WO2011051962A2 - Procédé pour la fabrication de ciment blanc - Google Patents

Procédé pour la fabrication de ciment blanc Download PDF

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Publication number
WO2011051962A2
WO2011051962A2 PCT/IN2010/000653 IN2010000653W WO2011051962A2 WO 2011051962 A2 WO2011051962 A2 WO 2011051962A2 IN 2010000653 W IN2010000653 W IN 2010000653W WO 2011051962 A2 WO2011051962 A2 WO 2011051962A2
Authority
WO
WIPO (PCT)
Prior art keywords
clinker
flue gases
cement
dryer
gases
Prior art date
Application number
PCT/IN2010/000653
Other languages
English (en)
Other versions
WO2011051962A3 (fr
Inventor
H.R. Kapoor
Inder Raj Vyas
Sunil Chhaperwal
Sanjeev Trehan
Rao P.M.V. Subba
Original Assignee
Ultratech Cement Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ultratech Cement Limited filed Critical Ultratech Cement Limited
Publication of WO2011051962A2 publication Critical patent/WO2011051962A2/fr
Publication of WO2011051962A3 publication Critical patent/WO2011051962A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C04B7/43—Heat treatment, e.g. precalcining, burning, melting; Cooling
    • C04B7/47—Cooling ; Waste heat management
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C04B7/48—Clinker treatment
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility
    • C04B2111/802—White cement
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • Y02P40/121—Energy efficiency measures, e.g. improving or optimising the production methods

