Execution of a cement project from Faugi Cement

Muhammad Arslan Zahid

uw-14-ch.e-bsc-028

Mobeen Akther

uw-14-ch.e-bsc-003

Waqas Anjum

uw-14-ch.e-bsc-026

Fasial Saleem

uw-14-ch.e-bsc-008

Hafiz Kamram

uw-14-ch.e-bsc-029

Figure 1 : Visit to

cement industry

Contents
1) History of Cement:........................................................2
2) Portland cement:..........................................................3
ii. Composition of Portland cement......................................3
3) Raw Material of Cement :................................................4
4) Process of cement production sketch by chemical engineer of
Fauji cement:-................................................................5
5) Flow Chart of Production of cement:-.................................6
6) Process of dry cement:-..................................................7
7) Belt Conveyor:.............................................................8
8) Chemical Reaction Of Cement:-........................................9
2

9) Structure of cement:-...................................................11
10) Chemistry of cement:-................................................12
11) Stage in hydration in cement:-......................................19
12) Packing of cement:....................................................20
13) PACKING:................................................................20
14) Types of cement:-......................................................21
15) Cement industry in the world:.......................................23
Production of cement in 2014.............................................24
16) Uses of cement:-.......................................................25
17) Reference:-.............................................................26
iii. History of Cement.......................................................26
iv. Portland cement.........................................................26
3

v. Raw Material of Cement................................................26

vi. Process of cement production sketch by chemical engineer of
Fauji cement.................................................................26
vii. Flow Chart of Production of cement................................26
viii. Chemical Reaction of Cement.......................................26
ix. Structure of cement.....................................................26
x. Stage in hydration in cement..........................................26
xi. Packing of cement.......................................................26
xii. Cement industry in the world........................................26
xiii. Uses of cement.........................................................26
18) Special Thanks..........................................................27

Table of Figures:
Figure 1 : Visit to cement industry.........................................1
Figure 2 : sir portland......................................................8
Figure 3: Quarries of cement............................................10
Figure 4 : Process of manufacturing cement in Fauji cement
industry......................................................................11
Figure 5: Lay out of production of cement...........................12
Figure 6 : belt conveyors.................................................14
Figure 7 : preheaded cyclone...........................................15
Figure 8 : World Production chart of cement in 2014..............30

1)History of Cement:
In 1824 an Englishman Joseph introduces an
Artificial cement made by the calcinations of an argillaceous
Limestone. He is called Portland because concrete made
from it resembled a famous building stone obtained from
Portland near England. This was start of Portland industry today.

Figure 2 : sir

portland

2)Portland cement:

Portland cement is the most common type of cement in general use around
the world, used as a basic ingredient of concrete, mortar, stucco, and most non6

specialty grout. It developed from other types of hydraulic lime in England in the
mid 19th century and usually originates from limestone.

i.

Composition of Portland cement

Compound

Formula

Range

Average

Calcium Oxide
Silicon oxide
Aluminum oxide
Magnesium oxide
Ferric oxide
Alkali oxide
Sulphur tri oxide
Gypsum

(CaO)
(SiO2)
(Al2O3)
(MgO)
(Fe2O3)
(K2O)
(SO3)
(CaSO4)

61 %
19 %
3.5 %
5%
1.5 %
0.5 %
2.5 %
4%

62 %
22 %
6%
2%
2%
2%
3%
1%

3)Raw Material of Cement :

The raw materials needed to produce cement ( calcium
carbonate, silica, alumina and iron ore) are generally extracted from limestone
rock, chalk, clayey schist or clay. Suitable reserves can be found in most
countries. These raw materials are extracted from the quarry by blasting .

Figure 3: Quarries

of cement

4)Process of cement production sketch by chemical

engineer of Fauji cement:-

Figure 4 :

Process of manufacturing cement in Fauji cement industry

5)

