All cement plants after 1980’s use the dry process for manufacture of cement. In wet process to make one tone of cement, 350 kg of coal is used. Burning & grinding process remains same for both dry & wet process. The burning is carried out in a rotary kiln.
2. Cement Plants – Portland cement manufacture accounts for about 98% of the cement production in the United States. The raw materials are crushed, processed, proportioned, ground, and blended before going to the final process, which may be either wet or dry.

In the dry process, the moisture content of the raw material is reduced to less than 1% before the blending process occurs. The dry material is pulverized and fed to the rotary kiln. Further drying, decarbonating, and calcining take place as the material passes through the rotary kiln. The material leaves the kiln as clinker, which is cooled, ground, packaged, and shipped.

How Cement is made? Dry process

For the wet process, a slurry is made by adding water during the initial grinding. The homogeneous wet mixture is fed to the kiln as a wet slurry (30–40% water) or as a wet filtrate (20% water). The burning, cooling, grinding, packaging, and shipping are the same as for the dry process.

Pollutant	Emissions (kg metric ton −1 )
Dry process	Wet process
Kilns	Dryers, grinders, etc.	Kilns	Dryers, grinders, etc.
Particulate matter	122.0	48.0	114.0	16.0
Sulfur dioxide a	5.1
Mineral source	Neg	—	5.1	—
Gas combustion	2.1 × S b	—	Neg	—
Oil combustion	3.4 × S	—	2.1 × S b	—
Coal combustion		—	3.4 × S	—
Nitrogen oxides	1.3	—	1.3	—

a If a baghouse is used as control device, reduce SO 2 by 50% because of reactions with an alkaline filter cake. b S is the percent of sulfur in the fuel. Source: Ref. Control of particulate matter emissions from the kilns, dryers, grinders, etc. is by means of standard devices and systems: (1) multiple cyclones (80% efficiency), (2) ESPs (95% + efficiency), (3) multiple cyclones followed by ESPs (97.5% efficiency), and (4) baghouses (99.8% efficiency).

What is the process of cement manufacturing?

Dry Process of Cement Manufacturing Our home is one of the safest places where almost all of us have found our solace and joy. The home is where we spend most of our day, knowing no matter what happens, we will be safe. But what is it about our home that makes it safe from psychological threats and physical as well? It is cement.

• The more strongly amalgamated a segment is manufactured, the better and strengthened a house will be.
• It is in the cement that the magic of safety lies.
• However, when it comes to how the cement is manufactured, very few know about it.
• Today we will discuss the dry process of cement manufacturing so that you can appreciate the bits that stayed unknown.

In dry and semi-dry processes for, the raw materials will be crushed and then fed in the correct proportions. It is then added to the grinding mill. Then, the raw material will be dried and reduced in size to a fine powder in there. The dry powder you will get there will be called the raw meal; then, the raw meal will be pumped into a blending silo.

• It is here where all kinds of adjustments are made.
• The proportions of the materials are fixed here as well.
• In short, the manufacture of cement is done in a silo.
• Then the raw meal will be blended by passing compressed air to obtain a coagulated and uniform mixture.
• Compressed air will be induced upward.

The upward movement of the powder will decrease the apparent density. The air will then be pumped over the quadrant of the silo. This will permit the heavier material from the non-aerated quadrants. Therefore, the aerated powder that you will acquire will behave like a liquid.

A uniform mixture will be obtained if it is aerated through the quadrants in turn for at least one hour. In some cement manufacturing plants like Surya Gold, continuous blending is used. The blended meal then will be further passed through a sieve. After getting it through the drive, it will be fed into a rotating disc called a granulator.

Finally, the quantity of water, about 12 % by weight, will be added to it to be blended into pellets. The blended meal will be sieved and then fed into the rotating dish in a semi-dry process. It is known to us as the granulator. The water content in this will also be about 12% of the meal being added simultaneously.

