PROJECT I

A Project Proposal on
To Study on Manufacturing Process of
OPC Cement (Dry Process)

Submitted by:
Table of Content
1. Introduction
2. Objectives
3. Statement of Problem

4. Methodology
5. Significance of the study
6. Literature review
7. Composition of Cement
8. Limitation of the study
9. Time Schedule
10. Conclusion Fig : (Entrance of hetauda cement industries ltd. )

11. References
1. INTRODUCTION

 Cement is an extremely fine material having

adhesive and cohesive properties which is
capable of bonding material.

 Cement is basically manufactured through a

closely controlled chemical combination of
lime, silicon, alumina, iron oxide and various
other(raw material) ingredients.
 Cement is any substance which binds together
other materials by a combination of chemical
Fig: Cement
processes known collectively as setting.
2. OBJECTIVES

The main objective of this proposal are:

 To Study manufacturing process of OPC cement.
 To Study different raw material use in manufacturing of cement.
3. STATEMENT OF PROBLEM

It is associated with several problems arise due to

 High cutting temperature, such as accelerated tool wear
 reduced tool life
 residual stress etc.
4. METHODOLOGY

 We visited cement factory in order to know about the manufacturing process (dry
process) of cement, quarry of limestone, import of gypsum and marketing of
cement.
 There are two types of sources
 Primary sources:

Field visit of Hetauda Cement Industries Ltd.

Interaction with site supervisor
 Secondary Sources:

Magazines
Internet and official website
5. SIGNIFICANCE OF THE STUDY

The major significance of this proposal is:

 To know more information about the raw materials (limestone, clay, gypsum etc.)
used in manufacturing of cement and its manufacturing processes.

Fig: Calcium Carbonate CaCO3 rocks

Fig: Gypsum Powder
(Limestone).
6. LITERATURE REVIEW

 Cement is an extremely fine material having adhesive and cohesive properties

which is capable of bonding material.
 Cement is basically manufactured through a closely controlled chemical
combination of calcium, silicon, aluminum, iron and various other ingredients.
 Different minerals like limestone, shale, gypsum, clay are mined in order to make
cement.
 When these ingredients are heater at a high temperature to form a rock like
substance, which is then grounded in the fine powder cement is formed.
6.1 Type of Cement

The following are the different types of cement:

 Ordinary Portland cement (OPC)
 Portland Pozzolana cement (PPC)
 Rapid hardening cement (RHC)/ High early strength cement
 White cement
 Extra rapid hardening cement
 Sulfate resisting cement
 Quick setting cement
 Hydrophobic cement etc.
6.2 Manufacturing of OPC Cement

 The name Ordinary Portland Cement (OPC) is reserved for a cement which is an
extremely finely ground product obtained by burning together at high temperature
specifically proportioned amounts of calcareous and argillaceous raw materials
adding nothing else to the burnt product except gypsum in small percentage.
 Cement is usually manufactured by two processes:

a) Dry Process
b) Wet process
6.3 Dry Process

 Dry cement process is the most common and modern way of manufacturing
cement.
 In this process, Calcareous and argillaceous raw materials are fed into the burning
kilns which are in entirely dry state.
 This method is used when the available raw materials are quite hard and are dried
and reduced in size in the grinding mill.
 It is reduced to a fine powder and that dry powder is known as raw meal.
 The dry cement process includes:
6.3.1 Treatment of raw materials:

 In this process, Crushing, drying, grinding, proportioning and blending of Limestone

and clay.
 Breaking of raw material to 6-14mm using crushers.
 Rotating drying kiln is used to dry the crushed materials
 Grinding is done in two stages as ball mill and tube mills and stored in SILOS.
Proportioning and blending the raw materials in different stages with adding low
quantity of water-12%

Fig : (limestone stored ) Fig : (limestone carrying belt for grinding

Fig : raw material grinding like limestone, clay

raw material after grinding

ready for making clinker

Fig : raw material after grinding which is ready for making clinker

Fig : raw material grinding like limestone, clay

6.3.2. Proportioning and blending:

 The raw material is then mixed together thoroughly either through mechanical or
pneumatic method, before they are fed into the kiln.
 The compressed rock is combined with other ingredients such as iron ore fly ash
and ground, mixed and fed to a cement kiln.
 In the pneumatic method, dry proportioned materials are inflated under passive
blending where from they are drawn in the mixed state.
 The blended materials are then ready for feeding in the burning kilns. After
completion of this process, there are no major differences between the dry and wet
process except the design of the rotary kiln.
Fig : (raw material like aclay carrying belt for mixing with clinker before grinding )

