Have ever wondered how cement is made, Let’s read this article.
It all started at the Quarry where most of the important raw materials for the production of cement are extracted and it all starts with a bang. Raw material for the production of cement consists of limestones Shale and Marl which are available in large quantities in the Quarries and other ingredients such as iron ore and gypsum are obtained from mines the raw materials are loaded onto Haul trucks with a loading capacity of 60 tons each these raw ingredients are transported in specified ratios to the crusher but in grinding to the consistency of rough graveling.
The cruiser can handle 6oo tons of raw materials per hour the crushed Limestone Shale and Maro are conveyed to the mixing Bay where it’s mixed into a homogenous material. The homogenous star has a radius of 81 meters and a height of 28 meters and has a blending Bay which can handle 25 000 tons of mixed materials the chemical composition of the raw material is carefully monitored to ensure that it contains the correct proportions of raw materials.
A small proportion of corrective materials are added to the mixture to the proportions that differ from those specified by the quality. Essentials additive such as iron ore are added to the homogenized Limestone shale and moral material and this mixture is then conveyed to the raw Mill where it’s ground to a fine powder which is known as a raw mix. The mixture is dried by means of the excessive heat generated by the Pyro. Milled using roller mills instead of the traditional bore Mills the roller mills save about 30 % of the total electrical power consumption compared to traditional homes.
The raw mix is tested once again to ensure that the chemical composition is correct in terms of the quality directive once the raw mix has passed the test in the laboratory. Conveyed the preheater of the plant. The raw Mill silo has the capacity to store 7 000 tons of raw mixture powder. Once the raw material has been processed in the preheated it enters the 54 meters long rotary where the material is burned to the clinker at temperature burned to the clinker at temperatures in excess of 145o degrees Celsius. The rotary klin can produce 2100 tons of clinker per day the clinker is now cooled down by using a method of air quenching in a great cooler after the cooling process the cleaner is stored in a clinker silo with a capacity of 55 000 tons. The clinker is dosed with an appropriate quantity of gypsum and extended with high-grade Limestone extension significantly reducing the carbon footprint of the cement products.
Finally, the mixture is milled to cement by using two types of cement mills each type of cement can produce up to 65 tons per hour. Cement products are then stored in different silos each silo has a capacity of 7500 tons. This ensures the continued viability of the cement product. A fully equipped chemical and physical laboratory takes samples of intermediates and final products at different stages of the cement manufacturing process to ensure maximum product quality.
The laboratory consists of 11 sampling stations that handle more than 140 samples per day seven days a week each cement type produced is subjected to an array of tests to ensure consistent world-class performance. Once the test in the laboratory is done then the next process of the production of the cement is packing. The cement in 50-kilogram bags is then arranged on a pallet in batches of 40 bags per pallet thereafter it’s shrink-wrapped for additional protection against weather conditions. The pallets are now ready to be dispatched and are loaded onto the trucks. Bulk cement is available in loose form and is transported by Road Rail and Sea.
Every step of the entire production process of the cement plant from the Quarry to dispatch is continuously monitored and controlled by highly qualified personnel in the control room when required any part of the cement-making process can be adjusted immediately to ensure that the highest quality standards are met.
Now let’s summarize the entire cement production process this is there are many machines used in the whole process of the production of cement manufacturing. process raw materials such as Limestones Shale and Marl are called to a machine called the crusher and crushed into very thin particles. One of the most important things which are regulated very carefully is the quality of the material. Because we all know that the most important use of cement is in the building infrastructure and any kind of bad particle added to the cement or any wrong ratio of the material added to the cement during the production of the cement will become very dangerous in the future. So that is why around two to three times the ratio and quality of the raw material were checked during the production of the cement.
The most expensive thing used in the production of cement is energy because it required a lot of energy from cruising to heating. There are many companies started using solar energy to reduce their cost of production and it really works for these companies. In a report, it is said that if all cement factories in the world started using solar energy instead of thermal or hydro energy then the price of cement reduced by around 30 %. So the catch over here is that we all know that global warming is one of the biggest problems of the present world and if we convert all our cement factories into green cement factories then it is not only beneficial for the production company but also very helpful for our environment and it is a very big positive in the field of global warming.
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