Cement

Currently are 24 cement plants in Pakistan

D.G. Khan Cement Company Limited,
(DGKCC) is amongst largest the
cement manufacturers of Pakistan with
a production capacity of 22,400 tons
per day (6.72 million tons/annum).
DGKCC has four cement plants
History :

Cement has been around for at least

12 million years. When the earth
itself was undergoing intense
geologic changes, natural cement
was being created. It was this
natural cement that humans first put
to use. Eventually, they discovered
how to make cement from other
materials.
12,000,000 BC :
Reactions between limestone and oil shale
during spontaneous combustion occurred in
Palestine to form a natural deposit of cement
compounds. The deposits were characterized by
the geologists in the 1960's and 70's.
3000 BC :
Egyptians Used mud mixed with straw to bind
dried bricks. They also used gypsum mortars
and mortars of lime in the pyramids.
Chinese Used cementitious materials to hold
bamboo together in their boats and in the Great
Wall
1828 :
I. K. Brunel is credited with the first engineering application of
portland cement, which was used to fill a breach in the Thames
Tunnel.
1830 :
The first production of lime and hydraulic cement took place in
Canada.
1836:
The first systematic tests of tensile and compressive strength took
place in Germany

1845:
Isaac Johnson claims to have burned the raw materials
of portland cement to clinkering temperatures.
1849:
Pettenkofer & Fuches performed the first accurate
chemical analysis of portland cement
1860:
The beginning of the era of portland cements of modern composition.
1886 :
The first rotary kiln was introduced in England to replace the vertical shaft
kilns.
1889:
The first concrete reinforced bridge is built
1890:
The addition of gypsum when grinding clinker to act as a retardant to
the setting of concrete was introduced in the USA. Vertical shaft kilns
were replaced with rotary kilns and ball mills were used for grinding
cement.
Definition :

Portland cements are hydraulic cements,

meaning they react and harden
chemically with the addition of water.
Cement contains limestone, clay ,
cement rock and iron ore, blended and
heated to 1200 - 1500 C°. The resulting
product "clinker" is then ground to the
consistency of powder. Gypsum is
added to control setting time.
 Cement is a pulverized material that develops binding
forces due to a reaction with water

Hydraulic Cement ------ Stable under water

 Non-hydraulic Cement -------- Products of hydration are
not resistant to water (i.e. limestone)

Hydraulic cements: Cements that harden by reaction

with water and form a water-resistant product.
Portland Cement (P.C.)

Portland cement is a hydraulic cement

capable of setting, hardening and
remains stable under water.
It is composed of calcium silicates and
some amount of gypsum
Blended Portland
Cements :
Blended cement, is a mixture of portland
cement and blast furnace slag (BFS) or a
"mixture of portland cement and a pozzolan
(most commonly fly ash)." The use of blended
cements in concrete reduces mixing water and
bleeding, improves finishability and
workability, enhances sulfate resistance,
inhibits the alkali-aggregate reaction, and
lessens heat evolution during hydration, thus
moderating the chances for thermal cracking
on cooling.
Blast furnace slag :
is a nonmetallic co-product produced in the process.
It consists primarily of silicates, aluminosilicates, and
calcium-alumina-silicates.
Pozzolan

An inert silicious material which, in the

presence of water, will combine with lime to
produce a cementitious matter with excellent
structural properties.

Advantages of Pozzolans :
Improved Workability
Economy
Reduced Alkali-aggregate Reaction
Increased Sulphate Resistance
Modified Portland Cement
(Expansive Cement)
Expansive cement, as well as expansive
components, is a cement containing hydraulic
calcium silicates (such as those characteristic
of portland cement) that, upon being mixed
with water, forms a paste, that during the early
hydrating period occurring after setting,
increases in volume significantly more than
does portland cement paste.
Manufacturing of
Portland Cement
Calcium silicates are the primary constituents of
portland cement.

