![]() The fused mass turns into a nodular form of size 3 mm to 20 mm known as clinker. ![]() New for You: Underpinning Methods, Procedure, Use in Foundation Strengthening and Repair This is where the oxides in raw materials will be combined to form compounds in the clinker. Lime, silica, and alumina get recombined. As the materials go ahead then, the material rolls down to the lower end of the rotary kiln, the dry material undergoes a series of chemical reactions until finally, in the hottest part of the kiln, where the temperature is in the order of 1500☌, about 20 to 30 percent of the materials get fused. Normally for the manufacturing of cement, the fuel used are powdered coal, oil or natural gas. The rotation of the rotary kiln causes the flakes to move from the upper end towards the lower end of the kiln subjecting itself to higher and higher temperatures. These flakes peel off and fall on the floor. The slurry on being sprayed against a hot surface of a flexible chain loses moisture and becomes flakes. The length of the rotary kiln may vary anything from 30 meters to 200 meters. Wet process of cement manufacturing (Flow chart) ![]() Rotary kiln is a 3m to 8m diameter steel cylinder, lined with fire resistance refractory materials, fitted on roller bearings and capable of rotating about its own axis at a designed speed.įig.1. That homogeneous corrected slurry is applied by nozzle spray on the upper end of the rotary kiln. One of the important parts of the cement production plant is the rotary kiln. After that, in the final storage tanks by the agitation of slurry, it is kept inhomogeneous condition. Also tested in the different storage tanks by blending the slurry. This slurry is maintained at the required chemical composition in a tube mill by testing and correcting time to time. In that tank, the limestone and clay particles are prevented to settle by blowing compressed air from the bottom of slurry are kept in ignited condition with help of rotating arms with chains. Then this slurry is pumped into slurry tanks or basins. The slurry is a liquid of creamy consistency with a water content of about 35 to 50 percent, wherein particles, crushed to the fineness are held in suspension. Then in the ball or tube mill, it is mixed with clay or shale with water to form a slurry. In the wet process, first of all, the newly quarried limestone is crushed into smaller pieces. Here, below you can read both “wet” and “Dry” process in detail. In the wet process, the drying process is fuel consumption. The dry process requires much less fuel as the materials are already in a dry state, whereas in the wet process the slurry contains about 35 to 50 percent water. Later, the dry process is wide uses, because of the modem development of the technique of dry mixing of powdered materials using compressed air. The techniques of the intimate mixing of raw materials in powder form were not available then. In the old age, because of the possibility of more accurate control in the mixing of raw materials, the wet process is popular. With a little change in the above process, we have the semi-dry process also where the raw materials are ground dry and then mixed with about 10-14 percent of water and further burnt to clickering temperature. There are two processes known as “wet” and “dry”processes depending upon whether the mixing and grinding of raw materials are done in wet or dry conditions. Related: 17 Types of cement their properties and Uses Types of Manufacturing of cement By this process, the product formed is Portland cement. The clinker is cooled and ground to a fine powder with the addition of about 3 to 5% of gypsum. During this process, these materials partially fuse to form nodular shaped clinker by broking of chemical bonds of the raw materials and recombined into new compounds. The manufacture of Portland cement is a complex process and done in the following steps: grinding the raw materials, mixing them in certain proportions depending upon their purity and composition, and burning them to sintering in a kiln at a temperature of about 1350 to 1500 ⁰C. Environmental Environmental Engineering.Material Calculation Material Calculation.Foundation Engineering Foundation Engineering.Construction tips Construction tips related to bridge construction, building construction, hydropower, etc construction.Construction Management Construction Management.Construction Equipments Construction Equipments.Construction Materials Construction Materials.Cement Concrete Applications cement concrete applications.Building Construction Building Construction.Formworks/Shuttering Formworks-Shuttering.Material testing guide Material testing guide.Brick Calculator for walls, Columns, foundations| Brick estimator.
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