I: OPR :07
Issue(1)
Date : 01/ 0 4/ 2012
Revision: ( 0 )
Date : 01/ 04 / 2012
Page: 1/ 3
) ) quarrying: 1- . 2- 3- . 2( : 1. . 2. . 3. . 4. ). (Benches
5. ) (Overburden . . Mining system : 1. . 2. . 3. 4. ) ( 5. . 6.
.70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 ( :Revision 2102 / 40
/10 : Date 3 /2 :Page
7. . . . .
Raw Materials preparation : 1- ) ( Crushing & Grinding
Comminution 2- ) (Raw Mix design ) (COMMINUTION . Blake 8581 Jaw
crusher : .Compression . Crushing Grinding compression or Impact .
Friction force Impact type crusher Hammer Crusher Impact crusher
Roll crusher 70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 (
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RAW MATERIALS STOCK PILE - ) ( ) .... ( - . ) ( STAKER 70: I:
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Date 3 /4 :Page
. Reclaimer .
HOMOGENIZATION ) ( ) (T ) ( ) (Q : . . ) ( . )Stacker and
(Reclaimer ) (LHO ) (CHO .
E Homogenizing or Blending effect
:70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 ( :Revision 2102 /
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S x =S / N : N : S : S x ) (
: 1. : = = = ) (CaO ) (CaO ) (CaO
Y
Q
P ) ( )001( =
Z : 001 ] ) Z = [ ( Y P ) / ( Q P 69% )%4 = (CaO )%56 = . (CaO
)= CaO 65 = 61 + 04( , : Z = 100{ [(0.04 0.65) ( 0.04 0.96)]} =
66.3 kg )001( 3.66 ) ( = ) 001 3.66( = 7.33 0001 . : 9 00 ~
0001C70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 ( :Revision 2102
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3CaCO )613X ) 001 ( ( X CaO + 2CO 04 + 21 + )])61[12 + (2X )65(
+ 44 (
+ )61 + 04( 3.66
= ) 3.66 * 001 ( / 65 = 93.811 2 : ) ( = 01% Clayey Sand &
Iron ore Calcined ore + Ignition loss + 76.81 % %33.18 001 % Y 7.33
001 = ) 7.33 * 001 ( / 33.18 = 44.14 ) 001 ( ) 93.811 ( ) 44.14( =
) 001 ( / ) 93.811+ 44.14( = 626.0
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RAW MEAL ) ( Bins ) ( LSF & SM & AM ) ( Bins ) ( Raw mix
) / ( .
70: I: OPR
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.
) ( Raw Meal Grinding Raw meal . ) ( 70: I: OPR )1(Issue 2102 /4
0 /10 : Date ) 0 ( :Revision 2102 / 40 /10 : Date 3 /9 :Page
. .
)(Vertical Roller Mill ) (LSF & SM & AM . Friction
Pressure - Roller Table . Seal Bin Table Chute Dam ring . Dam ring
Nozzle ring .
70: I: OPR
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) (Vertical Roller Mill ) / ( . Grindability
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) ( Bins ) (Mechanical recirculation ) (Seal bin . 051 ) ( Dust
bin CF. Silo ).(Kiln feed
) (Raw Mix Blending Blending Silo : : . : .70: I: OPR )1(Issue
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:Page
: ) . (Multi stage 1. ) Continuous 2.
) (Continuous Controlled Flow ) ( ) ( . 5.1% CaO 51.0%
Homogeneous Kiln Feed : :Kiln Feed Standard deviation
requirements < S < S 1.0 % LSF , Or 0.1 % CaO , Or
S < 0.2 % CaCO3 , Or < S 3.0 % C3S
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Kiln Feed System - - .
Pyroprocessing
Preheater Calciner Rotary Kiln Cooler
1. 2. 3. 4.
70: I: OPR
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PRE-HEATER
), (Co-Current - . .
70: I: OPR
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:- ) ( . . . . .
:- , : , . . , , . ) (Head , ). (Flap gate
) / ( :70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 ( :Revision
2102 / 40 /10 : Date 3 /61 :Page
, . ) / ( , :- ) ( ) ( . . ) ( . :- 1. . ) 2. ( ). (CO 3. . )
(False air . 4.
ROTARY KILN
0541 - ) ( ) ( . . .. .70: I: OPR )1(Issue 2102 /4 0 /10 : Date
) 0 ( :Revision 2102 / 40 /10 : Date 3 /71 :Page
:- 1. ) 02 ( . 2. ) 5 ( . ) 3. 003 004 ( . 4. ) 8/1 ( . 5. ) 003
( . ) 088 029 ( 6. )08% - 09 %( . ) 004 ( .
* ) 2% - 6% ( 70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 (
:Revision 2102 / 40 /10 : Date 3 /81 :Page
) 5.2 % - 4 % ( . . * ) ( . )5% - 71 %( :-
* ) 3.42 / ( ) 6.54 / ( . : ) ( ) / K Cal (m2 .hr ) 000.003 / 3
. ( . : ) . (K Cal / hr : = 0722 ~ 0023 / . = 345 ~ 567 /
) ( Free water 70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 (
:Revision 2102 / 40 /10 : Date 3 /91 :Page
)2. (SO ) (C2S ) , (C3A )( C4AF )02 53 %( ) (C3S )(Solid-state
reaction ) (C3A) (C4AF .
. :- 1. . 2. ) 003 ( . 3.
1- ) : ( Free Lime CaO . ) 5.1 % ( : ) ( 70: I: OPR )1(Issue
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:Page
) ( LSF . 2- ) : ( Liter weigh . ) (CaO . ) 0021 ~ 0031 / (
)0021 / ( )0031 ( .
) 2 : ( O 1.
. . 2- ) : ( CO . . . . ) ( O2& CO . 3- ) 2 : ( CO .
