A CASE STUDY ON PREPARATION OF OPC AND PPC CEMENT IN

NEPAL

A Project Report
Submitted to the Department of Chemistry, Nobel Academy Secondary School, Baneshwor Kathmandu
in the partial fulfillment for the requirement of Under Graduate Course.

By

Name of student IsmitGuragai

Grade 12 P2 (Day)
Roll no. 16
Date 2082
 RECOMMENDATION

It is certified that Mr. Ismit Guragai has carried out the project work entitled " A case study on
preparation of OPC and PPC cement in Nepal "under the my supervision/guidance. I recommend
the project work in the partial fulfillment for the under graduate science program.

...............................
Supervisor

Parmatma Mishara
Faculty of Chemistry
Nobel Academy Secondary School
Kathmandu, Nepal

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 ACKNOWLEDGEMENT
Taken this opportunity to express my respect and gratitude to my esteemed guide Mr. Ishan
Guragai for his valuable guidance in making this project a reality. I am thankful to his for his
constant support and encouragement and valuable supervision, guidance and encouragement
through out this project completion period.

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 EVALUATION

We certified that we have read this project report and in our opinion, it is good in the subject
matter and quality as project work in partial fulfillment for the requirement of under graduate
science program.

Evaluation Committee

.............................. .................................
Supervisor Pramatma Mishra
Pramatma Mishra Head of Department
Nobel Academy
Kathmandu, Nepal

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ABSTRACT
Cement is a fundamental construction material, and its production plays a crucial role in
Nepal's infrastructure development. This case study focuses on the manufacturing processes
of Ordinary Portland Cement (OPC) and Portland Pozzolana Cement (PPC) in Nepal.
The study explores the raw materials used, production techniques, and the differences
between the two types of cement in terms of composition, strength, durability, and
environmental impact.

OPC is manufactured primarily using limestone, clay, and gypsum, while PPC incorporates
fly ash or pozzolanic materials, making it more eco-friendly. The production process involves
mining, crushing, grinding, clinkerization, and final blending. Nepal houses several cement
industries that contribute significantly to the economy, but challenges such as energy
consumption, environmental concerns, and the need for sustainable alternatives remain.

This study highlights the advantages and limitations of both OPC and PPC, along with
Nepal's cement industry's growth potential. Understanding these factors can help promote
sustainable cement production and efficient usage in Nepal's construction sector.

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PREFACE Chemical equilibrium is a fascinating concept that lies at the heart of nu

Cement is one of the most essential materials in the construction industry, playing a vital role
in infrastructure development. This case study, titled "Preparation of OPC and PPC
Cement in Nepal," aims to provide a detailed understanding of the manufacturing processes,
raw materials, and differences between Ordinary Portland Cement (OPC) and Portland
Pozzolana Cement (PPC).

The study explores how cement industries in Nepal produce these two types of cement, the
significance of their composition, and their applications in construction. Additionally, it
highlights the challenges faced by Nepal’s cement sector and the potential for sustainable
production practices.

The objective of this project is to enhance knowledge about cement production and its impact
on the environment, economy, and infrastructure. I hope this study will be beneficial for
students, researchers, and professionals interested in the field of material science and civil
engineering.

I sincerely hope that this case study meets the expectations of my mentors and provides
valuable insights into Nepal’s cement industry.

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 TABLE OF CONTENT
Certificate………………………………………………………………………………………………...................
Declaration……………………………………………………………………………………………………………….
Abstract……………………………………………………………………………………………………………………
Acknowledgment……………………………………………………………………………………………………
1 Introduction………………………………………………………………………………………………………..
2 Raw materials for cement production…………………………………………………………………
3 Major considerations while selecting raw materials…………………………………………….
4 Types of raw materials………………………………………………………………………………………..
5 Main steps in cement production………………………………………………………………………..
6 Types of cement………………………………………………………………………………………………….
7 Composition of the cement…………………………………………………………………………………
8 Difference between OPC and PPC………………………………………………………………………..
9 Flow sheet diagram for Portland cement…………………………………………………………….
10 Conclusion…………………………………………………………………………………………………………
11 Bibliography……………………………………………………………………………………………………….