Flow Chart of Production of cement:-

Figure 5: Lay out of production of cement

10

6)Process of dry cement:The most common way to manufacture Portland cement is through a dry method. The first
step is to quarry the principal raw materials, mainly limestone, clay, and other materials. After
quarrying the rock is crushed. This involves several stages. The first crushing reduces the
rock to a maximum size of about 6 inches. The rock then goes to secondary crushers or
hammer mills for reduction to about 3 inches or smaller.
The crushed rock is combined with other ingredients such as iron ore or fly ash and ground,
mixed, and fed to a cement kiln.
The cement kiln heats all the ingredients to about 2,700 degrees Fahrenheit in huge
cylindrical steel rotary kilns lined with special firebrick. Kilns are frequently as much as 12 feet
in diameterlarge enough to accommodate an automobile and longer in many instances
than the height of a 40-story building. The large kilns are mounted with the axis inclined
slightly from the horizontal.
The finely ground raw material or the slurry is fed into the higher end. At the lower end is a
roaring blast of flame, produced by precisely controlled burning of powdered coal, oil,
alternative fuels, or gas under forced draft.
As the material moves through the kiln, certain elements are driven off in the form of gases.
The remaining elements unite to form a new substance called clinker. Clinker comes out of
the kiln as grey balls, about the size of marbles.
Clinker is discharged red-hot from the lower end of the kiln and generally is brought down to
handling temperature in various types of coolers. The heated air from the coolers is returned
to the kilns, a process that saves fuel and increases burning efficiency.
After the clinker is cooled, cement plants grind it and mix it with small amounts of gypsum and
limestone. Cement is so fine that 1 pound of cement contains 150 billion grains. The cement

11

is now ready for transport to ready-mix concrete companies to be used in a variety of

construction projects.
Although the dry process is the most modern and popular way to manufacture cement, some
kilns in the United States use a wet process. The two processes are essentially alike except
in the wet process, the raw materials are ground with water before being fed into the kiln.

7)Belt Conveyor:

Figure 6 : belt conveyors

12

Figure 7 : preheaded cyclone

8)Chemical Reaction Of Cement:Non-hydraulic cement, such as slaked lime (calcium hydroxide mixed with water), hardens
by carbonation in the presence of carbon which is naturally present in the air.
First calcium oxide is produced by lime calcinations at temperatures above 825 C (1,517 F)
for about 10 hours at atmospheric pressure:
CaCO3 CaO + CO2
The calcium oxide is then spent (slaked) mixing it with water to make slaked lime:
CaO + H2O Ca (OH)2

13

Once the water in excess from the slaked lime is completely evaporated (this process is
technically called setting), the carbonation starts:
Ca (OH)2 + CO2 CaCO3 + H2O
This reaction takes a significant amount of time because the partial pressure of carbon
dioxide in the air is low.
The carbonation reaction requires the dry cement to be exposed to air, for this reason the
slaked lime is non-hydraulic cement and cannot be used under water.
This whole process is called the lime cycle.
Conversely, the chemistry ruling the action of the hydraulic cement is hydration.
Hydraulic cements (such as Portland cement) are made of a mixture of silicates and oxides,
the four main components being:
Belite (2CaOSiO2);
Alite (3CaOSiO2);
Celite (3CaOAl2O3);
Brownmillerite (4CaOAl2O3Fe2O3).
The silicates are responsible of the mechanical properties of the cement,
the celite and the brownmillerite are essential to allow the formation of the liquid phase during
the kiln sintering (firing).
The chemistry of the above listed reactions is not completely clear and is still the object of
research.

14

9)Structure of cement:-

15

10) Chemistry of cement:As with the development of any cellular-automaton-type model, rules must be selected to
govern the state transitions occurring at each lattice element (site) of the microstructure.
For cement, this requires a detailed understanding of the chemical reactions occurring
when cement reacts with water.
Review articles describing cement chemistry are available (Brown 1991, Gartner and
Gaidis 1989, RILEM Technical Committee 66-MMH 1986) but, as will be outlined below, a
well defined quantitative account is still lacking.
This section provides a generally plausible outline of cement hydration, which should be
viewed as a simplification of the complicated and poorly understood processes taking place
in real cement.
For example, the composition of the cement particles is conventionally broken down into
several pure phases, but this is an idealization
Real particles may have regions which are not pure, but are hybrids of different proportions
of silicate, ferrite and aluminate; in oil well cements the situation is particularly
complicated (Bergstrom et al 1991/92).
The 'true' chemical composition of the cement phases remains an open question. Attempts
have been made since the time of Bogue (1929) to predict such phase compositions starting
from oxide analyses of the original clinker but, although these predictions are still widely
used, e.g. for furnishing American Petroleum Institute (API) specifications of oil well
cements,
They can only be regarded as approximations. The amorphous gels and crystalline products
produced during hydration may also have a variety of chemical forms (Taylor 1990).

