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Friday, August 12, 2016

Cement Plant Process: Ashoka Group

What is 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.

Lets Understand the Cement Plant Process

During the cement plant's cement manufacturing process there are several steps and procedures where mainly includes seven steps and these are following:
  • Preparation of Raw Material
  • Raw Material Homogenization
  • Preheating And Precalcining
  • Burning Cement Clinker
  • Cement Grinding
  • Cement Packing And Storage

At cement plant process is to broken and crushing of raw material, like limestone, iron ore, clay and coal etc so crusher part is very important in cement plants, Limestone is the key raw material for cement creation, each producing a ton of clinker required near about 1.25 tons of limestone, around 80% of raw material required for cement production is limestone. Machines and material handling equipment for cement plant should capable for crushing and equipment required like jaw crusher, impact crusher, Ashoka Cement Plants: manufacturing hummer crusher also to give best output of raw material.

The raw materials are delivered in bulk, crushed and homogenized into a mixture which is fed into a rotary kiln. This is an enormous rotating pipe of 60 to 90 m long and up to 6 m in diameter. This huge kiln is heated by a 2000°C flame inside of it. The kiln is slightly inclined to allow for the materials to slowly reach the other end, where it is quickly cooled to 100-200°C. 

We know requirement of quality cement process, our rotary kiln cylinder vessel slowly rotates at .5 to 4.5 revolutions per minute to allow the raw materials and at last ground coal is fed for the firing end of the kiln exactly where its burned to create a temperature of more than 2,000°C.

The series of chemical reactions between calcium and silicon dioxide compounds form the primary constituents of cement i.e., calcium silicate. Kiln is heating up from the exit side by the use of natural gas and coal. When material reaches the lower part of the kiln, it forms the shape of clinker.
Kiln Mills
After passing out from the kiln, clinkers are cooled by mean of forced air. Clinker released the absorb heat and cool down to lower temperature. Released heat by clinker is reused by recirculating it back to the kiln. This too saves energy.

There is a horizontal filled with steel balls. Clinker reach in this rotating drum after cooling. Here, steel balls tumble and crush the clinker into a very fine powder. This fine powder is considered as cement. During grinding gypsum is also added to the mix in small percentage that controls the setting of cement.
Material is directly conveyed to the silos (silos are the large storage tanks of cement) from the grinding mills. Further, it is packed to about 20-40 kg bags. Only a small percent of cement is packed in the bags only for those customers whom need is very small. The remaining cement is shipped in bulk quantities by mean of trucks, rails or ships.
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