As of 2010, America, China, and India are the top three cement producers in the world. Among these nations, China alone generates about 45 percent of the world’s total cement supply. It is a non-recyclable material and therefore every new construction and renovation requires new cement, thereby continuing to increase global usage. Especially in the economies of Asia and Eastern Europe, cement production is an important element of progress.
The cement clinker is removed from clinker stores or silos and finely ground in the final process phase of cement production, along with gypsum as a setting controller or probably other filler materials with hydraulic or pozzolanic properties.
The composition and fineness decide the properties of cement and therefore the strength of the concrete made. The various types and grades of the strength of cement were processed in different silos and then discharged into charging networks.
Cement producers have expanded their brand sizes significantly in recent years–a phenomenon that can be expected to continue for economic and environmental purposes. Another factor is the substitution of cement clinker with secondary components that are or occur naturally e.g. calcareous or pozzolana waste materials from other sectors e.g. granulated blast furnace slag or fly ash.
Cement Manufacturing Process
The manufacturing process of cement starts with the calcareous mining which is excavated from open cast mines. The calcareous stone is then crushed to the size of -80 mm and filled in longitudinal stockpiles. Limestone is taken out of these stockpiles diagonally for grinding in raw hopper mills. As mentioned earlier, coal is used as fuel in the cement manufacturing process for heating the raw materials.
After obtaining cement raw materials from the Indian mining industry, the calcareous stone is converted into a fine powder for grinding in raw mill. That fine calcareous powder is then heated for clinkerisation at a very high temperature of 1450 degrees centigrade. To heat up, this fine powder is used in the clinkerisation section at such high-temperature coal. Such blinkered raw material is then fed into electrostatic precipitator to be deposited in concrete silo form. This is also fodder for kilns. Kiln feed is fed into pyro-processing preheaters.
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Cement clinkers are produced by pyro-processing kiln feed. The hot clinkers are then refrigerated to store in clinker stockpiles and bucketed. After this stage, the clinker and gypsum are mixed together and sent to the inlet of the mill to form a fine gray powder for the further grinding process. The fine gray powder is the cement that is then packaged and sent for sale into the market.