Cement Production Manufacturing Proccess

Cement is a fine powder which sets after a few hours when mixed with water, and then hardens in a few days into a solid, strong material. Cement is mainly used to bind fine sand and coarse aggregates together in concrete.  Cement is a hydraulic binder, i.e. it hardens when water is added.

There are 27 types of common cement which can be grouped into 5 general categories and 3 strength classes: ordinary, high and very high.  In addition, some special cements exist like sulphate resisting cement, low heat cement and calcium aluminate cement.

The quarry is the starting point

Cement plants are usually located closely either to hot spots in the market or to areas with sufficient quantities of raw materials. The aim is to keep transportation costs low. Basic constituents for cement (limestone and clay) are taken from quarries in these areas.

A two-step process

Basically, cement is produced in two steps: first, clinker is produced from raw materials. In the second step cement is produced from cement clinker. The first step can be a dry, wet, semi-dry or semi-wet process according to the state of the raw material.

Making clinker

The raw materials are delivered in bulk, crushed and homogenised into a mixture which is fed into a rotary kiln. This is an enormous rotating pipe of 60 to 90 m long and up to 6 m in diameter. This huge kiln is heated by a 2000°C flame inside of it. The kiln is slightly inclined to allow for the materials to slowly reach the other end, where it is quickly cooled to 100-200°C. 

Four basic oxides in the correct proportions make cement clinker: calcium oxide (65%), silicon oxide (20%), alumina oxide (10%) and iron oxide (5%). These elements mixed homogeneously (called “raw meal” or slurry) will combine when heated by the flame at a temperature of approximately 1450°C. New compounds are formed: silicates, aluminates and ferrites of calcium. Hydraulic hardening of cement is due to the hydration of these compounds. 

The final product of this phase is called “clinker”. These solid grains are then stored in huge silos. End of phase one.

From clinker to cement

The second phase is handled in a cement grinding mill, which may be located in a different place to the clinker plant. Gypsum (calcium sulphates) and possibly additional cementitious (such as blastfurnace slag, coal fly ash, natural pozzolanas, etc.) or inert materials (limestone) are added to the clinker. All constituents are ground leading to a fine and homogenous powder. End of phase two. The cement is then stored in silos before being dispatched either in bulk or bagged.

What is concrete?

Concrete is a solid material made of cement, water, aggregates and often with admixtures. When fresh, it has a certain workability and takes the form of the mould into which it is put. When set and hardened, it is as strong as natural stone and resists time, water, frost, mechanical constraints and fire. Typically, concrete is the essential material used in all types of construction [residential (housing), non-residential (offices) and civil engineering (roads, bridges, etc.)].

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Geothermal Powerplant Energy

Geothermal energy is the heat from the Earth. It's clean and sustainable. Resources of geothermal energy range from the shallow ground to hot water and hot rock found a few miles beneath the Earth's surface, and down even deeper to the extremely high temperatures of molten rock called magma.

Almost everywhere, the shallow ground or upper 10 feet of the Earth's surface maintains a nearly constant temperature between 50° and 60°F (10° and 16°C). Geothermal heat pumps can tap into this resource to heat and cool buildings. A geothermal heat pump system consists of a heat pump, an air delivery system (ductwork), and a heat exchanger-a system of pipes buried in the shallow ground near the building. In the winter, the heat pump removes heat from the heat exchanger and pumps it into the indoor air delivery system. In the summer, the process is reversed, and the heat pump moves heat from the indoor air into the heat exchanger. The heat removed from the indoor air during the summer can also be used to provide a free source of hot water.

In the United States, most geothermal reservoirs of hot water are located in the western states, Alaska, and Hawaii. Wells can be drilled into underground reservoirs for the generation of electricity. Some geothermal power plants use the steam from a reservoir to power a turbine/generator, while others use the hot water to boil a working fluid that vaporizes and then turns a turbine. Hot water near the surface of Earth can be used directly for heat. Direct-use applications include heating buildings, growing plants in greenhouses, drying crops, heating water at fish farms, and several industrial processes such as pasteurizing milk.

Hot dry rock resources occur at depths of 3 to 5 miles everywhere beneath the Earth's surface and at lesser depths in certain areas. Access to these resources involves injecting cold water down one well, circulating it through hot fractured rock, and drawing off the heated water from another well. Currently, there are no commercial applications of this technology. Existing technology also does not yet allow recovery of heat directly from magma, the very deep and most powerful resource of geothermal energy.

Many technologies have been developed to take advantage of geothermal energy - the heat from the earth. NREL performs research to develop and advance technologies for the following geothermal applications:

Geothermal Energy Technologies:

• Geothermal Electricity Production
  Generating electricity from the earth's heat.
• Geothermal Direct Use
  Producing heat directly from hot water within the earth.
• Geothermal Heat Pumps
  Using the shallow ground to heat and cool buildings.

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Biomass Energy

Biomass energy or bioenergy - the energy from organic matter - for thousands of years, ever since people started burning wood to cook food or to keep warm.
And today, wood is still our largest biomass energy resource. But many other sources of biomass can now be used, including plants, residues from agriculture or forestry, and the organic component of municipal and industrial wastes. Even the fumes from landfills can be used as a biomass energy source.
The use of biomass energy has the potential to greatly reduce our greenhouse gas emissions. Biomass generates about the same amount of carbon dioxide as fossil fuels, but every time a new plant grows, carbon dioxide is actually removed from the atmosphere. The net emission of carbon dioxide will be zero as long as plants continue to be replenished for biomass energy purposes. These energy crops, such as fast-growing trees and grasses, are called biomass feedstocks. The use of biomass feedstocks can also help increase profits for the agricultural industry.

