Methods, Processes, and Equipment Involved in Manufacturing Cement

Methods, Processes, and
Equipment Involved in
Manufacturing Cement
Submitted by:
Anonuevo, John Michael E.
Bobis, Anthony L.
Malaca, Darelle David B.
BSME 5A
Submitted to:
Engr. Gene M. Llorando
Definition of Cement
• Cement is a greenish grey colored powder, made of

calcined mixtures of clay and limestone. When mixed with
water, it becomes a hard and strong building material.
• It 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. 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.
NOTE: Portland cement is the most common type of cement

in general use around the world. Portland cement is not a
brand name but a type of cement. The inventor Joseph
Aspdin patented the basic process in 1824, naming it for the
resemblance of the cement when set to portland stone, a
limestone from the Isle of Portland, Dorset, England.
Cement Manufacturing Process Phases
1. Raw Material Extraction

2. Grinding, Mixing, Proportioning, and
Blending
3. Pre-Heater Phase
4. Kiln Phase
5. Cooling and Final Grinding
6. Packing and Shipping
Phase 1: Raw Material Extraction
• 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.
Calcareous Argillaceous Materials

Materials
Calcium Silicon Aluminum Iron
Limestone Clay Clay Clay
Marl Marl Shale Iron Ore
Calcite Sand Fly Ash Mill Scale
Aluminum Ore
Aragonite Shale Shale
Refuse
Shale Fly Ash Blast Furnace Dust
Sea Shells Rice Hull Ash
Cement Kiln Dust Slag
NOTE: Calcareous materials contain calcium while

argillaceous materials contain silicon, aluminum, and/or iron.
• 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. By means of
conveyor belt, material is transported to the cement
plant.
• 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.
Phase II: Grinding, Mixing, Proportioning,

and Blending
The mixing procedure of the manufacture of

cement is done in two methods:
• Dry Process
• Wet Process
Dry Process
• The both calcareous and argillaceous raw materials
are firstly crushed in the gyratory crushers to get 2-5
cm 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.
Flow Chart of Cement Manufacturing 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.
Flow Chart of Cement Manufacturing 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
Inferior
Quality Superior quality
quality
Cost of production High Low
Overall cost Costly Cheaper
Raw mix
Physical state Slurry (liquid)
(solid)
Phase III: Pre-Heater Phase

• After grinding, the material is ready to face the pre-
heating chamber. Pre-heating chamber consists of
series of vertical cyclone from where the raw
material passes before facing the kiln. It utilizes the
emitting hot gases from kiln. Pre-heating of the
material saves the energy and make plant
environmental friendly.
• The burning process is carried out in the rotary kiln
while the raw materials are rotated at 1-2 rpm 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 90-120 meter. The inner side of
the kiln is lined with refractory bricks.
• The kiln is supported on the columns of masonry or
concrete and rested on roller bearing in slightly
inclined position at the gradient of 1 in 25 to 1 in 30.
The raw mix of dry process or corrected slurry of wet
process is injected into the kiln from the upper end.
The kiln is heated with the help of powdered coal or
oil or hot gases from the lower end of the kiln so
that the long hot flames is produced. As the kiln
position is inclined and it rotates slowly, the material
charged from upper end moves towards lower end
at the speed of 15 m/hr.
Figure of pre-heating chamber
Phase IV: Kiln Phase
Three Zones in Kiln:

• Drying Zone
– In the upper part, water or moisture in the
material is evaporated at 400°C temperature.
• Calcination Zone
– In the central part, the temperature is around
1000°C, where decomposition of lime stone takes
place. The remaining material is in the form of small
lumps known as nodules after the carbon dioxide is
released.
• Clinkering Zone
– The lower part have temperature in between
1500-1700°C where lime and clay are reacts to
yielding calcium aluminates and calcium silicates.
This aluminates and silicates of calcium fuse to
gather to form small and hard stones are known as
clinkers. The size of the clinker is varies from 5-10
mm.
Figure of Rotary Kiln
Phase V: 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.
• 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.
•
Phase VI: Packing and Shipping

• Material is directly conveyed to the silos or 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.
SUMMARY
REFERENCE(S):
• https://www.engineeringintro.com/uncategorized/cement-manufacturing-
process/
• https://theconstructor.org/building/manufacture-of-cement/13709/

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Methods, Processes, and Equipment Involved in Manufacturing Cement

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Methods, Processes, and

• Cement is a greenish grey colored powder, made of

NOTE: Portland cement is the most common type of cement

1. Raw Material Extraction

Phase 1: Raw Material Extraction

• The major raw materials used in the manufacture of

Calcareous Argillaceous Materials

Calcium Silicon Aluminum Iron

Limestone Clay Clay Clay

Marl Marl Shale Iron Ore

Calcite Sand Fly Ash Mill Scale

Shale Fly Ash Blast Furnace Dust

Sea Shells Rice Hull Ash

Cement Kiln Dust Slag

NOTE: Calcareous materials contain calcium while

• Generally cement plants are fixed where the quarry

Phase II: Grinding, Mixing, Proportioning,

The mixing procedure of the manufacture of

Flow Chart of Cement Manufacturing by Dry Process

Comparison of Dry Process and Wet Process of

Hardness of raw material Quite hard Any type of raw material

Fuel consumption Low High

Time of process Lesser Higher

Cost of production High Low

Overall cost Costly Cheaper

Phase III: Pre-Heater Phase

Phase IV: Kiln Phase

Three Zones in Kiln:

Phase V: Cooling and Final Grinding

• After passing out from the kiln, clinkers are cooled

Phase VI: Packing and Shipping

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