PAMANTASAN NG LUNGSOD NG MAYNILA

College of Engineering and Technology

Chemical Engineering Department

Assignment No. 1
Chemical Process Industries
Introduction to Chemical Engineering

Submitted by:
SALAZAR, Marc Joshua J.
BS ChE 3-1
2018-00747

Submitted to:
Engr. Milagros R. Cabangon

Submitted on:
October 09, 2020
1. What is Chemical Engineering?

Among the branches of engineering, chemical engineering was known as a

versatile career path to take as it is concerned with processes in which materials
undergo a change in composition, energy or physical state, with the means of
processing, with the resulting products and with their application to useful ends.
This definition of chemical engineering is a broad statement as it covers variations
of products and processes. It also tackles pure physical and chemical processes,
as well as plants and their applications.
“Surely, we all subconsciously believe that the real core of chemical
engineering is powerful methodology” (Sargent, 1990). Thus, it allowed chemical
engineering to be the first system engineering. Furthermore, chemical engineering
is a diverse course for students as it acts as a compilation of knowledge of basic
sciences, mathematics, technology, analysis that can be applied to real-life
problems.

Figure 1. Chemical Engineer in a Power Plant

After years of technological advancements, chemical engineers are in great

demand because of companies that depend on the chemical processes and
production of daily products. These products can be in the form of soap, paints,
oil, wine, pharmaceutical products, paper, etc. Modern chemical
engineering emerged with the development of large-scale operations from early
civilizations of process industries thus proving how chemical engineers known as
universal engineers.
2. What are the works of a chemical engineer?

Chemical engineers have been the universal engineers starting from early
centuries as they provide products and services for our daily living. From the
innovations of technology, water treatment, energy production and processes that
chemical engineers aided to became relevant for every aspect of the ever-
changing world. These engineers are also part of new frontiers in multiple fields of
energy, medicine, environment, economy, and food production. Here are some
career paths for chemical engineering degree holder:

a. Chemical Plant and System Operator

Figure 2.a Chemical Plant and System Operator Adjusting the Gauge in a
Pipeline System

Chemical plant and system operators control the entire chemical processes
and system of machines with the use of panelboards or semi-automatic
equipment. They also ensure that all the equipment used in chemical plants
are working according to standards. Also, they monitor recording instruments,
panel lights, or other indicators and listen for warning signals to verify
conformity of process conditions. The main responsibility of a chemical plant
and system operator is to improve plant quality, efficiency and safety
 b. Manufacturing Production Technician

Figure 2.b Manufacturing Production Technician

Manufacturing production technician are also known as quality or

engineering technician. They are capable of verifying the functionality of safety
equipment.and adhering to all applicable regulations, policies, and procedures
for health, safety, and environmental compliance. Furthermore, their
responsibility is to calibrate equipment to ensure quality production, using tools
such as calipers, micrometers, height gauges, protractors, or ring gauges. As
chemical engineers, they work directly with machinery and equipment used in
the process of manufacturing raw materials or goods

c. Biotechnologist

Chemical engineers are of high

importance for pharmaceutical
companies and medical institutes.
In the field of biotechnology, their
responsibility is to innovate new
drugs, vaccines, and new
processes that can be useful for the
human system. Furthermore, they
can also apply principles of human
genetics to produce varieties of
Figure 2.c Biotechnologist drugs such as antibiotics,
antiseptics, analgesics and also
hormones.
d. Food Scientist

Figure 2.d Food Scientist

Food industries are one of the biggest and popular industries to work with
as a chemical engineering degree holder. Thus, being a food scientist is a great
option for having an influential career. Their main job is to produce and
research new food products that benefit the consumer standards through the
combination of principles of gastronomy, chemistry and microbiology.

e. Environmental and Healthcare Engineer

Figure 2.e Environmental and Healthcare Engineer

One of the best jobs for anyone is to help our environment and healthcare
system. Therefore, being an environmental and healthcare engineer interests
many chemical engineers. Their duty is to research and develop ideas about
saving the environment whether by water treatment, waste management,
minimizing pollutants and other environmental catastrophes.
f. Materials Engineer

Figure 2.f Materials Engineer

Materials engineers work in both basic and applied research. Their job is to
analyze various chemical compounds to determine their respective uses on
how they can be used for our society. They are also responsible for creating
equipment and processes to manufacture such products.

g. Energy Engineer

Figure 2.g Energy Engineer

Energy engineer is the one that develops and research energy-related

projects to enhance energy efficiency and reduce energy costs of a certain
structure. They apply the principles of thermodynamics and heat and mass
transfer.
3. Why you took up chemical engineering?

