Cement Manufacturing Processes and Equipment

Dr Ananta Kumar Das

Professor
Department of Environmental Science
Maulana Abul Kalam Azad University of Technology
 Introduction
• Cement plays vital role in building economic development of any country. Indian
cement industry is the largest cement producing country in the world, next only to
China.
• The first cement company became operational in Porbandar, Gujarat with a capacity
of 10,000 tonnes in 1914.
• The Industry recorded an exponential growth with the introduction of partial
decontrol in 1982 culminating in total decontrol in 1989 and delicensing in 1991.
• With the adoption of massive modernization and assimilation of state-of-the-art
technology, Indian cement plants are today the most energy-efficient and
environment-friendly and are comparable to the best in the world in all respects,
whether it is size of the kiln, technology, energy consumption or environment-
friendliness.
 The cement industry contributes to environmental cleanliness by consuming
hazardous wastes like Fly Ash (around 30 million tonnes per year) from Thermal
Power Plants and the entire 8 million tonnes per year of Granulated Slag produced by
Steel manufacturing units and also using alternate fuels and raw materials using
advanced and environment friendly technologies.
 Status in India and in The World
India is the second-largest producer of cement in the world producing 502 million tonnes
of cement per year. There are

 210 large cement plants producing 410 million tonnes of cement every year
 350 mini cement plants producing 92 million tonnes of cement per year.

• The cement manufacturing industries share a major part in the Indian economy.

The amount of cement produced in the world is around 4,000 million tonnes or even more,
out of which nearly 35 to 40% is produced in China and 12 to 15% in India.
 Production

• Majority of the cement plants installed capacity (about 35%) is located

in the states of south India.
• Cement production reached 329 million tonnes (MT) in FY20 and is
projected to reach 381 MT by FY22.
• However, the consumption stood at 327 MT in FY20 and will reach
379 MT by FY22.
• As India has a high quantity and quality of limestone deposits through-
out the country, the cement industry promises huge potential for
growth
Per capita consumption of cement
• The per capita consumption of cement in India is 195 kg
which is far less than world average of 500 kg and 1000 kg
of China.
 Binding Materials in The Past
• Principally –Lime based materials, Major use of Pozzolans( sometimes
inadvertently),Bitumen
Mostly, lot of our heritage monuments are in stone and brick and these masonry units were
bound typically by
 binders which were based either with lime or
 some binders were based on gypsum and sometimes even
 Bitumen has been used in the past quite significantly, and in
 some cases the use of pozzolanic materials was also quite prevalent in the past.
There is a very clear cut understanding, how the system actually works but in the past people had
used pozzolans quite inadvertently.
For example, in Greece and Italy there were several examples of the use of volcanic ash as an
ingredient to the lime mortar and the people who were using it found that the use of
*volcanic ash gave the lime mortar very good properties in terms of improved strength and
applicability and so on like
Silica fume, fly ash, rice husk ash, & one more prominent type is calcined clay.
• L.J.Vicat:
PORTLAND CEMENT
Prepared artificial hydraulic lime by calcining an intimate mixture of lime
stone (Chalk) and clay( argillaceous rocks source of alumina & silica) -principal
forerunner to Portland cement.
Development to Modern Cement
> Proto- Meso- Normal Portland Cement
• In1824-Joseph Aspdin, while obtaining a patent for his hydraulic cement, termed it
as Portland Cement upon Portland Stone(lime stone from Dorset,UK) while had a
high quality and durability and a similar appearance ‘Proto’ Portland Cement .
Later ,William Aspdin( Son) – ‘Meso’ Portland cement( Beginning of 20th Century)
Willium Aspdin was the really pioneered the art of modern cement manufacture.
• Today we have completely different product, we call it modern Portland cement.
• The requirements of cement have changed quite a bit in the last 100 years.
 Transformation

• But today we moved from the test match generation to the T20
generation, so we want everything quickly.
• While in the past people were willing to cure concrete for 28 days
and today we have curing done for 3 days, probably no curing at
all, people want the concrete to be ready right after it is poured so
anyway the upshot is that cement has undergone massive changes
in the past 100 years and because of that today it is a completely
different kind of material.
COMPARISON OF PORTLAND CEMENT-THEN &
NOW

C3S: 3CaO·SiO2
Tricalcium silicate(Alite)
C2S: 2CaO·SiO
Dicalcium silicate (Belite)
 Components of Portland Cement
• Portland cement is made by mixing substances containing CaCO3 with
substances containing SiO2, Al2O3, Fe2O3 and heating them to a clinker

which is subsequently ground to powder and mixed with 2-6 % gypsum.

• Raw Materials necessary for Portland Cement Manufacture must
provide the following
 Calcium
 Silica
 Alumina
 Iron
 Portland Slag Cement
• It is prepared with a combination of up to 45-50% slag, 45-50%
clinker and 3-5 % gypsum.

• PSC has been voted as the most suitable cement for mass
construction because of its low heat of hydration.

