Assignment

Subject Chemical Process

Industry
Submitted By Hamza Naeem
Reg No# 2016-CH-421
Submitted To Dr. Sajjad

University Of Engineering & Technology Lahore

(FSD CAMPUS)
 Additives of cement industry

List of contents
 A brief explanation of cement

 Types
o Hydraulic
o Non-hydraulic
 Main ingredients
 Cements in different origins
 History
 Manufacturing of cement
 References
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ADDITIVES OF CEMENT INDUSTRY

What is CEMENT
“Cement is a product material obtained by the calcinations of
calcareous (a material containing lime) and argillaceous (a
material which contains silica) materials”

Detail
Cement is a binder, a substance used in construction
that sets, hardens and adheres to other materials, binding them
together. Cement is seldom used solely, but is used to bind sand
and gravel (aggregate) together. Cement is used with fine
aggregate to produce mortar for masonry, or with sand and
gravel aggregates to produce concrete.

The word "cement" can be traced back to the Roman term opus
caementicium, used to describe masonry resembling
modern concrete that was made from crushed rock with burnt
lime as binder. The volcanic ash and
pulverized brick supplements that were added to the burnt lime,
to obtain a hydraulic binder, were later referred to
as cementum, cimentum, cäment, and cement. In modern times,
organic polymers are sometimes used as cements in concrete.
Types
Cements used in construction are usually inorganic,
often lime or calcium silicate based, and can be characterized as
 Additives of cement industry

being either hydraulic or non-hydraulic, depending upon the

ability of the cement to set in the presence of water
(see hydraulic and non-hydraulic lime plaster).

Non-hydraulic cement
It will not set in wet conditions or
underwater; rather, it sets as it dries and reacts with carbon
dioxide in the air. It is resistant to attack by chemicals after
setting.

Chemistry

Non-hydraulic cement such as slaked lime (calcium

hydroxide mixed with water), hardens by carbonation in the
presence of carbon dioxide which is naturally present in the air.
First calcium oxide (lime) is produced from calcium
carbonate (limestone or chalk) by calcination at temperatures
above 825 °C (1,517 °F) for about 10 hours at atmospheric
pressure:
CaCO3 → CaO + CO2
The calcium oxide is then spent (slaked) mixing it with water
to make slaked lime (calcium hydroxide):
CaO + H2O → Ca (OH)2
Once the excess water is completely evaporated (this
process is technically called setting), the carbonation starts:
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Ca(OH)2 + CO2 → CaCO3 + H2O

This reaction takes a significant amount of time because

the partial pressure of carbon dioxide in the air is low.
The carbonation reaction requires the dry cement to be
exposed to air, and for this reason the slaked lime is a
non-hydraulic cement and cannot be used under water.
This whole process is called the lime cycle.

Hydraulic cement
It set and become adhesive due to
a chemical reaction between the dry ingredients and water. The
chemical reaction results in mineral hydrates that are not very
water-soluble and so are quite durable in water and safe from
chemical attack. This allows setting in wet condition or
underwater and further protects the hardened material from
chemical attack. The chemical process for hydraulic cement
found by ancient Romans used volcanic ash (pozzolana) with
added lime (calcium oxide).

Chemistry

Conversely, hydraulic cement hardens by hydration when

water is added. Hydraulic cements (such as Portland cement) are
made of a mixture of silicates and oxides, the four main
components being:
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 Belite (2CaO·SiO2);
 Alite (3CaO·SiO2);
 Tricalcium aluminate (3CaO·Al2O3) (historically, and
still occasionally, called 'celite');
 Brownmillerite (4CaO·Al2O3·Fe2O3).
The silicates are responsible for the mechanical
properties of the cement, the tricalcium aluminate and
the brownmillerite are essential to allow the
formation of the liquid phase during the kiln sintering
(firing). The chemistry of the above listed reactions is
not completely clear and is still the object of research

Main ingredients of cement

 Lime stone
 Clay
 Gypsum

Detail:
Lime stone is a source of CaO which makes silicates, aluminates
and aluminoferates. These all contain CaO2 & Al2O3 and these
are provided to cement by clay. Similarly, gypsum is used to
increase the setting time of the cement. The formula of cement is
following.
(CaSO4.7H2O)
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HISTORY:
Alternatives to cement used in antiquity:

Cement, chemically speaking, is a product that includes lime as

the primary curing ingredient, but is far from the first material
used for cementation. The Babylonians and Assyrians
used bitumen to bind together burnt brick or alabaster slabs. In
Egypt stone blocks were cemented together with a mortar made
of sand and roughly burnt gypsum (CaSO4·2H2O), which often
contained calcium carbonate (CaCO3).

Macedonians and Romans

Lime (calcium oxide) was used on Crete and by the ancient

Greeks. There is evidence that the Minoans of Crete used
crushed potshards as an artificial pozzolan for hydraulic
cement. It is uncertain where it was first discovered that a
combination of hydrated non-hydraulic lime and
a pozzolan produces a hydraulic mixture, but concrete made
from such mixtures was used by the Ancient Macedonians and
three centuries later on a large scale by Roman engineers.
There is... a kind of powder which from natural causes produces
astonishing results. It is found in the neighborhood of Baiea and
in the country belonging to the towns round about Mt. Vesuvius.
This substance when mixed with lime and rubble not only lends
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strength to buildings of other kinds, but even when piers of it are
constructed in the sea, they set hard under water.
The Greeks used volcanic tuff from the island of Thera as their
pozzolan and the Romans used crushed volcanic ash
(activated aluminum silicates) with lime. This mixture was able
to set under water increasing its resistance. The material was
called pozzolana from the town of Pozzuoli, west of Naples
where volcanic ash was extracted. In the absence of pozzolanic
ash, the Romans used powdered brick or pottery as a substitute
and they may have used crushed tiles for this purpose before
discovering natural sources near Rome. The huge dome of
the Pantheon in Rome and the massive Baths of Caracalla are
examples of ancient structures made from these concretes, many
of which are still standing. The vast system of Roman
aqueducts also made extensive use of hydraulic cement.

