Escolar Documentos
Profissional Documentos
Cultura Documentos
Wet Process :
The wet process is mostly used for manufacturing as the quality
of cement obtained in this process is much better and the various
ingredients are thoroughly mixed.
Manufacturing of Portland Cement
calcareous mtrl (cement rock, lime stone , chalk ,marine shell)
argillaceous mtrl ( silicates of alumina in the form of clay , shale and blast furnace
slag)
Flow diagram of Cement Manufacture
Clinker
Clinker storage
• In case the raw materials are not found in a finely divided form these are
crushed to pebble size separately.
• Clayey material is taken to “wash mills”, which are thick steel cylinders, nearly
3 meters in diameter and 10 meters in height.
• Lime stone, broken to the size of pebbles, is mixed with clay slurry
according to the proportion required, in the proportioning equipment.
• After proportioning wet mixture containing calcareous and argillaceous
material, it is passed through Ball and Tube mills respectively, to form thin paste
of uniform consistency.
• This is known as “cement slurry” and is stored in big tanks known as silos or
basins.
• These basin are also known as “correcting Silos”, and from these silos
corrected cement slurry is taken to storage basins, where it is constantly stirred.
(iii) Burning
•From the storage basins slurry is pumped into the upper end of rotary kiln in a
regulated stream through a kiln feeder.
•The rotary kiln consists of a cylinder made from steel plates 2 to 4 cms thick.
•It is 60 to 90 metres in length, 3 to 4 metres in diameter and is given an inclination of
1 in 20 along its length.
•Inner surface of the kiln is lined with fire bricks and it is mounted on roller bearings
which are supported by masonry, concrete or steel columns.
•The kiln is rotated at a speed of about one revolution per minute.
•Through the upper end of the kiln slurry is fed at a uniform rate and through the lower
end powdered coal is injected by the blast of air.
• Due to the burning of coal, temperature near the lower end is higher while near the
upper end it is lower.
•As the slurry reaches inside the kiln, where temperature is neary 2500C, moisture gets
evaporated and slurry changes into flakes.
• Due to gravity these flakes reach next zone known as calcination
zone. Here temperature is about 700-12000C and carbondioxide from
the calcareous material gets eliminated.
• As the particles pass down further and reach nearer to lower end
where temperature is nearly 16000C, calcareous and argillaceous
materials combine together to form silicates, aluminates and ferrites
of calcium.
• From these silos cement is taken out and automatically weighed and
packed in bags.
• The materials from the silos is fed into the rotary kilns through
the rotary feeder.
• The remaining procedure carried out for burning on the rotary
kiln and grinding is the same as the wet process.
Testing Portland Cement
To check the suitability of ordinary portland cement which is
commonly used, is tested. As per IS : 269-1967 the following tests are
performed:
1. Fineness Test
2. Consistency Test
3. Soundness Test
1. Fineness Test : The object of this test is to check the proper grinding of cement.
If grinding is not uniform and fine, large quantity of water will be needed for mixing
and the chemical reactions set up during setting, will be delayed. Moreover, “bleeding”
will occur even before concrete begins to set, as water will come to the top due to
settlement of solids. Finer the cement, more surface area of the aggregates will be
covered by it.
(a) Sieve test : 100 gms of cement is continuously sifted for a period of 15
minutes on I.S. test sieve No. 9 and the residue by weight retained on sieve shall not
be greater than 10%.
(b) Surface Area test : It is also known as Specific Surface
test and is generally adopted.
water required for obtaining the cement paste of normal consistency, used in other
tests. Following procedure is adopted for determining the same. About 300 gm of
cement is weighed and nearly 30% of water (90 gm) is added to it and mixed
• Needle is taken out and same process is repeated after every minute,
till it ceases to pierce fully, but remains 5 mm above the glass plate. At
this stage note the time, known as initial setting time. Initial setting
time should not be less than 30 minutes.
• Final setting time of cement is found by changing the
needle. It has a sharp point projecting in the centre with an
annular attachment.
• A stage will reach when the needle makes an impression, but not
the attachment. Time is noted, which gives the final setting time. Final
setting time of ordinary cement should not be greater than 10 hours
TYPES OF CEMENT
1. Portland Cement
(a) Ordinary Portland Cement
(b) Rapid Hardening Cement
(c) Low Heat Cement
(d) Blast Furnace Slag Cement
(e) Sulphate Resistant Cement
(f) Air Entraining Cement
(g) White and Coloured Cement
2. Other varieties of Cement
(a) High Alumina Cement
(b) Pozzolanic Cement
(c) Oil Well Cement