Chemical engineering reminded me of a bright future when I was a kid. At

first, I really wanted to be an accountant since I am fond of mathematics and
counting principles. Thus, I excelled in math and science competitions starting from
primary level to secondary level of education. However, I also wanted to be a chef
and a doctor someday. These interests confused me on what path and college
course should I take. Therefore, I searched for courses that deals with the subject
I am fond of, which leads me to the doors of chemical engineering course. There
are factors that I considered in taking the course, first is the career path that a
chemical engineer can do. Second, is the salary and availability of jobs in the
Philippines and in abroad. Lastly, is the contentment I can have when I became a
chemical engineer.

After days of deciding, I realized that I can fulfill all of my interests if I take
chemical engineering course. I can use my knowledge in mathematics and science
and apply it to solve real problems in the near future. I can also be in a chef-like
position if chose to specialize in food production and technology. More so, I can
be a doctor if I pursue this course as a pre-med. Having all these realizations leads
me to the present time- a third year chemical engineering student of Pamantasan
ng Lungsod ng Maynila.

For almost less than two years, I can fulfill all of my dreams when I get the
license as a chemical engineer. This can bring me to another path to decide on
what should I do and what purpose should I live as a professional and as a human
being. Also, continue pursuing passion and walking with the mistakes that I have
learned.
PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

Assignment No. 2
Chemical Process Industries
Cement Industry

Submitted by:
SALAZAR, Marc Joshua J.
BS ChE 3-1
2018-00747

Submitted to:
Engr. Milagros R. Cabangon

Submitted on:
October 09, 2020
1. Discuss the history of cement industry

Around 12-10,000 BC, variations of cement materials has been firstly used
by ancient Greeks, Romans and Egyptians. The ancient Romans produced
hydraulic cements through a mixture of lime and pozzolan (crushed volcanic
ash). On the other hand, Greeks and Egyptians used crushed brick, tiles and
ceramic pottery as aggregates which lead them to build historical structures
(Colosseum and Pantheon in Rome, Hagia Sophia in Istanbul).

Colosseum in Rome Hagia Sophia in Istanbul

Hydraulic cement used by Romans to Build Concrete

During the Middle Ages, cement discoveries remain unknown; although

masons are known to utilized hydraulic cements to establish canals and
structures.
 In the late 18th century, Europe witnessed new developments in cement,
made possible by significant contributions from John Smeaton. He discovered
that the hydraulicity of lime was directly related to the limestone’s clay content.
Furthermore, the developments for cement was made possible by Joseph
Aspdin, a British bricklayer and builder, who heated a mix of ground limestone
and clay in his kitchen stove, then pulverized the concoction into a fine powder.
He named this as Portland cement, after the name of building stone from the
Isle of Portland in Dorset, UK. His son, named William made the first cement
containing alite (an impure form of tricalcium silicate). In 1824, he obtained a
patent of the Portland cement paving the way for establishing a foundation in
today’s cement industry.

Rotary Kilns

Vertical Shaft Kilns

In 1845, Isaac Johnson tested higher temperatures to chalk and clay than
the Aspdins (around 1400-1500 degrees Celsius), which led to the mixture
clinkering, and generated what is the nature of modern-day cement.
After decades, rotary kilns were used as substitute to the vertical shaft kilns
since they use radiative heat transfer that generates stronger cement. Other
innovations in the last century include calcium aluminate cements for efficient
sulphate resistance, the blending of Rosendale and Portland cements to make
a durable and fast-setting cement in the USA, and the increased usage of
cementitious materials to store nuclear waste. At the present time, cements are
also being developed which can absorb carbon dioxide over their lifetimes,
reducing the carbon footprint of the building material.
2. List down the companies in the Philippines that manufactures cement.

a. Cemex Holdings Philippines, Inc.