Fig : (raw material like clay, clinker etc are grinding before heating
6.3.4. Burning of the Dry Mix:

 The finely powdered mixture is charged into long

steel cylindrical tubes known as rotary kiln.
 The kiln is attuned in an inclined position, making
an angle of 15 degrees in a horizontal position,
it moves around its longer axis.
 The raw mix of dry process of corrected slurry of
wet process is inserted into the kiln from the
upper end.
 The kiln is heated with the support of powdered
coal or oil or hot gas from the lower end of the
kiln so that the long hot flames is formed.
 The raw mixture is burnt in the kiln unless proper Fig : (raw material are heating about 13000+ 0C)
burning is acquired. This is shown by a greenish
black color and vitreous luster. The burnt material in the cement is the composition known as clinker.
6.3.3. Grinding of the clinker:

 In this process, Calcined hot clinker is first fed into cooling chamber and then
Gypsum is added and mixture is pulverized.
 Then grinding is done in two stages as coarser grinding and finer grinding.

Fig : (Hot clinker collection chamber after heated raw material Fig : (Gypsum stored site)
Fig : (clinker and gypsum adding)

Fig : (clinker and gypsum grinding mill for making powder (cement)
 6.3.5. Packaging and Storing:

 In this process, cement is first placed into concrete storage tanks- SILOS and
packed into high density polyethylene bags, jute and packing cloths of 50kg
capacity.

Fig : (packaging plant) Fig : (50 kg package of cement

Fig: Dry process for the manufacturing of cement.
7. COMPOSITION OF CEMENT
S.N Ingredient Limits % Average %

1. Lime (Cao) 60-66 62

2. Silica (Sio2) 17-25 22

3. Alumina (Al2O3) 3-8 5

4. Iron oxide (fe2O3) 1-0.5 3

5. Magnesia (MgO) 1-4 2

6. Calcium sulphate (Caso4) 3-5 4

7. Sulphur 1-2 1

8. Alkalis 1-2 1

Total 100

Table: Composition of cement (Source: Er.R.K. Rajput)

The following are the main composition (Raw material) of
cement:

 Lime(Cao) (60-65) %
 Major component of cement and its proportion need to be maintained carefully.
 Right proportion makes the cement sound and strong.
 Excess of Cao makes cement unsound and cause the cement to expand and
disintegrate.
 Silica(Sio2) (17-25) %:
 Second must important ingredient and it is responsible for strength of the cement
due to formation of di calcium and tri calcium.
 Excess amount of silica provides greater strength to the cement quickly setting are
reduces the strength of cement.
The following are the main composition (Raw material) of
cement:

 Alumina (Al2O3) (3-8) %:

 Responsible for quick setting of cement.
 Excess makes cement quick setting and reduces the strength of cement.
 Iron oxide(Fe2O3) (0.5-6) %:
 Provides color, hardness and strength to the cement.
 It helps in the fusion of raw material during manufacture of cement.
 Magnesia oxide (Mgo) (0.5-4) %:
 If present in small amount imparts hardness and color to the cement.
 Excess amount of it makes cement unsound.
The following are the main composition (Raw material) of
cement:

 Sulphuric trioxide (So3) (1-2) %:

 Present in very small amount, make the cement sound.
 Excess amount make cement unsound.
 Alkalis (0.4-1.3) %:
 They should be present in small quantities.
 Excess of alkali cause the cement unsound.
 Calcium sulphate (CaSO4) (2-3) %:
 It is present in the form of gypsum.
 It helps in increasing the initial setting time of cements.
8. LIMITATIONS OF THE STUDY

 The study cannot be carried out on the manufacturing process of 53 grade OPC
Cement and manufacturing by wet process.
 9. TIME SCHEDULE
This research study planned to complete in 2 months from the data successful registration as:

S.N. Description Mangsir Mangsir Poush Poush

1st-2nd 2nd-last week 1st-2nd 2nd-last week

week week

1 Literature review

2 Project class

3 Proposal writing

4 Submission of final
proposal

Table: Gantt chart

10. CONCLUSION

 The proposal has been prepared with including the important topic and is prepared
with sketches on site observations and their descriptions also.
 From the field, we were able to study and identify about manufacture of (Dry
process of OPC) cement.
11. REFERENCES

 Rajput, R.K. (2004): ‘Engineering Materials’, S. Chand Company Ltd., New Delhi
 Singh, P. (2008): ‘Civil Engineering Materials’, Kaston Books
THE END