:-
:- . Burnability 1. Secondary air . 2. Excess air 3. . False air
. 4. ) . ( Coating / Lining 5.70: I: OPR )1(Issue 2102 /4 0 /10 :
Date ) 0 ( :Revision 2102 / 40 /10 : Date 3 /12 :Page
6. .
Clinker cooling , , ) . (Liquid phase ) ( :- ) 055 ~ 009 ( 1. :
) ( Powder ( Liquid phase ( C3A + C4AF ) ( C2S 72 % . ) ( C2S ) (
C3S ) + C2S ( Free lime ) ( Free lime 051 . :- 2. ) ( grain )
(Hydration Liquid phase Glass phase ) ( C3A . ) ( Dust Elite ( (C3S
. ( ( Belite C2S
) ( Grate cooler
: . :- . . . 70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 (
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. .
OXIDES CaO 2SiO 3Al2O 3Fe2O MgO K2O + Na2O 3SO ( % ) RANGE 06 ~
96 81 ~ 42 4 ~ 8 1 ~ 8 3 ~ 5 1 ~ 2 1 ~ 2 ( % ) AVERAGE 56 12 6 3 2
1 1
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) ( ) ( C3A C3A :- : 06 01 06 ) . ( C3A ) ( C3A Expansion . :- )
(C3A 1. ) 3( SO 2.
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ball mill : E : F ) ( : G : A : B : C : D
Tube mill in closed circuit, Rotor type separator70: I: OPR
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) 2 (
packing 05 2 % kg .
. : ) : (Minor component & MgO & Na2O 1. 3K2O & SO )
: ( Trace component , 5TiO2 , P2O 2. Cr2O3 , F , Mn2O3 , CL 3. ) (
Minor component 1 ) : ( MgO ) ( MgO ). 3CaCO 3 (MgCO - - ). (MgO70:
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) (MgO 2% ) ( ) ( MgO 2) . Mg(OH , 2) Mg(OH MgO ) ( . ) (MgO )
2% ( , ) 4% ( . 2 ) (Na2O ) : (K2O , Alkalis . , , . . : . . ) 6.0
%( . 3 ) 3: ( SO , . 5.3% ) ( . )3 (SO )2 3 %( ) 1% (70: I: OPR
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) 3 (SO :- )3 (SO )2 (SO . , . - - . : 1- ) : (Alkalis
Equivalent (A.E. = Na2O + 0.659 K2O %6.0 < : (USUAL 2- ) :
(Sulphate Modulus 3M.SO3 = (0.85K + 1.29N 1.13CL) / SO )00.1 <
3( USUAL : 0.83 < MSO 3- ) : ( Alkalis / Sulphate ) A.S.R = SO3
/ ( K + 0.5 N < (USUAL 0.6 < A.S.R 4.1( ) ( Trace elements 1
) 2: ( TiO 1% : ) (C3S ) (C2S ). (Free Lime . 2- ) 5: (P2O , 2% : )
(C3S ) (C2S . 70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 (
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3 ) 3: ( Cr2O , : : ) Early & increase the (compressive
strength : , . EKSEMA 4- ) : (CL , . ) ( . . ) 1.0 % ( . 5 ) : ( F
)2 (CaF , : ) (Dusting ) (B-C2S ). (-C2S . . ) (C3S ) (C2S . 6- )
3: (Mno ) (C3S ) (C2S
70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 ( :Revision 2102 /
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. , :- ) ( 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 :- 3HM = CaO/ SiO2 + Al2O3 +
Fe2O 3.2 ~ 7.1 2 - ( Lime Saturation Factor ( LSF ) 2SiO 3 . ( +
Al2O3 + Fe2O ) (CaO :- 3(LSF = CaO /2.8( SiO2) +1.18( Al2O3) +0.65(
Fe2O 66 ~ 201 ) 2 ( SiO ) ( CaO ) ( C3S ) 3 ( Fe2O ) ( C4AF ) . (
C3A :- ) ( CaO 001 = LSF70: I: OPR )1(Issue 2102 /4 0 /10 : Date )
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) ( LSF ) ( Compressive strength ) (LSF ) ( Free lime ) (C2S ) (
C3S ) (Free lime ) (C2S ) ( LSF : ) (LSF ) 66 ( )= C3S 0 ( ) SM
)Silica Modules 3 - ~ 8.1 6.3
3SM = SiO2 / Al2O3 + Fe2O
) ( SM ) ( C3S ) (C2S ) ( C3S Free lime . . 4 - ) AM ) Alumina
Modules 3AM = Al2O3 / Fe2O 2 ~ 1
) ( AM ) ( AM Liquid phase ) ( C3S Dust ) IL ) Ignition Loss
:-IL = 0.44 ( CaCO3 ) + 0.524 ( MgCO3 ) + + ( H2O )COM + ( MO )OR
)( Burning Index ( BI70: I: OPR )1(Issue 2102 /4 0 /10 : Date ) 0 (
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) ( : BI = C3S / C3A + C4AF 5.4 6.2
) BF ) Burning Factor ) (kiln operator : ( BF = (LSF ) + 10 (SM
) + 3 ( MgO + Alkalis )801 = USUAL : 100 < B.F. < 120 , best
( Liquid phase ( PL 0541 : ( PL = 1.13 ( C3A ) + 1.35 ( C4AF ) + (
MgO + Alkalis 82 ~ % 32 ( : ( % Usually )Hydration of portland
cement ) : ( Hydration , . ) :( Normal setting 1. ) ( Initial
setting 54 ) ( Final setting 01 2 . ) : ( Flash setting ) 3 ( SO )
( C3A.3CS.31H ) ( C3A . 3 . ) : ( False setting70: I: OPR )1(Issue
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. ) 041 (
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