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Dry Process

The dry process of cement manufacturing involves: 1) Grinding raw materials like limestone, shale and red alluvium into a fine powder using vertical roller mills. 2) Burning the blended materials in a rotary kiln at around 1450°C to form clinker. 3) Cooling and grinding the clinker along with gypsum and other additives to produce the final cement powder, which is then packaged.

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Fahamidur Rahman Shawon
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295 views4 pages

Dry Process

The dry process of cement manufacturing involves: 1) Grinding raw materials like limestone, shale and red alluvium into a fine powder using vertical roller mills. 2) Burning the blended materials in a rotary kiln at around 1450°C to form clinker. 3) Cooling and grinding the clinker along with gypsum and other additives to produce the final cement powder, which is then packaged.

Uploaded by

Fahamidur Rahman Shawon
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Dry process of cement

Describe the dry process of cement?

Solution: The process of manufacture of cement consists of grinding the raw


materials, mixing them intimately in certain proportions depending upon their
purity and composition and burning them in a kiln at a temperature of about 1300
to 1500°C, at which temperature, the material sinters and partially fuses to form
nodular shaped clinker. The clinker is cooled and ground to fine powder with
addition of about 3 to 5% of gypsum. The product formed by using this procedure
is Portland cement.

The procedure of dry process is describing below: When the available raw
materials are quite hard, then this process is used. The cement by this process
can be prepared by using the following operations:-
Raw Grinding: The basic operations in this section include raw material
preparation and pre-heating and grinding units. The feed materials to the kiln are
prepared in the required mixture of limestone, shale and red alluvium. After the
materials have been blended, they are then ground into a fine powder. The dry
process of fine grinding is accomplished with the use of a vertical roller mill which
combines drying, grinding and separation processes in a single compartment.
It essentially comprises of a rotating, circular grinding table that turns around a
vertical shaft as well as tapered rollers that are pressed on to the roller paths on the
surface of the table. An hydraulic system which provide the source of pressure to
the rollers, a stream of gases flowing upwards around the table, entraining and
drying the material and a classifier which screens fine particles from coarse
particles. The drying process is effected by ducting part of the kiln exhaust gas
through the mill with inlet temperature

Burning: The pyro-processing (burning) operation of the blended material is carried


out in a rotatory kiln. The rotary kiln is a poor heat exchanger which would require
a long length and larger diameter for a complete burning. For good clinker and
increased heat exchange efficiency, a pre-heat tower is added to rotary kiln where
materials are preheated before entering the kiln. A pre clinker can be added to
increase the material de-carbonation rate from 40 to 95%. The reaction is completed
in the kiln at about 1450C and the material exits into a clinker cooler where the
clinker temperature is reduced to about 100C. Cold air is blown crosswise to cool
the clinker, the recuperated heat is utilized in the kiln to further reduce the fuel input
in the kiln. The cooled clinker is then transported to storage.

Finish grinding: The basic operations in this section include additive preparation and
grinding. In this section, the cooled clinker is mixed with about 3 to5% gypsum and
other additives such as limestone which will help regulate the setting time when the
cement is mixed with other materials and becomes concrete. The mixtures are milled
in a pre-ground circuit before being finally ground in a close circuit ball mill. The
pre-ground circuit ground to the fineness of sand, and the final ball mill ground to
the fineness of flour, which is the final product ready for packaging.

Packaging: The final product is extracted into a number of packers where cement is
bagged into 50 kg bags. The packers are designed with a capacity of 90 tones per
hour (1800 bags per hour). Other means of packaging cement are bulk loading
whereby 30 tons are loaded into dedicated trucks for bulk transport and a 2-tonne
jumbo bag. The mode of operation here is mostly manual requiring up to 50 workers
in a day's operation. Diesel powered front loaders are used to remove spilt and off-
standard bags of cement in order to ensure proper housekeeping.

Develop a comparison between dry and wet manufacturing process of cement?


Solution: The process, by which cement is manufactured, depends upon the technique
adopted in the mixing of raw materials. Therefore, on the basis of mixing the raw
materials, the processes may be classified as:-

1. Wet Process

2. Dry Process

Difference between dry process and wet process is given below:


Dry process Wet process

1. Mixing of raw material in dry state in 1. Mixing of Raw materials in wash mill
blenders. with 35 to 50% water.

2. Materials exiting the mill are called


2. The dry materials exiting the mill are
“slurry” and have flow ability
called “kiln feed”.
characteristics.

3. Fuel consumption is low i.e., 100 kg 3. Fuel consumption is high i.e., 350 kg
of coal per tons of cement produced of coal per tons of cement produced

4. Cost of production is less. 4. Cost of production is high

5. Capital cost (Cost of establishment) is


5. Capital cost is high due to blenders.
comparatively less

6. Size of the kiln needed for 6. Size of the kiln needed for
manufacturing of cement is smaller. manufacturing of cement is bigger.

7. Difficult to control mixing of Raw 7. Raw material can be mixed easily, so


materials, so it is difficult to obtain a a better homogeneous material can be
better homogeneous material. obtained

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