CEMENT INDUSTRIES

Mechanical Technology
Group 2
From 15 to 35
 TABLE OF CONTENTS
 Introduction
 Raw materials of Portland
cement
 Composition of Raw Material
 Applications
 Cement Manufacturing
Process
 Mixing and Crushing
 Dry Process
 Wet Process
 Rotary Klin zones
 Chemical Reactions
 Grinding
 INTRODUCTION
• Cement is a powdery substance
made by calcining lime and clay,
mixed with water to form mortar or
mixed with sand, gravel, and water
to make concrete.
• The essential components for cement
are lime, silica and alumina.
 COMMON RAW MATERIAL
• (CaO) Calcium oxide which
is also called quick lime
• Fe2O3
• Al2O3
• MgO
• SiO2
PORLAND RAW MATERIAL
 COMPOSITION OF RAW MATERIAL
Lime 63%
Silica 22%
Alumina 06% lime
5% 3%
6%
Iron oxide 03% silica
alumina
Gypsum 01 to 04% 22% gypsum
64%Iron oxide
 MANUFACTURING OF CEMENT
Manufacturing of cement involves either dry process or wet process.
The choice of dry or wet process depend on the following factors:
• Physical condition of raw Material
• Local climatic condition of the factory
• The price of fuel
In Pakistan most of the factories use wet process for manufacturing of cement.
Dry process needs excessive fine grinding and it is most suited for hard
materials, Wet process, on the other hand, is free from dust, grinding is easier
and composition of cement can be easily control.
 WET PROCESS
• In this process grinding is being done in the presence of water.

DRY PROCESS
• In this process grinding is being done in the absence of water.
FLOW CHART OF
DRY AND WET
PROCESS
COMPARISON OF DRY PROCESS AND
WET PROCESS OF CEMENT
MANUFACTURE:
 FIVE STAGES IN THE MANUFACTURE
OF CEMENT
• 1. Crushing and grinding of raw materials.
• 2. Mixing the material in correct proportion.
• 3. Heating the prepared mixture in a rotary kiln.
• 4. Grinding the heated product known as clinker.
• 5. Mixing and grinding of cement clinker with gypsum.
• 6. Storage and packing.
• Now we discuss each step in detail.
 CRUSHING AND GRINDING OF RAW
MATERIALS:

• Soft raw materials are crushed into

suitable size, often in two stages,
and then ground in the presence of
water, usually in rotating cylindrical
ball or tube mills containing a
charge on steel ball.
 MIXING OF RAW MATERIAL:
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 in
proper proportion(75% limestone and 25% clay) and the paste is formed, i.e.,
known as slurry.
• The slurry contains around 38-40% water that is stored in storage tanks and
kept ready for the rotary kiln.
 HEATING THE PREPARED MIXTURE
IN ROTARY KILN:
• The burning process is carried out in the rotary kiln while the raw materials
are rotated at 1-2rpm at its longitudinal axis.
• The rotary kiln is made up of steel tubes having the diameter of 2.5-3.0
meter and the length differs from 90- 120meter. The inner side of the kiln is
lined with refractory bricks.
• • Now charge is heated by burning oil, coal or natural gas. In rotary kiln
charge passes through different zones of temperature where different
reactions takes place. These zones are describe in next slides.
DIAGRAM
REACTION
 CLINKER FORMATION:
• The resulting product of kiln is known as cement clinkers. This has the
appearance of greenish black or grey colored varying in size from 5 to
10mm.
 GRINDING OF CLINKERS WITH
GYPSUM:
• 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 5% as retarding agent during final
grinding. The final obtained product is cement that does not settle quickly
when comes in contact with water.
• • Gypsum acts as a retarding agent for early setting of the cement.
 SETTING AND HARDENING OF
CEMENT
• The Change from fluid to rigid state of a cement paste is termed
as setting of cement.
• The hardening refers to the gain of strength of set cement paste.
During setting, cement acquires some strength.
We determine the srenght of cement by
Specific gravity
Tensile Strenght
Compression Strenght
 SPECIAL CEMENT
Waterproof Cement
Is a cement obtained by adding water proofing substances like calcium
stearate, aluminium stearate and gypsum with tannic acid to ordinary
Portland cement
White Cement
Is white in color due to absence of iron compounds
Obtained by calcining the raw materials of Portland cement which are free
from iron oxide Properties.
More expensive than ordinary Portland cement .
Acts as pore – blocking and water – repelling agent.

Both are very Expensive than porland.