Cement and its manufacturing

Cement
a cement is a binder, a substance that sets and hardens independently, and can bind other materials together.

Types and uses

Cement used in construction is characterized as hydraulic or non-hydraulic Hydraulic cements (e.g., Portland cement) harden because of hydration, they can harden even underwater or when constantly exposed to wet weather. 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.

Composition
INGREDIENT Lime Silica Alumina Calcium Sulphate Iron Oxide Magnesia Sulphur Alkalies CaO SiO2 Al2O3 CaSO4 Fe2O3 MgO S PERCENT 62 22 5 4 3 2 1 1 RANGE 62 to 67 17 to 25 3 to 8 3 to 4 3 to 4 0.1 to 3 1 to 3 0.2 to 1

Total

100

Mnaufacturing
Quarry raw grinding burning Grinding storage Packing dispatch

Quarry
dumper loader

Quarry face
1. BLASTING 2. TRANSPORT

crushing conveyor

storage at the plant

3. CRUSHING & TRANSPORTATION

1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted from the quarry. 2. TRANSPORT : The raw materials are loaded into a dumper. 3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are transported to the plant by conveyor. The plant stores the materials before they are homogenized.

storage at the plant conveyor

Raw mill Raw mix

preheating

1. RAW GRINDING

kiln cooling clinker

2. BURNING 1. RAW 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

2. STORAGE, PACKING, DISPATCH

Grinding, storage, packing, dispatch

Gypsum and the secondary additives are added to the clinker. clinker storage

Finish grinding

1. GRINDING

silos

dispatch

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.

Safety Issues
Bags of cement routinely have health and safety warnings printed on them because not only is cement highly alkaline, but the setting process is exothermic. As a result, wet cement is stronglycaustic and can easily cause severe skin burns if not promptly washed off with water. Similarly, dry cement powder in contact with mucous membranes can cause severe eye or respiratory irritation. Cement users should wear protective clothing

Cement industries in world

In 2002 the world production of hydraulic cement was 1,800 million metric tons. The top three producers were China with 704, India with 100, and the United States with 91 million metric tons for a combined total of about half the world total by the world's three most populated states.