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The Process of Production: Assignment 1

The process of cement production involves 3 main steps: 1) Extraction of raw materials like limestone and clay from quarries 2) Grinding the raw materials into a fine powder, preheating it, and firing it in a kiln at 1500°C to form clinker 3) Grinding the clinker with gypsum, adding other additives, storing the cement in silos, and shipping for construction use.

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38 views7 pages

The Process of Production: Assignment 1

The process of cement production involves 3 main steps: 1) Extraction of raw materials like limestone and clay from quarries 2) Grinding the raw materials into a fine powder, preheating it, and firing it in a kiln at 1500°C to form clinker 3) Grinding the clinker with gypsum, adding other additives, storing the cement in silos, and shipping for construction use.

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saimhatre1122004
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© © All Rights Reserved
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THE PROCESS OF PRODUCTION

Assignment 1
Production & total quality management
Sairaj D Mhatre / roll no 41/ SYBMS A [Finance]
INTRODUCTION

 Ambuja Cements Limited, formerly known as Gujarat Ambuja Cement Limited, is a major Indian cement
producing company. The Group markets cement and clinker for both domestic and export markets.
 Ambuja Cement was founded in 1983 by Narotam Sekhsaria and Suresh Neotia, two traders with very little
knowledge of cement or manufacturing. What made up for this lack was their farsightedness: Anticipating
that cement would be a critical resource for a developing economy like India, they invested in a state-of-the-
art cement plant in Gujarat and went on to build a trusted cement brand that has become synonymous with
quality and strength.
CEMENT

A cement is a binder, a substance that sets and hardens and can bind other materials together.
The word “cement” can be traced back to the Roman term opus caementicium, used to
describe masonry resembling modern concrete that was made from crushed rock with burnt
lime as binder. The volcanic ash and pulverized brick supplements that were added to the
burnt lime, to obtain a hydraulic binder, were later referred to as cementum, cimentum,
cäment, and cement.
Cements used in construction can be characterized as being either hydraulic or non-hydraulic,
depending upon the ability of the cement to set in the presence of water.
PROCESS OF PRODUCTION

Step 1: extraction of raw materials

The raw materials needed to produce cement (calcium carbonate, silica, alumina and iron ore)
are generally extracted from limestone rock, chalk, clayey schist or clay. Suitable reserves can
be found in most countries.

These raw materials are extracted from the quarry by blasting. They are then crushed and
transported to the plant where they are stored and homogenized.
PROCESS OF PRODUCTION

Step 2: raw grinding and burning

Very fine grinding produces a fine powder, known as raw meal, which is preheated and then sent to the kiln.
The material is heated to 1,500°C before being suddenly and dramatically cooled by bursts of air.
This produces clinker, the basic material required for the production of all cements.
Cement manufacturing is the source of 5% of global CO2 emissions. The cement industry is a natural producer
of CO2: 60% of emissions are due to the transformation of raw materials at high temperatures (the
“decarbonation” of limestone), 40% result from the combustion required to heat the cement kilns to 1500°C.
PROCESS OF PRODUCTION

Step 3: cement grinding and shipping


A small amount of gypsum (3-5%) is added to the clinker to regulate how the cement will set.
The mixture is then very finely ground to obtain “pure cement”. During this phase, different
mineral materials, called “cement additives”, may be added alongside the gypsum. Used in
varying proportions, these additives, which are of natural or industrial origin, give the cement
specific properties such as reduced permeability, greater resistance to sulfates and aggressive
environments, improved workability, or higher-quality finishes.
Finally, the cement is stored in silos before being shipped in bulk or in bags to the sites where
it will be used.
PROCESS DIAGRAM

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