MEINPRO

INDUSTRIAL PROCESS AND PLANT INSPECTION

Methods, processes and

equipment involved in
manufacturing
“CEMENT ”
 CHAPTER 2
OBJECTIVES
■ At the end of the chapter, the learner should
be able to:

– Identify concepts involved in cement manufacturing process;

– Understand the processes involved in manufacturing
cement; and
– Learn the practical application of the different industrial
process in the field of cement manufacturing .
INTRODUCTION
- Cement is a binding agent that, when mixed with sand, stone or other aggregates and
water, produces either ready-mix concrete or mortar
- It is a very useful binding material in construction.
The applications of cement over various fields of construction have made it a very
important civil engineering material.
• The Romans in the middle ages used the first hydraulic cement from volcanic
ashes, crush pottery, burnt gypsum and hydrated lime.
• James Parker patented Roman cement in 18th Century which gained popularity
but was replaced by Portland Cement in the 1850s.
• In the 19th century, Frenchman Louis Vicat laid the foundation for the chemical
composition of Portland cement.
• Egor Cheliev published the methods of making cement, uses of cement and
advantages.
Application
• It is used in mortar for plastering, masonry work, pointing, etc.

• It is used for making joints for drains and pipes.

• It is used for water tightness of structure.

• It is used in concrete for laying floors, roofs and constructing lintels, beams,
stairs, pillars etc.

• It is used where a hard surface is required for the protection of exposed surfaces
of structures
against the destructive agents of the weather and certain organic or inorganic
chemicals.
Types of cement
• HYDRAULIC CEMENT - is a product used to stop water and leaks in
concrete and masonry structures. It is a type of cement, similar to
mortar, that sets extremely fast and hardens after it has been
mixed with water.

• NON-HYDRAULIC CEMENT- are created using materials such as

non-hydraulic lime and gypsum plasters and oxychloride, which has
liquid properties
Stage 1 : CEMENT PREPARATION

Raw materials are limestone, clay and sand.

Limestone is for calcium.
It is combined with much smaller proportions
of sand and clay. Sand & clay fulfill the need of
silicon, iron and aluminum.
Generally cement plants are fixed where the
quarry of limestone is nearby
Raw materials are extracted from the quarry
and 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.
Stage 2 : proportioning, blending, and
grinding
The raw materials from quarry are now routed
in plant laboratory .
Generally, limestone is 80% and remaining 20%
is the clay.

Now cement plant grind the raw mix with the

help of heavy wheel type rollers and rotating
table.
Rotating table rotates continuously under the
roller and brought the raw mix in contact with
the roller.
Roller crushes the material to a fine powder
and finishes the job.
Raw mix is stored in a pre-homogenization pile
after grinding raw mix to fine powder.
Stage 3 : Pre-Heating Raw Material

After final grinding, the material is ready to

face the pre-heating chamber.

Pre-heater chamber consists of series of

vertical cyclone from where the raw material
passes before facing the kiln. Pre-heating
chamber utilizes the emitting hot gases from
kiln.
Stage 4 : Kiln Phase

Kiln is a huge rotating furnace also called

as the heart of cement making process.
Raw material is heated up to 1450 ⁰C.
The series of chemical reactions between
calcium and silicon dioxide compounds
form the primary constituents of cement
i.e., calcium silicate.

Kiln is heating up from the exit side by the

use of natural gas and coal. When material
reaches the lower part of the kiln, it forms
the shape of clinker.
Stage 5 : 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.

There is a horizontal filled with steel balls.

Clinker reach in this rotating drum after
cooling.

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.
Stage 6 : Packing and Shipping
Cement is conveyed from grinding mills to
silos where it is packed in 20-40 kg bags.

Most of the product is shipped in bulk

quantities by trucks, trains or ships, and
only a small amount is packed for customers
who need small quantities.
End…
• Human factors in process plant operation by Strobhar, David A. c2014
• Fundamentals of Modern Manufacturing; Materials, Processes, and Systems 6 th Edition, Mikell P.
Groover, c2015
• Fundamental of Industrial Instrumentation and Process Control 2 nd Edition c2018
• Overview of industrial process automation by K.L.S. Sharma -- Waltham, MA: Elsevier, Inc., c2011
• Manufacturing processes: materials, productivity, and lean strategies by John Barry DuVall, David R.
Hillis -- Tinley Park, Ill.: Goodheart-Willcox, c2012.
• Manufacturing facilities design and material handling by Fred E. Meyers, Matthew P. Stephens --
Upper Saddle River, NJ: Pearson, c2005
• https://www.understanding-cement.com/history.html
• https://marketrealist.com/2014/08/must-know-cements-final-manufacturing-process
• https://civiltoday.com/civil-engineering-materials/cement/46-uses-of-cement
• https://www.lafargeholcim.com/directory?term_node_tid_depth=69&field_activity_tid=All
• https://www.lafargeholcim.com/about-us
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• http://www.engineeringintro.com/uncategorized/cement-manufacturing-process/