130 TPH New Surplus Cement Grinding Plant – 4.6m X 13m ... · PDF file130 TPH New...

ACE Group

Cairo Rep. Office: ACE Group 3 Samir Mokhtar St., Ard Al Golf, Cairo – Egypt Tel: 00202 26903100/200, Fax: 00202 26903500 E-mail: [email protected] [email protected] website: www.aceindustry.net

130 TPH New Surplus Cement Grinding Plant – 4.6m X 13m Ball Mill

One (1) Unused Surplus Cement Grinding Plant - Delivered new in 2009 - Nominal capacity 130 tons per hour / 1 million tons per year - 4.6m X 13.0m Cement Mill , key features: * Shell Supported on Slide Shoe Bearings, lubrication systems * Two Compartments * Complete with all liners, partition, discharge grates * Complete with initial grinding ball charge * Central Gearbox Drive 750/15 rpm * 4500kW 750rpm 3/50/6600V Slip Ring Drive Motor * Liquid Rotor Starter for drive motor * Auxiliary drive * Water injection system - O-Sepa N3000 High Efficiency Separator, 150kW variable speed - All necessary ancillaries for closed circuit operation, including: * Circulating Fan, 180000 Bm3/h, 400kW motor, soft starter * Air Slides (imported part) * Air Slide Fans * Mill Dedusting Filter, 65000 Bm3/h (imported part ) * Aux. Dedusting Filter, 50000 Bm3/h (imported part) * Fans for Dust Filters, 160kW, 80kW * Flow Meter for Rejects * Foreign Material Trap - Ancillaries for Clinker and Gypsum Feed to Mill Bins, including: * Clinker Belt Conveyor with Magnetic Separator * Dedusting Filter, 25000 Bnm3/h (imported part) * Bucket Elevator to Mill Feed Bins (imported part)

mailto:[email protected]


http://www.aceindustry.net/

ACE Group


- Ancillaries for Cement Product Handling, including: * Finish Product Bucket Elevator (imported part) * Air Slides (imported part) * Dedusting Filters - Electrical cables - Control cables




ACE Group





ACE Group


Summary of Completion Engineering 98% Basic mechanical: 100% comp. Detail mechanical: 99% completed Civil: 97% completed Electrical: 90 % completed Civil construction 84 % Earth movement finished, except: ashes silo, NOx installation, electrical canalization, pluvial pull, urbanization and small foundation. Main foundation finished. Erecting main building, truck weighers and truck drivers building. Finished erection structures for coal mill, cover additives storage, cover limestone and coal storage, raw material conveyors to storage and platforms inside raw and cement silos, raw mill dosage building and preheater. Erecting structures for, raw mill building, feeding building to preheater, cover for platform kiln, clinker conveyors structure, cover for clinker and raw mill silo, cement mill dosage building, packing building and cement mill. Finished cladding in additives storage. External fence finished. Pending parking fence. Mechanical erection 67 % Limestone, coal and additives storage: 98% advance. Bridges for raw materials conveyors: 96% advance. Coal mill: 95 % advance. Preheater: 97% advance, even refractory. Equipments for extraction raw mill and cement silos: 95 % advance. Raw mill: 95 % advance. Kiln and clinker cooler: 99 % advance. Clinker conveyors: 35 % advance. Cement mill: 75 % advance. Main filters: 90 % advance. Electrical installation 37 % Electrical line 132 kV: 99 % advance. Main Substation: 98 % advance.




ACE Group


Coal mill installation: 98 % advance. Installing cables and trays in main gallery, raw mill conveyors, preheater building and main filters. Installing electrical cupboards in PE 07, PE 05, PE 03 and PE 02. Finished PLC,s locals in Raw mill. Finished unload test in hydraulic equipments for raw mill. Starting unload test in raw materials. Weight of materials summary:-

Units

INSTALLED

NOT INSTALLED

EQUIPMENTS Ton 3.684 STRUCTURES Ton 5.125 210 CHUTES Ton 1.103 STAINLESS STEEL CHUTES Ton 3 ENGRAVED FLOOR PLATE Ton 361 21 GRATING m2 2.907 9 BOTTOM RAIL 140 X4 Ton 3 HAND RAIL linear m 6.528 491 STAIRTREADS linear m 2.298 198 INSULATION m2 1.913 BROCOTELLA SHEET m2 3.087 COVER SHEET m2 14.653 9.704

