CLASSNOTE

ACCE-2107: INORGANIC CHEMICAL INDUSTRIES

CHAPTER: CEMENT INDUSTRIES

Cement used in construction is usually inorganic. The word cement comes from
the roman term “Opus caementicium”.

Raw materials for the manufacture of cement classified are classified into
2 groups.
a. Calcareous materials,
b. Argillaceous materials.

Calcareous materials are rich in Ca. These materials provide CaO to the
cement. They Contain less than 33% MgO. Lime stone, cement nock, chalk etc.
are example of calcareous materials.

Argillaceous materials are rich in SiO2. These materials provide SiO2, Al2O3
and Fe2O3 to the cement. Clay and shell are the examples of argillaceous
materials. They contain 2.5 to 4 times more SiO 2 than Al2O3.

General composition of cement

Ingredient Percentage in cement

CaO 66-66

SiO2 17-25

Al2O3 3-8

Fe2O3 2-6

MgO 0.1-5

Alkaline (Na2O/K2O) 0.5-1.5

SO3 1-1.3

Basic Raw materials are found in the cement as the following formations-
 C3S (Tricalcium silicate) 3CaO.SiO 2
 C3A (Tricalcium aluminate) 3CaO. Al2O3

 C2S (Dicalcium silicate) 2CaO.SiO2

 C2A (Dicalcium aluminate) 2CaO. Al2O3
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ACCE-2107: INORGANIC CHEMICAL INDUSTRIES
CHAPTER: CEMENT INDUSTRIES

 C4A (Tetra calcium aluminate) 4CaO. Al 2O3

 C4AF (Tetra calcium aluminoferrite) 4CaO. Al 2O3. Fe2O3

Portland Cement

The name Portland cement was given by Joseph Aspidin in 1824. This is
because the set product of cement (sand and water) has got similar color and
strength to that of a natural stone, quarried obtained at Portland of England.

Physical properties of cement

a. Soundness of cement : Soundness refers to the ability of cement not

to shrink upon hardening. Good quality cement retains volume after
setting without delayed expansion which is caused by excessive free
time and magnesia.
b. Strength of cement: Three types of strength cement are measured-
compressive, tensile and flexural. Various factors affect the strength
such as H2O-cement ratio, aggregate ratio, curing conditions, manners
of molding, loading conditions etc.

Compressive strength varies from 2500 psi to 400psi.

Tensile strength varies from 300 psi to 700 psi.
Flexural strength varies from 400 to 500 psi.

c. Setting time of cement: Cement sets and hardens when water is

added. Setting time can vary depending on multiple factors such as
fineness of cement, cement-H2O ratio etc. Initial setting time is not
too low and final setting time is not too high. Initial set typically occurs
within 30-45 mins. Final setting time occurs below 10 hours.

d. Specific gravity

e. Bulk density of cement: Cement has a varying range of density

depending on the cement percentage. Density of cement may be from
62-78 lb./ft3.
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ACCE-2107: INORGANIC CHEMICAL INDUSTRIES
CHAPTER: CEMENT INDUSTRIES

f. Fineness of cement : The size of cement particle is known as the

fineness of. It can be achieved through grinding.
g. Heat of hydration: When H2O is added to cement, the reaction takes
place is called hydration. Hydration generates heat. It is calculated by
determining the difference between dry and hydrated cement.
h. Loss of ignition : Heating of cement sample at 900o C-1000o C causes
weight loss. Less weight of cement is calculated as loss of ignition.

Chemical properties of cement(Functions of ingredients)

Lime:
 Deficiency of lime reduces the strength of the cement.
 Deficiency of lime causes the cement set quickly.
Silica:
 Imparts strength of the cement.
Alumina:
 Alumina imparts quick setting property of cement.
 Excess alumina weakens the cement.
Magnesia:
 Excess Magnesia reduces the strength of cement.
Iron oxide:
 Imparts color of the cement.
Sulphur Trioxide:
 Excess SO3 causes the cement to unsound.
Alkaline:
 Excess alkaline matters cause efflorescence.
 Efflorescence appears as a white deposit of mineral salts on face of
concrete walls and floors.
C2S: It is responsible for the progressive strength of the cement. A higher
percentage of C2S results in slow hardening, less heat of hydration & great
resistance to chemical attack. It hydrates and hardens slowly and takes a long
time to add to the strength(1 year).

C3S: It undergoes hydration within one within one week and helps in the
development of strength of cement.
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ACCE-2107: INORGANIC CHEMICAL INDUSTRIES
CHAPTER: CEMENT INDUSTRIES

C4AF: The amount of C4AF is responsible for flash set but generates less
heat. It has poorest cementing value, raising the C4AF cement reduces the
strength slightly. It is responsible for long term gain of strength of the
cement.

