5/18/2018 Cement industry

Group no 3

Group members
1. Ibrahim humayun (170501012)
2. Hussnain zeb (170501015)
3. Qaim abass (170501013)
4. Shoaib imtiaz (170501017)
 Cement industry
Basic chemistry and types
slaked lime (calcium oxide mixed with water), hardens by carbonation in the presence of carbon
dioxide which is naturally present in the air. Firstcalcium oxide (lime) is produced from calcium
carbonate (limestone or chalk) by calcination at temperatures above 825 °C (1,517 °F) for about
10 hours at atmospheric pressure.basically limestone decomposes into lime after getting heated
to a high temperature.

The calcium oxide is then spent (slaked) mixing it with water to make slaked lime (calcium
hydroxide):

CaO + H2O → Ca(OH)2

Once the excess water is completely evaporated (this process is technically called setting), the
carbonation starts:

Ca(OH)2 + CO2 → CaCO3 + H2O

This reaction takes a significant amount of time because the partial pressure of carbon dioxide in
the air is low. The carbonation reaction requires the dry cement to be exposed to air, and for this
reason the slaked lime is a non-hydraulic cement and cannot be used under water. This whole
process is called the lime cycle.Conversely, hydraulic cement hardens by hydration when water
is added. Hydraulic cements (such as Portland cement) are made of a mixture of silicates and
oxides, the four main components being:

Belite (2CaO·SiO2)
The lime produced in first reaction reacts with silicon dioxide to produce dicalcium silicate.

Alite (3CaO·SiO2)
Lime also reacts with silicon dioxide to produce one more compound tricalcium silicate.
Tricalcium aluminate (3CaO·Al2O3) (historically, and still occasionally, called 'celite')
Lime also reacts with aluminum oxide to form tricalcium aluminate.

Brownmillerite (4CaO·Al2O3·Fe2O3). 5. In the last step calcium oxide, aluminium oxide and
ferric oxide react together to form cement.

The silicates are responsible for the mechanical properties of the cement, the tricalcium
aluminate and the brownmillerite are essential to allow the formation of the liquid phase during
the kiln sintering (firing).

Types of Cement
Depending upon our requirements i.e. using it at a suitable place, we use different types of
cement.
 Ordinary Portland Cement
 Portland Slag Cement
 White Cement
 Portland Pozzolona Cement
 Sulphates Resisting Cement
 Hydrographic cement

Ordinary Portland Cement (OPC)

Ordinary Portland cement is the most widely used type of cement which is suitable for allgeneral
concrete construction. It is most widely produced and used type of cement around the world
Portland Slag Cement
It is obtained by mixing clinker, gypsum and granulated slag in a proper proportion. The
Properties of this cement is very similar to that of OPC which are as under. It has lesser heat of
hydration and has better resistance of soils, sulphates of alkali metals, alumina and iron.
White Cement
It is the cement of pure white colour and having same properties as those of Ordinary Portland
Cement. Greyish colour of cement is due to iron oxide (FeO). White cement is manufactured
from chalk and clay free from Iron Oxide. Oil fuel and not the coal is used for the burning of this
cement.It is much more costly than ordinary cement. .
Portland Pozzolona Cement
Portland Pozzolona cement is produced by grinding together Portland cement and Pozzolona.
This cement has properties similar to those of OPC and can therefore be used for all general
purpose. Portland Pozzolona cement produces less heat of hydration and offers greater resistance
to attack of aggressive water or sulphates bearing than OPC.

Sulphates Resisting Cement

Sulfate resisting cement is used to reduce the risk of sulphate attack on concrete and thus is used
in construction of foundations where soil has high sulphate content..Sulfate resisting cement is
used in construction exposed to severe sulphate action by water and soil in places like canals

Hydrographic cement
Hydrographic cement is prepared by mixing water repelling chemicals and has high workability
and strength. It has the property of repelling water and is unaffected during monsoon or rains.
Hydrophobic cement is mainly used for the construction of water structures such dams, water
tanks, spillways, water retaining structures etc.

