Professional Documents
Culture Documents
JK CEMENT LTD.
Submitted to
Mewar University, Chittorgarh
Towards the partial fulfillment of
The degree of
Bachelor of Technology In
Chemical Engineering
Session: - 2019-2020
Faculty of Engineering&Technology
Department of Chemical Engineering
Mewar University,
Chittorgarh (Raj)
July 2020
i
STATEMENT OF ORIGINALITY
In accordance with the requirements for the degree of Bachelor of Technology in
Mewar University, in Faculty of Chemical Engineering, I present this report Entitled
“CEMENT MANUFACTURING PROCESS” This report is completed under the
guidance of Mr.Ankit Mathur I declare that the work presented in the report is
my own work except as acknowledged in the text and foot notes, and that to my
knowledge this material has not been submitted either in whole or in part, for a degree
at this University or at any other such Institution.
Faculty of Engineering&Technology
Department of Chemical Engineering
Mewar University
Chittorgarh (Raj.)
July 2020
RECOMONDATION
This training entitled “CEMENT MANUFACTURING PROCESS” submitted by
Anupam Kumar Thakur to Chemical Department of Engineering of Mewar
University Chittorgarh is a satisfactory account of his training report and is
recommended for the award of marks sheet.
iii
July 2020
iv
CERTIFICATE
This is to certify that Anupam Kumar Thakur Roll No. 160100090001 has
submitted the summer industrial training report entitled “CEMENT
MANUFACTURING PROCESS” in partial fulfillment of the award of the degree
of BACHELOR OF TECHNOLOGY (CHEMICAL ENGINEERING). The
report is
up to my satisfaction and as per the formats prescribed for the writing of the report.
His report is approved for presentation.
DATE. DATE.
Faculty of Engineering&Technology
Mewar University,
Chittorgarh (Raj.)
July 2020
DECLARATION
In accordance with the requirements for the degree of B-tech. Program in Chemical
Engineering and technology, I present this report Entitled “CEMENT
MANUFACTURING PROCESS”. This report is completed under the guidance of
Ms. Shekhawat.
I declare that the work presented in the report is my own work expect as
acknowledged in the text and foot notes, for a degree at this university or at any other
such institution.
Mewar University
Chittorgarh (Raj.)
July 2019
ACKNOWLEDGEMENT
I am deeply indebted to our Chancellor, Dr. Ashok Kumar Gadiya, Mewar
University, and Chittorgarh for providing us the infrastructural facilities to complete
our project work
I also express my thanks to my Head of Department Ms. Shalinee Gupta and other
faculty member for providing me an opportunity to present the training report on
“CEMENT MANUFACTURING PROCESS”.
Enrollment MUR1600063
Mewar University
Chittorgarh (Raj.)
July 2019
ABSTRACT
This study evaluates cement manufacture, Cement any substance which binds together
other materials by a combination of chemical processes known collectively as setting.
Cements are dry powders and should not be confused with concretes or mortars, but
they are an important constituent of both of these materials, in which they act as the
'glue' that gives strength to structures, Cement is an extremely important construction
material, Cements used in construction can be characterized as being either hydraulic
or non-hydraulic.
The first step in the manufacture of cement is to combine a variety of raw ingredients
so that the resulting cement will have the desired chemical composition. These
ingredients are ground into small particles to make them more reactive, blended
together, and then the resulting raw mix is fed into a cement kiln which heats them to
extremely high temperatures.
The basic mixture of cement industry consists of Chalk Lime stone Clay Calcium
carbonate Silicon oxide Aluminum oxide and iron (II) oxide.
Portland cement is by far the most common type of cement in general use around the
world. This cement is made by heating limestone (calcium carbonate) with other
materials (such as clay) Raw Materials processing included: Setting and curing and
cement manufacturing process , Process Discretion: Wet process, Semi-dry process,
Dry process and Finish process.
