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    Cement

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    Yahya Isied
    The document provides information about the cement industry, including: 1) Cement is produced through a process involving crushing and mixing raw materials like limestone and clay, burning the mixture in a kiln at high temperatures to form clinker, and grinding the clinker into a fine powder which is then packaged and sold. 2) The major raw materials used are limestone, clay, and other materials like slag. World cement production is about 1.5 billion tons annually, with China, Japan and the US being the top producers. 3) When mixed with other materials, cement forms concrete which is one of the most widely used construction materials. The chemical reactions that occur when cement hydrates and hard

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    Cement

    Uploaded by

    Yahya Isied
    41 views24 pages
    The document provides information about the cement industry, including: 1) Cement is produced through a process involving crushing and mixing raw materials like limestone and clay, burning the mixture in a kiln at high temperatures to form clinker, and grinding the clinker into a fine powder which is then packaged and sold. 2) The major raw materials used are limestone, clay, and other materials like slag. World cement production is about 1.5 billion tons annually, with China, Japan and the US being the top producers. 3) When mixed with other materials, cement forms concrete which is one of the most widely used construction materials. The chemical reactions that occur when cement hydrates and hard

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    The document provides information about the cement industry, including: 1) Cement is produced through a process involving crushing and mixing raw materials like limestone and clay, burning the mixture in a kiln at high temperatures to form clinker, and grinding the clinker into a fine powder which is then packaged and sold. 2) The major raw materials used are limestone, clay, and other materials like slag. World cement production is about 1.5 billion tons annually, with China, Japan and the US being the top producers. 3) When mixed with other materials, cement forms concrete which is one of the most widely used construction materials. The chemical reactions that occur when cement hydrates and hard

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    41 views24 pages

    Cement

    Uploaded by

    Yahya Isied
    The document provides information about the cement industry, including: 1) Cement is produced through a process involving crushing and mixing raw materials like limestone and clay, burning the mixture in a kiln at high temperatures to form clinker, and grinding the clinker into a fine powder which is then packaged and sold. 2) The major raw materials used are limestone, clay, and other materials like slag. World cement production is about 1.5 billion tons annually, with China, Japan and the US being the top producers. 3) When mixed with other materials, cement forms concrete which is one of the most widely used construction materials. The chemical reactions that occur when cement hydrates and hard

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    of 24

    Chemical Industries

    ChE 422/521

    Module #7
    Cement Industries
    By
    Dr. Ghadeer Al-Malkawi

    Spring 2017
    Cement
    A special ceramic is hydraulic (or water-cured) cement.
    World production of hydraulic cement is about 1.5 billion tons
    per year.
    The top three producers are China, Japan, and the United States.
    When mixed with sand and gravel, we obtain concrete, the most
    widely utilized construction material in industrialized nations.

    2
    Cements History
    Ancient Romans and Greeks, 2,000 years ago, pioneered
    the use of cement.

    Its unique chemical and physical properties produced a


    material so lasting that it stands today in magnificent
    structures such as the Pantheon in Rome.\
    Roman cement consisted of a mixture of powdered lime
    (CaO) and volcanic ash (a mixture of mainly SiO2, Al2O3,
    and iron oxide)called pozzolana.

    This mixture hardens in the presence of water.

    Contemporary hydraulic cementfor example Portland


    cement (invented by Joseph Aspdin and named after a
    natural stone from the island of Portland in England,
    which it resembles)has a composition similar to that of
    pozzolanic cement.
    Basic composition
    The chief ingredients of Portland cement are
    di- and tricalcium silicates and tricalcium
    aluminate.

    In the reduced nomenclature given in the


    table to the right

    These ingredients would be expressed as


    C2S, C3S, and C3A, respectively.

    Portland cement is produced to have a


    specific surface area of ~ 300 m2/kg and
    grains between 20 and 30 m.

    4
    Portland cement composition.

    The average overall composition of Portland cement is given in the


    following Table

    5
    Setting and hardening reactions
    The setting reactions for Portland cement are similar to those for the ancient pozzolanic
    cement. The first reaction is the hydration of C3A. This reaction is rapid, occurring within
    the first 4 hours. It causes the cement to set.

    C3A + 6H = C3AH6 + heat

    The C3AH6 phase, or ettringite, is in the form of rods and fibers that interlock.

    The second reaction, which causes the cement to harden, is slower. It starts after about 10
    hours and takes more than 100 days to complete. The product is tobermorite gel, a
    hydrated calcium silicate (Ca3Si2O7.3H2O), which bonds everything together.

    2C2S + 4H = C3S2H3 + CH + heat

    2C3S + 6H = C3S2H3 + 3CH + heat


    6
    Cement Hardening
    Scanning electron microscopy
    (SEM) has been one tool that
    has been used to examine
    cement at various stages in the
    setting and hardening process.
    Figure 2.8 shows an SEM
    image recorded 8 days into the
    hardening process.
    The plate-like features are
    calcium hydroxide (CH); the
    cement (Ct) grains are already
    completely surrounded by the
    tobermorite gel (called CSH in
    the figure).

