(Approved by:AICTE & Affiliated to Maulana Abul Kalam Azad University of Technology)

Campus: Bishnupur, Dist.: Bankura, WB

CA2 Technical Report Writing

on
Manufacturing of Cement
Academic Year: 2022-2023

Student’s Full Name: MILAN GHOSH

University Roll Number: 15801322067

University Registration Number: 221580120083

Department: CIVIL ENGINEERING

Paper Name: CONCRETE TECHNOLOGY

Paper Code: CE (PC) 404

Semester: 4TH

Year: 2ND

E-mail id: milanghosh8348@gmail.com

INTRODUCTION: -
Cement is the basic ingredient of construction and the most widely used
construction material. It is a very critical ingredient, because only cement has the
ability of enhancing viscosity of concrete which in returns provides the better
locking of sand and gravels together in a concrete mix.
A cement is a binder, a substance used for construction that sets, hardens,
and adheres to other materials to bind them together. Cement is seldom used on its
own, but rather to bind sand and gravel (aggregate) together. Cement mixed with
fine aggregate produces mortar for masonry, or with sand and gravel, produces
concrete. Cement is the most widely used material in existence and is only behind
water as the planet's most-consumed resource.
The word "cement" can be traced back to the Roman term opus
caementicium, used to describe masonry resembling modern concrete that was
made from crushed rock with burnt lime as binder. The volcanic ash and pulverized
brick supplements that were added to the burnt lime, to obtain a hydraulic binder,
were later referred to as cementum, cimentum, cäment, and cement. In modern
times, organic polymers are sometimes used as cements in concrete.
MANUFACTURING OF CEMENT: -
PROCESS: -
Production of cement completes after passing of raw materials from the following
six phases. These are:
 1. Raw material extraction/ Quarry
2. Grinding, Proportioning and Blending
3. Pre-heater Phase
4. Kiln Phase
5. Cooling and Final Grinding
6. Packing & Shipping

1. Raw Material Extraction: -

Cement uses raw materials that cover calcium, silicon, iron, and aluminium.
Such raw materials are limestone, clay, and sand. Limestone is for calcium. It
is combined with much smaller proportions of sand and clay. Sand & clay fulfil
the need of silicon, iron, and aluminium.

Extraction of raw material and crushing of material

Generally, cement plants are fixed where the quarry of limestone is nearby.
This saves the extra fuel cost and makes cement somehow economical. Raw
materials are extracted from the quarry and by means of conveyor belt material
is transported to the cement plant.

There are also various other raw materials used for cement manufacturing. For
example, shale, fly ash, mill scale and bauxite. These raw materials are directly
brought from other sources because of small requirements.
 Before transportation of raw materials to the cement plant, large size rocks are
crushed into smaller size rocks with the help of crusher at quarry. Crusher
reduces the size of large rocks to the size of gravels.

2. Proportioning, Blending and Grinding: -

The raw materials from quarry are now routed in plant laboratory where, they
are analysed and proper proportioning of limestone and clay are making
possible before the beginning of grinding. Generally, limestone is 80% and
remaining 20% is the clay.

Proportioning of raw materials

Now cement plant grind the raw mix with the help of heavy wheel type rollers
and rotating table. Rotating table rotates continuously under the roller and
brought the raw mix in contact with the roller. Roller crushes the material to a
fine powder and finishes the job. Raw mix is stored in a pre-homogenization
pile after grinding raw mix to fine powder.
3. Pre-heating Raw Materials: -
After final grinding, the material is ready to face the pre-heating chamber. Pre-
heater chamber consists of series of vertical cyclone from where the raw
material passes before facing the kiln. Pre-heating chamber utilizes the
emitting hot gases from kiln. Pre-heating of the material saves the energy and
make plant environmental friendly.

Pre-heating of raw material | Vertical Cyclone

4. Kiln Phase: -
Kiln is a huge rotating furnace also called as the heart of cement making
process. Here, raw material is heated up to 1450 ⁰C. This temperature begins a
chemical reaction so called decarbonation. In this reaction material (like
limestone) releases the carbon dioxide. High temperature of kiln makes slurry
of the material.
 Rotary Kiln

The series of chemical reactions between calcium and silicon dioxide

compounds form the primary constituents of cement i.e., calcium silicate. Kiln
is heating up from the exit side using natural gas and coal. When material
reaches the lower part of the kiln, it forms the shape of clinker.

5. Cooling and Final Grinding: -

After passing out from the kiln, clinkers are cooled by mean of forced air.
Clinker released the absorb heat and cool down to lower temperature. Released
heat by clinker is reused by recirculating it back to the kiln. This too saves
energy.

Clinker Cooling | cement making process Rotating Ball Mill

 Final process of 5th phase is the final grinding. There is a horizontal filled with
steel balls. Clinker reach in this rotating drum after cooling. Here, steel balls
tumble and crush the clinker into a very fine powder. This fine powder is
considered as cement. During grinding gypsum is also added to the mix in
small percentage that controls the setting of cement.

6. Packing and Shipping: -

Transportation of cement from silos

Material is directly conveyed to the silos (silos are the large storage tanks of
cement) from the grinding mills. Further, it is packed to about 20-40 kg bags.
Only a small percent of cement is packed in the bags only for those customers
whom need is very small. The remaining cement is shipped in bulk quantities
by mean of trucks, rails, or ships.

TYPES OF PROCESS: -
Two types of process are used for manufacturing of cement i.e., Wet Process and
Dry Process. Generally, dry process is preferred rather than wet process in the
cement industries.
Wet Process: -
During the wet process, the raw mix is fed into the kiln in the form of slurry that
may contain water up to 30 to 40%. In the wet process, the kiln is a very long tube
in comparison to dry process, and the slurry that is easy to blend and homogenize
due to the water, is directly being fed into the kiln. Wet process could be selected
as manufacturing technology is when raw materials have natural high moisture
content. The amount of moisture in mineral sometimes can be even more than 12%,
as in case of chalk and in marlstone. The use of wet process is also essential when
relatively poor grade limestone needs to be enriched through the beneficiation
process. In this process, water is required as a process media. Until 1950, most of
the cement processing kilns were wet kilns due to the ease of blending and
homogenizing the components of the raw mix. In the wet process, the fuel
consumption is in the range of 1300 to 1600 Kcal/Kg of clinker. Power
consumption in manufacture process is about 110-115 kWh/ton of cement (Cement
Industry, India, 2004).
Dry Process: -
To reduce the moisture content of minerals below 1%, which is required for dry
process, the raw materials are dried in a combined drying and grinding plant. This
drying of materials is reached by using exhaust gases coming from the kiln. The
raw ground mix is homogenized in large silos. Development of appropriate
blending and homogenizing systems, in general, is crucial for making the dry
process practicable. The blended and homogenized raw mix is then fed into dry
kiln with air suspension preheater where partial calcination of the raw mix starts
to take place. Dry process is mostly limited to the use of air suspension preheater.
This provides maximum benefits since the heat consumption is an important issue.
Development of the dry process, using air suspension preheaters, is being
integrated with pre-calcinators. Pre-calcinators ensure complete calcination of the
raw mix before its entry to the kiln. The advantage of this process is that the fuel
consumption is lowest in the existing technologies. In the dry process, the fuel use
in this process is in the range of 750-950 Kcal/Kg of clinker and the power
consumption is in the range of 120-125 kWh/ton of cement (Cement Industry,
India, 2004).