Cost of setting up medium size cement plant

Project Background

thyssenkrupp Industrial Solutions is one of the few full-range suppliers for the cement industry – from individual machines

Cost of setting up medium size cement plant

Your cement plant - our products and services

thyssenkrupp Industrial Solutions is one of the few full-range suppliers for the cement industry – from individual machines, all the way up to complete plants. We also have compelling solutions for the modernisation of existing systems. We have unique expertise in the field of process engineering. In accordance with customer-specific requirements, we develop innovative machinery, technologies and processes to create intelligent production lines.

From the planning process, to construction, to the commissioning of plants, our clients have a single contact person. This accelerates procedures, prevents conflicts of interests, and ensures fast and trouble-free commissioning.

The trend in the global cement industry is moving towards the awarding of turnkey orders: from individual grinding plants to entire production lines.

Thanks to the application of ultra-modern production processes, our plants protect resources and the environment and guarantee plant owners maximum productivity and economy of operation.

cement plant

Cement Manufacture Processes

The process of manufacturing cement requires the following three stages:

Raw material preparation: grinding a mixture of raw materials to make a ‘raw mix’.

Clinker burning (Pyro-processing): heating the raw mix to a sintering temperature of >1400°C in a cement kiln to produce ‘clinker’.

Cement preparation: grinding the resulting clinker with gypsum and other additives to make cement.

Simplified Cement Making Process Schematic

The most common raw materials used for cement manufacture are limestone, marls and clay (although others can be used). The selected materials are crushed, ground and mixed to produce a raw mix of suitable composition and form for pyro-processing. Approximately 1.50-1.60 t of (dry) raw mix are required to produce 1 t of clinker, due to the calcination of the limestone component of the raw mix.

The second stage in the process involves feeding the raw mix into a kiln system where it is gradually heated. Successive chemical reactions take place as the temperature of the raw mix rises.

Typically, a peak temperature of 1400-1450 °C is required to complete the reactions and produce alite, the characteristic constituent of Portland cement. Partial melting causes the material to aggregate into lumps or nodules known as clinker which is then cooled with air to 100-200°C. Waste heat from the kiln system is usually used for drying the raw materials in the raw grinding section of the production process.

Magnification of a Clinker Nodule

The final stage in the manufacturing process involves grinding clinker with additives, such as gypsum, limestone, granulated blast furnace slag and fly ash, to control the properties of the cement.

The Four ‘Integrated Plant’ Process Routes

The three manufacturing stages previously mentioned are common to four main ‘integrated plant’ process routes by which cement can be produced. These process routes are distinguished by the moisture content of the feed going into the kiln and are known as follows:

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