NATIONAL INSTITUTE OF TECHNOLOGY,

HAMIRPUR

SEMINAR REPORT
TOPIC: - OVERVIEW OF CEMENT INDUSTRY AND
MANUFACTURING OF ORDINARY PORTLAND CEMENT

SUBMITTED TO: SUBMITTED BY: -

Dr. Arvind K. Gautam KANISHKA SHARMA
Dr. Vineet Rathore ROLL No. – 16733
Chemical Engineering
Sr.No. Page No.
1. Abstract 3
2. Introduction 4
3. Process Description 5
4. Dry Process 7
5. Wet Process 9
6. Uses & Applications 10
7. Summary 11
8. References 12
 ABSTRACT
Cement is one of the fundamental elements for setting
up strong and healthy infrastructure of the country
and plays an important role in economic development
and welfare of the nation. Cement is generally
manufactured in six phases of manufacturing process.
Cement is commonly manufactured by two processes
which I will discuss later with their process flow
diagrams. After this I m going to discuss a comparison
between the two processes of manufacturing cement
in which we can see both merits as well as demerits of
the processes. After this I m going to discuss the
various uses of cement and then I m going to end my
report by summarizing it.
 INTRODUCTION
Cement is one of the fundamental elements for setting up
strong and healthy infrastructure of the country and plays
an important role in economic development and welfare of
the nation.
Cement is manufactured by two processes wet and dry
process. In the wet process, the slurry is fed to the rotary
kiln, which contains the moisture of about 35 to 50%. In
the dry process, the slurry which is fed to rotary kiln
contains the moisture of about 10 to 12%.
Both the processes have some merits as well as demerits
which can be seen later.
The term cement is many times confused with the term
mortar. The basic difference in these two is that the
cement is the constituent of mortar which is further used
in the building purposes.
Cement is a very useful binding material in construction.
It is used for making joints for drains and pipes. It is used
when a hard surface is required for the protection of
exposed surfaces of structures against the destructive
agents of weather and certain organic or inorganic
chemicals.
 PROCESS DESCRIPTION
The first stage in cement manufacturing process is the
extraction of raw material from quarry. A quarry is a type
of open-pit mine in which dimension stone, rock,
construction aggregate, riprap, sand, gravel, or slate is
excavated from the ground. Now by using the belt
conveyors the material is transported to the plant.
The second stage comes is of grinding, proportioning and
blending. The raw material which we got from the first
stage is in the form of big rocks. So for mixing it in a
correct proportion, we need its powder form. Hence, we
apply the grinding operation to them. In ordinary Portland
cement manufacturing generally 80% calcareous material
and 20% argillaceous material is used.
The third stage is pre-heating stage. This is the optional
stage and depends on the size of rotary kiln used in the
next step. If rotary kiln used is large, then there is no need
of pre heater. The preheating chamber uses the hot gases
emitted from kiln to preheat the material using the series
of vertical cyclone separators.
The fourth stage is the stage of rotary kiln which is the
heart of any cement industry. Rotary kiln has an average
operating temperature of 1450°C.

 70 to 110 °C - Free water is evaporated.

 400 to 600 °C - Clay-like minerals are decomposed
into their constituent oxides; principally SiO2 and
Al2O3. Dolomite (CaMg(CO3)2) decomposes to calcium
carbonate (CaCO3), MgO and CO2.
 650 to 900 °C - Calcium Carbonate reacts with SiO2 to
form belite (Ca2SiO4) (also known as C2S in the Cement
Industry).
 900 to 1050 °C - The remaining calcium carbonate
decomposes to calcium oxide (CaO) and CO2.
 1300 to 1450 °C - Partial (20–30%) melting takes
place, and belite reacts with calcium oxide to form Alite
(3CaO·SiO4) (also known as C3S in the Cement
Industry).
Clinkers are formed in this step.
The next step is cooling and final grinding step. Clinkers
coming from the rotary kiln are very hot. So they are
passes through coolers which use the air to cool them.
This hot air is used in burning of coal. In this cooling step
the clinkers are cooled up to 100°C. Now for the final
grinding of the cooled clinkers we also add 2-3% of
gypsum in it as a retarding agent, which is used to regulate
the settling time of cement.
The final step is the packing and shipping step. In this step
the product formed which is cement is directly conveyed
to silos. Small percentage of cement is packed in bags and
remaining is shipped in bulk by means of trucks, rails and
ships.
 Figure 1
Source: https://theconstructor.org/concrete/ordinary-portland-cement/23181/
The diagram shown above is showing manufacturing of
cement by dry process at Port Elizabeth.
First there is a quarry from where they are extracting the
raw material for the process. This raw material is going to
crushing plant. This crushed material is going to the raw
material storage. From where by proportionation step the
material is going to feed bins. Then the raw mills are
mixing the coming raw material and sending it to the
rotary kiln. They have used a long rotary kiln so they don’t
need the preheaters. Coal is coming as fuel in the rotary
kiln from the coal mill. Clinkers formed in rotary kiln are
stored in clinker storage. And then final crushing take
place in cement mill where we add some gypsum to it. So
that the settling time of resulting cement can be
controlled.

And in the last step of shipping the final product that

is cement, depending upon whether we need bulk
storage or small storage the cement is packed. If the
cement is to be transported in bulk then bulk
storages are used. And if only small amount is
required for the use then it is packed in some kind of
plastic bags by using the packing machine.
 Figure 2
Source:-https://nptel.ac.in/courses/103106108/lecture
%2024.pdf

Wet process
The above diagram is showing how to manufacture
the cement from wet process. Only 26% of total
cement produced is produced by this process, other
74% is manufactured by the dry process only.
The calcareous material and argillaceous material is
fed to the jaw crushers for their proper sizing. And
then when they are stored some amount of water is
added to the bins so that the resultant slurry coming
from the mixer will contain 35-50% of moisture. As
moisture content is quite high, the slurry uses extra
amount of heat to form clinkers. The remaining
process is same as that of dry process. These
clinkers obtained are cooled and grinded by adding
gypsum. Cement is finally obtained.
USES & APPLICATION

Following are the various possible applications or

uses of cement:
1. The most common use of cement is production of
concrete and mortar.
2. Cement mortar can be used for masonry work,
plaster, pointing, etc.
3. Cement concrete can be used for laying floors,
roofs, constructing lintels, beams, weather sheds,
stairs, pillars, etc.
4. It can be used for construction of important
engineering structures such as bridges, culvert,
dams, tunnels, storage reservoirs, light houses,
docks, etc.
5. It can be used for making joints for drains, pipes
etc.
6. It can be used for preparation of foundations,
watertight floors, footpaths, etc.
 SUMMARY
At present, the cement is widely used across the
world in the construction of various engineering
structures. It has proved to be one of the leading
engineering materials of modern times and has no
rivals in production and applications. It can be used
as a constituent of mortar and mortar can be used
further as a building material. It can be used in
construction of bridges, dams, etc. These all are the
merits of the cement. Cement has also some
demerits. Structure once build out of cement are
difficult to be displaced or reused. They can’t be
recycled like plastics or steels.
REFERENCES:-
 https://en.wikipedia.org/wiki/cement
 https://theconstructor.org/concrete/ordinary-
portland-cement/23181/
 https://www.slideshare.net/types-and-
manufacturing-of-cement
 https://2CL211.wordpress.com
 https://nptel.ac.in/courses/103106108/lecture
%2024.pdf
 www.civileblog.com/uses-of-cement/