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How is Portland Cement Manufactured by Wet Process?

Published in Cement Manufacturing Wet Process 4 mins read

Portland cement manufactured by the wet process involves grinding raw materials into a watery mixture called slurry, which is then fed into a rotating kiln for high-temperature processing to produce cement clinker. This method is one of the foundational approaches to cement production, distinguished by its unique raw material preparation.

Understanding the Wet Process

The wet process of cement manufacturing refers to grinding raw material into slurry after mixing with water and then feeding them into the wet process kiln for drying and calcination and finally forming clinker. This method ensures a highly homogenous mixture, which is crucial for consistent cement quality. The slurry's water content is usually between 32%-36%.

Let's explore the step-by-step manufacturing process:

1. Raw Material Acquisition and Proportioning

The first stage involves sourcing and preparing the primary raw materials, typically consisting of:

  • Calcareous materials: Rich in calcium carbonate, like limestone or chalk.
  • Argillaceous materials: Rich in alumina and silica, such as clay, shale, or marl.
  • Corrective materials: Iron ore, bauxite, or sand, used to adjust the chemical composition.

These materials are extracted from quarries and then undergo initial crushing to reduce their size, making them suitable for subsequent grinding. Precise weighing and proportioning are critical at this stage to achieve the desired chemical composition of the final cement.

2. Wet Grinding and Slurry Preparation

This is the defining stage of the wet process. The pre-crushed raw materials are introduced into large ball mills or other grinding equipment along with a significant amount of water. As stated in the reference, the process involves grinding raw material into slurry after mixing with water.

  • Formation of Slurry: The raw materials are ground finely in the presence of water, forming a thick, homogeneous paste known as "slurry."
  • Water Content: A key characteristic of this slurry is its water content, which is usually between 32%-36%. This high water content helps in achieving a thorough and intimate mixing of the raw components.
  • Homogenization: The continuous grinding and mixing ensure that the chemical components are evenly distributed throughout the slurry, which directly impacts the quality and consistency of the final cement.

3. Slurry Homogenization and Storage

After grinding, the raw slurry is transferred to large blending tanks or basins. These tanks are equipped with agitators or air bubbling systems to keep the slurry continuously mixed, preventing segregation of particles and ensuring a perfectly uniform chemical composition. From these blending tanks, the homogenized slurry is then pumped to storage tanks, ready to be fed into the kiln.

4. Clinkerization in the Wet Process Kiln

The heart of cement manufacturing is the rotary kiln, a massive, inclined rotating furnace. In the wet process, the prepared slurry is fed into the wet process kiln for drying and calcination and finally forming clinker.

A typical wet process kiln is very long to accommodate the high water content of the slurry, which needs to be evaporated before calcination can occur. The kiln is divided into several zones, each with specific temperature ranges:

Kiln Zone Temperature Range Primary Process
Drying Zone Up to 200°C Evaporation of water from the slurry.
Preheating Zone 200°C - 800°C Further drying and initial chemical reactions.
Calcining Zone 800°C - 1000°C De-carbonation of limestone (CaCO₃ → CaO + CO₂).
Burning Zone 1400°C - 1450°C Formation of cement compounds (clinkerization).
Cooling Zone Descending from 1400°C Initial cooling of hot clinker.

Within the burning zone, at temperatures reaching 1400-1450°C, the raw materials undergo complex chemical reactions, forming various calcium silicates and aluminates. These new compounds fuse together to form hard, nodular particles known as cement clinker.

5. Clinker Cooling

Upon exiting the burning zone of the kiln, the hot clinker, typically at temperatures over 1000°C, is rapidly cooled in specialized clinker coolers (e.g., grate coolers). Rapid cooling helps to preserve the desired mineralogical structure of the clinker, which is essential for cement performance. The recovered heat from cooling is often recycled back into the kiln, improving energy efficiency.

6. Finish Grinding

The cooled clinker is then transported to ball mills or vertical roller mills for finish grinding. At this stage, a small percentage (typically 3-5%) of gypsum is added to the clinker. Gypsum acts as a set retarder, controlling the setting time of the cement when mixed with water. Other additives might also be included to impart specific properties to the final cement.

The result is the fine, grey powder known as Portland cement, ready for packaging and distribution.

Advantages and Disadvantages

While the wet process ensures excellent homogeneity of the raw mix, its main drawback is the high energy consumption required to evaporate the large amount of water from the slurry in the kiln. This has led many modern cement plants to favor the more energy-efficient dry process, although the wet process remains a significant method globally.