Cement Manufacturing

Cement Definition
• Cement is a fine powder, obtained from the calcination at 1,450°C of a mix
of limestone, clay, and iron ore.
• substance used for binding and hardening other materials
Cement Chemistry Notation based on Oxides

Oxide Form Notation

CaO C
SiO2 S
Al2O3 A
Fe2O3 F
SO3 𝑆−
H2O H
Cement Minerals and Products Notation
 Cement Ingredients
• Lime
• Silica
• Alumina
• Magnesia
• Iron oxide
• Calcium Sulfate
• Sulfur trioxide
• Alkaline
 Functions of Cement Ingredients
• Lime - calcium oxide or calcium hydroxide
• Presence of lime in a sufficient quantity is required to form silicates and aluminates of
calcium.
• Deficiency in lime reduces the strength of property to the cement.
• Deficiency in lime causes cement to set quickly.
• Excessive presence of lime cause cement to expand and disintegrate.
 Functions of Cement Ingredients
• Silica – silicon dioxide
• Sufficient quantity of silica should be present in cement to form dicalcium and
tricalcium silicate.
• Silica imparts strength to cement.
• Silica usually present to the extent of about 30 percent in cement
 Functions of Cement Ingredients
• Alumina – aluminum oxide
• Imparts quick setting property to the cement
• Clinkering temperature is lowered by the presence of the requisite quantity of alumina.
• Excess alumina weakens the cement.
 Functions of Cement Ingredients
• Magnesia – Magnesium oxide
• Magnesia should not be present more than 2% in cement.
• Excess magnesia will reduce the strength of the cement

• Calcium Sulfate
• This is present in cement in the form of gypsum(CaSO4.2H2O)
• It slows down or retards the setting action of cement.
 Functions of Cement Ingredients
• Sulfur trioxide
• Should not be present more than 2%.
• Excess Sulfur Trioxide increases expansion in lime and sulfate
• Beyond 3%, increases the drying shrinkage for all cement
• Concrete strength data indicate that for cements low in alkali and aluminate content, increasing the SO3 to
3.6% increases the strength loss at 180 days.

• Alkaline
• Should not be present more than 1%.
• Excess Alkaline matter causes efflorescence.
 Functions of Cement Ingredients
• Iron oxide
• Iron oxide imparts color to cement.
• It acts as a flux.
• Tricalcium alumino-ferrite imparts hardness and strength to cement.
Some Raw Materials in the Production of Cement
 Types of Cement
• Portland cement
• Type 1: Regular Portland Cement
• Type II: Moderate-heat-of-hardening Portland
• Type III: High-early-strength cements
• Type IV: Low-heat Portland cements
• Type V: Sulfate-resisting Portland cements
• Pozzuolana Cement
• Calcium aluminate cement
• Special or corrosion-resisting cements
 Portland Cement
• "the product obtained by pulverizing clinker consisting essentially of
hydraulic calcium silicates, to which no additions have been made subsequent
to calcination other than water and/or untreated calcium sulfate, except that
additions not to exceed 1.0 percent of other materials may be interground
with the clinker at the option of the manufacturer“
• R. Norris Shreve. Second Edition. The Chemical Process Industries. McGraw-Hill Book
Company, Inc
 Types of Portland Cement
Type of Portland
Classification Characteristics Applications
Cement
Fairly high C3S content for
General construction (most buildings,
Type I General Purpose good early strength
bridges, pavements, precast units, etc.)
development
Moderate Sulfate Structures exposed to soil or water
Type II Low C3A content (<8%)
Resistance containing sulfate ions
Ground more finely, may Rapid construction, cold weather
Type III High early strength
have slightly more C3S concreting
Low heat of Low content of C3S (<50%)
Type IV Massive structures such as dams
hydration and C3A
Very low C3A content Structures exposed to high levels of
Type V High sulfate resistance
(<5%) sulfate ions
 ATTACK ON CONCRETE BY SOILS AND WATERS
CONTAINING VARIOUS SULFATE CONCENTRATIONS

* Or approved portland-pozzolan cement providing comparable sulfate resistance when used in concrete.
** Should be approved pozzolan that has been determined by tests to improve sulfate resistance when used in concrete with Type V
cement.

Source: U.S. Bureau of Reclamation, Concrete Manual, 1975, pg. 11.

 Pozzoulana Cement
• Italians have successfully employed pozzuolana cement, made by grinding
two to 4 parts of a pozzuolana with 1 part of hydrated lime.
• A "Pozzuolana” is a material which is not cementitious in itself but which
becomes so upon admixture with lime. The natural pozzuolanas are volcanic
tuffs; the artificial ones are burnt clays and shales.
 Calcium Aluminate Cement
• sometimes called high-alumina cement
• manufactured by fusing a mixture of limestone and bauxite, the latter usually
containing iron oxide, silica, magnesia, and other impurities.
• It is characterized by a very rapid rate of development of strength and
superior resistance to sea water and sulfate-bearing water.
 Special or corrosion-resisting cements
• used in large quantities for the fabrication of corrosion proof linings for
chemical equipment such as brick-lined reactors, storage tanks, absorption
towers, fume ducts and stacks, pickling tanks, floors, sumps, trenches, and.
acid digesters to name but a few.
• furane, phenolic, sulfur and silicate cements
 Dry Process Cement
Manufacturing

Source: https://theconstructor.org/building/manufacture-of-cement/13709/
Dry Process Cement Manufacturing

Source: https://gharpedia.com/dry-
process-manufacturing-cement/
 Wet Process Cement
Manufacturing

Source: https://theconstructor.org/building/manufacture-of-cement/13709/
Wet Process Cement Manufacturing

Source: https://gharpedia.com/dry-
process-manufacturing-cement/
 Comparison between
Dry and Wet Process

Source:
http://www.hkdivedi.com/2016/12/cement
-manufacturing-process-and-its.html
 Video
• Dry Process Manufacturing