NAME :SARDAR

SHAHADAT HUSSAIN
ROLL :20CH044
DEP:CHEMICAL
ENGINEERING
TEACHER:MAM
AYISHA KAUSAR
Q NO 1: Cement manufacture process. DRY/WET.

ELaborate detail process and explain the equipment used in the cement industry?

Manufacturing of Cement
In the manufacturing of cement, the following three important and distinct operations occur:
1. Mixing of Raw materials.
2. Burning

3. Grinding
The process, by which cement is manufactured, depends upon the technique adopted in the
mixing of raw materials. Therefore, on the basis of mixing the raw materials, the processes
may be classified as:-

1. WET PROCESS

2. DRY PROCESS
Out of this wet process is generally used.

The Raw material, which is used for manufacturing of cement, contains the following
materials:

 CALCAREOUS (i.e. chalk consists of limestone.)

 ARGILLACEOUS (i.e. clay consists of silicates of alumina.)
 
Here is the manufacturing of cement by wet process

WET PROCESS
When the raw materials are soft, then the wet process is preferable to be used. The cement is
manufactured by the following procedure:-

Mixing of Raw Materials:

1. In the wet process, there are two raw materials e.  calcareous and argillaceous.
Initially, Calcareous materials are crushed using crushers and argillaceous material is
washed With water in the container.
2. After crossing the line stones are stored in silos similarly after washing the clay is
stored in basins.

3. The crushed materials from different silos and basins are drawn in correct proportions
in a channel called wet grinding mills. Both the materials are intimately mixed in
the presence of water and to form a fine thin paste known as slurry
4. Slurry is then stored in another silo may be called as slurry silo where it is constantly
stirred. The composition of raw materials is checked again and, if required, corrected
by adding clay or chalk materials as desires.

Burning: In this operation, the slurry is directly fed into a long inclined steel cylinder called a
Rotary kiln. In this kiln there are 3 different zones shown in fig. below

Cement Manufacturing Process Flow Chart

(i) Drying Zones: In the wet process, the drying zone is comparatively larger than the dry
process. It is because the raw material in slurry form is directly fed into the kiln which has
more amount of water. As shown in the figure it is the upper portion of the kiln. In this zone,
water is evaporated at a temperature of 100-400°C.

(ii) Formations of modules: As the slurry gradually descends in the kiln, the carbon dioxide
from the slurry evaporates and small lumps formed which may be called modules.

(iii) Burning Zone:- The modules enter this zone where temperatures are kept about 1400-
1500° C. The modules are converted into dark greenish balls and the product obtained in the
kiln, known as clinker, is of varying size 5 to 20 mm. The clinkers are very hot when coming
out of this zone.

(iv) Cooling of Clinkers:- As shown in the figure another rotary kiln is provided in an opposite
direction which is also inclined. It is used to cool down the clinkers up to about 90°C.

Grinding: The cooled clinkers are finely ground in ball mills or tube mills.
Also, the gypsum is added during grinding about 2-4%. The gypsum acts as a retarder and so
allows the cement to mix with sand or aggregate and to be placed in position. i.e. it increases
the initial setting time of cement.
Storage and Packing: As cement comes out from grinding mills, it is collected in a hopper
and taken in bucket elevator for storage in silos.
The cement from silos is packed by machines in bags. Each bag of cement contains 50 kg or
0.035 m3 of cement.
Now let’s know the manufacturing of cement by the dry process

DRY PROCESS
When the available raw materials are quite hard, then this process is used. The cement by this
process can be prepared by using the following operations:-

 Mixing of raw materials

 Burning and Grinding

Mixing of Raw Materials: The raw materials i.e. argillaceous and calcareous materials
undergo the following stages:-
 Crushing: The raw materials, first of all, are broken into crushers into small fragments
that vary in size.
 Drying: The crushed materials are dried by heating at a sufficiently high temperature.
It may be done in drying kilns.
 Reduction of size: The drying materials are then ground by using ball mills and tube
mills to reduce the size of materials to find powder.
 Mixing in correct proportion: The finely dried materials are mixed in exact
proportions. The mixing may be done either mechanically or by pneumatic
methods(eg. pumped under pressure).

Burning and Grinding: These operations are the same as for the wet process. Except for the
mixing of raw materials. In the dry process, the raw materials mixed, fined, and then fed into
kiln whereas, in the wet process, the raw materials are crushed separately and then directly
mixed in correct proportion in the presence of water to make a fine thin paste known as
Slurry.
Cement manufacturing process
 In general, we can divide the cement production line into three main steps: raw material
preparation of cement, clinker production, and finished cement. Each step has some cement
manufacturing machines, such as raw mill, cement crusher, cement mill, cement kiln, cement
cooler, cement dryer, cement silo, packing machine, etc.

