Wet process vs. dry process cement – which is the better one? Do you know the correct answer? As we all know, wet process and dry process are two methods of manufacturing cement, according to whether the raw materials are ground in wet or dry state.
The raw materials of wet process are wet ground (by adding water) to form a slurry, then dried by wet process kiln, and finally form clinker. The water content of the slurry is usullly between 32% and 36%. There is also a process, known as semi-wet process, by which the raw material slurry can be dehydrated into raw material blocks and put into the kiln to calcine clinker. Semi-wet process cement still belongs to the wet process cement products.
While, the raw materials of dry process are dry ground to form a powder-like substance. Then they will be sent into the dry process kiln for calcining, finally forming clinker. There is also a processing method, known as semi-dry process, by which raw powder can be made into material balls by adding a proper amount of water and then be directly sent to be calcined. This method also belongs to the dry process production.
Nowadays, both of the processes are widely used with their own unique characteristics in different applications. In wet process, grinding is easier, while in dry process, the fuel consumption is saved involved in drying up the slurry.
How to choose the suitable process for different applications? The answer depends upon several factors, including but not limited as below:
1.Raw Materials Suitability to Particular Process
2.Overall Technological and Economical Feasibility
3.Storage and Transportation of Finished Cement
Related: What Is Cement Mortar
Differences Between Wet Process Cement And Dry Process Cement
Due to the two different cement mixing methods, there are obvious differences in cements produced by the two treatment methods.
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Wet Process Cement |
Dry Process Cement |
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Cement State and Storage Time |
1. It is wet mixture and can be used directly at the construction site before solidification. 2.The longest storage time should not exceed 24 hours. |
1. It is dry mixture and usually supplied in bulk or in bags. When used, it needs to be mixed with suitable water or additives at the construction site. 2.Dry process cement can be stored for a long time, usually 3-6 months. |
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Production Equipment |
Wet process cement is usually produced by cement batching plants. |
Dry process cement is mixed by special mixing equipment. |
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Products Varieties |
Wet process is not suitable for the production of cement mortar with high viscosity, so there are few types of wet process cement. At present, there are only mortar types for masonry, plastering and ground. |
Dry process cement is dry-mixed materials, so it is not limited by the production method. There are various types of products, and the variety of raw materials required for production is much more than that of wet process cement mixtures. |
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Transportation Methods |
The wet process cement mortar needs to be transported by a mixer truck to ensure it does not occur stratification and segregation during transportation. |
The bagged dry process cement is transported by truck, and the bulk dry process cement is transported by tanker. Dry-mixed cement tank can be used on the construction site, and there is no problem with the storage and use of wet-mixed cement. |
Cement State And Storage Time
Wet process cement is the wet mixture including all components and water. It can be used directly at the construction site before solidification, and the longest storage time should not exceed 24 hours.
Dry process cement is actually a dry-mixed mixture in which dry materials are uniformly mixed. Usually dry process cement is supplied in bulk or in bags. When used, it needs to be mixed with an appropriate amount of water or additives at the construction site. Dry process cement can be stored for a long time, usually 3-6 months.
Production Equipment
By far, wet process cement is usually produced by cement batching plants, while dry process cement is mixed by special mixing equipment.
Products Varieties
Wet process is not suitable for the production of cement mortar with high viscosity, so there are few types of wet process cement. At present, there are only mortar types for masonry, plastering and ground.
Dry process cement is dry-mixed materials, so it is not limited by the production method. There are various types of products, and the variety of raw materials required for production is much more than that of wet process cement mixtures.
Transportation Methods
The wet process cement mortar needs to be transported by a mixer truck to ensure it does not occur stratification and segregation during transportation.
Moreover, the transportation time of wet process cement shall not exceed 4 hours, and the materials shall be used up within 24 hours, otherwise they will solidify and cannot be used.
The bagged dry process cement is transported by truck, and the bulk dry process cement is transported by tanker. Dry-mixed cement tank can be used on the construction site, and there is no problem with the storage and use of wet-mixed cement.
Related: Cement Batching Plant Dry Concrete Batching Plant Wet Concrete Batching Plant
Advantages and Disadvantages of Wet Process vs. Dry Process Cement
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Wet Process Cement |
Dry Process Cement |
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Advantages |
1.High and stable quality, accurate ingredient ratio, durable service life after solidification. 2.Fluidity, nice homogeneity and perfect quality of clinker 3.Lower energy consumption 4. Suitable for mass production and more suitable for the use of cement in large and medium-sized projects. 5.In wet process, cement can be produced by simply operation, low dust and easy conveying. |
1. Long storage time, no need to worry about segregation and collapse of cement materials. 2. More flexible to use in small batches, ready to mix and use. 3. The moisture content of dry process cement is about 1%-2%, it saves the heat consumption needed for the moisture evaporation. 4. Dry process cement with advantages of energy-saving, high production efficiency and stable output can meet the production needs of large cement plants. |
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Disadvantages |
1. Transportation factors and setting time. 2. Wet process cement once is done, it should be used within 24 hours, or it will be scrapped caused waste. 3. Not suitable to produce the clinker with a high silica rate and high aluminum-oxygen rate. 4. Not suitable for producing cement mortar with high viscosity. |
1. The raw material composition of dry process cement is uneven. 2. Water is added on construction site, so the ratio is not precise as wet process cement. 3. High dust content will appear during working process. |
Advantages of Wet Process Cement
1.Wet process cement is with high and stable products quality, accurate ingredient ratio, durable service life after solidification.
2.The wet process cement slurry has fluidity, so that it has nice homogeneity and perfect quality of clinker.
3.The energy consumption of raw material grinding in the wet process is lower by nearly 30%.
4.It is more suitable for mass production and more suitable for the use of cement in large and medium-sized projects.
5.In wet process, cement can be produced by simply operation, low dust and easy conveying. Wet process method can be used to produce various typed of Portland cement, such as ordinary Portland cement, white Portland cement, oil well cement, etc.
Disadvantages of Wet Process Cement
1.Quality is affected by transportation factors and setting time. The transportation should be completed within 4 hours, and during transporting, continuous mixing the cement mortar is required to avoid material segregation. What’s more, if the setting time is too long, the subsequent construction will affected and if the setting time is too short, the cement mortar will be easily scrapped.
2.Wet process cement once is done, it should be used within 24 hours, or it will be scrapped caused waste.
3.The clinker manufactured by wet process, compared with other processing methods, has a lower temperature when it comes out of the kiln, so this method is not suitable to produce the clinker with a high silica rate and high aluminum-oxygen rate.
4.Wet process is not suitable for producing cement mortar with high viscosity.
Advantages of Dry Process Cement
1.Dry process cement has long storage time, so no need to worry about segregation and collapse of cement materials.
2.More flexible to use in small batches, ready to mix and use.
3.The moisture content of dry process cement is about 1%-2%, it saves the heat consumption needed for the moisture evaporation.
4.Dry process cement with advantages of energy-saving, high production efficiency and stable output can meet the production needs of large cement plants.
Disadvantages of Dry Process Cement
1.The raw material composition of dry process cement is uneven.
2.Water is added on construction site, so the ratio is not precise as wet process cement.
3.High dust content will appear during working process.
