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Cement Manufacturing Process

India is the world’s second largest producer of cement. Let us understand the manufacturing process-

· Quarry-Extraction of raw material from mines -Raw Mat can be Limestone, Clay or sand. They are cut from crusher and are brought to the plant. Lime and silica make up about 85% of the mass.
· Proportioning, Blending and Grinding -Raw material is analyzed in the lab and blended in the proper proportion and then grinded into powder through rollers. Now this material is ready for the kiln for preheating process.
· Per heater Tower - Per heater has vertical cyclone chambers through which raw mat is passed. To save energy, now cement plants is preheat the material before they enter to klin (rotating furnace) from preheater . Entering into klin is the main step to cement manufacturing. Here the raw mat is heated up to 1870 degree Celsius with the help of powdered coal/coke or natural gas. The raw material reaches to about 1400 degree Celsius and become partially molten.This intense heat brings chemical and physical changes which convert calcium and silicon oxides into calcium silicates (which is cement’s primany constituents.) and at the lower end to klin, a new substance in the form of red hot particles, emerges: called Cinker.
· Clinker Cooler and Finish Grinding -Now clinker passes through a great cooler, which brings clinker to the temperature of 200 degree Celsius. Once cooled, clinker is ready to be ground into the gray powder. Again clinker is ground in a ball mill, filled with steel balls. Both are crushed together along with small amount of gypsum, flyash or slag into super fine powder, called as “Portland cement”. The percentage of these additives and the fineness of the final product determines the type of the cement like Ordinary Portland Cement, Portland Pozzolana Cement , Oil Well Cement etc. Now cement is brought to stores and packaging done.