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    Cement 2

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    Tejas Yadav
    Cement is produced through a process involving mixing raw materials like limestone, clay, coal and gypsum, burning them in a rotary kiln at high temperatures, and grinding the resulting clinkers with gypsum. The raw materials are either mixed dry or as a slurry with water. In the kiln, they undergo drying, calcination and clinkering as the temperature increases. Chemical reactions form calcium silicates and aluminates that fuse into clinker balls. The clinkers are cooled, ground into powder, and mixed with gypsum before packing as finished cement.

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    Cement 2

    Uploaded by

    Tejas Yadav
    21 views3 pages
    Cement is produced through a process involving mixing raw materials like limestone, clay, coal and gypsum, burning them in a rotary kiln at high temperatures, and grinding the resulting clinkers with gypsum. The raw materials are either mixed dry or as a slurry with water. In the kiln, they undergo drying, calcination and clinkering as the temperature increases. Chemical reactions form calcium silicates and aluminates that fuse into clinker balls. The clinkers are cooled, ground into powder, and mixed with gypsum before packing as finished cement.

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    cement 2

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    Cement is produced through a process involving mixing raw materials like limestone, clay, coal and gypsum, burning them in a rotary kiln at high temperatures, and grinding the resulting clinkers with gypsum. The raw materials are either mixed dry or as a slurry with water. In the kiln, they undergo drying, calcination and clinkering as the temperature increases. Chemical reactions form calcium silicates and aluminates that fuse into clinker balls. The clinkers are cooled, ground into powder, and mixed with gypsum before packing as finished cement.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    21 views3 pages

    Cement 2

    Uploaded by

    Tejas Yadav
    Cement is produced through a process involving mixing raw materials like limestone, clay, coal and gypsum, burning them in a rotary kiln at high temperatures, and grinding the resulting clinkers with gypsum. The raw materials are either mixed dry or as a slurry with water. In the kiln, they undergo drying, calcination and clinkering as the temperature increases. Chemical reactions form calcium silicates and aluminates that fuse into clinker balls. The clinkers are cooled, ground into powder, and mixed with gypsum before packing as finished cement.

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    © All Rights Reserved
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    of 3

    CEMENT

    Definition: A material possessing adhesive and cohesive properties, and capable of bonding
    other materials like stones, sand, bricks, building etc. is called as cement.
    Cements have the property of setting and hardening under water and air. Based
    on this, cements are classified into two types.
    1. Hydraulic cement: Cement which is having the property of setting and hardening
    under water. Eg., Portland cement.
    2. Non- hydraulic cement: Cement which is having the property of setting and hardening
    under air. Eg., lime.
    Manufacture of Portland cement
    Raw materials:
    1. Calcareous materials like lime, chalk, etc.
    2. Argillaceous materials like alumina, silica, clay, etc.
    3. Powdered coal.
    4. Gypsum (CaSO42H2O).
    Steps:

    1. Mixing of raw materials

    Raw materials can be mixed either by dry process or by wet process.

    (a) Dry process

    Lime stone and clay are separately crushed and converted into fine powder in
    ball mills. These powdered materials are mixed together and stored in storage bins (silos).
    This mixture is known as raw mix or raw meal.

    (b) Wet process

    Lime stone is crushed, powdered and stored in big storage tank. Clay is washed
    with water in wash mills to remove organic materials. Both materials are ground in a machine
    where they are converted to a paste called raw slurry. Slurry has 40% of water.

    2. Burning or calcination

    Raw mix or slurry is burnt in a rotary kiln.It is a steel cylinder lined inside with
    refractory bricks. The kiln is kept in slightly inclined position for moving the charge from the
    upper end to the lower end. The kiln rests on the roller bearings and it rotates about its axis at
    a rate of 1 revolution per minute. Hot flame is produced by injecting coal dust and air at the
    lower end. It heats the interior of the kiln up to 1700ºC. Raw mixture is injected into the
    upper part of the kiln. As the kiln rotates, the charge slowly moves from the upper end to the
    lower end.
    Rotary kiln
    There are three portions in the rotary kiln.

    (i) Upper part or Drying zone - water is evaporated at 400ºC and clay gets decomposed
    into individual components.
    Al2O3.SiO2.Fe2O3.2H2O → Al2O3+ SiO2 +Fe2O3 + 2H2O

    (ii) Middle part or Calcination zone–lime stone gets decomposed to form CaO and CO2 at
    1000ºC.

    (ii) Lower part or Clinkering zone - chemical interaction between lime and clay takes
    place at 1700ºC ie., aluminates and silicates of calcium are fused together to form
    small, hard greyish stone called clinkers. These hot clinkers fall into the cooler and
    the hot air released from the cooler is sent for burning coal dust.
    The reactions are as follows,

    2CaO + SiO2 2CaOSiO2 (Dicalcium silicate)


    3CaO + SiO2 3CaOSiO2 (Tricalcium silicate)
    3CaO + Al2O3 3CaOAl2O3 (Tricalcium aluminate)
    4CaO + Al2O3 Fe2O3  4CaOAl2O3Fe2O3 (Tetracalcium aluminoferrite)

    3. Mixing clinkers with gypsum

    Cooled clinkers are ground into fine powder and mixed with 3% gypsum. It retards
    the quick setting of cement.

    3CaOAl2O3 + 3(CaSO4.2H2O) + 2H2O  3CaOAl2O3.3CaSO4.2H2O + 2H2O

    4. Packing
    The ground cement is stored in silos and packed.

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