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Cement Manufacturing Process

The cement manufacturing process involves 6 key phases: 1) Raw material extraction through quarrying, 2) Grinding, proportioning, and blending of raw materials, 3) Pre-heating of materials using hot gases from the kiln, 4) Firing materials in a rotating kiln at 1450°C to form clinker, 5) Cooling of clinker using forced air, 6) Final grinding of clinker along with gypsum into a fine powder to produce cement.

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1K views

Cement Manufacturing Process

The cement manufacturing process involves 6 key phases: 1) Raw material extraction through quarrying, 2) Grinding, proportioning, and blending of raw materials, 3) Pre-heating of materials using hot gases from the kiln, 4) Firing materials in a rotating kiln at 1450°C to form clinker, 5) Cooling of clinker using forced air, 6) Final grinding of clinker along with gypsum into a fine powder to produce cement.

Uploaded by

Morning Kalal
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Cement Manufacturing Process

Process Description
Production of cement completes after passing of raw materials from the following six phases,
that are listed below:

1. Raw material extraction/ Quarry


2. Grinding, Proportioning and Blending
3. Pre-heater Phase
4. Kiln (Pyro) Phase
5. Cooling and Final Grinding
6. Packing & Shipping

Cement uses raw materials that are classified as Calcareous Materials (Compounds that contains
Calcium) and Argillaceous Materials (Compounds that contains Alumina and Silica), which is
combined with small proportion of Iron. Here, limestone fulfills the requirement of Calcium,
which is the main constituent during the production of Cement. Cosmos Cement Industries
(Private) Ltd. has its own limestone quarry situated at Udayapur District. Basically, High-Grade
Limestone and Low-Grade Limestone is transported to the plant site.
The limestone lumps are first transported to the plant site and are stored in a duct. The lumps are
then subjected to series of crushers, initially to a primary crusher where the lumps size reduces to
about 150- to 250-mm lumps, which is then followed by a secondary crusher where the lump
size reduces to 40- to 60- mm lumps. The raw materials from quarry are now routed in plant
laboratory where, they are analyzed and proper proportioning of limestone (high and low) and
iron are making possible before the beginning of grinding.

Simultaneously, in the coal mill, the coal stock is grinded to fine powder by subjecting it into
grinding mill, loaded with spherical balls. The fine powder is then transported to a separator
followed by a cyclone separator. The final fine dry powder is then stored in KC and PC, which is
then transported for use in Kiln and pre-heater respectively.

Thus, the raw materials are crushed and fed in the correct proportions into a raw grinding mill,
where they are dried and reduced in size to a fine powder. The dry powder, called raw meal, is
then transported to a separator followed by a cyclone separator, so as to extract just the fine
powders where the small lumps are then recycled back to raw grinding mill. 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. Pre-heating of the material saves the energy that is
required in the kiln. Kiln is a huge rotating furnace also called as the heart of cement making
process. Here, raw material is heated up to 1450 ⁰C. Kiln is heating up from the exit side by the
use of coal. When material reaches the lower part of the kiln, it forms the shape of clinker.

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. The final phase is then Final Grinding. There is
a horizontal grinding mill filled with steel balls. Clinker reach in this rotating drum after cooling.
During grinding, gypsum is also added to the mix in small percentage that controls the setting of
cement. Here, steel balls tumble and crush the clinker and gypsum mixture into a very fine
powder. This fine powder is considered as cement.

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