2.6.

Process Description

2.6.1 Quarrying

The production of cement begins with the quarrying of the needed raw materials for the cement
production. In quarrying, the needed raw materials, mainly limestone and clay, are blasted and broken
from the ground in order to be used in the cement production [1]. The obtained rocks form the process
are then transported and stored in the designated storage areas until it is to be utilized [2].

2.6.2 Mixing of Raw Materials

Calcium, silicon, iron, and aluminum are the major raw materials needed in the production of cement.
These materials are divided into two: calcareous and argillaceous materials. The calcium-containing
components such as limestone, calcite, and shale are considered calcareous while argillaceous materials
are raw materials with silicon, aluminum, and iron [3]. The ash obtained from the volcanic eruption
contains silicon, and is considered as a natural pozzolan as per ASTM C618-93, which is a standard
specification for “Fly Ash and Raw or Calcinated Natural Pozzolan for Use as a Mineral Admixture in
Portland Cement Concrete” [4].

2.6.2.1 Dry Process

In the dry process, the crushing of the calcareous and argillaceous materials takes place twice, first using
a gyratory crusher, then using a ball or tube mill after. The materials, now finely grinded, are screened,
and stored in a hopper. These will then be mixed in a known proportion, and then stored in silos.

2.6.2.2 Wet Process

Wet process is another process commonly used in the production of cement. Its capital cost is
comparatively less than dry process, but its fuel consumption is higher. The quality of the end materials
mixed using the wet process is also known to be superior to the dry process [5]. In the wet process, the
powdered raw materials are first stored in silos. The clay is then washed so that the attached organic
matters adhered will be removed. The mixing of the dry, powdered limestone and the wet clay will take
place in a grinding mill, forming a paste. This paste is known as a slurry. The slurry contains approximately
38 to 40 percent of water, and is now ready to be transferred to the next process.

2.6.3 Burning of Raw Materials

The mixed materials enter the pre-heater chamber consisting of a series of vertical cyclones. Afterwards,
the materials enter the inclined rotary kiln, which is usually fuelled by powdered coal. When the materials
are in the upper part of the kiln and heated to about 400 °C, any water or moisture content is evaporated.
This period is known as the drying zone. At the middle part, where the temperature is approximately 1000
°C, the calcination zone occurs. In this period, the decomposition of limestone takes place as follows:

CaCO3  CaO + CO2

Calcium aluminates and calcium silicates are produced in the clinkering zone, at about 1500 °C.

2CaO + SiO2  Ca2SiO4

3CaO + SiO2  Ca3SiO5

 3CaO + Al2O3  Ca3Al2O6

These aluminates and silicates then react to form clinkers.

4CaO + Al2O3 + Fe2O3  Ca4Al2Fe2O10

Since the production of clinkers occur in the kiln, the products are very hot. Air quenching is done in order
to lower the temperature of the clinker produced, making it ready to be stored in silos.

2.6.3 Grinding of Clinkers

The cooled clinkers are then grinded finely using ball or tube mill. Additives such as powdered gypsum is
also incorporated, which slows down the settling time of cement when it comes to contact with water [6].

2.6.4 Storage and Packaging

The cement is loaded and stored in silos, and is ready to be packaged according to the costumer’s demand
[7].

REFERENCES

[1] Eagle Cement. (n.d.). Retrieved from https://www.eaglecement.com.ph/

[2] Institute of Quarrying. (n.d.). What is Quarrying? Retrieved from https://www.quarrying.org/about-

quarrying/quarrying-explained

[3] Posted in Building Materials, B. T. G. (2017, September 18). Manufacture of Portland Cement-
Materials and Process. Retrieved from https://theconstructor.org/building/manufacture-of-
cement/13709/

[4] Siddique, R. (2012). Properties of concrete made with volcanic ash. Resources, Conservation and
Recycling, 66, 40–44. doi: 10.1016/j.resconrec.2012.06.010

[5] Discoveries, A. E., Engineering Discoveries, & *, N. (2019, November 6). Difference Between Wet And
Dry Process Of Cement. Retrieved from https://engineeringdiscoveries.com/2019/11/06/difference-
between-wet-and-dry-process-of-cement/

[6] Concrete Technology. (2018, September 27). Role of Gypsum in Cement and its Effects. Retrieved from
https://theconstructor.org/concrete/gypsum-cement-role-effects/25282/

[7] Leetham, D., & Gasdia-Cochrane, M. (2019, August 5). The Cement Manufacturing Process. Retrieved
from https://www.thermofisher.com/blog/mining/the-cement-manufacturing-process/