Pangasinan State University

Urdaneta City, Campus

College Of Engineering and Architecture
Mechanical Engineering Department

2nd SEMESTER 2022-2023

MANUFACTURING AND INDUSTRIAL
PROCESSES

CEMENT

SUBMITTED BY:
GROUP 1
BULATAO, AARON JAY
MONIS, CLIFFORD
OLIVEROS, HANNSON MARC
BSME 4-A

SUBMITTED TO:
ENGR. ALYSSA HANNAH A. NICANOR
INSTRUCTOR
INTRODUCTION

What is a cement?

Cement is a mixture of calcareous, siliceous, argillaceous and other substances. Cement

is used as a binding material in mortar, concrete, etc.

When cement is mixed with fine aggregate (sand), it produces mortar for masonry, or
with sand and gravel, it produces concrete.

History

Cement as we know it was first developed by Joseph Aspdin, an enterprising 19th-

century British stonemason, who heated a mix of ground limestone and clay in his kitchen stove,
then pulverized the concoction into a fine powder. The result was the world's first hydraulic
cement: one that hardens when water is added

Types of Cement

Cement is mainly classified into two categories depending on the hardening and setting
mechanism. These are hydraulic cement and non-hydraulic cement.

Non-hydraulic cement doesn’t set in wet conditions or underwater. Instead, it sets because it
dries and react with carbon dioxide in the air. It is resistant to attack by chemicals once set.
Hydraulic cement (cement that not only hardens by reacting with water but also forms a water-
resistant product) is those which harden by hydration in the presence of water. Limestone, clay,
and gypsum are the main raw material to produce non-hydraulic cement. This raw material is
burned at a very high temperature to manufacture Hydraulic Cement.

Along with these main types, there are variety of types of cement that can be used depending on
project's purpose and conditions.

1. Ordinary Portland Cement

 Ordinary Portland cement is the most widely used type of cement manufactured
and used worldwide.
 “Portland” is a generic name derived from a type of building stone quarried on the
Isle of Portland in Dorset, England.
 OPC is suitable for most general concrete jobs and mortar or stucco construction
projects.

2. Portland Pozzolana Cement

 Manufacturers create Portland pozzolana cement by grinding pozzolanic clinker,
sometimes with additives of gypsum or calcium sulfate, with ordinary Portland
cement.
 Compared to OPC, it has a higher resistance to various chemical reactions within
concrete.
  PPC is often used for projects like bridges, piers, dams, marine structures, sewage
works or underwater concrete projects.

3. Rapid Hardening Cement

 Rapid Hardening Portland Cement (RHC) is suitable for the repair of roads and
bridges. Also used when the load is going to be applied in a short period of time.

4. Extra-rapid-hardening cement
 Construction professionals achieve this by adding calcium chloride to rapid-
hardening cement
 This cement type may be useful for cold-weather concrete projects due to its fast-
setting rate.
5. Quick-setting cement
 Quick-setting cement may be beneficial for time-sensitive projects or those
located near stagnant or running water.

6. Low-heat cement
 It may be suitable for mass concrete construction or projects to help prevent
cracking due to heat.
 May have a longer initial setting time than other types.
7. Sulfate-resisting cement
 helps reduce the risk of sulfate side effects on concrete.
 Its most common use is for constructing foundations in soil with high sulfate
content.
 This concrete type can also be beneficial for projects like canal linings, culverts
and retaining walls.
8. Portland Slag Cement
 Produced by mixing Portland cement clinker, gypsum and granulated blast
furnace slag which shall not exceed 65%
 blackish grey in color.
 Lesser heat of hydration.
 Suitable for marine works, mass concreting.
 Offers good resistance to the attack of sulphate.
9. High-alumina cement
 type of rapid-hardening cement created by melting bauxite and lime together and
grinding it with clinker.
 It has high compressive strength and may be more flexible and workable than
OPC.
 Construction teams can use high-alumina cement for projects where cement is
subject to extreme weather like high temperatures or frost.

10. White cement

 A type of OPC that's white instead of gray.
 It's prepared from raw materials that don't include iron oxide and may be more
expensive than other cement types.
 It's often useful in architectural projects and interior and exterior decorative
projects like designing garden paths, floors, swimming pools and ornamental
concrete products
11. Colored cement
 Suitable pigments used to impart desired color.
 Contractors often use this type for decorative purposes and projects to enhance
their designs

12. Air-entraining cement

 OPC with small quantity of air entraining materials (oils, fats, fatty acids) ground
together.
 Air is entrained in the form of tiny air bubbles which enhances workability and
reduces segregation and bleeding.
 It increases sulphate water resistance of concrete.

13. Expansive cement

  Expansive cement can grow slightly over time without shrinking during the
hardening process.
 It may be beneficial for projects like grouting anchor bolts or concrete ducts.
 Teams can also use it in structure joints or to reinforce other concrete structures.

14. Hydrophobic cement

 Manufacturers create hydrographic cement by mixing in water-repelling
chemicals.
 This cement type has high workability and strength and also repels water to
prevent weather damage.
 Teams can use hydrophobic cement for projects such as dams, water tanks,
spillways and water retaining structures.
 15. Masonry Cement
 Unlike ordinary cement, it is more plastic
 Made by mixing hydrated lime, crushed stone, granulated slag or highly colloidal
clays are mixed with it.

