400 Inde x

Carbon footprint, feasibility of AFR project, 109 fuels, 74–81

Carbon monoxide calorific value, 74
electrochemical CO2 reduction, 359 coal, oil, and gas, comparative behavior of,
emissions, 291 80–81
flue gas component, 273, 278–279 coal, ranks and properties of, 74–77
measurement technique, 275–276 liquid fuels, types and properties, 77–79
presence and quantity, 278 natural gas and synthetically produced gaseous
production, 84 fuels, properties, 79–80
Carbon nanotubes (CNTs), tensile strength, 367 hazardous waste, 105–106
Categories, of reserves, 14–15 material, AFR, 109–118
Cell parameters, of belite phase on doping, 339, 341t biomass residues, 112, 113t
CEMBUREAU, countries of, 373, 374f hazardous waste, 114–115
Cement rock, defined, 42 industrial plastic waste, 117
Cement(s) miscellaneous, 117–118
AFR, see Alternative fuels and raw materials (AFR) MSW, 110–112
clinker grinding and cement making, see Clinker overview, 109–110
grinding scrap motor tires, 112, 114
consumption, national economy vs., 377–378 sewage sludge, 115–117
environmental mitigation and pollution control material, energy conservation and, 200–205
technologies, see Environmental mitigation blast furnace slag and limestone powder, 204–205
and pollution control technologies grinding of mineral admixtures and fillers,
fuels, in clinker production, see Fuels 203–204
global and regional growth trends, see Global and gypsum, dehydration of, 202–203
regional growth trends overview, 200–202
hydration, see Hydration Portland cements, 219–225
performance requirements, 380–381 blended, 227
plant-based QC practice, see Plant-based QC practice chemical composition, 219
Portland cements, see Portland cements color, 219
production, mineral resources for, see Mineral hydration of pure cement compounds, 220
resources hydrophobic Portland cement, 224
pyroprocessing and clinker cooling, see LHPC, 223–224
Pyroprocessing, clinker cooling and oil well cements, 224–225
raw mix, see Raw mix phase composition-property relationship, 222t
top cement-producing countries, 373, 375–377, 375t principal phases, 219
trends of R&D, see Research and development (R&D) reactivity, 220, 222
Central inverted-cone silos, 210 RHPC, 222–223
Central Pollution Control Board, 106, 107, 114, 318 SRPC, 223
CEN/TS 15442, 118 stages, 221
Chalk, 19 strength development, 221f
Change drivers, of production and application, 379–382 white and colored, 224
cement performance requirements, 380–381 Characterization
high-performance building materials, 382 minerals and rocks, 2–6
overview, 379–380 Portland cements, 230–235
Characteristics compositional aspects, 232
chemical and mineral, raw meal, 64 density and related parameters, 231
clinker, 176–185 fineness, effect of, 233
broad characteristics, 184–185 heat evolution over time, 233–235
granulometry, 184 hydraulic cements, 230–231
phase composition, 176–178 setting behavior, 233
proportions of clinker phases and their testing and, 230–231
microstructure, 178–184 Chemical analysis, online systems for, 268
dust, 293–313 Chemical properties
cyclones and multicyclones, 297–298 gypsum, 34–35
ESP, 303–310 raw meal, 64
fabric filters/bag filters, 298–303 Chemical requirements, of API, 225t
fugitive dust control methods, 311–313 Chemistry, of combustion, 83–86
gravel bed filter, 310–311 flame emissivity, 86
operational controls and design measure, 296 fuel and air mixing, 84–85
overview, 293–296 heat transfer, 86
trends and progress in dust abatement technologies, overview, 83–84
296–297 Chemoluminescence detectors, 276
 Inde x 401

Chert, 18 high-pressure grinding rolls, 195–198

Chevron method, 56–57 horizontal roller mill (horomill), 198–200
China, 8, 229 overview, 185–186
standard specifications for cements in, 218–219 VRMs, 193–195
Chlamydomonas reinhardtii, 358 Clinkering reactions and kiln systems, 143–146
Chlorine compounds, 292 Clinker making process
Chlorine content, in raw meal, 117 Bogue equations, 43, 44–46
Chlorite, 31, 32 burning process, Q-T diagram of, 147, 148f
Chromite bricks, 164 cooling, pyroprocessing and, see Pyroprocessing
Chugoku Electric Power Co. Inc., 364–365 fluidized bed, 331–332
Circular stockpile, 57–58 formation process, 141–146
Classification(s), 104–107 overview, 141, 142f, 143
ASTM, portland cements, 215–216 reactions and kiln systems, 143–146
broad, 104–107 fuels in, see Fuels, in clinker production
hazardous waste, 104, 105–106 liquid phase, calculation of, 46–47
overview, 104, 105t LSF and SM ratios in, 44f
of dust categories, 289 minor constituents, 64–65
hazardous waste raw materials for, 41–43, 42t
biological parameters in, 106–107 Closed-circuit ball mill system, 187f
defined, 104, 105–106 Closed-circuit crushing plant, 55, 56f
limestone deposits, 9–10, 19 Coal(s)
overview, 104, 105t ash absorption, calculation of, 47–48
petcoke, 96–97 combustion of, 91
rocks, 4t composition, 76
Classifiers, defined, 58 gas, 79, 80t
Clay minerals, 29–32 gasification processes, 133–135
Clean gas, defined, 273 preparation and firing, 87–92
Clinker(s) ash absorption on clinker, 92
cooling rate, on cement strength parameter, 339, 340t characteristics on combustion, 91–92
defined, 175 direct system, 87, 88f
phases, monitoring online kiln for, 268–270 indirect system, 87, 89f
Clinker grinding, cement making and, 175–211 semi-direct system, 87, 90f
bagging of cement, 211 ranks and properties of, 74–77
characteristics, 176–185 resources of world, 81–83
broad, 184–185 in Asia-Pacific Region, 81, 82t
granulometry, 184 inventory in India, 82–83
phase composition, 176–178 regional distribution, 81t
proportions of clinker phases and microstructure, R/P ratio, 81
178–184 status, 82
dispatch of, 210 thermal characteristics of coal, oil, and gas,
energy conservation and material characteristics, comparison, 80–81
200–205 Coarse-grained compact limestone, 20f
blast furnace slag and limestone powder, Color, Portland cements, 219, 224
204–205 Combined grinding, 200
grinding of mineral admixtures and fillers, Combustible wastes, 104
203–204 Combustion
gypsum, dehydration of, 202–203 chemistry and physics, 83–86
overview, 200–202 flame emissivity, 86
grinding aids, 205–209 fuel and air mixing, 84–85
on cement hydration, 206 heat transfer, 86
dosing, 209 overview, 83–84
flow properties of cement, improving, 206 of coal, 91
operational features of ball mill and effect, kiln, 155–156
206–208 multistage, 316–317
overview, 205–206 oxy-fuel combustion, 355
for roller press systems, 208–209 oxygen-enriched air combustion, 355
for VRMs, 208 post-combustion capture, 354, 355
overview, 175 pre-combustion capture, 354–355
storage of cement, 209–210 relation of process parameters with, 92–95
systems, 185–200 excess air, 93, 94
ball mills, 186–192 flame temperature, 94–95
402 Inde x

primary air, 92–93 Conveying systems, alternative fuels, 125–131

secondary air, 93, 94f automation and control, 131
zone conditions in cement kiln, 122t to kilns, 128, 130
Compositional aspects, Portland cements, 232 overview, 125–127
Compositions Coolers, clinker, 157–161
AFR, 104, 105t effects on clinker quality, 159–161
clinker, CSA–BC, 342–343, 343t overview, 157–159
coal, 76 Cooling, clinker
limestone, 18–24 pyroprocessing and, see Pyroprocessing
phases, of clinker, 176–178 Co-processing, of alternative fuels, 121–124
Portland cements, see Portland cements cement kilns, advantages of, 121–124
Compressive strength, in hydrating portland cement, 232 defined, 121
Computation, raw mix emission norms of cement plants, 124t
adoption of computer programming, 53, 54f Coquina, 19
overview, 48 Corona discharge, 305
step-wise matrix method, 49–53 Corona power-based method for monitoring ESP
stoichiometric requirements, 41, 42–48 performance, 321–322
clinker liquid phase, 46–47 Corrective materials, 32–33
coal ash absorption, 47–48 Corrosivity, hazardous waste, 105
overview, 41–43, 44f COSMA, 269
potential phase computation by Bogue equations, Costs
43, 44–46 fuel oil, 78
trial-and-error method, 49 petcoke, 96
Computer-aided run-of-mine limestone QC, 256–257 raw materials and fuels, 103
Computer programming, adoption of, 53, 54f sweetener-grade limestone, 20
Concentration, LC, 107 Cradle-to-gate LCA, 247
Concretes, low-carbon, 359–366 Cristobalite, 31t
Calera process for calcium carbonate cement, Cross bar cooler, 159
360–361 Crosscut samplers, 254
Calix and novacem processes for magnesia-based Crude oil, 77
products, 362–363 Crushing operation, 53, 55–56
CO2-SUICOM technology, 364–365 Crystalline limestone, 7
overview, 359–360 Curing, temperature on, 238–239
Solidia cement and concrete, 363–364 Cut-off stripping ratio (COSR), 25
SWOT analysis of carbonation technologies in Cyanide residues, 117
development, 365, 366t Cyclone design, preheater, 151, 152
TecEco cements based on reactive magnesia, Cyclone gravel bed filter, 311
361–362 Cyclone preheater kiln, see Preheater-precalciner systems
Conditional simulation, 257 Cyclones, 297–298
Cone-bottom silos, 210 separators, high-efficiency, 190–191
Cone shell method, 57
Confederation of Indian Industries, 247 D
Conservation, energy
material characteristics and, 200–205 Datamine, 28
blast furnace slag and limestone powder, Decarbonation
204–205 capacity of preheater, 147
grinding of mineral admixtures and fillers, reactions, limestone, 143–145
203–204 Degradation, of refractory lining in service, 166
gypsum, dehydration of, 202–203 Dehydration
overview, 200–202 defined, 34
Consistency, of cement paste, 231 gypsum, 202–203, 210
Consumption, of cement, 385, 386 Delayed petcoke, 96
Control Density, Portland cements, 231
kiln, strategies, 169–170 Deposition, of calcium silicate hydrates, 221
storing, dosing, and conveying, alternative fuels, 131 Deposits, limestone, 8–18
Controlled flow gate (CFG), 159 classification and exploration intensity, 9–10
Control(s), raw mix, 260–263 dimension, quantity, and preparation of samples, 17–18
homogeneity, monitoring, 262–263 industrial implications of categorization of reserves,
hot meal quality monitoring, 263 14–15
overview, 260, 261f overview, 8–9
XRF, 261–262 reliability of different categories of reserves, 14
 Inde x 403

