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    Clinker Manufacturing Process

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    Anirudh
    The document summarizes the process for manufacturing cement clinker. It involves (1) extracting and preparing raw materials like limestone and clay, (2) homogenizing the materials, (3) preheating and partially decomposing them in cyclones, (4) completing the decomposition reactions in a kiln at high temperatures, and (5) cooling and storing the finished clinker. Key steps in the kiln include decomposing clay minerals, dolomite, and calcite to form oxides, and eventually melting and sintering the mixture into nodules of clinker.

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    Clinker Manufacturing Process

    Uploaded by

    Anirudh
    240 views14 pages
    The document summarizes the process for manufacturing cement clinker. It involves (1) extracting and preparing raw materials like limestone and clay, (2) homogenizing the materials, (3) preheating and partially decomposing them in cyclones, (4) completing the decomposition reactions in a kiln at high temperatures, and (5) cooling and storing the finished clinker. Key steps in the kiln include decomposing clay minerals, dolomite, and calcite to form oxides, and eventually melting and sintering the mixture into nodules of clinker.

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    Tells the major process

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    Clinker manufacturing process

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    The document summarizes the process for manufacturing cement clinker. It involves (1) extracting and preparing raw materials like limestone and clay, (2) homogenizing the materials, (3) preheating and partially decomposing them in cyclones, (4) completing the decomposition reactions in a kiln at high temperatures, and (5) cooling and storing the finished clinker. Key steps in the kiln include decomposing clay minerals, dolomite, and calcite to form oxides, and eventually melting and sintering the mixture into nodules of clinker.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    240 views14 pages

    Clinker Manufacturing Process

    Uploaded by

    Anirudh
    The document summarizes the process for manufacturing cement clinker. It involves (1) extracting and preparing raw materials like limestone and clay, (2) homogenizing the materials, (3) preheating and partially decomposing them in cyclones, (4) completing the decomposition reactions in a kiln at high temperatures, and (5) cooling and storing the finished clinker. Key steps in the kiln include decomposing clay minerals, dolomite, and calcite to form oxides, and eventually melting and sintering the mixture into nodules of clinker.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
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    The key takeaways are the main steps involved in the clinker manufacturing process which are extraction and preparation of raw materials, homogenization, pre-heating, kiln phase, cooling and storing.

    The main steps involved in the clinker manufacturing process are extraction and preparation of raw materials, homogenization, pre-heating, kiln phase, cooling and storing.

    The main reactions that take place during the kiln phase are clay decomposition, dolomite decomposition, low-temperature calcite decomposition, and reactions of alumina and iron oxide.

    CLINKER

    MANUFACTURING
    PROCESS
    C.V. Anirudh
    111117026
    EXTRACTION AND PREPARATION
    OF RAW MATERIALS
     The main raw materials (limestone, clay chalk or basalt)
    are quarried from natural rocks. They are crushed and
    transferred to pre-blending storage where other
    substances (such as sand, iron ore, bauxite, shale, slag, fly
    ash) are added to get the desired chemical composition.
    HOMOGENIZATION
     The raw materials are ground in the raw mill where the
    particle size is reduced on a 90 um sieve and then
    transferred to a homogenization silo to ensure the
    production of uniform and good quality clinker.
    PRE-HEATING
     The homogenous mixture of raw materials is heated and
    transformed into oxides (that are ready for the burning phase in
    the kiln) in pre-heater cyclones fitted with a pre-calciner fired
    with petroleum, natural gas or coal.
    KILN PHASE
     Evaporation of free water: A pressure above atmospheric
    is required to vaporize the water from the slurry mixture
    of raw materials. Water becomes superheated and the
    evaporation gradually stops when the temperature rises
    above 120°C.
     Clay decomposition: “Clay” minerals account
    for most of the alkalis in the raw materials,
    the most common of which is kaolinite,
    Al2Si2O5(OH)4. The detached alkalis react with
    the acid gases present in the kiln at high
    temperature. The effective reactions here
    are:

    Si2Al2O5(OH)2→ 2 SiO2 + Al2O3 + 2 H2O (vapor)

    KAlSi3O8 (orthoclase) + 0.5 SO2 + 0.25 O2 → 


    3 SiO2 + 0.5 Al2O3 + 0.5 K2SO4
     Dolomite decomposition: The magnesia in
    the raw-mix exists mainly as dolomite,
    CaMg(CO3)2, but also as silicate or in
    carbonate form. Dolomite reacts as follows: 

    CaMg(CO3)2→ CaCO3 + MgO + CO2 


     Again, non-carbonate magnesium compounds
    (for example, phlogopite) react thus:

    KMg3AlSi3O10(OH)2 + 0.5 SO2 + 0.25 O2 →


    0.5 K2SO4 + 3 MgO + 0.5 Al2O3 + 3 SiO2 + H2O
    (vapor)
     Low-temperature calcite decomposition:
    Calcium carbonate, present in the raw-mix
    as calcite, produces carbon dioxide, the
    amount of which exceeds half the mass of
    the finished clinker. This requires a huge
    heat input. The efficiency of this reaction is
    one of the factors that determine the output
    and heat consumption in the kiln. Pure
    calcite in the kiln decomposes at around
    650°C: 
    2 CaCO3 + SiO2 → Ca2SiO4 + 2 CO2 
     Alumina and iron oxide react: Calcium
    carbonate continues to react with other oxides
    and no free lime is yet formed. Though
    tricalcium aluminate is stable here, poorly
    crystallized mayenite (Ca12Al14O33) seems to be
    formed. The reactions at this stage are: 
    12 CaCO3 + 7 Al2O3 → Ca12Al14O33 + 12 CO2 
    4 CaCO3 + Al2O3 + Fe2O3 → Ca4Al2Fe2O10 + 4 CO2 
    4 CaCO3 + Al2O3 + Mn2O3 → Ca4Al2Mn2O10 + 4 CO2
     Decomposition of remaining calcite: A little
    amount of calcite remains at this stage and
    forms free lime for the first time:
    CaCO3 → CaO + CO2
     Sintering: Sintering is the process of compacting and
    forming a solid mass of material by heat or pressure to the
    point of liquefaction without actually melting it. When the
    temperature inside the kiln reaches about 1300°C (the
    eutectic melting point of aluminate, ferrite and silicate),
    clinker flux is produced. The rate of melting varies, and
    when the liquid is formed, alite, which becomes stable at
    above 1250°C, begins to form. The principal reaction of
    this stage is as follows: 
    Ca2SiO4 + CaO → Ca3SiO5
     The liquid formed both acts as a solvent of ion exchange
    between the solid phases and draws the reactant particles
    together by surface tension. The powdery or granular
    mixture quickly solidifies into spherical nodules of clinker.
    COOLING AND STORING
     The mixture inside the slightly inclined kiln is rapidly
    cooled from 2000°C to 100°C-200°C. Thus, the final
    product, clinker, is produced, and then stored, ready for
    the production of cement.
    REFERENCES
     Pictures – Google Images
     Content and Information – 1.
    www.civiltoday.com
    2. Engineering Chemistry – Jain
    and Jain 3. Wikipedia -
    Clinker

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