Process of making cement

QUARRYING THE RAW MATERIALS

The first step is to quarry the raw materials necessary to make cement, which is mainly limestone
coupled with clay and sand. Using fly ash or other byproducts to partially replace the raw
materials keeps things like fly ash and industrial byproducts out of landfills and contributes to a
circular economy.

THE PRIMARY CRUSHER

After quarrying the rock, it is crushed into baseball sized pieces. Once crushed, the raw materials
are then sent to a laboratory and analyzed – each step of the cement production process is
carefully monitored to ensure efficiency and quality
MIXING, GRINDING, AND BLENDING THE INGREDIENTS
The crushed rock is then ground finer (in this case, in a vertical roller mill) and combined with
other ingredients. Common materials used to manufacture cement include limestone, chalk, and
marl combined with shale, clay, slate, blast-furnace slag, silica sand, and iron ore. Numerous
industrial byproducts are used to supplement some or all of these components. Examples of
recycled materials that are used include spent pot liners, slags, fly ash or bottom ashes, and
various incinerator ashes

THE PREHEATER TOWER

The material then moves through the preheater tower, starting at the top and moving to the
bottom. The pre-heater tower helps make the kiln process more efficient by adding heat
generated from the plant to the raw materials, starting the chemical reaction.
Doing this makes the cement process more efficient. Cement production is one of the most
efficient in heavy industry, at approximately 80% – for comparison, a typical car runs at about
20% efficiency.
Promising innovations have been developed over the years, such as carbon capture and storage
technology, which are being evaluated and can help cement plants reduce their overall carbon
footprint.
THE MATERIALS ENTER THE KILN

The cement kiln heats all the ingredients to about 2,700 degrees Fahrenheit in huge cylindrical
steel rotary kilns lined with special firebrick and the material becomes partially molten. The
finely ground raw material is fed into the higher end of the cement kiln. At the lower end is a
roaring blast of flame, produced by the precisely controlled burning of powdered coal, oil,
alternative fuels (such as scrap vehicle tires, for example), or natural gas under forced
draft. During this process, cement manufacturers have been a leader in the use of
alternative fuels to reduce waste going to landfills. In fact, alternatives fuels now represent
more than 15% of total cement plant energy consumption in the U.S.
THE FORMATION OF CLINKER
As materials move through the kiln, certain elements are driven off in the form of gases. The
remaining elements chemically unite to form a new substance called clinker, which comes out of
the kiln as grey balls about the size of marbles.
The Clinker Is Cooled for Use

The clinker comes out of the kiln red-hot and has a consistency similar to a lava flow. It is
brought down to handling temperature in a clinker cooler. Heated air from the coolers is
returned to the kilns, a process that saves fuel and increases efficiency.
THE BALL MILL

After the clinker is cooled, it is ground with small amounts of gypsum, limestone, and other
ingredients to make cement. In this case a ball mill with steel balls is used to reach the fineness
needed to achieve desired properties. To reduce the carbon footprint by an additional 10% or
more, higher limestone contents or SCMs can be blended in. This permits cements and
concrete to achieve the same levels of strength, resiliency, and durability.
READY FOR CONSTRUCTION

The cement is ready to be used for construction projects to build long-lasting concrete structures
and pavements. Many construction projects are conveniently located within 15 miles of a
ready-mix concrete plant, again limiting energy use and emissions associated with
transportation.

Cement is the main ingredient in concrete. Concrete pound for pound is a low carbon footprint
material, lower than wood, steel, plastic, or asphalt.

As a versatile and durable material, it is the most widely produced material on earth, providing
housing, transportation, water processing and storage facilities, hospitals, and schools. It is a
foundational material for modern civilization.
Different Cement Industrial Plant in the Philippines

1.EagleCement
-Eagle Cement is the sole cement company in the Philippines with a fully integrated cement
manufacturing process from quarrying, clinker production, cement milling up to distribution.

Location: Barangay Akle, San Ildefonso, 3010 Bulakan

2. Northern Cement Corporation -It is a blended Portland cement and highly cementitious
pozzolanic materials

Location: Sison, Pangasinan

3.) Apo Cement (Under Cemex Holding Philippines)

Location: Naga City, Cebu

APO Cement in the City of Naga, Cebu, have been operating in the Philippines for multiple
decades. They offer a broad product mix and work closely with other CEMEX companies to
develop and introduce innovative products to the Philippine market.

4. Holcim Cement

La Union Plant, Quirino, Bacnotan La Union

-Premium quality general purpose cement, Holcim Excel is a special formulation of Portland
cement with advanced mineral additives, conforming to both ASTM C595 and PNS 063.
REFERENCES:

Sahu, Suschismita. (2015). Cement. Slideshare. Retrieved from:

https://www.slideshare.net/BhaswatiSharma1/1-cement-ppt?fbclid=IwAR0-
L55uQ6nDOv1zZXxGsC4yari8s_I9cbi2aiDRgryfvfoIHJ9VKZWpgig

Indeed. (2023). 15 Types of Cement and Their Common Uses in Construction. Retried from:
https://www.indeed.com/career-advice/career-development/cement-types

greenspec. (n.d). Cement: Materials and manufacturing process. Retrieved from:

https://www.greenspec.co.uk/building-design/cement-materials-and-manufacturing-process/

Syeda Tahsin Hasan. (n.d). How Cement is Made - Cement Manufacturing Process. Civil Today.
Retrieved from: https://civiltoday.com/civil-engineering-materials/cement/106-cement-
manufacturing-process.