Cement Manufacturing | constguide.com

Cement Manufacturing

1- Cement manufacturing and What is cement?

The most crucial component in the construction process is cement.

It has utilized in the production of concrete, and it is used to cover walls and make construction units like tiles, when mixed with water, it becomes a material that has the ability to cohesion and adhesion, and all varieties have the ability to doubt and solidify.

2- The essential components required to finish the cement manufacturing process.

The following are the industry's basic materials:

• Limestone.

• Clay.

• Silicate sand.

• Bauxite dust and surface dust.

• Water.

• Iron oxides, which are utilized as solvents.

• Gypsum, which is added toward the end of the cement manufacturing process.

• Chemicals used in laboratories to perform quality checks

• The most important elements to generate combustion gases in furnaces, diesel and natural gas are used.

3- Stages of the cement manufacturing.

Manufacturing techniques divided into two categories:

1- Wet method: raw materials are ground and combined with water, and then the suspended product is separated in an oven.

2- Dry method: in which the raw ingredients are dried before or during grinding, before going into the oven.

The following are the main steps to take when driving on wet technique:-

1- Material crushing and mixing

Crushers crush raw materials like clay, dust, and limestone, which are subsequently sifted via sieves and stacked in piles.

2- The grinding phase

The raw materials are transported to the slurry mills, where they are mixed with water and ground until they reach a high degree of fineness, the suspension then transferred to the storage container, where it becomes homogeneous after final component adjustments, and samples are analyzed on a regular basis to ensure that it meets the specifications. slurry basins, where rotating arms homogenize the mixture.

3- Stage of the furnace and cooling

The suspension is drawn from the bottom of these pans into the rotary kiln (which is a rotating furnace in the shape of a long cylinder with a refractory brick lining that rotates slowly around an axis inclined slightly from the horizontal plane, allowing the contents of the oven to be pushed forward while rotating).

The output is clinker, which has a high temperature of around 1400 degrees; hence, a cooler is used to cool it down As a result, a cooler is used to cool the clinker to a temperature of 60 to 200 degrees Celsius.

4- Final Grinding and packing

The clinker is moved to ball mills, where it is combined with gypsum and the filling process is completed.

The following are the main steps to take when driving on dry technique:-

1- Material crushing and mixing

Crushers crush raw materials like clay, dust, and limestone, which are subsequently sifted via sieves and stacked in piles.

2- The grinding phase

The materials are heated and dried in a rotary dryer, after which they are crushed in mills and transferred to storage containers before being mixed with 30% clay and 70% limestone.

3- Stage of the furnace and cooling

The raw material is taken from the containers to the primary heating tower that may reach 120 meters above sea level and then enter the furnace, Natural or other gas is a source of heating (thermal energy) and hot air is utilized as another source of heat as a result of cooling the clinker, the three types of coolers used to cool clinker are Rotary coolers, planetary coolers, and grate coolers, the grate cooler is the most popular.

4- The grinding phase

The clinker is moved to ball mills, where it is combined with gypsum and the filling process is completed

4- Various forms of cement.

• Portland cement rapid hardening: It is utilized when a rapid hardening is required, for example by eliminating the reuse form, It is not utilized in concrete blocks, increasing the speed of hardening because increased in Tri-calcium silicate concentration (C3S).

• Portland cement sulfate-resistant: It is utilized in locations where concrete is exposed and also used in maritime installations to sulphate salts in land or groundwater, its sulphate resistance due to the rise in the dicalcium silicate (C2S), it is sluggish to harden because it includes a small amount of tri- Calcium aluminate (C3A).

• Low-temperature Cement Portland: - It is a kind that can lead to significant fractures when utilized in block concretes, is used for dam’s concrete, in regular setups, it is not preferable to utilize this kind, this temperature is low because, owing to a lack of Contents (C3S) and (C3A), it gets strength after a long period.

• Iron Portland cement: - utilized for water resistance and construction, It is not utilized in cold conditions, It has a lower temperature than ordinary cement for this reason, It is considered a low-temperature cement and is used in block concrete, its cost is inexpensive, its strength is excellent with respect to salts and sulphates, and it needs less energy for its manufacturing, it is sluggish to harden so that after 90 days it achieves its strength.

• White cement: - Using ceramic, porcelain and outside blanks as a decorative and installation, is produced from calcite and white clay, white cement manufacturing costs up to four times that of conventional cement, but it has the same characteristics as ordinary cement.

• Colored cement: - is used in decoration, which is white or ordinary cement, but with added colors of oxides, with a percentage not exceeding 10% because if this percentage exceeds 10%, it affects the resistance of cement.

• Mixed cement: It is produced for economic reasons and to increase production, where fine sand or fine lime is added to it, it is used for construction work and laundry; it is not utilized in concrete supported constructions, as it is weak, and Karnack concrete in Egypt is one example.

5- Health hazards in the cement manufacturing.

The cement manufacturing affects the health of its workers, as everyone who is exposed for long periods suffers from silicosis (Silicosis poisoning); this is because cement contains silica, especially in factories that produce

Acid-resistant cement

6- Egyptian cement factories.

• Company of Suez Cement: Founded in 1977, this company is one of the largest, It is one of Egypt's major cement manufacturers, There are two plants, one plant in Suez and one plant in Kattameya, both operating on dry roads.

• Torah Cement Company: Founded in 1927, it is one of Egypt's oldest cement businesses, The Suez Company owns approximately 66% of the Torah Company, in 2006, torah Cement Company received a quality accreditation from API (American Petroleum Institute) for the manufacture of oil well cement.

• Helwan Cement Company: Founded in 1929, however the Suez Company has held more than 98% of Helwan Company since August 2005.

• RMB Corporation: - It has been in business since 1985 and is one of the largest companies in the ready-mix concrete sector, Suez Company has acquired 52% of Ready Mix Company since 2006, and Ready Mix Company operates 20 batching facilities that produce about 1.2 million cubic meters of ready-mix concrete.

7- The clarification

The cement Manufacturing is one of the largest business, what are the composition of cement?

What are the techniques of cement manufacturing? What are the types of cement?

What are the applications of cement? What are Egypt's largest cement factories?