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India is the 2nd largest cement producer in world after china .Right from laying concrete bricks of
economy to waving fly over¶s cement industry has shown and shows a great future. The overall outlook
for the industry shows significant growth on the back of robust demand from housing construction,
Phase-II of NHDP (National Highway Development Project) and other infrastructure development
projects. Domestic demand for cement has been increasing at a fast pace in India. Cement consumption
in India is forecasted to grow by over 22% by 2009-10 from 2007-08.Among the states, Maharashtra
has the highest share in consumption at 12.18%,followed by Uttar Pradesh, In production terms,
Andhra Pradesh is leading with 14.72% of total production followed by Rajasthan. Cement production
grew at the rate of 9.1 per cent during 2006-07 over the previous fiscal's total production of 147.8
mt(million tons). Due to rising demand of cement the sales volume of cement companies are also
increasing & companies reporting higher production, higher sales and higher profits. The net profit
growth rate of cement firms was 85%.
Cement industry has contributed around 8% to the economic development of India. Outsiders (foreign
players) eyeing India as a major market to invest in the form of either merger or FDI (Foreign Direct
Investment). Cement industry has a long way to go as Indian economy is poised to grow because of
being on verge of development.
Despite the growth of Indian cement industry India lags behind the per
capita production. Supply for cement is expected to remain tight which, in turn, will push up prices of
cement by more than 50%. The most important factor for better prices is consolidation of the industry.
It has just begun and we will see more consolidation in the coming years. Other budget measures such
as cut in import duty from 12.5 per cent to nil etc. are all intended to cut costs and boost availability of
cement.
Sadly the adverse effects of global slowdown have not speared this
industry too. Demand is sluggish, the government is keeping an eagle eye on prizes, domestic coal and
pet coke, prizes have increased sharply and utilizations rates are down. The numbers coming out are a
reflection of grim times. ACC the country¶s largest cement company that¶s controlled by Swiss giant
HOLCIM, registered 2% fall in august sales. The biggest fall since Feb. 2007. Production fell by 5%.
To stand against the problematic situation, government as well as cement industry has taken some
steps. Companies are focusing on cost of transportation. One of the strategy is to decrease dependence
on road & opt for sea logistics as that can cut transportation cost by 30- 50 %. Some plants are adopting

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futuristic plan such as setting up captive power plant, moving closer to the customers by creating
clicker, crushing, and capacity in key markets, to be more customer centric to generate better
revenue.India should push for stricter regulations of market place as to control the prices of big
companies and prevent them from forming cartels and exchanging information. To fight with the high
inflation, government wants to import more cement from Pakistan .However cement prizes are not very
much high as other items but still they are increasing.And the reason of high prize is surging cost of
raw material and transportation cost. Apart from this government also discussed with cement industry
not to have increase in prizes and keep consumer interest in mind.

Now the question arise in front of the government is whether the demand by the
government is possible to increase through expenditure on infrastructure or not according to the current
state of economy when so many crises are going on or how the government allocation of US$ 3.23
billion for the National Highway Development, Project will keep the demand for cement alive?And to
what extent the prizes of cement should be increase so that consumer can¶t affect.
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Portland Cement‘ is a gray, finely ground combination of minerals which, when mixed with
water, sand, gravel, and other materials form  . Cement provides the chemical bond that holds
the other materials together. Concrete, when newly mixed, is plastic and malleable, which allows it to
be cast into shapes to build homes, sidewalks, superhighways, dams, skyscrapers and many other
objects. Concrete is inert, nontoxic, naturally waterproof, and fire resistant. It is the world¶s most
commonly used construction material.

