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Cement Manufacturing Process

The document describes the cement manufacturing process used by Lafarge, a French industrial company. The process involves 5 main steps: 1) mining of raw materials like limestone and clay, 2) crushing and storing the materials, 3) drying, grinding and mixing the materials into raw meal, 4) firing the raw meal in a kiln to produce cement clinker, and 5) grinding the clinker together with gypsum to produce cement powder and storing it in silos. Natural gas is the main fuel used in the kiln to heat the materials to over 1350 degrees Celsius to produce clinker.

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91 views

Cement Manufacturing Process

The document describes the cement manufacturing process used by Lafarge, a French industrial company. The process involves 5 main steps: 1) mining of raw materials like limestone and clay, 2) crushing and storing the materials, 3) drying, grinding and mixing the materials into raw meal, 4) firing the raw meal in a kiln to produce cement clinker, and 5) grinding the clinker together with gypsum to produce cement powder and storing it in silos. Natural gas is the main fuel used in the kiln to heat the materials to over 1350 degrees Celsius to produce clinker.

Uploaded by

Dovah Kiin
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 13

PANTONE®

COLOR OF THE YEAR 2022


LA FARGE REPUBLIC
CEMENT / HOLCIM

Lafarge is a French industrial company specializing in


three major products: cement, construction
aggregates, and concrete. It was founded in 1833 by
Joseph-Auguste Pavin de Lafarge and a part of the
Holcim Group.
MANUFACTURING PROCESS
STEP 1 : MINING

The cement manufacturing process starts from the mining


of raw materials that are used in cement manufacturing, mainly
limestone and clays. A limestone quarry is inside the plant area
and a clays quarry is as far from the plant area as 25 km.

The limestone is excavated from open cast mines after


drilling and blasting and loaded onto dumpers which transport
the materials and unload into hoppers of limestone crushers.
The clays are excavated from open cast mines and loaded onto
dumpers which transport the materials and unload into open
yard storage. Then it is transported by trucks and unloaded into
the hopper of a clay crusher.
MANUFACTURING PROCESS
STEP 1 : MINING

The limestone is excavated from


open cast mines after drilling and
blasting and loaded onto dumpers
which transport the materials and
unload into hoppers of limestone
crushers. The clays are excavated
from open cast mines and loaded
onto dumpers which transport the
materials and unload into open yard
storage. Then it is transported by
trucks and unloaded into the
hopper of a clay crusher.
MANUFACTURING PROCESS
STEP 2: CRUSHING, STACKING, AND RECLAIMING OF RAW MATERIALS

The limestone is crushed in the first


crusher called a jaw crusher and then fed
into the second crusher called an impact
crusher with mixing of clays to reduce JAW CRUSHER
particle size below 50mm. The discharged
raw mix (limestone 70%, clays 30%) is fed
onto a belt conveyor and passed across a
bulk material analyzer. The raw mix is fed
into a circular storage unit called a raw mix
storage. Then, the mix is extracted
transversely from the stockpile by reclaimers
and conveyed to a raw mill bin called the raw
mix bin for grinding. IMPACT CRUSHER
MANUFACTURING PROCESS
STEP 2: CRUSHING, STACKING, AND RECLAIMING OF RAW MATERIALS

The other raw materials that are used in cement manufacturing, called
additives, are high purity limestone, sand and iron ore. The high purity
limestone is crushed in a lone in jaw crusher and then crushed more in a
secondary crusher to reduce the size to completely pass through a 50mm
sieve. Then, it is stacked by a limestone stacker into a longitudinal storage
unit called the limestone storage stockpile. Finally, the limestone is
extracted transversely from the stockpile by reclaimer and conveyed to a
raw mill bin, called the limestone bin, for grinding.
MANUFACTURING PROCESS
STEP 3: RAW MEAL DRYING, GRINDING, AND HOMOGENIZATION

The raw mix, high grade limestone, sand, and iron ore are fed from their
bins to raw mills, called air swept mills, for drying and fine grinding. The raw
mill contains two chambers, separated by diaphragm, namely a drying
chamber and a grinding chamber. The hot gases coming from a preheater
(preheater / kiln system) enter the mill and are used in raw mills for drying.