AREA DENOMINATION 2 LIMESTONE RECEPTION 3 LIMESTONE STORAGE




ACE Group


4 RAW MATERIAL RECEPTION 5 RAW MATERIAL STORAGE 6 LIMESTONE TRANSPORT TO RAW DOSIFICATION 7 RAW MATERIAL TRANSPORT TO RAW DOSIFICATION 8 RAW MILL DOSIFICATION 9 RAW MILL

10 FLY ASH FOR RAW MATERIAL 11 RAW MATERIAL SILO 12 PREHEATER TOWER AND FILTER 13 KILN 14 KILN COOLER 15 COAL RECEPTION 16 COAL STORAGE 17 COAL MILL 18 COAL DOSING 19 CLINKER TRANSPORT TO SILO 20 CLINKER TRUCK LOADING INSTALLATION 21 CLINKER SILO 22 UNCOOKED SILO 23 CLINKER TRANSPORT TO CEMENT MILL 24 RAW MATERIAL TRANSPORT TO CEMENT MILL 25 CEMENT MILL DOSING 26 FLY ASH FOR CEMENT 27 CEMENT MILL 28 FERROUS SULPHATE DOSING 29 CEMENT TRANSPORT 30 CEMENT SILOS 31 BRIDGE TO BAGGING PLANT (NOT SUPPLIED) 32 BAGGING STRUCTURE 33 PALLETIZING BUILDING 34 AIR COMPRESSOR ROOM 35 CONVERTER STATION 36

MCC'S 41 FUEL DEPOSIT




ACE Group


42 WATER TREATMENT PLANT (NOT SUPPLIED)




ACE Group





Project: Diagram Elaborated by:

Project number: Date: Approved by:

Location: Revision:

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max DeviationSiO2 % 21.89 43.1 - 1.048 2.20Al2O3 % 4.80 26.9 - 0.361 0.78 Dust mg/Nm3 30Fe2O3 % 3.80 17.8 - 0.271 0.30 HCl mg/Nm3 -CaO % 67.09 0.91 - - 0.06 HF mg/Nm3 -MgO % 0.92 5.89 - 32.138 53.50 NOx mg/Nm3 -SO3 % 0.06 1.24 - 0.167 0.60 SO2 mg/Nm3 600

Na2O % 0.04 - - 42.264 0.17 mg/Nm3 0.5

K2O % 0.83 1.25 - 0.067 0.10 CO mg/Nm3 500TiO2 % 0.10 0.07 - 0.006 - Cd + Ti mg/Nm3 0.05P2O5 % 0.25 0.001 - - - Hg mg/Nm3 0.05Cl- % 0.00 0.45 - 0 - TOC mg/Nm3 -L.O.I. % - 1.56 - 23.62 - mg/Nm3

Lime saturation factor (LSF) % - - - - -Silica modulus (MS) % - - - - -Alumina modulus (MA) % - 0 - 1 5.00Fluoride % 0.00 . - - -C4AF % - . - - -C3A % - . - - -C2S % - . - - -C3S % - . - - -Moisture % - . - - -Bulk density t/m3 - - - - -Particle size mm - - - - -Grindability index - - - - -Cohesive strenght m - - - - -Repose angle ° - - - - -Wall friction angle ° - - - - -

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max DeviationClinker proportioning %FBC ash proportioning %Blaine cm2/gMoisture %Particule size %R 0.075 mm

0

0

Required dust and gas emissions Cement mill dust collector

Chemicals

Chemical-physical characteristics of cement materials

Clinker Fly ash Ferrous Sulfate Slag (Endesa)

Ground slag Ground limestone

Sb +As +Pb +Cr +Co +Cu +Mn +Ni +V

Dioxins + Furans

Crushed limestone

OPC cementSemi cementCement mill products characteristics

Gypsum

600- CEMENT PREPARATION

December 20, 2007

Present limit

Future Limit

R.N.G.KILN 1 (PHASE 1)

0

8 12 N/A 13 14 25

N/A N/A N/A N/A

GYPSUM BIN (1400 TM)

FLY ASH BIN (1400 TM)

LIMESTONE BIN (1400 TM)

CEMENT MILL (135 TPH)

CEMENT MILL DUST

COLLECTOR

CLINKER BIN (600 TM)

HOT GAS GENERATOR

1413 12

258

600 CEMENT PREPARATION

Project: Diagram: Clinker production (TPY): Elaborated by:

Project number: Date: Cement production (TPY): Approved by:

Location: Revision:

