Cement Processing Plant

There are 27 types of common cement which can be grouped into 5 general categories and 3 strength classes: ordinary, high and very high.  In addition, some special cements exist like sulphate resisting cement, low heat cement and calcium aluminate cement.

Cement is a fine powder which sets after a few hours when mixed with water, and then hardens in a few days into a solid, strong material. Cement is mainly used to bind fine sand and coarse aggregates together in concrete.  Cement is a hydraulic binder, i.e. it hardens when water is added. Here are cement manufacturing process flow chart.

The process is divided in 3 parts:

1. Raw Mill Section 

All the raw materials should be of less than 25 mm size. If the size of the raw material is bigger than 25 mm, It has to be crushed through a crusher and Hammer Mill. All the materials are crushed stored in the storage yards through belt conveyors.

Now, the raw materials are taken as per their required percentage with the help of a weigh belts( Control by PLC ).The measured materials is went to feed belt conveyor and after that shifted to a feed hopper through elevator .The feed of material is controlled with the help if ratchet Feeder/Table feeder.

2. kiln Section 

From Surge silo the mixed raw materials are taken to Nodulizer with the help of a screw conveyor.Then water is sprayed on the mix (10%) to make nodules with the help of nodulizer. These nodules are fed into the kiln through feed chute for burning and Fusion. The temperature goes up to 1350OC in the burning zone. The material travels very slowly in the kiln. All the material get fused here. After passing through the burning zone the material starts cooling slowly. The Clinkerisation starts and the clinker finally comes out of the kiln.

3. Clinker Grinding Section 

The clinker so obtained is crushed to make its size less than 25 mm. The crushers/Roller crusher are used to crush the clinker. The Gypsum is used as an additive. Both material crushed together and went into feed hoppers through elevator. They are collected through the feeders provided below the feed hoppers. The clinker and gypsum are mixed in certain ratios (5%). So, the weigh belt is used to weigh the ingredients for mixing. A modern electronic weighing & control system may also be used to weigh and measure the ingredients The ratchet/Tables feeder is used to control the feed in the mill and control the fineness of the Cement.

The ground Cement is taken to the aeration and storage silo with the help of elevator or air lift.The aerated Cement is filled in 50Kg bags with the help of packing machine. The product is stored in the godown through belt conveyor and stacking/dispatched as per requirements. The pollution control equipments are necessary as there may be dusting in the plant.