Types of Cement Manufacturing Process [Explained in Detail]

Here I have explained the types of cement manufacturing process in detail so that you can understand all the minor and major details about the cement manufacturing process.

Table of Contents

Types of Cement Manufacturing Process

There are two types of cement manufacturing process known as “wet” and “dry” processes relying on whether the blending and granulation of raw materials are done in wet or dry conditions.

With a little change in the above process, we have the semi-dry process likewise where the raw materials are ground dry and afterward blended in with around 10-14 percent water and further consumed to clinkering temperature.

In the mature age, as a result of the chance of more exact control in the blending of raw materials, the wet process is famous. The strategies of the cozy blending of raw materials in powder structure were not accessible at that point.

Afterward, the dry process is widely used, in light of the modem improvement of the procedure of dry blending of powdered materials utilizing packed air.

The dry process requires considerably less fuel as the materials are as of now in a dry state, while in the wet process the slurry contains around 35 to 50 percent water. In the wet process, the drying process is fuel utilization. Here, beneath you can peruse both the “wet” and “Dry” process in detail.

WET Process

Wet process is one of the first types of cement manufacturing process. In the wet process, above all else, the recently quarried limestone is squashed into more modest pieces. At that point in the ball or cylinder plant, it is blended in with mud or shale with water to frame a slurry.

The slurry is a fluid of rich consistency with a water substance of around 35 to 50 percent, wherein particles, squashed to the fineness are held in suspension.

At that point this slurry is siphoned into slurry tanks or bowls. In that tank, the limestone and mud particles are forestalled to settle by blowing packed air from the lower part of slurry are kept in touched off condition with assistance of pivoting arms with chains.

This slurry is kept up at the necessary substance arrangement in a cylinder plant by testing and revising time to time. Likewise tried in the distinctive stockpiling tanks by mixing the slurry. From that point forward, in the last stockpiling tanks by the fomentation of slurry, it is kept inhomogeneous condition.

One of the significant pieces of the cement creation plant is the revolving oven. That homogeneous remedied slurry is applied by a spout shower on the upper finish of the rotating oven.

Turning furnace is a 3m to 8m distance across steel chamber, fixed with imperviousness to fire recalcitrant materials, fitted on roller orientation and equipped for pivoting about its own personal hub at a planned speed.

The length of the turning furnace may differ from 30 meters to 200 meters. The slurry on being showered against a hot surface of an adaptable chain loses dampness and becomes pieces.

These drops strip off and fall on the floor. The pivot of the rotating oven makes the chips move from the upper end towards the lower end of the furnace exposing itself to increasingly elevated temperatures.

The furnace is terminated from the lower end. Typically for the manufacturing of cement, the fuels utilized are powdered coal, oil or petroleum gas.

As the materials proceed at that point, the material moves down to the lower end of the turning furnace, the dry material goes through a progression of substance responses until at long last, in the most sweltering piece of the oven, where the temperature is in the request for 1500°C, around 20 to 30 percent of the materials get melded.

Lime, silica, and alumina get recombined. This is the place where the oxides in raw materials will be consolidated to shape mixes in the clinker.

The melded mass transforms into a nodular type of size 3 mm to 20 mm known as clinker. At that point, the clinker is cooled under controlled conditions in a rotational cooler. The clinker is put away in storehouses or receptacles. For the most part, the clinker weighs around 1100 to 1300 gms for every liter.

The liter load of the clinker demonstrates the nature of the clinker.

At that point, cooled clinker ground in a ball plant. For the avoidance of blaze setting of the cement 3 to 5 % of gypsum is added. Ball plant is a solidified steel ball that has various chambers that are charged in arrangement forward. The particles are squashed into the necessary fineness level.

Also, particles are isolated via air flows and taken to capacity. At that point, gracefully to the market as an end result and used in different development works, for example, Buildings, asphalts, dams or other huge work locales.

In the advanced technique for granulating, a very much evaluated cement molecule is shaped by the molecule size circulation of cement particles.

As a whole Civil Engineer realizes that for the development of good cement a decent evaluation of total is required, acceptable reviewing cement particles are additionally needed for good concrete.

I am additionally revealing to you that an all around evaluated cement likewise improves the quality of cement.

Dry Process

In the dry and semi-dry process the raw materials are squashed in a dry state. At that point, they are processed in a pounding factory, dried and decreased to fine powder-like. That dry force is additionally mixed, rectified for the correct structure and blended in with the progression of compacted air.

Almost around one hour of air circulation, a uniform combination is acquired, that circulated air through force will in general act like a fluid.

At that point, the mixed supper is sieved and applied to the process in a pivoting plate called granulator. An amount of water around 12 percent by weight is added to make the mixed feast into pellets.

The mixed feast is changed over into pellets by the expansion of water around 12 percent by weight. This is accomplished for the simple trade of warmth via wind current during the further substance response.

More modest types of hardware are utilized in dry process similar to wet process and dry process is additionally affordable.

These days many cement processing plants utilize present day creation innovation to expand the limit and nature of cement.

In current innovation, they utilize the hardware, for example, a cross belt analyzer made by Gamma-Metrics of USA to discover the synthesis of limestone at the transport lines, high-pressure twin roller press, six-stage preheater, and vertical roller factory.

The most recent Technology with a cutting edge control framework incorporates stacker and reclaimer, on-line X-beam analyzer, Fuzzy Logic oven, and different process control.

Note that the quality properties of cement are impressively affected by the cooling pace of the clinker. The pace of cooling impacts the level of crystallization, the size of the precious stone and the quantity of shapeless materials present in the clinker.

The properties of this formless material for comparative synthetic creation will be not the same as the one which is solidified. This about the manufacturing of cement.