16

The most widely used cement is portland cement. The four major Bogue clinker phases
present in portland cement are tricalcium silicate (C 3S), dicalcium silicate (C2S), tricalcium
aluminate (C3A), and tetracalcium aluminoferrite (C 4AF); the clinker is ground with gypsum
(C H2). The formulae in parentheses use the standard cement chemistry abbreviations: C =
CaO, S = SiO2, A = Al2O 3, F = Fe2O3, = SO3, and H = H2O.
Table 1: Densities and molar volumes of cementations materials
Compound Name

Compound Formula

Density
(g cm-3)

Molar
Volume
(cm-3 mol -1)

Tricalcium silicate

C3S

3.21

71

Dicalcium silicate

C2S

3.28

52.4

Tricalcium aluminate

C3A

3.03

89.1

Tetracalcium aluminoferrite

C4AF

3.73

128

Gypsum

C H2

2.32

74.2

Calcium silicate hydrate

C1.7SH4

1.85

124

Pozzolanic C-S-H

C1.1SH2.1

1.97

81

Calcium hydroxide

CH

2.24

33.1

Ettringite

C6A

H32

1.75

715

Monosulphate

C4A H12

1.99

313

Hydrogarnet

C3AH6

2.52

150

Iron hydroxide

FH3

2.2

95.2

17

The numbers below each reaction equation indicate the volume units of each phase required
to balance that particular chemical reaction.
Knowing the molar volumes and the reaction stoichiometries, these volume stoichiometries
can be easily calculated for each reaction.
Since Bogue phases are only approximations, so too are these idealized cement hydration
reactions.
Indeed, there is considerable controversy in the cement chemistry literature concerning
what reactions are actually occurring, what are their spatial distributions, which are slow or
fast, what are the mechanistic details and even the exact chemical composition of the
species that may exist during hydration.
It is a virtue of the CA approach that we can deliberately avoid pursuing an overdetailed
chemical description, and still obtain realistic physical properties of the evolving dynamical
system.
the silicate reactions are simpler than those for the aluminate and ferrite phases of portland
cement. Tricalcium silicate is the major component of portland cement.
it is generally present in a mass fraction of 50-70%, and is considered to be responsible for
controlling many of the ultimate properties of cement-based materials including transport
and strength properties.
When C3S reacts with water, a nanoporous, amorphous calcium silicate hydrate (C-S-H )
gel is redeposited on the surfaces of the original C 3S and and on previously deposited C-S-H
, while calcium hydroxide (CH) crystals nucleate and grow in the available capillary pore
space.

18

As time proceeds, the C-S-H gel polymerizes, but we do not include this process in our list
of reactions.
The reactions for C2S are similar, but less CH is formed due to the lower Ca/Si molar ratio
of the initial C2S.
Additionally, in portland cement, the C2S typically reacts at a much slower rate than the
C3S.
Due to the extensive use of pozzolanic materials such as silica fume and fly ash in
concrete, the pozzolanic reaction between calcium hydroxide and reactive silica has been
included in the list of reactions.
The stoichiometry for this reaction is based on recently published data and is an
approximation as it is likely to vary with water-to-cement (w/c) ratio and silica fume
content.

19

Figure 1: Cement model reactions numbers indicate volume stoichiometries

20

Tricalcium aluminate, C3A, is generally the fastest reacting phase in portland cement. In
fact, gypsum is specifically added to portland cement to slow down this reaction, thus
avoiding 'flash set' of the material. Because the aluminate phase is critical to early hydration
properties, it is of great interest in oil well cementing.
When gypsum is not present in the system, C3A reacts with water to form a variety of
crystalline hydration products, with hydrogarnet, C 3AH6, being the ultimately stable
hydration product.
Reactions are much more complex in the presence of gypsum. In this case, the C 3A will
react with the gypsum to form ettringite, C6A3 H32, whose crystals are often observed to
grow as needles within the cement paste.
Microscopic analysis has shown the wide range of morphologies of growing ettringite
crystals and their sensitivity to additives such as sucrose retarders and to
temperature (Kuzel and Pllmann 1991).
When all of the gypsum is consumed, the ettringite may decompose, reacting with more of
the C3A to form the monosulphate phase, C4A H12.
Additionally, ettringite is unstable above 60 C, exemplifying that cement reactions are a
function of temperature as well as solution concentrations.
Ambient conditions are assumed in this paper. The sulfate ions are generally more mobile
than the aluminates ions so that ettringite forms either in solution or at the surfaces of the
aluminates phases in cement paste.
There is also evidence that the ettringite changes from a gel to a crystalline form during
cement hydration: application of ATR/FTIR techniques to measure changes in chemical
composition during hydration does not indicate any C-S-H formation at early time, but the
attainment of a steady level of ettringite (though this does not preclude a phase change of
ettringite, such as from gel to crystalline form) (Jones 1992).

