The Step by Step Process of Cement Production

Cement can be a reliable ingredient for many construction projects. It has been useful in all kinds of buildings ranging from the small commercial buildings to large skyscrapers. Nonetheless, its ability to become sturdy and durable are the reasons why it can be an excellent choice. This guide will discuss the cement production process from start to finish.

You will learn about the materials that consist of it. From there, you’ll also learn some of the elements that go into the process before it can be used for any project. Let’s get started with what you need to know now.

1. Acquisition of raw materials

The production process starts with the raw materials that are needed for creating cement. What are they exactly? Typically the components consist of limestone, gypsum, shale, clay, sand, and iron ore. Most of them are sourced from mines or quarries by way of various techniques like extraction, blasting, or drilling.

Gypsum is one of the best materials included for cement as it controls the amount of time it takes to set. The remaining materials can bind together to determine the durability and strength of the cement itself. Now, let’s continue on with the next part of this step by step process of cement production.

2. Crushing and pre-homogenization process

Next, the raw materials will go through this process. First, they will be crushed into smaller pieces before they are pre-homogenized. This part of the production process is critical since the mixture has to be consistent enough for use. Without this consistency, the cement won’t be strong enough to maintain its overall durability.

If cement is not as durable or if the mixture is inconsistent, it can lead to a whole host of problems. For example, the structural integrity will be less than ideal. Water may also enter the pores that are present due to poor mixture, which can lead to damage. The likelihood of cracks being formed will increase as well.

3. Raw meal preparation

Now crushed and blended, the raw materials will be taken to a raw mill so they are grinded into particles. They become what is known as “raw meal”. This process will make sure that the cement is uniform and consistent when it comes to the composition aspect. Once again, it’s also a critical process to make sure that the cement’s strength and quality are strong enough for many construction projects that will rely on it.

This preparation process in particular accounts for 40 percent of the homogenization. Thus, it is considered one of a handful of critical steps in the cement production process. 

4. Clinker production

This part involves what is known as pyroprocessing. Here, the raw meal will go inside a rotary kiln that will heat up to around 2700 degrees (F). During this process, the materials will undergo a chemical reaction that will form what is known as clinker nodules.  Once formed, they will need to be cooled and grounded into a powder before moving on to the next stage.

5. Cooling and grinding

The cooling process exists here because it is to prevent chemical compositions from breaking down. So it needs to be done rapidly. Once complete, it will be grounded into a fine powder. Then the powder will be stored accordingly before it can be properly packaged and distributed.

During this part of the stage, gypsum will be added as a setting property for the cement.

6. Packaging and shipping

Next, we take a look at the packaging and distribution phase. The cement will be packed into bags or similar packaging materials. From there, they will be shipped to their necessary destinations. This can include hardware stores, construction sites, or storage facilities owned by construction companies where they need a consistent supply of cement for their projects.

These cement packages may be pre-ordered by companies who may have an existing business relationship with the suppliers. Construction businesses could be paying for wholesale prices on cement supplies as opposed to paying more via hardware stores. 

Regardless, it is important for project managers to take into account how much cement is being used for each project. This will help construction businesses forecast the amount of cement needs to be ordered in the future. It will keep things cost effective and optimize the supply of cement they have on hand - preventing overstocking or lacking the stock they need.

7. Usage for construction projects

This next stage is self-explanatory. Construction crews can use cement whenever their projects call for it. It could be a masonry project or building the next major building that can change a city’s skyline. Whatever it might be, cement will make it possible.

Nonetheless, the demand for cement will be steady. With the demand comes the supply that can be created to meet it. The cycle continues and the process repeats itself over and over again.

Are there any other environmental considerations regarding cement production?

In today’s day and age, sustainability and making a positive environmental impact is always discussed. How does it fit into cement production? Typically, it does require the use of energy-intensive tools and equipment to produce cement. However, cement companies are looking to adopt sustainable measures in order to reduce pollution while producing cement.

This includes utilizing energy-efficient tools and equipment, ways to extract the raw materials without further damaging the surrounding environment, and optimizing their production processes to lessen their emission in greenhouse gasses. 

Let PermuTrade help with physical commodity trading

Cement is a commodity that has steady supply and demand. At PermuTrade, we are familiar with the important raw materials often needed for the production process. That is why we work with traders who are focused on physical commodities. We also work with those who want to include digital assets like cryptocurrency as part of their trading plan for a better financial future.

Are you ready to see what PermuTrade can do for you? All that’s left for you to do is contact us through our website. We will be happy to help with any questions you may have.