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    Cement Industry

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    Chaudary Usman Gondal
    Cement is produced through a process involving mixing raw materials like limestone and clay, burning the mixture in a rotary kiln at high temperatures, and grinding the resulting clinker. There are two main processes for cement production - the dry process, which mixes dry raw materials, and the wet process, which mixes materials with water to form a slurry. The burned clinker is then ground into a fine powder and packaged for use.

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    Cement Industry

    Uploaded by

    Chaudary Usman Gondal
    48 views22 pages
    Cement is produced through a process involving mixing raw materials like limestone and clay, burning the mixture in a rotary kiln at high temperatures, and grinding the resulting clinker. There are two main processes for cement production - the dry process, which mixes dry raw materials, and the wet process, which mixes materials with water to form a slurry. The burned clinker is then ground into a fine powder and packaged for use.

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    Cement industry

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    Cement is produced through a process involving mixing raw materials like limestone and clay, burning the mixture in a rotary kiln at high temperatures, and grinding the resulting clinker. There are two main processes for cement production - the dry process, which mixes dry raw materials, and the wet process, which mixes materials with water to form a slurry. The burned clinker is then ground into a fine powder and packaged for use.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    48 views22 pages

    Cement Industry

    Uploaded by

    Chaudary Usman Gondal
    Cement is produced through a process involving mixing raw materials like limestone and clay, burning the mixture in a rotary kiln at high temperatures, and grinding the resulting clinker. There are two main processes for cement production - the dry process, which mixes dry raw materials, and the wet process, which mixes materials with water to form a slurry. The burned clinker is then ground into a fine powder and packaged for use.

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    © All Rights Reserved
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    Cement Industry

    YOUR DREAMS ARE LIKE THE  CEMENT. IF YOU WATER IT WITH


    ACTIONS, IT BECOMES A HARD CONCRETE MASS.
     Cements are materials that exhibit characteristic
    properties of setting and hardening when mixed to a paste
    with water. This makes them join rigid masses into
    coherent structures. It is powdery bonding material having
    adhesive and cohesive properties.
     Chemically it is a finely ground mixture of calcium silicates
    and aluminates which set to a hard mass when treated with
    water. These are called as Hydraulic Cements (Portland
    Cement) and those setting in air are Non Hydraulic
    cements (Ordinary Lime).
    MANUFACTURE

    It involves the following steps:


     Mixing of raw material
     Burning
     Grinding
     Storage and packaging
    Mixing of raw material
    Mixing can be done by any one of the following two
    processes
    (a) Dry process.
    (b) Wet process.
    RAW MATERIALS
    Process
    Dry Process
    Dry Process

    Lime stone or chalk and clay are crushed into


    gyratory crusher to get 2-5 cm size pieces.
    Crushed material is ground to get fine particle into
    ball mill or tube mill.
    Each material after screening stored in a separate
    hopper.
    The powder is mixed in require proportions to get
    dry raw mix which is stored in silos (storage tank)
    and kept ready to be fed into the rotary kiln.
    Raw materials are mixed in required proportions.
    So that average composition of the final product is
    maintained properly.
    Wet Process
    Wet Process

    Raw materials are crushed, powdered and stored in silos.


    The clay is washed with water in wash mills to remove adhering
    organic matter.
    The washed clay is stored separately.
    Powdered lime stone and wet clay are allowed to flow in channel
    and transfer to grinding mills where they are intimately mixed
    and paste is formed known as slurry.
    Grinding may be done either in ball mill or tube mill or both.
    Then slurry is led to correcting basin where chemical
    composition may be adjusted.
    The slurry contains 38-40% water stored in storage tank and
    kept ready for feeding to a rotary kiln.
    Comparison of dry process and wet process:

    The remaining two operations burning and grinding


    are same for both the process.
    Burning

    Burning is carried out in rotary kiln which rotating at 1-2 rpm


    at its longitudinal axis.
    Rotary kiln is steel tubes having diameter in between 2.5-3.0
    meter and length varies from 90-120 meter. The inner side of
    kiln is lined with refractory bricks.
    The kiln is rested on roller bearing and supported columns of
    masonry or concrete in slightly inclined position.
    The raw mix or corrected slurry is injected into the kiln from
    its upper end.
    Burning fuel like powdered coal or oil or hot gases are forced
    through the lower end of the kiln so long hot flame is
    produced.
    Burning

    Due to inclined position and slow rotation of the kiln, the


    material charged from upper end is moving towards lower end
    (hottest zone) at a speed of 15meter/hour.
    As gradually descends the temperature is rises.
    In the upper part, water or moisture in the material is
    evaporated at 4000°C temperature, so it is known as drying
    zone.
    In the central part (calcinations zone), temperature is around
    1000°C, where decomposition of lime stone takes place.
    After escapes of CO2, the remaining material in the forms small
    lumps called nodules.
    CaCO3 CaO + CO2
    Burning zone
    Burning zone
    Burning

    The lower part (clinkering zone) have temperature in


    between 1500-1700°C.
    Where lime and clay are reacts to yielding calcium
    aluminates and calcium silicates.
    This aluminates and silicates of calcium fuse to
    gather to form small and hard stones are known as
    clinkers.
    The size of the clinker is varies from 5-10mm.
    Cont’d

    As clinkers are coming from burning zone, they are


    very hot.
    The clinkers are cooled down by air admitting
    counter current direction at the base of rotary kiln.
    Resulting hot air is used for burning powdered coal
    or oil and cooled clinkers are collected in small
    trolleys or in small rotary kiln.
    Grinding:

    Cooled clinkers are ground to fine powder in ball mill or


    tube mill.
     2-3% powdered gypsum is added as retarding agent
    during final grinding.
    So that, resulting cement does not settle quickly, when
    comes in contact with water.
    After initial set, cement - water paste becomes stiff, but
    gypsum retards the dissolution of tri-calcium aluminates
    by forming tri calcium sulfoaluminate which is insoluble
    and prevents too early further reactions of setting and
    hardening.
    Storage and packaging:

    The ground cement is stored in silos, from which it is


    marketed either in container load or 50kg bags.
    CLASSIFICATION OF CEMENT

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