21

The reactions of the ferrite phase, C4AF, are the least well understood of those occurring
during portland cement hydration.
The ferrite phase is often said to react slowly (in comparison to the other phases) and only
contributes to longterm properties of cements (although exceptions to this have been noted
in the presence of special additives (Chiesi et al 1992), and the bulk A//F ratio does have a
strong effect on thickening time in oil well cements).
In the present work, we have assumed that the reactions of the ferrite phase are similar to
those of tricalcium aluminate, with the production of extra calcium hydroxide and iron (III)
hydroxide FH3 to account for the extra calcium and iron present in the C 4AF phase, based on
experimental evidence given by Brown (1987).
No density information was available in the literature for the iron hydroxide gel forming in
cement paste, so the value of 2.2 g cm-3 given in Table 1 was assumed.
Cement hydration does not proceed at a fixed rate. The evolution of hydrating cement can
be qualitatively characterized by the heat evolution curve sketched in Figure 2 (Nelson
1990). The process can be broken down into five stages:
(1) preinduction,
(2) induction,
(3) acceleration,
(4) deceleration
(5) diffusion limited.

22

11) Stage in hydration in cement:-

23

12) Packing of cement:

The cost of transportation of cement bags, due to the nature and weight of this
material, is relatively high compared to
Its purchasing cost. Damages and losses resulting from poor packaging, and the
replacement cost can be significant.
It is therefore proven that adequate packaging of this material is essential, and
turns out to be a good investment in this
Particular case. The same packaging process and criteria can be used for similar
bagged materials.
An acceptable standard package (Cargo Unit) of cement bags will include the
illustrated features and the following
Components:

13) PACKING:
1) Cement bags are stacked on standard-sized wooden pallet (skid), as it may be
originally received from the supplier;
3) A sheet of plywood is placed on the top to the full extent of the surface, or
rigid
wooden right angles made out of 1X6 wood pieces could be used across the full
24

Length of the front and the back sides, to reduce the risk of damages that may
result
From stacking during warehousing and transportation stages;
4) Due to the heavy weight of this type of Cargo, heavy duty - inch metal
straps are
Used to tightly fasten the bundle onto the pallet. A two-way strapping is
Recommended, depending on the height of the bundle;

14) Types of cement:types of Cement

Composition

Purpose

Rapid Hardening
Cement

Increased Lime content

Attains high strength in early days

it is used in concrete where form
work are removed at an early
stage.

Quick setting
cement

Small percentage of
aluminium sulphate as an
accelerator and reducing
percentage of Gypsum with
fine grinding

Used in works is to be completed

in very short period and
concreting in static and running
water

Low Heat
Cement

Manufactured by reducing
tri-calcium aluminate

It is used in
massive concreteconstruction like
gravity dams

Sulphates

It is prepared by

It is used in construction exposed

25

resisting Cement

maintaining the percentage

of tricalcium aluminate
below 6% which increases
power against sulphates

to severe sulphate action by water

and soil in places like canals
linings, culverts, retaining walls,
siphons etc.,

Blast Furnace
Slag Cement

It is obtained by grinding
the clinkers with about 60%
slag and resembles more or
less in properties of
Portland cement

It can used for works economic

considerations is predominant.

High Alumina
Cement

It is obtained by melting
mixture of bauxite and lime
and grinding with the
clinker it is rapid hardening
cement with initial and final
setting time of about 3.5
and 5 hours respectively

It is used in works where concrete

is subjected to high temperatures,
frost, and acidic action.

White Cement

It is prepared from raw

materials free from Iron
oxide.

It is more costly and is used for

architectural purposes such as
pre-cast curtain wall and facing
panels, terrazzo surface etc.,

Coloured cement

It is produced by mixing
mineral pigments with
ordinary cement.

