7/28/22, 9:08 PM Cement Manufacturing Process - Civil Engineering

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Cement Manufacturing Process

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 Syeda Tahsin Hasan

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7/28/22, 9:08 PM Cement Manufacturing Process - Civil Engineering

Stage of Cement Manufacture

There are six main stages of cement manufacturing process.

Stage 1
Raw Material Extraction/Quarry
The raw cement ingredients (/civil-engineering-materials/cement/10-cement-ingredients-with-
functions) needed for cement production are limestone (calcium), sand and clay (silicon,
aluminum, iron), shale, fly ash, mill scale and bauxite. The ore rocks are quarried and crushed
to smaller pieces of about 6 inches. Secondary crushers or hammer mills then reduce them to
even smaller size of 3 inches. After that, the ingredients are prepared for pyroprocessing.

Stage 2
Grinding, Proportioning and Blending
The crushed raw ingredients (/civil-engineering-materials/cement/51-raw-cement-
ingredients)are made ready for the cement making process in the kiln by combining them with
additives and grinding them to ensure a fine homogenous mixture. The composition of cement
(/civil-engineering-materials/cement/10-cement-ingredients-with-functions) is proportioned
here depending on the desired properties of the cement. Generally, limestone is 80% and
remaining 20% is the clay. In the cement plant, the raw mix is dried (moisture content reduced
to less than 1%); heavy wheel type rollers and rotating tables blend the raw mix and then the
roller crushes it to a fine powder to be stored in silos and fed to the kiln.

Stage 3
Pre-Heating Raw Material
A pre-heating chamber consists of a series of cyclones that utilizes the hot gases produced
from the kiln in order to reduce energy consumption and make the cement making process
more environment-friendly. The raw materials are passed through here and turned into oxides
to be burned in the kiln.

Stage 4
Kiln Phase
The kiln phase is the principal stage of the cement (/civil-engineering-materials/cement/46-
uses-of-cement)production process. Here, clinker is produced from the raw mix through a
series of chemical reactions between calcium and silicon dioxide compounds. Though the
process is complex, the events of the clinker production can be written in the following
sequence:

1. Evaporation of free water

2. Evolution of combined water in the argillaceous components
3. Calcination of the calcium carbonate (CaCO3) to calcium oxide (CaO)
4. Reaction of CaO with silica to form dicalcium silicate
5. Reaction of CaO with the aluminum and iron-bearing constituents to form the liquid
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6. Formation of the clinker nodules
7. Evaporation of volatile constituents (e. g., sodium, potassium, chlorides, and sulfates)
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8. Reaction of excess CaO with dicalcium silicate to form tricalcium silicate

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7/28/22, 9:08 PM Cement Manufacturing Process - Civil Engineering

The above events can be condensed into four major stages based on the change of
temperature inside the kiln:

1. 100°C (212°F): Evaporation of free water

2. 100°C (212°F)-430°C (800°F): Dehydration and formation of oxides of silicon,
aluminum, and iron
3. 900°C (1650°F)-982°C (1800°F): CO2 is evolved and CaO is produced through
calcination
4. 1510°C (2750°F): Cement clinker is formed

The kiln is angled by 3 degrees to the horizontal to allow the material to pass through it, over
a period of 20 to 30 minutes. By the time the raw-mix reaches the lower part of the kiln, clinker
forms and comes out of the kiln in marble-sized nodules.

Stage 5
Cooling and final grinding
After exiting the kiln, the clinker is rapidly cooled down from 2000°C to 100°C-200°C by
passing air over it. At this stage, different additives are combined with the clinker to be ground
in order to produce the final product, cement (/cement). Gypsum, added to and ground with
clinker, regulates the setting time and gives the most important property of cement (/civil-
engineering-materials/cement/45-properties-of-good-cement), compressive strength. It also
prevents agglomeration and coating of the powder at the surface of balls and mill wall. Some
organic substances, such as Triethanolamine (used at 0.1 wt.%), are added as grinding aids
to avoid powder agglomeration. Other additives sometimes used are ethylene glycol, oleic
acid and dodecyl-benzene sulphonate.

The heat produced by the clinker is circulated back to the kiln to save energy. The last stage
of making cement (/civil-engineering-materials/cement/hydraulic-cement/101-what-is-
hydraulic-cement-history-composition-use-procedure)is the final grinding process. In the
cement plant, there are rotating drums fitted with steel balls. Clinker, after being cooled, is
transferred to these rotating drums and ground into such a fine powder that each pound of it
contains 150 billion grains. This powder is the final product, cement (/civil-engineering-
materials/cement/81-cement-definition-and-full-details).

Stage 6
Packing and Shipping
Cement is conveyed from grinding mills to silos (/structural-engineering/39-difference-
between-bunker-and-silo-with-sketch) (large storage tanks) where it is packed in 20-40 kg
bags. Most of the product is shipped in bulk quantities by trucks, trains or ships, and only a
small amount is packed for customers who need small quantities.

