DEBRE BRHAN UNVERSITY

COLLEGE OF ENGINEERING
Department of Chemical Engineering

Process industry Individual Assignment

Submitted To: Instructor Aberha

Prepared by: Mikiyas Kassahun
ID: DBUR/0711/10
Section: B

January 2021
Table of Contents
Introduction ........................................................................................................................................... 1
Cement definition .................................................................................................................................. 1
History of the origin of cement .............................................................................................................. 1
Raw materials used to produce cement ................................................................................................ 2
Ingredients used in cement production ................................................................................................. 2
Process descriptions............................................................................................................................... 4
Types of equipment used in cement industry ....................................................................................... 6
Working principles ................................................................................................................................ 7
Cement Types and Applications ........................................................................................................... 7
Conclusion ............................................................................................................................................. 8
References .............................................................................................................................................. 9
Introduction

Cement definition
Cement is a manmade mineral structure created at high temperatures, mainly comprising lime
(CaO), Silica (SiO2) and oxides of aluminum and iron (Al2O3 and Fe2O3.
Cement is a hydraulic powder material, which reacts with water to produce strength-bearing
lattices.
The mixture of aggregates, cement and water is concrete. The strength and durability of concrete
makes it one of the most useful materials developed by man.
Cement is a powdery substance made with calcined lime and clay as major ingredients.

History of the origin of cement

John Smeaton made an important contribution to the development of cements when he was
planning the construction of the third Eddystone Lighthouse (1755–9) in the English Channel. He
needed a hydraulic mortar that would set and develop some strength in the twelve-hour period
between successive high tides.

In 1824, Joseph Aspdin patented a similar material, which he called Portland cement, because the
render made from it was in colour similar to the prestigious Portland stone.
The investigations of L.J.Vicat led him to prepare an artificial hydraulic lime by calcining an
intimate mixture of limestone and clay.

Later in 1845 Isaac Charles Johnson burnt a mixture of clay and chalk till the clinkering stage to
make better cement and established factories in 1851.

The German standard specification for Portland cement was drawn in 1877.
The British standard specification was first drawn up in 1904. The first ASTM specification was
issued in 1904.

In India, Portland cement was first manufactured in 1904 near Madras, by the South India
Industrial Ltd. But this venture failed.

Between 1912 and 1913, the Indian Cement Co. Ltd., was established at Porbander (Gujarat) and
by 1914 this Company was able to deliver about 1000 tons of Portland cement. Throughout history,
cementing materials have played a vital role and were used widely in the ancient world. · Lime
and clay have been used as cementing material on constructions through many centuries.

1|P a ge
Raw materials used to produce cement

The raw materials are naturally occurring mineral and basically all CaO, SiO2, Al2O3 and Fe2O3
bearing minerals can be used to manufacture cement.

Plants generally rely on nearby quarries for limestone to minimize transport costs.

1. Primary raw materials

Limestone (CaCO3) & limestone containing minerals,

2. Secondary raw materials

Clay (Al2O3), sand & silica (aluminum andiron oxides).

3. Tertiary raw materials

Gypsum other "alternative" raw materials slag, millscale, fly ash. Therefore, the raw materials
sources required for cement manufacture are - Some form of calcium carbonate provide the CaO
requirements.

Ingredients used in cement production

Table (1): Raw ingredients used to provide each of the main cement elements (Kosmatka
et.al 2002)

Calcium Silicon Aluminum Iron

Limestone Clay Clay Clay

Marl Marl Shale Iron ore

Calcite Sand Fly ash Mill scale
Aragonite Shale Aluminum Shale

Shale Fly ash Blast furnace dust

Sea Shells Rice hull ash

Cement kiln dust Slag

2|P a ge
Major unit operations
1. Quarrying
2. Crushing
3. Proportionating/Pre-homogenization

4. Raw mill Grinding

5. Homogenization/Silo
6. Raw meal preheating
7. Kiln operation
8. Clinker cooling/storage
9. Cement mill and gypsum addition

3|P a ge
Process descriptions
1. Quarrying
Rock blasted from the quarry is transported to the primary crusher where large "run of mine" rocks
are broken into pieces of approximately 100mm.Generally the other raw materials do not require
crushing. Cement factory raw material deposits are extracted using open pit quarries in the vast
majority of cases. There are just a few examples around the world where the raw materials are
extracted from underground mines. This significantly increases the costs of raw material extraction
and cement manufacture.

2. Crushing
Cement plant raw materials blasted in the quarry requires size reduction for further processing,
size reduction is performed in crushers and grinding mills. Crushing is commination in the coarse
range.

