gases
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B7/00—Hydraulic cements
- C04B7/36—Manufacture of hydraulic cements in general
- C04B7/361—Condition or time responsive control in hydraulic cement manufacturing processes
- C04B7/362—Condition or time responsive control in hydraulic cement manufacturing processes for raw materials handling, e.g. during the grinding or mixing step
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/20—Details, accessories, or equipment peculiar to rotary-drum furnaces
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/20—Details, accessories, or equipment peculiar to rotary-drum furnaces
- F27B7/2016—Arrangements of preheating devices for the charge
- F27B7/2025—Arrangements of preheating devices for the charge consisting of a single string of cyclones
Definitions
- the present invention relates to a method of adjusting the cement clinker chemistry in terms of LSF (Lime Saturation Factor) and SM (Silica Module) 5 during production of cement clinker, where cement raw meal is prepared by feeding metered amounts of different cement raw materials, the compositions of which have been pre-analysed at least for the contents of Si0 2 and CaO, into a grinding machine, co-grinding the cement raw materials in said grinding machine, sorting the ground cement raw materials into a fine fraction and a coarse fraction i o in a separator, directing the fine fraction suspended in gases to a separation device, separating the fine fraction in form of finish prepared cement raw meal from the gases in said separation device and filtering said gases in a filter installation. Further, the invention relates to a plant for carrying out the method according to the invention.
- cement raw materials used in cement production are limestone, chalk, marl, clay, shale and other supplementary materials such as sand, pulverised fuel ash, pyrite ash or iron ore to achieve the desired bulk composition.
- the essential reactions in making cement are the calcination of limestone to produce lime (CaO) and the combination of this lime with silica to make belite (CaO) 2 Si0 2 and, especially, alite (CaO) 3 Si0 2 .
- the composition of the blended cement raw materials fed into the grinding machine has to be continuously
- LSF is defined by the contents of the oxides:
- LSF 100 * %CaO / (2.8 %Si0 2 + 1 .18 %AI 2 0 3 + 0.65 %Fe 2 0 3 ) and SM is defined by:
- the only available fuel is low grade coal of high ash content and low heating value.
- the use of low grade coal gives a fixed, unavoidable flow of coal ash into the kiln system of the cement production plant and thus into the clinker.
- the raw meal of such a plant must accordingly be adjusted to a high LSF in order to produce clinker of normal LSF, as the coal ash usually contains little CaO. This may be problematic, if no high-grade limestone is available at the plant.
- the amount of certain alternative fuels containing high ash content may also be limited for the same reason.
- the main raw materials are marls of low and high CaC0 3 content, respectively, but the two types of marl may not be available in the quarry in the right ratio for cement raw material, thus preventing an optimum utilisation of the quarry, as only one of the marls can be used up completely, while a proportion of the other marl must be left unused.
- this is achieved by a method of the kind mentioned in the introduction, and being characterized in that a metered proportion of the coarse fraction from the separator is discarded if the content of Si0 2 in the cement raw materials fed into the grinding machine is higher than a predetermined value and a metered proportion of the filtered material from the filter installation is discarded if the content of CaO in the cement raw materials fed into the grinding machine is higher than a predetermined value.
- the discarded material flows may be turned into valuable products.
- the filtered material constitutes a good filler material in for instance cement, whereas the coarse fraction from the separator, often being sand with mean grain size 200-300 micron, in certain cases may be used as a raw material for other mineral products. It is also an option to process the discarded material flows further by various separation methods in order to obtain materials that could be recycled to plant.
- the chemistry of the discarded materials are analysed and used for calculating the feed amounts into the grinding machine of the different cement raw materials.
- the chemistry of the cement raw meal in storage may be analysed and used for calculating the feed amounts into the grinding machine of the different cement raw materials.
- the chemistry of the cement raw meal being fed into the kiln system may be analysed and used for calculating the feed amounts into the grinding machine of the different cement raw materials.
- 20 clinker comprises feeding means for feeding metered amounts of different cement raw materials, the compositions of which have been pre-analysed at least for the contents of Si0 2 and CaO, grinding machine for co-grinding the cement raw materials, a separator for sorting the ground cement raw materials into a fine fraction and a coarse, a separation device for separating the fine fraction in form 25 of finish prepared cement raw meal from gases and a filter installation for filtering said gases, and is characterized in that it comprises means for discarding a metered proportion of the coarse fraction from the separator if the content of Si0 2 in the cement raw materials fed into the grinding machine is higher than a predetermined value and means for discarding a metered proportion of the
- the separation device may comprise one or more cyclones or a filter installation.
