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Process

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Quarrying & Crushing
Raw Milling
Clinkerisation
Grinding
Dispatch
Quarrying & Crushing
Raw Milling
Clinkerisation
Grinding
Dispatch

The cement manufacturing process at Lagan Cement, comprised the following main stages:
 

  • Blasting
  • Crushing
  • Blending
  • Milling in the Raw Mill
  • Pyro-processing in the Kiln
  • Milling in the Cement Mill
  • Storage in Cement Silos
  • Dispatch via tankers and bags
  • Clinker Explained
    Cement manufacture firstly requires the production of a material called 'clinker'. This is the material which is produced when limestone and shale/clay mixes are burned in combination at very high temperatures. (>1400°C), after careful crushing, blending and milling.
    Other than Limestone, materials that are typically used include marl, iron ore, clay, sand, bauxite and fly ash. These materials provide the required ratios of the main elements of the raw material ’mix’, which are silica, alumina, iron and calcium carbonate.
    On-line analytical systems continually fine-tune the chemical composition of the resulting mix of these materials, before they are pulverised and fed to the pyro processing stage of the process. This consists of the preheating tower, where all the material is precalcined up to 900°C and passed to the Kiln.

    Clinkerisation occurs in the burning zone of the rotating kiln, as the material passes through. Flame temperatures of 2000°C convert the mix into the black nodular material (less than 40mm), known as clinker. The entire combustion process takes circa twenty minutes from preheater entry to kiln exit, which enables complete clinkerisation and also destruction of all organic fuel components.The resulting clinker contains the tricalcium silicate and aluminate minerals which are essential to the hydraulic properties of the cement.
  • Process Control

    Continuous process sampling and X-Ray analysis of the process intermediates and clinker ensures that the burning process is continuously optimised to produce the highest quality clinker. 

    For each tonne of material that goes into the feed end of the kiln, approximately two thirds of a tonne exits the kiln as nodular clinker. The clinker is then very finely ground in a large rotating ball mill to produce different types of Portland Cement. A small amount of gypsum is also added during the grinding process to control the cement's setting characteristics. 

    While the basic principles of the Cement Manufacturing process have fundamentally changed very little in the past hundreds of years, the technologies employed in order to achieve maximum clinker production per energy expended, coupled with the lowest emissions possible, have continually developed to their current high levels of efficiency. 

    As a new and modern manufacturing facility, utilising all the state-of-the-art technologies, Lagan Cement are well prepared to meet the environmental and production challenges of the coming years.

    Lagan Cement uses a combination of traditional and alternative fuels to fire its kiln at the Killaskillen plant. Apart from additional Fuel-handling systems, the use of alternative fuels does not involve any changes to the actual cement making process.

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