DEBRE BRHAN UNVERSITY

COLLEGE OF ENGINEERING
Department of chemical
engineering
Process industry individual assignment
Submitted by; MIKIYAS AWEKE
ID/NO-DBUR/0712/10 SECTION-A
TABLE OF CONTENT
1. Introduction
2. History of cement
production
3.
1. Introduction
 cement is a powdery substance made with
calcined lime and clay as major ingredients. Clay
used provides silica, alumina, and iron oxide,
while calcined lime basically provides calcium
oxide. In cement manufacturing, raw materials
of cement are obtained by blasting rock quarries
by boring the rock and setting off explosives.
 0ese fragmented rocks are then transported to
the plant and stored separately in silos. 0ey are
then delivered, separately, through chutes to
crushes where they are then crushed or pounded
to chunks of ∼1/2 inch–sized particles [3].
 Depending on the type of cement being
produced, required proportions of the crushed
clay ,lime stones, and any other required
materials are then mixed by a process known as
prehomogenization and milled in a vertical steel
mill by grinding the material with the pressure
exerted through three conical rollers that roll
over a turning
2. History of cement production
 John Smeaton made an important contribution to the
development of cements when he was planning the
construction of the third Eddystone Lighthouse (1755–
9) in the English Channel. He needed a hydraulic
mortar that would set and develop some strength in the
twelve hour period between successive high tides.
 In 1824, Joseph Aspdin patented a similar material,
which he called Portland cement, because the render
made from it was in color similar to the prestigious
Portland stone.
 The investigations of L.J.Vicat led him to prepare an
artificial hydraulic lime by calcining an intimate
mixture of limestone and clay.
 Later in 1845 Isaac Charles Johnson burnt a mixture of
clay and chalk till the clinkering stage to make better
cement and established factories in 1851.
 The German standard specification for Portland cement
was drawn in 1877.
 The British standard specification was first drawn up in
1904. The first ASTM specification was issued in 1904.
 In India, Portland cement was first manufactured in
1904 near Madras, by the South India Industrial Ltd.
But this venture failed.
 Between 1912 and 1913, the Indian Cement Co. Ltd.,
was established at this Company was able to deliver
about 1000 tons of Portland cement.
 Throughout history, cementing materials have played a
vital role and were used widely in the ancient world. ·
Lime and clay have been used as cementing material on
constructions through m

3. Raw materials
 The raw materials are naturally occurring mineral and
basically all CaO, SiO2,Al2O3 and Fe2O3 bearing
minerals can be used to manufacture cement.
 Plants generally rely on nearby quarries for limestone
to minimize transport costs. 1.Primary raw materials
• limestone (CaCO3) & limestone containing minerals,

1.Primary raw materials

• limestone (CaCO3) & limestone containing minerals

2.Secondary raw materials

 clay (Al2O3), sand & silica (aluminum andiron oxides).

3.Tertiary raw materials

 Gypsum Other "alternative" raw materials slag,
millscale, fly ash. Therefore, the raw materials sources
required for cement manufacture are:- Some form of
calcium carbonate provide the CaO requirements.
 4. Ingredients used in cement
production
Raw ingredients to provide cement production elements

Calcium Silicon Aluminum Iron

Limestone Clay Clay Clay

Marl Marl Shale Iron ore

Calcite Sand Fly ash Mill scale

Aragonite Shale Aluminum Shale

Shale Fly ash Blast furnace dust

Sea Shells Rice hull ash

Cement kiln dust Slag

5. Major unit operations

1. Quarrying
2. Crushing
3. Proportionating/Pre-homogenization
4. Raw mill Grinding
5. Homogenization/Silo
6. Raw meal preheating
7. Kiln operation
8. Clinker cooling/storage
9. Cement mill and gypsum addition
 6. Unit operations in detail
1. Quarrying
Rock blasted from the quarry is transported to the
primary crusher where large "run of mine" rocks are
broken into pieces of approximately 100mm.Generally
the other raw materials do not require crushing.
Cement factory raw material deposits are extracted
using open pit quarries in the vast majority of cases.
There are just a few examples around the world where
the raw materials are extracted from underground
mines.
This significantly increases the costs of raw material
extraction and cement manufacture.

