Cement (2025)

14/08/2023

Is there are any possibility that kiln inlet read actual CO on the other side there is excess O2 or high O2 at the kiln inlet ?!

Wait our full answer tomorrow, with another case.

$of refractory materials in cement rotary killn. • Before beginning we should satisfy the ...$

13/09/2020

of refractory materials in cement rotary killn.

• Before beginning we should satisfy the
following

▪︎ Safety for installation personnel.

▪︎ Maximize quality installation, that The bricks must be installed in such a way that the lining fits tightly against the kiln shell and subsequent loosening or twisting is impossible.

▪︎ Acceptable bricking progress.
This can also be improved by the use of fork-lift trucks, rollerconveyers and other equipment.

▪︎Installation of the bricks without damages and prevention of damage the bricks during installation.
▪︎ Correct arrangement of the joints

□ By studying the perivious criteria you should select the technique of installation the kiln bricks for example, the time planning, the safety, the quality and finally often the length of damage could help to select the technique required.

the ring bricks through correlations depends on the killn diameter.

• Start rings according to the indicated mixing ratio.

•Knock the bricks in place with rubber hammer Frequently check that rings are parallel to radiallines.

Important note.
always that cold face of brick is in full contact with kiln shell.

○ key bricks.

It is used to close the ring, the gap is measured and a combination of whole bricks and split ones are used to complete the ring Then steel shims are driven between the bricks to tighten the lining.

○ shell deformation
Some times a challenge for bricklayers is the shell deformation with mortar or castable. So it is necessary to clean the shell surface well before installation the bricks to prevent the bad quality of installation.

To be continued with the installation technique.

26/06/2020

The following posts will be focused on the killn thermal insulation:
The main point of view is the and the thought strategy at the perivious posts there were many critical points and another opinions about the the problems we show, so we would like to stand with the key words or references that the cases we show may not specified to your the problem occurring in your plant, that may happen due to many variable parameter as the plant design, the process operating, the material difference, and the strategy followed to over come problem
But in other cases such as the following one we are going step by step to help our audience the killn insulation.
Today we are standing at the entrance of

■ The unique conditions in cement manufacturing have always required specialized , especially now,
when more and more alternative fuels are used.

○ Know how ?

The key to establishing your question comes from specifying the problem so you can solve it step by once. Know how selection criteria.

● Top priorities for the cement industry today are to and solve the corrosion problems related to increased usage of alternative fuels.

● in the form of alkali pe*******on is unavoidable in cement production.
The worst damage occurs in lower cyclone stages and riser ducts, kiln inlets and even calciner.

So we are now standing in the opposite of two main problems in our industry thermo chemical attacking, and thermodynamics attacks.

¤ Thermo chemical attacks as result of the high process temp and the the material action.

¤ Thermodynamic attacks as a result of the process temp and the the fluidity material passing.

● preheater
• Cyclone stage 1
Refractory lining thickness: 114 mm
Insulating thickness: 38 mm
Process temp: ≈ 306°C
External shell temp: ≈ 70°C

• Cyclone stage 2
Refractory lining thickness: 114 mm
Insulating thickness: 50 mm
Process temp: ≈ 503°C
External shell temp: ≈ 83°C

• Cyclone stage 3
Refractory lining thickness: 114 mm
Insulating thickness: 64 mm
Process temp: ≈ 665°C
External shell temp: ≈ 93°C

• Cyclone stage 4
Refractory lining thickness: 114 mm
Insulating thickness: 76 mm
Process temp: ≈ 806°C
External shell temp: ≈ 101°C

• Cyclone stage 5
Refractory lining thickness: 114 mm
Insulating thickness: 76 mm
Process temp: ≈ 890°C
External shell temp: ≈ 109°C

● Heat transfer phenomena
As known for every one the driving force of heat transfer is the temperature difference.
Note that the driving force in mass transfer is the concentration difference.

Modes of heat transfer

1_ conduction
Apply for solid (single phase )

2_ convection
Applying between two phases for example fluid phase

3_ radiation
Apply between fluid and solid at very high temp
Or between gasses.

Shortly out needs is to save the heat energy inside the killn system and minimize losses as possible.