Cement: Materials and manufacturing process

CEMENT MANUFACTURING GENERAL PROCESS PHASES
Production of cement completes after passing of raw materials from the following six phases.
These are;

1. Raw material extraction/ Quarry

2. Grinding, Proportioning and Blending
3. Pre-heater Phase
4. Kiln Phase
5. Cooling and Final Grinding
6. Packing & Shipping

CEMENT MANUFACTURING PROCESS PHASE 1: RAW MATERIAL EXTRACTION

Cement uses raw materials that cover calcium, silicon, iron and aluminum. Such raw materials
are limestone, clay and sand. Limestone is for calcium. It is combined with much smaller
proportions of sand and clay. Sand & clay fulfill the need of silicon, iron and
aluminum.Extraction of raw material and crushing of materialGenerally cement plants are fixed
where the quarry of limestone is near bye. This saves the extra fuel cost and makes cement
somehow economical. Raw materials are extracted from the quarry and by means of conveyor
belt material is transported to the cement plant..Before transportation of raw materials to the
cement plant, large size rocks are crushed into smaller size rocks with the help of crusher at
quarry. Crusher reduces the size of large rocks to the size of gravels.

CEMENT MANUFACTURING PROCESS PHASE II: PROPORTIONING, BLENDING &

GRINDING
The raw materials from quarry are now routed in plant laboratory where, they are analyzed and
proper proportioning of limestone and clay are making possible before the beginning of grinding.
Generally, limestone is 80% and remaining 20% is the clay. Proportioning of raw material at
cement plant laboratoryNow cement plant grind the raw mix with the help of heavy wheel type
rollers and rotating table. Rotating table rotates continuously under the roller and brought the raw
mix in contact with the roller. Roller crushes the material to a fine powder and finishes the job.
Raw mix is stored in a pre-homogenization pile after grinding raw mix to fine powder.

This can be done in two ways

1. Wet Process for Manufacturing of Cement
In wet process if chalk is used, it is finely broken up and dispersed it in water in a wash mill.
Wash mill is a circular pit consisting of revolving radial arms having rakes which breaks the
solid materials into lumps. In similar wash mill, clay is also broken up and mixed with water.
Now the two mixtures are pumped so as to mix in predetermined proportion and passed through
a series of screens. The resulting cement slurry flows into storage tanks.When lime stone is used,
first blast it, then crushed in two progressively smaller crushers and then fed into a ball mill with
the clay dispersed in water. The resultant slurry is pumped in to storage tanks.then the raw
material is passed through the heating stage

2. Dry Process for Manufacturing of Cement

In dry and semi dry processes for manufacturing of cement, the raw materials are crushed and
fed in the correct proportions into a grinding mill. The raw materials are dried and reduced in
size to a fine powder in to grinding mill. The dry powder is called the raw meal. The raw meal is
pumped into a blending silo. Adjustment in the proportion of the materials required for the
manufacture of cement is done in silo.The raw meal blended by passing compressed air to obtain a
uniform and intimate mixture then the raw meal is passed to heating stage

CEMENT MANUFACTURING PROCESS PHASE III: PRE-HEATING RAW MATERIAL

After final grinding, the material is ready to face the pre-heating chamber. Pre-heater chamber
consists of series of vertical cyclone from where the raw material passes before facing the kiln.
Pre-heating chamber utilizes the emitting hot gases from kiln. Pre-heating of the material saves
the energy and make plant environmental friendly.

CEMENT MANUFACTURING PROCESS PHASE IV: KILN PHASE

Kiln is a huge rotating furnace also called as the heart of cement making process. Here, raw
material is heated up to 1450 ⁰C. This temperature begins a chemical reaction so called
decarbonation. In this reaction material (like limestone) releases the carbon dioxide. High
temperature of kiln makes slurry of the material.The series of chemical reactions between
calcium and silicon dioxide compounds form the primary constituents of cement i.e., calcium
silicate. Kiln is heating up from the exit side by the use of natural gas and coal. When material
reaches the lower part of the kiln, it forms the shape of clinker.

