DEBRE BERHAN UNIVERSITY

COLLEGE OF ENGINEERING
CHEMICAL ENGINEERING DEPARTMENT
PROCESS INDUSTRY TWO
INDIVIDUAL ASSIGNMENT
NAME GETAW SHEWAN TASEW
ID NO 0464/10
SUBMISSION DATE 28/04/2013
SUBMITTED TO Mr ABREHA A
 1. Introduction TO Cement definition
 Cement is a manmade mineral structure created at high
temperatures, mainly comprising lime (CaO), Silica (SiO2)
and oxides of aluminum and iron (Al2O3and Fe2O3.
 Cement is a hydraulic powder material, which reacts with
water to produce strength-bearing lattices.
 The mixture of aggregates, cement and water is concrete. The
strength and durability of concrete makes it one of the most
useful materials developed by man.
• History of cement
• The origin of hydraulic cements goes back to ancient Greece and Rome.
The materials used were lime and a volcanic ash that slowly reacted
with it in the presence of water to form a hard mass. This formed the
cementing material of the Roman mortars and concretes of more than
2,000 years ago and of subsequent construction work in western
Europe. Volcanic ash mined near what is now the city of Pozzuoli, Italy,
was particularly rich in essential aluminosilicate minerals, giving rise to
the classic pozzolana cement of the Roman era. To this day the term
pozzolana, or pozzolan, refers either to the cement itself or to any finely
divided aluminosilicate that reacts with lime in water to form cement.  
• (The term cement, meanwhile, derives from the Latin word caementum, which
meant stone chippings such as were used in Roman mortar—not the binding
material itself.)
• Portland cement is a successor to a hydraulic lime that was first developed by
John Smeaton in 1756 when he was called in to erect the Eddystone Lighthouse
off the coast of Plymouth, Devon, England. The next development, taking place
about 1800 in England and France, was a material obtained by burning nodules
of clayey limestone. Soon afterward in the United States, a similar material was
obtained by burning a naturally occurring substance called “cement rock.” These
materials belong to a class known as natural cement, allied to portland cement
but more lightly burned and not of controlled composition.
• 
 The most quality parameter of cement
The most important quality parameter is the compressive
strength of the concrete produced with the cement. The
cement hydraulic reactions continue for many hours,
days, weeks and months beyond the initial setting of the
cement, increasing the strength of the mortar or concrete
made from the cement.
 Higher variability means higher standard deviation in concrete
strength and therefore higher cement content and cost
Workability is just as important as the strength, because the
two characteristics are effectively linked.
Setting time of the cement and the wet concrete is also
important.
In cold climates rapid set will be required to allow finishing
during the working day. In hot climates slower setting will be
required to allow the concrete to be placed. Control of the
setting time is therefore the most important consideration
 Durability is a critical consideration in applications where the
environment could attack and destroy the concrete;
• This is what is required of the cement product:
High early and late (28-day) strength.
 Good workability characteristics.
Controlled setting, matched to local climatic conditions.
 Reliable durability in the long term.
Consistent color.
 Cement Types and Applications
• The vast majority (>95%) of cement produced in the world is
based on Ordinary Portland Cement clinker.
• That Ordinary Portland Cement clinker can be ground together
with gypsum to produce Ordinary Portland Cement (OPC).
• However, the production and use of blended cements
containing pozzolan additions is assuming ever greater
importance (PPC).
1.White cements, with low Fe2O3 content, and therefore higher
SM and silicate content, are used in decorative applications.
The whiteness of the concrete produced with the cement can
save significant costs for surface treatment of prestige
buildings. The low Fe2O3 content is achieved by selection of
appropriate raw materials. The clinker must also be quenched in
water rather than cooled with air.
2. Sulphate resisting cements, with low alumina ratio, and
therefore low C3A content, are used in applications where
concrete may be attacked by sulphates in ground water. Again
selection of appropriate raw materials, and the use of additional
iron oxide, are the main requirements.
• 3. Low alkali cements are used in applications where the aggregates used in
concrete manufacture contain reactive silica, which may be attacked by the
alkalis in cement. Again selection of appropriate raw materials is the main
requirement.
 Raw materials used to produce cement
The raw materials are naturally occurring mineral and
basically all CaO, SiO2, Al2O3 and Fe2O3 bearing minerals
can be used to manufacture cement.
Plants generally rely on nearby quarries for limestone to
minimize transport costs.
1.Primary raw materials
 limestone (CaCO3) & limestone containing minerals,

