Manufacturing of cement using computer in cement industry

1. I N T H E N A M E O F A L L A H

2. GRIGNARD REAGENTRole of computer in Cement
Industry

3. Introduction
Role of computer in cement manufacturing process
Raw-Materials Extraction
Grinding, proportioning and blending of raw-materials
Heating of Slurry
Packing and storage of cement
Conclusion

4. Introduction:
 Cement is a powdery substance made by calcining of
lime and clay.
 Cement is a binding material used in construction.
 Cement was first invented by Joseph Aspdin in 1824.
 Different process-computers are used to control different
processes in cement industry.

5. Role of Computer in cement
manufacturing process:
 Plant designing
 Quality control of Raw-materials
 Supervision and reporting of plant
performance
 Background programming of process-technical
calculations
 Packing and Storage of cement

6. Steps of formation of cement:-
 Raw-Material extraction
 Grinding, Proportioning and blending
 Pre-heater phase
 Kiln phase
 Cooling and final grinding
 Packing and shipping

7.  Involves extraction of limestone,
gypsum, clay, shale, slate etc.
 Raw-materials are extracted using
different machines which are
controlled by computer or remote
control devices.
 Extraction are carried out in rocks
by drilling and bombing.
Raw-material Extraction

8. Grinding, proportioning and blending of
raw-materials:
 Grinding is done for brittle and hard
materials in rotatory ball mill which is
controlled by computers e.g. limestone,
gypsum etc.
 Type of grinding mill used depends on grain
size, moisture, drying ability etc.
 Ideal raw mix contains Cao 62%,SiO₂
22%,Al₂O₃ 7.5%,MgO 2.5%,Fe₂O₃
2.5%, SO 1.5%,K₂O 1.0%

9. Heating of slurry in kiln:
 Slurry contains 40% water which is to be evaporated to form
clinker inside the kiln.
 The temperature of kiln is checked and regulated by computer
devices.
 Kiln has four zones in which slurry is heated to form clinker
1. Pre-heating zone/Minimum temperature zone(500 ⁰C).
2. Decomposition zone/Moderate temperature zone(900⁰C).
3. Burning zone/Maximum temperature zone(1500⁰C).
4. Cooling zone/low temperature zone(150-200⁰C).

10. Heating of slurry in kiln:
 Figure shows heating of slurry rotatory kiln

11. Packing of cement:
 Packing of cement is almost automatic
process by using process-computers aided by
2-3 labours to supply storage bags to
machine and 2-4 operators.
 Packing of cement is done in Kraft's process
rotatory machine in which cement from
cement silos comes and a fixed amount of
cement is put in the storage bags.

12. Storage of cement:
 Storage of cement is properly done to
prevent it from dampness and moisture.
 Cement bags must be stored in dry and
closed structures.
 Stored cement bags must be covered with
plastic sheets to prevent from moisture.

13. Plant Designing Using Computers:
 Cement plants are designed using
different types of software such as
AutoCAD,3D studio max, sketch
up etc.
 Programmer sometimes uses C++
builder. This development was based
on software engineering techniques
and standards.

14. Quality Control of raw material:
 X-Rays spectroscopy is used to
check the quality of raw materials
by using computers in many hours
per day.
 The analysed sample is then
compared with the ideal case to
obtain an ideal composition of
cement.

15. Supervision and Reporting of plant
performance:
 Digital and analog signals are used
to check the performance of plant
which shown to the operator in the
control room.
 When abnormalities happens in the
plant the analog signals are operated
and sends information to operator in
the form of alarm.

16. Laboratory Automation:
 In cement industry process computers are used
to check quality of raw mix.
 In normal operation 60-70 analysis 12-14
material per day.
 This analysis period must be reasonably short to
do a lot of analysis in very short time interval.
 This method is usually used to check the quality
and producing ideal results.

17. Conclusion
 Computers are used in cement industry as Plant designing,
Extraction of raw materials, Quality control of raw materials,
Checking performance of plant, in different process of
formation of cement etc.
 In cement industry computer reduces the labor force, supplier
and production engineer.
 Using computers in cement formation processes becomes reliable,
easy and quick.