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Contents
Introduction
History
i. All over
ii. In Pakistan
Present
i. Historical Analysis of Cement Production Capacity &
Dispatches
ii. Pakistan cement Production
Additives Used in Cement Manufacturing
i. Major Additives
ii. Cement Additives (Function and Definition)
Types of cement
Future plan
Conclusion
References
pg. 1
Additives involved in cement industry
What is Cement?
Definition:
Defined as a product material obtained by calcination of calcareous (a
material containing lime) and argillaceous (a material which contain silica) materials.
History
Cement dates back to antiquity, and one can only speculate as to its discovery[2] . A
cement was used by the Egyptians in constructing the pyramids. The Greeks and
Romans used volcanic tuff mixed with lime for cement, and a number of these
structures are still standing . In 1824 an Englishman, Joseph Aspdin, patented an
artificial cement made by the calcination of an argillaceous limestone. He called this
‘Portland’ because concrete made from it resembled a famous building stone
obtained from the Isle of Portland near England. This was the start of the Portland
cement industry of today. The hard clinker resulting from burning a mixture of clay
and limestone or similar materials is known by the term Portland cement to
distinguish it from natural or pozzolan and other cements. Concrete and cements
are not synonymous terms. Concrete is artificial stone made from a carefully
controlled mixture of cement , water, and fine and coarse aggregate (usually sand
and coarse rock).
pg. 2
Additives involved in cement industry
In Pakistan:
Cement industry is one of the few industries that existed in Pakistan before the
partition of the sub-continent. The major reason for the existence of this industry is
the availability of the raw materials. Pakistan has inexhaustible reserves of limestone
and clay, which can support the industry for another 50-60 years. The annual
production of the cement at the time of the creation of Pakistan was only 300000
tons per year. By 1954 the production increased to 660000 tons per annum against
a demand of 1000000 tons per annum. At this time PIDC took initiative and
established two cement factories Zealpak (240,000 tons) and Maple Leaf (100,000
tons) having a capacity of 340000 tones, thereby increasing the production to
1000000 tons per annum. Since then besides expansion of the existing plants, new
plants have also established. Besides producing OPC, the Pakistani cement industry
also started producing SRC, Slag cement and white cement.
In 1921 the first cement plant was established at WAH. At the time of independence
in 1947 there were four cement factories with an installed capacity of 470,000 tons
per annum. These units were located at Karachi, Rohri, Dandot and WAH. In 1956
PIDC established two plants at Daudkel and Hyderabad and subsequently more
plants were established in the private sector.
Present
Historical Analysis of Cement Production Capacity & Dispatches
(Operational Units Data)[3]
pg. 3
Additives involved in cement industry
pg. 4
Additives involved in cement industry
Accelerators
Function
Accelerators may be added to the mix water to reduce the thickening and setting
times of the slurry, with the purpose of avoiding unnecessary time spent waiting on
cement.
Calcium Chloride is the most common type of accelerator used. Other, less
frequently used accelerators are Sodium Chloride and Potassium Chloride.
Additive Formula Concentration Comments
Calcium Chloride CaCl2 - 2 % BWOC High gels may form
(Accelerator) at higher
concentrations.
pg. 5
Additives involved in cement industry
Note:
In general accelerators increase the viscosity of the cement slurry and decrease the
effectiveness of most other additives
Calcium Chloride can cause skin burns and sever irritation to eyes, nose and lungs.
Gloves, goggles and respirators shall be used during mixing. Calcium Chloride is
available in 50lb sacks.
Retarders
Additive
Lignin
Organic Acids
Function
As the temperature increases, the chemical reaction between cement and water is
accelerated which, in turn, reduces the pump able time. Increased depths and
pg. 6
Additives involved in cement industry
formation temperatures may require the use of retarders in order to extend the pump
able time of the cement.
Thixotropic slurries may require retarders at shallow depths and low temperatures.
Effects on Viscosity
Most retarders affect the viscosity of the cement as follows:
Type of Retarder Effect on Viscosity
Lignin Derivatives (HR 5, HR 6 etc) Reduce
Organic Acids Organic Acids
Cellulose Derivatives (CMC) Cellulose Derivatives (CMC)
The combined use of retarders and accelerators in the same mix should be avoided
High Density Additives
Additives
sintered bauxite
silicon carbide,
Function
There are two main methods of increasing the gradient of the cement slurry:
reducing the water/cement ratio
pg. 7
Additives involved in cement industry
Note: When drilling with a mud gradient of 14.8 ppg or more, a batch mixing unit and
sufficient weighting material must be on site as a contingency. If very large volumes
need to be mixed, batch mixing is not achievable
pg. 8
Additives involved in cement industry
squeezing) the cement. As a result, higher pumping rate are possible and higher
displacement efficiencies may be achieved.
pg. 9
Additives involved in cement industry
Function
The main application of thixotropic slurries is cementing in lost circulation
environments.