CEMENT MANUFACTURING PROCESS PHASE V: COOLING AND FINAL GRINDING

After passing out from the kiln, clinkers are cooled by mean of forced air. Clinker released the
absorb heat and cool down to lower temperature. Released heat by clinker is reused by
recirculating it back to the kiln. This too saves energy.Final process of 5th phase is the final
grinding. There is a horizontal filled with steel balls. Clinker reach in this rotating drum after
cooling. Here, steel balls tumble and crush the clinker into a very fine powder. This fine powder
is considered as cement. During grinding gypsum is also added to the mix in small percentage
that controls the setting of cement.

CEMENT MANUFACTURING PROCESS PHASE VI: PACKING AND SHIPPING

Material is directly conveyed to the silos (silos are the large storage tanks of cement) from the
grinding mills. Further, it is packed to about 20-40 kg bags. Only a small percent of cement is
packed in the bags only for those customers whom need is very small. The remaining cement is
shipped in bulk quantities by mean of trucks, rails or ships.

Setting and Hardening:

setting
Setting time is defined as the transition from a fluid state to plastic state.The stiffening of the
concrete after it has been placed. A concrete can be 'set' in that it is no longer fluid, but it may
still be very weak; you may not be able to walk on it, for example. Setting is due to early-stage
calcium silicate hydrate formation. The terms 'initial set' and 'final set' are arbitrary definitions of
early and later set; there are laboratory procedures for determining these using weighted needles
penetrating into cement paste.It has been found that this transition can occur in less than one
hour or could take up to 24 hours.
Initial set of cement paste is defined as the time when the paste has gained enough rigidity to no
longer be in a fluid state.
The final setting time is when rigidity has increased to a point that the paste becomes a solid of
very low strength.In general, cement exhibit initial set in 2 to4 hours and final set in 5 to 8 hours.
Final set is then followed by substantial increases in strength, referred to as the hardening stage.

Hardening The process of strength growth and may continue for weeks or months after the
concrete has been mixed and placed. Hardening is due largely to the formation of calcium
silicate hydrate as the cement hydrates.Hardening time is when concrete has a sufficient bearing
capacity to support construction loads.This hardening of concrete may occur in a few hours, or
could take up to 2-3 weeks.

Criteria for cement quality

A good cement should:
meet the strength requirements as measured by compressive strength,
fulfill durability requirements to resist the environment in which the structure is expected to
serve,
be mixed, transported and compacted as efficiently as possible and will be as economical as
possible
Test of Cement for checking quality
Consistency Test
It is used to determine the % of water required for preparing cement pastes for other tests .

Compressive strength It is used to determine the strength of cement materials It is tested in

compressive testing machine
Tensile Strength It is used to determine the strength and hardness of cemnet

Making good cement involves:

Good quality raw materials, Proportioning of materials, Mixing, Transporting, Placing,
Compacting, Curing.

Environmental impacts and health concerns

Many environmental studies have detailed the impacts of the different processes involved in the cement
manufacturing.Environmental impact are due either to the direct emissions on the cement kiln or to
indirect impact associated to the preparation of the fuels.

Global Scale Over

the last decades, the emphasis has clearly shifted towards a global focus on climate changeA typical
modern rotary cement kiln with a specific heat consumption of 3.1 GJ/ton clinker emits approximately
0.31 kg of Carbon dioxide.Under optimum conditions heat consumption can be reduced to less than 2.9
GJ/ton clinker.Possibilities to reduce RM-CO2 emissions are rather limited. Partially replacing the
traditional raw materials by blast-furnace slag (BFS).
Regional Scale
Regional environmental impacts include SO2 and NOx emissions which contribute to acid rain.The
majority of SO2 emitted is derived from the fuel combustion and the processing of raw materials in the
kilns However, the majority of the SO2 leaves the kiln with the clinker as it is absorbed due to the high
alkalinity of clinker.The generation of NOx and CO is mainly as outputs from fuel usage during clinker
production. Their emissions are highly dependent on temperature and oxygen availability.

Local Scale
Cement kiln dust (CKD) emissions are the main contributors to the local impact.The size of CKD (0.05 to
5 nanom) is within the size range of respirable particles and are considered as a potential hazardous
waste due to their caustic and irritative nature.