Chemical Reactions during Cement Manufacturing

Process
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The reactions that take place (after evaporation of free water) between the reactants in the
Service
kiln phase of cement making process are as follows:
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7/28/22, 9:08 PM Cement Manufacturing Process - Civil Engineering

1. Clay Decomposition:

Si2Al2O5(OH)2 → 2 SiO2 + Al2O3 + 2 H2O (vapor)

KAlSi3O8 (orthoclase) + 0.5 SO2 + 0.25 O2 → 3 SiO2 + 0.5 Al2O3 + 0.5 K2SO4
2. Dolomite Decomposition:

CaMg(CO3)2 → CaCO3 + MgO + CO2

KMg3AlSi3O10(OH)2 + 0.5 SO2 + 0.25 O2 → 0.5 K2SO4 + 3 MgO + 0.5 Al2O3 + 3 SiO2 +
H2O (vapor)
3. Low Temperature Calcite Decomposition:

2 CaCO3 + SiO2 → Ca2SiO4 + 2 CO2

2 MgO + SiO2 → Mg2SiO4

Ca5(PO4)3OH + 0.25 SiO2 → 1.5 Ca3(PO4)2 + 0.25 Ca2SiO4 + 0.5 H2O (vapour)
4. Alumina and Oxide Reaction:

12 CaCO3 + 7 Al2O3 → Ca12Al14O33 + 12 CO2

4 CaCO3 + Al2O3 + Fe2O3 → Ca4Al2Fe2O10 + 4 CO2

4 CaCO3 + Al2O3 + Mn2O3 → Ca4Al2Mn2O10 + 4 CO2

5. Reaction of Remaining Calcite:

CaCO3 → CaO + CO2

6. Sintering:

Ca2SiO4 + CaO → Ca3SiO5

Cement

What is Cement? (/civil-engineering-

materials/cement/81-cement-definition-
and-full-details)
Types of Cement (/civil-engineering-
materials/cement/250-types-of-cement)
Cement Composition (/civil-engineering-
materials/cement/10-cement-ingradients-
with-functions)
Physical & Chemical Properties of
Cement (/civil-engineering-
materials/cement/111-properties-of-
cement-physical-chemical-properties)
Cement Manufacturing Process (/civil-
engineering-materials/cement/106-
cement-manufacturing-process)
Uses of Cement (/civil-engineering-
materials/cement/46-uses-of-cement)
Raw Cement Ingredients (/civil-
engineering-materials/cement/51-raw-
cement-ingredients)
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Properties of Good Cement (/civil-

Service
engineering-materials/cement/45-
properties-of-good-cement)
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7/28/22, 9:08 PM Cement Manufacturing Process - Civil Engineering

Field Test of Cement (/civil-engineering-

materials/cement/14-cement-field-tests)
Storage of Cement  (/civil-engineering-
materials/cement/275-storage-of-cement)
Fineness of Cement (/civil-engineering-
materials/cement/112-fineness-of-
cement-definition-importance-tests)
Cement Manufacturing Industries and
Plants (/civil-engineering-
materials/cement/107-cement-
manufacturing-industries-and-plants)
Specific Gravity of Cement (/civil-
engineering-materials/cement/120-
specific-gravity-of-cement-definition-
meaning-calculation-test-procedure)
Difference Between OPC and PPC (/civil-
engineering-materials/cement/237-
difference-between-opc-and-ppc)
Cement Storage Godown or Warehouse
Requirements (/civil-engineering-
materials/cement/276-cement-storage-
godown-or-warehouse-requirements)

Clinker

What is Cement Clinker? Composition,

Types & Uses (/civil-engineering-
materials/cement/108-what-is-cement-
clinker-clinker-definition-composition-
types-uses)
Difference between Clinker and Cement
(/civil-engineering-materials/cement/109-
difference-between-clinker-and-cement)
Clinker Manufacturing Process (/civil-
engineering-materials/cement/110-
cement-clinker-manufacturing-process-
with-reactions)

White cement

What is White Portland Cement? (/civil-

engineering-materials/cement/47-white-
cement)
Uses of White Portland Cement (/civil-
engineering-materials/cement/48-uses-
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of-white-portland-cement)

ServiceRefractory Cement
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7/28/22, 9:08 PM Cement Manufacturing Process - Civil Engineering

Refractory Cement - Composition,

Installation, Use (/civil-engineering-
materials/cement/194-refractory-cement)
Advantages and Disadvantages of
Refractory Cement (/civil-engineering-
materials/cement/195-advantages-and-
disadvantages-of-refractory-cement)

Hydraulic Cement (/civil-engineering-

materials/cement/hydraulic-cement/101-
what-is-hydraulic-cement-history-
composition-use-procedure)

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