In our next posts we are going to focus on every part as shown in the pic attached and the selection of the refractory chemistry.

If you can share your problem & don't forget rating the page.

17/06/2020

Today we are going to speak about a very important point take place at the cement killn

Coating in the cement killn is a protective layer on the lining in the sintering zone in the killn.

Coating in the killn can be classified as the following:
1_ thick coating layer (30:50 Cm)
2_ noal coating layer (10:20 Cm)✅
3_ thin coating layer about (10 Cm)

Benefits of coating layer:
That layer have an important role to keep the killn performance as
1_ reduction the heat transfer by radiation (we will speak about this point with the killn isolation &refractory in details )
As a result for the perivious point we will protect the killn shell from the thermal load.
2_ reduction the wear and abrasion.
3_ protect the refractory from the chemical attack by the clinker liquid phase.

is a thermo chemcal process occurs by the reaction between the clinker materials with the refractory (spinal), also some studies refer to the the best coating can be expected with liquid phase range about (25:27%) with silica ratio about (2.3:2.8).

Operational parameters to influence and keep coating layer in stable conditions
1_ Flame shape, and also the type of fuel..
2_ sintering zone temp
3_ also keep the killn in a steady state operational parameters.

Short note
Keep the theoretical parameters as a reference and the real or operating parameters in the other side for example, the shell diameter, the type of kill cement produced....etc

Keep in touch with next post
● thermal insulation
● Heat transfer conditions
● materials

15/06/2020

Suggest a topic to discuss in the next post or select of the following:

1/ ball mill charge.
2/ killn bricks & selection criteria.
3/ trump curve and separator performance.

○ you can send your problem and we will search for help you.

08/06/2020

From inbox
" in our plant there a raw ball mill we observed that the distribution of the ball isn't stable for the mill length that the big balls take place at the mill out let"
This problem lead to big balls make the small size balls deformed and the mill grindability processes doesn't complete, so what is the reasons of this problem?

08/06/2020

Known that it is a coal mill feeding hopper
Describe the bic and the physical phenomena of material passage.

16/03/2020

God save the world from Corona virus 🤲

13/03/2020

Transportation cement killn bricks during annual maintenance using machine instead of man power.

11/03/2020

Could you please find the formula to calculate consumption of grinding media at cement ball mill?
Thank you...
It was our friend's question l..

11/03/2020

Hi every one
Really I respect all members that belong to such this industry, feel his efforts. It is a huge body brain load.
Really you are strong enough to be here.
Welcome every one

06/03/2020

Hi every one
Let your problem and wait our strategy to overcome it,
Don't forget rating us .✍

28/12/2019

1_ Rapid hardening cement (RHC)
2_ Quick-setting cement (QSC).
3_ low heat cement (LHC).
4- Sulphate-resisting cement (SRC).
5_ Blast furnace slag cement (BFSC).
6_ High-alumina cement (HAC).
7_ White cement (WC).
8_ Coloured cement (CC).
9_ Pozzolanic cement (PzC).
10_ Air-entraining cement (AEC).
11_ hydro phobic cement (HpC).

Finally the most known type of cement Ordinary Portland Cement.

Which type/s of cement your plant produces?

15/12/2019

Simply you can can calculate the maximum feed rate of cement mill through the following.
1- tube mill
Feed rate = (main drive power)/ 35

2_ vertical mill
Feed rate = (main drive power) / 25

18/11/2019

Here the yesterday's problem analysis, we see none could reach the main reason and satisfied the problem well.
This problem hasn't any operational reasons but that is cause of the difference chemical formation of iron ore & slag, which also has an affect of the temp of decomposition.
Slag has much impurities than iron ore, I think that's well known for the all here.
slag lead to kiln over heating and more sulfur evaporation lead to closed cycle ...check sulfur in clinker and liquid phase percentage..

17/11/2019

It was our page's friend question, check your information & share your knowledge with the others.
Send your question to the page messages .

26/10/2019

Today's discussion about the killn and cooler bricks ? What is the Composition should be? And the mechanism of matching each area with the specified bricks? .. let's start check your information ?

28/09/2019

Ball mill charge during annual maintenance " raw mill "🌌

Cement

14/08/2023

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28/12/2019

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