Authored by Eonchemicals

Solution

The grinding process in the cement industry is a critical stage in cement production that involves crushing cooled clinker with the addition of gypsum and other supplementary materials, such as fly ash or slag, to produce fine cement.

The grinding machine aims to reduce the particle size of the clinker to the fine powder required for cement production. Grinding is performed meticulously to ensure the appropriate particle size distribution and optimal hydration capability, which significantly affects the final quality of the cement product.

Here are some problems and solutions from Eonchemicals:

 1. Problem: High Temp Grease

The high temp grease issue in the grinding process of the cement industry involves challenges in maintaining lubricant performance at the high temperatures generated during grinding. Machines like ball mills and roller mills used to grind raw materials such as limestone and clay generate extreme heat, which can cause regular lubricants to lose viscosity (become thinner) and become unstable.

This can increase friction and wear on heavy components like bearings and gears, accelerate corrosion and oxidation, ultimately reducing operational efficiency and machine lifespan.

Solution: Molykote / Dow / LE

Molykote, Dow, and Lubrication Engineers (LE) are high-temperature greases specially formulated to work at high temperatures. These products contain additives such as molybdenum disulfide (MoS2) or other additives that enhance the grease’s resistance to extreme temperatures, maintaining viscosity and lubrication stability during intensive operations.

Eonchemicals is the official distributor in Indonesia for these products, ensuring authenticity and quality. Please chat with us on WhatsApp for more information or for a free consultation regarding high-temperature lubrication programs at your site.

2. Problem: Motor Cleaner on Gear Box

The motor cleaner issue on gear boxes in the grinding process of the cement industry includes the challenge of maintaining cleanliness and optimal performance of the gear box components used in grinding raw materials like limestone and clay.

Dust and fine particles from raw materials often accumulate around the gear box, interfering with internal functions like bearings and gears. If not properly addressed, this can disrupt operations and overall product quality.

Solution: EonMotor 100

EonMotor 100 functions as an effective electric motor cleaner. Made from a solvent blend, it is designed to clean electric motors and dynamos from dust, oil, and grease.

With proper use, this product can keep electric motors clean and functioning well, thereby extending their service life and enhancing overall performance.

Regular use of EonMotor is a crucial step in maintenance that can save repair and replacement costs.

3. Problem: Road Dust

The road dust issue around the grinding process area in the cement industry involves the challenge of controlling dust generated from grinding and transporting raw materials like limestone and clay.

Scattered dust can cause visibility issues, health risks for workers, and potential equipment damage. Additionally, uncontrolled dust can spread to the surrounding environment, causing complaints from the local community.

Solution: DustDown 369, CSS

DustDown 369 and CSS are both effective solutions for addressing dust issues as described above. DustDown 369 is a dust control material that can be applied to roads to bind dust particles, preventing them from becoming airborne and spreading.

Chemical Stabilizing Solution (CSS) serves to stabilize road surfaces, reducing abrasion and dust formation caused by heavy vehicles and wind.

4. Problem: Grease Quality

Low-quality grease or grease that is not suited to the application challenges will result in unsatisfactory lubrication. This is because such grease does not have the capability to adapt to challenging environments like high temperatures, high speeds, heavy loads, and significant dust.

Solution: Molykote / Dow / LE

Eonchemicals provides solutions in the form of high-quality specialty greases like Molykote, Dow, and Lubrication Engineers (LE). These greases are highly suitable and effective for lubrication systems in challenging conditions as mentioned above.

These grease products are uniquely designed to withstand high pressure, high temperatures, and high contaminants. It is crucial to maintain the optimal performance of machinery and equipment in the cement industry.

For more information or consultation about these products, please contact us.

5. Problem: Slippery and Damaged Floors

Slippery and damaged floors can certainly disrupt worker safety and operational efficiency. Slippery floors are caused by activities in the cement industry where material spills, oil, grease, and water frequently occur.

