MANUFACTURING PROCESS OF CEMENT

MATERIALS USED IN MANACTURING OF CEMENT ARE AS FOLLOWS:

1. Limestone (rich in Calcium Carbonate (CaCO3 )) 2. Clay, marl or shale (supplies the bulk of the silica, alumina and ferric oxide 3. other supplementary materials such as sand, pulverized fuel ash , or ironstone to achieve the desired bulk

Stages of cement production at a cement plant:

1. Procurement of raw materials 2. Raw Milling - preparation of raw materials for the pyroprocessing system 3. Pyroprocessing - pyroprocessing raw materials to form cement clinker 4. Cooling of cement clinker 5. Storage of cement clinker 6. Finish Milling 7. Packing and loading

1. Procurement of raw materials:

Most of the raw materials used are extracted from the earth through mining and quarrying limestone is the predominant raw material, most plants are situated near a limestone quarry Quarry operations consist of drilling, blasting, excavating, handling, loading These naturally occurring minerals are then crushed through a milling process

 After milling, the raw meal is transported to the plant where it is stored.
The plant must minimize the transportation cost since one third of the limestone is converted to CO2 during the pyroprocessing

2. Raw Milling:
Raw milling involves mixing the extracted raw materials to obtain the correct chemical configuration and grinding them to achieve the proper particle-size to ensure optimal fuel efficiency in the cement kiln and strength in the final concrete product IN Raw Milling two process are used: 1. Dry process 2. Wet process DRY PROCESS: In the dry process the raw materials are dried using rotating mill, impact dryers, drum dryers, rapid dryers, air separators, or autogenous mills, before grinding, or in the grinding process

 The raw materials are ground to a size where the majority of the materials are less than 75 microns

The dry materials exiting either type of mill are called "kiln feed and it is stored in silos until required

2. WET PROCESS: In the wet process, water is added during grinding The raw materials are ground to a size where the majority of the materials are less than 75 microns Materials exiting the mill are called "slurry" and have flow ability characteristics The slurry is stored in tanks or basins until required.

 70% lime stone + 30% shale + water is mixed in slurry mill to give slurry

3. Pyroprocessing: In pyroprocessing, the raw mix is heated to produce cement clinker In the wet process, the slurry is fed to a rotary kiln, which can be from 3.0 m to 5.0 m in diameter and from 120.0 m to 165.0 m in length Process temperatures can reach as high as 1450 degree Celsius during the clinker making process In the dry process, kiln feed is fed to a preheater tower, which can be as high as 150.0 meters The preheater tower and rotary kiln are made of steel and lined with special refractory materials to protect it from the high process temperatures the rotary kiln is fired with an intense flame, produced by burning coal, coke, oil, gas or waste fuels

At the temperature of 1450 degree Celsius carbon dioxide is liberated from calcium carbonate to form calcium oxide thios process is called calcinations The resulting hard substance, called 'clinker is obtained

4. Clinker Cooling
The clinker cooling operation recovers up to 30% of kiln system heat

 Common types of clinker coolers are reciprocating grate, planetary, and rotary. Air sent through Type of cooling reflects the quality of cement After cooling clinkers are sent to the clinker storage with the help of conveyers Based on the cooling efficiency and desired cooled temperature, the amount of air used in cooling process is approximately 1-2kg/ kg of clinker The clinker is combined with small amounts of gypsum and additives such as limestone slag and fly ash, and finely ground in a finishing mill to produce cement

5. Clinker Storage
clinker storage capacity is based on the state of the market, a plant can normally store 5 - 25% of its annual clinker production capacity Equipment such as conveyors and bucket elevators is used to transfer the clinkers from coolers to storage areas and to the finish mill. Gravity drops and transfer points typically are vented to dust collectors

6. Finish Milling
IT is the final stage of production of cement 5% of gypsum is added to cement clinker and it is crushed with the help of crushers

 Grinding process occurs in a closed system with an air separator that divides the cement particles according to size Material that has not been completely ground is sent through the system again

7. Packing and Loading

Once the production of cement is complete, the finished product is transferred using bucket elevators and conveyors to large, storage silos in the shipping department.

 Cement is dispatched either in bulk or in 50kg bags and distributed from the manufacturing plant via rail or road

Bags are used primarily to package masonry cement. Once the cement leaves the plant, distribution terminals are sometimes used as an intermediary holding location prior to customer distribution. The same types of conveyor systems used at the plant are used to load cement at distribution terminals.

