Cement

Manufacturing
By John Patrick Eustaquio & Josiah Garduque
 About the Project
01. HISTORY
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topic of the section
Sneak Peek
04. PROBLEMS & SOLUTIONS
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ENCOUNTERED
02. RAW MATERIALS
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topic of the section
topic of the section
Project Stages
Project Goals 05. LATEST
Here youDEVELOPMENT
could describe the IN
03. PROCESSES
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MANUFACTURING
topic of the section
PROCESS
topic of the section
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