The environmental impact of the cement production and its variations between
different cement plants, using Life Cycle Impact assessment. For that purpose, details
of the cement production processes are investigated in order to show the respective
part of raw materials preparation and clinker production using
TABLE OF CONTANT
STATEMENT OF ORIGINALITY...............................................................................ii
RECOMONDATION...................................................................................................iii
CERTIFICATE.............................................................................................................iv
DECLARATION...........................................................................................................v
ACKNOWLEDGEMENT............................................................................................vi
ABSTRACT.................................................................................................................vii
CHAPTER 1:.................................................................................................................1
CHAPTER 2...................................................................................................................2
CHAPTER 3………………………………………………………………………… 8
PROCESS DESCRIPTION.....................................................................................10
CHAPTER 5.................................................................................................................13
CHAPTER 6.................................................................................................................15
PLANT LAYOUT...................................................................................................15
6.5 Maintenance...................................................................................................18
6.10 Warehouse....................................................................................................20
CONCLUSION........................................................................................................22
REFERENCE...........................................................................................................23
LIST OF FIGURES
Figure 1.Location map of chalk depodite in jorden..............................................................................................4
Figure 2.location map of kaoline deposite in jorden.............................................................................................6
Figure 3. Cement raw material processing...........................................................................................................8
Figure 4The wet Process of Cement...................................................................................................................10
Figure 5.Cement Roasting flow sheet.................................................................................................................11
Figure 6. Cement production flow sheet by the dry process...............................................................................12
xi
v
LIST OF TABLE
Table 1: Raw ingredients used to provide each of the main cement elements..............2
xv
CHAPTER 1:
Non-hydraulic cement will not set in wet conditions or underwater; rather, it sets as it
dries and reacts with carbon dioxide in the air. It can be attacked by some aggressive
chemicals after setting (Blezard, 2004).
Hydraulic cements (e.g., Portland cement) set and become adhesive due to a chemical
reaction between the dry ingredients and water. The chemical reaction results in
mineral hydrates that are not very water-soluble and so are quite durable in water and
safe from chemical attack.
1
CHAPTER 2
RAW MATERIALS FOR CEMENT MANUFACTURE
Location: (AbuQudera,1998)
1. Al – Umary (Abar Al Hazim) / Dahikiya Area.
This area is located about 45km south east of Al- Azraq.
2. Wadi Al-Ghadaf Area.
This area is located about 35km south of Al-Azraq.
3. Qaser Al-Harrana Area.
This area is located about 50km east of Amman.
4. Wadi Al- Dha'abi Area
This area is located about 60km east of Amman.
Chemical and Physical Properties
The Chemical and Physical Properties listed in table (1)
Area CaO% Brightness
Table 2:-Chemical and physical properties of the studied areas. (H.F.W. Taylor 1997)
However, these rocks that were once regularly bedded have been metamorphosed into
irregularly shaped bodies that are more difficult and costly to mine
(Technostone,1984).
• In industries of white cement, iron and steel, glass, paper, sugar-refining, water
purification, sewage and waste treatment, and gas desulphurization.
• As a filler material in paints, rubber, paper, ceramics, floor tiles, tooth paste, medicine.
• Cement industry.
2.6 Location:
Location map of Pure Limestone deposits in Jordan show in figure 2.
Figure 2.location map of kaoline deposite in jorden
Cement industry:- In white cement industry pure limestone should have CaO >52%.
The insistent need for pure limestone deposit are due to the increasing prices of
cement and the development of construction industries, so the investment opportunity
will be increased in this industry (Teimeh and Hiyari,1978).
Clay Defination and Uses:-
Kaolin is white, soft, plastic clay mainly composed of the fine grained platy mineral
kaolinite; a white hydrous aluminum silicate, Al2Si2O5(OH)4, containing 23.5%
alumina, 46.5% silica It is used in the manufacturing of white-ware ceramics and in
filling and coating of paper. It is also used as filler in paints, rubber, plastics and many
OTHER productions (Ajlouni and Gharaybeh, 1986).
2.7 Mining
The mining and processing of kaolin begins with exploration. Geologists study the
earth’s surface, research literature and other data to identify land with potential kaolin
deposits.
2.8 Location
Location of Kaoline deposits in Jordan shown in Figure (3)
• Batn el-Ghoul area
• Mudawwara area
CHAPTER 3
RAW MATERIALS PROCESSING
Cement starts to set when mixed with water which causes a series of hydration
chemical reactions. The constituents slowly hydrate and the mineral hydrates solidify;
the interlocking of the hydrates gives cement its strength. Contrary to popular
perceptions, hydraulic cements do not set by drying out; proper curing requires
maintaining the appropriate moisture content during the curing process.
