Cement
Manufacturing
By John Patrick Eustaquio & Josiah Garduque
About the Project
01. HISTORY
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Sneak Peek
04. PROBLEMS & SOLUTIONS
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ENCOUNTERED
02. RAW MATERIALS
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Project Stages
Project Goals 05. LATEST
Here youDEVELOPMENT
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03. PROCESSES
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MANUFACTURING
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PROCESS
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Our Team
HISTORY
HISTORY
ANCIENT USE OF
CEMENT
EGYPTIANS USE OF
LIME GYPSUM
PLAIN MUD Commonly used cement in all Egypts alternative to lime
Earliest cement used in ancient Civilization. Can be due to limestones
masonry and extracted through calcining ridiculous calcining fuel
construction consumption
CALCINING
-Breaking apart chemical compounds in high temperatures of 2280°F or 1249°C or
higher depending on today's modern cement manufacturing standard.
HISTORY
ANCIENT USE (Romans)
POZZOLAN-LIME
CEMENTS ANCIENT ROMANS
Romans mixed Discovered the Further using it they
Pozzolana came from
pozzolana (volcanic hydraulic cement were given the credit
the village near Mt
ash) and quick lime for Development of
Vesuvius called
hydraulic cement
Pozzuoli.
HYDRAULI NON-HYDRAULIC
CAble to set even under wet It needs dry conditions to
conditions strengthen
Non-Soluble in water Soluble in water
Commonly used to patch Typically found indoors as it
concrete, leaks and repair needs dry conditions to
work on structures. achieve it’s best structural
strength
HISTORY
18TH- 19TH CENTURY
JAMES NEW CEMENT
PARKER(1796)
Received a patent for hydraulic Has good strength and New cement became the
cement with the use of argillaceous hydraulic properties dominant cement type
limestone that sets faster produced in england
HISTORY
JOSEPH ASPDIN(1824)
- Was awarded a patent for his “ Portland Cement” in
December 15 1824.
- Aspdin’s “An improvement in the modes of producing
an artificial stone” (British patent 5022)
- Joseph Aspdin’s portland cement’s “artificial stone”
concrete is not as strong as the “Portland stone”
PORTLAND STONE (Dorset, Portland)
HISTORY
WILLIAM ASPDIN(1840’s)
-The son of Joseph Aspdin that solved the
strength problem of portland cement
-Discovered the need to heat the raw
materials in the kiln to much higher
temperatures than that merely needed to
calcine the limestone.
RAW MATERIALS
RAW MATERIALS
RAW MATERIALS
Limestone (Lime) Iron Oxide (Natural)Hematite and magnetite
Consists of mainly calcium
carbonate which helps the
cements compressive Enhances the mechanical properties of the
strength cement.
RAW MATERIALS
Aluminum Oxide Silicon Dioxide
(Natural) Bauxite, Cryolite (Natural)Quartz
Provides a significant Provides strength to the
increase in compressive cement
strength of cement
RAW MATERIALS
Magnesium Oxide Sulphur Trioxide
(natural)Magnesite (Natural)
Reduces the overall water- Enhances the setting time of
cementitious materials ratio cement
RAW MATERIALS
Alkalis (Natural) Gypsum (Natural)
Delays also the setting time
Further delays the time of and allows the cement to
final setting mix with sand .
CEMENT
MANUFACTURING
PROCESSES
TYPES
CEMENT MANUFACTURING
PROCESS
DRY WET
DRY PROCESS
DRY PROCESS
1. QUARRYING
Process of extracting and
segregating the raw materials
coming from the quarries of the
certain raw materials required
for ordinary portland cement.
DRY PROCESS
2.) CRUSHING
Process of crushing both
Calcareous(chalkey) and
Argillaceous(Clayey) materials
on a hammer crusher.
Hammer Crusher
DRY PROCESS
CALCAREOUS & ARGILLACEOUS
DRY PROCESS
3.) FINE GRINDING
Process of Fine Grinding the
raw materials in Ball mills
producing a fine Dry powder
which is called a “Raw meal”
DRY PROCESS
Raw Meal
It is the Raw material used for
producing cement clinker
DRY PROCESS
4.) DRYING
Process of drying the Raw
meals through the exhaust gas
of the kiln that is feeded to
drying silos to avoid excess
moisture of the materials for dry
mixing
DRY PROCESS
5.) DRY MIXING OR BLENDING
The process on where the raw
meal is mixed in exact
proportions to obtain a uniform
and intimate mixture turning it
to a “mixed meal”
DRY PROCESS
5.) DRY MIXING OR BLENDING
The mixed meal progresses to the
sieve and then fed into a a granulator.
