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Cement Manufacturing
History Of Cement
What is cement?
 It’s a powder form of adhesive substance.
 When mixed with water set to a hard mass.
 Is a key building material in both residential and
commercial construction works.
Major Components of cement
 C3S – Tricalcium Silicate
 C2S – Dicalcium Silicate
 C3A – Tricalcium Aluminate
 C4AF –Detracalcium Alumino Ferrite
CEMENT INDUSTRY SYMBOLS
Name of substance Chemical
symbol
Cement
industry symbol
Calcium oxide or lime CaO C
Silica SiO2 S
Alumina Al2O3 A
Iron oxide Fe2O3 F
Typical compound composition of ordinary
Portland cement
CHEMICALNAME CHEMICAL
FORMULA
CEMENT
NOTATIONa
Content
(%)
Tricalcium silicate 3CaO•SiO2 C3S 61.7
Dicalcium silicate 2CaO•SiO2 C2S 20.5
Tricalcium aluminate 3CaO•Al2O3 C3A 5.13
Tetracalcium aluminoferrite 4CaO•Al2O3•Fe2O3 C4AF 12.15
Calcium sulfate dihydrate
(gypsum)
CaSO4•2H2O CSH2 3-5
a C = CaO, S = SiO2, A = Al2O3, F = Fe2O3, S = SO3, H = H2O
(Actual cement phases are more or less close to this ideal view)
Types of cement manufacturing
 Wet process
 Dry process
Cement Manufacturing Process
Raw material grinding
Raw material grinding
Raw Mill Grinding -
VRM
Limestone(CaCo3) Shale(Si + Al) Iron ore( Fe + Al)
Raw meal Preparation
Raw meal
final
product
Kiln (Clinkerization section)
Process Reactions Temperature ºC
Drying/ Pre-
heat
Free water evaporates 20 - 100
Crystallization water driven out 100-300
Chemical water driven out 400 - 900
calcining
CO2 Driven out
CaCO3 --> CaO+CO2
600 - 900
sintering
clinkering
Formation of Liquid Phase,
Formation of alite and belite
1450 exothermic
cooling
Crystallization of aluminates and
ferrites
1300 - 1240
Kiln Process
English Units
68 – 212 deg F
212 -572 deg F
752 -1652 deg F
1112-1652 deg F
2642 deg F
(2440-2642 degF)
2264 -2372 deg F
General Diagram of Preheater Reactions
Cyclone
Pyro(Sintering) system
Hot Clinker discharge from
kiln
Clinker formation
Sintering
Raw Meal Powder Clinker
Cement Grinding
Cement Grinding –
Ball Mill
Clinker Gypsum Cement
Cement Grinding
Grinding
Controlled fineness as per
customer needs
 OPC – Ordinary Portland Cement
 SRC - Sulphate Resistant Cement
 PLC – Portland Limestone Cement
 OWC – Oil Well Cement
Types of cement
Cement packing Machine
Cement Bags conveying system
Cement bags Loading
By Machine Manual
Packing section
Cement Storage silo
Raw mill Building
Old Kiln with planetary cooler
Line#3 Kiln
Line#2
Kiln
Pre-heater
One More view of pyro section
Vertical Roller Mill
Raw Material Storage shed
Cement Grinding section
Cement Manufacturing Process.pptx

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Cement Manufacturing Process.pptx

Editor's Notes

  1. Many 50's-era homes were built with wood shake or wood shingle roofs. By now, the house has had several roof replacements; likely now has a composition shingle, Hardie shake, Aluminum or other type of roof covering. The bathrooms in these houses were almost indestructible.
  2. Cement, in general, adhesive substances of all kinds, but, in a narrower sense, the binding materials used in building and civil engineering construction. Cements of this kind are finely ground powders that, when mixed with water, set to a hard mass. Setting and hardening result from hydration, which is a chemical combination of the cement a powder of alumina, silica, lime, iron oxide, and magnesium oxide burned together in a kiln and finely pulverized and used as an ingredient of mortar and concrete
  3. Cement is manufactured through a closely controlled chemical combination of calcium, silicon, aluminum, iron and other ingredients
  4. Selection of process is depend on nature of raw material, if the raw material is hard and dry then dry process is preferred, if the raw material is soft then wet process is preferred.
  5. Sintering is a thermal process of converting loose fine particles into a solid coherent mass by heat and/or pressure without fully melting the particles to the point of melting.
  6. Preheaters are used industrial dry kiln cement production plants to heat the raw mix and drive off carbon dioxide and water before it is fed into the kiln.
  7. The cyclone separator is a device for separating solid particles from contaminated gas streams Working principle : A cyclone is a centrifugal separator in which particles, due to their mass, are pushed to the outer edges as a result of centrifugal force
  8. Clinkering is the formation of non-combustible residue that is fused into an irregular lump that remains after combustion of coal [3]. Clinkers are mainly a mass formed on the furnace walls due to low fusion temperature of ash present in coal these clinkers are rough and strong bonded with surface in appearance [3].