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Cement Manufacture: CHE 432 Industrial Process
Cement Manufacture: CHE 432 Industrial Process
MANUFACTURE
CHE 432
INDUSTRIAL PROCESS
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
blasted
Limestone + clay
quarries
(25mm 1.2m)
storage yard
crusher
(30 mm)
Raw material
grinding mills
drying &
coarse
grinding
particles
homogenizing
silo
dynamic
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 CO 2,
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
Sulfur cements
Resistant to nonoxidizing acids and salts
Not applicable for alkalies, oils, greases or
solvents
Crystalline change in sulfur structure at 93 oC
limits usage
Polymer concrete
Consists of aggregate resins eg. Epoxy or
polyester
Resins imparts properties eg. Rapid curing,
corrosion resistance or high compressive
strength