Cement Production Technology Principles and Practice

The book is an outcome of the author’s active professional involvement in research, manufacture and consultancy in the field of cement chemistry and process engineering. This multidisciplinary title on cement production technology covers the entire process spectrum of cement production, starting from extraction and winning of natural raw materials to the finished products including the environmental impacts and research trends. The book has an overtone of practice supported by the back-up principles.

1. BASICS OF MINERAL RESOURCES FOR CEMENT PRODUCTION 1.1 PREAMBLE 1.2 CHARACTERIZATION OF MINERALS AND ROCKS 1.3 NATURE OF LIMESTONE OCCURRENCE 1.4 ASSESSMENT OF LIMESTONE DEPOSITS 1.5 MINERAL COMPOSITION AND QUALITY OF LIMESTONE 1.6 LIMETONE MINING 1.7 QUARRY DESIGN AND OPERATIONAL OPTIMIZATION 1.8 ARGILLACEOUS MATERIALS 1.9 CORRECTIVE MATERIALS 1.10 NATURAL GYPSUM 1.11 INFLUENCE of Raw Materials ON THE UNIT OPERATIONS 1.12 SUMMARY 1.13 REFERENCES 2. RAW MIX PROPORTIONING, PROCESSING AND BURNABILITY ASSESSMENT 2.1 PREAMBLE 2.2 STOICHIOMETRIC REQUIREMENTS IN RAW MIX COMPUTATION 2.3 RAW MIX COMPUTATION 2.4 PREPARATION PROCESS FOR RAW MIX 2.5 BURNABILITY FEATURES OF RAW MIX 2.6 USE OF MINERALIZERS 2.7 SUMMARY 2.8 REFERENCES 3. FUELS COMMONLY IN USE FOR CLINKER PRODUCTION 3.1 PREAMBLE 3.2 CHARACTERISTICS OF FUEL 3.3 COAL RESOURCES OF THE WORLD 3.4 BASIC CHEMISTRY AND PHYSICS OF COMBUSTION 3.5 COAL PREPARATION AND FIRING 3.6 RELATION OF PROCESS PARAMETERS WITH COMBUSTION 3.7 PETCOKE AS A SUBSTITUTE FUEL 3.8 SUMMARY 3.9 REFERENCES 4. ALTERNATIVE FUELS AND RAW MATERIALS 4.1 PREAMBLE 4.2 BROAD CLASSIFICATION 4.3 FEASIBILITY OF AN AFR PROJECT 4.4 INVENTORY AND MATERIAL CHARACTERISTICS 4.5 SYSTEMATIC QUALITY ASSESSMENT 4.6 CO-PROCESSING OF ALTERNATIVE FUELS 4.7 SYSTEMIC REQUIREMENTS FOR USING ALERNATIVE FUELS 4.8 GASIFICATION TECHNOLOGY 4.9 ALTERNATIVE RAW MATERIALS 4.10 ENVIRONMENTAL ASPECTS 4.11 SUMMARY 4.12 REFERENCES 5. PYROPROCESSING AND CLINKER COOLING 5.1 PREAMBLE 5.2 CLINKER FORMATION PROCESS 5.3 PREHEATER-PRECALCINER SYSTEMS 5.4 ROTARY KILN SYSTEMS 5.5 KILN BURNERS AND COMBUSTION 5.6 CLINKER COOLERS 5.7 VOLATILES CYCLE IN PREHEATER-PRECALCINER KILN SYSTEMS 5.8 REFRACTORY LINING MATERIALS IN THE KILN SYSTEM 5.9 ENERGY CONSUMPTION AND KILN EMISSIONS 5.10 KILN CONTROL STRATEGIES 5.11 SUMMARY 5.12 REFERENCES 6. CLINKER GRINDING AND CEMENT MAKING 6.1 PREAMBLE 6.2 CLINKER CHARACTERISTICS 6.3 CLINKER GRINDING SYSTEMS 6.4 ENERGY CONSERVATION AND MATERIAL CHARACTERISTICS 6.5 GRINDING AIDS IN CEMENT MANUFACTURE 6.6 STORAGE, DISPATCH AND BAGGING OF CEMENT 6.7 SUMMARY 6.8 REFERENCES 7. COMPOSITION AND PROPERTIES OF PORTLAND CEMENTS 7.1 PREAMBLE: THE ADVENT OF PORTLAND CEMENTS 7.2 BASIC GRADES AND VARIETIES 7.3 CHARACTERISTICS OF PORTLAND CEMENTS 7.4 PHASE-MODIFIED PORTLAND CEMENTS 7.5 BLENDED PORTLAND CEMENTS 7.6 CHARACTERIZATION OF CEMENTS AND PRACTICAL IMPLICATIONS OF PROPERTIES 7.7 OVERVIEW OF THE HYDRATION REACTIONS 7.8 CEMENT FOR DURABLE CONCRETE 7.9 SUMMARY 7.10 REFERENCES 8. ADVANCES IN PLANT-BASED QUALITY CONTROL PRACTICE 8.1 PREAMBLE 8.2 SAMPLING GUIDELINES 8.3 SAMPLING STATIONS IN CEMENT PLANTS 8.4 COMPUTER-AIDED RUN-OF-MINE LIMESTONE QUALITY CONTROL 8.5 PRE-BLENDING OPERATION 8.6 RAW MIX CONTROL 8.7 KILN OPERATION MONITORING 8.8 CEMENT GRINDING PROCESS 8.9 X-RAY DIFFRACTOMETRY FOR PHASE ANALYSIS 8.10 ON-LINE QUALITY CONTROL IN CEMENT PLANTS 8.11 FLUE GAS ANALYSIS 8.12 8.14 SUMMARY 8.15 REFERENCES 9. ENVIRONMENTAL MITIGATION AND POLLUTION CONTROL TECHNOLOGIES 9.1 PREAMBLE 9.2 POLLUTANTS EMITTED TO ATMOSPHERE DURING THE MANUFACTURE OF CEMENT 9.3 GENERATION AND BROAD CHARACTERISTICS OF DUST 9.4 SULFUR DIOXIDE EMISSION 9.5 NITROGEN OXIDE EMISSION 9.6 NOISE POLLUTION 9.7 SELECTED MONITORING TECHNIQUES 9.8 CURRENT ENVIRONMENTAL OUTLOOK 9.9 SUMMARY 9.10 REFERENCES 10 TRENDS OF RESEARCH AND DEVELOPMENT IN CEMENT MANUFACTURE AND APPLICATION 10.1 PREAMBLE 10.2 SUSTAINING TECHNOLOGIES IN THE GROWTH OF CEMENT INDUSTRY 10.3 STATUS OF POTENTIALLY DISRUPTIVE PYROPROCESSING TECHNOLOGIES 10.4 PORTLAND CEMENT DERIVATIVES WITH NICHE APPLICATION POTENTIAL 10.5 COMPLEX BUILDING PRODUCTS FORMULATION WITH CAC 10.6 RESEARCH THRUST TOWARDS LOW-CARBON CEMENT INDUSTRY 10.7 TECHNOLOGY OPTIONS FOR CONVERTING CO2 INTO FUEL PRODUCTS 10.8 LOW CARBON CEMENTS AND CONCRETE 10.9 NANOTECHNOLOGY IN CEMENT RESEARCH 10.10 NONHYDRAULIC CEMENTS 10.11 SUMMARY 10.12 REFERENCES 11 GLOBAL AND REGIONAL GROWTH TRENDS IN CEMENT PRODUCTION 11.1 PREAMBLE 11.2 CAPACITY AND PRODUCTION GROWTH PERSPECTIVES 11.3 NATIONAL ECONOMY VERSUS CEMENT CONSUMPTION 11.4 CHANGE DRIVERS OF PRODUCTION AND APPLICATION OF CEMENT 11.5 FUTURE DESIGNS OF CEMENT PLANTS 11.6 GROWTH OF THE INDIAN CEMENT INDUSTRY – A CASE STUDY 11.7 REFERENCES EPILOGUE