resource, reserve, and exploitability, 10, 11–13 fugitive dust control methods, 311–313
sampling, for evaluation, 15, 16–17 gravel bed filter, 310–311
Design(s) operational controls and design measure, 296
ESP, 303–304 overview, 293–296
future, of cement plants, 382–384 trends and progress in dust abatement
measure, dust, 296 technologies, 296–297
precalciner systems, 131–132 pollution monitoring, 292–293
preheater-precalciner systems Dynamic impact, crushing method, 54
cyclon, progress in, 151, 152 Dynamic pressure, defined, 281
variations, 150, 151
quarry, 27–29 E
raw mix, 48–53
step-wise matrix method, 49–53 E-axis, economic and social viability, 11
trial-and-error method, 49 Economic Commission for Europe (ECE), 10
silos, 210 ECS/Process Expert, 284
Desulfurization mechanism, 314 Eisen Portland Cement Association, 228
Diaspore, 33 Electricity consumption, Indian cement industry, 388, 389t
Dicalcium silicate, 41, 363 Electric resistance furnace, 334
Diesel oil, 77 Electrochemical CO2 reduction, 359
Differential scanning calorimeter (DSC), 230 Electron beam/radiation process, 334–336
Differential thermal analyzer (DTA), 230 Electronic waste (e-waste), 117–118
Diffusion charging, 306 Electrostatic precipitator (ESP), 303–310
Dihydrate form, 202 advantages and limitations, 309–310
Dimension, of samples, 17–18 application, 309
Dioxins, 118 in cement making process, 278
Direct system, of coal firing, 87, 88f components, 303–304
Discharge electrodes, ESP, 304, 305, 306 design, 303–304
Dispatch, of cement, 210 disadvantage, 310
Dispersive mode, IR radiation, 276 discharge electrodes, 304, 305, 306
Disruptive innovation, 327 dust abatement technologies, 296
Dissociation rate dust-related problems, 309
activation energy vs., 145, 146f efficiency, 306
calcium carbonate, 144–145 efforts, 323–324
Distributed control system (DCS), 284 gas sampling, 280
Distribution, limestone occurrence, 7–8 hot ESPs, 309
Docking station, AFR, 125, 127f moisture conditioning, 307, 308f
Dolomite, 64 negative ions, 305, 306
bricks, 164, 166 operation, 307
Dolomitic limestone, 19 operational principle, 305
Dome silos, 210 performance, corona power-based method for
Dosing monitoring, 321–322
grinding aids, 209 problems of design and construction, 309
LD, 106 resistivity, 307–309
systems, alternative fuels, 125–131 temperature, 307, 308f
automation and control, 131 Emissions
to kilns, 128, 130 air, 108
overview, 125–127 carbon dioxide, 168–169, 288–289, 354, 359, 365
tires and whole large packages, 130 carbon monoxide and hydrocarbon, 291
Double roll crushers, 55 dust, 136, 289
Drilling operations, 27–28 greenhouse gases, 344
Dry gas, 79 kiln, energy consumption and, 167–169
DSC (differential scanning calorimeter), 230 nitrogen oxide, 169, 290, 315–319
Durable concrete, cements for, 245–247 AAQ standards, 318–319
Dust overview, 315
abatement technologies, trends and progress in, reduction, primary methods for, 315–317
296–297 reduction, secondary methods for, 317–318
emissions, 136, 289 norms of cement plants, 124t
generation and broad characteristics of, 293–313 sulfur dioxide, 289–290, 313–315
cyclones and multicyclones, 297–298 overview, 313–314
ESP, 303–310 prevention and abatement opportunities, 314–315
fabric filters/bag filters, 298–303 water and land, 108
404 Inde x

Emissivity, flame, 86 Eurocement, 377

EN 197, 227t European Pollution Release and Transfer (E-PRTR)
EN 197-1, 216, 217t, 227, 348 data, 119
EN 197-1:2000, 216, 217t European standard, types of portland cements, 216–218
EN 197-4, 217 European Union, 115
EN 413-1, 217–218 Evaluation, sampling of limestone deposits for, 15, 16–17
EN 13649:2001, 120t Evolution
EN 13725:2003, 108 heat, 233–235
EN 15359:2011, 111 process profiles, 387
Energy Excess air, 93, 94, 95
conservation and material characteristics, 200–205 Expansive cement, phase-modified portland cements,
blast furnace slag and limestone powder, 204–205 225–226
grinding of mineral admixtures and fillers, 203–204 Expansive grouts, 226
gypsum, dehydration of, 202–203 Experimental approaches, reactivity and burnability of
overview, 200–202 raw meal, 66–68
consumption and kiln emissions, 167–169 Expert Optimiser, 284
Energy-dispersive XRF (EDXRF), 261 Exploitability, limestone deposits, 10, 11–13
Entrained- flow gasifier, 133 Exploitation, limestone occurrence, 7–8
Environmental aspects, AFR, 136–137 Exploration intensity, limestone deposits, 9–10
Environmental Management Systems, 323 External recirculation, 85
Environmental mitigation and pollution control Extractive gas sampling system, 274–276
technologies, 287–324 Extrinsic properties, minerals, 3
dust, generation and broad characteristics of, 293–313
cyclones and multicyclones, 297–298 F
ESP, 303–310
fabric filters/bag filters, 298–303 Fabric filters (FFs), 296, 298–303
fugitive dust control methods, 311–313 False set, 202, 233
gravel bed filter, 310–311 F-axis, field project status and feasibility, 11
operational controls and design measure, 296 FCB, 198
overview, 293–296 FCT ACTech COSMA, 269
trends and progress in dust abatement Feasibility, AFR project, 107–109
technologies, 296–297 air, emissions to, 108
monitoring techniques, 321–323 carbon footprint, 109
AQM monitors, 322 noise pollution, 108
corona power-based method for monitoring ESP odor issues, 108
performance, 321–322 overview, 107–108
manual monitoring, 323 stakeholders engagement, 109
opacity/photometric measurement, 322 visual impacts, 108–109
nitrogen oxide emissions, 315–319 water and land, emissions to, 108
AAQ standards, 318–319 Feldspar, 18
overview, 315 Felted fabrics, 299
reduction, primary methods for, 315–317 Ferric oxide, melt formation due to, 47f
reduction, secondary methods for, 317–318 Ferroaluminate cement (FAC), 343
noise pollution, 319–321 Ferruginous limestone, 19
level in cement plants, 319–320 Fertilizer sludge, 136
overview, 319 FFs (fabric filters), 296, 298–303
reduction, 320–321 Field charging, 306
outlook, 323–324 Fillers, grinding, 203–204
overview, 287–288 Filtering velocity, 299
pollutants emitted into atmosphere, 288–293 Filtration mechanisms, in FFs, 298, 299f
lesser concern, 290–292 Fine-grained moderately compact limestone, 20f
overview, 288–289 Fineness
pollution monitoring, basic concepts, 292–293 effect of, 233
principal pollutants, 289–290 raw meal, 63
sulfur dioxide emissions, 313–315 Fineness modulus (FM), 184
overview, 313–314 Firing shrinkage, test method based on, 67, 68
prevention and abatement opportunities, 314–315 Firing system
Environmental Protection Agency (EPA), 119 coal, 87–92
ESP, see Electrostatic precipitator (ESP) ash absorption on clinker, 92
Estimation variance, 256–257 characteristics on combustion, 91–92
Ettringite, 223, 237, 240, 353 direct system, 87, 88f
 Inde x 405