Biomass Energy technology applications:

• Biofuels
  Converting biomass into liquid fuels for transportation.
• Biopower
  Burning biomass directly, or converting it into a gaseous fuel or oil, to generate electricity.
• Bioproducts
  Converting biomass into chemicals for making products that typically are made from petroleum.

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Hydrogen Power System Fuel Cell

Hydrogen is the simplest element. An atom of hydrogen consists of only one proton and one electron. It's also the most plentiful element in the universe. Despite its simplicity and abundance, hydrogen doesn't occur naturally as a gas on the Earth - it's always combined with other elements. Water, for example, is a combination of hydrogen and oxygen (H₂O).

Hydrogen is also found in many organic compounds, notably the hydrocarbons that make up many of our fuels, such as gasoline, natural gas, methanol, and propane. Hydrogen can be separated from hydrocarbons through the application of heat - a process known as reforming. Currently, most hydrogen is made this way from natural gas. An electrical current can also be used to separate water into its components of oxygen and hydrogen. This process is known as electrolysis. Some algae and bacteria, using sunlight as their energy source, even give off hydrogen under certain conditions.

Hydrogen is high in energy, yet an engine that burns pure hydrogen produces almost no pollution. NASA has used liquid hydrogen since the 1970s to propel the space shuttle and other rockets into orbit. Hydrogen fuel cells power the shuttle's electrical systems, producing a clean byproduct - pure water, which the crew drinks.

A fuel cell combines hydrogen and oxygen to produce electricity, heat, and water. Fuel cells are often compared to batteries. Both convert the energy produced by a chemical reaction into usable electric power. However, the fuel cell will produce electricity as long as fuel (hydrogen) is supplied, never losing its charge.

Fuel cells are a promising technology for use as a source of heat and electricity for buildings, and as an electrical power source for electric motors propelling vehicles. Fuel cells operate best on pure hydrogen. But fuels like natural gas, methanol, or even gasoline can be reformed to produce the hydrogen required for fuel cells. Some fuel cells even can be fueled directly with methanol, without using a reformer.

In the future, hydrogen could also join electricity as an important energy carrier. An energy carrier moves and delivers energy in a usable form to consumers. Renewable energy sources, like the sun and wind, can't produce energy all the time. But they could, for example, produce electric energy and hydrogen, which can be stored until it's needed. Hydrogen can also be transported (like electricity) to locations where it is needed.
Flowing water creates energy that can be captured and turned into electricity. This is called hydroelectric power or hydropower.
The most common type of hydroelectric power plant uses a dam on a river to store water in a reservoir. Water released from the reservoir flows through a turbine, spinning it, which in turn activates a generator to produce electricity. But hydroelectric power doesn't necessarily require a large dam. Some hydroelectric power plants just use a small canal to channel the river water through a turbine.
Another type of hydroelectric power plant - called a pumped storage plant - can even store power. The power is sent from a power grid into the electric generators. The generators then spin the turbines backward, which causes the turbines to pump water from a river or lower reservoir to an upper reservoir, where the power is stored. To use the power, the water is released from the upper reservoir back down into the river or lower reservoir. This spins the turbines forward, activating the generators to produce electricity.
A small or micro-hydroelectric power system can produce enough electricity for a home, farm, or ranch.

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Ocean Thermal Energy

 

Workers install equipment for an ocean thermal energy conversion experiment in 1994 at Hawaii's Natural Energy Laboratory. Credit: A. Resnick, Makai Ocean Engineering, Inc.

The ocean can produce two types of energy: thermal energy from the sun's heat, and mechanical energy from the tides and waves.

Oceans cover more than 70% of Earth's surface, making them the world's largest solar collectors. The sun's heat warms the surface water a lot more than the deep ocean water, and this temperature difference creates thermal energy. Just a small portion of the heat trapped in the ocean could power the world.

Ocean thermal energy is used for many applications, including electricity generation. There are three types of electricity conversion systems: closed-cycle, open-cycle, and hybrid. Closed-cycle systems use the ocean's warm surface water to vaporize a working fluid, which has a low-boiling point, such as ammonia. The vapor expands and turns a turbine. The turbine then activates a generator to produce electricity. Open-cycle systems actually boil the seawater by operating at low pressures. This produces steam that passes through a turbine/generator. And hybrid systems combine both closed-cycle and open-cycle systems.

Ocean mechanical energy is quite different from ocean thermal energy. Even though the sun affects all ocean activity, tides are driven primarily by the gravitational pull of the moon, and waves are driven primarily by the winds. As a result, tides and waves are intermittent sources of energy, while ocean thermal energy is fairly constant. Also, unlike thermal energy, the electricity conversion of both tidal and wave energy usually involves mechanical devices.

A barrage (dam) is typically used to convert tidal energy into electricity by forcing the water through turbines, activating a generator. For wave energy conversion, there are three basic systems: channel systems that funnel the waves into reservoirs; float systems that drive hydraulic pumps; and oscillating water column systems that use the waves to compress air within a container. The mechanical power created from these systems either directly activates a generator or transfers to a working fluid, water, or air, which then drives a turbine/generator.

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Martabak Telor dan Martabak Manis (Terang Bulan)

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