BEBRE BERHAN UNIVERSITY

INSTITUTE OF TECHNOLOGY
COLLEGE OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING

PROCESS INDUSTRY II INDIVIDUAL

ASSIGNMENT
NAME MARKOS WELDEYOHANES
ID NO 0632/10
SECTION A

SUBMISSION DATE 28/04/2013

SUBMITTED TO MR ABREHA
Tables of content
Title page

Abstract ………………………………………………………………... 3

Introduction ………………………………………………………… …4

History of cement …………………………………………………….... 5

Raw material ………………………………………………………...... 6

Cement manufacturing process ……………………………………….. 6

Ingredients for cement production ……………………………… …. 7

Equipment used in cement production ………………………………... 8

Applications of cement ………………………………………………… 9

Major unit operations ……………………………………………………10

Diagram process for cement production ……………………………….. 11

Conclusion ………………………………………………………………12

References ………………………………………………………………. 13

2
Abstract
Cement production is an energy-intensive process. The cost of energy constitutes more than 60%
of the cost of the cement; hence cement plants have to consider minimizing the cost of energy
when planning production. However, there are several challenging issues regarding the
production plan. First, there are some operational constraints for the production process itself,
such as keeping a proper level of inventory. Second, electricity prices are not fixed; they change
on an hourly basis. Hence the cost of the electricity consumed may change substantially
depending on the time of production. In this study, we developed a mixed integer programming
model to minimize the cost of production (including energy, labor, and storage) by shifting
working times to hours with low energy costs and trying to maintain activities during hours with
high energy costs

Calculate the unit price for c-25 concrete per meter cubic of weir

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Introduction
Cement is a binder substance used for construction that sets hardens and adheres to other
materials to bind them together. Cement is seldom used on its own, but rather to bind sand and
gravel (aggregate) together. Cement mixed with fine aggregate produces mortar for masonry, or
with sand and gravel, produces concrete. Concrete is the most widely used material in existence
and is only behind water as the planet's most-consumed resource.
Cement is a fine mineral powder manufactured with very precise processes. Mixed with water,
this powder transforms in to a paste that binds and hardness when submerged in water. Because
the composition and fineness of the powder may vary, cement has different properties depending
up on its makeup.
Cement is a basic material for all types of construction including housing, road, hospitals, dams,
schools and ports, as well as for decorative applications for patios, floors, drive ways pool decks
and items like tables, sculpture.
The cement production process, for example, starts with mining of limestone, which is then
crushed and ground to powder. It is then preheated to save energy before being transferred to the
kiln, the heart of the process. The kiln is then heated to a high temperature of up to 1480 degrees
to convert the material to a molten form called clinker
History of cement
Cement has been in use by humans throughout history; variations of the material were used by
the ancient Greeks, Romans and Egyptians, with the earliest archaeological discovery dated to
12-10,000BC in modern-day Turkey. The Romans used a mixture of lime (calcium oxide) and
crushed volcanic ash – to create hydraulic cements, which could set under water. Other cements
used crushed brick, tiles and ceramic pottery as aggregates. Famous historical buildings made
from concrete, still standing today, are the Coliseums and Pantheon in Rome, and the Hagias
Sophia in Istanbul.
The middle Ages were a quiet time in the history of cement; any discoveries made during this era
remain unknown, although masons are known to have used hydraulic cements to build structures
such as fortresses and canals.
The Industrial Revolution in Europe in the late 18th century saw a flurry of new developments in
cement and concrete, with important contributions made by John Smeaton, who discovered that
the hydraulic city of lime was directly related to the limestone’s clay content, James Parker,
Louis
The precursor to modern-day cement was created in 1824 by Joseph Asp din, a British bricklayer
and builder, who experimented with heating limestone and clay until the mixture calcite,
grinding it and then mixing it with water. Asp din named this Portland cement, after the
famously strong building stone from the Isle of Portland in Dorset, UK. His son, William Asp
din, made the first cement containing alite (an impure form of tri calcium silicate).
In 1845, Isaac Johnson fired chalk and clay at much higher temperatures than the Asp dins, at
around 1400-1500oC, which led to the mixture clinkering, and produced what is essentially
modern-day cement.
Since the 1900s, rotary kilns have replaced the original vertical shaft kilns, as they use
radioactive heat transfer, more efficient at higher temperatures, achieving a uniform clinkering
temperature and produces stronger cement. Gypsum is now also added to the resulting mixture to
control setting and ball mills are used to grind clinker.
Other developments in the last century include calcium aluminates cements for better sulphate
resistance, the blending of Rosendale (a natural hydraulic cement produced in New York) and
Portland cements to make a durable and fast-setting cement in the USA, and the increased usage
of cementations’ materials to store nuclear waste.
New technologies and innovations are constantly emerging to improve the sustainability,
strength and applications of cement and concrete. Some advanced products incorporate fibres
and special aggregates to create roof tiles and countertops, for example, whilst offsite
manufacture is also gaining prominence with the rise of digitalisation and AI, which could
reduce waste and improve efficiency and on-site working conditions. Cements are also being
developed which can absorb CO2 over their lifetimes, reducing the carbon footprint of the
building material.

