CEMENT

MANUFACTURE
CHE 432
INDUSTRIAL PROCESS

Definition for cement:

Finely
ground
material
formed by addition of water,
binding paste capable of
hardening under water or air
and
binding
together
particulate materials

 Cement and concrete not

synonymous terms
Concrete artificial stone
made
from
a
carefully
controlled mixture of cement,
water, and fine and coarse
aggregate (usu. Sand and
coarse rock)

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

Production of Portland cement

Cement clinker produced by wet and dry
processes
Wet process displaced by dry process
because saving in heat, accurate control
and mixing of raw mixtures

Production of Portland cement

1.Raw materials preparation
Two types of materials:
a) calcium (75%) eg. Limestone, chalk
b) Silica eg. Clay
Other compounds added eg. Sand, waste
bauxite and iron ore to adjust composition,
gypsum (4-5%) added to regulate setting
time of cement.

blasted

Limestone + clay

quarries
(25mm 1.2m)

storage yard

crusher
(30 mm)

Bauxite, iron ore, coal and gypsum unloaded from

ships/ barges
storage yards

2. Raw material grinding

weighed, mixed

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

High alumina cements

Fusing mixture of limestone and bauxite
Advantage: rapid rate of development of
strength and superior resistance to seawater
and sulfate bearing water
Silicate cements
Resist all inorganic acids except HF
Not suitable for pH > 7 or crystal forming
systems
2 parts of silica powder to 1 part sodium silicate

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

Pictorial flow diagram establishes key processing

steps: Cement manufacture