Then the drying materials enter the grinding chamber of raw mills for fine
grinding. The grinding chamber contains a certain quantity of ball charge in a
different sizes ranging from 30mm to 90mm. The hot gas and grinding
materials mill outlet feeds to a separator which separates fine and course
product. The latter, called reject, is sent to the mill inlet via an air slide for
regrinding. The hot gas and fine materials enter a multistage "cyclone" to
separate a fine materials and gases.
MANUFACTURING PROCESS
STEP 3: RAW MEAL DRYING, GRINDING, AND HOMOGENIZATION

The fine material, called raw meal, is collected from the multi-cyclone and
then fed into an air slide for lifting called an Aeropol. The hot gases with very
fine materials enter an electrostatic precipitator to separate the fine materials
from gases. The very fine materials called preheater dust or electrostatic
separator dust is collected from filters and fed into screw conveyors and are
then mixed with the fine material in an air slide and transported to an air lift
vessel via air slide. In the air lift, the raw meal is lifted to the silo by
compressed air to the air slide and then stored and homogenized in a concrete
silo. Raw meal extracted from the silo, now called kiln feed, is fed to the top of
the preheater via an air lift called the Poldos for pyro-processing.
MANUFACTURING PROCESS
STEP 4: CLINKERIZATION
Cement clinker, which is the glassy clinkerlike product of fusing together clay
and limestone, is made by pyro processing of kiln feed into the preheater-kiln
system. The preheater-kiln system consists of a multi-stage cyclone The main
source of heat is natural gas. Natural gas is fired as a main fuel (100 %) in the
CEMENT CLINKER
main burner rotary kiln and a 95% natural gas and 5.0% heavy oil combination in
the combustion chamber. The fuel is used to provide the heat required to convert
the kiln feed into clinker. Hot clinker discharge from the kiln drops onto the grate
cooler for cooling from approximately 1350-1450 C to approximately 120 C. In
the cooler, the quantity of cooling air required for clinker cooling is extracted
from the atmosphere by different cooling fans and fed into the cooler chambers
and pressurized through the cooler plate and clinker bed.

KILN
MANUFACTURING PROCESS
STEP 4: CLINKERIZATION
The cooled clinker discharges from the cooler into the pan conveyor and
it is transported to the clinker storage. The clinker is taken from the clinker
storage to cement ball mill hoppers for cement grinding. Part of the hot air
extracted from the cooler is utilized as a secondary and tertiary air for
combustion in rotary kiln and combustion chamber, respectively.    
MANUFACTURING PROCESS
STEP 5: CEMENT GRINDING AND STORAGE
Clinker and gypsum for OPC (Ordinary Portland Cement), limestone for
limestone cement, and slag for slag cement are all extracted from their
respective hoppers and fed to the cement mills. The ball mill grinds the feed to
a fine powder in two chambers, namely the first and second chambers. The
two chambers have a certain quantity of ball charge of different sizes from
17mm to 90 mm. The mill discharge is fed to a bucket elevator which takes the
material to a separator which separates fine and coarse product. The latter is
sent to the mill inlet for regrinding and the final product is stored in concrete
silos.

CONCRETE SILOS
AMUSEMENTS

Use this color palette when you want to tell a


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PANTONE Very Peri injects a sense of playful
freshness into the design, exuding a good-
natured warmth that quickly engages the eye.
USE THESE COLORS IN ANY
POWERPOINT PRESENTATION
1. Select a shape or text box border. When you do that, the
Shape Format tab appears.
Tip: To change multiple shapes or text boxes, click the first shape or text box,
and then press and hold Ctrl while you click the other shapes or text boxes.

2. On the Shape Format tab, select Shape Fill > More Fill
Colors.
3. In the Colors box, select the Custom tab.
4. Enter the Hex value of the color you want to use.

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