CEMENT

MANUFACTURE

CHE 432
INDUSTRIAL PROCESS
 Definition for cement:
• Finely ground material
formed by addition of water,
binding paste capable of
hardening under water or air
and binding together
particulate materials
• Cement and concrete not
synonymous terms
• Concrete – artificial stone
made from a carefully
controlled mixture of cement,
water, and fine and coarse
aggregate (usu. Sand and
coarse rock)
 History
• Cement used by Egyptians to construct
Pyramids.
• Greek and Romans used volcanic tuff
mixed with lime for cement
• 1824, Joseph Aspdin patented artificial
cement made by calcinations of an
argillaceous limestone.
 Advantages:
• Convenience
• Low cost
• Adaptability
• Strength
• Durability
 Functions
• Buildings
• Tunnels
• Dams
• Roads
• Decoration purposes
 Portland cements
• Definition: product obtained by pulverising
clinker consisting essentially of hydraulic
calcium silicates.
• Insuitable for corrosive conditions esp. sea
water conditions
• 5 types of portland cement:
– Type I : regular
– Type II : Moderate-heat-of hardening and
sulfate-resisting
– Type III : High-early-strength
– Type IV : Low-heat
– Type V : Sulfate-resisting
 Production of Portland cement
• Cement clinker produced by wet and dry
processes
• Wet process displaced by dry process
because saving in heat, accurate control
and mixing of raw mixtures
 Production of Portland cement
1.Raw materials preparation
Two types of materials:
a) calcium (75%) eg. Limestone, chalk
b) Silica eg. Clay
Other compounds added eg. Sand, waste
bauxite and iron ore to adjust composition,
gypsum (4-5%) added to regulate setting
time of cement.
 blasted
Limestone + clay quarries
(25mm– 1.2m)

storage yard crusher

(30 mm)
Bauxite, iron ore, coal and gypsum unloaded from
ships/ barges storage yards
2. Raw material grinding
weighed, mixed
Raw material grinding mills
drying &
coarse grinding

particles

homogenizing dynamic
silo separators usg.
air
3. Clinker burning
• Formation of clinker – important process in
cement manufacture
• Dry powdered material fed to rotary kilns
• During burning various rxns take place:
evaporation of water, evolution of CO2,
reaction between lime and clay
• Final product: Hard regular masses of 3 to
20 mm in size
• Clinker discharged from kilns (800oC) into
coolers (100oC – 200oC)
4. Cement grinding
• Final stage of grinding clinker and adding
setting retarders eg. gypsum, plaster etc.
• Resulting in cement packed
into bags or bulk cement lorries

Pollution Control:
• Main pollutant – dust particles
• Equipment used: electrostatic
precipitators, gravel bag filters, dust
collectors and water spray
 Other Cements
Pozzolans :
• grinding 2 to 4 parts of pozzolan with 1
part of hydrated lime
• Inhibit cementitious behaviour but
becomes so on mixing with lime
• Advantage: resists corrosive action of
saline solutions and seawater
High alumina cements
• Fusing mixture of limestone and bauxite
• Advantage: rapid rate of development of
strength and superior resistance to seawater
and sulfate bearing water

Silicate cements
• Resist all inorganic acids except HF
• Not suitable for pH > 7 or crystal forming
systems
• 2 parts of silica powder to 1 part sodium silicate
Sulfur cements
• Resistant to nonoxidizing acids and salts
• Not applicable for alkalies, oils, greases or
solvents
• Crystalline change in sulfur structure at 93oC
limits usage

Polymer concrete
• Consists of aggregate resins eg. Epoxy or
polyester
• Resins imparts properties eg. Rapid curing,
corrosion resistance or high compressive
strength
Pictorial flow diagram establishes key processing
steps: Cement manufacture