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Cement: Dr. Prashant Mehta Assistant Professor, National Law University, Jodhpur
Cement: Dr. Prashant Mehta Assistant Professor, National Law University, Jodhpur
• Crushing
• Mixing (Wet Process)
• Mixing (Dry Process)
• Grinding (Ball Mill and Tube Mill)
• Storage of Ground Materials
• Burning
– Drying Zone
– Calcination Zone
– Clinkering Zone
• Grinding
– Retarder
– Dispersing Agent
– Water Proofing
• Packaging
CRUSHING
• Ball Mill
• Tube Mill
• Slurry is burnt in rotary klin where actual chemical changes takes place.
• Klin is long steel cylinder 30-40 meter in length, 2-4 meter in diameter, lined by refractory bricks. It is
inclined at gradient of 0.5-0.75 inch and can be rotated at the desired speed.
• The material is introduced in the klin from the upper end as the klin rotates material passes slowly towards
the lower end.
• Klin is heated by burning pulverized coal or oil and temperature is maintained at about 1400-1500°C. At
clinkering temperature actual chemical reactions takes place.
BURNING ZONE
A. DRYING ZONE
• The upper part of the klin is known as drying zone.
• The temperature is about 200-500°C.
• Most of the water gets evaporated from the slurry by means of hot gases.
B. CALCINATING ZONE
• This the middle zone of the klin with temperature around 1000°C.
• Organic matter burns away and CaCO3 decomposes to quick lime and CO2
escapes out. The material forms small lumps called as nodules.
BURNING ZONE
C. CLINKERING ZONE
This is lowest portion of Klin with a temperature of about
1400-1600°C. Lime and clay nodules melts with chemical
fusion and gives calcium aluminates and silicates. These
silicates and aluminates then fuse together to form small
hard stones called Clinkers which than fall down from
lower end of the Klin.
Clinker Constitution
– Ca2SiO4 Dicalcium Silicate
– Ca3SiO5 Tricalcium Silicate
– Ca3Al2O6 Tricalcium Aluminate
– Ca4Al2Fe2O10 Tetracalcium Aluminoferrite
– MgO Magnesia
– Cao When burning is incomplete
GRINDING
Retarder
Gypsum CaSO4.2H2O or Plaster of Paris CaSO4.½H2O
acts as retarder to prevent quick setting. After initial
setting gypsum retards the dissolution of tricalcium
aluminate by forming tricalcium sulphoaluminate
(3CaO.Al2O3.xCaSO4.7H2O).
Dispersing Agent
Sodium salts and polymers of condensed napthlene or
sulphonic acid are added to prevent the formation of
lumps and cakes in the cement.
Water proofing agents are also added.
PACKAGING
– MgO Magnesia 4%