Raw material for cement production

Raw materials used for manufacturing of cement are found naturally in the earth’s crust. It is
made primarily from calcareous and argillaceous materials and gypsum. Calcareous materials
contain lime

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stone or chalk while argillaceous materials comprise an oxide of silica-alumina and iron. Both
are found as clay or shale. Let’s understand the various types of cement raw materials used in the
cement manufacturing process.

The most common raw rock types used in cement production are:

Limestone (supplies the bulk of the lime)

Clay, marl or shale (supplies the bulk of the silica, alumina and ferric oxide)

Other supplementary materials such as sand, fly ash/ pulverized fuel ash (PFA), or ironstone to
achieve the desired bulk composition

Cement Manufacturing Process

The cement manufacturing process involves several key steps, including preparing the raw
materials, grinding the materials together, heating the newly formed clinker in a kiln, and
finishing the cement with fine grinding. Some of the main ingredients used to make cement
include limestone, clay, shale, iron, and sand. Different manufacturing techniques will use either
wet or dry grinding, but each cement manufacturing process will culminate in heating and fine
grinding to finish the product.

Preparing the raw materials is often the first step in the cement manufacturing process, and
involves mining the limestone or obtaining safe industrial waste products. Drilling, blasting, and
crushing machinery convert mined limestone to fragments about 0.39 inches (about 1 cm) in
diameter, after which it is stored until needed. Crushing practices will sometimes be used on the
other materials as well, especially if they contain large or irregularly sized fragments.

Grinding is the next step in the cement manufacturing process, and it can occur in either wet or
dry forms. Wet grinding involves combining all of the materials in a mill with water and grinding
it into slurry. In contrast, dry grinding processes combine and grind the materials without water,
creating a substance known as kiln feed. Both types of grinding will yield material that contains
an average particle size of about 75 micrometers. After each process, the materials are further
mixed for proper homogeneity and placed in storing units.

Heating occurs next, and it takes place in a rotary kiln that is fired at high temperatures. The kiln
heats the clinker, the name for the dried material formed after the grinding process, until it
reaches upwards of 2732°F (about 1500°C). Afterward, the material is sent to a clinker cooler
where the temperature lowers to a reasonable level, at which point the material can be stored
once again.
The cement manufacturing process is completed when the cooled clinker is ground once again in
a rotating finishing mill. A combination of gypsum and limestone will usually be added in small
amounts to the heated cement during this last grinding step, and coloring agents can also be
added here. The fineness of the finished particles will vary according to individual preferences,
and the cement can reach a level of fineness where it will travel through liquid sieves.
Completion of the finishing step means that the cement is ready to be packaged and distributed
to builders and consumers.

Ingredients for cement production

The general percentage of these ingredients in cement is given below the table.

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 Percentage in
 Ingredient
cement

Lime 60-65

Silica 17-25

Alumina 3-8

Magnesia 1-3

Iron oxide 0.5-6

Calcium Sulfate 0.1-0.5

Sulfur Trioxide 1-3

Alkaline 0-1

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Equipment in cement production
Cement crusher

As we all know, the first step of the cement production line is raw material preparation. Cement
crusher is the main equipment of this step. The raw materials are fed into cement crusher by
vibratory feeder; the breaking material is transported by the belt conveyor to the impact crusher
for further crusher.

There are various types of cement crusher on the market, including jaw crusher, cone crusher ,
hammer crusher , impact crusher, and etc. AGICO Cement can provide all types of cement
crusher. Our cement crusher can fully crush the raw material, reduce feed size into the mill, and
increase the reaction of raw material in the following cement manufacturing process, reduce the
energy consumption of the whole cement production line.

Cement mill
Cement mill is another necessary cement equipment of the cement plant. After raw material
crushing, cement mill plays vital role in the further cement manufacturing process. Cement ball
mill, vertical cement mill and cement roller press are common types of cement grinding plant.

Cement mill has two functions of the cement production line. Firstly, cement mill is used to
grind the crushed material into fine size before clinker production. A cement mill is also applied
for grinding clinker into finished cement. The cement clinker grinding is the last step of the
cement manufacturing process, in this step, cement mill grinds cement clinker, gelatinizing agent
and other materials into the required size, which can meet the requirement of cement.

