CLINKER

MANUFACTURING
PROCESS
C.V. Anirudh
111117026
EXTRACTION AND PREPARATION
OF RAW MATERIALS
 The main raw materials (limestone, clay chalk or basalt)
are quarried from natural rocks. They are crushed and
transferred to pre-blending storage where other
substances (such as sand, iron ore, bauxite, shale, slag, fly
ash) are added to get the desired chemical composition.
HOMOGENIZATION
 The raw materials are ground in the raw mill where the
particle size is reduced on a 90 um sieve and then
transferred to a homogenization silo to ensure the
production of uniform and good quality clinker.
PRE-HEATING
 The homogenous mixture of raw materials is heated and
transformed into oxides (that are ready for the burning phase in
the kiln) in pre-heater cyclones fitted with a pre-calciner fired
with petroleum, natural gas or coal.
 KILN PHASE
 Evaporation of free water: A pressure above atmospheric
is required to vaporize the water from the slurry mixture
of raw materials. Water becomes superheated and the
evaporation gradually stops when the temperature rises
above 120°C.
 Clay decomposition: “Clay” minerals account
for most of the alkalis in the raw materials,
the most common of which is kaolinite,
Al2Si2O5(OH)4. The detached alkalis react with
the acid gases present in the kiln at high
temperature. The effective reactions here
are:

Si2Al2O5(OH)2→ 2 SiO2 + Al2O3 + 2 H2O (vapor)

KAlSi3O8 (orthoclase) + 0.5 SO2 + 0.25 O2 → 

3 SiO2 + 0.5 Al2O3 + 0.5 K2SO4
 Dolomite decomposition: The magnesia in
the raw-mix exists mainly as dolomite,
CaMg(CO3)2, but also as silicate or in
carbonate form. Dolomite reacts as follows: 

CaMg(CO3)2→ CaCO3 + MgO + CO2 

 Again, non-carbonate magnesium compounds
(for example, phlogopite) react thus:

KMg3AlSi3O10(OH)2 + 0.5 SO2 + 0.25 O2 →

0.5 K2SO4 + 3 MgO + 0.5 Al2O3 + 3 SiO2 + H2O
(vapor)
 Low-temperature calcite decomposition:
Calcium carbonate, present in the raw-mix
as calcite, produces carbon dioxide, the
amount of which exceeds half the mass of
the finished clinker. This requires a huge
heat input. The efficiency of this reaction is
one of the factors that determine the output
and heat consumption in the kiln. Pure
calcite in the kiln decomposes at around
650°C: 
2 CaCO3 + SiO2 → Ca2SiO4 + 2 CO2 
 Alumina and iron oxide react: Calcium
carbonate continues to react with other oxides
and no free lime is yet formed. Though
tricalcium aluminate is stable here, poorly
crystallized mayenite (Ca12Al14O33) seems to be
formed. The reactions at this stage are: 
12 CaCO3 + 7 Al2O3 → Ca12Al14O33 + 12 CO2 
4 CaCO3 + Al2O3 + Fe2O3 → Ca4Al2Fe2O10 + 4 CO2 
4 CaCO3 + Al2O3 + Mn2O3 → Ca4Al2Mn2O10 + 4 CO2
 Decomposition of remaining calcite: A little
amount of calcite remains at this stage and
forms free lime for the first time:
CaCO3 → CaO + CO2
 Sintering: Sintering is the process of compacting and
forming a solid mass of material by heat or pressure to the
point of liquefaction without actually melting it. When the
temperature inside the kiln reaches about 1300°C (the
eutectic melting point of aluminate, ferrite and silicate),
clinker flux is produced. The rate of melting varies, and
when the liquid is formed, alite, which becomes stable at
above 1250°C, begins to form. The principal reaction of
this stage is as follows: 
Ca2SiO4 + CaO → Ca3SiO5
 The liquid formed both acts as a solvent of ion exchange
between the solid phases and draws the reactant particles
together by surface tension. The powdery or granular
mixture quickly solidifies into spherical nodules of clinker.
COOLING AND STORING
 The mixture inside the slightly inclined kiln is rapidly
cooled from 2000°C to 100°C-200°C. Thus, the final
product, clinker, is produced, and then stored, ready for
the production of cement.
REFERENCES
 Pictures – Google Images
 Content and Information – 1.
www.civiltoday.com
2. Engineering Chemistry – Jain
and Jain 3. Wikipedia -
Clinker