indirect system, 87, 89f indirect system, 87, 89f

semi-direct system, 87, 90f semi-direct system, 87, 90f
petcoke, 98–99 coal resources of world, 81–83
Fischer-Tropsch (F-T) process, 358–359 in Asia-Pacific Region, 81, 82t
Flame(s) inventory in India, 82–83
emissivity, 86 regional distribution, 81t
ionization method, 276 R/P ratio, 81
momentum, 156 status, 82
photometer, 230 combustion, basic chemistry and physics, 83–86
temperature, 94–95 flame emissivity, 86
Flash point, 77 fuel and air mixing, 84–85
Flash set, 202, 233 heat transfer, 86
Flat-bottom silos, 210 overview, 83–84
Flexi-coke, 96 combustion, relation of process parameters with,
Flowability, defined, 206 92–95
Flow properties, grinding aids for, 206 defined, 73
FLSA, 285 overview, 73
FLSmidth, 132, 193, 284 petcoke as substitute fuel, 96–100
Flue gas analysis, 272–280 classification, 96–97
in cement production, 278 firing of, 98–99
extractive sampling and measurement techniques, grinding, 97–98
274–276 merits and demerits, 99–100
gas sampling points and probes, 279–280 overview, 96
interlock and warning systems, 278–279 production, world status, 96
overview, 272–274 properties, 97
special considerations for gas sampling systems, types, 73
276–278 Fuel usage, Indian cement industry, 387, 388, 389f
Fluid coke, 96 Fugitive dust (FD)
Fluidization, of dry raw meal, 61 control methods, 300, 311–313
Fluidized bed clinker making process, 331–332 pollutants of principal concern, 289
Fluidized-bed gasifier, 133 primary sources of generation, 294–295
Fluidized-bed sintering plants, 383 Fuller Company, 331
Fluoride-bearing sludge, 135 Furans, 118
Fluoride residues, 117 Future design, of cement plants, 382–384
Fluorine compounds, in feed constituents, 291 F-value, 239–240
Fluorogypsum, 342–343
Fly ash cement, hydration chemistry of, 240–241, 242f G
“Foraminifera” fossil, in limestone, 21f
Fossiliferous limestone, 19 Gas analysis, flue, see Flue gas analysis
Fourier-transform infrared spectroscope (FT-IR), 230 Gas(es)
Fractional distillation, process of, 77 coal, 79, 80t
Freedonia Group, 375 dry, 79
Free lime (CaO) grains, 182, 183f flow, measurements, 280–281
Free lime temperature relation, 67 natural gas, 2, 79–80
FT-IR (Fourier-transform infrared spectroscope), 230 oil, 79–80
Fuel-grade petcoke, 96 producer, 79, 80t
Fuels, AFR, see Alternative fuels and raw materials R/P ratio for, 81
(AFR) thermal characteristics of coal, oil, and gas, 80–81
Fuels, in clinker production, 73–100 water gas, 79, 80t
characteristics, 74–81 wet, 79
calorific value, 74 Gasification technology, AFR, 133–135
coal, oil, and gas, comparative behavior of, overview, 133, 134f
80–81 tire-derived and other secondary fuels through
coal, ranks and properties of, 74–77 gasification, 133, 134f, 135
liquid fuels, types and properties, 77–79 Gas sampling systems, special considerations for,
natural gas and synthetically produced gaseous 276–278
fuels, properties, 79–80 G-axis, geological knowledge, 11
coal preparation and firing, 87–92 GBFs (gravel bed filters), 296, 310–311
ash absorption on clinker, 92 GCV (gross calorific value), 74, 79, 82–83
characteristics on combustion, 91–92 Generation, of dust, 293–313
direct system, 87, 88f cyclones and multicyclones, 297–298
406 Inde x

ESP, 303–310 Granite, 2

advantages and limitations, 309–310 Granulated blast furnace slag, defined, 227
application, 309 Granulometry, clinker, 184
components, 303–304 Graphene, 367
design, 303–304 Grate coolers, 157–159
disadvantage, 310 Gravel bed filters (GBFs), 296, 310–311
discharge electrodes, 304, 305, 306 Gravity coolers, 157
dust-related problems, 309 Gravity impact, crushing method, 54
efficiency, 306 Green coke, 96
hot ESPs, 309 Greenhouse gases, emissions, 344
moisture conditioning, 307, 308f Grinding
negative ions, 305, 306 aids, in cement manufacture, 205–209
operation, 307 on cement hydration, 206
operational principle, 305 dosing, 209
problems of design and construction, 309 flow properties of cement, improving, 206
resistivity, 307–309 operational features of ball mill and effect,
temperature resistivity, 307, 308f 206–208
fabric filters/bag filters, 298–303 overview, 205–206
fugitive dust control methods, 311–313 for roller press systems, 208–209
gravel bed filter, 310–311 for VRMs, 208
operational controls and design measure, 296 clinker, see Clinker grinding
overview, 293–296 index, HGI, 87, 97
trends and progress in dust abatement technologies, mineral admixtures and fillers, 203–204
296–297 petcoke, 97–98
GEOVIASurpac, 28 process, cement, 264–265
Gibbsite, 33 RRSB plot of PSD, 265
Glauconite, 32 rolls, high-pressure, 195–198, 201, 202
Global and regional growth trends, 371–391 Grit separators, 188, 189
capacity and production growth perspectives, Gross calorific value (GCV), 74, 79, 82–83
372–377 Gross national product (GNP), 377–378, 385, 386
during 2001–2013, 373 Growth
CEMBUREAU, countries of, 373, 374f global and regional, see Global and regional growth
country-wise distribution, 373, 374f trends
top cement-producing countries, 373, 375–377, 375t sustaining technologies, 328–330
twentieth century, 372 advanced engineering features, 328, 329
change drivers of production and application, 379–382 changes in technology and scale of operation,
cement performance requirements, 380–381 328, 329f
high-performance building materials, 382 Portland cement chemistry, critical milestones
overview, 379–380 in, 328t
future design of cement plants, 382–384 pyroprocessing, course-changing developments
Indian cement industry, case study, 384–391 in, 330t
consumption, population growth, and national raw and finish grinding processes, tentative
economy, 385, 386 technological milestones, 330t
current technological status, 386–391 Gypsum
national policies, 384–385 dehydration of, 202–203, 210
overview, 384 fluorogypsum, 342–343
national economy vs. cement consumption, 377–378 natural, 33–35
overview, 371–372 chemical properties, 34–35
Global Cement Directory, 377 producing countries, 33–34
Global warming potential (GWP), 247 phosphogypsum, beneficiation of, 391
Glutanic acid, 361 transportation, 247
Glycine, 361 Gyratory crushers, 55
GNP (gross national product), 377–378, 385, 386
Goethite, 31t, 32 H
Grades, Portland cements, 214–219
ASTM classification, 215–216 Hammer crushers, 55
European standard, 216–218 Hardened cement paste, microstructure, 237–238
Indian standards, 218 Hardening, defined, 220
overview, 214–215 Hardgrove grindability tester, 77, 121
standard specifications for cements in China, Hardgrove grinding index (HGI), 87, 97
218–219 Hardness, Mohs scale of, 4, 33
 Inde x 407