AGICO Cement adopts the advanced internal selection and special compartment device, add the
activation device. The grinding tail has a special discharge grate plate, which greatly reduces the
size of the grinding media of the grinding bin, greatly improves the grinding efficiency, and
achieves the goal of high output and low energy.

Cement kiln

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Cement kiln is used to make cement clinker, and it is the core equipment of cement production
line; usually, apply for dry method cement production. There are two main kinds of cement kiln
to manufacture cement clinker. One is the cement rotary kiln and it is horizontal and can rotate.
Rotary kiln is widely applied to the cement clinker production. Another one is vertical and fixed
kiln, so it is called as a vertical kiln

Clinker cooler and dryer

Clinker cooler and dryer are two necessary parts of cement clinker production. The dryer
produced by AGICO can apply for various raw materials and easy to adjust. During the
operation, the dryer supplies heat stably, ensures the drying quality and cement quality.
The cement cooler is also used for clinker production. Using blower blowing cold air, quench the
cement clinker that laid on the grate plate, decrease the temperature of clinker from 1200℃ to
100℃ and below, the cooling exhaust gas enters into the kiln as secondary air.

In fact, every cement plant requires different cement equipment. Except for the cement
equipment we mentioned above, there are many other cement making machines applied for the
cement plant. In the real application, as a professional EPC cement plant project provider,
AGICO Cement always provides a solution according to clients ’ needs, such as mini cement
plant VSK cement plant We also provide single cement equipment with high quality and
competitive price, welcome to contact!

Cement crusher is the equipment adopted in cement production lines and stone crushing plants
for raw material crushing. Manufactures cone crusher, jaw crusher, impact crusher e.t.c

Major unit operations

Quarrying

Crushing

Proportionating /Pre-homogenization

Raw mill Grinding

Homogenization/Silo

Raw meal preheating

Kiln operation

Clinker cooling/storage

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Cement mill and gypsum addition/ storage

Process descriptions

1. Quarrying

• Rock blasted from the quarry is transported to the primary crusher where large "run of mine"
rocks are broken into pieces of approximately 100mm.

• Generally the other raw materials do not require crushing.

• Cement factory raw material deposits are extracted using open pit quarries in the vast majority
of cases. There are just a few examples around the world where the raw materials are extracted
from underground mines. This significantly increases the costs of raw material extraction and
cement manufacture.

2. Crushing • Cement plant raw materials blasted in the quarry requires size reduction for further
processing, size reduction is performed in crushers and grinding mills. Crushing is communition
in the coarse range. • Primary crushing involves limestone rock fed through large capacity
crushers. This reduces the rock to a maximum size of approximately 150 mm. Secondary
crushing further reduces this to 75mm or under. Residue material is stacked and reclaimed with a
bridge re claimer in a cross section so that the homogeneous limestone is fed further in the
process.

3. Proportionating/prehomogenization/. Raw Material Storage & Blending

• The raw materials are then proportioned to the correct chemical balance and milled together to
a fine powder, raw meal, to ensure high quality of cement, the chemistry of the raw materials and
raw meal is very carefully controlled.

4. Drying for dry process the raw material has to be dried before milling. • Kiln exhaust gases are
used to dry the raw materials. In some gases with wet materials, additional heat sources are
required for drying.

5. Grinding • grinding refers to comminuting in the fine range. The grinding media (steel ball)
and the feed material to be ground are brought together in a rotating tubular or drum-shaped
compartment. The media and material rises to an optimum height, necessary for grinding
operation, and come tumbling down (cascading and/or contracting).

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The actual height to which they are lifted depends on a number of factors: the speed of mill, the
type of lining, the filing ratio (mill loading percentage), and the properties of mill feed material
(like moisture content.

6. Kiln feed Homogenization

• Materials are homogenized to ensure consistency of product quality. • The kiln feed is routed to
a homogenization silo, where it is mixed by blowing compressed air through pads in the base of
the silo. The blending silo is maintained full and some of the blended raw mix continuously
cascades to a further blending silo where it is further mixed by air blown through pads in the
base of the silo. The twice blended raw mix is continuously extracted to the kiln feed storage
silos. • Modern dry process cement factories have large combined homogenization and storage
kiln feed silos. Raw mill product is distributed in layers in the silo, and extracted in funnels
rotating around the radius of the silo. Some of these silos have an internal, pressure relieved
mixing chamber.

7. Pre heater/ Cyclones/

A pre-heater is a series of vertical cyclones. Where the raw meal is passed down through these
cyclones it comes into contact with the swirling hot kiln exhaust gases moving in the opposite
direction and as a result heat is transferred from the gas to material.