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 Introduction:
 Cement is one of the most important construction materials, essential for
infrastructure development in Nepal and worldwide. Among various types of
cement, Ordinary Portland Cement (OPC) and Portland Pozzolana Cement
(PPC) are the most widely used due to their strength, durability, and versatility.
The production of these cements involves several processes, including the
extraction of raw materials, clinkerization, grinding, and blending, which
significantly impact the economy and environment.

In Nepal, the cement industry has been growing rapidly due to increasing
demand for housing, roads, bridges, and commercial infrastructure. The
country has several cement manufacturing plants that produce both OPC and
PPC using locally available limestone and imported additives like gypsum
and fly ash. While OPC is known for its quick setting and high strength, PPC
is preferred for its improved durability and environmental benefits.

This study aims to analyze the preparation process of OPC and PPC cement
in Nepal, compare their properties, and highlight the advantages and
challenges associated with their production. Additionally, it explores the role
of Nepalese cement industries in meeting the country's construction needs
while addressing sustainability concerns.

This case study will provide a comprehensive understanding of cement

production in Nepal, helping to assess the industry's future potential and
environmental impact.

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  Raw Materials for Cement Production
 The production of cement requires a combination of naturally occurring and
industrially processed raw materials. These materials provide the necessary
chemical components for the formation of clinker, which is the primary
ingredient in cement. The key raw materials used in the production of
Ordinary Portland Cement (OPC) and Portland Pozzolana Cement (PPC)
are:

1. Primary Raw Materials

1. Limestone (CaCO₃) – The main source of calcium carbonate, which

forms the primary component of clinker. It is the most important raw
material, usually making up 60-65% of the cement composition.
2. Clay/Shale (Al₂O₃, SiO₂, Fe₂O₃) – Provides silica, alumina, and iron
oxide, which are essential for forming the chemical compounds in
cement.
3. Gypsum (CaSO₄·2H₂O) – Added during the final grinding process
to regulate the setting time of cement.

2. Additional Raw Materials (For PPC Cement)

1. Fly Ash – A by-product of coal-fired power plants, rich in silica,

improves durability and reduces the environmental impact of cement
production.
2. Pozzolanic Materials (Volcanic Ash, Rice Husk Ash, etc.) –
Helps enhance the long-term strength and workability of PPC
cement.

3. Minor Additives (Optional)

 Iron Ore – Used to adjust the iron content in the raw mix.
 Bauxite – Provides additional alumina, improving cement properties.

Raw Material Proportions in OPC and PPC

Raw Material OPC (%) PPC (%)

Limestone 60-65% 55-60%

Clay/Shale 20-25% 15-20%

Gypsum 3-5% 3-5%

Fly Ash/Pozzolana 0% 15-35%

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 Major Considerations While Selecting Raw Materials
for Cement Production
 The selection of raw materials is a critical step in cement manufacturing, as
it directly affects the quality, strength, cost, and sustainability of the final
product. The key factors considered while selecting raw materials for
Ordinary Portland Cement (OPC) and Portland Pozzolana Cement
(PPC) production include:

1. Chemical Composition

 Calcium Oxide (CaO) – Essential for clinker formation, primarily

obtained from limestone.
 Silica (SiO₂) – Contributes to cement strength, sourced from clay or sand.
 Alumina (Al₂O₃) – Improves the setting properties, obtained from
clay, bauxite, or shale.
 Iron Oxide (Fe₂O₃) – Enhances cement color and strength, derived
from iron ore or clay.
 Sulfur Content – Excess sulfur can lead to clinker quality issues
and operational challenges.

2. Availability and Cost

 Locally Available vs. Imported Materials – Locally sourced

limestone reduces transportation costs, whereas gypsum and fly
ash are often imported in Nepal.
 Extraction and Processing Costs – The ease of mining and refining
raw materials affects overall production expenses.