- Fig. 1 a plant for production of cement clinker comprising a raw milling system 1 and a kiln system 2.
- the shown milling system 1 comprises a raw storage for four different raw materials a to d, a vertical mill 3 having a grinding machine 4 and a separator 5, a cyclone 6, a fan 7, a filter installation 8, a stack 9, two filter dust storage 10, 1 1 and a cement raw meal storage 12,
- the shown kiln system 2 comprises a multi stage cyclone preheater 21 having feed inlet F for feeding cement raw meal into the preheater 21 , a calciner 22 with separation cyclone 23, a rotary kiln 24, clinker cooler 25 and burners 26, 27 for firing coal or other fuel into the calciner 22 and kiln 24, respectively. Gases are drawn through the kiln system by means of a fan 28.
- a metered proportion of the coarse fraction from the separator 5 is discarded if the content of Si0 2 in the cement raw materials fed into the vertical mill 3 is higher than a predetermined value. In practise this may be done by means of a splitter gate 31 dividing the coarse fraction into two sub flows of which one is returned to the vertical mill 3 and one is directed to a storage 32 for discarded coarse material. Further it is suggested according to the invention that a metered proportion of the filtered material from the filter installation 8 is discarded if the content of CaO in the cement raw materials fed into the vertical mill 3 is higher than a predetermined value. This may simply be done by sending a flow of the material from the filter installation 8, which otherwise is intended for being blended into the cement raw meal in storage 12, to storage 33 for discarded filter material, as shown by arrows 34.
- cement clinker chemistry in terms of LSF and SM may easily be adjusted to optimum composition for the respective cement raw material deposit.
Abstract
A description is given of a method as well as a plant of adjusting the cement clinker chemistry in terms of LSF (Lime Saturation Factor) and SM (Silica Module) during production of cement clinker, where cement raw meal is prepared by feeding metered amounts of different cement raw materials (a-d), the compositions of which have been pre-analysed at least for the contents of Si02 and CaO, into a grinding machine (4), co-grinding the cement raw materials in said grinding machine (4), sorting the ground cement raw materials into a fine fraction and a coarse fraction in a seperator (5), directing the fine fraction suspended in gases to a seperation device (6), seperating the fine fraction in form of finish prepared cement raw meal from the gases in said seperation device (6) and filtering said gases in a filter installation (8). The method and plant are peculiar in that metered proportion of the coarse fraction from the seperator (5) is discarded if the content of Si02 in the cement raw materials fed into the grinding machine (4) is higher than a predetermined value and a metered proportion of the filtered material from the filter installation (8) is discarded if the content of CaO in the cement raw materials fed into the grinding machine (4) is higher than a predetermined value.
Description
A METHOD FOR ADJUSTING THE CEMENT CLINKER CHEMISTRY
The present invention relates to a method of adjusting the cement clinker chemistry in terms of LSF (Lime Saturation Factor) and SM (Silica Module) 5 during production of cement clinker, where cement raw meal is prepared by feeding metered amounts of different cement raw materials, the compositions of which have been pre-analysed at least for the contents of Si02 and CaO, into a grinding machine, co-grinding the cement raw materials in said grinding machine, sorting the ground cement raw materials into a fine fraction and a coarse fraction i o in a separator, directing the fine fraction suspended in gases to a separation device, separating the fine fraction in form of finish prepared cement raw meal from the gases in said separation device and filtering said gases in a filter installation. Further, the invention relates to a plant for carrying out the method according to the invention.
15
The most common cement raw materials used in cement production are limestone, chalk, marl, clay, shale and other supplementary materials such as sand, pulverised fuel ash, pyrite ash or iron ore to achieve the desired bulk composition.
20
The essential reactions in making cement are the calcination of limestone to produce lime (CaO) and the combination of this lime with silica to make belite (CaO)2Si02 and, especially, alite (CaO)3Si02.
25 In order to obtain optimum burnability of a blend of cement raw materials, meaning the easiness the cement raw materials react with each other to produce the clinker minerals and thus to obtain optimum clinker composition being one of the key factors determining the cement quality, the composition of the blended cement raw materials fed into the grinding machine has to be continuously
30 controlled with regard to different material parameters, such as LSF and SM. The fineness of the cement raw materials and the AR (Alumina ratio) are material parameters to be taken into consideration when preparing an optimum cement raw material blend.