7. MACHINES USED IN MANUFACTURING OF CEMENT :

a) Cement grinders b) Cement rotary kilns c) Cement crushers

d) Pre heaters e) Coolers f) Ball mills

a) CEMENT GRINDERS: For floor and slab surfaces, you can find walk-behind grinders ranging in size from single-disc units for working in small or restricted areas to dual-, triple- or even four-disc machines for high-production grinding of large slabs. A single-disc grinder has a working width of 10 to 12 inches while a dual-disc unit covers 20 or more inches in one pass. Disc rotation speeds range from about 250 to over 3,000 rpm. On multiple-disc units, the discs usually are counter-rotating to provide balanced torque so the grinder won't pull from side to side. For more even grinding, some machines are also equipped with floating heads that will follow the contour of the floor and adjustable rear wheels to keep the grinding discs level. Many manufacturers offer a choice of power options, including electric, gasoline and propane. Most machines are equipped with vacuum ports for dust-free dry grinding. Some models also include water mist systems so they can be used with wet- or dry-cutting attachments

b) Rotary kiln:

Cement rotary kiln calcining cement clinker removal, also used to calcined clay, limestone and slag drying; the production of refractory materials, using a limestone rotary kiln calcinations of raw materials, make its dimensional stability, strength increase, and then molding processing Rotary kiln is composed of cylinder, gears, support device, kiln liner and kiln tail sealing equipment, kiln head hood and combustion. Cylinder as heated pivoting part, made of highquality carbon steel plate, is supported on the support device by type, and there is mechanical or hydraulic pressure catch wheel on the first or some gear in order to control the turning of cylinder. Gearing gyrate is according to process-required rotating speed by ring gear in the middle of cylinder. Because of the need of installation or maintenance, the bigger clinker rotary kiln has auxiliary gears, which makes cylinder gyrate more slowly. To prevent cold air come in and dust overflow, the reliable kiln tail and head sealing equipment is installed on feed and discharge end Cement kiln is used for making of cement clinker and there are dry and wet methods to make cement. metallurgy chemical kiln is used for magnetic roasting of iron ore and oxidizing roasting of chrome and nickel in the steel factory; baking high-alumina mine in the refractory material factory; baking chamotte and alumina in the aluminium factory and baking chrome ore and chrome powder in the chemical plant Cement kiln is used for making of cement clinker and there are dry and wet methods to make cement. metallurgy chemical kiln is used for magnetic roasting of iron ore and oxidizing roasting of chrome and nickel in the steel factory; baking high-alumina mine in the refractory material factory; baking . Rotary kiln, namely clinker rotary kiln, belongs to building material equipment, which can be divided into Cement rotary kiln, metallurgy chemical kiln and Limestone rotary kiln according to different materials.

1. Cement rotary kiln is used for making of cement clinker and there are dry and wet methods to make cement. 2. Metallurgy chemical kiln is used for magnetic roasting of iron ore and oxidizing roasting of chrome and nickel in the steel factory; baking high-alumina mine in the refractory material factory; baking chamotte and alumina in the aluminium factory and baking chrome ore and chrome powder in the chemical plant. 3. Limestone rotary kiln is used for baking active lime and dolomite in the steel factory and ferroalloy factory.

c) Cement crusher:
Cement crushing process is the important coal processing in cement production industry. SBM offer the complete cement powder producing equipments in the cement crushing process. Cement crushing plant acts as the key crushing plant in this process. Primary cement crusher works in the first stage of cement crushing process. Cement raw materials are firstly poured into vibrating feeder, which they will be fed into primary cement crusher continuously and evenly. Primary crusher is usually jaw crusher or impact crusher, producing lump cement cinder. Secondary cement crusher crushes the lump cement cinder transported by cement conveyor. Secondary cement crusher usually includes hydraulic impact crusher, cone crusher and JC jaw crusher. It produces sand size cement particle which can be used in pretreatment of cement directly. Tertiary cement crusher resizes cement particle into cement powder.

Tertiary crusher is used in special occasions like the cement grinding mill has special requirements on the feeding size. Cone crusher can act as the tertiary cement crusher because of its fine final outlets.

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a hard and fire-proof material which may further be employed in designing buildings, shop floors, reservoirs and other foundations. Any kind of iron or timber structure is exposed to corrosion either by air or water. But with a concrete casing, made by utilizing Portland cement, they can be effectively protected. Any structure that is meant to support huge amounts of weight will bring Portland cement into use. These structures range from ground floors of multi-storey buildings to bridge floors and from bridge spans to dams. Due to its ability to prevent corrosion, it is also put to use in ships, tanks and bunkers. A blaze or a devastating fire may leave a structure completely burnt but with the use of Portland cement, this can be prevented.

10. IT is also brought into usage in mortars, plasters, screeds and grouts as a material which can be squeezed into gaps to consolidate the structure

Indias cement production capacity is currently estimated at about 320 million t, with 148 large and 365 mini cement plants, including public sector facilities. The CMAs longterm target calls for Indias cement industry to reach a capacity of 550 million tpa by 2020, which will involve adding a further 230 million tpa. With the cement industry due to install around 25 million t in new cement production capacity this year, Indias total cement production capacity will reach approximately 345 million t by the end of FY12/13.