Cement

Iran is the eighth largest cement producer in the world and the second in the Middle East after Turkey. In 2009, the total cement production of Iran was over 65 million tons and was exported to more than 40 countries worldwide. In 2010, the number of operational cement plants was 57. The production of these plants accounted for 1.8% of the total global cement production, and domestic cement consumption was 1.6%.

Cement is a binding material that has the ability to adhere particles together and form a coherent body from the constituent particles. It is made by combining limestone, clay, silica, and mineral oxides at temperatures of 1400 to 1500 degrees Celsius. The resulting product after heating is called clinker, and by grinding it together with an appropriate amount of gypsum, different types of cement are obtained. Additionally, by adding pozzolan to clinker and gypsum, pozzolanic cement is produced. Clinker particle size ranges from 5 to 20 millimeters, and its color is dark green.

Cement kilns are used in the production stage of Portland cement and other hydraulic cements, which have an annual production of over one billion tons, and the kiln is the heart of this production process. A rotary kiln consists of a tube made from steel plates lined with refractory bricks inside. The tube has a slope of 1 to 4 degrees and slowly rotates around its axis at about 30 to 250 revolutions per hour. Rotary kilns in the cement industry are among the largest, heaviest, and hottest reactors invented and used by humans. Since its operation or shutdown directly affects the profitability of the plant, it is referred to as the center of gravity or the heart of cement factories. The metal part of this equipment weighs over 500 tons, and the refractory material inside exceeds 1500 tons.

Razi Metallurgy Research Center has collaborated with the cement industry in various areas. Optimizing the design of wear-resistant alloys and developing the technology and technical knowledge for manufacturing wear parts such as grinding balls, crusher hammers, liners, and grates to increase component life are among the projects Razi Center has provided to this industry. Developing production technology, supervision, and quality control of heavy and ultra-heavy parts such as main kiln rings, gears, and rollers are also part of the collaboration. In addition to providing metallurgical services and non-destructive research tests, Razi Center’s laboratories have significantly assisted this industry by investigating causes of failure, component breakage, and offering solutions to prevent them.