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    Manufacturing of Cement

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    RizwanSaifi
    The document discusses the manufacturing process of Portland cement. It begins with an introduction to cement and defines the difference between cement and Portland cement. It then discusses the key components and history of Portland cement. The main manufacturing process involves mixing raw materials like limestone and clay and heating them in a kiln to form clinker. The clinker is then ground along with gypsum to form the final cement powder. There are two main processes - the dry process which uses dry raw materials and the wet process which uses raw materials made into a slurry with water. The finished cement is stored and packaged for distribution.

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    Manufacturing of Cement

    Uploaded by

    RizwanSaifi
    52 views19 pages
    The document discusses the manufacturing process of Portland cement. It begins with an introduction to cement and defines the difference between cement and Portland cement. It then discusses the key components and history of Portland cement. The main manufacturing process involves mixing raw materials like limestone and clay and heating them in a kiln to form clinker. The clinker is then ground along with gypsum to form the final cement powder. There are two main processes - the dry process which uses dry raw materials and the wet process which uses raw materials made into a slurry with water. The finished cement is stored and packaged for distribution.

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    The document discusses the manufacturing process of Portland cement. It begins with an introduction to cement and defines the difference between cement and Portland cement. It then discusses the key components and history of Portland cement. The main manufacturing process involves mixing raw materials like limestone and clay and heating them in a kiln to form clinker. The clinker is then ground along with gypsum to form the final cement powder. There are two main processes - the dry process which uses dry raw materials and the wet process which uses raw materials made into a slurry with water. The finished cement is stored and packaged for distribution.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    52 views19 pages

    Manufacturing of Cement

    Uploaded by

    RizwanSaifi
    The document discusses the manufacturing process of Portland cement. It begins with an introduction to cement and defines the difference between cement and Portland cement. It then discusses the key components and history of Portland cement. The main manufacturing process involves mixing raw materials like limestone and clay and heating them in a kiln to form clinker. The clinker is then ground along with gypsum to form the final cement powder. There are two main processes - the dry process which uses dry raw materials and the wet process which uses raw materials made into a slurry with water. The finished cement is stored and packaged for distribution.

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    Manufacturing Of Cement

    PORTLAND CEMENT
    Points To Discuss…
    • What is CEMENT ?
    • Introduction
    • Diff. B/w Cement and Portland Cement
    • Components Of Portland Cement

    • History of PORTLAND CEMENT.


    • Manufacturing of PORTLAND CEMENT.
    • Components
    • Processes
    • Dry Process
    • Wet Process
    INTRODUCTION TO CEMENT
    • Cement is a fine mineral powder manufactured with very precise
    processes. Mixed with water, this powder transforms into a paste that
    binds and hardens when submerged in water. Because the composition
    and fineness of the powder may vary, cement has different properties
    depending upon its makeup.
    • Cement is mainly used as a binder in concrete, which is a basic
    material for all types of construction, including housing, roads, schools,
    hospitals, dams and ports, as well as for decorative applications (for
    patios, floors, staircases, driveways, pool decks) and items like tables,
    sculptures or bookcases
    DIFFERENCE BETWEEN..

    CEMENT PORTLAND CEMENT

    • A cement is a binder, a substance used • Portland cement is the most common


    in construction that sets, hardens and type of cement in general used around
    adheres to other materials, binding the world as a basic ingredient of
    them together. Cement is seldom used concrete and mortar.
    solely, but is used to bind sand and
    gravel (aggregate) together. Cement is • It is a fine powder, produced by
    used with fine aggregate to heating limestone and clay minerals in
    produce mortar for masonry, or with a kiln to form clinker, grinding the
    sand and gravel aggregates to clinker, and adding small amounts of
    produce concrete. other materials.
    Components of PORTLAND CEMENT

    • Basic Chemical Components • Typical Raw Materials


    • Calcium (Ca) • Limestone (CaCO3)

    • Silicon (Si) • Sand (SiO2)

    • Aluminum (Al) • Shale, Clay (SiO2, Al2O3, Fe2O3)

    • Iron (Fe) • Iron Ore/Mill Scale (Fe2O3)


    HISTORY of Portland Cement
    Portland cement was developed from natural
    cements made in Britain beginning in the middle
    of the 18th century.

