Dr.

Harisingh Gour Vishwavidyalaya

(A Central University)
Sagar, (M.P.) - 470003

Department Of Applied Geology

Presentation
On
Cement and Cement industries in India
Sub. Code:- Geo SE -331
 Contents

Sr.No. Topics
01 Introduction
02 Classification of cement
03 Raw material used in cement
04 Manufacturation of cement
4.1 Mixing and crunhing of raw materials
4.2 Burning
4.3 Grinding and Shiping
05 Cement industries in India
06 State wise Reserve and number of cement plant
07 Conclusions
08 Reference
https://civilsuccessonline.com/cement-raw-material-history-chemical-composition-functions-of-compound/
 Introduction
Cement, in general, adhesive substances of all kinds. Cement is a mixture of calcium silicates and smaller
amounts of calcium aluminates that react with water and cause the cement to set.

Cement is a manufactured product

made by blending different raw
materials and firing them at a high
temperature in order to achieve
precise chemical proportions of
lime, silica, alumina and iron in
the finished product, known as
cement clinker.
Fig 1: Cement
https://civilsuccessonline.com/cement-raw-material-history-chemical-composition-fu
nctions-of-compound/
Classification of Cements

Cements

Natural Cement
mixtures of of portland
It is the variety artificial
cement and a pozzolanic
cement.Portland cement is
material that may be either
Puzzolana Cement Natural cement is hydraulic
natural or artificial.
a low priced heavy The
product.
cement pozzolanas
natural made from
are
It is called Portland
limestone that cement
has a high
mainly materials of
Portland Cement clay content
volcanic
because on (argillaceous
origin buthardening
include
limestone).
some diatomaceous earths.
(setting) its color resembles
Artificial materials include
fly ash, burned
to rocks clays, andin
near Portland
shales.
England.
Formation and Raw materials used in Portland cement

The most important raw materials for making cement are limestone, clay and gypsum.

The raw materials for the manufacture of cement contain (U.S. Standard) A.S.T.M.:
Maximum Minimum

Silicon dioxide (Sio2) 23.06% 19.32%

Aluminium oxide (Al2o3) 7.59% 4.05%

Ferric oxide (Fe2o3) 5.77% 1.45%

Calcium oxide (CaO) 66.93% 62.01%

Magnesium oxide (MgO) 4.91% 0.68%

Manufacturing Cement

1. Mixing and Crushing of raw materials

a) Dry process

a) Wet process

2. Burning

3. Grinding

4. Packing

Fig 2: cement plant

https://www.cementequipment.org/home/cement-manufacturing-process/

7
Manufacturing of Portland cement
Agillaceous Callareous Powdered
materials materials A Rotary Klin
coal + air

NO Crushing & Hot Clinkers

Is Wet Grinding
process

YES Cooler
Silos

Washing
Grinding in Ball 2 -4 %
Mill Gypsum

Storage Silos

Grinding Water

Packing

Slurry

Correcting Basin A
Flow Chart of Portland cement manufacturing process

8
 Mixing and Crushing: a) Dry Process

1. Mixing
2. Burning

3. Grinding 4. Storage & Shipping

Fig 3: Process of manufacture of cement
https://www.cementequipment.org/home/cement-manufacturing-process/ 9
 Mixing and Crushing: b) Wet Process

• Limestone is crushed,
powdered and stored in silos

• Clay is washed with water to

remove organic matter and
stored in basin

• Both these materials are mixed

in grinding mill to form slurry

• Slurry contains 38-40% water

Fig 4: showing manufacturing of cement using wet process stored in correcting basin
https://www.cementequipment.org/home/cement-manufacturing-process

10
 Burning Process : Zones of Rotary Kiln

Rotary Kiln ne Slurry

yi n g Zo
Dr
n Zone • Upper part of the kiln
a t io
eC alcin • About 400 0C
on
e ring Z oC • Most of the water in the slurry
k 400
Clin
10 00 C
o
gets evaporated
–
700
oC
00
5 0 – 15
12
20 m • Center part of the kiln
90 -1
5 to 6 o inclined • About 700oC – 1000oC
• Lime gets decomposed into CaO
and CO2

• Lower part of the kiln

• About 1250oC - 1500oC
• Reacts with clay to form various
bouge compounds

11
Burning Process : Chemical Reactions in Rotary Kiln Zones

• Calcination Zone :

CaCO3 CaO + CO2

• Clinkering Zone :
https://sciencephotogalleryfeatured/laboratoryflask

2CaO + SiO2 Ca2SiO4 ( Dicalcium silicate)

3CaO + SiO2 Ca3SiO5 ( Tricalcium silicate)

3CaO + Al2O3 Ca3Al2O6 ( Tricalcium aluminate)

4CaO + Al2O3 + Fe2O3 Ca4Al2Fe2O10

(Tricalcium aluminoferrite)

12
 Grinding and Packaging
Grinding
• Cooled clinkers are ground to fine powder in
ball mills
• At final stages of grounding about 2-3% of
powdered gypsum is added.
Fig 5: Ball mills
https://www.jxscmachine.com/new/hball-mill/

Packaging

• Ground cement is stored in silos

• From silos they are automatically
packaged into bag which are about 50 Kg

Fig 6: Cement bags 50kg

https://usa.exportersindia.com/universal-fish-farm/high-quality

13
  Cement Industries are in almost
all the States of India, except Goa,
Arunachal Pradesh, Manipur,
Mizoram, Nagaland, Sikkim and
Tripura.

Legend
States having
Cement Industries
States having Major
Cement Plants
States having no
Cement Plants

Fig 5: Map showing cement industries in India

https://www.slideegg.com/india-map-ppt-template
 Table 1: State wise Reserve and number of cement plant
Sr. State Number of cement Total Reserve (in million
No. plant tonnes)
01 Rajasthan 26 88.65
02 Andhra Pradesh 34 80.22
03 Karnataka 18 53.7
04 Gujarat 19 46
05 Madhya Pradesh 15 44.2
06 Tamil Nadu 25 42.65
07 Maharastra 14 37.7
08 Telangana 21 35.5
09 Chhattisgarh 12 28.35
10 Uttar Pradesh 17 25.5
11 West Bengal 16 21.7
12 Bihar & Jharkhand 10 19.2
13 Meghalaya & Assam 17 16.9
14 Odisha 4 10.4
 Chittorgarh
Kalaburgi
Sirohi
Gulbarga
Ajmer
Belagavi etc...
Suratgarh
Jaipur etc...

Anantpur
Krishna
Satna Guntur
Neemuch Cuddapah
Rewa Kurnool
Damoh etc...
Dhar etc...

Amreli
Surat
Junagadh etc...

Fig 5: Map showing cement industries in India

https://www.slideegg.com/india-map-ppt-template
 Conclusions
The Cement Industry in India is among the core Industries
that is vital for economic growth and development.

The Indian Cement Industry plays a key role in the national

economy, not only by generating substantial revenue for State
and Central Governments but also as a key industry that
generates maximum employment directly or indirectly.

India exported a bout 2.84 million tonnes cement valued at

954 crore in 2019-20.
 References
 Deb S., (1976), Industrial Minerals And Rocks Of India (A Handbook of Economic
Geology), Allied Publishers Private Limited, pp. 436-447.

 Indian Minerals Yearbook (Part-III : Mineral Reviews), (2022) - 59 th Edition.

 https://civilsuccessonline.com/cement-raw-material-history-chemical-
composition-functions-of-compound/

 https://www.cementequipment.org/home/cement-manufacturing-process/

 https://www.jxscmachine.com/new/ball-mill
 NK YOU
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