Pre-industrial production of CSA cement

Location: Mersin, Turkey.

Partners involved: Türkiye Çimento Müstahsilleri Birliği (TÇMB)

General description: The production of Calcium Sulpho-Aluminate (CSA) cement needed the collaboration of different industries to collect all the materials needed, a good example of industrial symbiosis. It has been produced by using Ladle furnace slag, Glass waste, Ceramic waste and Aluminium waste.

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1. Glass

The glass waste from Trakya Şişecam.

 

2. LF Slag

LF slag from Ekinciler Iron and Steel Industry.

 

3. Ceramic

Ceramic waste from Çanakkale Ceramic.

 

4. Serox

Serox from BEFESA.

Once all the materials have been collected, the all CSA clinker production process is monitored by a special software inside the operation centre.

6. Pilot Scale Ball Mill

The pilot ball mill is used to grind waste materials in order to feed the pilot rotary kiln and to grind clinker respectively.

7. Preparing Raw Meal

The next phase is related to the preparation of the raw material with SRMs (23.38% Serox, 1.00% Glass waste, 6.47% Ceramic waste, 13.93 % LF). The raw meal was prepared for the first production trial in the pilot rotary kiln.

9. Raw Meal Feed

12. Full View of Pilot Rotary Kiln

Mix-2 CSA cement was manufactured with the pilot rotary kiln.

 

14. The First CSA Clinker

Finally, the first CSA clinker produced with wastes in the pilot rotary kiln.

Industrial production of Blended cement

Location: Adana, Turkey.

Partners involved: Türkiye Çimento Müstahsilleri Birliği (TÇMB)

General description: The production of this particulr eco-cement needed the collection of different materials in the stockpile at the Adana cement plant. The Blended cement has been produced by using Glass waste, Ceramic waste and Ladle furnace slag.

Supply chain:

CSA Cement and New Blended Cement

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1. LF Slag

The LF slag provided by Ekinciler Iron and Steel Industry.

2. Glass

The glass waste provided by Trakya Şişecam.

3. Ceramic

Ceramic waste provided by Çanakkale Ceramic.

Finally, the SRM mixtures were prepared and brought in the facility for the storage and the pre-homogenization.

4. SRM Mixture

5. Storage and Prehomogenization

The whole process has been monitored by software and live cameras inside the operation centre. Then, clinkers have been moved with the conveyor belt from clinker silos into the ball mill. In the mix-22 production process, the Liquid Antimony Trioxide (Sb2O3) was sprayed onto clinker particles as a Chromium VI reducer to reduce CrVI value below 2 ppm.

8. Chromium VI Reducing

The produced cement has been directly transported into the cement trailer with an external by-pass line.

10. By-pass Line

11. Cement Trailer

The produced cement was then transferred to big bags to be moved to TCMA, ACCIONA, TECNALIA and FERALPI, for analyses and applications.

13. Big Bag Storage