Cement Plant

Coordinator: Dem etrio Fuentes

Students: Catalin Miroiu
Cristina Tom escu
Valen tin Nastasa

Index:
1.General Information about Romania
2.Memory of the Project:
2.1 General Information
2.2 Environmental Considerations
3.Legal Procedures
4.Cement Plant Equipment
5.Buget

General Information about Romania

Romania is located at the intersection of

Central and Southeastern Europe. The

Romanian language, like a number of
others in southern Europe, is directly
descended from Latin.
After the 1989 Revolution, Romania began

its transition from communism towards

democracy and a capitalist market
economy.
The country has considerable natural

resources: oil, natural gas, coal, iron,

copper and bauxite. Metal-working,
petrochemicals and mechanical engineering
are the main industries.

Neighbours:

Ukraine (N & E)

Moldova (E & N-E)

Bulgaria (n S)

Serbia (S-V)

Hungary (N-V)

Membership:
European Union (2007), NATO (2004), United Nations (1995), WTO (1995), OSCE (1973) and more
Area : 238,391 km2 (83rd in the world)
Capital and largest city : Bucharest
Official language : Romanian
Population : 20,121,641 (58th)
GDP(nominal) :124,67 Billion (Spains Pib : 989 Billion)
GDP per Capita : 5886 (Spains Pib per capita: 22 000)
Official Currency : Romanian Leu (RON)

2.Memory of the Project

2.1 General Informations
A cement is a binder, a substance that sets

and hardens independently, and can bind

other materials together.
Cements used in construction can be
characterized as being either hydraulic or
non-hydraulic.

An example of how cement can be made

1.) Limestone is taken from a quarry. It is the
major ingredient needed for making cement.
Smaller quantities of sand and clay are also
needed. Limestone, sand and clay contain the
four essential elements required to make cement.
The four essential elements are calcium, silicon,
aluminum and iron.
2.)Boulder-size limestone rocks are
transported from the quarry to the
cement plant and fed into a crusher
which crushes the boulders into
marble-size pieces.

3.)The limestone pieces then go

through a blender where they are
added to the other raw materials in
the right proportion.

4.)The raw materials are ground to a powder.

This is sometimes done with rollers that
crush the materials against a rotating
platform.
5.)Everything then goes into a huge, extremely
hot, rotating furnace to undergo a process
called "sintering". Sintering means: to cause
to become a coherent mass by heating
without melting. In other words, the raw
materials become sort of partially molten.
The raw materials reach about 2700 F
(1480C) inside the furnace. This causes
chemical and physical changes to the raw
materials and they come out of the furnace
as large, glassy, red-hot cinders called
"clinker".

6.)The clinker is cooled and ground into a fine

gray powder. A small amount of gypsum is
also added during the final grinding. It is now
the finished product - Portland cement.
The cement is then stored in silos (large
holding tanks) where it awaits distribution.
The cement is usually shipped in bulk in
purpose-made trucks, by rail or even by
barge or ship. Some is bagged for those who
want small quantities.

Properties of Cement.
Ingredient

%age

Effect

Lime (CaO)

60-65

Controls strength and

soundness

Sillica (SiO2)

20-25

Gives strength, excess

quantity causes slow
setting

Alumina (Al2 O3)

4-8

Quick setting, excess

lowers strength

Iron Oxide (Fe2 O3)

2-4

Imparts color, helps in

fusion of ingredients

Magnesium Oxide
(MgO)

1-3

Color and hardness,

excess causes cracking

Na2 O

0.1-0.5

Controls residues,
excess causes cracking

Sulphur Trioxide (SO3) 1-2

Makes cement sound

Final Products using Cement

Cement mixed with water,

sand and gravel, forms

concrete.
Cement mixed with water

and sand, forms cement

plaster.

Cement mixed with water,

lime and sand, forms mortar.

