Manufacturing of cement in the industry ? How to make cement in the factory ? cement making process

Cement is the material which binds the other ingredients like fine aggregates, coarse aggregates, steel reinforcement, etc.  In this blog post you are able to learn about types of methods used in manufacturing of cement, complete details of dry process in the manufacturing of the cement.

Types of methods used in the manufacturing of cement

The following are the general methods used in the making process of cement materials

1. Wet process
2. Dry process

Wet process

In this stage the cement making process is done in the presents of the water. In this method fuel consumption takes more and the final product obtained in the last stage has more size of grains.

Dry process

Now a days this process is using because of various advantages like saving fuel and it makes the fine material.

Steps used in the manufacturing of cement by dry process which are

1. Selection of raw materials
2. Grinding process
3. Heating process
4. Cooling process
5. Addition of gypsum
6. Final product

Selection of Raw materials

The raw materials which are related to the lime, silica, clay (or) shale are collected initially. The materials are considered in the proportion of 2C: 1A (2 proportions of calcareous and 1 portion of argillaceous materials). The collected materials are transferred to the tube mills through the conveyer belts.

Grinding process

The raw materials which are collected through the conveyer belts are now there in tube mills. The grinding process is made in this stage to make the powder form material. After obtaining the power it is transferred to the rotary kiln for the heating purpose.

Heating process

The powder material which is collected from the grinding process is now available at rotary kiln. In this stage the temperature of 1300^oC to1500^oC is supplied to the power form. Due to the presents of high temperature the powder material is converted in to small balls. Those small balls are also called as clinkers. Now after forming the clinkers they are allowed to cool in the next stage.

Cooling process

The cooling process of clinkers is made in this stage with the help of the cooling chambers. The 1500^oC temperature is converted to room temperature in this stage. Initially the 1500^oC to 500^oC is made at the time interval of 15 minutes. After this in the second stage the 500^oC temperature is converted in to room temperature at the time interval of 10 minutes. The total time required for the cooling process is 25 minutes.

Addition of gypsum

After the cooling process the clinkers are again transferred to ball mills. In the ball mills the clinkers are grinder to make the fine pozzolana material. At this stage the gypsum of 3% to 5% is added to the grinded material. The main purpose of adding gypsum to the pozzolona material in this stage is to prevent the setting time of the cement.

Final product

After adding gypsum material of 3% to 5% to the mixture in the ball mills grinding process the final product is obtained from the ball mills it is called as our final cement product.

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Conclusions of manufacturing of cement in the industry

Well now the above explained concepts are related to the manufacturing of cement in the industry. Basically the six steps which are related to the, selection of raw materials, grinding process, heating process, cooling process, addition of gypsum and final product cement.

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Note: The above concepts and information only helps for the civil engineering students to get brief idea regarding the topic. Do not consider it for the real time applications.

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