When is the dry process used?

Hard raw materials such as limestone and shale and costly fuel

Soft chalk and clay with cheap fuel

What is the role of preheater cyclones?

Heat raw meal with kiln gases to 800-900 C before the kiln

Compared with wet process, dry process has:

Short kiln and lower fuel use but more dust

2078 Kartik · 4 marks

Dry process of cement manufacture

Short answer

In the dry process, raw materials are crushed, dried, ground to raw meal, and blended in silos. The meal passes through preheater cyclones, a rotary kiln at 1400–1500°C to form clinker, then cooled, mixed with gypsum, ground, and packed. It uses low fuel (3–3.5 GJ/t) and suits hard raw materials.

Draw the flow chart of manufacturing of cement by the dry process.

In the dry process the raw materials are ground and blended dry, and the dry powder (raw meal) is burnt in the kiln. It is used when the raw materials are hard (limestone and shale) and fuel is costly; because it uses much less fuel, it is now the standard modern process.

 Limestone + Clay/Shale (+ correctives)
              |
        Crushing (jaw/impact)
              |
      Drying (if moisture > 1%)
              |
   Raw mill: fine dry grinding (raw meal)
              |
    Blending & storage silo (air agitation)
              |
    Preheater cyclones (800-900 C)
              |
    Rotary kiln (1400-1500 C) -> Clinker
              |
        Clinker cooler
              |
   + Gypsum (3-5%) -> Cement mill
              |
         Cement silo
              |
          Packing

Features: short kiln, fuel use of 3-3.5 GJ/t of clinker (much lower than the wet process) and higher output, but more dust and a need for good blending.

✓ Answer checked by Claude Opus 5.5 (high effort)

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