Portland cement is by far the most common type of cement in general use around the world. This articles looks at the cement manufacturing process in 4 steps.Get A Quote
Portland cement is by far the most common type of cement in general use around the world. This articles looks at the cement manufacturing process in 4 steps.
The first step of Cement manufacturing process is to quarry the principal raw materials mainly limestone clay and other materials.
After quarrying the rock is crushed. This involves several stages. The first crushing reduces the rock to a maximum size of about 6 inches. The rock then goes to secondary crushers or hammer mills for reduction to about 3 inches or smaller.
Next in cement manufacturing process the crushed rock is combined with other ingredients such as iron ore or fly ash and ground mixed and fed to a cement kiln.A kiln is a thermally insulated chamber a type ofoven that produces temperatures sufficient to complete some process such as hardening drying or chemical changes
The finely ground raw material or the slurry is fed into the higher end. At the lower end is a roaring blast of flame produced by precisely controlled burning of powdered coal oil alternative fuels or gas under forced draft.
As the material moves through the kiln certain elements are driven off in the form of gases. The remaining elements unite to form a new substance called clinker. Clinker comes out of the kiln as grey balls about the size of marbles.
Clinker and gypsum for Ordinary Portland CementOPC limestone for limestone cement and slag for slag cement are all extracted from their respective hoppers and fed to the cement mills. The ball mill grinds the feed to a fine powder in two chambers namely the first and second chambers.
The two chambers have a certain quantity of ball charge of different sizes from 17mm to 90 mm. The mill discharge is fed to a bucket elevator which takes the material to a separator which separates fine and coarse product. The latter is sent to the mill inlet for regrinding and the final product is stored in concrete silos.
This is the story of how Limestone is processed to produce cement of the highest quality. Cement is the foundation on which we build our homes roads and societies so we take pride in ensuring that our product has consistent and reliable quality. At Wonder Cement we deploy state-of-the-art German machinery and a variety of technological innovations like ROBOTIC LAB to create cement that you can trust.
Scroll through the graphic below to see how our process works.
First we need limestone which is extracted from mother earth by using NONEL Shock Tube eco-friendly blasting technology. Then with the help of dumpers and shovels we put the limestone into the dump hopper where it is carried by apron feeder to the Wobbler for further processing by screening sizing by crushing.
Limestone deposits are mainly extracted by bench mining in which holes are charged with ammonium nitrate and fuel oil explosive and blasted. The rock is excavated with front end loaders 10 m3 capacity loaded into 55 to 60 tons and then transported to the crusher. Clay and shale is normally extracted using front end loaders and loaded into haul trucks. When they occur as overburden the unused clays and shales are stored and often reused for reclamation in the mined out areas of the quarry.
Our high-tech crusher breaks the limestone boulders to the required Raw Mill feed size. Chittorgarh Area in Rajasthan is known for its superior quality limestone deposits possessing high lime content that gives high early strength and ultimate long-term strength. Another characteristic feature of this limestone is low alkali low magnesia and low chloride content which are highly desirable parameters for concrete durability.
As limestone passes through the Wobbler particles less than 50 mm are separated and passed to the secondary vibrating screening equipment where particles smaller than 10mm are rejected and removed. The limestone larger than 50 mm goes to the Rotary impact crusher where it is further reduced to less than 75 mm and sent to surge hopper by belt conveyor for pile preparation. The limestone of larger than 10 mm from secondary screen plant is then added to this mixture.
The job of grinding is done by the Vertical Roller Mill which works like a cyclone to create a fine dust of evenly sized particles. As the feed is ground on the horizontal grinding table hot air is pushed upwards from underneath forcing the smallest particles to rise. The finest particles pass through a separator into the mill compartment at the top while the heavier particles descend again to the table for further grinding.
In the final manufacturing stage gypsum is measured and added to the clinker in order to yeild the final product. After first passing the mixture through a roller press it is further reduced into a fine powder with the help of a single chamber ball mill.
The final manufacturing stage occurs in our two combi-circuit grinding ball mills where the clinker is mixed into a fine powder with 4-6 gypsum. Gypsum is responsible for retarding the setting time and increasing the workability of cement. After first passing the mixture through a roller press it enters the single chamber ball mill where 155 metric tons of tiny steel balls carry out the fine grinding. Finished product with separator air is passed through multiclones where finished product is separated and stored in cement silos with the help of mechanical conveyors.
Simple and efficient production of 100 tons of limestone production line with different production results 1. Larger crush ratio and fusion of two crush modes The size of the jaw crusher is up to 210mm. The two machines can easily supply the operation of the high-efficiency sand making machine.
Based onnbspUnited States Geological Survey 2006 Wikipedia has produced the following useful insights giving data regarding crushed limestone.
The data are old but impressive enough to think about an increased utility of crushed limestone in various industries and purposes.
With enough curiosity I invite you all to learn something regarding crushed limestone today on behalf of World of Stones USA. Of course we have discussed before the formation of limestone rocks so I am not going to repeat all here.
Crushed limestone typically produced by mining limestone or dolomite rock deposits. The process involves breaking of collected rocks down to the specific sizes with the help of different rock crushersmachines. It further screeningfiltering into different grit sizes for suitable applications.nbsp
Remember Limestone gravels are the results of weathering processes that take place in nature. So gravels are typically more rounded in shape.nbsp
However pulverizedcrushed limestone aggregatesgrits have angular in shape and have sharp edges thanks to machine grinding processes.
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