HISTORY

Natural cement is assumed to have existed on earth as a result of the earth having undergone
intense geological change for at least 12 million years. Natural cement was utilized for
construction in the past, but as time passed and technology advanced, man discovered how to
make cement using various materials.
Today's cement has a wide range of features and attributes. The advancement of technology has
transformed the entire dimension of the cement manufacturing process, resulting in higher-
quality cement. Analysis and study of the cement manufacturing process, as well as its use in the
past, helped cement become such an important material in the construction process and the
development of human civilization.

INTRODUCTION
Reliance Cement P. Ltd., a renowned cement brand in Nepal, was established in 2005. It is
situated in semari of Rupandehi, which is 7 km west from Bhairahawa city. Bhairahawa lies near
the ancient site of Lumbini, where Siddhartha Gautam was born. A government policy bans the
operation of factories within a 15 km radius of the holy site. The city also has a relatively good
infrastructure. Similarly, it is easy to get to different parts of the country by road, as the town is
connected to key highways.
Reliance Cement has a capacity of 500 TPD of Portland Pozzolana Cement (PPC) and Ordinary
Portland Cement (OPC). This company plays a vital role in development in the economic growth
in Nepal .

COMPOSITION OF CEMENT
The raw materials used for manufacturing cement are mostly natural that is used in the making of
cement. The major raw ingredients Reliance cement P. Ltd., used for cement manufacturing are
lime, silica, alumina, iron oxide and magnesium oxide. Here, limestone are extracted from quarry
and processed it further to make clinker and gypsum to it at the final stage to produce cement.
1. Lime Stone
Limestone is the main raw material of cement and is composed mainly of calcium
carbonate. Limestone required for cement production is estimated about 85 percent.
Lesser than the required amount will bring about diminishing in the quality of the
concrete.
2. Silica (SiO2)
It reacts chemically with calcium to generate hard silicate, which reduces the cement's
strength. It also interacts chemically with calcium and forms hard silicates, which are in
charge of ensuring the concrete's quality.
3. Alumina or dirt
Al2O3 (aluminum oxide) is a common engineering material. It has a good
combination of mechanical and electrical qualities, making it suitable for a wide range of
applications. The setting quality of concrete is conferred by alumina, which frames
complex aluminates with silica and calcium.
4. Iron Oxide
The majority of the time, this gives shading to the concrete. Aside from that, it gets
into the substance mix and improves the quality and hardness of the concrete.
5. Magnesium Oxide (MgO)
MgO provides quality and hardness to the concrete.

6. Gypsum
It is added to control the “setting of cement”. If not added, the cement will set
immediately after mixing of water leaving no time for concrete placing. During the
cement manufacturing process, upon the cooling of clinker, a small amount of gypsum is
introduced during the final grinding process.
 7. Clinker
Reliance cement P. Ltd. procure the clinker and process further to produce cement.

Major Pollutants from a Cement Factory

The cement sector is the third largest industrial source of pollution, emitting more than 500,000
tons per year sulfur dioxide, nitrogen oxide and carbon monoxide. In today’s business world,
environment issue has been a hot topic and center concern for every business sector. Some of the
major pollutants are:

1. Carbon dioxide
During the clinker burning process, CO2 is emitted. CO2 is responsible for the
main share of these gases. These are produced during limestone decarbonation
(CaCO3) and account for about 60% of total CO2 emmisions.
2. Dust
To manufacture 1 ton of Portland cement, about 1.5 to 1.7 ton of raw materials,
0.1-ton coal and 1-ton clinker (besides other cement constituents and Sulphate agents)
must be ground to dust fineness during production. In this process, the steps of raw
material processing, fuel preparation, clinker burning, and cement grinding constitute
major emission sources for particulate components.
3. Nitrogen oxide (NOx)
The clinker burning process is a high-temperature process resulting in the
formation of nitrogen oxides (NOx). The amount formed is directly related to the
main flame temperature (typically 1850 – 2000 °C). Nitrogen Monoxide (NO)
accounts for about 95 %, and nitrogen dioxide (NO2) for about 5 % of this compound
present in the exhaust gas of rotary kiln plants. As most of the NO is converted to
NO2 in the atmosphere, emissions are given as NO2 per cubic meter exhaust gas.
After the formation of thermal NO, staged combustion is done to reduce NO. This
causes CO to form which then reduces the NO into molecular nitrogen:
2 CO + 2 NO 2 CO2 + N2
4. Sulfur dioxide (SO2)
Sulfur is input into clinker burning process via raw materials and fuels.
Depending on their origin, the raw materials may contain sulfur bound as sulfide or
sulfate. Higher SO2 emissions by rotary kiln systems in the cement industry are
frequently attributed to sulfides in the raw material, which are oxidized to create SO2
at temperatures in the kiln preheater between 370°C and 420°C.
5. Carbon monoxide (CO)
The modest amounts of organic elements introduced via natural raw materials
create CO and organically bound carbon emissions during the clinker burning
process. These are transformed to CO and CO2 during the kiln feed preheating
 process. Small amounts of organic trace gases (total organic carbon) are also
generated during this process.
6. Chlorine compounds (HCL)
Chlorides are minor additional constituents contained in the raw materials and
fuels of the clinker burning process. When the fuels are burned or the kiln feed is heated,
they are released, and they mostly react with the alkalis in the kiln feed to generate alkali
chlorides. Gaseous inorganic chlorine compounds are emitted in extremely small
amounts or none at all during the clinker burning process.