One of the fascinating focuses about cement is that the quality properties of cement rely on the cooling pace of the clinker, in light of the fact that the pace of cooling impacts the level of crystallization, the size of the precious stone and the quantity of shapeless materials present in the clinker.

Cement Manufacturing Process

From the limestone quarry to the conveyance of the finished result, follow each progression in the cement manufacturing process.

Stage 1: Mining

The cement manufacturing process begins from the mining of raw materials that are utilized in cement manufacturing, predominantly limestone and muds. A limestone quarry is inside the plant zone and a muds quarry is a long way from the plant territory as 25 km.

The limestone is uncovered from open cast mines in the wake of penetrating and impacting and stacked onto unloaders which transport the materials and empty into containers of limestone smashers. The dirts are uncovered from open cast mines and stacked onto unloaders which transport the materials and empty into open yard storage. At that point it is moved by trucks and emptied into the container of a mud smasher.

They are three types of mud utilized in cement manufacturing, to be specific silty mud, Zafarana mud, and Kaolin.

Other raw materials are utilized to control the oven feed blend configuration, in particular sand, and iron metal. The sand and iron minerals are transported from outside the plant (from various providers) by trucks and emptied into open yard heaps, called sand and iron metal heaps.

Stage 2: Crushing, stacking, and reclaiming of raw materials

The limestone is squashed in the primary smasher called a jaw smasher and then taken care of into the subsequent smasher called an effect smasher with blending of muds to lessen molecule size beneath 50mm. The released raw blend (limestone 70%, dirts 30%) is taken care of onto a belt transport and passed over a mass material analyzer.

The raw blend is taken care of into a roundabout storage unit called a raw blend storage. At that point, the blend is removed dynamically from the store by reclaimers and passed on to a raw plant receptacle called the raw blend container for grinding.

The other raw materials that are utilized in cement manufacturing, called added substances, are high immaculate limestone, sand and iron minerals.

The high immaculateness limestone is squashed in a solitary jaw smasher and then squashed more in an optional smasher to diminish the size to totally go through a 50mm strainer.

At that point, it is stacked by a limestone stacker into a longitudinal storage unit called the limestone storage reserve. At long last, the limestone is extricated dynamically from the reserve by reclaimer and passed on to a raw plant receptacle, called the limestone container, for grinding.

Stage 3: Raw meal drying, grinding, and homogenization

The raw blend, high evaluation limestone, sand, and iron metal are taken care of from their containers to raw factories, called air cleared plants, for drying and fine grinding. The raw plant contains two chambers, isolated by stomach, specifically a drying chamber and a grinding chamber.

The hot gases originating from a (preheater/oven framework) enter the plant and are utilized in raw factories for drying. At that point the drying materials enter the grinding office of raw plants for fine grinding. The grinding chamber contains a specific amount of ball charge in an alternate size going from 30mm to 90mm.

The hot gas and grinding materials factory outlet feeds to a separator which isolates fine and course items. The last mentioned, called reject, is shipped off the plant channel by means of an air slide for regrinding. The hot gas and fine materials enter a multistage “tornado” to isolate fine materials and gases.

The fine material, called raw meal, is gathered from the multi-tornado and then taken care of into an air slide for lifting called an Aeropol. The hot gases with fine materials enter an electrostatic precipitator to isolate the fine materials from gases.

The fine materials called preheater dust or electrostatic separator dust are gathered from channels and taken care of into screw transports and are then blended in with the fine material in an air slide and shipped to an airdrop vessel through an air slide.

In the airdrop, the raw meal is lifted to the storehouse by packed air to the air slide and then put away and homogenized in a solid storehouse. Raw meal separated from the storehouse, presently called oven feed, is taken care of to the highest point of the preheater by means of a transport called the Poldos for pyro-processing.

Stage 4: Clink erization

Cement clinker is made by preprocessing of furnace feed into the preheater-oven framework. The preheater-furnace framework comprises of a multi-stage twister

preheater with five phases, ignition chamber, riser channel, turning oven, and mesh cooler. In the preheater, the oven feed is preheated by hot gas originating from the burning chamber and rotational furnace.

At that point the preheated furnace feed is halfway calcined (made fine) in an ignition chamber and riser pipe and then totally calcined in a rotational oven just as warmed to around 1400 C to shape clinker parts C3A, C4AF, C2S, and C3S. The fundamental wellspring of warmth is gaseous petrol.

Petroleum gas is terminated as a principle fuel (100 %) in the fundamental burner turning furnace and a 95% flammable gas and 5.0% substantial oil blend in the ignition chamber.

The fuel is utilized to give the warmth needed to change over the oven feed into clinker. Hot clinker release from the furnace drops onto the mesh cooler for cooling from around 1350-1450 C to roughly 120 C.

In the cooler, the amount of cooling air needed for clinker cooling is extricated from the air by various cooling fans and took care of into the cooler chambers and pressurized through the cooler plate and clinker bed.

The cooled clinker releases from the cooler into the container transport and it is moved to the clinker storage. The clinker is taken from the clinker storage to cement ball plant containers for cement grinding. A piece of the hot air extricated from the cooler is used as an auxiliary and tertiary air for ignition in a rotating oven and burning chamber, individually.

Stage 5: Cement grinding and storage

Clinker and gypsum for OPC, limestone for limestone cement, and slang for slag cement are totally separated from their individual containers and taken care of to the cement factories.

The ball plant pounds the feed to a fine powder in two chambers, specifically the first and second chambers. The two chambers have a specific amount of ball charge of various sizes from 17mm to 90 mm.

The plant release is taken care of to a pail lift which takes the material to a separator which isolates fine and coarse items. The last is shipped off the plant gulf for regrinding and the eventual outcome is put away in solid storehouses.