4|P a ge
Primary crushing involves limestone rock fed through large capacity crushers. This reduces the
rock to a maximum size of approximately 150 mm. Secondary crushing further reduces this to
75mm or under. Residue material is stacked and reclaimed with a bridge reclaimer in a cross
section so that the homogeneous limestone is fed further in the process.

3. Proportionating/ Pre-homogenization / Raw Material Storage & Blending

The raw materials are then proportioned to the correct chemical balance and milled together to a
fine powder, raw meal, to ensure high quality of cement, the chemistry of the raw materials and
raw meal is very carefully controlled.

4. Drying
For dry process, the raw material has to be dried before milling. Kiln exhaust gases are used to dry
the raw materials. In some gases with wet materials, additional heat sources are required for drying.

5. Grinding
Grinding refers to comminution in the fine range. The grinding media (steel ball) and the feed
material to be ground are brought together in a rotating tubular or drum-shaped compartment. The
media and material rises to an optimum height, necessary for grinding operation, and come
tumbling down (cascading and/or contracting).

6. Kiln feed Homogenization

Materials are homogenized to ensure consistency of product quality. The kiln feed is routed to a
homogenization silo, where it is mixed by blowing compressed air through pads in the base of the
silo. The blending silo is maintained full and some of the blended raw mix continuously cascades
to a further blending silo where it is further mixed by air blown through pads in the
base of the silo. The twice blended raw mix is continuously extracted to the kiln feed storage silos.

Modern dry process cement factories have large combined homogenization and storage kiln feed
silos. Raw mill product is distributed in layers in the silo, and extracted in funnels rotating around
the radius of the silo. Some of these silos have an internal, pressure relieved mixing chamber.

7. Preheater/Cyclones/
A pre-heater is a series of vertical cyclones. Where the raw meal is passed down through these
cyclones it comes into contact with the swirling hot kiln exhaust gases moving in the opposite
direction and as a result heat is transferred from the gas to material.

This pre-heats the material before it enters the kiln so that the necessary chemical reactions will
occur more quickly and efficiently. By retaining energy from the exhaust gases, energy is saved.

8. Pre -Calcinations

5|P a ge
The calciner is a combustion chamber at the bottom of the pre-heater above the kiln backend. Up
to 65% of the total energy needs of the kiln, system can be supplied to the calciner.

Calciners allow for shorter rotary kilns and for the use of lower grade alternative fuels. Calcination
is the decomposition of CaCO3 to CaO and CO2.CaCO3 CaO CO2.
These process emissions comprise 60% of the total emission from a cement kiln. The combustion
of the fuel generates the rest.

9. Kiln operation (pyro-processing)

Raw meal, more accurately termed "hot meal" at this stage then enters the rotary kiln. The kiln is
the world's largest piece of industrial equipment.

Types of equipment used in cement industry

6|P a ge
Working principles
The basic principles of cement manufacturing is a complex process that begins with milling and
then grinding raw materials that includes lime stone and clay to fine powder, called raw mill which
is then heated to a sintering temperature as high as 14500c in cement kiln.in this process the raw
materials are broken dawn and then they are recombined into new compound the result is called
clinker. then clinker is ground to a fine product powder in cement mill and mixed with gypsum to
create cement. and then the cement is aggregated with water to create concrete.

Cement Types and Applications

The vast majority (>95%) of cement produced in the world is based on Ordinary Portland Cement
clinker. That Ordinary Portland Cement clinker can be ground together with gypsum to produce
Ordinary Portland Cement (OPC). However, the production and use of blended cements containing
pozzolan additions is assuming ever greater importance (PPC)

7|P a ge
Conclusion
Basically, different types of cements and their chemical composition and applications in the
current engineering and chemical world have been of enhancing materials and fillers developed
using nanotechnology for the productive and effective cement manufacturing have been mentioned
with the chemical background. 0e mechanical defects when concrete is concerned and possible
solutions that can be given through chemistry and nanotechnology have been deliberated in detail.

8|P a ge
References
 S. P. Dunuweera and R. M. G. Rajapakse, “Cement types, composition, uses,
environmental impact and possible solutions,” in Proceedings of the 28th International
Symposium on Transport Phenomena, Peradeniya, Sri Lanka, September 2017.
 T. C. Powers and T. L. Brownyard, “Studies of the physical properties of hardened
Portland cement paste,” ACI Journal Proceedings, vol. 43, no. 9, pp. 101–132, 1946.
 F. Lea, 7e Chemistry of Cement and Concrete, February 2018,
https://ci.nii.ac.jp/naid/10003996296/.

9|P a ge