The words cement and concrete in every day usage are frequently interchanged, even though
cement is only one of the multiple materials used in the making of concrete . Cement manufacturing
and concrete production are bound together in any analysis of energy use and emissions.
The raw materials used to produce cement are primarily limestone, clay, shale, and silica sand
These materials are quarried, crushed, and, for economy, are usually transported to a nearby cement
plant. The cement plant proportions the raw materials to the correct chemical composition and grinds
the material to a fine consistency. Small quantities of iron ore, alumina, and other minerals may be

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added to adjust the raw material mixture. The finely ground raw material, ³raw meal,´ is fed into large
rotary kilns, cylindrical furnaces 10 to 25 feet in diameter and 200 to 1,000 feet in length. The rotary
cement kiln is the world's largest moving manufacturing machine and one of the hottest. It is typically
set on a slight incline and rotates from 1 to 4 revolutions per minute. A large kiln may ³pyroprocess´
more than 300 tonnes of raw meal an hour. The raw meal is heated in the kiln to extremely high
temperatures, about 1,500°C (2,700°F). The high temperature pyroprocessing causes the raw meal to
react and form complex mineral compounds. These compounds exit the kiln as a hard nodular material
called ³ .´ Many newer cement plants use the hot exiting kiln gases to preheat the raw meal.
Clinker is cooled and ground with approximately 5% gypsum (which controls concrete setting time)
and other minor additives to produce cement.

Concrete is produced by blending cement with fine aggregate (sand), coarse aggregate (gravel or
crushed stone), and frequently with small amounts of chemicals, called ³admixtures.´ Admixtures are
used to accelerate or retard setting time, control early plasticity properties, increase strength, improve
resistance to acid and sulfates, control shrinkage, and improve freeze/thaw cracking. When water is
added to the concrete mix at the job site, it forms a slurry that coats the surfaces of the aggregate and
fills the voids to form rock-solid concrete. The process of hardening or setting is the result of the water
hydration chemical reaction of the cement. The properties of concrete are determined by the exact
chemical composition of cement used, the additives, and the overall proportions of cement, aggregate,
and water. Concrete contains about 12 weight percent cement. Because of the relatively small cement
content, concrete is not energy intensive when compared to other construction materials.
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Cement has been made since Roman times, but over time the recipes used to make cement have been
refined. The earliest cements were made from lime and pozzolana (a volcanic ash Containing
significant quantities of SiO2 and Al2O3) mixed with ground brick and water. This cement was not
improved upon until 1758, when Smeaton noticed that using a limestone That was 20 - 25 % clay and
heating the mixture resulted in a cement that could harden under water . He called this new cement
'hydraulic lime'. When the mixture was heated, a small quantity of it was sintered1. Normally this was
discarded as waste, but in the 1800s Asp din and Johnson discovered that when the entire batch was
sintered and then ground, a superior Cement was formed. This substance became designated Portland
cement (after the region in which they were working) and is the most common cement in use today.
Portland cement was first produced commercially in New Zealand in 1886 by James Wilson and Co.,
and has been produced here ever since. Portland cement is currently defined as a mixture of
argillaceous (i.e. clay-like) and calcaneous (i.e. containing CaCO3 or other insoluble calcium salts)
materials mixed with gypsum (CaSO4ß2H2O) sintered and then pulverised into a fine powder. The
precise definition of Portland cement varies between different countries, and in New Zealand are
controlled by New Zealand's Standard Specification (NZS) 3122. Portland cement differsfrom its
precursors primarily in the fact that it is sintered.

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The ASTM standards have specified certain physical requirements for each type of cement.
These properties include·

1) Fineness

2) Setting time

3) Soundness

4) Compressive strength

5) Heat of hydration

6) Loss of ignition.

