ASSIGNMENT OF PROJECT MANAGEMENT On

CEMENT MANUFACTURING PROCESS

Submitted to Lec. Satindera Kumar

Submitted by Akshay Kanwar Roll No.5497(C) MBA 2nd year

What is Cement?

In the most general sense of the word, a cement is a binder, a substance that sets and hardens independently, and can bind other materials together. The word "cement" traces to the Romans, who used the term opus caementicium to describe masonry resembling modern concrete that was made from crushed rock with burnt lime as binder. The volcanic ash and pulverized brick additives that were added to the burnt lime to obtain a hydraulic binder were later referred to as cementum, cimentum, cment and cement. Cement used in construction is characterized as hydraulic or non-hydraulic. Hydraulic cements (e.g., Portland cement) harden because of hydration, chemical reactions that occur independently of the mixture's water content; they can harden even underwater or when constantly exposed to wet weather. The chemical reaction that results when the anhydrous cement powder is mixed with water produces hydrates that are not water-soluble. Nonhydraulic cements (e.g., lime and gypsumplaster) must be kept dry in order to retain their strength. The most important use of cement is the production of mortar and concretethe bonding of natural or artificial aggregates to form a strong building material that is durable in the face of normal environmental effects. Concrete should not be confused with cement, because the term cement refers to the material used to bind the aggregate materials of concrete. Concrete is a combination of a cement and aggregate.

The Manufacturing Process

TCL uses what is known in the industry as a wet process technology for the manufacture of cement. The process derives its name from the fact that the basic raw material, naturally occurring limestone, is crushed and mixed with water to form slurry. Though more modern plants utilize dry process technology, TCL is forced to maintain a wet process owing to the fact that limestone reserves are located in Mayo which is approximately sixteen kilometres from the cement manufacturing facilities at Claxton Bay. The already simple cement manufacturing process can be conveniently classified into a number of simpler steps.

1. Limestone Quarrying The quarrying of limestone, the main raw material used in the production of cement, is the first step in the manufacturing process. Trinidad Cement Limited obtains its limestone from its own quarry at Mayo, in Central Trinidad, which is one of three major deposits of yellow or impure limestone in Trinidad. It is estimated that this deposit will sustain TCLs proposed production rates for at least the next two hundred years. Traditionally, the limestone was obtained by blasting which involved the use of explosives. Today, a heightened degree of environmental awareness coupled with greater consideration for the growing Mayo community, have lead us to review our methods. Limestone is now extracted from the quarry by literally ripping it out of the ground. TCL uses one of the largest tractor rippers in the Caribbean, the Caterpillar D11R, to rip and push raw limestone out for production. 2. Crushing The limestone is transported via dump trucks to a 530-tonnes/hour Hazemag crusher, which reduces the limestone to an average size of 25mm. The limestone is separated according to high or low carbon content, then crushed and transported by conveyor to a large storage shed. 3. Raw Milling The crushed limestone is extracted from storage and transported by conveyor to the Raw Grinding Mills where water is added for grinding. Based on the silica content of the raw material, it is sometimes necessary to add sand in the grinding process. This process is called wet grinding; the aim of which is to reduce the material size from 25 mm to 90 micron. The resulting mixture of limestone, water and sand resembles a thick soup, which is called slurry.

4. Slurry Storage & Pumping Slurry is stored in one of two slurry tanks at the Mayo quarry. The stored slurry is finally pumped along a pipeline from Mayo to TCLs works at Claxton Bay, straight into large concrete storage tanks commonly known as slurry basins where it is constantly agitated by compressed air and revolving mechanical paddles to prevent the slurry from settling. Slurry is moved to Claxton Bay through a continuous pipeline measuring 10-inches in diameter and approximately 9 miles in length. The slurry leaving Mayo for Claxton Bay must be of a consistently high quality. Any slurry that does not meet the stringent quality requirements is adjusted and recycled until correct.

5. Clinker Production From mixers, the slurry is pumped to rotary kilns, which are long, revolving steel cylinders lined with refractory bricks. Refractory bricks are insulators for the kiln shell and serve to protect the kiln against relatively high temperatures. In TCL the largest of the kilns is 145m long and 5m in diameter. The company has two kilns with a combined production capacity of 2160 tonnes per day. TCLs kilns are fueled by natural gas supplied by the National Gas

Company. The slurry enters the back end of the kiln, which is sloped down to allow for the free passage of slurry from the inlet to the outlet. In the early stage, the slurry is dried off at a temperature of approximately 230 degrees Celsius. The semi-dry product continues along the length of the kiln where it is literally cooked at a temperature of about 1450 degrees Celsius. The slurry now takes the form of wet cement.

Cement producing countries?

Environmental impacts
Cement manufacture causes environmental impacts at all stages of the process. These include emissions of airborne pollution in the form of dust, gases, noise and vibration when operating machinery and during blasting in quarries, and damage to countryside from quarrying. Equipment to reduce dust emissions during quarrying and manufacture of cement is widely used, and equipment to trap and separate exhaust gases are coming into increased use. Environmental protection also includes the re-integration of quarries into the countryside after they have been closed down by returning them to nature or re-cultivating them.

Cement manufacturing releases CO2 in the atmosphere both directly when calcium carbonate is heated, producing lime and carbon dioxide and also indirectly through the use of energy if its production involves the emission of CO2. The cement industry is the second largest CO2 emitting industry behind power generation. The cement industry produces about 5% of global man-made CO2 emissions, of which 50% is from the chemical process, and 40% from burning fuel. The amount of CO2 emitted by the cement industry is nearly 900 kg of CO2 for

every 1000 kg of cement produced. The high proportion of carbon dioxide produced in the chemical reaction leads to large decrease in mass in the conversion from limestone to cement. So, to reduce the transport of heavier raw materials and to mimimize the associated costs, it is more economical for cement plants to be closer to the limestone quarries rather than to the consumer centers. In certain applications, lime mortar, reabsorbs the same amount of CO2 as was released in its manufacture, and has a lower energy requirement in production than mainstream cement. Newly developed cement types from Novacem and Eco-cement can absorb carbon dioxide from ambient air during hardening. Use of the Kalina cycle during production can also increase energy efficiency.

Social cost benefit analysis

As cement demand is increasing day in day out , it also increases the pressure of more and more manufacturing of cement .Especially in developing countries such as India ,Brazil ,China ,Bangladesh ,Pakistan and many more counties all over the world where the demand is so high as well as construction of buildings are so rapid for MNC offices , Housing , Amusement parks etc. This increasing demand pressurizes on more production and gives rise to increase in employment in this sector. More and more talent is recruiting to strengthen this industrial growth. Talent from every stream are getting recruited in this sector such as from Engineering, Management and also unskilled workers. Due to this growth, it also helps in shaping the new face of society and helps to strengthen the economy of the country. On the other hand it has some negative effect on the society which tends to increase the social cost of this sector such as the manufacturing of cement is a very complex process and it is also hazardous to society as Cement manufacture causes environmental impacts at all stages of the process. These include emissions of airborne pollution in the form of dust, gases, noise and vibration when operating machinery and during blasting in quarries, and damage to countryside from quarrying.