LSF is defined by the contents of the oxides:
LSF = 100 * %CaO / (2.8 %Si02 + 1 .18 %AI203 + 0.65 %Fe203) and SM is defined by:
SM = %Si02 / (%AI203 + %Fe203)
Many raw material deposits vary a great deal in composition, and in some cases it is not even possible to adjust the clinker chemistry to desired LSF and SM with the available ingredients. This is the case, if for instance (A) the ratio % Si02 to % CaO is too high in the main ingredient marl, where addition of other ingredients such as clay, iron ore etc. only tend to aggravate the problem. If on the other hand (B) the ratio % Si02 to % CaO is too low, it will not help to add limestone or chalk.
Further, in many regions the only available fuel is low grade coal of high ash content and low heating value. The use of low grade coal gives a fixed, unavoidable flow of coal ash into the kiln system of the cement production plant and thus into the clinker. The raw meal of such a plant must accordingly be adjusted to a high LSF in order to produce clinker of normal LSF, as the coal ash usually contains little CaO. This may be problematic, if no high-grade limestone is available at the plant. The amount of certain alternative fuels containing high ash content may also be limited for the same reason.
It is very common that the main raw materials are marls of low and high CaC03 content, respectively, but the two types of marl may not be available in the quarry in the right ratio for cement raw material, thus preventing an optimum utilisation of the quarry, as only one of the marls can be used up completely, while a proportion of the other marl must be left unused.
It is the objective of the present invention to provide a method as well as a plant for adjusting the cement clinker chemistry in terms of LSF and SM during
production of cement clinker, whereby the mentioned disadvantages are eliminated or at least significantly reduced.
According to the present invention this is achieved by a method of the kind mentioned in the introduction, and being characterized in that a metered proportion of the coarse fraction from the separator is discarded if the content of Si02 in the cement raw materials fed into the grinding machine is higher than a predetermined value and a metered proportion of the filtered material from the filter installation is discarded if the content of CaO in the cement raw materials fed into the grinding machine is higher than a predetermined value.
It is hereby obtained that certain marginal cement raw material deposits may be used and fuelling with non-expensive low grade coal may be done. This is because the cement clinker chemistry in terms of LSF and SM may easily be adjusted to optimum composition by discarding metered amounts of material from appropriate process stages where the concentration of the surplus cement raw material component, being either Si02 or CaO, is high. As a side effect, reduced wear rate on the grinding machine components may be expected, if a metered proportion of the coarse fraction from the separator is discarded, as this coarse fraction has a high concentration of hard components.
The discarded material flows may be turned into valuable products. Thus, the filtered material constitutes a good filler material in for instance cement, whereas the coarse fraction from the separator, often being sand with mean grain size 200-300 micron, in certain cases may be used as a raw material for other mineral products. It is also an option to process the discarded material flows further by various separation methods in order to obtain materials that could be recycled to plant.
In order to control the chemistry balance of the production it is preferred that the chemistry of the discarded materials are analysed and used for calculating the feed amounts into the grinding machine of the different cement raw materials. As an alternative or as a supplement the chemistry of the cement raw meal in storage may be analysed and used for calculating the feed amounts into the
grinding machine of the different cement raw materials. Also, the chemistry of the cement raw meal being fed into the kiln system may be analysed and used for calculating the feed amounts into the grinding machine of the different cement raw materials.
5
Further, at plants using large amounts of alternative fuels appearing in small portions and in many variant with quite different content of ash and ash composition, it may be advantageously to calculate the actual oxide flows with the fuels fed into the kiln system on the basis of the fuel consumption and the i o fuel ash composition and to use these to calculate the feed amounts into the grinding machine of the different cement raw materials and/or to calculate the amount of coarse fraction from the separator or the amount of filtered material respectively that has to be discarded.
15 It may be advantageously to pre-analyse for the different cement raw materials also for Al203 and Fe203.
The plant for carrying out the method according to the invention for adjusting the cement clinker chemistry in terms of LSF and SM during production of cement
20 clinker comprises feeding means for feeding metered amounts of different cement raw materials, the compositions of which have been pre-analysed at least for the contents of Si02 and CaO, grinding machine for co-grinding the cement raw materials, a separator for sorting the ground cement raw materials into a fine fraction and a coarse, a separation device for separating the fine fraction in form 25 of finish prepared cement raw meal from gases and a filter installation for filtering said gases, and is characterized in that it comprises means for discarding a metered proportion of the coarse fraction from the separator if the content of Si02 in the cement raw materials fed into the grinding machine is higher than a predetermined value and means for discarding a metered proportion of the
30 filtered material from the filter installation if the content of CaO in the cement raw materials fed into the grinding machine is higher than a predetermined value.
The separation device may comprise one or more cyclones or a filter installation.