Cemex Holdings Philippines, Inc. (CHP), a subsidiary of CEMEX

Asian South East Corporation (CASEC), was incorporated on September
17, 2015 as a stock corporation. Their main facility is located at 8th Floor
Petron Mega Plaza, 358 Senator Gil J. Puyat Avenue, Makati City, Metro
Manila, National Capital Region, 1209.

b. Holcim Philippines Inc.

Holcim Philippines, Inc. (Philippine Stock Exchange: HLCM) is one

of the leading building solution companies in the country. With cement
manufacturing facilities in La Union, Bulacan, Misamis Oriental and Davao,
as well as aggregates and dry mix business and technical support facilities
for building solutions, Holcim Philippines is a reliable partner of builders in
the country.
c. Goodfound Cement Corporation

Goodfound Cement Corporation is an enterprise based in

Philippines. It operates in the Nonmetallic Mineral Product Manufacturing
sector. Their headquarters is located at Palanog, Camalig, Albay, Albay.

d. San Miguel Yamamura Packaging Corporation

San Miguel Yamamura Packaging Corporation (SMYPC), provides

total packaging solutions across the globe: a wide range of quality products
- glass, plastics, metal, flexibles, PET, molds and paper and reliable
services and technical expertise. Their facilities are located in Pandacan
and Mandaluyong, Metro Manila.
e. Mabuhay Filcement Inc.

Mabuhay Filcement Inc. is probably the largest Filipino and privately

owned company in the Visayas and Mindanao. It uses state of the art
technology in manufacturing and engineering design. It currently produces
the following cement brands: Mabuhay Portland, Mabuhay Premium
Portland, Mabuhay Pozzolan, and Mabuhay Masonry.

f. Eagle Cement Corporation

Eagle Cement has the largest single plant production capacity in

terms of number of cement bags in the Philippines through its primary
cement production facility located in San Ildefonso, Bulacan. The
company’s Bulacan cement plant consists of two production lines, and
together with its grinding plant in Bataan, combines cement production
capacity of approximately 5.1 million metric tons or 130 million bags per
annum.
g. Taiheiyo Cement Philippines, Inc.

Taiheiyo Cement Philippines, Inc. (TCPI) is a subsidiary of and

wholly owned by Japan’s biggest cement manufacturer, Taiheiyo Cement
Corporation (TCC). TCC is the core company of huge international groups
and operates 14 cement plants in 5 countries. TCPI’s main facility is located
at San Fernando, Cebu.

h. CRH Philippines

CRH Philippines manufactures and supplies a diverse range of superior

building materials and products for use in the construction and maintenance of
infrastructure, housing and commercial projects. Our materials and
products are used extensively, in construction projects of all sizes, all across
the world. They are located in Batangas, Bulacan, Danao, Norzagaray and
Rizal.
i. Phinma Corporation

PHINMA Corporation is a public company listed with the Philippine

Stock Exchange (PSE) under the trading symbol PHN. Their facility is
located in Mariveles, Bataan.

j. Big Boss Cement

BIGBOSS Cement (BBCI) is a 100% Filipino-owned start-up

company specializing in production of environment-friendly cement in the
country. They utilize advanced technological infrastructure and methods
that are capable of producing high-quality and environment-friendly cement.
3. Identify the raw materials, properties, uses and classifications of cement.

a. Raw materials of Cement

Cement is produced through a closely controlled chemical combination

of calcium, silicon, aluminum, iron and other ingredients. Common materials
used to manufacture cement include the following:

• Limestone- it supplies the bulk of the lime

• Clay, marl or shale- it supplies the bulk of silica, alumina and
ferric oxide)
• Bauxite- is a naturally occurring sedimentary rock, non-
chemically treated and contains one or more aluminum hydroxide
minerals. It is a rich source of aluminum as a raw material in the
manufacture of Portland cement.
• Bottom ash- can be used as a source of aluminum, iron oxide,
and silica in the manufacture of Portland cement.
• Fly ash- can be used as a source of alumina and silica processing
of cement.
• Granulated Blast Furnace Slag (GBFS)- used to provide
additional strength and durability, and improved finish in cement
and concrete, while reducing the overall cost of production.
• Natural gypsum- is used in building products such as drywall,
cement additives and plaster.
• Pozzolan- is used to strengthen and enhance the durability of
concrete and cement.

Bauxite Bottom Ash

Fly Ash GBFS

 Natural Gypsum
Limestone

Pozzolan

b. Properties of Cement

Physical Properties of Cement:

The following physical properties are some of the key factors
for manufacturing good cement.
• Strength
• Good resistance to moisture
• Excellent binding material
• Good plasticity
• Fineness- the specific surface area should not be less
than 2250 𝑐𝑚2 /𝑔𝑚.
• Soundness- it should retain its volume after setting
without delayed expansion, which is caused by
excessive free lime and magnesia. (Le Chatelier test or
Autoclave test to determine the soundness of cement)
• Setting time- stiffens or hardens early
• Bulk density- The density of cement may be anywhere
from 62 to 78 pounds per cubic foot depending on its
percentage composition.
 • Specific gravity- Portland cement usually have a
specific gravity of 3.15.

Mechanical Properties of Cement:

• Compressive strength- at the end of 3 days should not
be less than 11.5 N/𝑚𝑚2 and that at the end of 7 days
should not be less than 17.5 N/𝑚𝑚2 .
• Tensile strength- at the end of 3 days should not be
less than 2 N/𝑚𝑚2 and that at the end of 7 days should
not be less than 2.50 N/𝑚𝑚2 .

Chemical Properties of Cement:

• The ratio of percentage of lime to alumina, iron oxide
and silica, known as Lime Saturation Factor (LSF)
should not be less than 0.66 and should not be more
than 1.02.
• The ratio of percentage of alumina to iron oxide should
not be less than 0.66.
• Total loss on ignition should not be more than 4
percent.
• Total sulphur content should not be more than 2.75
percent.
• Weight of insoluble residue should not be more than
1.50 per cent.
• Weight of magnesia should not exceed 5 percent.
c. Uses of Cement

Some of the uses of cement are the following:

• Aesthetic Structures. Colored cement is a trend nowadays for
aesthetic floors and walls through the addition of iron oxide as a
coloring agent
• Precast Members. Cement is used as a binding material to
manufacture precast members
• Cement Concrete Roads and Structures. Rigid pavements and
buildings are mostly developed because of its high rigidity and long-
life span even without maintenance.
• Grouting. Portland and microfine cement are very suitable for filling
cracks, joints, openings in foundations of structures.
• Joints. Cement can be used for producing joints for pipes and drains.
• Chemical Proof Structures. Acid resistant cement is used for
chemical storages and structures.
• Protection coating. Protection of exposed surfaces of structures
through cement against the destructive agents of the weather and
certain organic or inorganic chemicals.
• Water tightness. It is used for water tightness of structure.

Cement Concrete Briddge Chemical Proof Structures

 Aesthetic Structures Cement Concrete Roads

Grouting

d. Classifications of Cement

• Portland Cement
➢ Type I (Regular Portland Cement)

This classification of cement is the most widely used

for general concrete construction. They are easily workable
because of its high plasticity.
➢ Type II (Moderate-heat-of-hardening Portland Cement)

It is mainly used for concrete constructions with

moderate heat of hydration and exposed to moderate sulfate
action.

➢ Type III (High-early strength Portland Cement)

They contain a higher proportion of tricalcium silicate

than regular portland cement. Thus, they harden much quickly
and quicker at higher temperatures.

