Manufacture of cement process

• Prepared by:-
• Rijan Pathak
• Rakesh kumar yadav
• Raju shah
 Cement and history
Cement is a common construction material, that hardens in the presence of water.
Cement is used as a binding materials in mortars, concrete, etc.
Cement has been made since Roman times, but over time the recipes used to
make cement has been refined. The earliest cements were made from lime and
pozzoulana (a volcanic ass containing significant quantities of SiO2 and Al2O3)
mixed with ground water. The cement was not improved upon until 1758, when
Smeaton noticed that using a limestone that was 20-25% clay and heating the
mixture resulted in a cement that could harden under water. He called this new
cement called “hydraulic lime.”
 Types of Cement
• Ordinary Portland cement
• High Alumina cement
• Portland Pozzolona cement
• Rapid Hardening cement
• Low Heat cement
• Quick setting cement
• White cement/colored cement
• Expansive cement
• Sulphur resistance cement
• Water proof Portland cement, etc.
 Cement Production
• A cement production plant consist of the following three processes:-
• 1.Raw materials process.
• 2.Clinkers burning process.
• 3.Finish grinding process.
• The raw materials process and the clinkers burning process are each
classified into wet and the dry process.
 Dry process
 In the dry process, crushed raw materials are dried in the cylindrical rotatory drier having a
diameter of 2m and the length of about 20m for example, mixed by automatic weigher, ground
and placed in the storage tanks. The resultant mixture is further mixed to make the ingredient
uniforms, and sent to rotatory klinfor clinker burning.
 In the dry process, there are the dry long kiln, the short kiln with boiler and the SP kiln. The dry
long kiln is mainly used in the near and middle East where rail falls less and alkaline
components in raw material are large; its characteristics are similar to the wet process long
kiln. A complex succession of chemical reactions take place as the formation of clinker requires
very high temperatures. Modern dry process cement plant use preheaters lowers such as
shown in figure below to pre-process the kiln feed and thus save energy. The temperature rises,
converting the calcium and silicon oxides into calcium silicates-cements primary constituent.
 At the lower end of kiln, the raw materials
emerge as a new substance called clinker.
 Steps in manufacture of Portland cement
 Wet Process
 In the wet process, raw materials are crushed to a diameter of approximately
20 mm by a crusher and mixed in appropriate ratio using an automatic
weigher. Then, with water added there to, the mixture is further made finer
by the combined tube mill with a and water content of 35-40%. The slurry is
put in a storage tank with a capacity of seven hundred tons, mixed to be
homogenized with corrective materials, and is sent to rotary kiln for clinker
burning. In the wet process, the slurry can be easily mixed but a large amount
of energy is consumed in clinker burning due to water evaporation.
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