Early History and Development of

Cement

#1: Assyrians and Babylonians (6500BC)

#2: Egyptians (2600 BC)

#3 Romans (2600 BC)

#4: Indian Subcontinent (2600 BC)

#5 John Smeaton

Types of Cement

Types of
Cement

Non- Water
Based or NonHydraulic
Cement

Common
Cement

Gray Cement

Water Based or
Hydraulic
Cement

Rapid
Hardening
Cement

Quick Setting
Cement

Low Heat
Cement

CEMENT
MANUFACTURING
PROCESS

SIMPLIFIED
FLOW
CHART

calcium oxide, CaO

aluminum oxide, Al 2O 3

silicon dioxide, SiO 2

BLASTING

Drilling and Blasting is the controlled use of explosives and

other methods such as gas pressure blasting pyrotechnics, to
break rock for excavation. It is practiced most often
in mining, quarrying and civil engineering such as dam or
road construction. The result of rock blasting is often known as
a rock cut.

CRUSHING AND TRANSPORTATION

The raw materials are loaded into a dumper.

The raw materials, after crushing, are transported to the plant

by conveyor. The plant stores the materials before they are
homogenized.

sffads

Secondary Crusher Station

RAW GRINDING

Mixing to obtain correct chemical configuration with proper

particle size, strength and efficiency comes under raw milling.
It can be achieved by any of three processes mentioned: the
dry process, the wet process, or the semidry process.

BURNING

Clinker is produced by heating raw mix in pyro-processing. It

forms hard, gray, spherical clinker nodules with diameters
ranging from 0.32 - 5.0 cm (1/8 - 2")[2]. Steps during pyroprocessing are: drying or preheating, calcining (a heating
lead ti calcium oxide formation), and burning (sintering).

COOLING

Subsequent to intense heating, the raw material is now sent to

a CFG cooler that brings the temperature of the material to
200 degrees Celsius.

CLINKER STORAGE

Clinker which is reinforced cement concrete, is now sent to

clinker silo to avoid weathering effects.

FINISH MILLING

The clinker is ground with other materials (which impart special

characteristics to the finished product) into a fine powder and
upto 5% gypsum and/or natural anhydrite is added to regulate the
setting time of the cement[4]. Other chemicals that regulate
flowability or air entrainment can be added. After preliminary size
via Roll Crusher materials are sent through ball or tube mills
(rotating, horizontal steel cylinders containing steel alloy balls)
which perform the remaining grinding. The grinding process occurs
in a closed system with an air separator that divides the cement
particles according to size. Partially or incomplete materials are
loop in production system again.

Usual Environmental Impact and Resolution

POLLUTION RELATED TO CEMENT INDUSTRY

AIR POLLUTION (MILLING, GRINDING, BLASTING, PYROPROCESS OF KILN)
WATER POLLUTION (WASTEWATER AND COOLING SYSTEM)
SOIL POLLUTION / SOIL CONTAMINATION (MINING OF CEMENT)
NOISE POLLUTION (MACHINERIES USED IN THE PROCESS)

Classification of Air Pollutants in Cement Industry

1. Gaseous Substance
2. Particulates
It is estimated that 5% of all carbon dioxide and greenhouse gases generated from
cement industry.

AIR POLLUTANTS FOUND IN CEMENT INDUSTRY

Sulfur Oxide (SOx)
Nitrogen Oxide (NOx)
Carbon Dioxide and Carbon Monoxide
Particulate Matters (PM10, PM 2.5)
Volatile Organic Compound (VOC)

Some Air Pollution Control

Use of Wet or Dry Scrubbers
Use of Filters or Filter System (Air Filter)
Enclosed Systems for Material Handling
Reducing Transfer Point

Environmental Impacts
Human Environment

Natural Environment (Landform)

Land (Terrestrial Ecology)
Water (Aquatic Ecology)
Air

PRACTICAL APPLICATION

Top 20 Global Cement Companies

Top 10 global cement producing countries by installed

capacity.

Cement Manufacturers in the Philippines

Prices of cement in the Philippines

(per 40 kg bag)

P 220.00

P 235.00

P 208.00

P 230.00

Classifications of Concrete:
1. Plain
2. Reinforced

Types of Cement used in Construction:

1. Ordinary Portland Cement
2. Rapid Hardening Portland Cement
3. Blast Furnace/ Sulfate Cement
4. Low heat Portland Cement
5. Portland Pozzolan Cement
6.High Alumina Cement

Main Composition of Cement:

Lime
Silica
Alumina
Iron Oxide
Sulfur Trioxide

1.6 - 65%
18 - 25%
3 - 8%
2 - 5%
1 - 5%

Lime

Silica

Alumina

Aggregates
is a broad category of coarse particulate material used in
construction that serves as reinforcement to add strength to
the overall composite material

Coarse Aggregates

Fine Aggregates

Concrete Proportion
Mixture
Class

Proportion

AA

Cement in bag

Sand
( )

Gravel
( )

40 kg

50 kg

1 : 1.5 : 3

12

9.5

0.5

1:2:4

0.5

1 : 2.5 : 4

7.5

0.5

1:3:6

0.5

AA
A
B
C

Strength of Mixture:

4000 psi

3500 psi

2500 psi

2000 psi