GROUP MEMBERS

MAWRA TEHREEM
ZAIN KHAN
CEMENT INDUSTRY IN
PAKISTAN
 WHAT IS CEMENT?

• FINE, SOFT POWDER TYPE SUBSTANCE

• MADE FROM MIXTURE OF ELEMENTS LIKE LIMESTONE, CLAY AND SAND
• IT IS USUALLY GREY IN COLOUR,WHITE CAN ALSO BE FOUND, BUT EXPENSIVE.
• CEMENT MIXED WITH WATER, SAND AND GRAVEL FORMS CONCRETE, WHEN
MIXED WITH ONLY WATER AND SAND FORMS CEMENT PLASTER
• ONE KILO CEMENT CONTAINS OVER 300 BILLION GRAINS
 HISTORY

• CEMENT LIKE PRODUCTS WERE USED IN GREEK AND ROMAN STRUCTURE OVER
2000 YEARS AGO
• 1824 JOSEPH ASPEDIN INVENTED PORTLAND CEMENT. WHICH HAS REMAINED
THE DOMINANT CEMENT USE IN CONCRETE PRODUCTION
• PAKISTAN HAD INHERITED 4 CEMENT PLANTS WITH TOTAL CAPACITY OF
0.5MILLION TONS IN 1947.CURRENTLY THERE ARE 29 FIRMS.WITH TOTAL
CAPACITY 45 MILLION TONS
 TYPES OF CEMENT PRODUCED IN PAKISTAN

1. ORDINARY PORTLAND CEMENT

2. PORTLAND BLAST FURNACE SLAG CEMENT
3. SULPHATE RESISTING CEMENT
4. WHITE CEMENT
• ORDINARY PORTLAND CEMENT:-IS AVAILABLE IN DARKEN SHADE AS WELL IN LIGHTER
SHADE, IN BAGS OF DIFFERENT SIZES UNDER DIFFERENT BRAND NAMES, IT IS USED IN ALL GENERAL
CONSTRUCTION ESPECIALLY IN MAJOR PROJECTS WHERE CEMENT IS TO MEET STRINGENT QUALITY
REQUIREMENTS

• PORTLAND BLAST FURNACE SLAG CEMENT:-ITS BEST QUALITY IS TO PROVIDE LONG

LASTING STRENGTH AGAINST SULPHATE ATTACK, AND IS VERY SUITABLE FOR CONSTRUCTION NEAR
SEA SHORE AND CANAL LINING.

• SULPHATE RESISTING CEMENT:-INCORPORATED INTO CONCRETE PROJECTS TO IMPROVE

DURABILITY AND REDUCE LIFE CYCLE COST.IT HAS HIGH COMPRESSIVE STRENGTH AND IMPROVED
RESISTANCE TO AGGRESSIVE CHEMICALS

• WHITE CEMENT:-HAS THE SAME PROPERTIES AS GREY CEMENT EXCEPT THE COLOR
 LOCATION OF CEMENT INDUSTRIES

• CLASSIFIED INTO 2 REGIONS

1. NORTHERN REGION
• 80% SHARE IN TOTAL CEMENT
• CAPACITY OF 38 MILLION TONS

2. SOUTHERN REGION
• 20% SHARE IN TOTAL PRODUCTION
• CAPACITY OF 7 MILLION TONS
 MATERIAL USED IN CEMENT MAKING

• THE FOLLOWING RAW MATERIALS ARE REQUIRED, WHICH ARE FREQUENTLY

AVAILABLE IN PAKISTAN
1. LIMESTONE (75-80%)
2. CLAY (15-20%)
3. GYPSUM (5%)
4. FURNACE OIL OR COAL
CEMENT PRODUCTION PROCESS
 SOURCES OF ENERGY

60-70% IS THE COST OF ENERGY IN PRODUCTION OF CEMENT

• COAL
• GAS
• OIL FURNACE
• ELECTRICITY
• MOST OF THE COMPANIES HAVE SWITCHED TO COAL OR GAS

1. FURNACE OIL RS 2083/TON

2. COAL RS 868/TON
• INITIALLY 90% OF COAL CONSUMPTION IS MET BY IMPORTS IN PAKISTAN, HOWEVER DUE
TO RISE IN PRICES COMPANIES ARE USING LOCAL COAL(DANDOT CEMENT,70% FROM
QUETTA)

• LOAD SHEDDING OF GAS IS ANOTHER MAJOR ISSUE,DOMESTIC CONSUMPTION IS

HIGH.FOR, ELECTRICITY COMPANIES WERE RELYING ON WAPDA,BUT NOW HAVE
INSTALLED ITS OWN GENERATION PLANT
 REASONS TO IMPORT COAL

• PRODUCTION OF 1TON OF CEMENT CONSUMES 3400-5000 MJ OF FUEL ENERGY(50% IN

CLINKER BURNING.20% IN PREHEATER EXHAUST GAS,14% IN COOLER EXHAUST GAS)