• Slag is a non-metallic product comprising of more than 90% glass

with silicates and alumino-silicates of lime.
 Portland Pozzolana Cement

• It is a kind of blended cement which is produced by either inter-

grinding of OPC clinker along with gypsum and pozzolanic materials in
certain proportions

Or,

• grinding the OPC clinker, gypsum and Pozzolanic materials such as

Fly ash separately and thoroughly blending them in certain proportions.
 A TYPICAL COMPOSITION OF CEMENT
• Oxide Mass %
• CaO 71.6
• SiO2 25.2
• Al2O3 1.0
• Fe2O3 0.7
• MgO 1.1 Based on this, the formula can be expressed as
• Na2O 0.1 Ca2.90Mg0.06Na0.01Fe0.03Al0.04Si0.95P0.01O5
• K2O 0.1
• P2O5 0.2
 CLINKER AND NON-HYDRATED PORTLAND CEMENT

• Four main phases are present in the clinker and in the non-hydrated
Portland cement.
• They are formed at high temperature (1450 °C) in the cement kiln and
are the following:
• Short Form Actual formula Name Mineral phase
• C3S 3CaO·SiO2 Tricalcium silicate Alite
• C2S 2CaO·SiO2 Dicalcium silicate Belite
• C3A 3CaO·Al2O3 Tricalcium aluminate Aluminate or Celite
• C4AF 4CaO·Al2O3·Fe2O3 Tetra calcium alumino ferrite Ferrite
• The four compounds referred as C3S, C2S, C3A and C4AF are known
as the main crystalline phases of Portland cement.
 SOURCES OF THE COMPONENTS
Calcium Iron Silica Alumina Sulfate
Alkali waste Blast-furnace flue Calcium silicate Cement Aluminum-ore refuse Anhydrite
Aragonite Calcite dust rock Bauxite Cement rock Calcium
Cement-kiln dust Clay Clay sulfate
Clay
Cement rock Iron ore Mill scale Copper slag Gypsum
Fly ash
Chalk Ore-washings Pyrite Fuller’s earth Limestone Fly ash
Clay Cinders Loess Fuller’s earth
Fuller’s earth Shale Marl Granodiorite
Limestone Marble Ore washings Quartzite Limestone Loess
Marl Seashells Shale Rice-hull ash Sand Ore washings
Slag Sandstone Shale Shale
Slag Slag Staurolite
Traprock
 RAW MATERIALS IN INDIA
• The Indian mining industry plays an important role in supplying the raw materials used
in cement industry.
• The most important raw material used in the cement manufacturing process is the Limestone
that is found in the sedimentary rock.
• Limestone rocks are changed by dynamic metamorphism to turn into marbles. Other
varieties of Limestone are marl(Mudstone), lime shell, algal limestone, coral limestone,
pisolite limestone, crinoidal limestone, travertine, onyx, hydraulic limestone, lithographic
limestone, etc.
• The lime shell and marl are thick calcareous mud contain a variable amount of clay and slits.
• Limestone mining extracts 203,224 million tonnes of limestone that is majorly used in
cement manufacturing industries.
• States like Andhra Pradesh, Karnataka, Madhya Pradesh, Rajasthan, Gujrat, Meghalaya,
Telangana have a major reservoir of limestone.
* Marl: carbonate material is calcite and other carbonate minerals such as aragonite, dolomite and siderite
• Lime shell: lime obtained by burning the shells of oysters, clams or mussels used for lime mortar
• Pisolite: a sedimentary rock, especially limestone made up of small pea-shaped pieces
 Wet Process
STEPS:
• 1. In the wet process the clay slurry is made in a wash-mill, where the clay is mixed with
water and agitated with special device.
• 2. The hard bigger particles are removed as the slurry passes out of the wash-mill through a
sieve.
• 3. Where chalk is used, the powder chalk is made into a slurry in wash mill.
• 4. Two slurries are then mixed in a ball-mill in proper proportion for further grinding.
• 5. The mixture from the ball-mill is stored is in the correcting tank where after analysis the
proportion for clay and calcium carbonate is adjusted.
• 6. Where limestone is used, the limestone is first crushed in one inch size pebbles then fed in
the ball-mill along with the clay slurry in proper proportion.
• 7. The ground mixture from ball-mill is further ground in tube-mill and then stored in the
correcting tank where after analysis additions are made to adjust the proportion.
• 8. The proportions are adjusted according to the formula mentioned previously.
 Water addition in wet process

