W E L C O M E

PRESENTATION
ON
CEMENT MANUFACTURING
PROCESS

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

CEMENT
MANUFACTURING
PROCESS
What is Cement?

Cement is a binder which when mixed with

water binds together sand & aggregates to
produce concrete or mortar.
Cement is defined as the mixture of
Calcareous & Argillaceous material burnt to
clinkering temperature and ground to the
powder with the addition of gypsum.

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

MATERIAL REQUIRED
RAW MATERIALS
Limestone
Bauxite/Laterite
Iron Ore

FUELS
Coal
Imported Coal
Lignite

ADDITIVES
Mineral Gypsum/Fertilizer
Gypsum
Fly Ash from Thermal Power
Stations
Slag from Steel Industries

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

PROCESS
1.

Mines
Drilling
Blasting
Loading & Transportation of
Limestone to Crusher

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

Crusher

Size Reduction depending

on the requirement of
Raw Mill

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

Stacker & Reclaimer

The crushed limestone received

from crusher is stocked layer by
layer to bring down quality
variation of limestone to
minimum.
This operation is called Preblending which helps in
manufacturing of Good Quality of
Clinker during pyro-processing.

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

Raw Mill

The Limestone from the stock pile is extracted

by reclaimer equipment and conveyed to
hoppers.
Nearly 3 to 4% of laterite / iron ore are to be
added along with limestone and inter-ground to a
fine powder called RAW MEAL
Limestone 96% + Laterite/Bauxite ~2% + Iron Ore
~2%

Raw Meal or Kiln Feed.

Raw meal is conveyed to the Blending
Silos for blending.
Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

Blending & Storage

Blending is nothing but mixing of
Raw Meal powder with pneumatic
aeration systems and forms
homogeneous mixture.
After blending, homogenous
mixture is then sent to storage
silo for pyroprocess system.
Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

Coal Mill
Fuels are pulverized into
Fine powder and used for
pyro process system.

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

Pyro Processing

The Homogenized Raw Meal is pumped to

preheater.

Raw Meal undergoes chemical reactions as it

travels from preheater to Kiln and then passing
through various process zones and finally to
burning zone transforming to Nodules called
CLINKER

Hot Clinker from Kiln outlet is rapidly cooled in

Cooler.

Cooled clinker is then transferred to clinker

stock pile.

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

10

PYRO PROCESSING FLOW

CHART
IV-A
Chimney

350o
C

WG
fan

IV-B
R
A
W

III

Preheater
II-A

Chimney

II-B

2000c
Coal to PC
ESP
Fan

PC
I

TA DUCT (700800oC)

Cooler
ESP

MC

Coal to Kiln

Burning
Zone

Cooling
Zone

1000-1100oC

Calcination
Zone

13001400oC

Rotary Kiln
Coole
r

CSP

Sunday, August
23, 2015

M
E
A
L

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

11

Phase Composition of
Clinker
Tri Calcium Silicate (C3S)

Early Strength -

Di Calcium Silicate (C2S)

Later Stregnth

48-55%

20-25%

7-8%

Tri Calcium Aluminate (C3A) Early Strength &

Setting Time
control & flux
Tetra Calcium alumino Ferrite (C4AF)

12-13%

Flux
Colour
Colour of cement is purely a personal choice. Colour has no
effect on the quality of cement.
Fcao Excess of Free lime causes expansion.
Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

12

CEMENT MILLS

Nearly 4-5% Gypsum is to be added

along with clinker and inter-ground to a
fine powder called CEMENT.

Then the cement is stored in different

cement silos depending upon the type
of cement.

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

13

False Set

During cement grinding , if the process temp.

exceeds 110 Deg.C, Gypsum dehydration takes
place, converting gypsum into plaster of paris
form and false set occurs.
To overcome this, mill temp. has to be maintained
below 110 Deg.C.

Quick Set
Insufficient dosage of
gypsum.
No Strength development
Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

14

GYPSUM

Acts

as a Retarder
Controls Setting Time

Sunday, August
23, 2015

THE INDIA CEMENTS

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15

Manufacturing of Different
Grades of Cement
Ordinary Portland Cement
Clinker (94-96%) + Gypsum - (4-6%)

OPC 33 Grade
OPC 43 Grade
Sunday, August
23, 2015

OPC 53 Grade

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16

PPC - Portland Pozzolona Cement

Clinker ( 60-80 %) + Gypsum - (4-6%) +

Fly Ash (15-35%)

PSC - Portland Slag Cement

Clinker
65 %)

Sunday, August
23, 2015

+ Gypsum - (4-6%) + Slag (25-

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

17

IRST-40 (Indian Railway Sleeper

Cement)
Clinker + Gypsum
Higher Fineness Min: 370 M 2/Kg.
C3S: Min: 45%
C3A: Max: 10%

SRC (Sulphate Resistant

Cement)
Clinker + Gypsum
C3A
: < 5%
2C3A + C4AF : <
25%
Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

18

Oil Well Cement

Clinker + Gypsum
C3S 48 to 65%
C3A Max: 3%
C4AF Max: 24%

White Cement
Clinker + Gypsum
Fe2O3 < 0.5%
Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

19

CEMENT HYDRATION
OPC

PPC

Cement + Water

Gel 70%

Lime 30%

Humidity(water)

Lime Leaching (Destruction)

Cement + Water

Gel 70%

Lime 30%

Reactive Silica

Gel

Double Action Longer Life

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

20

PACKING HOUSE

The Cement which is stored in cement

silos is drawn from the silos as and
when required to packing machine and
cement is packed in 50 Kg HDPE /
Paper bags.
The packed cement is sent to various
destination by Road / Rail as per orders.

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

21

CEMENT
MANUFACTURING
PROCESS FLOW CHART

Sunday, August
23, 2015

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22

MINES
L.S.Drilling &
Blasting

LIMESTONE STOCK
PILE
Pre Blending of LImestone

CRUSHER
Size Reduction

Pre
Blended
L.S.

350 Deg.C
RAW MILL
PREHEATER &
PRECALCINATO
R

HG/
LG
LS

Laterite

Iron
Ore

Powdering

BLENDING &
STORAGE SILO
Homogenization

COAL
TIPPLER

1000 to 1000 Deg.C

KILN

1300 to
1400
Deg. C

COAL
MILL
Powdering

COAL
STOCK
PILE

COOLER
Rapid
Cooling

GYPSU
M

CEMENT
MILL
Pulverizing
CEMENT
SILO

CLINKER
STOCK
PILE

CLINK
ER

FLY ASH/
SLAG

CLINKER EXPORT
BY WAGON

PACKING
PLANT

Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

23

THANK YOU
Sunday, August
23, 2015

THE INDIA CEMENTS

LIMITED,VISHNUPURAM

24