Raw mill feed Kiln feed Clinker Special

clinker By-pass dust

Average Average Average Average Average

SiO2 % SiO2 % SiO2 % 12.40 14.26 21.89 21.89Al2O3 % Al2O3 % Al2O3 % 3.84 3.12 4.80 4.80Fe2O3 % Fe2O3 % Fe2O3 % 1.14 2.48 3.80 3.80TiO2 % TiO2 % CaO % 44.29 43.69 67.09 67.09CaO % CaO % MgO % 0.65 0.60 0.92 0.92MgO % MgO % SO3 % - 0.04 0.06 0.06SO3 % SO3 % Na2O % 0.02 0.02 0.04 0.04K2O % K2O % K2O % 0.33 0.54 0.83 0.83Na2O % Na2O % TiO2 % 0.20 0.07 0.10 0.10Cl- % Cl- % P2O5 % 0.06 0.16 0.25 0.25P2O5 % P2O5 % Cl- % - 0.00 0.00 0.00L.O.I. (1200°C) % L.O.I. % L.O.I. (1200°C) % 36.82 34.87 - -TOC % TOC % Lime saturation factor (LSF) % - - - -S-2 % S-2 % Silica modulus (MS) % - - - -Moisture % Data by RLDLM 16/11 Moisture % Alumina modulus (MA) % - - - -Particle size mm Particle size mm Fluoride % - 0.00 0.00 0.00Bulk density t/m3 Bulk density t/m3 C4AF % - - - -Grindability index Grindability index C3A % - - - -Cohesive strenght m Cohesive stren m C2S % - - - -Repose angle ° Repose angle ° C3S % - - - -Wall friction angle ° Wall friction an ° Moisture % - - - -

Mail FGMC 24/10 Mail FGMC 24/10 Mail FGMC 24/10 Mail FGMC 24/10 Mail FGMC 24/10 Bulk density t/m3 - - - -Particle size mm - - - -Grindability index - - - -Cohesive strenght m - - - -Repose angle ° - - - -Wall friction angle ° - - - -

FLS Rep 2005 Mail JCM 29/08 Mail JCM 29/08 Mail JCM 29/08

Dust mg/Nm3 30 30HCl mg/Nm3 - -HF mg/Nm3 - -NOx mg/Nm3 500 -SO2 mg/Nm3 600 600As + Pb + Cr +Cu +Zn + Ni

mg/Nm3 0.5 0.5

CO mg/Nm3 500 500Cd mg/Nm3 0.05 0.05Hg mg/Nm3 0.05 0.05TOC mg/Nm3 - -Dioxins + Furans mg/Nm3 0.1 -

Mail MEMN 21/09 Mail MEMN 21/09NOTE : Concentration at Pressure and Temperature Normal conditions (101.3 kPa & 273°K) dry basis.

For normalized combustion gases to 10% of O2.

Location: Andorra, Spain ValueAverage altitude above sea level m 714 MW

Temperature (summer) Average °CMaximum °C 35 kV

Minimum °CTemperature (winter) Average °C

Maximum °CMinimum °C -10

Annual average temperature °C 20Average relative humidity % 80Maximum relative humidity % Noise pollution Decibels

Average rain fall per year mm 430-480 Visual impactMaximum rain fall per year mm 480 Building height restriction m

Average speed of wind m/s Maximum vibration levelMaximum speed of wind m/s Color codingPredominant wind direction OdorMaximum roof dust load g/m2 solid waste tSnow load Kg/m2 pluvial m3

Lightning strike frequency (lightning rod) domestic waste m3

Seismic conditions process m3 ° CMail AR 22/10

Clinker %FBC ash %Slag %Gypsum %Limestone %Fly ash %By-pass dust %Blaine cm2/gMoisture %Particule size %R 0.075 mm

SiO2 %

Al2O3 %

Petcoke Petcoke Considered Min Max Fe2O3 %

Average Average Limestone (Endesa % 81.0 TiO2 %Volatiles % 9.70 - Clay (High Alumina) % 2.5 CaO % Clinker % 78Ash content % 0.55 0.16 Thermal Slag % 5.0 MgO % Gypsum % 5Carbon % 81.65 88.66 Sand (From Zone) % 11.5 SO3 % Thermal Slag % -Sulphur % 5.65 5.26 Iron Ore (Limonite) % 0.05 K2O % Fly Ash % 12Chlorine % - - % Na2O % FCB Ash % -Nitrogen % - 1.41 % Cl- % Limestone (Endesa) % 5Oxygen % - 0.69 Mail LM 31/08 P2O5 % Fe2SO4 (Ferrous Sulfate) %Hydrogen % - 3.82 L.O.I. % %VOC % - - TOC % %TOC % - - S-2 % Feed moisture maximum %Moisture % 8.1 0.8 Moisture % Feed moisture average %Density t/m3 - - Average Design Particle size mm Blaine cm2/gParticle size mm - - Moisture % 8.1 Bulk density t/m3 Total cement production t/hIgnition temp. ° C - - Bulk density t/m3 Grindability index Total cement production %Viscosity Cp - - Particle size mm Cohesive streng m Bulk packing %NET calorific value Kcal/Kg 7705 7739 Calorific value Kcal/Kg Repose angle ° Pallet packing %Angle of repose ° - - Wall friction ang ° seasonality factor value/ months(1-12)