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Portland cements can be characterized by their chemical composition although

they rarely are for pavement applications. However, it is a portland cement's chemical properties that
determine its physical properties and how it cures. Therefore, a basic understanding of portland cement
chemistry can help one understand how and why it behaves as it does. This section briefly describes
the basic chemical composition of a typical portland cement and how it hydrates. ‘

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A summary of the uses of cement in World is given in u !. Cement is produced here in three main
grades· ordinary Portland cement (80% of Milburn's and 95% of Golden Bay's domestic sales), rapid
hardening cement and moderate-heat cement. Rapid-hardening cement is used in precast concrete,
pipes and tiles. It is finer ground so that it hydrates more quickly and has more gypsum than other
cements. Moderate-heat cement is used for the construction of hydro-electric dams, as the heat
produced by ordinary cement creates uneven expansion and hence cracking when such a large volume
of concrete is used. In addition, a few special cements are manufactured in New Zealand for larger
projects or export· these include sulphate resisting, fly ash blend, blast furnace slag and Price Mer
cement.

 
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The Indian cement industry is the second largest producer of quality cement, which meets
global standards. The cement industry comprises 130 large cement plants and more than 300
mini cement plants. The industry's capacity at the end of the year reached 188.97 million tons
which was 166.73 million tons at the end of the year 2006-07. Cement production during April
to March 2007-08 was 168.31 million tons as compared to 155.66 million tons during the same
period for the year 2006-07.Despatches were 167.67 million tons during April to March 2007-
08 whereas 155.26 during the same period. During April-March 2008-09, cement export was
3.65 million tons as compared to 5.89 during the same period.

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The quarried clay and limestone are crushed separately until nothing bigger than a tennis ball remains.
Samples of both rocks are then sent off to the laboratory for mineral analysis. If necessary, minerals are
then added to either the clay or the limestone to ensure that the correct amounts of aluminium, iron etc.
are present. The clay and limestone are then fed together into a mill where the rock is ground until more
than 85% of the material is less than 90ȝm in diameter.
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The clay is mixed to a paste in a wash mill - a tank in which the clay is pulverised in the presence of
water. Crushed lime is then added and the whole mixture further ground. Any material which is too
coarse is extracted and reground. The slurry is then tested to ensure that it contains the correct balance
of minerals, and any extra ingredients blended in as necessary.
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Dry process cement production line means utilizing the outside kiln pre-calcining technology as new
type process to produce cement. The production takes suspension pre-heater and outside kiln pre-
calcining technology as the core, taking advantage of new type raw material and fuel homogenization
and energy-saving grinding technology and equipment, utilizing the computer distributed control
system in the whole line, so as to realize the automation, high efficiency, best quality, low energy
consumption, and environmental protection in the process of cement production.

New type dry process cement production technology began to develop since 1950s. Till now, the
production equipment ratio of new type dry process cement and clinker, featured with suspension pre
heater and pre calcining technology, has taken up 95% in Japan, Germany and such developed
countries. The first set suspension pre-heater and pre calcining kiln were put into production in 1976.
The advantages of the technology are as follows·

1. Transferring heat rapidly;

2. High heat efficiency;

3. Having larger production per unit volume compared with wet process cement;

4. Low heat consumption.

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Cement production process· technology advanced; automatically control; low cost, enviroment
friendly; fast return. ‘

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There are 11 steps of the cement production process, relying on the 11 step, we can know the basic
cement equipment. The whole set cement plant cost maybe high ,but when we install this cement line
plant, the profit will be come true at one time.

1.Mining system

limestone mining advanced technology, fine equipment, the equipment have the big type drilling rig,
mucking equipment and transport cars, the blasting used quarry bench, middle-deep hole, non-
electrical short-delay extrusion, safe blasting, big block ratio small, the blasting can reach to no waste
production and make full use of the limestone resource.

2. Raw material crushing system

Single-stage hammer crusher break up the limestone, the max size 1500mm of limestone break up less
than 70mm one time, technology process is simple, stable ,advanced, having the package dust collector,
environment cleaning, meet the environmental protection requirement.

3. Raw material homogenization and storage system

A. Limestone homogenization store

Using the long or rounded pre-homogenization silo, homogenization result well , the program control
automatically stacker and reclaimer operation. After homogenization limestone chemical composition
is stable.
B. Clay and sand rock homogenization store Using the long pre-homogenization silo , homogenization
result well ,stacker and reclaimer according to the clay characteristic automatically control operation.
After homogenization clay and sand rock chemical composition is stable.

