Cement manufacturing process pdf

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PDF | On Dec 9, , Momen Marwan Mohsen and others published Figure ( 7): The Cement Production Flow Sheet By the dry process. Process Flow diagram – Jamul Plant. Raw material extraction. & preparation. Raw meal preparation. Clinkerization. Cement. Grinding. word cement, but it is often confused with concrete or mortar. Cement Cement manufacture. The cement-making process can be divided into two basic steps.

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Cement Manufacturing Process Pdf

Bin. Mixer. Pulverizer. Rotary kiln. Hot air out. Hot air in. Clinker for grinding. Packaging and storage. Gypsum. Figure: Manufacturing of Cement by Dry Process. Cement is a building material which has a cohesive and adhesive properties in The process of manufacture of cement consists of grinding the raw materials. Two basic types of clinker production processes exist, depending on the . CEMENT PRODUCTION PROCESSES– The two Oxide Manufacturing industries, May ,; ftp://osakeya.info 2.

Such raw materials are limestone, clay and sand. Limestone is for calcium. It is combined with much smaller proportions of sand and clay. Extraction of raw material and crushing of material Generally cement plants are fixed where the quarry of limestone is near bye. 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.

There are more than twenty types of cement used to make various specialty concrete, however the most common is Portland cement.

In this process, the chemical bonds of the raw materials are broken down and then they are recombined into new compounds. The result is called clinker, which are rounded nodules between 1mm and 25mm across.

The clinker is ground to a fine powder in a cement mill and mixed with gypsum to create cement. The powdered cement is then mixed with water and aggregates to form concrete that is used in construction. Clinker quality depends on raw material composition, which has to be closely monitored to ensure the quality of the cement. Raw mix is stored in a pre-homogenization pile after grinding raw mix to fine powder.

Pre-heater chamber consists of series of vertical cyclone from where the raw material passes before facing the kiln.

Manufacturing of Cement By Dry and Wet Process

Pre-heating chamber utilizes the emitting hot gases from kiln. Pre-heating of the material saves the energy and make plant environmental friendly.

This temperature begins a chemical reaction so called decarbonation. In this reaction material like limestone releases the carbon dioxide.

Cement Manufacturing Process

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.

Kiln is heating up from the exit side by the use of natural gas and coal. When material reaches the lower part of the kiln, it forms the shape of clinker. Clinker released the absorb heat and cool down to lower temperature.

Cement Manufacturing Process

Released heat by clinker is reused by recirculating it back to the kiln. This too saves energy.

The cement by this process can be prepared by using the following operations:- Mixing of raw materials Burning and Grinding Mixing of Raw Materials : The raw materials i. Drying: The crushed materials are dried by heating at a sufficiently high temperature. It may be done in drying kilns.

Reduction of size: The drying materials are then grind by using ball mills and tube mills to reduce the size of materials to find powder. Mixing in correct proportion : The finely dried materials are mixed in exact proportions.

The mixing may be done either mechanically or by pneumatic methods e. Burning and Grinding: These operations are same as for wet process. Except for the mixing of raw materials. In the dry process, the raw materials mixed, fined and then fed into kiln whereas in the wet process, the raw materials are crushed separately and then directly mixed in correct proportion in the presence of water to make a fine thin paste known as Slurry.

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