CORE JAVAPresentation On Project :- Cement Manufacturing process

Presented By :- ANAND KUMAR (ME/13/710)

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Outline

History About Cement Raw materials Description Manufacturing Process Manufacturing Steps Process Scheme Uses

History

Cement was first invented by the Egyptians. Cement was later reinvented by the Greeks and

the Babylonians who made their mortar out of lime.

About ninety-nine percent of all cement used today is Portland cement.

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What is Cement?

Cement is a fine grayish powder which, when mixed with water, forms a thick paste. When this paste is mixed with sand and gravel and allowed to dry it is called concrete.

The term cement is commonly used to refer to powdered materials which develop strong adhesive qualities when combined with water.

Gypsum plaster, common lime, hydraulic lime, natural pozzolana, and Portland cements are the more common hydraulic cements.

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Raw Materials Required

There are two types of raw materials which are combined to make cement:• Lime-containing materials, such as limestone,

marble, oyster shells, marl, chalk, etc.• Clay and clay-like materials, such as shale,

slag from blast furnaces, bauxite, iron ore, silica, sand, etc.

It takes approximately 3,400 lbs. of raw materials to make one ton (2,000 lbs.) of Portland cement.

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Manufacturing Process

The production of cement takes place with several steps:• Quarrying of limestone and shale• Dredging the ocean floor for shells• Digging for clay and marl• Grinding• Blending of components• Fine grinding• Burning• Finish grinding• Packaging and/or shipping

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Manufacturing Steps

The most common way to manufacture Portland cement is through a dry method.

The first step is to quarry the principal raw materials, mainly limestone, clay, and other materials. After quarrying the rock is crushed. This involves several stages.

The first crushing reduces the rock to a maximum size of about 6 inches. The rock then goes to secondary crushers or hammer mills for reduction to about 3 inches or smaller.

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Manufacturing Steps

The crushed rock is combined with other ingredients such as iron ore or fly ash and ground, mixed, and fed to a cement kiln.

The cement kiln heats all the ingredients to about 2,700 degrees Fahrenheit in huge cylindrical steel rotary kilns lined with special firebrick.

In its simplest form, the rotary kiln is a tube up to 200 meters long and perhaps 6 meters in diameter, with a long flame at one end.

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Manufacturing Steps

The material formed in the kiln is described as 'clinker' and is typically composed of rounded nodules between 1mm and 25mm across.

After cooling, the clinker may be stored temporarily in a clinker store, or it may pass directly to the cement mill. The cement mill grinds the clinker to a fine powder.

A small amount of gypsum - a form of calcium sulfate - is normally ground up with the clinker. The gypsum controls the setting properties of the cement when water is added.

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Short Description

The mixture of raw materials is finely ground in a raw mill.

The resultant raw mix is burned in a rotary kiln at temperatures around 4482 degrees Celsius to form clinker. 

The clinker nodules are then ground with about 3 % gypsum to produce cement with a fineness typically of less than 90 micrometers.

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Process Scheme

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View of a cement kiln and preheater tower

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Uses

Its modern uses include:• Building (floors, beams, columns, roofing, piles, bricks,

mortar, panels, plaster).• Transport (roads, pathways, crossings, bridges,

sleepers, viaducts, tunnels, stabilization, runways, parking).

• Water (pipes, culverts, kerbing, drains, canals, weirs, dams, tanks, pools).

• Civil (piers, docks, retaining walls, silos, warehousing, poles, pylons, fencing).

• Agriculture (buildings, processing, housing, feedlots, irrigation).

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Any Questions ???

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CORE JAVATHANK YOU