Mail FGMC 24/10 FLS Rep 2005 Mail JCM 29/08 Mail FGMC 24/10 Mail AR 20/11Process Diag 500-14-01-001 Rev B

--

--

Average

-

5.73 0.489.28-

--

Average

-

--

-10.00

--

--

0.83-

0.500.16

-5.00

Mail RLDM 05/11

Iron Ore (Limonite)

Average

12.004.0060.00

-

7.00

-5

-

-

-

--

--

0.780.3

0.17

0.06

Chemical-physical characteristics of processed

materials in the raw meal

Limestone Iron Ore (Limonite) Thermal Slag

Average

797,708

1,000,000

0.60

Ferrous Sulfate

AverageChemical-physical

characteristics of cement materials

Fly ash

Average

Fuel / Gas

----

Climafuel / Fluff

7.35 6.6919.74

7.49 14.10

-

6.7

0.453.60

--

66.30

0.070.001

2.99

-

-

--

CEM

28.2027.40

-4.840.800.171.00

-

-

Average Average AverageThermal Slag

-

0.167

Cement final products proportioning design CEM CEM

--

0.60

CEM Type II

0.100.17

CEMCEM

Gypsum

CEM

Semi cement

CEM

Average

Future limit

Network confiability

Present limitPresent limit

Present limit Future Limit

Local General Information

Main Dust Collector Residual air dust collector

Present limit

Limestone (Endesa)

Cement mill semi-products characteristics

-32.138 53.50

1.0480.361

0.271

-

Ground limestone

0.06

0.30

OPC cement Ground slag

0.78

Network availabilityIndicators

Contaminants

Tension level

Environmental restrictions

2.20

Petcoke mill dust collectorRequired dust and gas emissions

Electric power availability

Future Limit

Future Limit

Chemicals Present limit

Future Limit

Discharge water

Cement mill dust collector

-

20.00--

4.935.53

- -

- -

-

-

-

80.83

1.6017.62 16.01

1.70

Coal

Average

-

7.00

0.30

53.72

-0.81

Average

46.25 17.90

--

- -

0.52 0.4645.67 26.62

-

Sewage Sludge

21.38

-

3.661.36 0.454.1

-

- --

- -

10

-

- -

--

0.21 2.41-

0.051 0.11

-

R.N.G.

Average Average

Chemical-physical characteristics of intermediate products

Dust from main collector (raw mill on)

Average

Dust from main collector (raw mill off)

Average

GENERAL PROCESS BLOCK DIAGRAMKILN 1 (PHASE 1)

December 20, 2007

Average AverageAverage

Sand (From Zone)Limestone

51.22.2

Thermal Slag

83.62

Clay (High Alumina) (From Zone)

38.18

43.126.9

17.8

0.91

.

.

.

.

1.25

6262-

5.891.24

-

-

-- -

5.00

.

6.6

--

0.01

-

17.8

- -- -

3.4--

-

- - -

-- - --

-

-7041

--

4775 2352 3500- - -

--

Chemical-physical characteristics of fuels

as received

Animal Meals

- - 25.10--

Chemical-physical characteristics of raw materials (run of mine)

Average

0.1-

Average

29.8

0.653.5

0.25

-

42.2640.0670.006

-0.00023.620

--

1.00-

----

1.56

.

