Untitled (Cement Factory)

There are four stages in the manufacture of Portland cement: (1) crushing and grinding the raw materials, (2) blending the materials in the correct proportions, (3) burning the prepared mix in a kiln, and (4) grinding the burned product, known as “clinker,” together with some 5 percent of gypsum (to control the time of set of the cement). The three processes of manufacture are known as the wet, dry, and semi-dry processes and are so termed when the raw materials are ground wet and fed to the kiln as a slurry, ground dry and fed as a dry powder, or ground dry and then moistened to form nodules that are fed to the kiln.

It is estimated that around 4–8 percent of the world’s carbon dioxide (CO2) emissions come from the manufacture of cement, making it a major contributor to global warming. Some of the solutions to these greenhouse gas emissions are common to other sectors, such as increasing the energy efficiency of cement plants, replacing fossil fuels with renewable energy, and capturing and storing the CO2 that is emitted. In addition, given that a significant portion of the emissions are an intrinsic part of the production of clinker, novel cements and alternate formulations that reduce the need for clinker are an important area of focus.