Comminution Processes of Cement Production Line

Comminution engineering describes the processes for the size reduction of bulk materials. The materials are crushed in one or several steps to the feed size required for the grinding process. In the grinding systems of a cement manufacturing plant the materials are ground to either raw meal or cement.

Crushing is characterized by the application of either compression or impact forces whereas grindingis effected with a combination of impact and friction forces.

Comminution theories have been developed in an attempt to determine the energy input required to crush or to grind a material of a given feed size to the required product fineness. These theories are only valid for a rather limited range of materials and of size-reduction-machine types and are therefore not suitable for the dimensioning of industrial machines.

Comminution is a major unit operation in a cement manufacturing plant, accounting for about 50 % - 75 % of plant electrical energy consumption. The comminution processes are divided, depending on feed-material size, into the crushing (breaking) processes and the grinding (pulverizing) processes.

COMMINUTION PROCESSES

1. Crushing of rock materials from the quarry (size 1 - 1.5 m) in one till three steps to an intermediate raw material state (size < 100 mm), used as input for the raw meal production process.
2. Grinding of the intermediate raw material to raw meal (< 2 % 12 200 mm), which degree of fineness is defined by the following kiln-firing process used.
3. Grinding(and simultaneously mixing) of clinker and additives (size < 25 mm) to the final product, cement, which degree of fineness is defined either by standards or customer requirements.
4. Grinding of raw coal (size 20 mm) to coal powder used for kiln firing.

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