Anjan Kumar Chatterjee is presently the Chairman of Conmat Technologies Private Limited, which is a research and consulting outfit in Kolkata, India, engaged in providing technical support services to the cement, concrete and mineral industry within and outside the country. Concurrently he is also Director-in-Charge of Dr Fixit Institute of Structural Protection and Rehabilitation, Mumbai, which is a not-for-profit knowledge centre specifically devoted to repair, restoration and renewal engineering of concrete buildings. He is also associated with the major cement companies in the country in various advisory capacity. Prior to taking up the above assignments, Dr Chatterjee was an employee of the Associated Cement Companies Limited (now called ACC Limited) for over two decades and retired as its Whole-time Executive Director. While in ACC, he was responsible for the Company’s Research & Development, Project Engineering and several diversified business units. Academically, Dr Chatterjee is a postgraduate in Geology and doctorate in Materials Science. He carried out extensive research in the field of electro-remelting slags, phase equilibrium studies on oxy-fluoride systems, and microstructural studies of cement, concrete and ceramics at the Institute of Metallurgy in Moscow, Moscow State University and the Building Research Establishment, UK. Beyond the national scene, Dr Chatterjee has been in various international assignments with UNIDO and an Environmental Research Company of University of Amsterdam. He holds the fellowship and membership of a large number of professional bodies. He is a Fellow of the Indian National Academy of Engineering, Indian Concrete Institute, and Indian Ceramic Institute. He is also a Founding Member of Asian Cement & Concrete Research Academy in Beijing, China. He has been conferred the lifetime achievement award by the Indian Concrete Institute, Association of Consulting Civil Engineers, Confederation of Indian Industries and Cement Manufacturers’ Association. He has many other awards and a large number of publications to his credit.