1. Chemical Engineering Process in Cement Production By: Eastern Cement Team: Eng. Ali S. Al-Qahtani Eng. Sayd Basheer Shafee Eng. Haridas Nair By: Eastern Cement Team: Eng. Ali S. Al-Qahtani Eng. Sayd Basheer Shafee Eng. Haridas Nair Presented to: SAUDI ARABIAN SECTION OF AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE) on Sunday, December 27, 2009 at Le Meridien Hotel, Al-Khobar Presented to: SAUDI ARABIAN SECTION OF AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (SAS-AIChE) on Sunday, December 27, 2009 at Le Meridien Hotel, Al-Khobar

2. Who Are we? Our Head Office - Khobar Our Plant is located at Khrsanih Three production line of 3.5 mty cement Joint Stock company listed in Tadawul 700 employees

3. Saudi Cement Industry Economic Contributions

4. Why are we here? Inform the Chemical Engineering Community about Cement Industry. Attract Chemical Engineers to start and build carriers in Cement industry. Attract Local Chemical Engineering Research in Cement Process.

5. Our Business We Produce and Sell …….. Glue …….. for construction Cement

6. Cement is….. Hydraulic BinderHydraulic Binder Solidify and gain compressive strength after mixing with water It binds gravel and sand to form Artificial Rock Sold MaterialIt binds gravel and sand to form Artificial Rock Sold Material Concrete

7. Limestone Cement & Concrete technologies There have been huge developments in the innovation and production of new binder materials in the last 10 years especially in the Epoxy chemicals. However Non can compete with cement and concrete materials for practicality and economic feasibility of production and construction Ancient construction Technologies

8. Cement Production Process Cement Grinding Systems Pyroprocessing (Chemical Reactions) Material handling Systems Raw Material Grinding Systems

9. Cement is Very Old Material…. 1812 Research by Louis Vicat on Hydraulic Binders 1824 Invention of Portland Cement by Joseph Aspedin 1838 Invention of chemical Engineering process by Isaac Johnson 1875 Cement Standard by Wilhelm Michaelis Basic Research and inventions Time Line

10. Cement Production Technologies 1830’s Vertical Kilns 1885 Rotary Kilns 1930’s Long Rotary Kilns 1970’s Short Rotary Kilns and Preheater Technology 2000’s Control and instrumentation Gears and bearings Cooling and heat transfer Material handling systems Cyclone and filters

11. Pyroprocessing System Preheater Rotary Kiln Cooler

12. Preheater What is happning at the Preheater? Raw material separation and suspension for heat absorption. Moisture Removal Decomposition of CaCO3, MgCO3, formation of CA,Decomposition of CaCO3, MgCO3, formation of CA, C2F and C3S begins. Formation of C 12 A 7 Formation of C 12 A 7

13. Rotary Kiln Formation of C3A and C4AF begins, decomposition ofFormation of C3A and C4AF begins, decomposition of CaCO3 completed, free lime reaches maximum CaCO3 completed, free lime reaches maximum Formation of C2S reaches maximum,Formation of C2S reaches maximum, C3A and C4AF formation completed C3A and C4AF formation completed Formation of liquid phaseFormation of liquid phase Formation of C3S, gradual decrease of free lime content. Formation of C3S, gradual decrease of free lime content.

14. Clinker Tricalcium silicate (C3S) or alite, dicalcium silicate (C2S) or belite, tricalcium aluminate (C3A) and tetracalcium aluminoferrite (C4AF) are the main clinker constituentsTricalcium silicate (C3S) or alite, dicalcium silicate (C2S) or belite, tricalcium aluminate (C3A) and tetracalcium aluminoferrite (C4AF) are the main clinker constituents MINERALOGICAL COMPOSITION OF CLINKER

15. Cooler

16. Final Chemical Process Addition of Gypsum CaSO 4.2H 2 O to control the setting time of cement Raw Material Grinding Systems Cement Grinding Systems Pyroprocessing (Chemical Reactions) Material handling Systems

17. Cement Chemical Composition Cement Compound Weight Percentage Chemical Formula Tricalcium silicate50 %Ca 3 SiO 5 or 3CaO. SiO 2 Dicalcium silicate25 %Ca 2 SiO 4 or 2CaO. SiO 2 Tricalcium aluminate10 %Ca 3 Al 2 O 6 or 3CaO. Al 2 O 3 Tetracalcium aluminoferrite 10 % Ca 4 Al 2 Fe 2 O 10 or 4CaO. Al 2 O 3. Fe 2 O 3 Gypsum5 %CaSO 4. 2H 2 O