Project :

”
”

SUBMITTED TO SUBMITTED BY

Bidhan Paudel KRISHNA SAPKOTA

GRADE; XII

SHREE JANAK MODEL SECONDARY SCHOOL

GAINDAKOT-5, NP(BSP)

YEAR : 2079 BS
 Abstract

This project presents an overview of the manufacture of cement, with a

focus on Hetauda Cement Factory. The project covers the different
stages of cement production, quality control and testing, and the
environmental impact of cement manufacturing. The project is based on
a visit to Hetauda Cement Factory by a group of students and teachers,
supervised by Bidhan Paudel. The project provides insights into the
technologies and processes used by Hetauda Cement Factory, as well as
its production capacity. The manufacturing process of cement is a
complex and intricate procedure that involves several stages and
requires the use of various equipment and materials. In this project, we
have explored the manufacturing process of cement by visiting the
Hetauda Cement Factory with our school teachers and under the
supervision of Bidhan Paudel. We observed the entire process, from the
extraction of raw materials to the final packaging of the finished
product. We learned about the various types of raw materials used, the
different stages of the manufacturing process, and the environmental
impact of cement production. Through this project, we gained valuable
insights into the cement manufacturing industry and its importance in
the construction sector. Our experience at the Hetauda Cement Factory
has provided us with a deeper understanding of the technical and
practical aspects of cement production.
 Acknowledgment

We would like to express our sincere gratitude to all those who have contributed
to the successful completion of this project on the manufacture of cement, which
was assigned to us by our school as a part of our Class 12 curriculum.

Firstly, we would like to thank our project supervisor, Bidhan Paudel, for his
invaluable guidance, support, and encouragement throughout the entire project.
His expertise and knowledge in the field of cement production helped us to
understand the process in depth and complete this project to the best of our
abilities.

We also extend our heartfelt thanks to the officials and staff members of Hetauda
Cement Factory for giving us the opportunity to visit the factory and providing us
with valuable information about the cement manufacturing process. We would
like to express our appreciation for their time and efforts in explaining the
complex process and for answering our numerous questions.

We would like to acknowledge our school for providing us with the resources,
materials, and time needed to complete this project. We are grateful for the
opportunity given to us to learn about the cement manufacturing process through
this project.

Finally, we would like to thank our classmates and friends for their constant
support and encouragement throughout the project.

Once again, thank you to all who have contributed to the successful completion of
this project.
Introduction:

Cement is one of the most widely used building materials in the world used in
construction and infrastructure development. Hetauda Cement Factory is one of the
leading cement producers in Nepal, with a production capacity of 600,000 tons per
annum. The purpose of this project is to provide an overview of the manufacture of
cement, with a focus on Hetauda Cement Factory located at Hetauda,Nepal.

Cement Manufacturing Process :

In short, Cement production involves several stages, including quarrying and

crushing of raw materials, blending and grinding, and the production of clinker and
cement. The quarrying and crushing of raw materials involves the extraction of
limestone, shale, and other materials from the earth's crust. These materials are
then crushed and transported to the cement plant for processing. The blending and
grinding stage involves the mixing of raw materials to create a homogenous
mixture, which is then ground into a fine powder. The production of clinker
involves the heating of the homogenous mixture at high temperatures, which
results in the formation of clinker. The final stage involves the grinding of clinker
into cement.
Cement is typically manufactured through a process that involves several stages,
including:

1. Quarrying and crushing of raw materials: Limestone, clay, shale, and

other materials are extracted from the earth's crust using explosives(blasting)
or drilling techniques . The raw materials are then transported to a crushing
plant where they are crushed into smaller pieces.

2. Blending and grinding: The crushed raw materials are then blended and
ground together to form a homogeneous mixture. This mixture is called the
raw mix.
3. Preheating: It involves heating the raw materials (typically limestone, clay,
and other minerals) to a high temperature in a kiln in order to chemically
transform them into clinker, which is the main component of cement.

4. Calcination: The preheated raw mix is then fed into a rotary kiln, where it is
heated to temperatures of up to 1450°C. The heat causes chemical reactions
to take place, resulting in the formation of the clinker .

5. Cooling: The clinker is then cooled and stored in a clinker silo.

6. Grinding: The cooled clinker is then ground into a fine powder with the
addition of a small amount of gypsum (calcium sulfate dihydrate) to control
the setting time of the cement.

7. Packaging and distribution: The finished cement is packaged in bags or

shipped in bulk to distributors, who sell it to retailers and construction
companies.
FLOW SHEET DIAGRAM FOR CEMENT MANUFACTURE
PROCESS
Quality Control and Testing Quality control:

It is an essential aspect of cement production, ensuring that the final product meets
the required standards. Hetauda Cement Factory has a well-equipped laboratory
that carries out various tests to ensure the quality of its products. The laboratory
tests include chemical analysis, physical testing, and strength testing. The
laboratory also carries out tests on the raw materials used in the production
process.

Environmental Impact of Cement Manufacturing Cement manufacturing has

significant environmental impacts, including air pollution, water pollution, and
greenhouse gas emissions. Hetauda Cement Factory has implemented several
measures to mitigate its environmental impact, including the use of modern
technologies and the adoption of sustainable practices. The factory has installed a
bag filter system to reduce particulate emissions, and it has implemented a water
recycling system to reduce water usage.

Visit to Hetauda Cement Factory:

The project is based on a visit to Hetauda Cement Factory by a group of students

and teachers, supervised by Bidhan Paudel . The visit provided insights into the
different stages of cement production, the quality control and testing procedures,
and the environmental impact of cement manufacturing. The group observed the
various processes involved in cement production, including the crushing and
grinding of raw materials, the production of clinker, and the grinding of
cement.We got there in the purpose of understanding the cement manufacturing
process included in new chemistry curriculum alongside to create some memories
of joy and happiness with friends and teachers in end phase of class XII.
Conclusion:

The manufacture of cement is a complex process that involves several stages and
requires careful attention to quality control and environmental impact. Hetauda
Cement Factory has implemented several measures to ensure the quality of its
products and mitigate its environmental impact. The visit to Hetauda Cement
Factory provided valuable insights into the manufacture of cement and the role of
Hetauda Cement Factory in the Nepalese cement industry.The manufacturing
process explanation and factory tour was done under the supervision of cement
experts of Hetauda Cement Factory and our Chemistry Teacher “Bidhan Paudel”

References:

"Cement manufacturing process." Cement Australia. Accessed March 7, 2023.

https://www.cementaustralia.com.au/about-cement/cement-manufacturing-process.

"Environmental impact of cement production." ScienceDirect. Accessed March 7