As a result, the hard pellet, which is supposed to be about 15 mm in diameter, will be formed. It is one of the necessary procedures as the cold powder will be fed directly into the kiln. However, it would not permit the airflow and the exchange of the heat necessary for the chemical reactions of the formation of cement clinker.

The pellets then will be baked hard in a pre-heating grate employing hot gases from the kiln. The pellets would normally enter the kiln where the temperature will be as high as 1450°C. The total consumption of coal in this process that one may use may range from 100kg to 220 kg.

However, it may depend on varying elements and specifications in producing a ton of cement in the wet process. The dry material will undergo a series of chemical reactions in the hottest part of the kiln. Only 20–30% of it will become liquid, and lime, silica, and alumina recombine. The fused mass will turn into balls of diameter 3 to 25mm, which we will call clinker.

Ending note: Now that you know the rigorous process of making cement, you will appreciate your home more. : Dry Process of Cement Manufacturing

What is the difference between wet process and dry process of cement?

DRY PROCESS – When the available raw materials are quite hard, then this process is used. The cement by this process can be prepared by using the following operations:-

• Mixing of raw materials
• Burning and Grinding

Mixing of Raw Materials: The raw materials i.e. argillaceous and calcareous materials undergo the following stages:-

• Crushing: The raw materials, first of all, are broken into crushers into small fragments that vary in size.
• Drying: The crushed materials are dried by heating at a sufficiently high temperature. It may be done in drying kilns.
• Reduction of size: The drying materials are then ground by using ball mills and tube mills to reduce the size of materials to find powder.
• Mixing in correct proportion: The finely dried materials are mixed in exact proportions. The mixing may be done either mechanically or by pneumatic methods( eg, pumped under pressure).

Burning and Grinding: These operations are the same as for the wet process. Except for the mixing of raw materials. In the dry process, the raw materials mixed, fined, and then fed into kiln whereas, in the wet process, the raw materials are crushed separately and then directly mixed in correct proportion in the presence of water to make a fine thin paste known as Slurry.

• Properties of Cement
• Types of Cement
• Composition of Cement Clinker
• Hydration of Cement
• Products of Hydration of Cement
• What is Cement?
• Various Tests on Cement
• Ordinary Portland Cement (OPC)
• Manufacturing of Cement By Dry and Wet Process
• Raw Materials of Cement
• History of Cement in Civil Engineering
• Composition of Cement Clinker
• Ordinary Portland Cement (OPC)
• What is Concrete with Definition & History

What are the raw materials used for manufacturing of cement?

DRY PROCESS – When the available raw materials are quite hard, then this process is used. The cement by this process can be prepared by using the following operations:-

• Mixing of raw materials
• Burning and Grinding

Mixing of Raw Materials: The raw materials i.e. argillaceous and calcareous materials undergo the following stages:-

• Crushing: The raw materials, first of all, are broken into crushers into small fragments that vary in size.
• Drying: The crushed materials are dried by heating at a sufficiently high temperature. It may be done in drying kilns.
• Reduction of size: The drying materials are then ground by using ball mills and tube mills to reduce the size of materials to find powder.
• Mixing in correct proportion: The finely dried materials are mixed in exact proportions. The mixing may be done either mechanically or by pneumatic methods( eg, pumped under pressure).

Burning and Grinding: These operations are the same as for the wet process. Except for the mixing of raw materials. In the dry process, the raw materials mixed, fined, and then fed into kiln whereas, in the wet process, the raw materials are crushed separately and then directly mixed in correct proportion in the presence of water to make a fine thin paste known as Slurry.

• Properties of Cement
• Types of Cement
• Composition of Cement Clinker
• Hydration of Cement
• Products of Hydration of Cement
• What is Cement?
• Various Tests on Cement
• Ordinary Portland Cement (OPC)
• Manufacturing of Cement By Dry and Wet Process
• Raw Materials of Cement
• History of Cement in Civil Engineering
• Composition of Cement Clinker
• Ordinary Portland Cement (OPC)
• What is Concrete with Definition & History