They are widely used for

decorative works in floors

Pozzolanic
Cement

It is prepared by grindin
pozzolanic clinker with
Portland cement

It is used in marine structures,

sewage works, sewage works and
for laying concrete under water
such as bridges, piers, dams etc.,

26

Air Entraining
Cement

It is produced by adding
indigenous air entraining
agents such as resins,
glues, sodium salts of
Sulphates etc during the
grinding of clinker.

This type of cement is specially

suited to improve the workability
with smaller water cement ratio
and to improve frost resistance of
concrete.

Hydrographic
cement

It is prepared by mixing
water repelling chemicals

This cement has high workability

and strength

15) Cement industry in the world:

In 2014, the world production of hydraulic cement was 3,300 million tones. The top three producers
were China with 1,800, India with 220, and USA with 63.5 million tones for a combined total of over
half the world total by the world's three most populated states
For the world capacity to produce cement in 2010, the situation was similar with the top three states
(China, India, and USA) accounting for just under half the world total capacity
Over 2011 and 2012, global consumption continued to climb, rising to 3585 Mt in 2011 and 3736 Mt in
2012, while annual growth rates eased to 8.3% and 4.2%, respectively.
China, representing an increasing share of world cement consumption, continued to be the main engine
of global growth. By 2012, Chinese demand was recorded at 2160 Mt, representing 58% of world
consumption. Annual growth rates, which reached 16% in 2010, appear to have softened, slowing to 5
6% over 2011 and 2012, as Chinas economy targets a more sustainable growth rate.

27

Outside of China, worldwide consumption climbed by 4.4% to 1462 Mt in 2010, 5% to 1535 Mt in

2011, and finally 2.7% to 1576 Mt in 2012.
Iran is now the 3rd largest cement producer in the world and has increased its output by over 10% from
2008 to 2011. Due to climbing energy costs in Pakistan and other major cement-producing countries,
Iran is a unique position as a trading partner, utilizing its own surplus petroleum to power clinker
plants. Now a top producer in the Middle-East, Iran is further increasing its dominant position in local
markets and abroad
The performance in North America and Europe over the 201012 period contrasted strikingly with that
of China, as the global financial crisis evolved into a sovereign debt crisis for many economies in this
region and recession. Cement consumption levels for this region fell by 1.9% in 2010 to 445 Mt,
recovered by 4.9% in 2011, and then dipped again by 1.1% in 2012.
The performance in the rest of the world, which includes many emerging economies in Asia, Africa and
Latin America and representing some 1020 Mt cement demand in 2010, was positive and more than
offset the declines in North America and Europe. Annual consumption growth was recorded at 7.4% in
2010, moderating to 5.1% and 4.3% in 2011 and 2012, respectively.
As at year-end 2012, the global cement industry consisted of 5673 cement production facilities,
including both integrated and grinding, of which 3900 were located in China and 1773 in the rest of the
world.
Total cement capacity worldwide was recorded at 5245 Mt in 2012, with 2950 Mt located in China and
2295 Mt in the rest of the world .

28

16) Production of Cement in 2014:

Figure 8 : World Production chart of cement in 2014

17) Uses of cement:1. It is used in mortar for plastering, masonry work, pointing, etc.

29

2. It is used for making joints for drains and pipes.

3. It is used for water tightness of structure.
4. It is used in concrete for laying floors, roofs and constructing lintels, beams,
stairs, pillars etc.
5. 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.
6. It is used for precast pipes manufacturing, piles, fencing posts etc.
7. It is used in the construction of important engineering structures such as bridges,
culverts, dams, tunnels, light houses etc.
8. It is used in the preparation of foundations, water tight floors, footpaths etc.
9. It is employed for the construction of wells, water tanks, tennis courts, lamp posts,
telephone cabins, roads etc.

30

18) Reference:ii.

History of Cement

iii.

Portland cement

iv.

Raw Material of Cement

v.

Process of cement production sketch by chemical engineer of Fauji cement

vi.

Flow Chart of Production of cement

vii.

Chemical Reaction of Cement

viii.

Structure of cement

ix.

Stage in hydration in cement

x.

Packing of cement

xi.

Cement industry in the world

xii.

Uses of cement

31

19) Special Thanks

Fauji Cement Company Limited (FCCL)

Colonel Abrar Hussain Shah ( CO of Faugi Cement )

Engr Mehmood ( chemical engr of FCCL)
Faugi Cement Mess

32