Cement processes
There are many processes that followed to produce cement started as >>
Crushing, grinding, proportioning and blending of materials.
Preheating (for dry process).
Raw material passes through inclined rotary kiln, and the output
is called “clinker”.
The clinker produced is cooled by air fans.
And then 5% of gypsum is added to clinker and grinded in a
cement mill to about 100 micron
Then the cement is packaged and transported.
Quarry
What is quarry? >> sand, lime, iron ore, and clay all are extracted from
quarries, but the main quarry that the cement planet constructed near it, is
the lime stone quarry, that because the lime is enter about 80% in the
composition of cement.
>Like in AL RAMLYA planet, the lime quarry is far 3 km from the main
planet.
Lime quarry must have an age of extracting from 100 to 200 years. Clay
and iron ore are extracted from other quarries, clay from ‘ZAAAFRANA’
and iron ore from ‘AL WAHHHAT’.
Lime stones are loaded by ‘loaders or power shovels’ into the trucks and
transported to the crusher to reduce the stones size.
‘AL RAMLYA’ Lime quarry Trucks
Geology
Geology is the science that studies the origin, history and structure of the earth.
It contains 3 main layers >
The crust. (10 – 40 km) __> it contain = lime + sand + igneous
Mantle (2,840 km).
The core (3,480 km).
The act of excavating the earth crust for
mining rock >> (RAMLYA quarry)
Quarry preparation is needed for ease of extracting the lime and this is
done by:
Planning the site> for identifying the quarry life time, and its lime
chemical properties.
Purchasing of suitable equipment (loaders, trucks, bulldozers...).
To keep it with stand of the abrasive wear materials.
Drilling for blasting to allow for ease of transporting the stones,
and to make roads in the quarry.
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Crushing
The main objective is the Reduction of the raw materials to a fine
powder, this process is important to produce a homogenous mixture,
which quickly be converted in the kiln into homogenous clinker
containing no free lime.
The crusher considers the primary step for reducing size.
Factors that affecting the choose of crushers
Capacity of crusher.
Reduction ratio.
Hardness fragment size.
Moisture control.
Plasticity and abrasiveness of material.
In this process clay is added to the lime from another feeder and crushed together to
form the ‘Raw mixture’, and then transported to the storage area.