Cement manufacturing process

Cement
Manufacturing Process
MADE BY:-
ABHINAV KP

• Cement sector notably plays a critical role in
the economic growth of the country
• Cement is vital to the construction sector
and all infrastructural projects.
• Occupies an important place in the Indian
economy because of
• Construction
• Transportation
• Coal
• Power
INTRODUCTION

• Concrete is the second most consumed material
after water, with nearly three tones used annually
for each person on the planet.
• One of the basic elements for setting up strong
and healthy infrastructure cement plays a crucial
role in the economic development of any country
• The Indian cement industry is the second largest
producer of cement in the world after China
• Cement industry in India comprises 183 large
cement plants and over 365 mini cement plants

• Produced strictly as per the Bureau of
Indian Standards (BIS) specifications and
their quality is comparable with the best in
the world.
• Indian cement majors—ACC Ltd, Gujarat
Ambuja Cements ,Ultratech

• Industry is split into five
geographical segments named as
• North
• South
• East
• West
• Central
GEOGRAPHIC DISTRIBUTION

Portland Cement
. A hydraulic cement made by finely
powderising the clinker produced
by calcining to incipient fusion
a mixture of argillaceous and
calcareous materials.
.Portland cement is a powder that is
the active ingredient in concrete.

Concrete
It is prepared by:-
. Shovel powder…………Portland Cement
. Shovels sand…………Mineral Aggregate
. Shovels Rock………. Mineral Aggregate
. Add water & mix.
. It is ready to mend .

• Mixture of ingredients into a paste &
triggers a chemical reaction – hydration.
• Reaction forms a gel which coats &
fills
spaces between the stone/sand;
• Hardens into a solid mass that
gets stronger & stronger.

• The world’s most widely used building
material.
• Global production is 5 billion cubic yards
per year (using approximately 1.25 billion
tons of cement).

Concrete owes its strength and
durability to one essential ingredient
-
Portland Cement.

Portland Cement
• Limestone + Shale/Clay + Heat = Clinker +
CKD + Exit Gas.
• Material Temperatures Exceed 2700 degrees F
• Pulverized Clinker + Gypsum = Portland
Cement.
• Cement is powder so fine that one pound
contains 150 billion grains.

– Calcium (Ca)
– Silicon (Si)
– Aluminum (Al)
– Iron (Fe)
• Typical Raw Materials:
– Limestone (CaCO3)
– Sand (SiO2)
– Shale, Clay (SiO2, Al2O3, Fe2O3)
– Iron Ore/Mill Scale (Fe2O3)
Basic Chemical
Components of Portland
Cement:

. Calcareous Component . Argillaceous
Component
(providing Lime - CaO) (SiO2, Al2O3, and
Fe2O3)
– limestone -clay
– marly limestone -shale
– chalk -calcareous marl
– coral limestone -marl
– marble -marly clay
– lime-sand -tuff, ash
– shell deposits - phyllite ,slate
– lime sludge -glass

• Clinker Chemistry
– Tricalcium silicate (3CaO.SiO2), (50-70%)
– Dicalcium silicate (2CaO.SiO2), (15-30%)
– Tricalcium aluminate (3CaO.Al2O3), (5-
10%)
– Tetracalcium aluminoferrite
(4CaO.Al2O3.Fe2O3), (5-15%)

SiO2
CaO CaO
CaO CaO
CaO CaO
Al2O3

History of Portland Cement
• First cements produced by early Greeks and
Romans from volcanic ash mixed with slaked lime.
• This art was lost during the Middle Ages.
• Portland cement developed in England by
bricklayer Joseph Aspdin in early 1800’s.
• Called “Portland” because concrete made with it
resembled natural stone from the Isle of Portland.

• First rotary kiln designed to produce Portland
cement patented in 1885 by Frederick Ransome.
• First economical U.S. kilns developed by Atlas
Cement Company in 1895.
• Thomas A. Edison first developed long kilns
(150
feet compared to 60 to 80 feet).

Types of Cement Processes
• Wet Process.
• Dry Process - 74% of cement
produced.
• Preheater/Precalciner Process.

Evolution of the cement
Process
• Wet process easiest to control chemistry &
better
for moist raw materials.
• Wet process high fuel requirements - fuel
needed
to evaporate 30+% slurry water.
• Dry process kilns less fuel requirements
• Preheater/Precalciner further enhance fuel
efficiency & allow for high production rates.

Cement Kilns
• High temperature
• Long residence time
• Natural alkaline
environment
• CKD is only by-product of the process.
• Thermal stability

Kiln Process Control
• Critical Parameters: Fuel, Feed,
Kiln Speed, Gas Flow
• Kiln Temperatures - Burning Zone
• Kiln Stability
• Chemistry
• Instrumentation

Cement manufacturing process

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