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Cement Manufacturing & Maintenance Processes

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Overview : History of Cement Manufacturing & Maintenance Processes

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2003 IBM Corporation Updated July 2005

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HISTORY OF CEMENT
In 1824, Joseph Aspdin, a British stone mason, obtained a patent for a Cement he produced in his kitchen. The inventor heated a mixture of finely ground limestone and clay in his kitchen stove and ground the mixture into a powder to create a hydraulic Cement - one that hardens with the addition of water. Aspdin named the product Portland Cement because it resembled a stone quarried on the Isle of Portland off the British Coast. With this invention, Aspdin laid the foundation for today's Portland Cement industry.

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HOW PORTLAND CEMENT IS MADE

Portland Cement, is a calcium silicate Cement made with a combination of calcium, silicon, aluminum, and iron. The first step is obtaining Raw Materials consisting of combinations of limestone, shells or chalk, and shale, clay, sand, or iron ore from a quarry. At the quarry, the Raw Materials are reduced by primary and secondary crushers. Mountains of rock are fed through Crushers capable of handling pieces as large as an oil drum. The first crushing reduces the rock to a maximum size of about 6 inches. The rock then goes to secondary crushers or Hammer Mills for reduction to about 3 inches or smaller. Once the Raw Materials arrive at the Cement Plant, they are proportioned with additives to create a Cement with a specific chemical composition and property.

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THE TWO METHODS OF MAKING CEMENT - 1

Producing a Cement that meets specific chemical and physical specifications requires careful control of the Manufacturing Process. The Dry Process : Dry, crushed Raw Materials are proportioned, ground to a powder, blended together and made ready to be used in a dry state. The Wet Process : Here, the Raw Materials, properly proportioned, are then ground with water and thoroughly mixed in the form of a "slurry" (containing enough water to make it fluid). The grinding and blending operations are then completed with the materials in slurry form. The next steps of both the Processes are essentially alike. . . .

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THE TWO METHODS OF MAKING CEMENT - 2

The next steps of both the Processes are essentially alike : The blended mixture of Raw Materials is fed into the upper end of a tilted, rotating, cylindrical Kiln. The mixture passes through the Kiln at a rate controlled by the slope and rotational speed of the Kiln. Burning fuel consisting of powdered coal or natural gas, that is forced into the lower end of the Kiln. Inside the Kiln, raw materials reach temperatures of 2600F to 3000F (1430C to 1650C). At this temperature, a series of chemical reactions cause the materials to fuse and become Cement Clinker - grayish-black pellets, often the size of marbles. Clinker is discharged red-hot from the lower end of the Kiln and transferred to various types of Coolers to lower the Clinker to handling temperatures. Cooled Clinker is combined with Gypsum and ground into a fine gray powder. The clinker is ground so fine that nearly all of it passes through a No. 200 mesh (75 micron) sieve. This fine gray powder is known as Portland Cement.
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TYPES OF PORTLAND CEMENT - 1

Different types of Portland Cement are manufactured to meet various physical and chemical requirements. The American Society for Testing and Materials (ASTM) Specification C-150 provides for eight types of Portland Cement :

Type I Portland Cement is a normal, general-purpose cement suitable for all uses. It is used in general construction projects such as buildings, bridges, floors, pavements, and other pre-cast concrete products.
Type IA Portland Cement is similar to Type I with the addition of airentraining properties. Type II Portland Cement generates less heat at a slower rate and has a moderate resistance to sulfate attack. Type IIA Portland Cement is identical to Type II and produces air-entrained concrete.

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TYPES OF PORTLAND CEMENT - 2

Type III Portland Cement is a high-early-strength cement and causes concrete to set and gain strength rapidly. Type III is chemically and physically similar to Type I, except that its particles have been ground finer. Type IIIA Portland Cement is an air-entraining, high-early-strength cement. Type IV Portland Cement has a low heat of hydration and develops strength at a slower rate than other cement types, making it ideal for use in dams and other massive concrete structures where there is little chance for heat to escape. Type V Portland Cement is used only in concrete structures that will be exposed to severe sulfate action, principally where concrete is exposed to soil and groundwater with a high sulfate content.

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TYPES OF PORTLAND CEMENT - 3

In addition to the eight types of Portland cement, a number of special purpose hydraulic cements are manufactured : White Portland Cement -This is identical to gray Portland cement except in color. During the manufacturing process, manufacturers select raw materials that contain only negligible amounts of iron and magnesium oxides, the substances that give gray cement its color. White cement is used whenever architectural considerations specify white or colored concrete or mortar. Blended Hydraulic Cements-These cements are produced by intimately blending two or more types of cementitious material. Primary blending materials are Portland cement, ground granulated blast-furnace slag, fly ash, natural pozzolans, and silica fume. These cements are commonly used in the same manner as Portland cements. Expansive Cements-Expansive cements are hydraulic cements that expand slightly during the early hardening period after setting.They are used to make shrinkage-compensating concrete that is used e.g. to compensate for volume decrease due to drying shrinkage, or to induce tensile stress in reinforcement, and (3) to stabilize long-term dimensions of post-tensioned concrete structures.