Raw material for P.C. is Calcium & Silica

Calcium: Limestone, chalk, etc (CaO+CO2)
Silica: Clays and shales (SiO2+Al2O3+Fe2O3+H2O)
 Manufacturing Process
1. Crushing and Proportioning:
Limestone rock is the principal raw material, the first
step after quarrying in the processes is the primary
crushing. Mountains of rock are fed through crushers
capable of handling pieces as large as an oil drum.
The first crushing reduces the rock to a maximum size
of about 15 cm.
The rock then goes to secondary crushers or hammer
mills for reduction to about 7.5 cm or smaller.
2. Raw milling & Blending:
The next step in the process is to grind the
above particles to a size of 90 microns or less
which is done in a closed circuit ball mill
equipped with high efficiency separator. After
achieving the 90 microns size the fine grinded
material also known as raw meal is sent to the
continuous blending silos (CFC) for
homogenization & extracted by means of load
cell hopper for the next step which is feeding to
the kiln pre heaters.
3. Pyro processing :
The raw material is heated to exceeding 1,450 °C
(2,700 degrees F) in huge cylindrical steel rotary kilns
lined with special firebrick. Kilns are frequently as much
as 3.7 M (12 pi) in diameter, large enough to
accommodate an automobile and longer in many
instances than the height of a 40-story building. Kilns
are mounted with the axis inclined slightly from the
horizontal. The finely ground raw material or the slurry
is fed into the higher end. At the lower end is a roaring
blast of flame, produced by precisely controlled burning
of powdered coal, oil or gas under forced draft .
4. Burning and cooling:
As the material moves through the kiln, certain
elements are driven off in the form of gases. The
remaining elements unite to form a new substance with
new physical and chemical characteristics. The new
substance, called clinker, is formed in pieces about the
size of marbles. Clinker is discharged red-hot from the
lower end of the kiln and generally is brought down to
handling temperature in various types of coolers. The
heated air from the coolers is returned to the kilns, a
process that saves fuel and increases burning efficiency.
5. Cement milling, Storage & Packing:
Portland cement, the basic ingredient of concrete, is a
closely controlled chemical combination of calcium,
silicon, aluminum, iron and small amounts of other
ingredients to which gypsum is added in the final
grinding process to regulate the setting time of the
concrete. Lime and silica make up about 85% of the
mass. Common among the materials used in its
manufacture are limestone, shells, and chalk or marl
combined with shale, clay, slate or blast furnace slag,
silica sand, and iron ore. The above mixture …….
Cement Chemistry

In cement chemistry, the individual oxides and

clincker compounds are expressed by their
abbreviations .

Short Hand Notation

• C (CaO, calcium oxide)
• A (Al2O3, alumina)
• S (SiO2, silica)
• S (SO3, sulfate)
• H (H20, water)
Reactive Compounds:

 C3S (tricalcium silicate)

C2S (dicalcium silicate)
 C3A (tricalcium aluminate)
 CSH2 (gypsm)
 C4AF (tetra-calcium alumino ferrite)
Compounds of Portland
Cement:
Cement Chemistry :
Other Compounds

• Magnesium Oxide, MgO

• Calcium Oxide, Lime, CaO
• Alkali, Na2O, K2O :
equivalent Na2O=(Na2O+0.46 K2O) limited
to about 1-2%
Types of Portland Cement
Standard Specifications for Portland Cement.

Type I: General purpose. For use when the special properties

specified for any other types are not required.

Type II: For general use, more specially when moderate sulphate
resistance or moderate heat of hydration is desired.

Type III: For use when high early strength is desired. (limit the
C3A content of the cement to maximum 15%)

Type IV: For use when low heat of hydration is desired.

Type V: For use when high sulfate resistance is desired.

(Maximum limit of 5% on C3A)
HEAT OF HYDRATION

Heat of hydration is the heat generated when

cement and water react. The amount of heat
generated is dependent chiefly upon the
chemical composition of the cement, with C3A
and C3S being the compounds primarily
responsible for high heat evolution.
Physical Properties of
Portland Cement
•Fineness
•Soundness
• Consistency
• Setting time
•False set
•Flash set
•Compressive strength
• Heat of hydration
• Loss on ignition
• Density
• Bulk density
Fineness

Fineness of cement is also important; it

affects:
• rate of hydration
• rate of setting
• rate of hardening
• durability
• rate of carbonation during storage
• cost
• rate of gypsum addition
Soundness
Setting Time
Density :
Bulk Density :
Effects of Impurities in
Mixing Water
Excessive impurities in mixing water
affect setting time and concrete strength
and also cause efflorescence (deposits
of white salts on the surface of
concrete), staining, corrosion of
reinforcement, volume changes, and
reduced durability
Sea Water

Seawater containing up to 35,000 ppm of

dissolved salts is generally suitable as
mixing water for plain concrete.
. Seawater is not suitable for use in
making steel reinforced concrete and pre-
stressed concrete due to high risk of steel
corrosion.
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