Hard type of limestone, 55 Hydraulic roll press, 195–198

Hauling factor, 26 Hydrocarbon emissions, 291
Hazardous waste Hydrogen, calorific value of fuel, 76
AFR inventory and material characteristics, 114–115 Hydrogen sulfide, 291
classifying, biological parameters in, 106–107 Hydrophobic portland cement, 224
defined, 104, 105–106 Hydrous aluminum silicates, 29
incinerators, cement kilns vs., 122t
Heat balance, in rotary kiln system, 153, 154–155 I
Heat evolution over time, portland cement, 233–235
Heat transfer, 86 iGantt, 28
HeidelbergCements, 375 Igneous rocks, 2
Hematite, 31t, 32 Ignitability, hazardous waste, 105
Hemihydrate, 34, 35, 202–203 Ignition temperature, of petcoke, 97–98
High Alumina Cement (HAC), 337 IHI-Chichibu, 331
High-belite cement (HBC), 339–342 Illite, 30t, 31
cell parameters of belite phase on doping, 339, 341t IMACON analyzer, 268
clinker cooling rate, on cement strength parameter, IMA Engineering: Quarcon, 268
339, 340t Impact crushers, 55
NMR spectroscopy, phase quantification by, 341, Incombustible wastes, 104
342, 342t India
stabilization of different polymorphs of, 341 AAQ standards, 318
High-efficiency cyclone separators, 190–191 ACC Limited in, 333
High-performance building materials, 382 agricultural crop residues in, 112
High-pressure grinding rolls, 195–198, 201, 202 All India Tire Manufacturing Association, 114
High-range water reducers (HRWR), 241, 242–243 ash content in coal, 76
Holcim, 375 Central Pollution Control Board, 106, 107
Homogeneity clinkers, characteristics of, 184–185
raw meal, 65 coal inventory in, 82–83
raw mix, 262–263 coal reserves, 81, 82, 101
Homogenization process, post-milling, 60–63 electronic waste in, 118
Homogenizing efficiency, chemical fluctuations using, fly ash generating countries, 229
255–256 fuel oils in, 79t
Horizontal roller mills (horomills), clinker grinding granulated slag and fly ash, 228
system, 185, 186, 198–200 growth in cement, 375
industrial installation, 200f gypsum production in, 33
typical illustration, 199t Indian Bureau of Mines, 8, 12
working principle, 198f limestone reserves in, 13t
Horomills, see Horizontal roller mills (horomills) limestone rocks of different geological ages, 24t
Hotdisc combustion, for AFR, 132 mineral resources, 12
Hot ESPs, 309 National Council of Cement and Building Material
Hot meal quality monitoring, 263 in, 9, 20, 270
HRWR (high-range water reducers), 241, 242–243 petcoke-producing country, 96
Human machine interfaces (HMIs), 284 plastic waste in, 117
Hybrid grinding, 200 PSC, 228
Hybrid milling systems, for raw materials, 58–60 Rajasthan gypsum, 34
Hydration sewage sludge in, 115
defined, 220 tire-derived fuel, 114
delayed, 222 Indian cement industry, case study, 384–391
grinding aids on, 206 consumption, population growth, and national
pure cement compounds, 220 economy, 385, 386
reactions, Portland cements, 235–245 current technological status, 386–391
cement, 236–237 captive power generation, 388, 389, 391
fly ash cement, chemistry of, 240–241, 242f electricity consumption, 388, 389t
microstructure of hardened cement paste, evolution of process profiles, 387
237–238 features, 386
overview, 235–236 fuel usage and thermal energy consumption, 387,
slag cement, chemistry of, 239–240 388, 389f
superplasticizers, 241, 242–245 future direction, 391
temperature on, 238–239 limestone resources, 386–387
Hydraulic cements, characterization, 230–231 phosphogypsum, beneficiation of, 391
Hydraulic modulus, defined, 43 product mixing, 390f, 391
408 Inde x

national policies, 384–385 torque, 170

overview, 384 zonation, refractory materials and, 163–165
Indian standards, types of portland cements, 218 Kiln systems
Indirect system, of coal firing, 87, 89f burners and combustion, 155–156
Indonesia, coal inventory, 83t clinkering reactions and, 143–146
Induction period, defined, 145 preheater-precalciner, volatiles cycle in, 161–162
Inductively coupled plasma spectrometer (ICP), 230 refractory lining materials in, 162–166
Industrial implications, of reserves, 14–15 degradation, in service, 166
Industrial plastic waste, 117 kiln zonation, 163–165
Industrial wastes, 104 overview, 162–163
Infrared radiation, 275–276 suspension preheater section, 166
Inline calciners (ILC), 150 rotary, 152–155
Insoluble anhydrite, 34, 35 heat balance, 153, 154–155
Inter-granular pores, limestone with, 21f overview, 152–153, 154f
Interlock systems, flue gas analysis, 278–279 Kleine’s compound, 337
Internals, ball mill, 187f Kriging, 257
International Energy Agency, 377 Krupp Polysius group, 190, 193
Intrinsic properties, minerals, 3–4 K-type Portland cements, 226
Inventory Kuel’s Index, 65
AFR, 109–118
biomass residues, 112, 113t L
hazardous waste, 114–115
industrial plastic waste, 117 Lafarge group, 284, 344, 363, 375
miscellaneous, 117–118 Land
MSW, 110–112 emissions to, 108
overview, 109–110 plaster, 33
scrap motor tires, 112, 114 Laterite, 32, 33
sewage sludge, 115–117 Le Chatelier method, 231
coal, in India, 82–83 Lepidocrocite, 32
Ion-specific potentiometry, 275 Lepol grate pre-heater, 152
Iron ore, limestone and, 50, 51–53 Le Teil Dry Process plant, 344
IS 269:2015, 218 Lethal concentration (LC), 107
ISO 14000, 14001 and 14004, 323–324 Lethal dose (LD), 106
Isokinetic gas sampling, 119 LHPC (low-heat Portland cement), 215, 223–224
Life cycle assessment (LCA), for cement, 246–247, 323
J Lignite, 74, 75
Lignosulfonate, 243
Jaw crushers, 55 Lime combinability temperature, 67
J-Catrel process, 110f Lime-rich sludge, 135, 136
Jet entrainment, process of, 84–85 Lime saturation factor (LSF), 43, 44f, 64, 66, 339
Juli flora, 112 Limestone
calcination, 144
K calcination system, for uncontaminated CO2
recovery, 355, 356f
Kajima Corporation of Japan, 364–365 calcined clay cement (LC3), 350–352
Kaolinite, 30t, 31 cement-grade, specification of, 20, 22
Kawasaki Heavy Industries, 331 cement production, 1–2
Kerneos Aluminate Technologies, 353 classification, 19
Kerosene oil, 77 decarbonation reactions, 143–145
KHD-Humboldt-Wedag, 190 deposits, assessment of, 8–18
Kiln(s) classification and exploration intensity, 9–10
ampere, 170 dimension, quantity, and preparation of samples,
control strategies, 169–170 17–18
cyclone preheater, see Preheater-precalciner systems industrial implications of categorization of
dosing and conveyance to, 128, 130 reserves, 14–15
emissions, energy consumption and, 167–169 overview, 8–9
exhaust gases, algae cultivation with, 357–358 reliability of different categories of reserves, 14
feed, 53 resource, reserve, and exploitability, 10, 11–13
inlet, 279 sampling, for evaluation, 15, 16–17
monitoring for clinker phases, online, 268–270 iron ore, 50, 51–53
operation monitoring, 263–264 microstructures, 20f, 21f
 Inde x 409

mining, 24–26 Maptek Vulcan, 28

occurrences Marble limestone, 7
distribution and exploitation, 7–8 Masonry cement, 215, 229–230
nature of, 6–8 Master rollers, 194
typical physicochemical properties of, 22–24 Material(s)
powder, blast furnace slag and, 204–205 argillaceous/clay, 29–32
production, 8 blended portland cements, 227–228
QC, computer-aided run-of-mine, 256–257 building, high-performance, 382
resources, Indian cement industry, 386–387 characteristics, AFR, 109–118
sand, 50, 51–53 biomass residues, 112, 113t
shale, 50, 51–53 hazardous waste, 114–115
types, 55 industrial plastic waste, 117
Limitations miscellaneous, 117–118
cyclone/multicyclones, 297–298 MSW, 110–112
ESP, 310 overview, 109–110
fabric filters, 303 scrap motor tires, 112, 114
Limonite, 32 sewage sludge, 115–117
Liquid fuels, types and properties, 77–79 characteristics, energy conservation and, 200–205
Liquid phase, clinker, calculation of, 46–47 blast furnace slag and limestone powder,
Lithium metaborate, 262 204–205
Lithium tetraborate, 262 grinding of mineral admixtures and fillers,
Loading rate, 26 203–204
Local exhaust ventilation, 311 gypsum, dehydration of, 202–203
Loesche, 193, 194 overview, 200–202
Longitudinal stockpile, 58 corrective, 32–33
Long-term integrated mine planning, 27 raw
Lots, sampling units in, 253 alternative fuels and, see Alternative fuels and
Low-carbon cement(s), 359–366 raw materials (AFR)
Calera process for calcium carbonate cement, for clinker making, 42t
360–361 refractory lining, in kiln system, 162–166
Calix and novacem processes for magnesia-based degradation, in service, 166
products, 362–363 kiln zonation, 163–165
CO2-SUICOM technology, 364–365 overview, 162–163
industry, research, 354–358 suspension preheater section, 166
algae cultivation with kiln exhaust gases, Matrix effect, 262
357–358 Matrix method, step-wise, 49–53
carbon dioxide, capture and recovery of, 354–356 Measurements
overview, 354 organic pollutants, 118–119, 120t
overview, 359–360 photometric, 322
Solidia cement and concrete, 363–364 process, plant-based QC practice, 280–284
SWOT analysis of carbonation technologies in gas flow and velocity, 280–281
development, 365, 366t overview, 280
TecEco cements based on reactive magnesia, 361–362 temperature, 282–284
Low-heat Portland cement (LHPC), 215, 223–224 velocity measurement by anemometers, 282
LSF (lime saturation factor), 43, 44f, 64, 66, 339 techniques, for different gases, 274–276
LUCIE, 284 Meat and bone meal (MBM), 117
Mechanical separators, 189–190, 190f
M Mechanical shaking methods, 300, 301f
Mercury, mineral in liquid form, 2
Macropores, 238 Mesopores, 238
Magma, defined, 2 Metamorphic rocks, 2
Magnesia, 46, 64 Micromine, 28
based products, Calix and novacem processes for, Microphones, decreasing, 188
362–363 Micropores, 238
bricks, 163, 164, 166 Microstructures
limestone, 19 cement hydration products, 245
reactive, 361–362 clinker phases, 178–184
Magnesium carbonate, 362 alite and belite crystals, 179f–180f
Magnesium silicate hydrate phase, 363 hardened cement paste, 237–238
Magnetite, 32 limestone, 20f, 21f
Manual monitoring, 323 oolitic limestone, 21f
410 Inde x