Definitions

  • the present invention relates to manufacturing of white cement.
  • the invention envisages recovery of heat and water from waste heat source generated in the production of white cement.
  • White ordinary Portland cement known is an important raw material used in the constmction of a building.
  • White cement with the exception of whiteness has the same properties as Gray ordinary Portland cement. It is as durable and strong as Gray ordinary Portland cement but has high degree of whiteness. Obtaining this color requires substantial modification to the method of manufacture, and because of this, it is somewhat more expensive than the gray product.
  • White Portland cement is used in combination with inorganic pigments to produce brightly colored concretes and mortars.
  • White Cement is used in decorative works and also wherever vibrant colors are desired.
  • White Cement is used to fill up the gaps between marble and ceramic tiles for a smoother and more beautiful finish.
  • the characteristic greenish-gray to brown color of ordinary Portland cement derives from a number of transitional elements in its chemical composition. These are. i n descending order of coloring effect, chromium, manganese, iron, copper, vanadium, nickel and titanium. The amount of these in white cement is minimized as far as possible. 0203 is kept below 0.003%, n203 is kept below 0.03%, and Fe203 is kept below 0.35% in the clinker.
  • Portland cement is usually made from quarried raw materials, and these usually contain substantial amounts of Cr, Mn and Fe.
  • limestones used in cement manufacture usually contain 0.3-1% Fe203, whereas levels below 0.1 % are sought in limestones for white cement manufacture.
  • the rotary kilns used to chemically combine the raw materials are operated at a higher peak temperature ( 1450- 1500°C) than that required for gray clinker manufacture ( 1400- 1450°C). This requires a higher fuel consumption (typically 20-50%) more). The reason for this is the relatively small amount of liquid produced during sintering, because of the low iron- content of the mix.
  • the various raw materials required for the production of White Cement are: Limestone, Clay, Sand, Iron Ore, Nickel, Titanium, Chromium and Vanadium.
  • Limestone sourced from mines is crushed in specific size (it is passed 100% through +50 mm sieve for vertical roller mil), in accordance with the grinding equipment requirement and conveyed through a belt conveyor to the stacker for homogenization.
  • Blended raw materials (Lime stone + Clay) are fed to a grinding mill through hoppers and weigh feeders to get a desired proportion of each material.
  • Ground material is collected in a blending silo for storage and homogenization. The fineness of the ground material may vary from 6.0% to 1 1 % as per the acceptance of the burning equipment specifications. 4. PREHEATING AND BURNING:
  • Homogenized material from the blending silo is extracted from below and fed at the top of the preheater.
  • the preheater section consists of a series of cyclones with a Pre-calcinator and flow of the material and gas in the pre heater is counter current. Fuel is fired in the pre-calcinator to provide heat for preheating and de-carbonation. Before entering in the kiln for burning, 70 to 85% of the de-carbonation is completed.
  • Fuel is fired in the kiln and pre-calcinator for preheating, de-carbonation and burning of the material.
  • oil is used as a fuel in white cement process
  • alternate fuels like petroleum coke, rubber, agro waste, can also be used in white cement process due to high cost of oil.
  • the clinker formed in the kiln is then discharged in a Quencher or Decoloriser for water quenching. Quenching is carried in a reducing atmosphere. In grey cement clinker is cooled by air while in white cement clinker is cooled in water in the absence of air.
  • the clinker is next ground to cement (perhaps after a drying stage).
  • Calcium sulfate is added to the control set, in the form of a high-purity grade of gypsum or anhydrite.
  • Ceramic grinding media is preferred in the case of white cement grinding in place of high chrome grinding media for avoiding the detoriation of cement whiteness.
  • the quantity of heat lost from preheater exist gases ranges from 180 to 250 kCal/ kg clinker at a
  • Figure 1 illustrates a flow diagram of a conventional white cement manufacturing process.
  • the raw material typically limestone along with other materials
  • the raw material from crusher enters the raw mill for fine crushing and drying and finally enters in to a kiln for heating.
  • the clinker from the exit of the kiln is quenched with the help of water in a cooler (decoloriser /dryer) and finally enters the cement grinding station.
  • the exhaust gases at raw mill, kiln and cooler (decoloriser/ dryer) are discharged in to atmosphere through Electrostatic precipitators (ESP) /Bag House.
  • ESP Electrostatic precipitators
  • Figure 2 illustrates a white cement manufacturing plant at operating condition.
  • the white clinker formed from a kiln is discharged to a decoloriser or quencher for water quenching.
  • the white clinker is cooled in a decoloriser with the help of water in the absence of air to avoid deterioration in whiteness.
  • the leinperature of the clinker at the discharge of the kiln is around 1200-1400°c.
  • the temperature of the clinker at the discharge of dryer after quenching process is around 150-200°C.
  • During the quenching process there is formation of super heated steam along with other gases and clinker dust.
  • This steam with dust laden gases (55% steam + 45% air) is taken to an ESP/Bag House through cyclones and then discharged into the atmosphere.
  • the kiln exhaust gases at 150 to 250°C are discharged into atmosphere through ESPs/ Bag House.
  • This waste heat can be effectively utilized for electric power generation. Besides mitigating the problem of power shortage, this method of heat recovery for power generation will also help in energy conservation as well as reducing green house gas emissions.
  • the main object of the present invention is to develop a process for manufacturing white cement whereby the heat generated during the process i s extracted and utilized for generating electric energy and water.
  • the quenched clinker contains moisture in the range of 10 to 15%.
  • the flue gases recovered from dryer contains 40 to 50 % moisture.
  • the dust particles are separated by passing the flue gases through a cyclone and a filter bag.
  • the dust content in the flue gases is reduced to less than 5mg/m 3 .
  • the present invention envisages a system and method to reduce the energy and water that is being wasted and to effectively generate power from a waste heat source in a white cement manufacturing plant.
  • waste heat recovery boilers e.g. Waste heat recovery boilers, recuplators, Heat disc etc.
  • waste heat source temperature are at lower ranges but have high heat content because it contains low temperature steam with good amount of latent heat, this needs a special thermodynamic cycle for extraction of heat and collection of condensate from the cooler exhaust gases.
  • a Thermodynamic cycle such as the Rankine cycle converts heat into work.
  • the heat is supplied externally to a closed loop, which usually uses water.
  • This cycle generates about 80% of electric power used throughout the world including virtually all solar thermal, biomass, coal and nuclear power plants.
  • the alina cycle is a thermodynamic cycle for converting thermal energy to mechanical power, optimized for use with thermal sources which are at a relatively low temperature compared to the heat sink (or ambient) temperature.
  • the cycle uses a working fluid with at least two components (typically water and ammonia) and a ratio between those components is varied in different parts of the system to increase thermodynamic reversibility and therefore increase overall thermodynamic efficiency.
  • Thermodynamic cycles for waste heat recovery are commonly designed on the ankine cycle which has been modified using binary fluid of ammonia and water as the working fluid in place of only water for improving the overall efficiency of conventional systems.
  • This modified system is called 'Kalina Cycle'.
  • efficiency gain of upto 50% for low temperature heat sources (200-280 Deg C) and upto 20% for higher temperature heat sources have been observed as compared to conventional Rankine cycle based power plants.
  • Figure 3 illustrates a flow diagram of a white cement manufacturing process in accordance with the present invention.
  • modified cement manufacturing process the latent and sensible heat in exhaust gases and steam from the exit of cooler (decoloriser/dryer) is recovered along with the recovery of condensate (water).
  • the exhaust gases from the raw mill and kiln are discharged in to atmosphere through ESP/Bag House.
  • the cement clinker is formed by using the above raw materials and following the general method as described earlier.
  • the clinker at a temperature range of 1 100 °C to 1400 °C is fed to decolourizer/quencher and is quenched by spraying water on the falling clinker.
  • the water is sprayed through nozzles in controlled manner for sudden cooling of clinker from 1 250- 1350° C to 200-250° Deg C, this process is carried out in the quencher under suction (in absence of air). Quenching of hot clinker results in formation of super saturated steam along some non-condensable gases.
  • Quenched clinker containing moisture around (10-15%) is fed to dryer where super saturated steam formed during quenching is used for drying of quenched clinker. Retention time of clinker in dryer is 15-20 min.
  • the gases at the exhaust of the dryer contain 45% moisture, 55% non condensable gases.
  • the gases as generated above are passed through a heat exchanger to extract sensible and latent heat form the exhaust gases, leaving behind hot condensate (water).
  • the condensed water is used for quenching purpose again.
  • a heat exchanger is part of special thermodynamic cycle which converts the heat extracted to electrical energy.
  • the gases as generated above are passed through a cyclone for removing clinker dust before passing through a heat exchanger.
  • dust content in the gas stream is in range of 25-35 gms/m3 ( 160-220° C).
  • a bag filter is further installed at the exhaust of the dryer to reduce dust content in the exhaust gases to less than 5mg/m3.
  • the thermal energy available at the decoloriser fan exit is about 15-17 MW and thermal energy available at the dryer fan exit is about 1 1-13 MW per hour for an 1 800tpd production.
  • the present invention of extracting latent and sensible heat from the decolorizer/ dryer gases, a large amount of condensate in form of water is recovered (about 30000 -38000 kl/hr) and about 1-5MW of electrical energy can be recovered.
  • Extracted clinker from storage is mixed along with dry Selenite and Gypsum cement setting time retarder, and is fed to the ball mill in a controlled way through weigh feeders and conveyor belts.
  • Roller press or vertical roller mill can also be used for white cement grinding for cost economy. Ceramic grinding media is preferred in case of white cement grinding for avoiding the detonation of cement whiteness.
  • a system and method for recovery of water, latent and sensible heat in quenching process for manufacture of white cement clinker as described in the present invention has several technical advantages including but not limited to the real ization of:

