Project:

“A Visit to Hetauda Cement Factory To Understand the Cement Manufacturing

Process”

SUBMITTED BY : SUBMITTED TO:

Name of student: Ritik kandel Department of Chemistry:
Class: XI Name of School: Vijaya Samudayik Siksha Sadan
Roll no: 15 Address:Gaindakot-5
E-mail Address: Year: 2080/81
kdlritik204@gmail.com
 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 11
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.

Established in [2032], the Hetauda Cement Factory has evolved into a beacon of excellence within
the region's industrial sector. From its humble beginnings to its current stature as one of Nepal's
leading cement producers, the factory has continuously embraced advancements in technology and
manufacturing practices to ensure the delivery of high-quality cement products to the market.

Overview of Hetauda Cement Factory: The Hetauda Cement Factory, established in

2032 BS, is one of Nepal's leading cement producers. Spanning over 1.47 kilometers acres of land,
the factory boasts state-of-the-art infrastructure and advanced manufacturing technologies. It plays
a significant role in fulfilling the country's growing demand for cement and contributes to the
development of Nepal's construction industry.

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:

Stage 1: Raw Material Acquisition

 1. Quarrying: The first step involves extracting limestone, clay, and sometimes other
materials like shale or iron ore from quarries . These materials are the foundation for the
chemical composition of cement.
Crushing: The extracted rocks are crushed into smaller pieces, typically down to a
size of around 6 inches . Further crushing reduces these pieces to an even finer size, around
3 inches or less .

Stage 2: Grinding and Blending

The crushed raw ingredients are made ready for the cement-making process in the kiln by
combining them with additives and grinding them to ensure a fine homogenous mixture.
The composition of cement is proportioned here depending on the desired properties of
the cement. Generally, limestone is 80%, and the remaining 20% is clay. In the cement
plant, the raw mix is dried (moisture content reduced to less than 1%); heavy wheel-type
rollers and rotating tables blend the raw mix and then the roller crushes it to a fine
powder to be stored in silos and fed to the kiln.

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. A pre-heating chamber consists of a series of cyclones that utilizes the hot
gasses produced from the kiln in order to reduce energy consumption and make the cement-making
process more environment-friend. The raw materials are passed through here and\turned into oxides
to be burned in the kiln

4. Calcinations: 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.
Limestone (calcium carbonate), a major component of the raw material mix,
undergoes thermal decomposition. This means that heat drives off carbon
dioxide (CO2) gas, transforming the calcium carbonate into calcium oxide (lime)

CaCO3 (limestone) -> CaO (lime) + CO2 (carbon dioxide)

This calcinations process is critical because:

It provides the calcium oxide necessary for the formation of clinker, the main
ingredient of cement.
It releases a significant amount of carbon dioxide, which contributes to about 60% of
the CO2 emissions associated with cement production.
 5.Burning and Clinker Formation: Clinker is a nodulized material consisting of
calcium silicates, calcium aluminates, and calcium ferrites. These are formed by heating a
finely ground mixture of limestone, clay, and other materials (known as raw meal) in a rotary
kiln at temperatures exceeding 1400°C (2552°F).

6. Cooling And Grinding:. After exiting the kiln, the clinker is rapidly cooled down
from 2000°C to 100°C-200°C by passing air over it. At this stage, different additives are
combined with the clinker to be ground in order to produce the final product, cement.
Gypsum added to and ground with clinker regulates the setting time and gives the most
important property of cement, compressive strength. It also prevents agglomeration and
coating of the powder at the surface of balls and mill walls. Some organic substances, such as
Triethanolamine (used at 0.1 wt.%), are added as grinding aids to avoid powder
agglomeration. Other additives sometimes used are ethylene glycol, oleic acid, and dodecyl-
benzene sulphonate.
The heat produced by the clinker is circulated back to the kiln to save energy. The last
stage of making cement is the final grinding process. In the cement plant, there are rotating
drums fitted with steel balls. Clinker, after being cooled, is transferred to these rotating drums
and ground into such a fine powder that each pound of it contains 150 billion grains. This
powder is the final product, 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 XI.

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, our Chemistry Teacher “Bidhan
Paudel” and Biology Teacher “Anil Joshi”.

The visit to the Hetauda Cement Factory provided valuable insights into the intricacies of
cement manufacturing and the significant role played by the factory in Nepal's industrial
landscape. The factory's dedication to excellence, innovation, and sustainability underscores its
importance as a key contributor to the nation's economic development and infrastructure
growth.

This report encapsulates our observations and experiences during the visit, highlighting the
Hetauda Cement Factory's commitment to producing high-quality cement while prioritizing
environmental conservation and community welfare.
References:

"Cement manufacturing process." All The Information About Cement

manufacture are taken from AI(Artificial Intelligence)
Gemini:https://gemini.google.com/app/66a385cc71ca92d9

Chatgpt:https://chat.openai.com/c/1eda4aaa-4dd1-4aba-a33c-3af10db56782

"Flow Sheet Diagram For Cement Manufacturing Process."

https://imgs.search.brave.com/
1COwLoxYbLnVf7U2MsrxRuequ1RodVjDIkOW0j_xsGw/rs:fit:860:0:0/g:ce/
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LTA0LTEzLTE5LjEy/LjA3LTk4NXgxMDI0/LmpwZz9yZXNpemU9/
OTg1LDEwMjQmc3Ns/PTE

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

"About Hetauda Cement Factory":https://baardali.org.np/