Microwave heating, 333–334 HBC/RBC, 339–342

Migration velocity, 306–307 cell parameters of belite phase on doping, 339,
Milling operation, raw, 58–60 341t
Mineral admixtures, grinding, 203–204 clinker cooling rate, on cement strength
Mineral characteristics, raw meal, 64 parameter, 339, 340t
Mineralizers, use of, 68, 69 NMR spectroscopy, phase quantification by, 341,
Mineral reserves, defined, 12 342, 342t
Mineral resources, for cement production, 1–37 stabilization of different polymorphs of, 341
argillaceous/clay materials, 29–32 MPC, 350–352
characterization, 2–6 overview, 338–339
corrective materials, 32–33 PLC, 348–350
defined, 12 Mohs scale of hardness, 4, 33
limestone Moisture conditioning, of dust, 307, 308f
cement-grade, specification of, 20, 22 Moisture content
classification, 19 in biomass residues, 112
composition and quality of, 18–24 combustion of coal, 91
microstructures, 20f, 21f Momentum, flame, 156
mining, 24–26 Monitoring
occurrences, typical physicochemical properties hot meal quality, 263
of, 22–24 kiln operation, 263–264
limestone deposits, assessment of, 8–18 online kiln, for clinker phases, 268–270
classification and exploration intensity, 9–10 pollution, basic concepts, 292–293
dimension, quantity, and preparation of samples, raw mix homogeneity, 262–263
17–18 techniques, pollutants, 321–323
industrial implications of categorization of AQM monitors, 322
reserves, 14–15 corona power-based method for monitoring ESP
overview, 8–9 performance, 321–322
reliability of different categories of reserves, 14 manual monitoring, 323
resource, reserve, and exploitability, 10, 11–13 opacity/photometric measurement, 322
sampling, for evaluation, 15, 16–17 Monolithic products, 163
limestone occurrence Montmorillonite, 30t, 31, 32
distribution and exploitation, 7–8 Moving-bed gasifier, 133
nature, 6–8 MPC (multi-blend Portland cements), 350–352
natural gypsum, 33–35 MSW (municipal solid waste), 110–112
chemical properties, 34–35 M-type Portland cements, 226
producing countries, 33–34 Multi-blend Portland cements (MPC), 350–352
overview, 1–2 Multicyclones, 297–298
properties, 3–4 Multiple-compartment silos, 210
quarry design and operational optimization, 27–29 Multistage combustion, 316–317
raw materials on unit operations, 36–37 Municipal solid waste (MSW), 110–112
rocks Muscovite, 31t, 32
characterization, 2–6
classification, 4t N
physical and technological properties of, 4–6
thermo-chemical reactivity of clay minerals, 31–32 Nanotechnology, in cement research, 366–367
Mining Naphthalene, 119, 120t
limestone, 24–26 National Council for Cement and Building Materials, 9,
opencast, 24, 25–26 20, 270
operational issues, 26 National economy, cement consumption vs., 377–378
terrace, 25 National Institute for Occupational Safety and Health,
Mitsubishi fluidized-bed calciner (MFC), 147, 148f 295
Model–based predictive techniques, 284 National Institute for Standards and Technology (NIST),
Modified Portland cements, advances in, 338–352 270, 271
AEC, 346–348 National policies, influencing growth trends, 384–385
CSA–BC, 342–346 Natural gas, 2
clinker compositions and strength properties, properties, 79–80
342–343, 343t Natural gypsum, 33–35
energy requirement and carbon dioxide, 343, chemical properties, 34–35
344t producing countries, 33–34
experimental structure, 344, 345f Negative corona, 305
findings of developmental project, 344, 346 Nesquihonite, 362
 Inde x 411

Net calorific value (NCV), 74 Operational issues in mining, 26

Neural Net technology, 284 Operational optimization, 27–29
Nitrogen Operational principle, ESP, 305
calorific value, 76 Optical microscopy, 45
in dried sludge, 117 Optical polarized microscope, 230
flue gas component, 273 Optical pyrometers, 282, 284
Nitrogen oxide, 137, 169 Ordinary Portland cement (OPC), 218, 219, 222–223
emissions, 315–319 Organic pollutants, measurement of, 118–119, 120t
AAQ standards, 318–319 Organic sedimentary rock, 7
overview, 315 Organo-chlorine compounds, 121
reduction, primary methods for, 315–317 O-Sepa model, 190, 191f
reduction, secondary methods for, 317–318 Overburden ratio, 26
flue gas component, 273 Oxy-fuel combustion, 355
measurement technique, 275–276 Oxygen
pollutant, 290 in flue gas, 278
pollution monitoring, 293 measurement, 275
presence and quantity, 278 Oxygen-enriched air combustion, 355
NMR (nuclear magnetic resonance) spectroscopy, phase
quantification, 341, 342, 342t P
NMVOC (non-methane volatile organic compounds),
118, 119, 120t Pack-set, 206, 233
Noise pollution, 319–321 PAHs (polycyclic aromatic hydrocarbons), 119, 120t
AFR project, 108 Palygorskite–Attapulgite–Sepiolite, 30t
level in cement plants, 319–320 Parameters, biological, in classifying hazardous wastes,
overview, 319 106–107
reduction, 320–321, 383 Particle density, of portland cement, 231
Non-dispersive mode, IR radiation, 276 Particle size, combustion of coal, 91
Non-hydraulic cements, 367–368 Particle size determination (PSD), 121
Non-methane volatile organic compounds (NMVOC), Particle size distribution (PSD)
118, 119, 120t cement, 201–202, 205
Normal Portland cement (NPC), 214–215, 218, 219, determining, 231, 264
222–223, 335, 336 RRSB plot of cement, 265
Novacem processes for magnesia-based products, 362–363 Pavillion8 MPC, 284
NPC (Normal Portland cement), 214–215, 218, 219, PCBs (polychlorinated biphenyls), 119, 120t, 121, 123
222–223, 335, 336 PCDDs (polychlorinated dibenzodioxins), 118, 119, 120t,
Nuclear magnetic resonance (NMR) spectroscopy, phase 137
quantification, 341, 342, 342t PCDFs (polychlorinated dibenzofurans), 118, 119, 120t,
137
O PCPs (polychlorinated phenols), 121
Peat, 74, 75
Odor issues, 108 Peiffer (MPS), 193
Oil(s) Performance(s)
gas, 79–80 ball mill, 192
R/P ratio for, 81 cement, 380–381
thermal characteristics of coal, oil, and gas, 80–81 cement milling systems, comparison, 185t
well cements, 224–225 corona power-based method for monitoring ESP,
Oil well cement (OWC), 215 321–322
Olivine, 362 high-performance building materials, 382
Online quality control, in cement plants, 267–272 improvers, 228
cement quality control, 270 requirements, of API, 225t
chemical analysis, 268 Periclase, 45, 64, 159, 163, 164, 176, 182, 184
kiln monitoring for clinker phases, 268–270 Petcoke, 73
overview, 267 ignition properties, 132
reference materials for calibration, 270–272 precalciner systems, 131
Oolitic limestone, 7, 19, 21f as substitute fuel, 96–100
Opacity/photometric measurement, 322 classification, 96–97
OPC (ordinary Portland cement), 218, 219, 222–223 firing of, 98–99
Opencast mining, 24, 25–26 grinding, 97–98
Operation, of ESP, 307 overview, 96
Operational controls, dust, 296 production, world status, 96
Operational features, of ball mill, 206–208 properties, 97
412 Inde x