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THE CEMENET MANUFACTURING PROCESS

CEMENT MFG. PROCESS - AN OVERVIEW

1. Quarrying 2. Raw Grinding and Burning 3. Grinding, Storage, Packing and Dispatch

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Quarry Management Plant Maintenance

1. BLASTING

Dumper Loader

Quarry face
2. CRUSHING 3. TRANSPORT & STORAGE

Crusher Conveyor

Storage at the Plant

1.BLASTING : The raw materials that are used to manufacture Cement (mainly Limestone and Clay) are blasted from the Quarry. The raw materials are loaded into a Dumper. 2. : The raw materials are crushed in Crusher Mills. to the Plant by Conveyors.The Plant stores the 3. CRUSHING TRANSPORT & STORAGE : After Crushing, it is transported materials before they are homogenized for further processing. Next
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Raw Grinding and Burning Plant Maintenance

1. RAW MILL GRINDING

Storage at the Plant Conveyor

Raw Mill Raw Mix

Preheating

2. BURNING

Kiln Cooling Clinker

1. RAW MILL GRINDING : The raw materials are very finely ground in order to produce the Raw Mix. 2. BURNING : The Raw Mix is preheated before it goes into the Kiln, which is heated by a flame that can be as hot as 2000 C. The Raw Mix burns at 1500 C producing Clinker which, when it leaves the Kiln, is rapidly cooled with air fans. So, the Raw Mix is burnt to produce Clinker : the basic material needed to make Cement. Back Next
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Grinding, Storage, Packing, Dispatch Plant Maintenance

1. GRINDING

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

silos

2.STORAGE,PACKING & DISPATCH

dispatch bags

1.GRINDING : The Clinker and the Gypsum are very finely ground, giving a Pure Cement. Other secondary additives and Cementitious materials can also be added to make a Blended Cement. 2. STORAGE, PACKING, DISPATCH :The Cement is stored in Silos before being dispatched either in bulk or in bags to its final destination. Home page Back
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THE CEMENT PLANT MAINTENANCE PROCESS

CEMENT PLANT MAINTENANCE - AN OVERVIEW

Cement Plants - Manufacturing Business Functions : 1. Quarry / Mining Activities 2. Clinker Manufacturing 3. Cement Manufacturing 4. Storage in Silos 5. Bagging Plant Activities

6. FG Storage and Dispatch

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THE CEMENT PLANT MAINTENANCE PROCESS

It is now obvious that a large Process of Cement Manufacturing will require a variety of high-tech Equipment that become Maintenance Objects in Cement Plants. Some are detailed below : 1. Quarry Equipments : - Mobile Equipment like Excavators, Dumpers and Loaders - Crushing Plants - Blasting, Test & Safety Equipments - Conveyors

2. Clinker Manufacturing Plant Equipments : - Conveyors - Raw Mill Grinders - Pre-heating Equipments - Rotary Kiln/s - Coolers - Flue-gas Recovery Equipment - Pollution Control Equipment / Systems

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THE CEMENT PLANT MAINTENANCE PROCESS

Details of Maintenance Objects in Cement Plants (contd.) : 3. Cement Manufacturing Equipments - Pre-Grinding Equipments - Finish Grinding Equipments - Pollution Control Equipment / Systems 4. Silo Storage Equipment for Cement 5. Bagging Plant Equipment

6. FG Bags Storage, Loading & Dispatch Equipments

7. Office & Laboratory Equipments 8. Material Handling, Maintenance & Repair Equipments 9 Transport Equipments like Cars,etc. 10. Residential Colony Maintenance
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THE CEMENT PLANT MAINTENANCE PROCESS

A cement Plant is, in some areas, a continuous Process Plant, like the Clinker Manufacturing and the Cement Manufacturing sections. This obviously then demands sophisticated Maintenance & Planning Processes to support the round-the-year Operational requirements. It also deprives the maintenance man the luxury of laxity, in any area of his function. Maintenance Processes in Cement Plants :
1)

Management of Technical Objects in The Plant

2)

Breakdown / Reactive Maintenance

Annual Shut down Planning Preventive Maintenance Calibration of Systems Reporting of Maintenance Data & Analysis
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3)

4)

5)

6)
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2003 IBM Corporation Updated July 2005