Ground fuel physical characteristics

Raw meal proportioning

Ground Petcoke


Average

-

7.01

Tires

-

Mail RLDM 05/11

-- -

87

N/A N/A N/A N/A

15 N/A N/A N/A N/A N/A N/A N/A

12 N/A 13 14

24 25

9 9 10 116

23

N/A N/A N/A N/A

321 54

IRON ORE (LIMONITE) STORAGE (1300 T)TRUCK TRANSPORT SYSTEM

300 RAW MATERIALS

RAW MILL (195 TPH)

HOMO SILO (8000 T)TRANSPORT SYSTEM

HOT GAS GENERATOR

400 RAW MEAL PREPARATION

CLINKER STORAGE (45000 T)

MAIN DUST COLLECTOR

PREHEATER TOWER (5 STAGES - 2350 TPD) CALCINER ROTARY KILN

(2350 TPD)

AIR-AIR HEAT EXCHANGER

CLINKER COOLER (2350 TPD)

PETCOKE BIN (80 M3)

RAW MEAL DOSING BIN

PETCOKE MILL (15

TPH)

PETCOKE FOR KILN BIN (150

M3)

PETCOKE FOR CALCINER

BIN (150 M3)

COMBUSTION CHAMBER SPECIAL

CLINKER BIN (765 T)

FUEL/GAS FOR HGG BIN

BY PASS SYSTEM

CLIMAFUEL / FLUFF

ANIMAL MEALS SEWAGE SLUDGE

RESIDUAL AIR DUST COLLECTOR

500 CLINKER PREPARATION

800 SERVICES

GYPSUM BIN (1400 T)

FLY ASH BIN (1400 T)

LIMESTONE BIN (1400 T)


CEMENT MILL DUST

COLLECTOR

CLINKER BIN (600 T)

BYPASS DUST BIN


700 CEMENT PACKING AND SHIPPING

CEMENT SILO (5000 T)

CEMENT TYPE II

17 18 19 20 N/A

22

11

109

8

76

1413 12

15

17 18 19

RAW MATERIALS

FUELS

INTERMEDIATE PRODUCTS

FINAL PRODUCTS

EMISSION POINTS TIRES

20

PETCOKE STORAGE (10,000 T)

16

2222

25

23

LIMESTONE STORAGE (20000 T)

CLAY (HIGH ALUMINA) (FROM ZONE) STORAGE (2500 T)TRUCK TRANSPORT SYSTEM

SAND (FROM ZONE) STORAGE (4000 T)TRUCK TRANSPORT SYSTEM

THERMAL SLAG STORAGE (3300 T)TRUCK TRANSPORT SYSTEM

5

1

2

3

4

IRON ORE (LIMONITE) (1 96 T)

LIMESTONE (600 T)

SAND (FROM ZONE) (224 T)

THERMAL SLAG (196 T)

24




CEMENT TYPE II

CEMENT TYPE II

CEMENT TYPE II

BAGGING (80 TPH)

PALLETIZING (3300 BAGS/H)

FUEL / GAS STORAGE

21

21

9

15

15

15

16

GAS FLOW

FUTURE FLOW

FUTURE EQUIPMENT

PROCESS AREA DIVISION

MATERIAL FLOW

PETCOKE MILL DUST

COLLECTOR

26

26

ALTERNATE FUELS

RECEPTION

HOT GAS GENERATOR

CLAY (HIGH ALUMINA) (224 T)

TRANSPORT SYSTEM

16

Project: Diagram: Elaborated by:


Location: Revision:

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation

SiO2 % 2.20 51.20 83.62 38.18 12.000 SiO2 % 43.100 1.048 2.20Al2O3 % 0.78 29.80 7.01 28.20 4.000 Al2O3 % 26.900 0.361 0.78Fe2O3 % 0.30 4.10 3.66 27.40 60.000 Fe2O3 % 17.800 0.271 0.30TiO2 % 0.06 1.36 0.45 - - TiO2 % 0.910 - 0.06CaO % 53.50 1.00 0.11 4.84 5.000 CaO % 5.890 32.138 53.50MgO % 0.60 0.25 0.05 0.80 0.500 MgO % 1.240 0.167 0.60SO3 % 0.17 - - 0.17 0.160 SO3 % - 42.264 0.17K2O % 0.10 0.21 2.41 1.00 0.830 K2O % 1.250 0.067 0.10Na2O % - - 0.00 - - Na2O % 0.070 0.006 -Cl- % - - 0.000 - - Cl- % 0.001 - -P2O5 % - - 0.00 - - P2O5 % 0.450 0.000 -L.O.I. % - - 0.00 - - L.O.I. % 1.560 23.620 -TOC % - - - - - TOC % - - -S-2 % - - - - - S-2 % - - -Moisture % 5.00 10.00 7.00 20.00 10.000 Moisture % 0.000 1.000 5.00Particle size mm - - - - - Particle size mm . - -Bulk density t/m3 - - - - - Bulk density t/m3 . - -Grindability index - - - - - Grindability index . - -Cohesive strenght m - - - - - Cohesive strenght m . - -Repose angle ° - - - - - Repose angle ° . - -Wall friction angle ° - - - - - Wall friction angle ° . - -

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max DeviationSiO2 %Al2O3 %Fe2O3 %TiO2 %CaO %MgO %SO3 %

K2O %

Na2O %Cl- %P2O5 %L.O.I. %TOC %S-2 %Moisture %

Particle size mm

Bulk density t/m3

Grindability indexCohesive strenght mRepose angle °Wall friction angle °

Thermal Slag Gypsum


LimestoneChemical-physical characteristics of cement

materials

Fly ash FBC ash

Chemical-physical characteristics of processed

materials in the raw meal

Thermal Slag Iron Ore (Limonite) Fly Ash

R.N.G.