• PAKISTAN HAS 4TH LARGEST COAL RESERVES BUT IS 2.5 MILLIONS TONS OF COAL PER
ANUM FOR CEMNT INDUSTRY
• LOCAL COAL CONTAIN 6% SULPHUR,NOT SUITABLE FOR CEMENT PRODUCTION,WHILE
IMPOTED COAL HAS 1% SULPHUR
 FUEL ALTERNATIVES

• THE CEMENT MAY UTILIZE USED TIRES TO MEET 40% OF FUEL

REQUIREMENT.LUKCY CEMENT AND DG CEMENT, THIS METHOD IS CALLED
REFUSED DRIVE FUEL PROJECT
• RECYCLING THE WASTE BY MAKING IT IN A BUNDLE SHAPE, AND THAN THESE
BUNDLES WOULD BURN IN THE KILN
• PAKISTAN CAN IMPORT SULPHUR WASHING PLANTS
• WASTE HEAT RECOVERY PLANT SET UP BY LUCK AND DG CEMENT, USES WASTE
HEAT TO GENERATE ELECTRICITY
 TECHNOLOGY

• UNTIL 1970’ FIRM WERE BASED ON WET PROCESS, IT WAS EXPENSIVE AND
REQUIRED GREATER AMOUNT OF ENERGY SOURCE
• AFTER 1980’, 85% INSTALLED CAPACITY IS BASED ON DRY PROCESS
• LUCKY CEMENT USES COMPUTERIZE CONTROL SYSTEM ADVANCED STATE OF
ART SOPHISTICATED EQUIPMENT LIKE X-RAY ANALYZER AND PLC’S
• MAPPLE LEAF HAS REDUCED THE EMISSION OF NO TO ENVIRONMENT FROM
4.5KG/TON TO 1.5KG/TON,TO REDUCED ENVIRONMENT POLLUTION.
 LABOR AND MACHINERY

• MORE THAN 150,000 PEOPLE ARE EMPLOYED DIRECTLY OR INDIRECTLY BY THE

INDUSTRY
• CHEAP LABOR COST IS AN ADVANTAGE. FOREIGN EXPERTS ARE CALLED IN TO
PROVIDE TRAINING
• MACHINERY IS IMPORTED,R&D WHEN IT COMES TO SETTING A PLANT IS ABSENT,
LUCKY CEMENT HAS NO R&D AND CONSIDERS IT TO BE USEFUL ONLY WHEN
PRODUCT INNOVATION IS POSSIBLE
 EXPORT

PAKISTAN EXPORTS TO FOLLOWING

COUNTRIES
• AFGHANISTAN
• SIRILANKA
• AFRICAN COUNTRIES
• SAUDIARABIA
• IRAN
 CEMENT ASSOCIATION(APCMA)

• ALL PAKISTAN CEMENT MANUFACTURING ASSOCIATION

1. PROJECTING THE CEMENT INDUSTRY TO GOVERNMENT
2. SUPPLIES INFORMATION ABOUT CEMENT INDUSTRY
3. INTERACTS FOR INDUSTRY PROBLEMS
4. TECHNICAL SUPPORT
 RELATED AND SUPPORTED INDUSTRIES

• HOUSING AND COMMERCIAL PLOTTING

• GOVERNMENT PROJECTS
• SHIPPING INDUSTRY
• PACKAGING INDUSTRY
• MINING AND QUERRING INDUSTRY
• TRANSPORT
• HOUSING AND COMMERCIAL PLOTTING:-40% OF THE CEMENT DEMAND,IT COMPRISES 50%
OF THE CONSTRUCTION SECTOR

• GOVERNMENT PROJECTS:-MAINTENANCE AND CONSTRUCTION OF

ROADS,DAMS,CANAL,BRIDGES,UNDERPASSES.NATURAL CALAMITES ALSO RAISE THE DEMAND

• SHIPPING INDUSTRY:-HIGH COST IS A BARRIER FOR EXPLOITING FULL POTENTIAL, INDIAN

CARGO LOADS UP IN 6 HOURS AND HERE IT TAKES 3 DAYS. OUTREACH IS UP TILL
SOUTHAFRICA,RUSSIAN MARKET IS UNREACHABLE

• PACKAGING INDUSTRY: IS DUE IMPORTANCE TO MAINTAIN CEMENT IN GOOD

CONDITION,TWO MAIN COMPANIES SUPPLY AND A SHORTAGE OF 12 MILLION BAGS

• MINING AND QUERRING INDUSTRY: IT DIRECTS DEMAND FROM CEMENT SECTOR, RICH
SOURCE OF MINERAL AND RAW MATERIAL ARE EXPLORED.IT PROVIDES HIGH EMPLOYMENT

• TRANSPORT: LOCAL TRANSPORTATION PAKISTAN($8/TON) IN INDIA($3/TON).TRUCKING SECTOR

DEPENDS A LOT ON CEMENT INDUSTRY.20% OF CEMENT COST GOES UNDER TRANSPORTATION.
 IMPROVEMENTS

• IMPORT SULPHUR WASHING PLANT FROM EUOROPE

• ENCOURAGE RESEARCH AND DEVELOPMENT
• COAL FIRED POWER PLANTS SHOULD BE IMPORTED