3. Physical Properties

 Fineness – Fine raw materials lead to better mixing and reaction

during clinker formation.
 Moisture Content – Excess moisture affects grinding
efficiency and fuel consumption.
 Hardness – Harder materials require more energy for crushing and grinding.

4. Environmental and Sustainability Factors

 CO₂ Emissions – Reducing clinker content by using alternative

materials (e.g., fly ash, slag) lowers carbon footprint.
 Waste Utilization – Using industrial by-products like fly ash and
slag enhances sustainability.
 Energy Efficiency – Raw materials that require less processing help conserve
energy.

5. Suitability for Cement Type

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 OPC – Requires high-purity limestone and clay for strong and fast-setting
cement.
  PPC – Needs pozzolanic materials (fly ash, volcanic ash) for improved
durability and eco-friendliness.

6. Impact on Final Cement Properties

 Strength & Durability – The chemical composition of raw

materials affects compressive strength and lifespan.
 Setting Time – Gypsum controls the setting time; variations can lead
to undesirable curing properties.
 Workability – The fineness and blend of raw materials influence the
ease of mixing and application.

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 Main Steps in Cement Production
 The production of cement involves a series of well-defined processes, from the extraction of
raw materials to the final grinding and packaging of the product. Below are the key steps in
the cement production process:

1. Mining and Extraction of Raw Materials

 Limestone, clay, and other raw materials are extracted from quarries or mines.
 The limestone is the primary source of calcium oxide (CaO), while clay provides
silica (SiO₂), alumina (Al₂O₃), and iron oxide (Fe₂O₃), which are essential for clinker
formation.

2. Crushing and Grinding of Raw Materials

 The extracted materials are transported to the crusher, where they are broken down
into smaller pieces.
 After crushing, the raw materials are ground into a fine powder, typically using ball
mills or vertical mills. This grinding process helps increase the surface area of the raw
materials, improving the efficiency of the subsequent chemical reactions.

3. Blending and Homogenization

 The powdered raw materials are mixed in the correct proportions to achieve the
desired chemical composition.
 Homogenization ensures that the materials are uniformly mixed, and any variations
in composition are minimized. This is typically done in large storage silos or blending
beds.

4. Heating (Clinkerization)

 The homogeneous raw mix is heated in a rotary kiln at temperatures around 1400°C
to 1600°C, a process known as clinkerization.
 The intense heat causes chemical reactions between the raw materials, leading to the
formation of clinker, which consists mainly of compounds like tricalcium silicate
(C₃S), dicalcium silicate (C₂S), tricalcium aluminate (C₃A), and tetracalcium
aluminoferrite (C₄AF).
 Fuels, such as coal or natural gas, are used to heat the kiln, and this is where a
significant amount of energy is consumed.

5. Cooling and Final Grinding

 The clinker produced in the kiln is extremely hot (around 1000°C), so it needs to be
rapidly cooled in a cooler to prevent over-hydration when mixed with water.
 After cooling, the clinker is finely ground with gypsum (to regulate setting time) and
any other additives (such as fly ash for PPC) to produce cement. The grinding
process helps achieve the desired fineness and particle size distribution for optimal
performance.

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6. Packaging and Distribution

 The finished cement is then packaged in bags or bulk containers, depending on

customer requirements.
 The cement is ready for transportation to the market or construction sites. In some
cases, it may be stored in silos before distribution.

7. Quality Control

 Throughout the cement production process, various tests are performed to ensure the
quality of the product. These include tests for fineness, strength, chemical
composition, and setting time.
 Laboratories are often used to check the raw materials, clinker, and final cement to
ensure compliance with industry standards and specifications.

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 Types of Raw Materials Used in Cement Production
 Cement manufacturing requires various raw materials, which can be classified into primary
raw materials, secondary raw materials, and additives. These materials contribute to the
chemical composition and properties of the final cement product.

