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Production Process of Cement

1. Portland cement is produced through a chemical process involving calcium, silicon, aluminum and iron. 2. In the dry process, raw materials like limestone and clay are crushed, homogenized, and dried in a preheater before being calcined in a rotary kiln at high temperatures to produce clinker. The clinker is then ground to produce cement. 3. In the wet process, limestone and clay are ground with water to form a slurry, which is dried and burned in a kiln at 1500 degrees Celsius to produce clinker. The clinker is then ground with gypsum to produce cement.

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366 views2 pages

Production Process of Cement

1. Portland cement is produced through a chemical process involving calcium, silicon, aluminum and iron. 2. In the dry process, raw materials like limestone and clay are crushed, homogenized, and dried in a preheater before being calcined in a rotary kiln at high temperatures to produce clinker. The clinker is then ground to produce cement. 3. In the wet process, limestone and clay are ground with water to form a slurry, which is dried and burned in a kiln at 1500 degrees Celsius to produce clinker. The clinker is then ground with gypsum to produce cement.

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Marwa
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Production process of cement

Introduction:
Portland cement is the basic ingredient of concrete. Concrete is formed when port-land cement
creates a paste with water that binds with sand and rock to harden.
Cement is manufactured through a closely controlled chemical combination of calcium, silicon,
aluminum, iron and other ingredients.
The most common way to manufacture Portland cement is through a dry method. new type dry
process cement plant is given below
Dry cement process:
1. Crushing and Pre-homogenizing
Most of the raw materials, like limestone, clay, iron ores, and coal, should be crushed
before their pre-homogenization. Limestone is the primary material in this line, and due to
its large particle size and high hardness, it’s good crushing plays an important role in the
whole line. Special stacking and reclaiming technology has been used in the pre-
homogenizing process so that raw materials can be better primarily homogenized.
2. Raw Meal Preparing
Since the raw meal grinding work takes up more than 30% labor force in the whole dry
process cement production line, it is quite important to choose appropriate grinding
equipment and technological process so that high-quality products can be obtained.
3. Raw Meal Homogenizing
The raw meal homogenization is a key factor for stable clinker calcination.
4. Preheating and Decomposing
The preheater is used to preheat as well as decompose raw meal. So the length of the rotary
kiln is effectively shortened. And the raw meal can fully exchange heat with the hot gases
from the kiln. Because of its rapid and high-efficiency heat transfer, the production
efficiency and heat consumption of this production line are greatly improved.
5. Clinker calcining
After its preheating and pre-decomposing, the raw meal will be calcined in the rotary kiln,
where the generated carbonate will be further decomposed. Meanwhile, a series of solid
phase reactions will take place.
6. Cement grinding
As the last process, the cement grinding will consume a great deal of electricity. And in
this process, special size granule cement will be obtained.
7. Cement Packaging
The cement can be transported in bulk or in bags.
Wet cement process:
The manufacture of cement is a very carefully regulated process comprising the following
stages:
1. Quarrying- a mixture of limestone and clay.
2. Grinding - the limestone and clay with water to form slurry.
3. Burning - the slurry to a very high temperature in a kiln, to produce clinker.
4. Grinding - the clinker with about 5% gypsum to make cement.
Raw materials extraction:
The limestone and clay occur together in our quarries at Cape Foul wind. It is necessary to
drill and blast these materials before they are loaded in 70t capacity trucks.
The quarry trucks deliver the raw materials to the crusher where the rock is crushed to smaller
than 100mm (4 inches). The raw materials are then stored ready for use.
Raw materials preparation:
About 80% limestone and 20% clay are ground in ball mills with water, producing very fine,
thin, paste called slurry. The chemical composition of the slurry is very carefully controlled by
adjusting the relative amount of limestone and clay being used.
The slurry is stored in large basins ready for use.
Clinker burning:
The slurry is fed into the upper end of a rotary kiln, while at the lower end of the kiln, a very
intense flame is maintained by blowing in finely ground coal.
The slurry slowly moves down the kiln and is dried and heated until it reaches a temperature
of almost 1500 degrees Celsius producing "clinker". This temperature completely changes
the limestone and clay to produce new minerals which have the property of reacting with water to
form a cementations binder. The hot clinker is used to preheat the air for burning the coal, and the
cooled clinker is stored ready for use.
Cement milling:
The clinker is finely ground with about 5% gypsum in another ball mill, producing cement.
(The gypsum regulates the early setting characteristic of cement). The finished cement is stored in
silos then carted to our wharf or packing plant facilities.

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