2. Crushing
• Cement plant raw materials blasted in the quarry
requires size reduction for further processing, size
reduction is performed in crushers and grinding mills.
Crushing is commination in the coarse range.
• Primary crushing involves limestone rock fed
through large capacity crushers. This reduces the rock
to a maximum size of approximately150 mm
  Secondary crush in further reduces this to 75mm
or under. Residue material is stacked and
reclaimed with a bridge reclaimer in a cross
section so that the homogeneous limestone is fed
further in the process.
3.proportionating/
prehomogenization/ Raw Material
Storage & Blending
 The raw materials are then proportioned to
the correct chemical balance and milled
together to a fine powder, raw meal, to ensure
high quality of cement, the chemistry of the
raw materials and raw meal is very carefully
controlled.
4. drying
• For dry process the raw material has to be dried
before milling.
• Kiln exhaust gases are used to dry the raw materials.
In some gases with wet materials, additional heat
sources are required for drying.

5. Grinding
• grinding refers to comminution in the fine range.The
grinding media (steel ball) and the feed material to be
ground are brought together in a rotating tubular or
drum-shaped compartment. The media and material
rises to an optimum height, necessary for grinding
operation, and come tumbling down (cascading and/or
contracting).

6.Kiln feed Homogenization

 Materials are homogenized to ensure consistency
of product quality.
 The kiln feed is routed to a homogenization silo,
where it is mixed by blowing compressed air
through pads in the base of the silo. The blending
silo is maintained full and some of the blended
raw mix continuously cascades to a further
blending silo where it is further mixed by air
blown through pads in the base of the silo. The
twice blended raw mix is continuously extracted to
the kiln feed storage silos.
 Modern dry process cement factories have large
combined homogenization and storage kiln feed
silos. Raw mill product is distributed in layers in
the silo, and extracted in funnels rotating around
the radius of the silo. Some of these silos have
an internal, pressure relieved mixing chamber.

7. Preheater/Cyclones/
 A pre-heater is a series of vertical cyclones. Where
the raw meal is passed down through these
cyclones it comes into contact with the swirling
hot kiln exhaust gases moving in the opposite
direction and as a result heat is transferred from
the gas to material.
 This pre-heats the material before it enters the
kiln so that the necessary chemical reactions will
occur more quickly and efficiently. By retaining
energy from the exhaust gases, energy is saved.

8. pre –Calcinations
 The calciner is a combustion chamber at the
bottom of the pre-heater above the kiln backend.
Up to 65% of the total energy needs of the kiln
system can be supplied to the calciner.
 Calciners allow for shorter rotary kilns and for
the use of lower grade alternative fuels.
Calcination is the decomposition of CaCO3 to
CaO and CO2.CaCO3 CaO CO2.
  These process emissions comprise 60% of the
total emission from a cement kiln. The
combustion of the fuel generates the rest.

9. Kiln operation (pyro-processing)

 Raw meal, more accurately termed "hot meal"
at this stage then enters the rotary kiln. The kiln is the
world's largest piece of industrial equipment. Types of
equipment used in cement industry
7. Types of equipment
8. Working principles

 The basic principles of cement manufacturing is a

complex process that begins with milling and then
grinding raw materials that includes lime stone
and clay to fine powder, called raw mill which is
then heated to a sintering temperature as high as
14500c in cement kiln.
 in this process the raw materials are broken dawn
and then they are recombined into new compound
the result is called clinker.
 then clinker is ground to a fine product powder in
cement mill and mixed with gypsum to create
cement. and then the cement is aggregated with
water to create concrete.
9. Cement Types and
Applications
 The vast majority (>95%) of cement
produced in the world is based on Ordinary
Portland Cement clinker.

 That Ordinary Portland Cement clinker can

be ground together with gypsum to produce
Ordinary Portland Cement (OPC).

 However, the production and use of blended

cements containing pozzolan additions is
assuming ever greater importance (PPC)
 10. Conclusion
Basically, different types of cements and their
chemical composition and applications in the
current engineering and chemical world have
been of enhancing materials and fillers
developed using nanotechnology for the
productive and effective cement
manufacturing have been mentioned with the
chemical background.
0e mechanical defects when concrete is
concerned and possible solutions that can be
given through chemistry and nanotechnology
have been deliberated in detail.