Cement is…..

•  Hydraulic Binder
Solidify and gain compressive
strength after mixing with
water

•  It binds gravel and sand

to form Artificial Rock
Sold Material

Concrete
Reference:
http://www1.kfupm.edu.sa/sas-aiche/Presentations/
Chemical%20Engineering%20Process%20in%20Cement%20Production.ppt
1
There have been huge developments in the
innovation and production of new binder
materials in the last 10 years especially in
the Epoxy chemicals.

gies
uc tion Technolo
cons tr
Ancient

Limestone

Cem
ent
&C
onc
ret e te
chn
olog
ies

However
None can compete with cement and
concrete materials for practicality and
economic feasibility of production and
construction
2
 Cement Production Process

Material Material
handling handling
Systems Systems

Cement
Raw Material Pyroprocessing Grinding
Grinding
Systems
(Chemical Reactions) Systems

3
Cement is Very Old Material….
Basic Research and inventions Time Line

Research by Invention of Invention of chemical Cement Standard

Louis Vicat on Portland Cement Engineering process by Wilhelm
Hydraulic Binders by Joseph Aspedin by Isaac Johnson Michaelis

1812 1824 1838 1875

4
Cement Production Technologies
•  Control and instrumentation
•  Gears and bearings
•  Cooling and heat transfer
•  Material handling systems
• Filters

Short Rotary Kilns and

Vertical Kilns Rotary Kilns Long Rotary Kilns Preheater Technology

1830’s 1885 1930’s 1970’s 2000’s

5
Pyroprocessing System

Preheater

Rotary Kiln
Cooler

6
Major Compounds in Cement:
In all the Portland Cements, there are four major compounds. The
variation in percentage composition of compounds influences the
properties of cement. These compounds are given below

7
Preheater
What is happening at the
Preheater?
•  Raw material separation
and suspension for heat
absorption.
• Moisture Removal
• Decomposition of CaCO3,
MgCO3, formation of CA,
C2F and C3S begins.

l  F o r m a t i o n o f C 12 A 7

8
 Rotary Kiln

• Formation of C3A and C4AF begins, decomposition of

CaCO3 completed, free lime reaches maximum

• Formation of C2S reaches maximum,

C3A and C4AF formation completed

• Formation of liquid phase

l Formation of C3S, gradual decrease 9

o f f r e e l i m e c o n t e n t .
Clinker

MINERALOGICAL COMPOSITION OF CLINKER

• Tricalcium silicate (C3S) or

alite, dicalcium silicate
(C2S) or belite, tricalcium
aluminate (C3A) and
tetracalcium aluminoferrite
(C4AF) are the main clinker
constituents

10
Cooler

Cooler

11
 Final Chemical Process

Material Material
handling handling
Systems Systems

Cement
Raw Material Pyroprocessing Grinding
Grinding
Systems
(Chemical Reactions) Systems

Addition of Gypsum
CaSO4.2H2O
to control the setting time of
cement 12
 Cement Chemical Composition
Weight
Cement Compound Chemical Formula
Percentage

Tricalcium silicate 50 % Ca3SiO5 or 3CaO.SiO2

Dicalcium silicate 25 % Ca2SiO4 or 2CaO.SiO2

Tricalcium aluminate 10 % Ca3Al2O6 or 3CaO .Al2O3

Tetracalcium Ca4Al2Fe2O10 or
10 %
aluminoferrite 4CaO.Al2O3.Fe2O3

Gypsum 5% CaSO4.2H2O

13
 Cement
Production, Composition
&
Types

Reference:
http://www.mychhs.colostate.edu/Charles.W.Smith/Reference%20materials/
Lecture%2010%20Concrete%20Condensed.ppt
14
Terminology

15
Raw Materials in Cement

16
Production of Cement

17
Production of Cement

18
Compounds in Cement

19
Compound Proportions

20
Cement Types

21
Cement Types & Compositions

22
Water to Cement Ratio
(W/C Ratio)

23