PROCESS DESCRIPTION
Wet Process
This process is make by cylindrical type kiln the length for it = 40times of the shell’s
inner diameter it is using to help dry the slurry see figure 4.
• long kiln, the short kiln with boiler, the SP kiln and the NSP
• the long kiln is use in the Near and Middle East (it used because rain falls less
It can be seen that the wet process is rapidly replaced by the dry process the cause it
for energy conservation (Mahadevan, et.al 2008).
The laying out of a plant is still an art rather than a science. It involves the placing
Maintenance costs
d) Construction costs
The first thing that should be done is to determine the direction of the prevailing wind
this can be done by consulting Weather Bureau records. Wind direction will
determine the general location of many things. All equipment that may spill
Flammable materials should be located on the downwind side. Then if a spill occurs
the prevailing winds are not apart to carry any vapors over the plant, where they
could be ignited by an open flame, spark, or a hot surface.
Other facilities that are generally placed upwind of operating units are plant officers,
Mechanical shops and central laboratories. All of these involve a number of people
who need to be protected also, shops and laboratories frequently that are used
primarily for quality control are sometimes located in the production area.
6.5 Elevation
If there is no special reason for elevating equipment it should be placed on the ground
Level. The superstructure to support on elevated piece of equipment is expensive. It
Can also be a hazard should there be an earthquake, fire or explosion. Then it might
Collapse and destroy the equipment it is supporting as well as that nearby. Some
Pieces of equipment will be elevated to simplify the plant operations. An example of
this is the gravity feed of reactors from elevated tanks. This eliminates the need for
some materials-handling equipment. This especially true for solids and slurry feed.
6.6 Maintenance
Maintenance costs are very large in the chemical industry. In some cases, the cost of
Maintenance exceeds the company’s profit. The engineer must design to reduce these
Costs. The easiest way to reduce maintenance costs is to allow lots of extra space and
to construct everything at ground level for easy access. However, this may increase
Construction and operating expenses and the ease of operability. The engineer should
determine what type of equipment need to be serviced by mobile cranes. These Pieces
of equipment will need to be located on the perimeters of the plant or on a Roadway.
The roadways along which the crane will travel must have adequate Overhead and
horizontal clearness. Adequate space must be left around all equipment So that it can
be easily serviced and operated. For instance, a floating-head heat Exchanger must
have enough space so that the tube bundle can be removed from the Shell and taken
elsewhere for repairs. For tanks containing coils and agitators, enough Headroom
must be provided so that these can be removed.
6.10 Building
Building with the layout of the plant is the direction as to what types of buildings are
to be construction, and the size of teach. When laying out buildings, a standard size
Bay (area in which there are no structural supports) is 20ft x 20ft (6m x 6m). Under
Normal conditions a 20-ft (6m) span does not need any centre supports. The extension
of bay in one direction can be done inexpensively. This only increases the amount of
Steel in the long girders, and requires stronger supports. Lavatories, change rooms,
Lunch rooms and medical facilities is dictated by OSHA. It depends on the number of
Workers employed. Research laboratories and office buildings usually not included in
the preliminary cost estimate. However, if they are contemplated, their location
should be indicated on the pilot plan.
6.12 Warehouse
The engineer must decide whether warehouses should be at ground level or at dock
Level. The latter facilitates loading trains and trucks, but costs 15-20 percent more
Than one placed on the ground. It is usually difficult to justify the added expense of a
Dock-high warehouse.
6.13 Utilities
The work utilities is now generally used for the ancillary service needed in operation.