1. Primary Raw Materials

These are the essential ingredients for cement production, forming the main chemical
components of clinker.

a) Calcareous Materials (Source of Calcium Oxide - CaO)

 Limestone (CaCO₃) – The most important raw material, providing calcium oxide for
clinker formation.
 Chalk – A soft, fine-grained limestone used in some cement plants.
 Marl – A mixture of clay and limestone with a balanced composition of calcium and
silica.

b) Argillaceous Materials (Source of Silica, Alumina, and Iron Oxide - SiO₂, Al₂O₃,
Fe₂O₃)

 Clay – Provides silica (SiO₂) and alumina (Al₂O₃) necessary for the cement structure.
 Shale – A fine-grained sedimentary rock rich in silica and alumina.
 Slate – Another source of alumina and silica, used in some cement plants.

2. Secondary Raw Materials

These materials help adjust the chemical composition and improve specific properties of the
cement.

 Gypsum (CaSO₄·2H₂O) – Added during final grinding to regulate setting time.

 Iron Ore (Fe₂O₃) – Enhances the strength and color of cement.
 Bauxite (Al₂O₃) – Increases alumina content to improve early strength development.

3. Additives and Supplementary Materials

These materials are used in specific types of cement, such as PPC and blended cements, to
improve performance and sustainability.

 Fly Ash – A by-product from coal-fired power plants, used in Portland Pozzolana
Cement (PPC) to enhance durability and reduce environmental impact.
 Pozzolanic Materials – Natural or artificial materials (volcanic ash, rice husk ash,
silica fume) that improve cement strength and resistance to chemical attacks.
 Slag (Ground Granulated Blast Furnace Slag - GGBFS) – A by-product of steel
manufacturing used in blended cement for improved strength and sustainability.
 Limestone Powder – Sometimes added to reduce clinker content and improve
workability.

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 Classification Based on Function

Category Examples Purpose

Calcareous Limestone, Chalk, Marl Source of Calcium Oxide (CaO)

Argillaceous Clay, Shale, Slate Provides Silica (SiO₂) and Alumina (Al₂O₃)

Corrective Iron Ore, Bauxite Adjusts Iron (Fe₂O₃) and Alumina content
Materials

Setting Regulators Gypsum Controls setting time

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 Composition of Cement
 Cement is a finely ground material that, when mixed with water, hardens into a strong
binding agent used in construction. Its composition is primarily determined by the
chemical compounds formed during the clinkerization process. The main compounds
found in cement are calcium silicates, aluminates, and ferrites, each contributing to
different properties of the cement.

Key Chemical Compounds in Cement

1. Tricalcium Silicate (C₃S) – 40-60%

o Formula: 3CaO·SiO₂
o Contribution: Provides early strength development. C₃S reacts quickly with
water to form calcium silicate hydrate (C-S-H), which is responsible for most
of the strength in the initial stages of setting and hardening.
o Properties: Hardens rapidly and is essential for strength in the early stages of
curing.
2. Dicalcium Silicate (C₂S) – 15-30%
o Formula: 2CaO·SiO₂
o Contribution: Contributes to long-term strength development. It hydrates
more slowly than C₃S but continues to strengthen over time.
o Properties: Provides strength over a longer period, making it crucial for long-
term durability.
3. Tricalcium Aluminate (C₃A) – 5-15%
o Formula: 3CaO·Al₂O₃
o Contribution: Responsible for the setting time of cement and early
hydration. It reacts rapidly with water, leading to the formation of calcium
aluminate hydrates.
o Properties: Reacts quickly with water and influences the initial set of cement.
It can also lead to high heat generation, especially in mass concrete pours.
4. Tetracalcium Aluminoferrite (C₄AF) – 5-15%
o Formula: 4CaO·Al₂O₃·Fe₂O₃
o Contribution: Improves the workability of cement and contributes to the
color of the final product (it often imparts a grayish hue).
o Properties: It is involved in the formation of minor hydration products and
helps in reducing the clinkerization temperature, which lowers the energy
requirement in cement production.