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4. Raw material mixing system

Rely on the local raw material resource , select limestone , sand rock , clay , iron raw material .etc, to
mix and produce .Upper raw material though the homogenization to mixing system , relying on the
cement special mixing formula, using the advanced electrical belt weight to accurately measurement
produce

5. Raw material grinding and waster gas processing system Using the advanced vertical roll mill
technology , outfitting advanced electrical dust collector and package dust collector ,after the grinding
raw material quality well , fine controllable , low energy , output friendly to environment .

6. Raw material homogenization and into kiln system

Adopted the continuous raw material homogenization storage technology , take the after grinded raw
materials homogenization again , used the advanced X-ray analyzer , making the raw material quality
monitoring , adjusting the kinds of raw material mixing on time , meet for the quality requirements.

7. Clinker calcining and waste heat power generation system

Adopted advanced pre-separate dry type rotary kiln cement production technology , equipping Yi gong
machinery independent research and development automatic control program ,control production
stable , product quality well , low coal waste , low energy and other main economic indicators reached
international advanced level.

reduced NOX ,dust , noise and inverter technology application and other sides have the Yi gong special
advantages .Used the kiln tail and head 's waste gas waste heat resource , taking the significant result
,under the daily output 5000t clinker production line , 1t clinker power generation reach to more than
40kw , achieved the international advanced level .

To the coal quality better region ,used vertical roll grind technology , coal power low energy , product
quality meet for production need , used coal power special antistatic package dust collector , the
density of coal power output less than country standard , according to the coal power flammable and

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explosive characteristic , designed the automatically check , alarm , fire-proof system , the whole
system safe and stable.

To the coal quality low , volatile lower defective or anthracite coal , selected specially ball mill, used
the ball mill easily control quality advantage , more mixed defective coal or anthracite coal , used the
resource , and also reduced cement production cost.

8.‘Clinker input bin and bulk cement transport according to the market difference need , can provide car
, train and ship three type clinker saling , also meet for the factory self grinding cement need.

9.‘Cement mixing and grinding system According to the cement kind difference need , mixed adequate
gypsum and mixed material , through high precision scale mixing material to input cement mill ,in
order to produce high quality cement adopted the advanced quality monitor to tracking , monitoring and
adjustment.
The cement grinding equipment can rely on the difference need to select roll presser system , taking the
high efficiency select dust system and vertical roll mill system , cement mill used the high efficiency
package type dust collecting technology .meted for the environmental protection high standard output
requirement .
Cement production process adopted Yi gong independent development soft, control automatically ,
produced control data well , product quality high ,low energy , low cost , having the strong market
competition advantage.

10.Cementstoringandtransporting system ,Though grinding cement are stored round roll bin, after series
of strict chemical and physical test, right cement can be as the finished product sale. Sling type
according to customer need, select car bulk packing, train bulk packing, ship bulk packing and car bag
packing, train bag packing ,and so on.

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1. The rise in the price of cement is because of the gap of demand & supply in the market. The demand
for cement is much higher than its actual supply. But with the production maximization, which can be
encountered in next few year, this gap may narrowed down, that may ensure the market to be in
equilibrium.

2. Decreasing per capita consumption doesn¶t affect the total consumption for the cement. It means the
infrastruct) - the raw materials of cement manufacture.ure; contacted housing is using the bulk of the
production.

3. In spite of High price of the product, the hick of demand because of the increasing rate of
infrastructural development.

4. Domestic price of cement is rising as well as the imported cement price is lowering. So altogether the
supply of the cement, which is affordable, will increase. This may in decrease the gap between supply
and demand.

5. Major Demand was from the housing sector, which may shift to infrastructure as lots of
infrastructural development processes has already being taken up & due to the increased price, housing
segment started showing a slowdown‘

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