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Cement Production and Kiln Processes

This document discusses the typical chemical composition of Portland cement, which consists mainly of calcium oxides (65.5%), silicon oxides (21.1%), aluminum oxides (5.6%), and iron oxides (3.0%). It also lists some minor constituents that make up the remaining 4.67% such as manganese oxide, phosphorus oxide, and titanium oxide. The raw materials used to produce cement, limestone and shale or clay, provide the necessary calcium, silicon, aluminum, and iron to form the clinker when fired at high temperatures in a rotary kiln.

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55 views1 page

Cement Production and Kiln Processes

This document discusses the typical chemical composition of Portland cement, which consists mainly of calcium oxides (65.5%), silicon oxides (21.1%), aluminum oxides (5.6%), and iron oxides (3.0%). It also lists some minor constituents that make up the remaining 4.67% such as manganese oxide, phosphorus oxide, and titanium oxide. The raw materials used to produce cement, limestone and shale or clay, provide the necessary calcium, silicon, aluminum, and iron to form the clinker when fired at high temperatures in a rotary kiln.

Uploaded by

Mohsin
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1/6 Cements

Cement Minor
Main chemist’s constituents
constituents shorthand % %
SiO2 S 21.1 Mn2O3 0.05
Al2O3 A 5.6 P2O5 0.15
Fe2O3 F 3.0 TiO2 0.30
CaO C 65.5 MgO 1.50
SO3(S) 1.20
95.2
Loss on ignition 0.50
C K2O 0.72
Na2O 0.18
Fluorine 0.04
Chloride 0.02
Trace elements 0.01
4.67

S
A F
Minor
constituents

Figure 1.2 Typical chemical composition of Portland cement clinker.

come close to 100, and this provides a useful check for errors. Oxidizing conditions are
maintained during the burning process and this ensures that the metallic elements present
are effectively present as oxides although combined in the clinker as minerals.
The source of lime for cement making is usually limestone or chalk. As typically 80%
of the raw mix consists of limestone, it is referred to as the primary raw material. The
secondary raw material, which provides the necessary silica, alumina and iron oxide, is
normally shale or clay. Small quantities of sand or iron oxide may be added to adjust the
levels of silica and iron oxide in the mix. When proportioning the raw materials, an
allowance must be made for ash incorporated into the clinker from the fuel that fires the
kiln. Most cement plants worldwide use finely ground (pulverized) coal as the primary
fuel. Increasingly, by-product fuels such as the residue from oil refining (petroleum coke)
and vehicle tyres are being used to partially replace some of the coal.
Typical contents of the four principal oxides in a simplified cement making operation
utilizing only two raw materials are given in Figure 1.3.
Note that the ratio of CaO to the other oxides is lower in the clinker than in the raw
mix. This is a result of the incorporation of shale from the coal ash. The levels of the
oxides are also increased as a result of decarbonation (removal of CO2).

1.3.2 The modern rotary kiln


The rotary kilns used in the first half of the twentieth century were wet process kilns
which were fed with raw mix in the form of a slurry. Moisture contents were typically
40% by mass and although the wet process enabled the raw mix to be homogenized
easily, it carried a very heavy fuel penalty as the water present had to be driven off in the
kiln.
In the second half of the twentieth century significant advances were made which have
culminated in the development of the precalciner dry process kiln. In this type of kiln, the

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