Features Incorporated In The Design Of Lone Star's Two New Dry Process Cement Plants

THE heavy postwar demand for Portland Cement has created shortages that are gradually being overcome by increases in plant capacity. In the post-war period, the Lone Star Cement Corp. has expanded several of its existing 15 plants and has built 2 new plants, now in operation, with a third new plant under construction in Brazil, of design somewhat different from that of the two preceding ones. The new domestic plants are located at Lone Star, Va., near Roanoke, and at Maryneal, Tex., near Sweetwater, and went into operation during 1951. Each plant is equipped with two rotary kilns and has an initial capacity of 1,500,000 bbl per year, or 6,000,000 sacks. The total cost of each plant was about $10,500,000, and on this basis $7.00 in 1951 money are required per bbl of annual capacity; at 376 lb per bbl, this corresponds to $37.00 per ton of output. The investment corresponds to approximately $80,000 per hourly-wage earner employed. The purpose of this paper is to describe the most interesting design features of the two new and almost identical Lone Star plants. Why the Dry Process Was Chosen The two new domestic Lone Star mills employ the dry process because: 1-The raw materials at both properties are particularly suitable and can be dried very, readily. 2-The Maryneal, Tex., plant does not have water available for slurry. 3-Very substantial kiln fuel savings can be obtained. 4-Dry raw grinding reduces ball and liner wear and- general maintenance, without any sacrifice in power. Operating costs to date have more than justified the choice of the dry process for these two plants. Raw Materials The chemical composition of Portland Cement raw material after crushing, grinding, and mixing, but before burning, is about as follows: [ ] sometimes tailings from an iron ore concentrating plant. Certain objectionable materials occur in raw mix: magnesia, limited in cement to 5 pct, in excessive amounts; alkalies, as sodium and potassium; phosphorous; and sulphur, generally present in coal and oil. The Roanoke raw, materials are dense limestone and shale. The Maryneal materials are soft limestone and a hard brittle clay that can be handled much like shale. Sand and iron ore are required in small quantities. General Plant Layout and Construction The two plants are so similar that one joint description will cover both, with such exceptions as will be especially indicated. The crushing plant is located in the quarry, and raw material is conveyed by belt to the storage building, where all materials are stored and handled. Fig. 1 identifies the various structures of the Roanoke plant. The large storage building is used for the storing and handling of all materials, including limestone, shale, sand, iron ore, coal, clinker, and gypsum. Directly adjoining the storage building is a structure under a similar arched roof, containing the raw and clinker grinding departments and the electrical substation. The discharge ends of kilns and coolers, and coal or gas burning equipment are also placed at one end of the mill building. The 340ft long kilns extend away from the main buildings to form the long leg of an L, at the end of which is the feeding and kiln dust collecting equipment, and the raw blending silos are conveniently located adjacent to the feed end of the kilns. The machine shop, storeroom, electrical shop, foremen's office, service rooms, and meeting hall are combined in one structure in the center of the plant, and the office and laboratory are close by. The cement silos and packhouse do not have to be tied directly into the manufacturing process and are therefore located at a point convenient to the railroad tracks.