Damaged floors are caused by heavy loads operating on the floor. Problematic floor conditions (slippery and damaged) can increase the risk of workplace accidents and hinder operational activities, thus requiring appropriate solutions to address them.

Solution: EonCoat 551 / EonCoat 470

EonCoat coating products from Eonchemicals have the benefit of forming a very hard layer after curing, resistant to impact, oil, and chemicals, making them durable and non-slippery.

These specialty coating products can be used on new or old construction surfaces for maintenance.

The resulting layer provides maximum protection against harsh environmental conditions, ensuring the floor can be used safely and comfortabl.

6. Problem: Water Treatment

The focus of water treatment in this division is to treat water to become clear and free from solid contaminants that would interfere with subsequent processes. Failure in this focus can cause blockages in piping systems and equipment, reduce cooling efficiency, and increase the risk of scale and corrosion, leading to machine damage.

Solution: Coagulants and Flocculants

Eonchemicals’ solution for the above focus is to use coagulants and flocculants. Both can synergize, complementing each other in precipitating solid contaminants in the water.

Coagulants function to bind small particles into larger sizes. Meanwhile, flocculants gather the already larger particles into even larger flocs for easier sedimentation.

With the correct application of coagulant-flocculant, contaminants in the water such as limestone and clay can be precipitated more effectively and efficiently.

Contact Eonchemicals for discussion and solutions.

7. Problem: Boiler

Maintaining boiler performance to remain optimal in providing steam or heat is a major challenge. This is because boilers often experience scaling, corrosion, and fouling problems due to feed water quality not meeting standards.

The above problems can reduce heat transfer efficiency, increase fuel requirements, and cause damage to boiler components. Failure to address these problems results in decreased productivity and increased operational costs.

Solution: Eon Boiler Chemicals

Eon Boiler Chemicals is an effective product package solution to keep boiler performance at its best. It includes a range of products to prevent corrosion, rust, and fouling issues.

With the correct application and dosage, Eon Boiler Chemicals help maintain optimal performance and operational reliability of boilers. Please contact our boiler expert team for further discussion.

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8. Problem: Cooling Tower

Issues with cooling towers include the challenge of maintaining optimal cooling efficiency. Cooling towers are used to dissipate heat generated during operations.

Common problems include scaling, rust, and algae growth on tower surfaces, as well as the accumulation of minerals and deposits from cooling water. The impact of these problems includes reduced heat transfer efficiency, increased water consumption, and effects on the quality of water reused in the production process.

Solution: Eon Cooling Tower Chemicals

Eon Cooling Tower Chemicals, such as EonBac GEO 9910, EonLine AG 5770, and EonScale T 2511, are specially formulated as effective solutions for addressing issues in cooling towers, including those in the cement industry.

Eonchemicals’ solution products are formulated to address threats like corrosion, scaling, algae growth, and other issues affecting the efficiency and quality of cooling water.

For more information, including usage instructions and recommended dosages, please contact our team via WhatsApp.

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9. Problem: Metal Repair

Metal repair issues in the grinding unit of the cement industry often occur due to kilns and other equipment being repeatedly and constantly exposed to high temperatures. Equipment such as kilns, preheaters, and coolers are prone to significant wear and corrosion due to extreme temperature exposure and chemicals in the production process.

Damage to these metal parts can disrupt cement production, increase maintenance costs and downtime for repairs, and threaten operational safety.

Solution: Metbond 581

Metbond 581 is a compound for metal repair, rebuilding damaged metal components due to erosion and corrosion without requiring welding, thus reducing the risk in its use.

This product is suitable for various metal components such as pump bodies, impellers, propellers, grids, valves, tube sheets, water tanks, rudders, and heat exchanger components in the industry.

Metbond 581 creates a layer highly resistant to abrasion, erosion, and physical impact, making it an effective solution to extend the life and performance of critical metal components in various industrial applications.

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