Raw material preparation of cement: it is a process of pre-homogenization. Most of raw

materials like limestone, clay should be broken by cement crusher. For example, limestone is
large and hard, crushing is necessary before grinding. After crushing, mix all materials by a
certain ratio. It is also vital to grind crushed material into fine size before cement clinker
production. Cement ball mill is always applied to manufacture raw material. In this step, stacker
and reclaimer will homogenize the material by using stacker technology.
Clinker production: pre-heat is a necessary process before rotary kiln. The preheating
and partial decomposition of the raw material are completed by the preheater, instead of the
partial function of the rotary kiln, the length of the kiln is shortened, and the gas heat exchange
process in the kiln is carried out in a stacked state, and moved to the preheater in a suspended
state. Under the process, the raw material can be fully mixed with the hot gas discharged from
the kiln, the contact area of the gas material is increased, the heat transfer speed is fast, and
the heat exchange efficiency is high, thereby improving the production efficiency of the kiln
system and reducing the heat consumption of the clinker. The raw materials are preheated and
pre-composed at the cement preheater. Next, all raw materials are sent into the rotary kiln to
make a cement clinker. Dryer and clinker cooler are all used in this section.
Finished cement: add some gypsum, admixture or additive into cement clinker, and
using cement mill grinding cement clinker into finished cement. The finished cement can be
stored in the cement silo and silo and packing machine are common equipment used in this
step

Equipments used in cement industry

There are 6 Essential Cement Equipment For Cement Plant

Q NO 2: What are different types of cement , how they differ: advantages and disadvantages,
chemical composition.Cement industry issues in Pakistan?

13 Types of Cement
 Ordinary Portland Cement (OPC)
 Portland Pozzolana Cement (PPC)
 Rapid Hardening Cement
 Quick setting cement
 Low Heat Cement
 Sulfates resisting cement
 Blast Furnace Slag Cement
 High Alumina Cement
 White Cement
 Colored cement
 Air Entraining Cement
 Expansive cement
 Hydrographic cement

The following are the advantages of Cement:

1. Availability of concrete ingredients easily.
2. Easy handling and moulding of concrete into any shape.
3. Easy transportation from the place of mixing to place of casting before initial set
takes place.
4. Ability to pump/spray to fill into cracks and lining of tunnels.
5. When reinforced, all types of the structures are made possible from an ordinary
lintel to massive fly overs
6. Monolithic character gives better appearance and much i rigidity to the
structure.
7. The property of concrete to possess high compressive strength, makes a
concrete structure more economical than that of steel structure.

The following are the disadvantages of Cement:

1. Due to low tensile strength, concrete is required to be reinforced to avoid cracks.

2. In long structures expansion joints are required to be provided if there is large
temperature variance in the area.
3. Construction joints are provided to avoid cracks due to drying shrinkage and
moisture-expansion.
4. Soluble salts in concrete cause efflorescence if moisture reacts with them.
5. Concrete made with ordinary Portland cement, gets integrated in the presence of
alkalies, sulfates etc.
6 . Sustained loads develop creep in structures.

Composition of Cement
  Lime or calcium oxide, CaO: from limestone, chalk, shells, shale or calcareous
rock
 Silica, SiO2: from sand, old bottles, clay or argillaceous rock
 Alumina, Al2O3: from bauxite, recycled aluminum, clay
 Iron, Fe2O3: from from clay, iron ore, scrap iron and fly ash
 Gypsum, CaSO4.2H20: found together with limestone

Cement industry issues in Pakistan

The cement industry in Pakistan faces two serious threats: closure of units based on wet
process, and poor cash flow rendering the units incapable of debt servicing due to increasing
cost of electricity, furnace oil and imported craft paper used for cement packing. The cost of
furnace oil alone has increased by nearly 100% in the last 15 months alone. With the increase in
furnace oil the increase in electricity tariff has also become inevitable.

Pakistan has remained a net importer of cement but due to the privatization of units operating
under state control and subsequent expansion programmes by the new owners supported by
financial has pushed the industry to a point where the country is bound to reach an oversupply
situation. However, the recent increase in energy cost provides opportunity for the efficient
units based on dry process to sustain the situation for a relatively longer period. It would also
be possible because the expansion by the existing units and establishment of new units are
being delayed.
*END*