Cement

A cement is a material that sets, hardens and binds other materials like bricks
together. When cement mixed with sand and gravel, produces concrete. Concrete
is one of the most widely used material in existence.
Cement is a fine powder which when mixed with water sets to a hard mass as a
result of hydration of the constituent components.
Based on the cement properties it is divided into two main categories.
1. Hydraulic cement
It is the cement which has ability to set and harden after being combined with
water. It is mainly made from limestone, certain clay materials and gypsum. It is
the main cement utilized in modern day construction.
2. Non-hydraulic cement
It is the cement which cannot harden while in contact with water. When non-
hydraulic cement is utilized in construction it must be kept dry so that it will hold
the structure. Due difficulties related with waiting long period for drying, non-
hydraulic cement is not used in Nepal.
Raw materials for the cement production
Raw materials required for manufacture of cement are:
1. Limestone which supplies the bulk of the lime.
2. Clay, marl or shale which supplies the bulk of the silica, alumina and ferric oxide
3. Other supplementary materials like sand, fly ash/ pulverized fuel ash of iron
stone etc.
Once the raw materials are ground fine enough they are blended in the
proportion required to produce clinker of the desired concentration.
01. Lime
It is the main constituent used in cement manufacturing. It is responsible for
imparting the cementing property to cement. Deficiency of lime causes decreased
strength and the cement sets quickly. If it is used in the right proportion, it makes
the cement sound and strong
02. Silica
This plays a major role in imparting strength to concrete. Excess silica adds
strength to cement but it prolongs the setting.
03. Alumina
It acts as a flux and lowers the clinkering temperature. Use of an excess amount of
alumina quickens the setting time but reduces the strength of cement.
04. Iron Oxide
This is mainly responsible for imparting color to cement. The hardness and
strength of the cement are also improved to a certain extent.
05. Magnesium Oxide
It acts as a filler and accelerate the rate of hardening.
06. Sulphur Trioxide
This makes the cement sound if present in small quantity
07. Alkali

It increases the early strength of cement. It should not be present more than 1%.
Excess Alkaline matter causes efflorescence.
08. Calcium Sulfate:

This is present in cement in the form of gypsum. It slows down or retards the
setting action of cement. It also gives the most important property of cement,
compressive strength.
Cement manufacturing process

Raw Material Extraction/Quarry

The raw cement ingredients needed for cement production are limestone
(calcium), sand and clay (silicon, aluminum, iron), shale, fly ash, mill scale and
bauxite. The ore rocks are quarried and crushed to smaller pieces.
Grinding, Proportioning and Blending
The crushed raw ingredients are made ready for the cement making process in the
kiln by combining them with additives and grinding them to ensure a fine
homogenous mixture. The composition of cement is proportioned here depending
on the desired properties of the cement.
Pre-Heating Raw Material
A pre-heating chamber consists of a series of cyclones that utilizes the hot gases
produced from the kiln in order to reduce energy consumption and make the
cement making process more environment-friendly.
Kiln Phase
The kiln phase is the principal stage of the cement production process. Here, clinker
is produced from the raw mix through a series of chemical reactions between
calcium and silicon dioxide compounds. The kiln is set at a temperature between
1250 to 1450 °C.
Cooling and final grinding
After exiting the kiln, the clinker is rapidly cooled down to 100°C-200°C by passing
air over it. At this stage, gypsum is combined with the clinker to be ground in order
to produce the final product, cement.
Packing and Shipping
Cement is conveyed from grinding mills to silos (Large storage tanks) where it is
packed in 20-50 kg bags. Most of the product is shipped in bulk quantities by trucks,
trains or ships, and only a small amount is packed for customers who need small
quantities.
Flow sheet diagram

Types of cement

OPC Cement (Ordinary Portland cement):

