ppc riebeeck mine and cement factory - Aurecon AME ...

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PPC Riebeeck West: Storm water Management Plan Page 23 RAW MATERIAL Sand / Shale mix Riebeeck Mine CURRENT SOURCE TRANSPORT Conveyor system Sweetener Sand Piketberg Road FDG – (60% iron oxide) Saldanha Rail Coal (for the coal mill) Delmas Colliery Milled clinker Clinker Gypsum NDM (Limestone extension) Additive / grinding agent. Different additive for OPC & Rapo Clinker – Crane Store BPB Boesmanland – (Natural) Riebeeck Mine CBA for OPC TDA for Rapo Rail and Road Conveyor system Rail Conveyor system Road STOCKPILE CAPACITY AND LOCATION (APPROXIMATE) 15 000 tons – covered stockpile 8 000 tons – stockpile 8000 tons - covered stockpile 16 000 – Circular blending bed 2500 – Crane store Crane store – 80 000 tons 2 500 tons - Crane store 1 000 tons – Crane Store 2 x 20 000 litres tanks - in bunded facilities Cement storage (clinker / blended with extenders such as limestone) OPC Cement silos Conveyor 3 x 3000 ton silos Rapo Cement silos system 1 x 3000 ton silo AVERAGE USAGE FOR CLINKER PRODUCTION 7 % 1% 2% App. 8 000 tons per month 91% 4.5% 4.5% 1250 ml per ton for Rapo 250ml per ton OPC 1.6.2 Raw milling and storage of raw meal Raw meal required for clinker production is achieved by the proportioning and monitoring the flow of sand, shale, FDG and limestone conveyed to the raw mill. This is controlled electronically from the control room. In the raw milling process, the input material is ground to a fine powder. PPC Riebeeck has two operating raw mills (ball mills). The mills operate in closed circuit, which means that the milled product is passed to a separator where the material which is fine enough, is separated from the coarse particles. The latter are returned to the mill for further grinding whilst the product (fine material) is transferred to a blending silo as raw meal. The raw meal from the blending silos is transferred by compressed air to a kiln feed silo from where it enters the kilns for the production of clinker. The gaseous emission‟s from the Raw Mills are drawn through Electrostatic Precipitators (ESP) to limit dust emissions. Emissions from mill stacks are reported monthly.
PPC Riebeeck West: Storm water Management Plan Page 24 1.6.3 Coal milling Coal is transported by means of a Japanese pipe to a tube ball mill called a coal mill.. Pulverised coal is then passed through a separator and a cyclone. Fines from the cyclone are fed directly to the kiln. The coal milling process is a closed system. There are temperature recording controls on the coal mill, to ensure that coal mill explosions do not occur. For emergency procedures, explosive discs and a system which can flood the mill with CO2 is maintained. 1.6.4 Clinker production Riebeeck currently has 2 operating kilns (Refer to Figure 1.14 below): No.1 kiln – a rotary kiln with an approximate capacity of 750 tons of clinker / day. No. 2 kiln – a rotary kiln with a one stage preheater capable of producing an approximate 840 tons of clinker / day. Raw meal is fed into the Kilns from one end and coal used to generate the heat in the kiln from the other. For Kiln No.2 while the material passes through the preheater, the raw meal is dried and partial calcinations takes place at approximately 900ºC. During calcination, limestone (predominantly CaCO3) breaks down and releases carbon dioxide (CO2), CaCO3 + heat CaO + CO2. For Kiln 1 all of the heating process occurs within the kiln. The heated material is then passed through the coal fired rotating kilns, where various minerals start to fuse together to form calcium silicate crystals, known as clinker. The coal is burnt through mono channel burners.
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