    Joseph Aspdin took out a patent in 1824 for


    "Portland Cement," a material he produced by
    firing finely-ground clay and limestone until the
    limestone was calcined.

    He called it PORTLAND CEMENT because the


    concrete made from it looked like Portland stone, Joseph Aspdin
    a widely-used building stone in England.
    Portland cement is made by heating raw
    MANUFACTURING
    materials rich in oxides of silicon, calcium,
    aluminum and iron to temperatures of
    Of
    around 1200 - 1400o C. PORTLAND CEMENT
    The chemical reactions that occur within the partially molten mass result
    from the formation of the four main cement materials.
     Tricalcium silicate (CaO)3•SiO2 C3S 45-75%

     Dicalcium silicate (CaO)2•SiO2 C 2S 7-32%

     Tricalcium aluminate (CaO)3•Al2O3 C 3A 0-13%

     Tetracalcium alumino-ferrite (CaO)4•Al2O3•Fe2O3 C4AF 0-18%

     Gypsum CaSO4•2H2O CS̅H2 2-10%


    Manufacturing Process Of Portland Cement
     Step 1. Mixing Of Raw Materials

    The major raw materials used in the manufacture of cement are Calcium,
    Silicon, Iron and Aluminum. These minerals are used in different form as per
    the availability of the minerals.

    The Calcareous and Argillaceous Materials used in Manufacturing Process


    of Portland Cement are shown in the Table in the Next Slide.
    Table shows the raw materials for Portland cement manufacture.
    Manufacturing Processes Of Portland Cement

    There are 2-Types of Processes that can be used to Manufacture


    Portland Cement.
    Which are :

    Wet Process

    Dry Process
    DRY Process
    • The both calcareous and argillaceous raw materials are firstly crushed in the
    gyratory crushers to get 2-5cm size pieces separately. The crushed materials are
    again grinded to get fine particles into ball or tube mill.

    • Each finely grinded material is stored in hopper after screening. Now these
    powdered minerals are mixed in required proportion to get dry raw mix which is
    then stored in silos and kept ready to be sent into rotary kiln. Now the raw
    materials are mixed in specific proportions so that the average composition of the
    final product is maintained properly.
    Manufacturing of cement By DRY process
    WET Process
    • The raw materials are firstly crushed and made into powdered form and stored in silos. The
    clay is then washed in washing mills to remove adhering organic matters found in clay.

    • The powdered limestone and water washed clay are sent to flow in the channels and transfer
    to grinding mills where they are completely mixed and the paste is formed, i.e., known as
    slurry.

    • The grinding process can be done in ball or tube mill or even both. Then the slurry is led into
    collecting basin where composition can be adjusted. The slurry contains around 38-40%
    water that is stored in storage tanks and kept ready for the rotary kiln.
    Manufacturing of cement By WET process
    Comparison of dry process and wet process of Cement Manufacture.

    Criteria Dry Process Wet Process

    Hardness of raw material Quite hard Any type of raw material

    Fuel consumption Low High

    Time of process Lesser Higher

    Quality Inferior quality Superior quality

    Cost of production High Low

    Overall cost Costly Cheaper

    Physical state Raw mix (solid) Slurry (liquid)


     Step 2. Grinding Of Clinkers

    • The cooled clinkers are received from the cooling pans and sent into mills. The
    clinkers are grinded finely into powder in ball mill or tube mill. Powdered gypsum
    is added around 2-3% as retarding agent during final grinding. The final obtained
    product is cement that does not settle quickly when comes in contact with water.

    • After the initial setting time of the cement, the cement becomes stiff and the
    gypsum retards the dissolution of tri-calcium aluminates by forming tricalcium
    sulfoaluminate which is insoluble and prevents too early further reactions of setting
    and hardening.

    3CaO.Al2O3 + xCaSO4.7H2O = 3CaO.Al2O3.xCaSO4.7H2O


     Step 3. Storage and Packaging

    • The grinded cement is stored in silos, from which it is marketed


    either in container load or 50kg bags.
    Manufacturing Process Of CEMENT
    THANK YOU
    Made By – Pushpraj Choudhary

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