2.2 Environmental
Considerations
A cement plant will always

have problems with dust

emissions in the
atmosphere.The legal limit
of dust emission is
30mg/Nm3

Another problem is represented

by the quality sewage and it
may be monitorised by :

-Own laboratories.
-An independent laboratory accredited
by competent institution.

-Water Department Buzau Ialomita.

The table below shows the emissions values performed

well in 2012:

Indicator

Unit

Best EU values

Furnace dust emission

kg/t clincker

0.01 - 0.4

NOx emissions from

the oven

kg/t clincker

< 0.4 - 6

SO2 emissions from

the oven

kg/t clincker

< 0.02 - 7

CO2 emissions from

the oven

kg/t clincker

1-4

3. Legal Procedures
Operation of a cement

factory involves exploitation

and processing of cement
which is found in quarries.
To own or operate a quarry

you must first participate at

an auction organized by the
Romanian State and win it .

To participate in this auction, you must demonstrate that you own

the amount
needed to purchase / operate a quarry and you must pay a fee
which is imposed by the state also.

 After obtaining the certificate that you own quarry or that

you are allowed exploitation will get legal procedures that

are clear, but at the same time complicated to obtain
planning certificate issued by the Office of Planning ,we
need the following approvals:
1.

Authorization Cadastre Office that deals with the study of

soil and removing certificate aside land (if agricultural
area).

2. Fire protection certificate - which is

obtained from the Fire Institution.
3. Population health certificate, which is
obtained from the Department of
Public Health SANEPID

 4.Operation of the grid

plan - which is obtained

from Electrica Romania.

 5. Operating plan of the

water, sewer - which is

obtained from the
Romanian Waters National
Company

6. Certified civil defense - which is obtained from the Local

Defense.
7. Bringing to the attention of the Romanian Police because the land
is in a special area.

8.Integrated environmental permit - obtained from Ministry of Water

and Environment.

4. Cement Plant Equipment

Cement Mills (Ball Mills)
Cement Kiln
Jaw Crusher
Elevator
Automatic Rotary Cement Packing Machine
Pollution Control Device
Tools
Media
Air Sliders and Air Lifters
Hoppers

 Acement millis the equipment used to grind the hard,

nodularclinkerfrom thecement kilninto the fine grey

powder that iscement.

Cement kilnsare used for thepyroprocessingstage of manufacture of

cement, in whichcalcium carbonate reacts withsilica-bearing minerals to
form a mixture ofcalcium silicates. Cement kilns are the heart of this
production process: their capacity usually defines the capacity of the cement
plant.

Ancillary equipment:

Preheaters
Cooler
Fuel mills
Fans
Exhaust gas cleaning equipment

 A jaw crusher uses compressive force for breaking of particle.Jaw

crusher is widely used asprimary crushermachine for coarse

crushing process in limestone quarrying plant.

Elevator

Cement packing machine

is divided into fixed

and rotary type. Fixed cement packing machine is the packing
machine with 1-4 mouth, which is movably installed bags by
workers. Rotary cement packing machine is 6-14 mouth, which is
installed bags in rotation by packing machine.

 Air Pollution Control

Devices
Electrostatic Precipitator (ESP)
- ESP control devices ionize
contaminated air flowing between
the electrodes.

Baghouse Filters
In these control devices,polluted
air is filtered through the bags.The
bags are closed at the bottom,and
are exposed to a clean air chamber
at the top.The bags are cleaned by
short bursts of pressured air.The
bags contracts and snaps which
releases the particulate layer.

Hoopers
Materials are discharged in discharging area with crab. Feeding

mouth of discharging area and crab block the dust cloud, so air
flow gets into dust collection area through dust bar grid, with
collected dust recycled in material flow, therefore good working
environment can be created.

Transport
In cement plants we use special trucks.
We need about 35 trucks in order to avoid congestions.
This calculation is made on an estimating cement production of 5300
tones per day . (aproximative 2 milion tones per year ).

5.Buget
Our estimated buget will be around 250

million .
We will have around 750 employees.
35 trucks

Thank you for your

attention !