Where then A quantity of water about
12 % by weight is added to make the
blended meal into pellets.
DRY PROCESS
6.) PRE-HEATING
The process on where the
pellets are baked hard in a pre-
heating grate by means of hot
gasses from the kiln. 800°C
DRY PROCESS
7.) HEATING
The pellets then enter the kiln where
temperature is about 1400°C to 1500°C.
About 20%-30% of the material turns to liquid
The fused mass turns the fuses into balls of
diameter 3 to 25 mm called a clinker.
DRY PROCESS
CLINKER
A mixture of material produced in the
kilning stage during the production of
cement.
DRY PROCESS
8.) COOLING
The grate cooler in a cement plant
cools and transports the cement
clinker from the rotary kiln.
DRY PROCESS
9.) GRINDING
The cooled clinkers are crushed
and about 2% to 4% of gypsum
is added to the mix.
Gypsum as a retardant
DRY PROCESS
10.) STORAGE ON CEMENT SILOS
The process of Storing of the
finished ordinary portland
cement product to be packaged
DRY PROCESS
11.) PACKAGING
The Final Process on branding,
packaging, and readying the output
product
PROCESS FLOW CHART
DRY PROCESS
QUARRYING CRUSHING FINE GRINDING DRYING BLENDING
PACKAGING CEMENT SILOS GRINDING PRE-HEATING
COOLING HEATING
WET PROCESS
WET PROCESS
1. QUARRYING
Process of extracting the raw
materials such as rocks, sands
and gravel for later use in
cement manufacturing
WET PROCESS
2.) CRUSHING
Process of crushing both
Calcareous and Argillaceous
materials on a crusher to prepare for
drying and grinding
Hammer Crusher
WET PROCESS
3.) WET GRINDING
Placing the crushed materials from
different tanks to a storage call Wet
Grinding Mills
Where both the materials are mixed
intimately with water to form the fine thin
paste which is called a “Slurry”
WET PROCESS
SLURRY
Mixture of Portland cement, water, and
additives.
WET PROCESS
4.) BLENDING
The Slurry is then placed into the
Slurry Silo where it is constantly
stirred.
If the composition is then lacking, it
can be corrected through adding
more materials
WET PROCESS
5.) HEATING
The slurry with the proper
composition is conveyed to the
rotary kiln.
The slurry is then supplied to the
kiln at the top, and the pulverized
coal is blown by air blast at the
bottom of the kiln at about 1450 °C
DRY PROCESS
6.) COOLING
The grate cooler in a cement plant
cools and transports the cement
clinker from the rotary kiln.
WET PROCESS
7.) GRINDING
The process on where the cooled
clinkers are then grinded in ball
mills or tube mills. Also, the
gypsum is added during grinding
about 2-4%.
WET PROCESS
8.) STORAGE ON CEMENT SILOS
The process of Storing of the
finished ordinary portland
cement product to be packaged
WET PROCESS
9.) PACKAGING
The Final Process on branding,
packaging, and readying the stored
product for transportation to a
certain client's construction site
requiring the cement
PROCESS FLOW CHART
WET PROCESS
QUARRYING CRUSHING WET GRINDING BLENDING HEATING
PACKAGING GRINDING COOLING
CEMENT SILOS
DIFFERENCE OF WET AND DRY PROCESS
DRY PROCESS WET PROCESS
NOTE
Mixture of raw and dry materials Mixture of raw and wet materials If we consider the quality and rate
in blenders with 30 to 50% water then wet process is better and if we
consider fuel consumption and
Dry materials that conveyed from Materials exiting the mills are time of process then dry process is
the mill is Raw Meal called Slurry better
Cost of production is less Cost production is higher due to
the additional materials
PROBLEMS & SOLUTIONS
ENCOUNTERED
PROBLEMS SOLUTIONS
Quarrying
Wide variation in raw materials Proper Mapping of your mines,
composition. It is generally overlooked regular and frequent analysis of
with the perception that it can be extracted materials.
compensated in pre-blending and raw mill
proportioning
PROBLEMS SOLUTIONS
Crushing
Broad variation in crushed material sizes. It Proper periodic maintenance and
is due to the infrequent maintenance, weak careful feed control to ensure
feed rate control for various input sizes specific size consistency.
PROBLEMS SOLUTIONS
Cement Silos
Coating in cement silos. This happens due Use cement coolers if temperature is
to storage of cement in silos at high higher than specified. DO not store
temperature and improper water spray cement for long time in silo.
system in cement mill
LATEST DEVELOPMENT IN
MANUFACTURING PROCESS
Making Concrete Change: Innovation in Low-carbon
Cement and Concrete
THANK YOU
