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Cement Part1

The document discusses the manufacturing process of Portland cement. It begins by listing the main ingredients of cement, which are lime, silica, alumina, ferrous oxide, and other compounds. It then describes the two processes for manufacturing cement - dry process and wet process. For the dry process, it explains the key steps: treatment of raw materials by crushing, drying, and grinding; burning the dry mix in a kiln to form clinker; grinding the clinker; and packaging. The wet process involves mixing raw materials with water and grinding before burning. The finished cement is stored in silos before packaging.

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Prakash Gupta
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
13 views

Cement Part1

The document discusses the manufacturing process of Portland cement. It begins by listing the main ingredients of cement, which are lime, silica, alumina, ferrous oxide, and other compounds. It then describes the two processes for manufacturing cement - dry process and wet process. For the dry process, it explains the key steps: treatment of raw materials by crushing, drying, and grinding; burning the dry mix in a kiln to form clinker; grinding the clinker; and packaging. The wet process involves mixing raw materials with water and grinding before burning. The finished cement is stored in silos before packaging.

Uploaded by

Prakash Gupta
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 15

BY: Er.

BED PRAKASH GUPTA


Introduction
• Cement is a adhesive and cohesive materials which is capable of bonding together particles of solid
matter into a compact durable mass.
• Invented by joseph aspidin.
• The manufacture of cement consists of grinding the raw materials mixing them in a certain proportion.
It is then burnt in a large rotary kiln at a temperature of about 1500* C, When the material sinters and
partially fuses into balls known as clinker. The clinker is cooled and ground to fine power with some
gypsum added, and the resulting product is the commercial Portland cement.

INGREDIENTS OF PORTLAND CEMENT:


a) Lime 60-65%
b) Silica 17-25%
c) Alumina 3-8%
d) Ferrous oxide 0.5-6%
e) Magnesium oxide 0.5-4%
f) Sulphur trioxide 1-2%
g) Soda and potash 0.5-1%
h) Gypsum 3-5%

BY: Er. BED PRAKASH GUPTA


FUNCTIONS OF VARIOUS INGREDIENTS:

 Lime:
• It makes the cement sound and strong.
• The lime in excess quantity makes the cement unsound and causes the cement to expand
and disintegrate.
 Silica:
• It provides strength to the cement due to the formation of dicalcium and tricalcium
silicates.
• The silica in excess quantity causes the cement to set slowly.
 Alumina
• It provides setting property to the cement.
• If excess, it lowers the strength of cement.
 Iron oxide
• It provides colour, hardness and strength to the cement.
• It also helps the fusion of raw materials during the manufacture of cement.

BY: Er. BED PRAKASH GUPTA


Contnd……

 Magnesium oxide
• It provides hardness and color to the cement, when present in small quantity.
• The magnesium oxide in excess quantity makes the cement unsound.
 Sulphur trioxide
• Makes cement sound.
• Excess of it causes unsound

NOTES:……….
• Volume of 1 bag cement= 0.035m3=35 litres.
• 1 m3 cement =28.8 bags
• Density of cement = 1440 kg/m3.
• 1 bag cement (50 kg) requires 22 litres water for 1:2:4 mix.
• Specific gravity of cement is taken as 3.15.

BY: Er. BED PRAKASH GUPTA


COUMPONDS IN CLINKER (BOGUE COMPOUNDS)
 Alite ( 3CaO.SiO2) (C3S):
• Tricalcium silicate
• 25-50%
• The presence of C3S in cement hydrates more rapidly.
• It generates more heat of hydration.
• It develops early strength and possess less resistance to sulphute attack.

 Belite (2CaO.SiO2) (C2S):


• Dicalcium silicates
• 20-35%
• The presence of C2S in cement hydrates slowly.
• It generates less heat of hydration.
• It hardens slowly and provides ultimate strength.
• Offers resistance to sulphate attack.

BY: Er. BED PRAKASH GUPTA


 Celite ( 3CaO.Al2O3) (C3A):
• Tricalcium aluminate
• 5-15%
• Causes initial setting of cement.
• It is the first compound which reacts with water.

 Felite (4CaO.Al2O3.Fe2O3) (C4AF):


• 8-18%.
• Has poor cementing value.
• Reacts slowly with water.

BY: Er. BED PRAKASH GUPTA


MANUFACTURE OF CEMENT:
 Cement is manufactured by two process:
1. Dry process
2. Wet process

BY: Er. BED PRAKASH GUPTA


Puzzle

1) There is a room with two doors. One door empties the room in 6 minutes and the other one
empties the room in 3 minutes. If both were open, how long would it take to empty the room?

BY: Er. BED PRAKASH GUPTA


FEW QUESTIONS.?????????
1. The main ingredients of cement is:
a) Alumina b) iron oxide
c) silica d) lime

2. Maximum permissible limit of magnesia content in opc cement is


a) 4% b) 6%
c) 8% d) 10%

3. The sp. Gravity of OPC cement is


a) 3.15 b) 2.55
c) 2.65 d) 1

4. What is the meaning of soundness of cement?


a) Ability to flow when mixed b) Ability to make ringing noise when struck
c) Ability to form strong and sound structure d) Ability to retain volume after setting.

BY: Er. BED PRAKASH GUPTA


5. Ultimate strength to cement is provided by
a) Tricalcium silicate b) Di-calcium silicate
c) Tri-calcium aluminate d) Tetra calcium alumino ferrite.

6. In the cement the compound quickest to react with water, is


a) Tricalcium aluminate b) Tetra-calcium alumino-ferrite
c) Tricalcium silicate d) Dicalcium silicate.

BY: Er. BED PRAKASH GUPTA


Contnd……(manufacture of cement)
1. Dry process:
 Steps involved in dry process are as follows:
• Treatment of raw materials
• Burning of dry mix
• Grinding of the clinker
• Packaging and storage.

 TREATMENT OF RAW MATERIALS:


1. Crushing stage:
• Breaking the raw materials to small fragments in size of 6-14 mm.
• Machine called crushers are used for this purpose.
2. Drying stage:
• Drying of crushed materials in done at high temperature in drying kiln.
3. grinding:
• Ball mills are generally used for preliminary grinding and tube mills are used for fine grinding.
4. Proportioning and blending:
• Predetermined proportions of finely dried and ground raw materials are mixed together before they fed
to the kiln BY: Er. BED PRAKASH GUPTA
5. Burning of the dry mix:
• Now, the well- proportioned finely powered mixture is charged into a long steel cylinder, called the
rotary kiln. ( at tempr of 11400-1500*C).
• The burnt material , now is called as clinker is cement in composition but not in size.
6. Grinding of the clinker:
• The completely burnt materials of cement are obtained in lump-shaped product called clinker whick is
drawn out from the lower end of the rotary kiln.
• It is extremely hot when discharged from the kiln and is therefore first cooled in clinker coolers. And
• Then a predetermined batch of gypsum is added and sent for pulverizing. Fine grinding is done in tube
mills.
7. Packing and storage of cement:
• The cement is now packed into bags by packing machine automatically.
• Each bag of cement contains 50 kg of cement whole volume is taken at 35 litres.

BY: Er. BED PRAKASH GUPTA


BY: Er. BED PRAKASH GUPTA
Lime stone Clay
Fig: flow
diagram of
To rotary kiln dry process

crushers
dryers Formation of clinkers

Dryers
Gypsum 3-4%
Grinders Clinker coolers

Grinders

Grinding of clinkers

Storage silos Storage silos

Storage in silos
Weighing and
Blending BY: Er. BED PRAKASH GUPTA
package
BY: Er. BED PRAKASH GUPTA

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