Cement Industry

Submitted to: Mr. Waqas Iqbal

Submitted by: Mr. Ubaid Mehmood

Mr. Hamza Sohail
Mr. Iftikhar Saleem
Cement(CaSiO3)

 A powdery substance made by calcining lime and clay,

mixed with water to form mortar, or mixed with sand,
gravel, and water to make concrete.
History of Cement

 It is believed that the early Egyptians mostly used

cementing materials, obtained by burning gypsum
 The early Greeks and Romans used cementing
materials, obtained by burning lime stones
 (1756) L.J.Vicat prepared an artificial hydraulic lime
by calcining an intimate mixture of limestone and clay
 (1800) The invention of Portland cement is attributed
to Joseph Aspdin
 In India, Portland cement was first manufactured in
1904 near Madras, by the South India Industrial Ltd
Process of Cement
Manufacturing
 Wet Process
 Dry Process
Wet Process

 The wet process includes 4 processes, which are:

1.Quarrying:

In this step, lime and stone are mixed together. About

80% limestone and 20% clay are ground
in ball mills with water, producing a
very fine, thin paste, called slurry
2. Grinding:
The limestone and clay are mixed with water to form a slurry
Cont…

3. Burning:
The slurry is burned to a very high temperature (900-1600
°C) in a kiln, to produce clinker
4. Grinding:
The clinker is mixed and grind with about 5% gypsum to
make cement
Dry Process(Portland Cement)

 Portland Cement → Gypsum + Portland Cement Clinker

(pulverizing)

 Portland Cement Clinker → Calcareous & Clayey Materials

(burning)

 Paste → P.C(Portland Cement) + Water

 Mortar → P.C. + Water + Sand

 Concrete → P.C. + Water + Sand + Gravel

Raw Material

1) Calcareous Rocks (CaCO3 > 75%)

 Limestone
 Marl
 Chalk
 Marine shell deposits

2) Argillocalcareous Rocks (40%<CaCO3<75%)

 Cement rock
 Clayey limestone
 Clayey marl
 Clayey chalk
Raw Material Cont…

3) Argillaceous Rocks (CaCO3 < 40%)

 Clays
 Shales
 Slates

 Portland cement is made by mixing substances containing

CaCO3 with substances containing SiO2, Al2O3, Fe2O3 and
heating them to a clinker which is subsequently ground to
powder and mixed with 2-6 % gypsum
Clinker gypsum
Clinker
 Production Steps

1) Raw materials are crushed, screemed & stockpiled.

2) Raw materials are mixed with definite proportions to obtain a

“raw mix”. They are mixed either dry (dry mixing) or by water
(wet mixing)

3) The Prepared raw mix is fed into the rotary kiln

4) As the materials pass through the kiln and their temperature is

raised upto 1300-1600 °C. The process of heating is
called“burning”. The output is known as “clinker”, which is
0.15-5 cm in diameter
Processing Steps Cont…

5) Clinker is cooled & stored

6) Clinker is ground with gypsum (3-6%) to

adjust the setting time

7) Packing & marketting

Reaction in the Kiln

~100°C→ free water evaporates

~150-350C°→ loosely bound water is lost from clay

~350-650°C→decomposition of clay→SiO2&Al2O3
~600°C→decomposition of

MgCO3→MgO&CO2 (evaporates)

~900°C→decomposition of

CaCO3→CaO&CO2 (evaporates)
Reaction cont…

 ~1250-1280°C→liquid formation and start of compound

formation

 ~1280°C→clinkering begins

 ~1400-1500°C→clinkering

 ~100°C→clinker leaves the kiln and falls into a cooler

 Sometimes the burning process of raw materials is

performed in two stages: preheating upto 900°C and the
sending it to the rotary kiln
Chemical Composition of P.C

 Portland cement is composed of four major oxides (CaO, SiO 2,

Al2O3, Fe2O3 ≥90%) & some minor oxides. Minor refers to the
quantity that is not of importance

 CaO→limestone
 SiO2-Al2O3→Clay
 Fe2O3→Impurity in Clays
 SO3→from gypsum, not from the clinker
Impurities In Cement

 Alkalies (Na2O & K2O) may cause some

dificulties if the cement is used with certain
types of reactive aggregates in making
concrete. The alkalies in the form of alkaline
hydroxides can react with the reactive silica of
the aggregate and resulting in volume
expansion after hardening. This process may
take years.

 Na2O & K2O ≤ 0.6%

Impurities Cont…

 Insoluble Residue: is that fraction of cement which is

insoluble in HCl. It comes mainly from the silica which has
not reacted to form compounds during the burning process
in the kiln. All compounds of Portland cement is soluble in
HCl, except the silica.

 The amount of insoluble residue is determined by chemical

analysis, which indicates the completion of the reactions in
the kiln.

 ASTM C 150 → Insoluble residue ≤ 0.75%

Any Questions