Petrol, 77 RRSB plot of PSD, 265

Petroleum sampling guidelines, 252–254
coke, see Petcoke principles, 252
derivatives, 77 purpose, 252
mineral in liquid form, 2 scheme, establishing, 252–254
PGNAA (prompt gamma neutron activation analysis), sampling stations, 254–256
258–260, 269–270 general statistical considerations, 255–256
Phase-modified portland cements total process control system, 284–285
expansive cement, 225–226 XRD, for phase analysis, 265–267
ultra-rapid-hardening cement, 226 Plastic waste, industrial, 117
Phases, of clinker PLC (Portland limestone cement), 215, 348–350
composition, 176–178 Pneumatic blending systems, 61–63
proportions and microstructure, 178–184 Pneumatic conveyance, 128, 130
Phosphogypsum, beneficiation of, 391 Pneumatic retractable tube samplers, 254
Photometric measurement, of opacity, 322 Polexpert KCE/MCE, 284
Physical properties, of rocks, 4–6 Pollutants
Physical requirements, of API, 225t emitted into atmosphere, 288–293
Physicochemical properties, of limestone occurrences, lesser concern, 290–292
22–24 overview, 288–289
Physics, of combustion, 83–86 pollution monitoring, basic concepts, 292–293
flame emissivity, 86 principal pollutants, 289–290
fuel and air mixing, 84–85 organic, measurement of, 118–119, 120t
heat transfer, 86 Pollution
overview, 83–84 monitoring, basic concepts, 292–293
Phytotoxicity, 107 noise, 319–321
Pit Navigator, 284 level in cement plants, 319–320
Pitot tube, basic construction, 281 overview, 319
Planetary coolers, 157–158 reduction, 320–321, 383
Planning, quarry, 27–29 Polyacrylamide-type polymers, 381
Plant-based QC practice, 251–285 Polyacrylate superplasicizers, 244
cement grinding process, 264–265 Polychlorinated biphenyls (PCBs), 119, 120t, 121, 123
computer-aided run-of-mine limestone, Polychlorinated dibenzodioxins (PCDDs), 118, 119, 120t,
256–257 137
flue gas analysis, 272–280 Polychlorinated dibenzofurans (PCDFs), 118, 119, 120t, 137
in cement production, 278 Polychlorinated phenols (PCPs), 121
extractive sampling and measurement techniques, Polycyclic aromatic hydrocarbons (PAHs), 119, 120t
274–276 Polyethylene, high-density, 211
gas sampling points and probes, 279–280 Polypropylene, high-density, 211
interlock and warning systems, 278–279 Polysius, 284
overview, 272–274 Portland cements
special considerations for gas sampling systems, chemistry, critical milestones in, 328
276–278 derivatives, application, 336–352
kiln operation monitoring, 263–264 modified, 338–352
online QC in cement plants, 267–272 overview, 336–338
cement quality control, 270 limestone cement, 204, 205
chemical analysis, 268 mineral admixtures, grinding, 203
kiln monitoring for clinker phases, 268–270 slag cement, 204
overview, 267 Portland cements, composition and properties, 213–249
reference materials for calibration, 270–272 blended, 226–230
overview, 251–252 characteristics, 227
preblending operation, 258–260 masonry cement, 229–230
process measurements, 280–284 materials, 227–228
gas flow and velocity, 280–281 merits, 226–227
overview, 280 overview, 226–227
temperature, 282–284 Portland fly ash cement, 229
velocity measurement by anemometers, 282 PSC, 228
raw mix control, 260–263 supersulfated cement, 230
homogeneity, monitoring, 262–263 characteristics, 219–225
hot meal quality monitoring, 263 chemical composition, 219
overview, 260, 261f color, 219
XRF, 261–262 hydration of pure cement compounds, 220
 Inde x 413

hydrophobic Portland cement, 224 Preblending operation, plant-based QC practice,

LHPC, 223–224 258–260
oil well cements, 224–225 Precalciner systems
phase composition-property relationship, 222t basic configurations, 149–150
principal phases, 219 design considerations, 131–132
reactivity, 220, 222 preheater and, 146–152
RHPC, 222–223 design variations of, 150, 151
SRPC, 223 overview, 146–151, 152f
stages, 221 preheater cyclone design, progress in, 151, 152
strength development, 221f types, 150
white and colored Portland cement, 224 Pre-combustion capture, 354–355
characterization and practical implications of Preheater-precalciner systems, 146–152
properties, 230–235 design variations of, 150, 151
compositional aspects, 232 kiln
density and related parameters, 231 sulphur cycle in, 160
fineness, effect of, 233 volatiles cycle in, 161–162
heat evolution over time, 233–235 overview, 146–151, 152f
setting behavior, 233 preheater cyclone design, progress in, 151, 152
testing and characterization, 230–231 Pre-homogenizing systems, 56–58
durable concrete, 245–247 Preparation
grades and varieties, 214–219 coal, 87–92
ASTM classification, 215–216 ash absorption on clinker, 92
European standard, 216–218 characteristics on combustion, 91–92
Indian standards, 218 direct system, 87, 88f
overview, 214–215 indirect system, 87, 89f
standard specifications for cements in China, semi-direct system, 87, 90f
218–219 process for raw mix, 53, 55–63
hydration reactions, 235–245 crushing operation, 53, 55–56
of cement, 236–237 homogenization process, 60–63
chemistry of fly ash cement, 240–241, 242f pre-homogenizing systems, 56–58
chemistry of slag cement, 239–240 raw milling operation, 58–60
microstructure of hardened cement paste, of samples, 17–18
237–238 Prevention, SO2 emissions, 314–315
overview, 235–236 Primary air, 92–93, 95
superplasticizers, 241, 242–245 Primary fuels, 73
temperature on hydration and curing, 238–239 Primary methods, for NOx emission reduction, 315–317
NPC, 214–215, 218, 219, 222–223 Principles
OPC, 218, 219, 222–223 plant-based QC practice, 252
overview, 213–214 SNCR, 317
phase-modified Portland cements Probes
expansive cement, 225–226 gas sampling points, 279–280
ultra-rapid-hardening cement, 226 sampling, 274
strength grades, 222 Processing, raw mix, see Raw mix
Portland fly ash cement, 229 Process measurements, plant-based QC practice, 280–284
Portlandite, 237 gas flow and velocity, 280–281
Portland limestone cement (PLC), 215, 348–350 overview, 280
Portland pozzolana cement (PPC), 215, 218, 229 temperature, 282–284
Portland slag cement (PSC), 215, 218, 228 velocity measurement by anemometers, 282
Positive corona, 305 Process parameters with combustion, relation of, 92–95
Post-combustion capture, 354, 355 excess air, 93, 94
Pour point, defined, 78 flame temperature, 94–95
Powitec’s Pit Navigator, 284, 285 primary air, 92–93
PPC (Portland pozzolana cement), 215, 218, 229 secondary air, 93, 94f
Practical implications, of properties Producer gas, 79, 80t
Portland cements, 230–235 Product fineness, raw meal, 63
compositional aspects, 232 Production growth perspectives, 372–377
density and related parameters, 231 during 2001–2013, 373
fineness, effect of, 233 CEMBUREAU, countries of, 373, 374f
heat evolution over time, 233–235 country-wise distribution, 373, 374f
setting behavior, 233 top cement-producing countries, 373, 375–377, 375t
testing and characterization, 230–231 twentieth century, 372
414 Inde x

Product mixing, Indian cement industry, 390f, 391 preheater-precalciner, volatiles cycle in, 161–162
Programmable logic controllers (PLCs), 284 refractory lining materials in, 162–166
Promine, 28 overview, 141, 142f
Prompt gamma neutron activation analysis (PGNAA), preheater-precalciner systems, 146–152
258–260, 269–270 overview, 146–151, 152f
Properties preheater cyclone design, progress in, 151, 152
alternative fuels, 104, 105t rotary kiln systems, 152–155
chemical heat balance, 153, 154–155
gypsum, 34–35 overview, 152–153, 154f
raw meal, 64 Pyzel process, 331
clay mineral groups, 29, 30t
clinker phases, 178–184 Q
coal, 74–77
CSA, 343 Q-T diagram, of clinker burning process, 147, 148f
flow, of cement, grinding aids, 206 Quality
fuels, 74 assessment, AFR, 118–121
liquid fuels, 77–79 organic pollutants, measurement of, 118–119,
minerals, 3–4 120t
natural gas and synthetically produced gaseous fuels, overview, 118
79–80 requirements of test facilities, 119, 121
petcoke, 97 clinker, cooling conditions on, 159–161
physical, of rocks, 4–6 limestone, 18–24
physicochemical, of limestone occurrences, 22–24 Quality control (QC)
Portland cements, see Portland cements cement, 270
practical implications of, cements, 230–235 online, in cement plants, 267–272
compositional aspects, 232 chemical analysis, 268
density and related parameters, 231 overview, 267
fineness, effect of, 233 practice, plant-based, see Plant-based QC practice
heat evolution over time, 233–235 Quantity, of samples, 17–18
setting behavior, 233 Quarry design and operational optimization, 27–29
testing and characterization, 230–231 Quartz, 18, 29, 31t
rocks, physical and technological properties of, 4–6
Proportioning, raw mix, see Raw mix R
Proportions, of clinker phases, 178–184
PSC (Portland slag cement), 215, 218, 228 Radiation energy, for clinker making, 334–336
Pseudowollastonite, 363 Rankinite, 363
PTFE, 301, 303 Ranks, of coal, 74–77
Pulse energization system, 309 Rapid fall-through (RFT) cooler, 159
Pulse jet filters, 301, 302f Rapid-hardening Portland cement (RHPC), 215, 222–223
Purpose, sampling, plant-based QC practice, 252 Ratio thermometer, 170
Pyrite, 18, 87 Raw gas, defined, 273
Pyrometers, optical, 282, 284 Raw materials
Pyrophyllite, 32 AFR, see Alternative fuels and raw materials (AFR)
Pyroprocessing on unit operations, 36–37
course-changing developments in, 330t Raw meals, 53
technologies, potentially disruptive, 331–336 analysis, 262
electron beam/radiation process, 334–336 burnability features of, 63–68
fluidized bed clinker making process, 331–332 chemical and mineral characteristics, 64
microwave heating, 333–334 minor constituents, effect of, 64–65
sol-gel process, 332f, 333 product fineness, 63
Pyroprocessing, clinker cooling and, 141–170 chlorine content in, 117
coolers, 157–161 defined, 60
cooling effects on clinker quality, 159–161 homogeneity, 65
overview, 157–159 reactivity and burnability, 65–68
energy consumption and kiln emissions, 167–169 experimental approaches, 66–68
formation process, 141–146 theoretical approaches, 65–66
clinkering reactions and kiln systems, 143–146 Raw milling operation, 58–60
overview, 141, 142f, 143 Raw mix, 41–70
kiln systems burnability features of raw meal, 63–68
burners and combustion, 155–156 chemical and mineral characteristics, 64
control strategies, 169–170 homogeneity, 65
 Inde x 415

