Lump formation in cement silo

1. 1. Lump formation in cement silos

2. 2. Lumps formed in cement silo
3. 3. Reasons for Lump formation in cement silo
4. Entry of humid Temperature of Air through aeration cement Blowers and lack of venting
surface conditions Of cone and the Entry of moisture Side walls Along with cement SO3
and Alkalis Storage time of In the cement in the cement
5. 4. Temperature of cement : Cement temperature must be less than 80 Deg C when
conveyed into silo. If it is more than 80 deg C the crystalline water from Gypsum gets
dehydrated and moisture moves to the colder part ie center cone and the walls .This
moisture Hydrates the fine cement and causes cake formation. Presence of alkalis
accelerates prehydration.In our clinker K2O+ Na2O is 0.8. Incement 0.63 (PPC) and SO3
is 1.8 %.The coating formed is Called Syngenite( K2SO4.CaSO4.H2O)
6. 5. Intensity of coating formation as a function Of cement temperature stored in cement
silo 100Percentage of heaviest coating 80 SO3=2.7 % 260 M2/kg 60 40 20 0 60 80 100
120 140 Cement temperature Deg C , stored
7. 6. Effect of surface on lump formationIf surface of the inner cone and side walls are
rough cement make dead layer and over a period of time they get hydrated And dislodged
causing blockage.To have a glassy surface, the walls and floor are coated withepoxy Or
materials which can form fine surface which facilitates smooth out flow of material
8. 7. Storage time High storage time and high cement temperature, both can aid cake
formation. Our cement in silo 4 and 5 is more than 12 days In silo 3 it is 2 to 3 days.
9. 8. Effect of gypsum content on cake formation Higher gypsum addition or higher SO3 in
cement accelerates the hydration of cement In silo. Anhydrate gypsum reduces coating
formation i.e., Caso4 Our cement
10. 9. Addition of anhydrate (Gypsum without water) Can reduce lump Formation in
silo.Ratio of anhydrate/gypsum(CaSO4.2H2O) ratio
11. 10. Ultimate solution1. Reduce the cement temperature from 90 deg C to 70 step by
step2. Reduce the storage time present 10 days to 6 days3. Silo venting must be on when
cement is extracted and aeration is done. When RH is high It can accelerate the hydration

The following possible measures will reduce lump formation in cement silo:

1.Since moisture in cement is mainly through dehydration of gypsum during grinding, it may be
attempted to reduce moisture concentration in cement by increasing cement grinding temperature in
the mill (max. 115 deg Cent.) so that extensive dehydration takes place in mill itself and moisture goes
out through the mill vent fan.

2. Emphasis must be given to reduce access to moisture during cement storage. A partial replacement of
gypsum with gypsum anhydrite can be possible way to reduce water vapour in cement storage silo.

3.The concentration of C3A mineral phase content increases sensitivity of cement towards moisture.
Therefore, control of C3A reduces tendency of lump formation.

4.Short term storage of cement in silo and ensure smooth functioning of all silo extraction gate by
regular monitoring will reduce tendency of lump formation.
5.Silo vent bag filter fan may be operated on continuous basis.

C3A is moisture sensitive mineral. In presence of moisture the C3A of clinker and sulphate of
the gypsum from ettringite (3CaO.Al2O3.3CaSO4.32H2O).Ettringite develop in the shape of
needle like crystals and causes limping of cement.

You may also check alkali sulphate (K2SO4) in clinker. In presence of moisture and calcium
sulphate (Gypsum/hemihydrate) .K2SO4 reacts to form Syngenite
(K2SO4.CaSO4.H2O).Syngenite also develop in the shape of needle like crystals and cause
lumping of cement just like ettringite. Syngenite generally formed in plant which have high K2O
in limestone.