These services will normally be supplied form a central site facility. The utilities
required include:
1. Water
2. Electricity
3. Steam requirement for process heating
4. Storage & movement of raw materials/products
5. Fire protection
6. Maintenance facilities
7. Plant sewer system and waste disposal
6.14 Water
Water is vital for any plant following types of water used for the plant. Natural and
forced draft cooling towers are generally used to provide the cooling water required
on site. Some treatment is necessary for once through system to prevent scale of small
quantity of surface active agents is added to the water. So, it increases the solubility of
the salt in the water by preventing. Prevented by adding corrosion inhibitors such as,
chromate or surfaces acidic phosphates. Dematerialized water from which all the
minerals have been removed by ion exchange, is used when pure water is needed for
process use and as boiler feed water. Requirement for fire water are intermittent and
assumed that other services will be shunt if necessary, to provide sufficient water
capacity. The fire water lop system should be so designed that breakdown at a specific
hydrant does into put the entire system out of operation. Provision should be made for
emergency connection of the fire water system into the large reservoir of water. Sea
water and brackish water is often used if plant is located at the coastal area.
6.17 Electricity
The power required for motor drivers, righting and general use, may be generated
onsite, but usual it is purchased form the local supply company. In our plant main air
blower is the high power consuming equipment. As in our plant large quantity of
excess is available, we produce power in plant itself by using steam turbine. Actually
electricity is one of the by-products of our company. The voltage at which the supply
is taken will depend on the demand. In this case three phases 415V is used for general
industrial purpose and 210V single phase for lighting and other low requirements.
CONCLUSION
• The mining sector enters significantly in the cement industry, this sector is considered
the most important in terms of extraction, mining, and processing of raw materials.
• 99% approximately from the raw materials used are considered mining material.
• Mining methods used in the extraction equipment for a cement raw material
considered ways rather easy and inexpensive and most commonly used material
extracted from quarries.
• Considered one of Lime stone and clay the most important raw material for the
manufacture of cement different kinds.
• Mining and processing of raw materials include Setting curing and clinker.
• Cement process include wet, dry, wet dry process and finish process.
• Roasting cement Considered one of the most important processing steps where they
are roasting constituent components through the roasting oven.
• After use cement (concrete) greatly affect on the environment in general, Bust greatly
affect the soil and groundwater.
• Environmental and health effects of pollutants resulting from the cement industry
include environmental impact caused by emissions into the air liquid waste disposal
of solid waste.
REFERENCE
1. Abu Lihie, O. (1988) Geological map of Dubaidib area.
2. Ajlouni, and Gharaybeh, M. (1986) Report clay Occurrences of Jable Mulayh Area,
Tafila.
3. Berkes, Howard (2011). EPA Regulations Give Kilns Permission To Pollute : NPR.
4. Chandak, Shobhit. (2011) Report on cement industry in India, Scribed pp 17.
5. Fadda, E. (1996) The Geology of Wadi El Ghadaf Area Map Sheet 3353-II. Bull. PP
26-38.
6. Fadda, E. (1998) The Geology of Wadi Ed-Dabi Area Map Sheet No. 3353-III.
7. Gamble, William. (2005) Cement, Mortar, and Concrete. In Baumeister; Avallone,
McGraw Hill. p177.
8. H.F.W. Taylor. (1997) Cement Chemistry, Thomas Telford, London.
9. Hahn, Thomas F, and Emory Leland Kemp (1994) Cement mills along the Potomac
River. Morgantown, West Virginia University Press.
10. Hunjul, N. (2001) The Geology of Qaser Al-Harana Map Sheet No. 3253-II.
11. Mahasenan, Natesan, Steve Smith, Kenneth Humphreys and Y. Kaya (2003). The
Cement Industry and
Global Climate Change: Current and Potential Future Cement Industry.
12. Mohammad, Abu Qudera. (1998) Studied the occurrences of chalk in the Azraq basin
areas PP 12-20. 13. Ridi, Francesca. (April 2010) Hydration of Cement: still a lot to
be understood La Chemical
Industrial Societal, Chimica Italiana.
14. Robert, G, Blezard. (2004) The History of Calcareous Cements in chemistry of
cement and concrete,
Elsevier Butterworth-Heinemann.
15. S.H. Kosmatka, B. Kerkhoff, and W.C. Panarese. (2002) Design and Control of
Concrete Mixtures: Portland cement Association, Skokie.
16. Technostone, S.P.A. (1984) Report on White Limestone, Ajlun Area: Study for the
Exploitation of Deposits of Lithic Materials in Jordan P 39.
17. Teimeh, M. and Hiyari, M. (1978) Report on The Lime stone Occurrences in
Southern Jordan, p22.