minor constituents, effect of, 64–65 kiln zonation, 163–165

product fineness, 63 overview, 162–163
reactivity and burnability, 65–68 suspension preheater section, 166
computation, 41, 42–53 Refuse-derived fuel (RDF), 110–112
adoption of computer programming, 53, 54f Regional distribution, of coal reserves, 81t
clinker liquid phase, 46–47 Regional growth trends in cement production, see Global
coal ash absorption, 47–48 and regional growth trends
overview, 41–43, 44f, 48 Rehydration, 34
potential phase computation by Bogue equations, Rejects, 190
43, 44–46 Reliability, of different categories of reserves, 14
step-wise matrix method, 49–53 Remelting reactions, 342
stoichiometric requirements, 41, 42–48 Remote terminal unit (RTU), 284
trial-and-error method, 49 Requirements
control, 260–263 cement performance, 380–381
homogeneity, monitoring, 262–263 of test facilities, 119, 121
hot meal quality monitoring, 263 Research and development (R&D), in cement
overview, 260, 261f manufacture, 327–368
XRF, 261–262 CAC, complex building products formulation with,
design, 48–53 352–353
step-wise matrix method, 49–53 electrochemical CO2 reduction, 359
trial-and-error method, 49 low-carbon cement industry, 354–358
materials for clinker making, 42t algae cultivation with kiln exhaust gases,
mineralizers, use of, 68, 69 357–358
overview, 41, 42t carbon dioxide, capture and recovery of, 354–356
preparation process for, 53, 55–63 overview, 354
crushing operation, 53, 55–56 low-carbon cements and concretes, 359–366
homogenization process, 60–63 Calera process for calcium carbonate cement,
pre-homogenizing systems, 56–58 360–361
raw milling operation, 58–60 Calix and novacem processes for magnesia-based
reactivity and burnability of, 141, 143 products, 362–363
Raymond, 193 CO2-SUICOM technology, 364–365
Reactive-belite cement (RBC), 339–342 overview, 359–360
cell parameters of belite phase on doping, 339, 341t Solidia cement and concrete, 363–364
clinker cooling rate, on cement strength parameter, SWOT analysis of carbonation technologies in
339, 340t development, 365, 366t
NMR spectroscopy, phase quantification by, 341, TecEco cements based on reactive magnesia,
342, 342t 361–362
stabilization of different polymorphs of, 341 nanotechnology in cement research, 366–367
Reactive magnesia, TecEco cements based on, 361–362 non-hydraulic cements, 367–368
Reactivity overview, 327–328
hazardous waste, 105 Portland cement derivatives, application, 336–352
raw meal, 65–68 modified, 338–352
experimental approaches, 66–68 overview, 336–338
theoretical approaches, 65–66 pyroprocessing technologies, potentially disruptive,
raw mixes, 141, 143 331–336
Rebinder’s effect, 206 electron beam/radiation process, 334–336
Receiving system, AFR, 125, 126f fluidized bed clinker making process, 331–332
Reciprocating grate coolers, 157–158 microwave heating, 333–334
Recirculation, combustion gases, 85 sol-gel process, 332f, 333
Reclaiming arrangement, 58 sustaining technologies in growth, 328–330
Recovery, of carbon dioxide, 354–356 advanced engineering features, 328, 329
Redhawk power plant, 357 changes in technology and scale of operation,
Reduction 328, 329f
noise pollution, 320–321, 383 critical milestones in Portland cement chemistry,
NOx emission 328t
primary methods for, 315–317 pyroprocessing, course-changing developments
secondary methods for, 317–318 in, 330t
Reference materials, for calibration, 270–272 raw and finish grinding processes, tentative
Refining, of petroleum, 77 technological milestones, 330t
Refractory lining materials, in kiln system, 162–166 technology options for converting CO2 into fuel
degradation, in service, 166 products, 358–359
416 Inde x

Reserve(s) SCMs (supplementary cementitious materials), 215, 361

industrial implications of categorization of, 14–15 Scrap motor tires, 112, 114
limestone deposits, 10, 11–13 Secondary air, 93, 94f, 95
reliability of different categories of, 14 Secondary fuels, 73
sizable, 387 Secondary methods, for NOx emission reduction,
Reserves and Resources and Minerals and Commodities, 317–318
10 Sedimentary rocks, 2
Reserve-to-production (R/P) ratio, for oil and gas, 81 Segregated combustible fractions (SCF), 110, 111–112
Residues, biomass, 112, 113t Selective catalytic reduction (SCR) technology, 137, 317
Resistance thermometers, 282 Selective non-catalytic reduction (SNCR) technology,
Resistivity, of dust, 307–309 137, 169, 317
Resource, limestone deposits, 10, 11–13 Selectivity curve, 191
Reverse air bag filters, 300, 301, 302f Selenite, 33
Revolving-disc cooler (RDC), 159 Self-cleaning property, 366–367
RHPC (rapid-hardening Portland cement), 215, 222–223 Self-compacting concretes, 366
Rice straw and husk, 112 Semi-direct system, of coal firing, 87, 90f
Rietveld refinement technique, 266 Semi-VOCs, 121
Rittinger’s law, 206 SEMs (scanning electron microscopes), 178, 230
Rocks Separate-line calciners (SLC), 150
characterization, 2–6 Separators, types of, 188, 189–191
classification, 2, 4t Sepax of FLSmidth & Co., 190
defined, 2 Sepmaster-SKS of KHD-Humboldt-Wedag, 190
physical and technological properties of, 4–6 Sepol of Krupp Polysius group, 190
Roller mills, 87 Setting behavior, portland cement, 233
VRMs, see Vertical roller mills (VRMs) Sewage sludge, 115–117
Roller press systems, grinding aids for, 208–209 Shale, limestone and, 50, 51–53
Roll presses Shrinkage-compensating concrete, 226
hydraulic, 195–198 Siderite, 18
raw milling operation, 58–60 Silica modulus (SM), 43, 44f, 64, 66
Roman cement, 213 Siliceous limestone, 19
Rosin-Rammler- Sperling-Bennet (RRSB) plot, of PSD, Silos
265 designs, 210
Rotary coolers, 157–158 homogenizing, 61–63
Rotary kiln systems, 152–155 storage, 210
heat balance, 153, 154–155 Silo-set, 206, 233
overview, 152–153, 154f Silo storage systems, 128, 129f
RRSB (Rosin-Rammler- Sperling-Bennet) plot, of PSD, Silver, as catalyst, 359
265 Sizable reserves, 387
Rubber Manufacturers Association, 114 Slag cement, hydration chemistry of, 239–240
Slates, 31
S Sludge
process-wise, 114–115
Sampling sewage, 115–117
dimension, quantity, and preparation, 17–18 Slurry, 114–115
gas, points and probes, 279–280 Smoldering coal, 87
limestone deposits for evaluation, 15, 16–17 SNCR (selective non-catalytic reduction) technology,
plant-based QC practice 137, 169, 317
general statistical considerations, 255–256 Software(s)
guidelines, 252–254 packages, basic feature, 28
principles, 252 RGB camera, 285
purpose, 252 Rietveld, 267
scheme, establishing, 252–254 spread-sheet, 53, 54f
stations, 254–256 SOLBAS, 269
probes, 274 Sol-gel process, of cement manufacture, 332f, 333
systems, gas, 276–278 Solidia cement and concrete, 363–364
Sand, limestone and, 50, 51–53 Solid pollutants, flue gas component, 273
Satin spar, 33 Solid recovered fuel (SRF), 110, 111–112
SCADA (supervisory control and data acquisition), 284 Solid-state electrolyte sensor, 275
Scanning electron microscopes (SEMs), 178, 230 Soluble anhydrite, 34
SCF (segregated combustible fractions), 110, 111–112 Solvay process, 348
Scheme, sampling, plant-based QC practice, 252–254 Sound level meter, defined, 323
 Inde x 417