The invention will now be described in further details with reference to the drawing, being diagrammatical, and where Fig. 1 shows a plant for production of cement clinker according to the invention.
In Fig. 1 is shown a plant for production of cement clinker comprising a raw milling system 1 and a kiln system 2. The shown milling system 1 comprises a raw storage for four different raw materials a to d, a vertical mill 3 having a grinding machine 4 and a separator 5, a cyclone 6, a fan 7, a filter installation 8, a stack 9, two filter dust storage 10, 1 1 and a cement raw meal storage 12, whereas the shown kiln system 2 comprises a multi stage cyclone preheater 21 having feed inlet F for feeding cement raw meal into the preheater 21 , a calciner 22 with separation cyclone 23, a rotary kiln 24, clinker cooler 25 and burners 26, 27 for firing coal or other fuel into the calciner 22 and kiln 24, respectively. Gases are drawn through the kiln system by means of a fan 28.
During operation of the plant cement raw materials are prepared into cement raw meal by feeding metered amounts of the four different cement raw materials a to d, the compositions of which have been pre-analysed at least for the content of
Si02 and CaO, into the vertical mill 3, wherein the cement raw materials are ground in the grinding machine 4. In the vertical mill 3 ground cement raw materials are lifted up to the separator 5 suspended in gases arriving from the kiln system 2 via fan 28 and sorted into a fine fraction and a coarse fraction. The coarse fraction is returned to the grinding machine 4 via a duct 13, whereas the fine fraction suspended in gases is directed to the separation cyclone 6 via duct 14, thereby being separated from the gases in form of finish prepared cement raw meal, which is directed to the cement raw meal storage 12 via duct 15. The gases from said separation cyclone 6 are via fan 7 directed into the filter installation 8, from where dusty cement raw materials are sent to storages 10, 1 1 via ducts 16, 17, whereas the cleaned gases are sent to the stack 9. Some of the gases leaving fan 7 may be returned to the vertical mill 3. Cement raw meal is via
a duct 18 conducted to the feed inlet F of the kiln system 2 and heat treated in known manner.
In order to adjust the cement clinker chemistry in terms of LSF and SM during production of cement clinker it is suggested according to the present invention that a metered proportion of the coarse fraction from the separator 5 is discarded if the content of Si02 in the cement raw materials fed into the vertical mill 3 is higher than a predetermined value. In practise this may be done by means of a splitter gate 31 dividing the coarse fraction into two sub flows of which one is returned to the vertical mill 3 and one is directed to a storage 32 for discarded coarse material. Further it is suggested according to the invention that a metered proportion of the filtered material from the filter installation 8 is discarded if the content of CaO in the cement raw materials fed into the vertical mill 3 is higher than a predetermined value. This may simply be done by sending a flow of the material from the filter installation 8, which otherwise is intended for being blended into the cement raw meal in storage 12, to storage 33 for discarded filter material, as shown by arrows 34.
In this way the cement clinker chemistry in terms of LSF and SM may easily be adjusted to optimum composition for the respective cement raw material deposit.
Claims
1 . A method of adjusting the cement clinker chemistry in terms of LSF (Lime Saturation Factor) and SM (Silica Module) during production of cement clinker, 5 where cement raw meal is prepared by feeding metered amounts of different cement raw materials (a-d), the compositions of which have been pre-analysed at least for the contents of Si02 and CaO, into a grinding machine (4), co-grinding the cement raw materials in said grinding machine (4), sorting the ground cement raw materials into a fine fraction and a coarse fraction in a separator (5), directing i o the fine fraction suspended in gases to a separation device (6), separating the fine fraction in form of finish prepared cement raw meal from the gases in said separation device (6) and filtering said gases in a filter installation (8), characterized in that a metered proportion of the coarse fraction from the separator (5) is discarded if the content of Si02 in the cement raw materials fed
15 into the grinding machine (4) is higher than a predetermined value and a metered proportion of the filtered material from the filter installation (8) is discarded if the content of CaO in the cement raw materials fed into the grinding machine (4) is higher than a predetermined value.
20 2. A method according to claim 1 , characterized in that the chemistry of the discarded materials are analysed and used for calculating the feed amounts into the grinding machine of the different cement raw materials.
3. A method according to claim 1 or 2, characterized in that the cement raw meal 25 in storage (12) is analysed and used for calculating the feed amounts into the grinding machine of the different cement raw materials.
4. A method according to claim 1 or 2, characterized in that the chemistry of the cement raw meal being fed into a kiln system is analysed and used for
30 calculating the feed amounts into the grinding machine of the different cement raw materials.
