APPLIED CHEMISTRY-1

NAME: RABIA FIAZ

ROLL NO#24
SECTION: A
DEPARTMENT: CHEMISTRY
SEMESTER: THIRD
COURSE CODE: CHEM-211
COURSE TITLE: APPLIED CHEMISTRY-1
SUBMITTED TO: MAM ANAM NOOR

1
APPLIED CHEMISTRY-1

Contents

Introduction Pg#3

Raw materials Pg#3

Flow chart diagram Pg #3

Manufacturing process Pg #4
➢ Grinding

➢ Pyro processing Pg #4

➢ Reactions in a kiln Pg #4-5

➢ Main constituents of clinker Pg #5-6

➢ Finish grinding Pg #6

➢ References Pg #6

2
APPLIED CHEMISTRY-1

CEMENT INDUSTRY
Manufacture of Portland Cement
Introduction:
Historically, cement can be traced back to the early Roman Empire. It contributed
to the building of the great structures of the Roman Empire. Portland cement is a
fine powder, generally gray in color. It is composed primarily of calcium silicates,
calcium aluminates, and calcium ferrites. When mixed with water (hydrated), cement
solidifies to an artificial rock, similar to Portland stone. A Portland stone is a yellow
limestone from the Isle of Portland, in Great Britain. Hence the name Portland cement.
By varying the amounts and types of the same basic ingredients, cement with various properties
may be obtained. Concrete is a mixture of gravel, sand and cement.
Raw materials:
The major components of cement in terms of metal oxides are CaO, SiO 2, Al2O3 And Typically,
Ca is provided from limestone, Si from sand or flyash, Al from Flyash or clay, and Fe from
iron ore or slag.
Flow Chart Diagram:
The above figure is the flow chart diagram of typical cement manufacturing plant.

Manufacturing process:
Grinding:

3
APPLIED CHEMISTRY-1

The feed to the grinding process is proportioned to meet a desired chemical composition.
Typically, it consists of 80% limestone, 9% silica, 9% flyash, and 2% iron ore.
These materials are ground to 75 micron in a ball mill. Grinding can be either wet or
dry. The “raw meal” from dry milling is stored in a homogenizing silo in which the
chemical variation is reduced. In the wet process, each raw material is fed with water
to the ball mill. This slurry is pumped to blending tanks and homogenized to correct
chemical composition. The slurry is stored in tanks until required.
Pyroprocessing:
In the preheater, the raw meal from the mill is heated with the hot exhaust gas from
the kiln before being fed into the rotary kiln to form a semi-product known as clinker.
The ash from fuel used is also absorbed into the clinker. The particle size range for
clinker is from about 2 inches to about 10 mesh.

Reactions in the kiln:

Basic chemical reactions are: evaporating all moisture, calcining the limestone to
produce free calcium oxide, and reacting the calcium oxide with the minor materials
(sand, shale, clay, and iron). This results in a final black, nodular product known as
“clinker” which has the desired hydraulic properties.
A summary of the physical and chemical reactions that take place in the kiln are:

4
APPLIED CHEMISTRY-1

Reactions in a cement kiln:

T°C Reaction Remarks

100 Evaporation of water. Solid phase reactions,

endothermic.

>500 Evolution of combined Solid phase reactions,

water from the clay. endothermic

900 Crystallization of amorphous Solid phase reactions,

dehydration products endothermic
Carbon dioxide evolution
from CaCO3.
900-1200 Main reactions between Fusion reactions, exothermic
lime and clay to form
clinker.
1250-1280 Beginning of liquid formation. Fusion reactions, endothermic

1280-1550 Further liquid formation Fusion reaction, endothermic

and final cement formation.

The main reactions which give the real strength of cement are as follows;

2CaO + CaO.SiO2 900-1200 °C CaO+2CaO.SiO2 1200-1500 °C 3CaO.SiO2

Main constituents of clinker:

2CaO.SiO2 Dicalcium silicate C2S Together with 3CaO.

SiO2, responsible for
final strength (I year).
3CaO.SiO2 Tricalcium silicate C3S Responsible for early strength
i.e. 7-8 days.

3CaO.Al2O3 Tricalcium aluminate C3Al Causes fast hardening; needs

retardation by gypsum by
forming
3CaO.AlO3CaSO4.3H2O.
3CaO.Al2O3.Fe2O3 Tetracalcium alumino-ferrate Improves chemical resistance
C4AF

5
APPLIED CHEMISTRY-1

The rotary kiln discharges the red-hot clinker under the intense flame into a clinker
cooler. The clinker cooler recovers heat from the clinker and returns the heat to the
pyroprocessing system thus reducing fuel demand and cooling the clinker to a temperature
conducive for handling in subsequent steps.
Finish Grinding:
The final process of cement making is called finish grinding. The clinker is dosed
with a controlled amount of gypsum and fed into a finish mill. Other additives may
be added during the finish grinding process to produce formulated cements such as
waterproofing and corrosion resistant cements.
The cement is stored in a bulk silo for packaging and/or bulk distribution.

References :
https://www.researchgate.net/publication/295858369_Industrial_Chemistry
https://www.google.com/url?sa=t&source=web&rct=j&url=https://en.m.wikipedia.org/
wiki/Cement&ved=2ahUKEwiZp6aFrr3sAhUODxQKHfASBi4QFjAAegQIARAB&usg
=AOvVaw2m3wtUFONHWDKo4kQELODZ
https://www.google.com/url?sa=t&source=web&rct=j&url=https://www.sciencedirect.c
om/topics/earth-and-planetary-sciences/cement-
industry&ved=2ahUKEwiZp6aFrr3sAhUODxQKHfASBi4QFjAJegQIBxAB&usg=AO
vVaw3Bv0gZOcwkW7gQFkSTqy5O
https://www.google.com/url?sa=t&source=web&rct=j&url=https://www.nature.com/art
icles/098368b0&ved=2ahUKEwi3-
JjBrr3sAhUHkRQKHTrYBGAQFjALegQIBBAB&usg=AOvVaw2jfREE-
nb9uV0NBUMs3MCA&cshid=1602997431618
http://www.mine-engineer.com/mining/cement.htm