It is manufactured by grinding a mixture of limestone and other raw materials. It
has 95% clinker and 5% gypsum. This cement is available in three types of grades,
such as OPC 33 grade, OPC 43 grade and OPC 53 grade. OPC is the most
commonly used cement in the world. This type of cement is preferred where fast
pace of construction is done. However, the making of OPC has reduced to a great
extent as blended cement like PPC has advantages, such as lower environmental
pollution, energy consumption and more economical.
PPC Cement (Portland pozzolana cement): PPC has 80% clinker, 15% pozzolana
and 5% gypsum and other materials. Pozzolana is a natural or artificial material
which contains silica in the reactive form. Portland Pozzolana Cement is cement
manufactured by combining Pozzolanic materials. This cement comprises of OPC
clinker, gypsum and pozzolanic materials in certain proportions. The Pozzolanic
materials include fly ash, volcanic ash, calcined clay or silica fumes. These
materials are added within a range of 15% to 35% by cement weight.
Difference between OPC and PPC Cement
OPC PPC
It has higher strength than PPC in the The strength of PPC is good than OPC
initial stage. in long terms.
The hydration process is slower than
It has high heat of hydration making it OPC resulting low heat of hydration.
unfavorable for mass concreting. Therefore, it is suitable for mass
concreting.
It has low percentage of sulphate
The presence of sulphates, alkalies,
alkalis, chlorides, magnesia and free
chlorides, etc. is higher and less
lime in its composition, which makes
resistant than PPC.
the concrete durable.
OPC is not favorable in aggressive Show greater resistance to aggressive
weather. weather.
OPC cement are available in three
grades, such as 33 Grade, 43 Grade, 53 PPC is available in any specific grades.
Grade

It is slightly costlier than PPC. Cheaper than OPC.

Cement Industry in Nepal

Nepal is a land-locked country lying between two biggest countries in
cement production and consumption (China is the 1st and India is the 2nd
country in cement industry worldwide) Almost all raw materials required for
cement production are naturally found in Nepal. Nepal is near to fulfill the
internal cement demands (about 80 %) and may be able to export in near
future.
Nepal is rich in limestone. The Department of Geology and Mines (DGM)
has estimated about 1.07 billion tonnes of limestone deposits, among that
540 million tonnes are proven, 110 million tonnes are semi-proven, and 420
million tonnes are feasible deposits. Exploration of limestone by DGM in
the past was able to identify a number of large to small size limestone
deposits in Nepal. Based on the known cement grade limestone deposits,
about 28 cement industries are already in production phase, few are under
construction and some are in the pipeline for operation. Establishment of
more cement industries based on its own limestone resources is still
rewarding since the demand of cement in Nepal, India and China is ever
increasing. Therefore, cement may be the most sustainable industry in
Nepal. The main cement grade limestone deposits in Nepal are Nigale of
Dhankuta; Sindhuli, Galtar, Chuladhunga and Gyampathumka of Udaypur;
Bhainse, Okhare, Majuwa, Nibuwatar, Sukaura and Budichaur of
Makwanpur, Jogimara and Beldada of Dhading; Kakaru Khola and
Shikharpur of Sindhuli; Chovar of Kathmandu; Bhattedanda of Lalitpur;
Lamatar, Balthali, Rosi, Nogure and Nandu of Kavre; Waling of Syangja;

Jyamire, Koldanda, Masyam, Kerabari, SisneDobhan and Argali of Palpa;

Narapani and Supa Khola of Arghakhanchi; Gandari, Sewar Khola, Arun
Khola of Dang Salendanda and Neupane of Pyuthan; Kajeri, Sarada Khola,
Kutichaur of Salyan; Bibang Khola and Rupla Khola of Rolpa; Chaukune and
Lakharpata of Surkhet, Diyarigad, Bhumeshor of Baitadi and few other
places in Lalitpur, Kavre, Khotang, Udayapur, Syangja, Palpa,
Arghakhanchi, Dang, Pyuthan, Sallyan, Rolpa, Rukum, Bajura, Bajhang,
Baitadi and Darchula districts. Preliminary studies indicate that there is a
possibility to find more than 2.5 billion tons of cement grade limestone
deposits only in the lower Himalayan region. Annual production of limestone
in 2018 was 6,621,614.96 metric tonnes. The cement industry has
experienced a sudden surge in demand due because of increasing demand
of the construction taking place these days. It is estimated that Nepal imports
about 15-20 % of the total cement consumed. The total FDI in this sector till
date is approximately NPR 4.1 billion (USD 40 million).