Limestone Clay (High Alumina) Sand (From Zone)Chemical-physical characteristics of raw

materials (run of mine)

KILN 1 (PHASE 1)

Iron Ore (Limonite)

300- RAW MATERIALS

December 20, 2007

Thermal Slag

1 2 3 12 N/A N/A 13 144 5

LIMESTONE

CLAY (HIGH ALUMINA) (FROM ZONE)

SAND (FROM ZONE)

1

2

3




1413 12

300 RAW MATERIALS

STORAGE (20000 T)TRANSPORT SYSTEM

STORAGE (1550 T)TRUCK TRANSPORT SYSTEM

STORAGE (3300 T)TRUCK TRANSPORT SYSTEM

IRON ORE (LIMONITE) STORAGE (2150 T)TRUCK TRANSPORT SYSTEM

THERMAL SLAG STORAGE (4000 T)TRUCK TRANSPORT SYSTEM

5

4

LIMESTONE (600 MT)

SAND (FROM ZONE) (224 MT)

THERMAL SLAG (196 MT)

CLAY (HIGH ALUMINA) (224 MT)

IRON ORE (LIMONITE) (196 MT)



Location: Revision:

Average Min-Max Deviation

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Limestone % 81.00SiO2 % 2.20 51.20 83.62 38.18 12.000 Clay (High Alumina) % 2.50Al2O3 % 0.78 29.80 7.01 28.20 4.000 Thermal Slag % 5.00Fe2O3 % 0.30 4.10 3.66 27.40 60.000 Sand (From Zone) % 11.50TiO2 % 0.06 1.36 0.45 - - Iron Ore (Limonite) % 0.05CaO % 53.50 1.00 0.11 4.84 5.000MgO % 0.60 0.25 0.05 0.80 0.500SO3 % 0.17 - - 0.17 0.160K2O % 0.10 0.21 2.41 1.00 0.830Na2O % - - 0.00 - -Cl- % - - 0.00 - -P2O5 % - - 0.00 - -L.O.I. % - - 0.00 - -TOC % - - - - -S-2 % - - - - - Average Min-Max DeviationMoisture % 5.00 10.00 7.00 20.00 10.000 SiO2 % 12.40Particle size mm - - - - - Al2O3 % 3.84Bulk density t/m3 - - - - - Fe2O3 % 1.14Grindability index - - - - - CaO % 44.29Cohesive strenght m - - - - - MgO % 0.65Repose angle ° - - - - - SO3 % -Wall friction angle ° - - - - - Na2O % 0.02

K2O % 0.33TiO2 % 0.20P2O5 % 0.06Cl- % -L.O.I. % 36.82TOC % -S-2 % -Moisture % -Bulk density t/m3 -Particle size mm -Grindability index -Cohesive strenght m -Repose angle ° -Wall friction angle ° -

Average Min-Max DeviationSiO2 % 14.26Al2O3 % 3.12Fe2O3 % 2.48CaO % 43.69MgO % 0.60SO3 % 0.04Na2O % 0.02K2O % 0.54TiO2 % 0.07P2O5 % 0.16Cl- % 0.00L.O.I. % 34.87TOC % -S-2 % -Moisture % -Bulk density t/m3 -Particle size mm -Grindability index -Cohesive strenght m -Repose angle ° -Wall friction angle ° -

R.N.G.