Cements in the 19th century

In Russia, Egor Cheliev created a new binder by mixing lime

and clay. His results were published in 1822 in his book A
Treatise on the Art to Prepare a Good Mortar published in St.
Petersburg. A few years later in 1825, he published another
book, which described the various methods of making cement
and concrete, as well as the benefits of cement in the
construction of buildings and embankments.
James Frost, working in Britain, produced what he called
"British cement" in a similar manner around the same time, but
did not obtain a patent until 1822. In 1824, Joseph
Aspdin patented a similar material, which he called Portland
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cement, because the render made from it was in color similar to
the prestigious Portland stone. However, Asp dins' cement was
nothing like modern Portland cement but was a first step in its
development, called a proto-Portland cement. Joseph Aspdin's
son William Aspdin had left his father’s company and in his
cement manufacturing apparently accidentally produced calcium
silicates in the 1840s, a middle step in the development of
Portland cement. William Aspdin's innovation was
counterintuitive for manufacturers of "artificial cements",
because they required more lime in the mix (a problem for his
father), a much higher kiln temperature (and therefore more
fuel), and the resulting clinker was very hard and rapidly wore
down the millstones, which were the only available grinding
technology of the time. Manufacturing costs were therefore
considerably higher, but the product set reasonably slowly and
developed strength quickly, thus opening up a market for use in
concrete. The use of concrete in construction grew rapidly from
1850 onward, and was soon the dominant use for cements. Thus
Portland cement began its predominant role.

Isaac Charles Johnson further refined the production of meso-

Portland cement (middle stage of development) and claimed to
be the real father of Portland cement.
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Cements in the 20th century

Calcium aluminate cements were patented in 1908 in France by

Jules Bied for better resistance to sulfates.

In the US, the long curing time of at least a month for Rosendale
cement made it unpopular after World War One in the
construction of highways and bridges and many states and
construction firms turned to the use of Portland cement. Bertrain
H. Wait, an engineer whose company had worked on the
construction of the New York City's Catskill Aqueduct, was
impressed with the durability of Rosendale cement, and came up
with a blend of both Rosendale and synthetic cements which had
the good attributes of both: it was highly durable and had a
much faster setting time. Mr. Wait convinced the New York
Commissioner of Highways to construct an experimental section
of highway near New Paltz, New York, using one sack of
Rosendale to six sacks of synthetic cement.
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Types of cement

Low heat cement Manufactured by reducing

tricalcium aluminate
Sulphates reducing cements It is prepared by maintaining
the percentage of tricalcium
aluminate below 6% which
increases power against
sulphates
Blast furnace slag cement It is obtained by grinding the
clinker with about 60% slag
and resembles more or less in
properties of Portland cement
High Alumina Cement It is obtained by melting
mixture of bauxite and lime
and grinding with the clinker it
is rapid hardening cement with
initial and final setting time of
about 3.5 and 5 hours
respectively
White cement It is obtained from raw material
free from iron
Coloured cement It is produced by mixing
mineral pigments with ordinary
cement.
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Pozzolanic cement It is prepared by mixing

Air Entraining Cement
pozzolanic clinker with
Portland cement
It is produced by adding
indigenous air entraining
agents such as resins, glues,
sodium salts of Sulphates etc
during the grinding of clinker.

Manufacturing process of cement

 Extraction and processing

Raw materials employed in the manufacture of cement are
extracted by quarrying in the case of hard rocks such as
limestones, slates, and some shales, with the aid of blasting
when necessary.
The excavated materials are transported to the crushing plant by
trucks, railway freight cars, conveyor belts, or ropeways. They
also can be transported in a wet state or slurry by pipeline. In
regions where limestones of sufficiently high lime content are
not available, some process of beneficiation can be used. Froth
flotation will remove excess silica or alumina and so upgrade the
limestone, but it is a costly process and is used only when
unavoidable.

Manufacture of Cement
There are four stages in the manufacture of portland cement: (1)
crushing and grinding the raw materials, (2) blending the materials in the
correct proportions, (3) burning the prepared mix in a kiln, and (4)
 Additives of cement industry
grinding the burned product, known as “clinker,” together with some 5
percent of gypsum (to control the time of set of the cement). The three
processes of manufacture are known as the wet, dry, and semidry
processes and are so termed when the raw materials are ground wet and
fed to the kiln as a slurry, ground dry and fed as a dry powder, or ground
dry and then moistened to form nodules that are fed to the kiln.the
diagram is following;

The other process involve in production of

cement are as follows;

 Crushing and grinding

 Blending
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 Burning

Conclusion

Cement is a basic need of history and the present, because it is

used in the construction of buildings and different statues. To
improve the efficiency of cement and to make it economic
different methods (as above) are applied. Different additives of
cement are used on the basis of their properties. And different
methods are implied to manufacture the cement. All the raw
materials are extracted from mines. Today the quality of cement
has been improved so much that there is no comparison between
first binder and present cement.
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References
1. http://www.hse.gov.uk/pubns/cis26.pdf
2. Jump
up^ http://www.cementaustralia.com.au/wps/wcm/connect/website/package
d-products/home/hints-and-tips/FAQ-Safety/#FAQ-safety-PPE.html
3. Jump up^ http://www.tdi.texas.gov/pubs/videoresource/stpcement.pdf
4. Jump up From shreve’s book.
5. Jump up Slides from dr. sajjad