Soundness, of cement, 231 Substitute fuel, petcoke as, 96–100

Soundproof cabin, 130 classification, 96–97
South Africa, coal inventory, 83t firing of, 98–99
Specifications grinding, 97–98
cement-grade limestone, 20, 22 overview, 96
fuel oils, 78, 79t production, world status, 96
hazardous waste fuels, 115t properties, 97
Specific surface area (SSA), 230, 231 Sulfate-resisting Portland cements (SRPC), 215, 223
Spectralflow Online Analyzers, 270 Sulfoaluminate cement (SAC), 343
Spent pot-liners, 117 Sulfonated melamine formaldehyde, 243
SRMs (standard reference materials), 261, 270, 271, 272 Sulfonated naphthalene formaldehyde, 243
SRPC (sulfate-resisting Portland cements), 215, 223 Sulfur content
SRPC (sulfate-resisting portland cements), 223 coal, 76
Stability, of clinker burning operation, 65 fuel oil, 78
Stack gas analysis, 272–280 petcoke, 98
in cement production, 278 sludge and sludge ash, 114
extractive sampling and measurement techniques, Sulfur dioxide, 136
274–276 emissions, 313–315
gas sampling points and probes, 279–280 overview, 313–314
interlock and warning systems, 278–279 prevention and abatement opportunities, 314–315
overview, 272–274 flue gas component, 273
special considerations for gas sampling systems, measurement technique, 275–276
276–278 pollutant, 289–290
Stacking, 57 pollution monitoring, 293
Stacking-and-reclaiming systems, 56 presence and quantity, 278
Stakeholders engagement, feasibility of AFR project, Sulphur cycle, in preheater-precalciner kiln, 160
109 Sumitomo, 331
Standard reference materials (SRMs), 261, 270, 271, 272 Superplasticizers
Standard specifications, for cements in China, 218–219 adsorption, 243
Static separators, 188, 189 applications, 243
Stations, sampling, plant-based QC practice, 254–256 in cement hydration, 241, 242–245
Statistical considerations, sampling stations, 255–256 clinker–calcium sulphate–superplasticizer, 244f
Status defined, 242
coal production, 82 developments, 381
petcoke, 96 incompatibility issues, 244–245
Steel slag, 135 key function, 243
Stefan–Boltzman equation, 284 sulfonated, 243–244
Step-wise matrix method, 49–53 Supersulfated cement, 230
Stockpiling Supervisory control and data acquisition (SCADA), 284
coals, 87 Supplementary cementitious materials (SCMs), 215, 361
methods, 56–58 Support rollers, 194
Stoichiometric requirements, raw mix computation, 41, Surface miner, 25
42–48 Suspended particulate matter (SPM), 318
clinker liquid phase, 46–47 Suspended solid particles (SPM), 289
coal ash absorption, 47–48 Suspension preheaters, see Preheater-precalciner
overview, 41–43, 44f systems
potential phase computation by Bogue equations, 43, Suspension preheater section, lining of, 166
44–46 Sustainable industrial development, 287–288
Storage systems Sustaining technologies, in growth of cement industry,
alternative fuels, 125–131 328–330
automation and control, 131 advanced engineering features, 328, 329
overview, 125–127 changes in technology and scale of operation, 328,
silo storage systems, 128, 129f 329f
storage yard with pit, 127–128 critical milestones in Portland cement chemistry,
cement, 209–210 328t
Strength pyroprocessing, course-changing developments in,
hardened cement paste, 238 330t
OPC/NPC, 222–223 raw and finish grinding processes, tentative
Stripping ratio, 25 technological milestones, 330t
S-type Portland cements, 226 SWOT analysis, of carbonation technologies in
Sub-bituminous coal, 74, 75 development, 365, 366t
418 Inde x

Synthetically produced gaseous fuels, properties, 79–80 Tokyo Tama Eco-cement facility, 348
Systematic quality assessment, AFR, 118–121 Topas BBQ, 267
organic pollutants, measurement of, 118–119, 120t Total organic carbon (TOC), 121
overview, 118 Total petroleum hydrocarbons (TPH), 121
requirements of test facilities, 119, 121 Total process control system, 284–285
Systemic requirements, alternative fuels, 124–132 Toxicity, hazardous waste, 105–106
overview, 124, 125f Toxicity characteristics leaching procedure (TCLP),
precalciner design considerations, 131–132 106, 121
storing, dosing, and conveying, 125–131 Trace elements, 290–291, 293
automation and control, 131 Transportation, of gypsum, 247
dosing and conveyance to kilns, 128, 130 Travertine, 19
silo storage systems, 128, 129f Trends, in cement production
storage yard with pit, 127–128 global and regional growth, see Global and regional
tires and whole large packages, 130 growth trends
research and development, see Research and
T development (R&D)
Trial-and-error method, 49
Tailings, 190 Tricalcium aluminate, 41
TCLP (toxicity characteristics leaching procedure), 106, Tricalcium silicate, 41, 363
121 Triethnolamine, 206
TecEco cements, based on reactive magnesia, 361–362 Tromp curve, 191, 192f
Technological properties, of rocks, 4–6 Tubular photobioreactor, 357
Technological status, Indian cement industry, 386–391 Tufa, 19
captive power generation, 388, 389, 391
electricity consumption, 388, 389t U
evolution of process profiles, 387
features, 386 Ultra-rapid-hardening cement, 226
fuel usage and thermal energy consumption, 387, Ultra violet–infrared spectrometer (UV-IR), 230
388, 389f Ultraviolet radiation, 276
future direction, 391 United Nations Economic and Social Council
limestone resources, 386–387 (ECOSOC), 11
phosphogypsum, beneficiation of, 391 United Nations Framework Classification (UNFC), 10,
product mixing, 390f, 391 11–13
Technology, converting CO2 into fuel products, 358–359 United Nations Industrial Development Organization, 377
Temperature Unit operations, raw materials on, 36–37
calcium carbonate, 144–146 Unstable flame, in kiln, 95
of flame, 94–95 Utilization, of fuels, 288
on hydration and curing, 238–239
ignition, of petcoke, 97–98 V
measurements, 282–284
resistivity, of dust, 307, 308f Variations, in opencast mining, 25–26
Ternal RG, 353 Varieties, Portland cements, 214–219
Terra alba, 33 ASTM classification, 215–216
Terrace mining, 25 European standard, 216–218
Test facilities, requirements of, 119, 121 Indian standards, 218
Testing, Portland cements, 230–231 overview, 214–215
Tetracalcium aluminoferrite, 41 standard specifications for cements in China,
Theoretical approaches, reactivity and burnability of raw 218–219
meal, 65–66 Variograms, 256
Thermal characteristics, of coal, oil, and gas, 80–81 Vaterite, 361, 365
Thermal energy consumption, Indian cement industry, Velocity, measurements
387, 388, 389f air/gas, 280–281
Thermal NOx, 137, 169 by anemometers, 282
Thermo-chemical reactivity, of clay minerals, 31–32 Vermiculite, 32
Thermocouples, 282, 283f Vertex mill, operating principles of, 123
Thermogravimetric analyzer (TGA), 230 Vertical roller mills (VRMs), 58–60, 98
Thermometer, ratio, 170 clinker grinding system, 193–195
Thermometers, resistance, 282 grinding aids for, 208
Tire-derived and other secondary fuels through main requirement, 194
gasification, 133, 134f, 135 schematic diagram, 193f
Tires and whole large packages, dosing of, 130 types, 193
 Inde x 419

typical flow chart, 195 Wavelength-dispersive XRF (WDXRF), 261

working principle, 194, 195 WDXRF (wavelength-dispersive XRF), 261
Vicat plunger, 231 Wet gas, 79
Viscosity, liquid fuels, 77–78 Wet probe, 279
Visual impacts, feasibility of AFR project, 108–109 Wet scrubbing, 315
Volatile matter, combustion of coal, 91 White Portland cement (WPC), 215, 224
Volatile organic compounds (VOCs), 121 Windrow method, 56, 57
Volatiles cycle, in preheater-precalciner kiln systems, Wollastonite, 363
161–162 Working principles
Volume shrinkage temperature relation, 68 horomills, 198f
Votorantim, 377 VRMs, 194, 195
VRMs, see Vertical roller mills (VRMs) World Bank, 377
V-separator, 196–197 World Business Council for Sustainable Development,
VSK separator, 197 377
World cement production
W during 2001–2013, 373
CEMBUREAU, countries of, 373, 374f
Warning systems, flue gas analysis, 278–279 country-wise distribution, 373, 374f
Waste(s) top cement-producing countries, 373, 375–377, 375t
agricultural, 104 twentieth century, 372
combustible, 104 World reserves
from diverse sources, 103 coal, 81–83
hazardous in Asia-Pacific Region, 81, 82t
AFR inventory and material characteristics, inventory in India, 82–83
114–115 regional distribution, 81t
classifying, biological parameters in, 106–107 R/P ratio, 81
defined, 104, 105–106 status, of production, 82
incinerators, cement kilns vs., 122t petcoke, 96
incombustible, 104 Woven fabrics, 299–300
industrial, 104
MSW, 110–112 X
plastic, industrial, 117
storage, 125 XPAC, 28
utilization and disposal, 288 X-ray diffractometry (XRD), 45, 230, 265–267, 268,
Water 269, 270, 271, 334
emissions to, 108 X-ray fluorescence spectrometry (XRF), 230, 261–262,
gas, 79, 80t 268, 269, 271, 272
mineral in liquid form, 2
reducers, 241, 242–243 Z
sprays, control of ball mill temperature, 187
spray systems, 311 Zirconia, 275
Waterproofing materials, 381 Zonation, kiln, refractory materials and, 163–165