0

0


December 20, 2007

Chemical-physical characteristics of materials

used in the raw meal

Limestone Clay (High Alumina) Sand (From Zone)

KILN 1 (PHASE 1)

0

Thermal Slag Iron Ore (Limonite)

Raw meal mix before entering raw millChemical-physical

characteristics of raw meal

Raw meal proportioning

Raw meal after grinding and homogenization (kiln feed)

Chemical-physical characteristics of raw meal

1 2 3 4 5

6

7


RAW MILL (195 TPH) HOMO SILO (8000 T)TRANSPORT SYSTEM

HOT GAS GENERATOR

RAW MEAL DOSING BIN

9

76

IRON ORE (LIMONITE) (196 MT)

LIMESTONE (600 MT)

SAND (FROM ZONE) (224 MT)

THERMAL SLAG (196 MT)

CLAY (HIGH ALUMINA) (224 MT)

5

1

2

3

4

Project: Diagram:

Project number: Date:

Location:

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-MaxSiO2 % 14.26 SiO2 % 21.89 21.89Al2O3 % 3.12 Al2O3 % 4.80 4.80Fe2O3 % 2.48 Fe2O3 % 3.80 3.80CaO % 43.69 CaO % 67.09 67.09MgO % 0.60 MgO % 0.92 0.92SO3 % 0.04 SO3 % 0.06 0.06

Na2O % 0.02 Na2O % 0.04 0.04K2O % 0.54 K2O % 0.83 0.83TiO2 % 0.07 TiO2 % 0.10 0.10P2O5 % 0.16 P2O5 % 0.25 0.25Cl- % 0.00 Cl- % 0.00 0.00L.O.I. % 34.87 L.O.I. % - -TOC % - Lime saturation factor (LSF) % - -S-2 % - Silica modulus (MS) % - -Moisture % - Alumina modulus (MA) % - -Bulk density t/m3 - Fluoride % 0.00 0.00Particle size mm - C4AF % - -Grindability index - C3A % - -Cohesive strenght m - C2S % - -Repose angle ° - C3S % - -Wall friction angle ° - Moisture % - -

Bulk density t/m3 - -Particle size mm - -Grindability index - -Cohesive strenght m - -Repose angle ° - -Wall friction angle ° - -

Chemical-physical characteristics of feed

materials

Kiln feed Chemical-physical characteristics of final products

Clinker Dust from main collector (raw mill on)

Dust from main collector (raw mill off) Special clinke

KILN 1 (PHASE 1) 500- CLINKER PRE

0 December 20

9 11 11 1210

CLINKER STORAGE (45000 TM)

PREHEATER TOWER CALCINERROTARY KILN

(2350 TPD)



BY PASS SYSTEM


BYPASS DUST BIN

13

10

28


7 9 9 108

CLINKER STORAGE (45000 TM)

PREHEATER TOWER CALCINERROTARY KILN

(2350 TPD)



BY PASS SYSTEM


BYPASS DUST BIN

11

8

24


HOMO SILO (8000 T)

RAW MEAL DOSING BIN

7

)

SPECIAL CLINKER BIN

(765 TM)12

)

COMBUSTION CHAMBER SPECIAL


10

MAIN DUST COLLECTOR

9

23

Elaborated by:

Approved by:

Revision:

Deviation Average Min-Max Deviation

Dust mg/Nm3 30HCl mg/Nm3 -HF mg/Nm3 -NOx mg/Nm3 500SO2 mg/Nm3 600

mg/Nm3 0.5

CO mg/Nm3 500Cd mg/Nm3 0.05Hg mg/Nm3 0.05TOC mg/Nm3 -

mg/Nm3 0.1

As +Pb +Cr +Cu +Ni + Zn

Dioxins + Furans

Required dust and gas emissions Main dust colector Residual Air dust

collector

Chemicals Present limit

Future Limit

Present limit

Future Limit

0

er By-pass dust

EPARATION R.N.G.

, 2007 0

13 27 2811 23 24

Project: Diagram Elaborated by:


Location: Revision:

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max DeviationSiO2 % 21.89 43.1 - 1.048 2.20Al2O3 % 4.80 26.9 - 0.361 0.78 Dust mg/Nm3 30Fe2O3 % 3.80 17.8 - 0.271 0.30 HCl mg/Nm3 -CaO % 67.09 0.91 - - 0.06 HF mg/Nm3 -MgO % 0.92 5.89 - 32.138 53.50 NOx mg/Nm3 -SO3 % 0.06 1.24 - 0.167 0.60 SO2 mg/Nm3 600

Na2O % 0.04 - - 42.264 0.17 mg/Nm3 0.5

K2O % 0.83 1.25 - 0.067 0.10 CO mg/Nm3 500TiO2 % 0.10 0.07 - 0.006 - Cd + Ti mg/Nm3 0.05P2O5 % 0.25 0.001 - - - Hg mg/Nm3 0.05Cl- % 0.00 0.45 - 0 - TOC mg/Nm3 -L.O.I. % - 1.56 - 23.62 - mg/Nm3