Additional Compounds and Materials

1. Gypsum (CaSO₄·2H₂O) – Typically 3-5%

o Added to the final grind of cement to control the setting time of cement. It
prevents the cement from setting too quickly after mixing with water.
2. Pozzolanic Materials (for PPC) – Can be 15-35%
o Fly Ash, Volcanic Ash, and Rice Husk Ash. These materials contribute to the
strength, durability, and workability of the cement, while also making it
more eco-friendly by reducing the amount of clinker required in the mix.
3. Minor Oxides –
o Magnesium Oxide (MgO): Present in small quantities, it can affect the
durability of cement.
o Alkali Oxides (Na₂O, K₂O): In small amounts, these oxides do not
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 Typical Composition of Ordinary Portland Cement (OPC)

Compound Typical Range (%)

Tricalcium Silicate (C₃S) 50-60%

Dicalcium Silicate (C₂S) 15-30%

Tricalcium Aluminate (C₃A) 5-10%

Tetracalcium Aluminoferrite (C₄AF) 5-15%

Gypsum (CaSO₄) 3-5%

Other Compounds Small amounts (≤5%)

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  Difference between OPC and PPC cement.
0rdinary Portland cement(OPC) Pozzolana Portland cement(PPC)
1. No fly ash or volcanic ashes are 1. Pozzolana materials like fly ash,
present. volcanic ash are added to OPC to make
2. This cement has synthectic things PPC.
therefore,it is less eco- 2. It uses natural and industrial waste
friendlythan PPC. anfd reduce environmental pollution.
3. It is generally used for 3. It is highly resistant to sulphate
constructions. attacks,it is primarily used in
construction of dams,
foundation,building near
reservoir,marine construction etc.

 Flowsheet diagram for portland cement:

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Fig: Flow sheet diagram for Portland cement

Conclusion
The cement industry in Nepal plays a crucial role in supporting the country's rapidly growing
construction sector. Both Ordinary Portland Cement (OPC) and Pozzolana Portland
Cement (PPC) are widely used in various construction projects, but each serves a different
purpose based on its properties. OPC is ideal for projects requiring quick strength gain, while
PPC is gaining preference for its long-term durability, cost-effectiveness, and environmental
benefits.

The production of both types of cement in Nepal faces unique challenges, such as limited
access to consistent energy supply, transportation issues due to the country's rugged terrain,
and the quality control of raw materials like fly ash for PPC. Despite these challenges, the
industry has made strides in meeting growing demand while incorporating more sustainable
practices, especially with the increasing use of PPC, which reduces the carbon footprint and
promotes environmental sustainability.

Moving forward, the cement industry in Nepal can benefit from investing in renewable
energy sources, improving raw material sourcing and logistics, and enhancing quality control
measures to ensure consistency in PPC production. By embracing these practices, Nepal can
not only meet its domestic cement demand but also contribute to the global efforts in
reducing the environmental impact of the construction sector.

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Bibliography
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and Growth Prospects. Nepal Economic Review. Retrieved from:
[Link]
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Technology. 9(1), 35-45.
3. Nepal Bureau of Standards and Metrology (NBSM). (2016). Nepal Cement
Industry and Standards Overview. Kathmandu: Government of Nepal.
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and Opportunities. Nepal Power Sector Review.
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Production in Nepal and Environmental Impact. Retrieved from: [Link]
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Cement Production. International Cement Review. Retrieved from: [Link]
8. Koirala, H., & Bista, R. (2020). Fly Ash Utilization in Cement Production: Case
Study of Nepal. Journal of Environmental Sustainability, 11(2), 67-76.
9. Bureau of Energy Efficiency (BEE). (2017). Energy Management in Cement
Industry: A Case Study in Nepal. Retrieved from: [Link]
10. Nepal Cement Manufacturers' Association (NCMA). (2021). Report on Cement
Manufacturing in Nepal. Kathmandu, Nepal.

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