During pumping the slurry behaves as normal, however, a gel structure develops
rapidly when static. Such slurries also find application in cementing across gas zones.
The major disadvantage of thixotropic slurries is their relatively high viscosity which
may adversely affect displacement efficiency
Defoamers and Antifoamers
Additive Function
BI-AF1(LIQUID) Liquid anti-foam agent; minimizes air
entrainment in a cement slurry during
mixing; effective at all temperatures;
normal concentration is 0.06
gallons/barrel of mix water.
BI-AF 1P Anti-foam agent; minimizes air
entrainment in a cement slurry during
mixing; effective at all temperatures;
normal concentration is 0.2 to 0.3 lb./sk
of cement.
BI-AF2(LIQUID) Liquid defoamer/anti-foam agent;
minimizes air entrainment in a cement
slurry during mixing; effective at all
temperatures; added to mix water or
can be sprayed into blender tub, normal
concentration is 0.06 gallons/barrel of
mix water.
pg. 10
Additives involved in cement industry
Function
During the hardening process, the cement slurry passes through a semi-solid phase
in which the liquid has gelled up. As a result, the overburden pressure will be lost
thus permitting gas migration into, and through, the cement matrix.
.Types of Cement[5]
The types of special cement now being produced can be roughly classified in the
following six categories according to the special purpose for which these have been
designed. These are:
pg. 11
Additives involved in cement industry
pg. 12
Additives involved in cement industry
This is cement specially meant for the concreting of structures where large masses
of concrete have to be poured at one time. Generally it is specified that heat of
hydration on 7 days will not exceed 250Kg. This is achieved by making this cement
with larger percentage of di-calcium silicates in its contents than normally presents
in OPC.
3-B Slag Cement:
This is another variety of low heat cement. Grinding 35% to 65 % of granulated blast
furnace slag with ordinary Portland cement clinker produces it. The higher the slag
contents, the lower are the 3 and 7 days strengths but better is the resistance to
chemical attack.
3-C Pozzolana:
Grinding various proportions of natural pozzolana, tars or volcanic ash with ordinary
Portland clinker makes this cement. It is very good cement in the sense that it has
good workability properties in addition to having low heat and moderate sulphate
resisting properties.
3-D Super Sulphate Cement:
This is another variety of low heat cement. Its standards exist under B.S but not
under A.S.T.M. it is made by grinding about 70-80% B. F. Slag with about 10% gypsum
and 1-2 % Portland clinker or lime. This cement is also middy resistant to sulphate
attack. It is very finely ground cement and its early strength at 3 day is comparable
to OPC although under the BS its 7 days strength is required to be comparable to at
least the 3 days strength of OPC. This cement is also good masonry cement due to
its good workability but it can be used in RCC and other construction work in the
same manner as OPC is used with excellent results.
Cement For Better Protection of Reinforcement against Corrosion:
The basic steps for the prevention of resulting of steel in concrete is to use such
cement aggregate and mixing water as are basically free from chlorides, maximum
contents of chlorides in concrete being limited to 0.02 % by weight. The following
properties in cement are essential for greater protection of steel:
1. Cement to be with minimum percentage of Chlorides says not exceeding 0.01
per cent.
2. Portland Cement preferably having about 6 to 8 per cent Tricalcium
Aluminates.
3. Cement made with slag as additive.
pg. 13
Additives involved in cement industry
pg. 14
Additives involved in cement industry
Future
The cement sector over the last six years and the industry itself has seen a growth
in volume every year something that is also reflected in the huge return on
investment cement stockholders have enjoyed. Considering the heavy
investment the Chinese have made in Pakistan with the China Pak Economic
Corridor (CPEC) and the barriers to entry for new entrants it seems the growth
will continue for few more years to come.
Cement industry comprises 24 cement plants with an annual installed capacity of
producing 44.22 million tons of cement. It is also expected that to add more
cement plants in the industry.
Conclusion
There are different types of additives which are used in the cement
manufacturing like gypsum, which is used to increase the settling time of cement
, lime, which provide essential component for the manufacturing of cement ,
clay and many other additives are used in the cement manufacturing process ,
each additive has its own function which provide a specific quality to the material.
Some additives also has effects on the materials.
There is also different types of cement like ordinary Portland cement , rapid
hardening cement , low heat of hydration cement etc. Each one is used according
to the requirements.
pg. 15
Additives involved in cement industry
References
[1]
Shreve’s Chemical Process industries,5th ed. , pg., 171
[2]
ECT, 3d ed., vol. 5, 1979, pp. 163-192 (excellent summary);
[3]
(http://www.apcma.com/data-history.htm)
[4]
http://www.oilfield-solutions.basf.com/ev/internet/oilfield-solution
/en_GB/applications/cementing/gas-blocking,
[5]
http://www.apcma.com/cement.html
pg. 16