Lime saturation factor (LSF) % - - - - -Silica modulus (MS) % - - - - -Alumina modulus (MA) % - 0 - 1 5.00Fluoride % 0.00 . - - -C4AF % - . - - -C3A % - . - - -C2S % - . - - -C3S % - . - - -Moisture % - . - - -Bulk density t/m3 - - - - -Particle size mm - - - - -Grindability index - - - - -Cohesive strenght m - - - - -Repose angle ° - - - - -Wall friction angle ° - - - - -


0

0

Required dust and gas emissions Cement mill dust collector

Chemicals

Chemical-physical characteristics of cement materials

Clinker Fly ash Ferrous Sulfate Slag (Endesa)

Ground slag Ground limestone

Sb +As +Pb +Cr +Co +Cu +Mn +Ni +V

Dioxins + Furans

Crushed limestone

OPC cementSemi cementCement mill products characteristics

Gypsum

600- CEMENT PREPARATION

December 20, 2007

Present limit

Future Limit

R.N.G.KILN 1 (PHASE 1)

0

8 12 N/A 13 14 25

N/A N/A N/A N/A





CEMENT MILL DUST

COLLECTOR


HOT GAS GENERATOR

1413 12

258




Location: Revision:


% 78% 5% -% 12% -% 5% -

Feed moisture maximum %Feed moisture average %Blaine cm2/gTotal cement production %Bulk packing %Pallet packing %seasonality factor value/ months(1-12)

FCB AshLimestone (Endesa)Fe2SO4 (Ferrous Sulfate)

ClinkerGypsumThermal SlagFly Ash

CEM CEM

R.N.G.

0

0

CEM CEM CEM CEMCement mix design CEM Type II

CEM

Cement mill products characteristics

Semi cement OPC cement Ground slag

KILN 1 (PHASE 1) 700- CEMENT PACKING AND SHIPPING

0 December 20, 2007

Ground limestone

15 N/A N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A

CEMENT SILO (5000 TM)

CEMENT TYPE II 15




CEMENT TYPE II

CEMENT TYPE II

CEMENT TYPE II

BAGGING (80 TPH)

PALLETIZING (3300 BAGS/H)

15

15

15

700 CEMENT PACKING AND SHIPPING



Location: Revision:

Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max Deviation Average Min-Max DeviationVolatiles % 9.70 - - - - - 25.10 Moisture % 8.1Ash content % 0.55 0.16 21.38 46.25 17.90 7.49 14.10 Bulk density t/m3

Carbon % 81.65 88.66 45.67 26.62 53.72 80.83 66.30 Particle size mmSulphur % 5.65 5.26 0.52 0.46 0.81 1.70 0.60 Calorific valu Kcal/KgChlorine % - - - - - - -Nitrogen % - 1.41 9.28 5.73 0.48 0.30 1.60Oxygen % - 0.69 17.62 16.01 19.74 2.99 7.00Hydrogen % - 3.82 5.53 4.93 7.35 6.69 3.60VOC % - - - - - - -TOC % - - - - - - -Moisture % 8.10 0.8 3.40 6.60 17.80 1.00 6.70Density t/m3 - - - - - - -Particle size mm - - - - - - -Ignition temp. ° C - - - - - - -

Viscosity Cp - - - - - - -

NET calorific value Kcal/Kg 7705.00 7739 4775.00 2352.00 3500.00 7041.00 6262.00Angle of repose ° - - - - - - -

Fuel / Gas Ground fuel physical characteristics

Ground PetcokeCoalTiresClimafuel / FluffSewage SludgeAnimal MealsPetcokeChemical-physical characteristics of fuels as

received

Petcoke

0

0

KILN 1 (PHASE 1) 800- SERVICES R.N.G.

December 20, 2007 0

16 17 18 19 20 2221N/A

800 SERVICES

PETCOKE BIN (80

PETCOKE MILL (15

TMPH)

PETCOKE FOR KILN BIN (150

M3)

PETCOKE FOR CALCINER

BIN (150 M3)

FUEL/GAS FOR HGG BIN

CLIMAFUEL / FLUFF

ANIMAL MEALS SEWAGE SLUDGE

17 18 19

TIRES

20

PETCOKE STORAGE

16

2222

FUEL / GAS STORAGE

21

PETCOKE MILL DUST

COLLECTOR

26

ALTERNATE FUELS

RECEPTION

16

130 TPH New Surplus Cement Grinding Plant – 4.6m X 13m ... · PDF file130 TPH New...

Documents

Transcript of 130 TPH New Surplus Cement Grinding Plant – 4.6m X 13m ... · PDF file130 TPH New...