    7
    Reactions rates

    The development of
    strength with time for
    Portland cement is
    shown in Figure 2.9.

    8
    Heat as a byproduct
    In very large concrete structures,
    such as the Hoover Dam at the
    NevadaArizona border in the
    United States, heat is a potential
    problem.
    Cooling pipes must be embedded in
    the concrete to pump the heat out.
    These pipes are left in place as a sort
    of reinforcement.

    9
    Heat as a byproduct
    In the case of the Hoover Dam,
    the construction consisted of a
    series of individual concrete
    columns rather than a single
    block of concrete.
    It is estimated that if the dam
    were built in a single continuous
    pour, it would have taken 125
    years to cool to ambient
    temperatures.
    The resulting stresses would have
    caused the dam to crack and
    possibly fail.
    Cement manufacturing
    It involves the following steps
    1) Crushing, and Grinding/Mixing of
    raw material
    2) Burning
    3) Grinding
    4) Storage and packaging
    1) Crushing, and Grinding/Mixing of raw material
    This stage can be done by any one of the following two
    processes

    (a) Dry process


    (account for more than 85% of the global production of cement)

    (a) Wet process


    Dry Process
    1. Lime stone or chalk and clay are crushed into crusher to get 2-5 cm size
    pieces.

    2. Crushed material is ground to get fine particle into ball mill or tube mill.

    3. Each material after screening stored in a separate hopper.

    4. The powder is mixed in require proportions to get dry raw mix which is
    stored in silos (storage tank) and kept ready to be fed into the rotary kiln.

    Raw materials are mixed in required proportions so that average composition


    of the final product is maintained properly.
    Wet Process
    1. Raw materials are crushed, powdered and stored in silos.

    2. The clay is washed with water in wash mills to remove adhering organic matter.
    The washed clay is stored separately.

    3. Powdered lime stone and wet clay are allowed to flow in channel and transfer to
    grinding mills where they are intimately mixed and paste is formed known as
    slurry. Grinding may be done either in ball mill or tube mill or both.

    4. Then slurry is led to correcting basin where chemical composition may be


    adjusted. The slurry contains 38-40% water stored in storage tank and kept ready
    for feeding to a rotary kiln.
    Comparison of dry process and wet process

    The remaining two operations burning and grinding are same for both processes.
    2) Burning
    Burning is carried out in rotary kiln which rotating at 1-2 rpm at its longitudinal axis.
    Rotary kiln is steel tubes having diameter in between 2.5 to 3 meter and length varies from 90
    to 120 meter.
    The inner side of kiln is lined with refractory bricks.
    The kiln is rested on roller bearing and supported columns of masonry or concrete in slightly
    inclined position at gradient of 1 in 25 to 1 in 30.
    The raw mix or corrected slurry is injected into the kiln from its upper end. Burning fuel like
    powdered coal or oil or hot gases are forced through the lower end of the kiln so long hot
    flame is produced.
    Cement Kiln
    Due to inclined position and slow rotation of the kiln, the material charged from
    upper end is moving towards lower end (hottest zone) at a speed of 15meter/hour.
    Burning . Drying and Calcining
    As gradually descends the
    temperature is rises.

    In the upper part, water or


    moisture in the material is
    evaporated at 400oC
    temperature, so it is known as
    drying zone.

    In the central part (calcination


    zone), temperature is around
    1000oC, where decomposition
    of lime stone takes place.
    CaCO3 CaO + CO2
    Burning . Clinkering
    The lower part (clinkering zone) have temperature in between 1500-1700oC where
    lime and clay are reacts to yielding calcium aluminates and calcium silicates.
    This aluminates and silicates of calcium fuse to gather to form small and hard
    stones are known as Clinkers.

    The size of the clinker is varies from 5-10mm.

    2CaO + SiO2 Ca2SiO4 (dicalcium silicate (C2S))


    3CaO + SiO2 Ca3SiO5 (tricalcium silicate (C3S))
    3CaO + Al2O3 Ca3Al2O6 (dicalcium aluminate (C2A))
    4CaO + Al2O3 + Fe2O3 Ca4Al2Fe2O10 (tetracalcium aluminoferrite (C4AF))
    Cooling
    As clinkers are coming from burning zone, they are very hot. The clinkers are
    cooled down by air admitting counter current direction at the base of rotary kiln.
    Resulting hot air is used for burning powdered coal or oil.
    Cooled clinkers are collected in small trolleys or in small rotary kiln.
    3) Clinker (cement) Grinding
    Cooled clinkers are ground to
    fine powder in ball mill or tube
    mill.
    2-3% powdered gypsum is
    added as retarding agent during
    final grinding.
    So that, resulting cement does
    not settle quickly, when comes
    in contact with water.
    4) Storage and packaging
    The ground cement is stored in silos, from which it is marketed either
    in container load or 50kg bags.
    Thank You

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