➢ Type 4 (Low-heat Portland Cement)

It is produced by maintaining the percentage of

tricalcium aluminate which leads to low heat of hydration. It is
usually used to mass concrete construction like gravity dams
to prevent cracking due to heat.

➢ Type 5 (Sulfate-resisting Portland Cement)

Sulfate-resisting cement is used in construction

exposed with high sulfate such as canals, retaining walls and
canal linings. This cement contains high amounts of
tetracalcium aluminoferrite and low amounts of tricalcium
aluminate.
• Pozzolana Cement

It is produced by grinding two to four parts of pozzolana with one

part of hydrated lime. This cement has a high resistance to various
chemical attacks which made it widely used for underwater
constructions.

• Calcium Aluminate Cement

It is manufactured by mixing bauxite and lime, then grinding with

clinker. It is used because of its high compressive strength and
utilized in high temperatures, frost and acidic action.

• Special/ Corrosion-Resisting Cement

It is used for corrosion-proof linings of chemical equipment such

as storage tanks, reactors, fume ducts and trenches,
• Rapid Hardening Cement

This cement contains high amounts of lime and higher grinding

which gives higher strength than regular Portland cement.

• White Cement

It is produced with the same raw materials of Portland cement free

from iron oxide. It is usually used in interior walls and aesthetic
designs of structures.

• Colored Cement

It is manufactured by mixing 5-10% pigments to ordinary cement.

It is usually utilized for decorative walls and floors.
• Expansion Cement

This cement expands at a short period of time and does not shrink
after the hardening time. It is mainly used for grouting anchor bolts.

• Blast Furnace Slag Cement

It is manufactured by grinding with about 60% slag and can be a

substitute for Portland cement. This cement is used for works where
economic costs are primary.

• Hydrographic Cement

It is produced by combining water-repelling substances and has

high rigidity. It has the property of repelling water and therefore used
in dams, spillways and water storing structures.
4. Discuss the manufacturing process of cement, include the following:

a. Raw materials

Portland cement is the basic component of concrete which is widely

used for building rigid structures. It is manufactured by mixing calcining
calcareous and argillaceous materials specifically raw materials containing
calcium, silicon, aluminum and iron. Such raw materials are limestone,
shale, clay, sand, iron ore, slate and blast furnace slag which are heated
at high temperatures then grind into fine powder.

Furthermore, first natural cement was from an argillaceous limestone

known as cement rock however was lime-deficient. This was corrected by
adding small portions of limestone. Also, some cement plants used artificial
raw materials such as blast furnace slag and precipitated calcium carbonate
to produce various kinds of cement.

Most of the cement plants are placed where the quarry of raw
materials is nearby, depending on the required source of cement. In this
way, they can minimize the fuel cost and make the cement considerably
economical. The extraction of raw materials can be done by means of
conveyor belt which is then transported to the cement plant.

Quarry operations to transport Raw Materials

b. Different unit operations involve

The production of cement involves different unit operations to

prepare the raw materials in processing into fine cement. This can take
place through chemical reactions at certain temperature in the kiln. More
so, the manufacturing of cement is subdivided into several unit operations
like (a) Raw materials crushing, (b) Raw materials grinding, (c) Pyro-
processing, (d) Cement grinding and Cooling, (e) Packing and
dispatch

There are two ways in manufacturing cement: (a) Wet process and
(b) Dry process. Both methods involved closed-circuit grinding wherein the
raw materials are continuously grinding until the desired fineness is
achieved.

• Raw materials crushing

From quarry operations, raw materials which are in large-size form

are crushed into smaller size rocks before transporting it into the
cement plant. With the help of crusher, it reduces the size of large
rocks into size of gravels.

• Raw materials grinding

After crushing the raw materials, it is then routed in the cement

plant which are meant to be analyzed and proportioned before the
grinding process. Generally, the proportions are 80% limestone and
20% clay. During the grinding operations, rotating table and heavy
wheel type rollers are utilized to do such process. The rotating table
rotates continuously under the roller and brought the raw mix in
contact with the roller. Then, the roller crushes the raw mix which is
stored in pre-homogenization pile into fine powder.

