How to Choose a Cement Manufacturer?

Whether you're building a home or a large commercial structure, choosing a cement manufacturer is crucial. You want to know who manufactures it, where it comes from, how its manufactured, and what the effects of the cement are on the environment.

Processes used by cement manufacturers

Generally, the manufacturing process of cement includes three main steps. These include quarrying, mining and transportation. The raw material for cement is usually limestone. After quarrying and mining, the raw material is crushed and ground into powder. The powder is stored in silos for later use.

The process of manufacturing hydraulic cements involves a chemical reaction between the limestone, clay and iron-bearing constituents and water. This chemical reaction results in the formation of mineral hydrates. These hydrates are durable and are resistant to chemical attack. These hydrates are then solidified and hardened. The resulting cement can be weakened if the material is dried out during the curing process.

A rotary kiln is used for this process. The largest rotary kilns can produce more than 5,000 tons of cement a day. These kilns can be up to six meters in diameter. The kilns are usually equipped with bag-filter systems. These systems filter the dust generated during the kiln process.

Origins of cement

During the 19th century, Joseph Aspdin, a British inventor, invented a cement. It was first produced in Leeds, England. Unlike other construction materials, it could set in water, which helped spur the development of the cement industry.

Ancient Greeks and Romans experimented with using lime-based mortars to bond building stones together. Bedouins use mortar and concrete to construct their structures. The first concrete street was laid in the US during 1891 by George Bartholomew.

During the pre-Christian era, Romans perfected the process of cement-making. They used volcanic ash and lime as a binder. It was the perfect material to build Roman empire aqueducts. It was also used by the Egyptians to build the Great Pyramid.

The ancient Romans also discovered that the chemical reaction of hydraulic lime with water formed mineral hydrates. These hydrates are resistant to chemical attack. They are also durable in water.

Joseph Aspdin later patented his "artificial stone" in 1924. It was made of limestone.

Wet process vs dry process

Generally, wet process is used for cement manufacturing. It involves crushing raw materials and adding water to make a slurry. This slurry is then sent into the kiln and formed into a clinker. The quality of the cement is also better when it is produced in the kiln. The amount of dust produced is also reduced in the dry process.

The new dry process cement production involves pre-decomposition and pre-homogenization of the raw materials. This method is more energy efficient than the wet process. The use of this technology reduces energy costs and increases quality.

The total energy intensity of wet process is estimated at 6545 MJ/ton, while the total energy intensity of dry process is 4197 MJ/ton. In both processes, the combustion energy is the highest. The cost of combustion energy is 59% of the total energy intensity of wet process and 67 of the total energy intensity of dry process.

The dry process of cement production is more energy efficient. The size of the kiln is bigger. It also facilitates the evaporation of the slurry. In this process, the slurry has a fluidity that allows the kiln to rotate in less time.

Environmental benefits of green cement

Several environmental benefits are offered by green cement. In particular, gren cement can reduce the carbon footprint of cement manufacturing process. Green cement is characterized by reduced carbon emissions, reduced heating and cooling costs, reduced self-drying time, and reduced porosity. It also offers fire resistance and better mechanical strength.

Green cement is produced using industrial by-products. These include fly ash, blast furnace slag, and other industrial waste. The main raw materials are similar to those of ordinary Portland cement. However, the process used for producing green cement is different. This is referred to as Carbon Negative Manufacturing process.

By using advanced manufacturing technologies, green cement manufacturing reduces the carbon emissions and minimizes carbon footprint of cement production. Moreover, the process is energy efficient and requires less natural materials. The process uses industrial by-products to replace the natural resources required for traditional cement production.

Moreover, the process minimizes the emission of noxious gases during various operations. It also reduces carbon dioxide emissions.