• The wet process of cement manufacturing involves adding water to

finely crushed raw material, such as limestone, clay or iron ore, in a
proportion of 35 to 50% water to 50 to 65 % raw material to make a
slurry that is fed into a cement kiln, whereas no water is added in the
dry process.
• So huge quantity energy loss in term of heat to evaporate those water.
 Kiln details(Wet)
The slurry (mixture) or the dry mixture is fed into a hopper continuously at the upper end of a rotatory
kiln for making the clinker.
> The rotatory kiln is a long steel cylinder inclined to the horizontal.
> The inclination is ½ inch to a ¾ inch to a foot.
> The cylinder is made of rivetted steel plates.
> The cylinder is 200 ft (76.2 mt) to 350 ft.(106.68 mt.) long, longest furnace in use is 450 ft.(137.16
mt.) long. The diameter varies from 7ft.(2.13mt.) to 12 ½ ft(3.84mt.).
> The upper end tapers where it enters into the flue. The lower end is broader.
> The lower end is provided with a fire-proof hood, to which is attached a short rotating cylinder
inclined in the opposite direction for the passing out of the hot clinkers and for cooling them.
> Upper 40 ft.(12.19mt.) is bare inside, middle portion is lined with 7 in thick firebrick lining, the
lower firing zone is lined with a firebrick (9 inch thick) made of fireclay consisting of equal
proportions of Al2O3 and SiO2, or the lining is made of a concrete made of cement clinker pebbles (½
inch dia.) and cement (2 parts of clinker and 1 to 1 ½ parts of cement).
Cement Manufacturing-Past (Wet Process)
 PRODUCTION STEPS IN DRY PROCESS
1) Raw materials are crushed, screened & stockpiled.
2) Raw materials are mixed with definite proportions to obtain “raw mix”.
> They are mixed either dry (dry mixing) or by water (wet mixing).
3) Prepared raw mix is fed into the rotary kiln.
4) As the materials pass through the kiln their temperature is raised up to
1300-1600 °C.
> The process of heating is named as “burning”. The output is known as
“clinker” which is 0.15-5 cm in diameter.
5) Clinker is cooled & stored.
6) Clinker is ground with gypsum (3-6%) to adjust setting time.
7) Packing & marketing.
 THE CEMENT MANUFACTURING STEPS
 Quarry
 Raw material( Meal) Grinding
 Burning
 Clinker Grinding
 Storage
 Packing
 Dispatch
 Quarry
• BLASTING : The raw materials that are used to manufacture cement
(mainly limestone and clay) are blasted from the quarry.
• TRANSPORT : The raw materials are loaded into a dumper.
• CRUSHING AND TRANSPORTATION : The raw materials, after
crushing, are transported to the plant by conveyor. The plant stores
the materials before they are homogenized.
 Raw materials are ground to powder and blended

2. Raw materials are ground, mixed with water to form slurry,

and blended.
Cont.
Clinker is ground with gypsum into portland cement
and shipped
Bag House, Bags arrangements
ESP
Kiln
 CHEMICAL COMPOSITION OF ORDINARY
PORTLAND CEMENT(OPC)
Oxide Common Name Abbreviation Approx. Amount (%)

CaO Lime C 60-67

SiO2 Silica S 17-25
Al2O3 Alumina A 3-8
Fe2O3 Iron-oxide F 0.5-6
MgO Magnesia M 0.1-4
Na2O Soda N
K2O Potash K 0.2-1.3

SO3 Sulfuric Anhydride 1-3

S
• CaO→ Limestone
• SiO2-Al2O3→Clay
• Fe2O3→Impurity in Clays
• SO3→from gypsum → not from the clinker
 AVERAGE COMPOUND COMPOSITION

Average Compound
ASTM Type & Name Composition
of P.C.
C3S C2S C3A C4AF
Type I - O.P.C. 49 25 12 8 General Purpose
For Moderate Heat of
Hydration
Type II - Modified 46 29 6 12
Type III - High Early C3S&C3A increased, C2S
Strength decreased
56 15 12 8
Type IV - Low Heat
P.C.
30 46 5 13 C2S increased
Type V - Sulfate Limit on C3A≤5%,
Resistant P.C. 2C3A+C4AF≤25%
43 36 4 12
 COMPOUND COMPOSITION OF O.P.C. (OR CLINKER)
• Oxides interact with each other in the kiln to form more complex
products (compounds). Basically, the major compounds of OPC
can be listed as:

Name Chemical Formula Abbreviations

Tri Calcium Silicate 3CaO.SiO2 C3S

Di Calcium Silicate 2CaO.SiO2 C2S

Tri Calcium Aluminate 3CaO.Al2O3 C3A

Tetra Calcium Alumino 4CaO.Al2O3.Fe2O3 C4AF

Ferrite
 TYPES OF PORTLAND CEMENT

• ASTM C 150 (AASHTO M 85)

• I Normal
• II Moderate sulfate resistance
• III High early strength
• IV Low heat of hydration
• V High sulfate resistance
Setting of cement
• i. At first (CaO)3Al2O3 hydrates to form CaO, Al2O3, 12H2O+2Ca(OH)2

• ii. then (CaO)3SiO2 hydrates to form CaO, SiO2, 2H2O+2Ca(OH)2

• iii. then (CaO)2SiO2 hydrates to form CaO, SiO2, 2H2O+2Ca(OH)2
iv. then (CaO)4, Al2O3, Fe2O3 hydrates.

v. At first the hydrated salts form colloidal gel coating on the anhydrous grains.
vi. The gel contains much free water which is gradually withdraw by the anhydrous core.
vii. In this way the core becomes hydrated and the surface becomes hard due to drying.

viii. At this stage cracking appears if sufficient water is not available, due to over drying, of
the surface. The process contains for 10 to 20 days.
ix. Then the hydrates and Ca(OH)2 crystallise. The crystals interlace with one another and
with sand grains, to form an impervious continuous hard mass.
Thank you