• Pyro-processing

Pyro-processing of the material involves the use of pre-heating

chambers and rotary kilns. Pre-heating chamber consists of series
of vertical cyclone where the raw material passes before facing the
kiln. This stage helps to save energy and make the cement plant
environment-friendly. After the pre-heating stage, kiln is utilized to
heat the material at high temperature up to 1450 degrees Celsius. It
is also heating at the exit side through the use of natural gas and
 coal. Then, the material forms the shape of clinker when it reaches
the lower part of the kiln.

• Cement grinding and Cooling

After the pyro-processing stage, clinkers are cooled as it releases

the absorbed heat from the kiln. The released heat can be reused by
recirculating it back to the kiln making the cement manufacturing
energy-saving. After cooling, cement grinding is processed through
the use of rotating drum filled with steel balls. The steel balls crush
the clinker into fine powder; gypsum can be also added during the
final grinding for the target setting of cement.

c. Chemical reactions involve

The manufacturing of cement involves different chemical reactions

depending on the raw materials used. Most of the reactions occur in the kiln
where high temperature is applied, such reactions are (a) Double
decomposition or Neutralization, (b) Decarbonation, (c) Dehydration
(d) Calcination. Also, both endothermic and exothermic reactions occur
when producing clinker and lime.
 Furthermore, there are dominant reactions that usually happened in
the manufacturing of cement which is the calcination of limestone and
formation of belite and alite. With this material, decarbonation can occur as
the limestone releases carbon dioxide because of immense temperature.
Meanwhile, the dehydration of clay and decarbonization or calcination of
limestone can also occur with values of about 380 and 665 Btu per lb.,
respectively. Lastly, such reactions occur in the pyro-processing stage of
cement manufacturing.
d. Equipment used

• Cement crusher

There are various types of cement crusher on the market,

including jaw crusher, cone crusher, hammer crusher and impact crusher.
Its purpose is for crushing raw materials from the quarry operations.

• Cement Mill

Cement mill is used for grinding crushed materials into fine

size before clinker production.
• Cement Kiln

It is the core equipment of cement production. It is used to

make cement clinker usually through the dry method of cement
manufacturing.

• Clinker cooler and dryer

Clinker cooler is used to cool produced clinker from the kiln

and is then used for the final grinding phase.
 • Pre-heating Chamber

It consists of vertical cyclones to preheat grinded raw

materials to save energy before proceeding to the kiln.

e. Flow of materials per operation

Raw Materials from quarry

(Limestone, Clay, others)

Crushing and Dry Process

Grinding

Preheating
Wet Process
Chamber

Kiln
Cooling

Storing and
Storing clinker Final Grinding
Dispatch
 The manufacturing of cement starts from the extraction of raw
materials such as limestone and clay from the quarry. The materials
are then crushed into smaller rock to save energy in the production
line. It is then transported to the cement plant for grinding, mixing and
proportion phase. There are two ways to manufacture cement: dry
process and wet process. Wet process differs in the amount of water
before entering the rotary kiln for heating. Also, dry process is more
practical and widely used in manufacturing cement because it is
energy saving and has low production cost. However, wet process
produces a better homogenous cement than the dry process.

The

material is then transported to the rotary kiln for pyro-processing at

around 1500 degrees Celsius. It is also heated at the lower part of
the kiln using natural gas and coal which produces clinkers. The
clinkers are then cooled where it releases the absorbed heat from
the kiln. The released heat can be reused by recirculating it back to
the kiln which is energy-saving. After cooling, cement grinding is
processed through the use of rotating drum filled with steel balls. The
steel balls crush the clinker into fine powder; gypsum can be also
added during the final grinding for the target setting of cement. The
cement is then ready for storing and dispatch.
 5. Draw using equipment flow chart the manufacturing process of cement.

Quarry Crusher and Grinder

Cooler
Dedusting

Electrostatic
Precipitator

Coal Mill

Clinker Cooler
Raw Mill
Rotary Kiln Feed Bins

Clinker Storage Cement Mill Filter Packing Machine

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