Cement Industry

Cement is a powdery substance made by calcining lime

and clay,mixed with water to form mortar and mixed with
sand to form concrete.

 Manufacturing Process of Portland Cement

Raw materials:-
1. Calcareous materials:-CaO , Lime
2. Agrillaceous
materials:-𝐴𝑙2 𝑂3 , 𝑆𝑖𝑂2
3. Powdered coal
4. Gypsum
Lime Stone

Crusher

Grinder

Raw material

Kiln

Clinker Additives

Grinder

Cement
 Flowsheet of Portland Cement
 MANUFACTURE PROCESS
It involves the following steps:-
1.Crushing
2.Mixing wet process
3.Grinding
4.Kiln
5.Grinding
6. Storage and packaging
1.Crushing:-
This is the first step in the manufacturing of Portland
cement.
Jaw crushers of various sizes are use for the crushing
process.
Raw materials are crushed by crushers till the size of the
raw material reduces to ¾ of an inch.
It is then send for either wet process or dry process.
2.Mixing wet process:-
calcareous materials are crushed , powdered and stored
in bins.
Argillaceous materials is mixed with water and washed.
Then it removes any adhering organic impurities.
Powdered, calcareous and washed argillaceous materials
are mixed in proper proportions to get a slurry.
This slurry is then fed into a rotary kiln.
3.Grinding:-
Grinding can be done by the two stages.
1.Ball mill
2.Tube mill
4.Kiln:-
Slurry is brunt in rotary kiln.
kiln is divided into three zones
1.Drying zone – 200-500°c
2.Calcinating zone – 1000°c
3.Clinkering zone – 1400-1600°c
1.Drying Zone :-
This is the upper part of the kiln.
Temperature is maintained about 200-500°c.
Most of water gets evaporated from the slurry by means
of hot gases.
2.Calcinating Zone:-
This process is done in the middle portion of the kiln.
The temperature is maintained about 1000°c
Here in organic matter burns away and 𝐶𝑎𝐶𝑂3decomposes
to quick lime and 𝐶𝑂2 escapes away.
Materials forms small lumps formed.
𝐶𝑎𝐶𝑂3 CaO + 𝐶𝑂2
Lime Quick
stone lime
3.Clinkering Zone:-
This is the lower portion of the kiln.
The temperature is between 1400-1600°c.
Here lime and clay nodules melts with chemical fusion and
gives calcium aluminates and silicates.
And then forms small hard stones called clinkers and then
cooled to form crystals.
2CaO + 𝑆𝑖𝑂2 𝐶𝑎2 4
3CaO+ 𝑆𝑖𝑂2 𝐶𝑎3 𝑆𝑖𝑂5
3Cao+𝐴𝑙2 3 𝐶𝑎3𝐴𝑙2𝑂6
4CaO+𝐴𝑙2 3 +𝐹𝑒2 𝑂3 𝐶𝑎4𝐴𝑙2𝐹𝑒2𝑂12

5.Grinding:-
Clinkers are finally grinded in the ball mill and tube mill
to a fine powder.
6.Packing:-
Cement is stored in bins from which it is fed to automatic
packing machines.Each bag usually contains 50 Kg of
cement.
Major Engineering Problems:-
1.Grinding
2.Kiln design
3.Heat economy
4.Quality control