This slide describes the CPI of manufacturing of portland Cement.

1. THE GOVERNMENT ENGINEERING
COLLEGE BHUJ KUTCH-370001
Presented :-
Raj patel. 150150105044
Bhavesh 150150105045
Dhruval 150150105046
Raj 150150105047
Jenish 150150105048
Satyam 150150105049
Prashant 150150105050
Raj Solanki 150150105051
Guided By :- Sejal mam

2. PORTLAND CEMENT PROCESS

3. CONTENTS
1. Introduction
2. History
3. Types
4. Manufacturing
5. Uses

4. INTRODUCTION
• Portland cement is the most common type of cement in
general use around the world, used as a basic ingredient
of concrete, mortar, stucco, and most non-speciality grout.
• Several types of Portland cement are available, with the
most common being called ordinary Portland cement (OPC)
which is grey in color, but a white Portland cement is also
available
• The low cost and widespread availability of the limestone,
shales, and other naturally occurring materials used in
Portland cement make it one of the lowest-cost materials
widely used over the last century throughout the world.

5. HISTORY
• Portland cement was developed from natural cements
made in Britain beginning in the middle of the 18th
century. Its name is derived from its similarity
to Portland stone, a type of building stone quarried on
the Isle of Portland in Dorset, England.
• In 1875 the first Portland cement was produced by
Coplay Cement Company under the direction of David
O. Saylor in Coplay, Pennsylvania. By the early 20th
century American-made Portland cement had
displaced most of the imported Portland cement.

6. GRADES OF PORTLAND CEMENT
• The grade 43 and 53 in cement mainly corresponds to the
average compressive strength attained after 28 days in
mega pascals (Mpa) of at least three mortar cubes ( area of
face 50 cm squared) composed of one part cement, 3 parts
of standards and ( conforming to IS 650:1966) by mass and
P/4 ( P is the percentage of water required to produce a
paste of standard consistency as per IS standard) + 3
percentage ( of combined mass of cement plus sand) of
water , prepared, stored and tested in the manner
described in methods of physical test for hydraulic cement.
• 6724 hrs not less than 43MPa for 43 grade, 53 MPa for 53
grade

7. • Chemical Reactions:
CaCO3 (s) → CaO (s) + CO2 (g)
CaO +Al2O3 + Sio2 →Mixture of of C3S, C2S ,C3A
MANUFACTURING PROCESS

8. • Quantitative Requirements:-
a) Basis:- 1 Ton of of type I cement.
Clay 0.1 – 0.3 ton
Limestone 1.2 – 1.33 ton
Gypsum 0.03 – 0.05 ton
Coal 0.25 – 0.40 ton
Water 3 ton
Electricity 80KWH
b) Plant Capacities:- 200 – 1200 tons/day

9. High Grade
Limestone +
Clay Rotary
Filter
Beneficiated
Rock Slurry
Air
Clinker
Storage
Fines
Tails
Peripheral
Screen
Tail
s
Cement to Baging and
shipping
Four Compartment Tube Mill
in Closed Circuit with Two
Air Classifiers
Flue
gases
Wet grind
Closed
Circuit
Flow sheet

10. Process Description
• Cement - grade limestone ( and possibly oyster shells) plus
clay or shale, sand, iron containing materials (such as blast
furnace slag), gypsum and coal (especially in India where it is
more plentiful than oil or gas for heating) are ground together.
• Grinding may be a wet or dry process, but dry process plant
now predominate because of saving in heat (less water to
evaporate) and accurate control possible the sequence main
include rough crushing , followed by gyratory and hammer
mills and then drying and fine grinding in the tube mills
followed by air separation and pneumatic blending

11. Contd…
• The dry powdered feed (or wet slurry ) in then fed to
a direct – fired counter-current rotary kiln. The
residence time is 1-3 hours and the feed mixture is
decarbonated and fused to form the cement
compound (C3S, C2S ,C3A). The word clinker (2-10
mm size) is dropped to the rotary cooler which also
pre heats combustion air for the kiln. The product
from the tube milling the clinker is a powdered of
which 90% passes 200 mesh, it is bagged or bulk
stored and shipped.

12. Major engineering problems
• Type of grinding : Importance of good design here is
emphasize by the fact about that about 80% of the total
power consumed in the manufacture of cement is used in the
crushing , grinding , blending operation
• Kiln design: Calcining involves decomposition of CaCO3 to Cao
and firing at 1400-1500 C to promote compound formation.
• Heat Economy : minimizing fuel consumption is an economic
balance between fuel costs and addition of waste heat boiler
and air pre heater with the equipment usually specified
because of favorable incremental investment.
• Quality control: product performance is quite sensitive to rock
composition, particle size and degree of calcining.

13. Uses
Mainly used for construction purpose