2.Secondary raw materials

 clay ( Al2O3 ),sand & silica (aluminum and iron oxides).
3.Tertiary raw materials
 Gypsum
 Other "alternative" raw materials slag, mill scale, fly ash
 Types of processes
There are two main process routes for the manufacture of
cement. These are:
1.Dry process:-In the dry process, the raw materials are ground
and dried to raw meal in the form of a flow-able powder. The
dry raw meal is fed to the pre-heater or pre-calciner kiln or,
more rarely, to a long dry kiln.
2.Wet process:- the raw materials (often with high moisture
content) are ground in water to form pump able slurry. The
slurry is either fed directly into the kiln or first to slurry dryer.
5/20/201
 Major unit operations
1. Quarrying
2. Crushing
3. Proportionating/Pre-homogenization
4. Raw mill Grinding
5. Homogenization/Silo 6. Raw meal preheating
7. Kiln operation 8. Clinker cooling/storage
9. Cement mill and gypsum addition/ storage
 Process descriptions
1. Quarrying
Rock blasted from the quarry is transported to the primary
crusher where large "run of mine" rocks are broken into pieces
of approximately 100mm.
Generally the other raw materials do not require crushing.
 Cement factory raw material deposits are extracted using open
pit quarries in the vast majority of cases. There are just a few
examples around the world where the raw materials are
extracted from underground mines.
• 2. Crushing
• •Cementplantrawmaterialsblastedinthequarryrequiressizereductionforfurtherpr
ocessing,sizereductionisperformedincrushersandgrindingmills.Crushingiscom
munitioninthecoarserange.
• •Primarycrushinginvolveslimestonerockfedthroughlargecapacitycrushers.This
reducestherocktoamaximumsizeofapproximately150mm.Secondarycrushingf
urtherreducesthisto75mmorunder.
• 3.proportionating/pre-homogenization/Raw Material Storage & Blending
• •Therawmaterialsarethenproportionedtothecorrectchemicalbalanceandmilledto
gethertoafinepowder,rawmeal,toensurehighqualityofcement,thechemistryofthe
rawmaterialsandrawmealisverycarefullycontrolled.
4. drying
For dry process the raw material has to be dried before
milling.
 Kiln exhaust gases are used to dry the raw materials. In some
gases with wet materials, additional heat sources are required
for drying.
5. Grinding
 grinding refers to comminution in the fine range. The grinding

media (steel ball) and the feed material to be ground are

brought together in a rotating tubular or drum-shaped
compartment. The media and material rises to an optimum
height, necessary for grinding operation, and come tumbling
down (cascading and/or contracting).
The actual height to which they are lifted depends on a number
of factors:
The speed of mill
The type of lining,
The filing ratio (mill loading percentage), and the properties of
mill feed material (like moisture content).
6.Kiln feed Homogenization
Materials are homogenized to ensure consistency of product
quality.
The kiln feed is routed to a homogenization silo, where it is
mixed by blowing compressed air through pads in the base of
the silo. Raw mill product is distributed in layers in the silo,
and extracted in funnels rotating around the radius of the silo.
7. Preheater/Cyclones/
A pre-heater is a series of vertical cyclones. Where the raw
meal is passed down through these cyclones it comes into
contact with the swirling hot kiln exhaust gases moving in the
opposite direction and as a result heat is transferred from the
gas to material.
 This pre-heats the material before it enters the kiln so that
the necessary chemical reactions will occur more quickly and
efficiently.
8. pre -Calcinations
 The calciner is a combustion chamber at the bottom of the
pre-heater above the kiln backend. Up to 65% of the total
energy needs of the kiln system can be supplied to the
calciner.
 Calciners allow for shorter rotary kilns and for the use of
lower grade alternative fuels. Calcination is the decomposition
of CaCO3 to CaO and CO2. CaCO3 CaO + CO2.
These process emissions comprise 60% of the total emission
from a cement kiln. The combustion of the fuel generates the
rest.
9.Kiln operation (pyro-processing)
The kiln is the world's largest piece of industrial equipment.
As the kiln rotates at about 3-5 revolutions per minute, the
material slides and tumbles down through progressively hotter
zones towards the flame
Raw meal, more accurately termed "hot meal" at this stage
then enters the rotary kiln.
 Fuel is fired directly into the rotary kiln and the heat is
absorbed into the material being processed.
Basic chemical reactions of burning zone
1.Alite formation: 3CaO + SiO2 ------> 3 CaO. SiO2 (C3S)
2. Belite formation:2CaO+ SiO2 ------>2 CaO. SiO2 (C2S)
3.Aluminates formation:3CaO+ Al2O3 -----> 3 CaO. Al2O3
(C3A)
4.Ferrite formation:4CaO+ Al2O3+ Fe2O3 -----> 4CaO.
Al2O3. Fe2O3(C4AF )