CE 1213

Building and Construction Materials

Slide 03
Cement Manufacturing

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Md. Kawsarul Islam Kabbo
Dept. of BECM, KUET
 Cement
• WHAT IS CEMENT ?
• TYPES OF CEMENT
• PROPERTIES OF CEMENT
• MANUFACTURING OF CEMENT
• TESTING OF CEMENT
• USES OF CEMENT
 What is Cement?

•A cement is a binder, a substance used in

construction that sets and hardens and can bind
other materials together.

•Cement is essentially a binding material used

for making concrete, which in turn the basic
material for building and other construction works
 Types of Cement
There are two classes of cement
Natural Cement:
This is manufactured by burning and
crushing natural stones containing 25 to
40% of clay, the remainder being the
carbonate of lime.
It is brown in color, not so strong and
sets very quickly when mixed with water
and also called ‘Roman Cement’.
 Types of Cement
Artificial Cement:
The best variety of artificial cement is known
as ordinary portland.
Portland cement developed in England by
bricklayer Joseph Aspdin in early 1800’s.
Called “Portland” because concrete made
with it resembled natural stone from the Isle
of Portland.
This is also called ‘Normal Setting Cement’.
In most of the engineering work Portland
cement is used.
 Ty p e s o f P o r tla n d C e me n t
• Ordinary Portland cement (OPC)
• Modified Portland cement
• Portland pozzolona cement (PPC)
• Sulphate resisting cement
• Rapid hardening cement
• Portland blast furnace slag cement
• Super Sulphate cement
• White grade cement
• Quick setting cement
• Low heat cement
 Portland Cement

•Limestone + Shale/Clay + Heat = Clinker +

CKD + Exit Gas.
• Material Temperatures Exceed 2700
degrees F
•Pulverized Clinker + Gypsum = Portland
Cement.
•Cement is powder so fine that one pound
contains 150 billion grains.
 Portland Cement (cont’d)
• Basic Chemical Components of Portland Cement:
– Calcium (Ca)
– Silicon (Si)
– Aluminum (Al)
– Iron (Fe)
• Typical Raw Materials:
– Limestone (CaCO3)
– Sand (SiO2)
– Shale, Clay (SiO2, Al203, and Fe203)
– Iron Ore/Mill Scale (Fe203)
 Portland Cement (cont’d)
. Calcareous Component . Argillaceous
Component
(providing Lime - CaO) (SiO2, Al203, and Fe203)
– limestone -clay
– marly limestone -shale
– chalk -calcareous marl
– coral limestone -marl
– marble -marly clay
– lime-sand -tuff, ash
– shell deposits - phyllite ,slate
– lime sludge -glass
 Portland Cement (cont’d)
• Clinker Chemistry or Mineral Constituents
– Tricalcium silicate (3CaO.SiO2), (50-70%)
– Dicalcium silicate (2CaO.SiO2), (15-30%)
– Tricalcium aluminate (3CaO.Al2O3), (5-
10%)
–Tetracalcium aluminoferrite
(4CaO.Al2O3.Fe2O3), (5-15%)
 Composition of Ordinary Portland Cement
Ingredient Percentage Property Oxide
form

Calcium Oxide or 60% - 67% Soundness and strength CaO

Lime of cement
Silica 17% - 25% Strength to the cement SiO2
Alumina 3% - 8% Quick setting property Al2O3
Calcium sulphate 3% - 4% Increase the initial setting CaSO4
time.
Iron oxide 3% - 4% Colour, Hardness and strength Fe2O3
Magnesia oxide 0.1% - 4% Hardness and colour MgO

Sulphur Trioxide 1% - 3% Making sound cement SO3

Potassium oxide 0.3% - 1% Harmful, carried away by flue K2O

gases.
Insoluble residue 0.3% - 0.5% Impurities in gypsum
 Manufacturing of Cement
There are generally two processes adopted for
manufacturing cement
• Wet Process.

• Dry Process - 74% of cement produced.