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Drying Of Solid Materials (AREA)

Abstract

L'invention concerne un procédé pour la fabrication de ciment blanc qui comprend les étapes consistant à récupérer des gaz de carneau générés pendant le processus de refroidissement et de séchage, à extraire la chaleur des gaz de carneau récupérés afin d'obtenir un condensat d'eau et de générer de l'énergie électrique.
PCT/IN2010/000653 2009-10-01 2010-09-30 Procédé pour la fabrication de ciment blanc WO2011051962A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN2286MU2009 2009-10-01
IN2286/MUM/2009 2009-10-01

Publications (2)

Publication Number Publication Date
WO2011051962A2 true WO2011051962A2 (fr) 2011-05-05
WO2011051962A3 WO2011051962A3 (fr) 2011-07-07

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PCT/IN2010/000653 WO2011051962A2 (fr) 2009-10-01 2010-09-30 Procédé pour la fabrication de ciment blanc

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110818296A (zh) * 2019-12-25 2020-02-21 河北乾宝特种水泥有限公司 一种新型白水泥漂白装置及工艺

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4059396A (en) * 1974-10-03 1977-11-22 F. L. Smidth & Co. Cement manufacture
US4767462A (en) * 1985-06-26 1988-08-30 Cia. Valenciana De Cementos Portland S.A. Method and apparatus for cooling and for further treatment of hot white cement clinker
CN2097834U (zh) * 1991-08-07 1992-03-04 四川省建材工业科学研究所 白水泥熟料的漂白装置
CN1142471A (zh) * 1996-08-01 1997-02-12 叶树基 白水泥熟料冷却新工艺
US5618104A (en) * 1994-04-23 1997-04-08 Krupp Fordertechnik Gmbh Method for cooling white cement clinker

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4059396A (en) * 1974-10-03 1977-11-22 F. L. Smidth & Co. Cement manufacture
US4767462A (en) * 1985-06-26 1988-08-30 Cia. Valenciana De Cementos Portland S.A. Method and apparatus for cooling and for further treatment of hot white cement clinker
CN2097834U (zh) * 1991-08-07 1992-03-04 四川省建材工业科学研究所 白水泥熟料的漂白装置
US5618104A (en) * 1994-04-23 1997-04-08 Krupp Fordertechnik Gmbh Method for cooling white cement clinker
CN1142471A (zh) * 1996-08-01 1997-02-12 叶树基 白水泥熟料冷却新工艺

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110818296A (zh) * 2019-12-25 2020-02-21 河北乾宝特种水泥有限公司 一种新型白水泥漂白装置及工艺

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Publication number Publication date
WO2011051962A3 (fr) 2011-07-07

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