5. A method according to claim 1 , characterized in that the actual oxide flows with the fuels fed into a kiln system are calculated on the basis of the fuel consumption and the fuel ash composition and used to calculate the feed amounts into the grinding machine of the different cement raw materials.
5
6. A method according to claim 1 , characterized in that the actual oxide flows with the fuels fed into a kiln system are calculated on the basis of the fuel consumption and the fuel ash composition and used to calculate the amount of coarse fraction from the separator or the amount of filtered material respectively i o that has to be discarded.
7. A plant for carrying out the method according to claim 1 for adjusting the cement clinker chemistry in terms of LSF and SM during production of cement clinker comprises feeding means for feeding metered amounts of different
15 cement raw materials, the compositions of which have been pre-analysed at least for the content of Si02 and CaO, a grinding machine (4) for co-grinding the cement raw materials, a separator (5) for sorting the ground cement raw materials into a fine fraction and a coarse, a separation device (6) for separating the fine fraction in form of finish prepared cement raw meal from gases and a
20 filter installation (8) for filtering said gases, characterized in that it comprises means (13, 31 ) for discarding a metered proportion of the coarse fraction from the separator if the content of Si02 in the cement raw materials fed into the grinding machine (4) is higher than a predetermined value and means (34) for discarding a metered proportion of the filtered material from the filter installation
25 (8) if the content of CaO in the cement raw materials fed into the grinding machine (4) is higher than a predetermined value.
8. Plant according to claim 7, characterized in that the separation device comprises one or more cyclones.
30
9. Plant according to claim 7, characterized in that the separation device comprises a filter installation.
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| DKPA201000863 | 2010-09-24 | ||
| DKPA201000863 | 2010-09-24 |
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| WO2012038859A1 true WO2012038859A1 (en) | 2012-03-29 |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104150794A (en) * | 2014-08-30 | 2014-11-19 | 中国地质大学（武汉） | Preparation method for Portland cement with iron tailings |
| WO2017080874A1 (en) * | 2015-11-10 | 2017-05-18 | Thyssenkrupp Industrial Solutions Ag | Method for producing cement clinker |
| CN108080123A (en) * | 2017-11-17 | 2018-05-29 | 邯郸金隅太行水泥有限责任公司 | A kind of cement grinding mill machine washing mill method |
| CN115321850A (en) * | 2022-09-05 | 2022-11-11 | 富源县宏发恒际水泥有限公司 | Raw material, clinker and cement formula and preparation method |
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| EP0911303A1 (en) * | 1997-10-22 | 1999-04-28 | Mitsubishi Heavy Industries, Ltd. | Method and system for controlling mixing of raw materials for cement |
| EP1277709A1 (en) * | 2001-07-13 | 2003-01-22 | Cemex Trademarks Worldwide Ltd. | Method to produce cement clinker using coke with a high content of sulfur |
| WO2005030669A1 (en) * | 2003-09-23 | 2005-04-07 | Polysius Ag | Method and device for the production of a hydraulic binding agent |
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| US2006939A (en) * | 1934-06-05 | 1935-07-02 | Valley Forge Cement Company | Manufacture of cement |
| EP0911303A1 (en) * | 1997-10-22 | 1999-04-28 | Mitsubishi Heavy Industries, Ltd. | Method and system for controlling mixing of raw materials for cement |
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104150794A (en) * | 2014-08-30 | 2014-11-19 | 中国地质大学（武汉） | Preparation method for Portland cement with iron tailings |
| CN104150794B (en) * | 2014-08-30 | 2016-08-31 | 中国地质大学（武汉） | A kind of preparation method of iron tailings portland cement |
| WO2017080874A1 (en) * | 2015-11-10 | 2017-05-18 | Thyssenkrupp Industrial Solutions Ag | Method for producing cement clinker |
| CN108080123A (en) * | 2017-11-17 | 2018-05-29 | 邯郸金隅太行水泥有限责任公司 | A kind of cement grinding mill machine washing mill method |
| CN108080123B (en) * | 2017-11-17 | 2019-10-15 | 邯郸金隅太行水泥有限责任公司 | A kind of cement grinding mill machine washing mill method |
| CN115321850A (en) * | 2022-09-05 | 2022-11-11 | 富源县宏发恒际水泥有限公司 | Raw material, clinker and cement formula and preparation method |
| CN115321850B (en) * | 2022-09-05 | 2023-06-23 | 富源县宏发恒际水泥有限公司 | Raw material, clinker and cement formulation and preparation method thereof |
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