• Preheater/Precalciner Process.
 Evolution of the cement Process

• Wet process easiest to control chemistry &

better
for moist raw materials.
• Wet process high fuel requirements
• Dry process kilns less fuel requirements
•Preheater/Precalciner further enhance fuel
efficiency & allow for high production rates.
 Wet Process of Cement Manufacturing
The manufacturing of cement by this process
is divided into three stages:
Preparation of cement slurry* To obtain
cement clinkers** To prepare cement

*Cement slurry is a mixture of Portland

cement, water, and additives.
**Portland cement clinker is ground to a fine
powder and used as the binder in many
cement products
 Ma n uf a c tur in g o f C e me n t
The manufacture of cement is a very
• A mixture of limestone and clay.
yrcr efully regulated process comprising
Quarry

the
follo• win
Th g sestto
elim ane
ges
an:d clay with water to form slurry.
Grinding

• The slurry to a very high temperature in a kiln, to

Burning produce clinker.

• The clinker with about 5% gypsum to make cement

Grinding

*Gypsum (CaSO4·2H2O ) plays a very important role in controllin

the rate of hardening of the cement. During the cement
manufacturing process, upon the cooling of clinker, a small
amount of gypsum is introduced during the final grinding process
Gypsum is added to control the “setting of cement”.
 Cement Kilns

• High temperature
• Long residence time
•Natural alkaline environment
• CKD is only by-product of the process.
• Thermal stability
 Kiln Process Control
•Critical Parameters: Fuel, Feed,
Kiln Speed, Gas Flow
• Kiln Temperatures - Burning Zone
• Kiln Stability
• Chemistry
• Instrumentation
 Manufacturing of cement
Three distinct operations are
involved in the manufacturing
of ordinary cement
1. MIXING OF RAW
MATERIAL
2. BURNING
3. GRINDING

1. MIXING OF RAW
MATERIALS :
Raw materials such as
limestone and clay are mixed
either by DRY PROCESS or
by WET PROCESS
• The raw materials are first
reduced in the size of about 25
mm in crushers in dry process.
• Wet process ( Old technology ),
cement industry underwent a
number of changes.
• In case of mixing of raw material
in wet process a SLURRY is
formed.
2. BURNING
• Carried out in a rotary kiln,
diameter varies from 8 to 12ft and
length varies from 200 to 400ft.
• Inclined about 0.5” to a foot.
• 2- 3 revolutions per minute about
its longitudinal axis.
• Temperature is about 400°F –
600°F.
3. GRINDING BALL MILLS AND TUBE MILLS
• Clinkers as obtained • Used to carry out grinding of
from rotary kiln are finely raw materials or mixture or
clinkers.
ground in ball mills and
tube mills • The ball mills are used to have
preliminary grinding and the
• GYPSUM is added about tube mills are used to carry out
3-4% during grinding. final grinding.
C e me n t
R a w mill
 Storing of Cement

• Cement should be stored in a dry place

and on a raised platform and should be
protected against wind and rain.
• Cement has better affinity for water and
absorb moisture lead to damp the cement
• Long period of storage should be avoided
 C e me n t s ilo s
• Cement silos are on-site storage containers used for the
storage and distribution of various types of cement
mixtures.
• The cement silo usually is equipped with some type of
blower to help expel the stored contents into a truck or
other receptacle.
• The cement silos have a capacity of 3500 metric ton
each and steel silo is having 700 metric ton capacity.
 Characteristics of good cement

• Provides strength to masonry and concrete.

• Stiffens or hardens early.
• Good binding material.
• An excellent building material.
• Easily workable.
• Good moisture-resistant.
 Uses of Cement

Cement plays a key, but often unnoticed, role in our

lives. Cement is mainly used as a binder in concrete,
which is a basic material for all types of construction,
including housing, roads, schools, hospitals, dams and
ports, as well as for decorative applications.
 Uses of cement
Some of the numerous functions of cement are given below

• It is used in mortar for plastering, masonry work, pointing,

etc.
• It is used for making joints for drains and pipes.
• It is used for water tightness of structure.
• It is used in concrete for laying floors, roofs and
constructing lintels, beams, stairs, pillars etc.
• It is used where hard surface is required for the protection
of exposed surfaces of structures against the destructive
agents of the weather and certain organic or inorganic
chemicals.
• It is used for precast pipes manufacturing, piles, fencing
posts etc.
• It is used in the construction of important engineering
structures such as bridges, culverts, dams, tunnels, light
houses etc.
• It is used in the preparation of foundations, water tight
floors, footpaths etc.
• It is employed for the construction of wells, water tanks,
tennis courts, lamp posts, telephone cabins, roads etc
THANK
YOU