C4A: It acts as a filler, contributes very little strength, concrete even though
it hydrates very rapidly.

C3A: It is the most reactive component and its hydration has an impact on the
workability and early strength of concrete.

Flash setting of cement

Flash set is the stiffening of the cement paste within a few minutes after
mixing the compound C3A in fast reacting with H20 and may lead to a
immediate stiffening of paste.

White cement
It is manufactured from pure limestone & clay that is totally free from Fe 2O3
and other pigments. It is comparatively costly and is therefore used only
selectively. It is mainly used for making highways curbs and for a variety of
ornament work.

Colored cement
In this type of cement pigment is mixed with the cement in a definite
proportion. I amount of pigment is used depends upon the shade of the desired
color. Chromium oxide is used for green color, Co is used for blue color, Mn
dioxide is used for black or brown color. Colored cement is extensively used
for top coat in flooring and for decorative purposes in various places in a
building.

Pozzolana Cement
It contains a mixture of alumina silicate and Ca silicate with small amount of
Fe silicate. It is obtained by mixing these components with lime. Pozzolana
cement is hydraulic in nature. It produces less heat. Due to this property, it
can be used in mega projects. It offers greater resistance to sulphates and
corrosive actions of sea water. Therefore, it is more useful for construction
near or along the coast and also in sulphate soil. It can be used in sewage works
and for under water construction.
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ACCE-2107: INORGANIC CHEMICAL INDUSTRIES
CHAPTER: CEMENT INDUSTRIES

Slag Cement

It is a modified type of Contains cement which (25/%-65%) of slag. It is

manufact by grinding clinker with slag. A small Percent of gypsum is added.
It is economical Compared to ordinary cement. It produces low heat. This
property makes it useful for use in mega projects like dams.

Slug is a waste product from blast furnace. It is useful in manufacture of

highways.

Di Alumina Cement
It is manufactured by calcining of lime stone and bauxite. No other raw
material is added. It is resistant to corrosive action of acids and salts of sea
water. It generates more heat during setting. It is It is commonly used in
work near and along sea shore.
Cement is a fine binding powder; mortar is composed of cement and sand;
concrete is composed of cement, sand and grabents.
Manufacturing of cement
It is done by two methods-
a. Dry process
b. Wet process
These two processes differ only in the treatment of raw materials. In dry
process no H2O is added to material during grinding and no slurry is made.
Both the processes are very similar.
Fine particle
Size 2.5

Calcareous Crushing Grinding Screening Storage

materials basin
Fine particle
Size 2.5

Argillaceous Crushing Grinding Screening Storage Mixing in correct

materials basin proportion

Retarding agent(2-3%) Minor ingredients

Storage in Grinding of Cooler Clinker Rotary Storage tank for

silos clinker (90oC) Kiln dry raw mix

5-10 mm

Air
Fuel(coal, oil, gas)

Weighting & Distribution

packing plant

Fig: Manufacturing of cement by dry process

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ACCE-2107: INORGANIC CHEMICAL INDUSTRIES
CHAPTER: CEMENT INDUSTRIES

Fine particle
Size 2.5
Calcareous Crushing Grinding Screening Storage
materials basin

Size 2.5
Argillaceous Crushing Grinding Screening Storage Mixing in correct
materials basin proportion

Retarding agent(2-3%) Minor ingredients H2O(38%-40%)

Storage in Grinding of Cooler Clinker Rotary Wet grinding Tube

silos clinker (90oC) Kiln Mill

5-10 mm

Air
Fuel(coal, oil, gas)

Weighting & Distribution

packing plant

Fig: Manufacturing of cement by wet process

Raw materials for manufacturing of cement

a. Calcareous materials
b. Argillaceous materials
c. Fuel
d. Retarding agents
Procedure of Manufacturing of cement
a. Mixing of raw materials
b. Burning raw materials
c. Grinding of raw materials
d. Storage and packing
e. Reactions:
CaCO3 → CaO + CO2 which takes place in rotary kiln.
2 CaO + SiO2 → 2CaO.SiO2
Clinker reactions

3 CaO + SiO2 → 3CaO.SiO2

3 CaO + Al2O3 → 3CaO.Al2O3
4 CaO + Al2O3 + Fe2O3 → 4CaO.Al2O3.Fe2O3
3 CaO Al2O3 + 3 (CaSO4.2H2O) + H2O → 3CaO.Al2O3 3 CaSO4. 3H2O
 CLASSNOTE
ACCE-2107: INORGANIC CHEMICAL INDUSTRIES
CHAPTER: CEMENT INDUSTRIES