• This pre-heats the material before it enters the kiln so that the necessary chemical reactions will
occur more quickly and efficiently. By retaining energy from the exhaust gases, energy is saved.

8. Pre - Calcinations

The calcite is a combustion chamber at the bottom of the pre-heater above the kiln backend. Up
to 65% of the total energy needs of the kiln system can be supplied to the calciner.

• Calciners allow for shorter rotary kilns and for the use of lower grade alternative fuels.
Calcination is the decomposition of CaCO3 to CaO and CO2.CaCO3 CaO + CO2.

• These process emissions comprise 60% of the total emission from a cement kiln. The
combustion of the fuel generates the rest.

Kiln operation (pyro-processing)

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Raw meal, more accurately termed "hot meal" at this stage then enters the rotary kiln. The kiln is
the world's largest piece of industrial equipment. As the kiln rotates at about 3-5 revolutions per
minute, the material slides and tumbles down through progressively hotter zones towards the
flame. Fuel is fired directly into the rotary kiln and the heat is absorbed into the material being
processed.

Applications of cement
The applications of cement over various fields of construction have made it a very important
civil engineering material. Some of the numerous functions of cement are given below. It is used
in mortar for plastering, masonry work, pointing, etc. It is used for making joints for drains and
pipes.
Cements may be used alone (i.e., “neat,” as grouting materials), but the normal use is in mortar
and concrete in which the cement is mixed with inert material known as aggregate. Mortar is
cement mixed with sand or crushed stone that must be less than approximately 5 mm (0.2 inch)
in size. Concrete is a mixture of cement, sand or other fine aggregate, and a coarse aggregate
that for most purposes is up to 19 to 25 mm (0.75 to 1 inch) in size, but the coarse aggregate
may also be as large as 150 mm (6 inches) when concrete is placed in large masses such as
dams. Mortars are used for binding bricks, blocks, and stone in walls or as surface renderings.
Concrete is used for a large variety of constructional purposes. Mixtures of soil and portland
cement are used as a base for roads. Portland cement also is used in the manufacture of
bricks, tiles, shingles, pipes, beams, railroad ties, and various extruded products. The products
are prefabricated in factories and supplied ready for installation.

Cement is primarily used to produce concrete the world’s most versatile and durable
construction material. Some other applications for cement, however, are now growing in
importance.

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Diagram process for cement production

14
15
Conclusion
Cement is a fine mineral powder manufactured with very precise processes. Mixed with water, this
powder transforms in to a paste that binds and hardness when submerged in water. Because the
composition and fineness of the powder may vary, cement has different properties depending up on its
makeup.
Cement is a basic material for all types of construction including housing, road, hospitals, dams, schools
and ports, as well as for decorative applications for patios, floors, drive ways pool decks and items like
tables, sculpture.
Cement has been in use by humans throughout history; variations of the material were used by the ancient
Greeks, Romans and Egyptians, with the earliest archaeological discovery dated to 12-10,000BC in
modern-day Turkey. The Romans used a mixture of lime (calcium oxide) and crushed volcanic ash – to
create hydraulic cements, which could set under water. Other cements used crushed brick, tiles and
ceramic pottery as aggregates. Famous historical buildings made from concrete, still standing today, are
the Coliseums and Pantheon in Rome, and the Hagias Sophia in Istanbul.
The most common raw rock types used in cement production are:
Limestone (supplies the bulk of the lime)
Clay, marl or shale (supplies the bulk of the silica, alumina and ferric oxide)
Other supplementary materials such as sand, fly ash/ pulverized fuel ash (PFA), or ironstone to achieve
the desired bulk composition
The cement manufacturing process involves several key steps, including preparing the raw materials,
grinding the materials together, heating the newly formed clinker in a kiln, and finishing the cement with
fine grinding. Some of the main ingredients used to make cement include limestone, clay, shale, iron, and
sand. Different manufacturing techniques will use either wet or dry grinding, but each cement
manufacturing process will culminate in heating and fine grinding to finish the product.
Major unit operations for cement manufacturing process are
Quarrying , Crushing, Proportionating /Pre-homogenization , Raw mill Grinding, Homogenization/Silo,
Raw meal preheating , Kiln operation , Clinker cooling/storage , Cement mill and gypsum addition/
storage.

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Reference
van Oss, Hendrik G.; Padovani, Amy C. (2002). "Cement manufacture and the environment, Part I:
Chemistry and Technology".Journal of Industrial Ecology.
Neville, A.M. (1996). Properties of concrete. Fourth and final edition standards. Pearson, Prentice Hall
Power points of mr Daniel