DRONACHARYA COLLEGE OF ENGINEERING Greater Noida

Presented By Sandeep Kumar

Manufacturing Process Of Cement

CONTENTS
Manufacturing Process Of Cement
(a) Mines (b) Blasting (c) Transportation (d) Crushing and transportation (e) Raw Mill (f) Raw Mill Silo (g) Preheater (h) Rotary Kiln (i) Cooler (j) Clinker Silo (j) Gypsum Mixing Tank (j) Cement Mill (k) Cement Mill Silo (l) Packing Plant

CEMENT MANUFACTURING PROCESS

dumper loader

Quarry face

1. BLASTING

2. TRANSPORT

crushing conveyor

storage at the plant

3. CRUSHING & TRANSPORTATION

CEMENT MANUFACTURING PROCESS

storage at the plant conveyor Raw mill Raw mix

1. RAW GRINDING

preheating

kiln cooling

clinker

2. BURNING

CEMENT MANUFACTURING PROCESS

Gypsum and the secondary additives are added to the clinker. clinker storage

Finish grinding

1. GRINDING

CEMENT MANUFACTURING PROCESS

clinker storage Gypsum and the secondary additives are added Finish grinding to the clinker.

1. GRINDING

bags

silos

dispatch

2. STORAGE, PACKING, DISPATCH

1.MINES

Mines

1.MINES:- It is the area which is required for the extraction of

the limestone,done by the mining engineers. Usually this mines is spread over a large area.

2.BLASTING
loader

Mines

2. BLASTING :- The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted and extracted from the quarry or mines.

5.GRINDING THROUGH THE RAW MILLS

Raw mill conveyor

Ball mills is used for grinding the raw material (lime stone) in to small particles of 90 micron size.

Ball mills consist of three chambers. (a) Dry Chamber- Moisture is removed from the raw material by passing
hot air.

(b)1st Chamber- Consist of balls size varying from (60mm to 90mm). (c)2nd Chamber- Consist of balls size varying from (25mm to 50mm). Ball mills consist of two diaphragm. (a) Intermediate diaphragm (b) Discharge diaphragm.

BALL MILL SPEED

Vcrit: critical speed

balls stay on the mill wall due to centrifugal force NO GRINDING POSSIBLE!

42.3 Vcrit Di
Vmax: maximum speed circa 75% of the critical speed

Vmax
Di

31.7 Di
= diameter inside liners

RAW MILL OR BALL MILL

INTERMEDIATE DIAPHRAGM

slotted plates adjustable lifters cone

diaphragm segment

DISCHARGEDIAPHRAGM

6.RAW MILL SILO

6.SILO:- Raw mill silo is a cylindrical building used for storing the grinded raw material in huge amount,before feeding it into the peheater.
In K# 4 unit of the dalla cement factory two silo is used,having height about 75m.
Blending Capacity- 1500tn Storing Capacity- 3000tn Each Silo having two parts 1-Blending (Top),2-Storage(bottom)

SILO

7.PREHEATER
preheater

PREHEATER:

Preheater is used for preheating and calcination of the ground raw material,before feeding it into the kiln. In K#4 unit four stage preheater are have been installed. Preheater is also used to increase the thermal efficiency of the hot gases and calcination of the lime stonewhich is fed in powder form. No. of preheater are inversely proportional to the length of the kiln. Capacity of the plant depend upon the no. of pre-heaters stage and size

SINGLE STAGE PRE-HEATERS

8.ROTARY KILN

kiln

clinker

KILN:- Kiln is used for making clinker after 60-70% calcination

in preheater section which is directly connected to kiln inlet In k#4 unit,kiln is inclined at 3% of the kiln length which is 68m long and 4.3m dia. Capacity of K#4 kiln is 1500TPD. The temp. at the inlet of the kiln is about 1000C and at outlet is about 1350C.

ROTARY KILN

9.COOLER

cooler clinker

COOLER:- Cools the hot clinker falling on it from kiln

from 350 degree to 120 degree. Cold atmospheric air is blown through the duct fan on the slow moving bed,having reciprocating grates on which hot clinker falls and get cooled. After cooling the clinker from 1350C to about 200C and it is carried out through the cooler.

COOLER

10.CLINKER SILO
clinker storage conveyor

CLINKER SILO:-

Silo is the storage cylindrical tank of about 60m height in which the cliker is stored and transported by the convyer belt to the silo.

Blending capacity- No. blending is needed. Storing capacity- 14000tn

11.GYPSUM MIXING TANK

Gypsum is added to the clinker. conveyor

After carrying out the clinker from the silo through the air slide gypsum and secondary additives is added to the clinker. Gypsum plays an important role in the setting time of the cement,it decreases the setting time of the cement and becomes easier to work with the cement.

12.CEMENT MILL
conveyor Cement mill

Ball mills is used for grinding the mixture of cliker,gypsum and other additives.

Ball mills consist of three chambers. (a)1st Chamber- Consist of balls size varying from (90mm to 60mm). (b)2nd Chamber- Consist of balls size varying from (50mm to 40mm). (c)3rd Chamber- consist of balls size varying from(30mm to 20mm).
Ball mills consist of two diaphragm. (a) Intermediate diaphragm no.1 (b) Intermediate diaphragm no.2 (c) Discharge diaphragm.

CEMENT MILL

13.CEMENT SILO
silo s

CEMENT SILO:- After grinding the mixture of clinker and

gypsum into fine powder,cement is manufactured and stored in the silo.
In k#4 two silo are in use,having height about 70m. Capacity single silo - 3500tn Total capacity - 7000tn

14.PACKING PLANT

bags Jaypee Cement

Now at the last cement from the silo is carried out to the packing plant through the air slide and is packed in the polyster bags and loaded to the trucks using packing machine, belt conveyor , truck loader and trains,send to different parts of the country.

THANK YOU