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CONTENT
Cementing property, lime and hydraulic materials.
Portland cement: Compositions, Properties
An Overview of the Portland Cement Manufacturing
Process
Clinker formations and clinker chemistry
Hydration of Portland cement
Introduction to other cements and cement products:
slacked lime, plaster of Paris
Introduction to concrete
Learning outcomes
Know cementing property, lime and hydraulic
materials.
Understand Portland cement (OPC, PCB)
Understand Portland cement manufacturing process
Know main raw materials for PC
Understand the purpose of the stages in Portland
cement process
Know various grinding equipments and cement kilns
Know various stages of firing and various factors
related to firing operation of PC
Know some other cements: composition, properties
and making
WHAT IS CEMENT
A cement is a binder, a substance that sets and
hardens and can bind other materials together.
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.
Cements used in construction can be characterized
as being either hydraulic or non-hydraulic,
depending upon the ability of the cement to set in the
presence of water
WHAT IS CEMENT
Non-hydraulic cement will not set in wet conditions
or underwater; rather, it sets as it dries and reacts
with carbon dioxide in the air. It can be attacked by
some aggressive chemicals after setting.
Hydraulic cements (e.g., Portland cement) set and
become adhesive due to a chemical reaction
between the dry ingredients and water.
Mineral hydrates 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.
A non-hydraulic cement: slacked 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 is produced by lime 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: CaO + H2O Ca(OH)2
Once the excess water is completely evaporated (this process
is technically called setting), the carbonation starts:
Ca(OH)2 + CO2 CaCO3 + H2O
This reaction takes a significant amount of time. The
carbonation reaction requires the dry cement to be exposed to
air, for this reason the slaked lime is a non-hydraulic cement
and cannot be used under water.
A non-hydraulic cement: gypsum cement
(Plaster of Paris)
It is often called plaster of Paris, because of the large deposits of pure gypsum at
Montmartre hill in Paris
A hydraulic cement: Portland cement
HISTORY
Silicon dioxide
Fe2O3
2 5%
Iron oxide
Jan 2009
CLINKER
Raw materials
grinding
mixing
raw meal
kiln feed
firing 14500C
cooling
Jan 2009
Influences of Major and Minor Phases
of clinker on Cement Properties
Major Phases
C3S - very reactive compound, high heat of hydration,
high early strength
C2S - low heat of hydration, slow reaction, late stage
strengths, durability
C3A - Initial set, high heat of hydration, problems with
sulfate attack
C4AF - Color
Minor Phases
CaOfree (free lime) - Setting time, early strengths
Alkali / sulfates - Early strengths
MgO - Expansion
Contribution of clinker phases on
strength development of PC
ASTM Portland Cements
Type I General Purpose
Type II moderate heat of hydration and sulfate
resistance (C3A < 8%) : general construction, sea
water, mass concrete
Type III high early strength (C3A < 15%) :
emergency repairs, precast, winter construction.
Type IV low heat ( C3S < 35%, C3A < 7%, C2S >
40%) : mass concrete
Type V sulfate resistant ( C3A < 5%) : sulfate in
soil, sewers.
Blended Portland Cement (PCB)
a hydraulic cement consisting of two or more
inorganic constituents, which contribute to the
strength gaining properties of cement.
Clinker
Gypsum
(Portland cement)
Blended
cement
Fly ash
Slag
Silica Fume
Portland Calcined Clay
cement
What do PC 50 and PCB 40 mean?
Cement Manufacturing Processes
Mechanical Processes Thermal & Mechanical Processes
Chemical
Raw Processes
Materials
Calcareous Alternative
Argillaceous
Silica correctives Fuels
Raw
Iron correctives
Meal Gypsum
Mineral
Clinker Components
Quarrying
Crushing
Pre-blending Burning...
Cement
Grinding
Homogenizing...
Grinding Dispatch
Blending...
4 different basic processes
Dry process: Dry raw meal is fed to a cyclone preheater or
precalciner kiln or, in some cases, to a long dry kiln with
internal chain preheater.
Semi-dry process: Dry raw meal is pelletised with water and
fed to a travelling grate preheater prior to the rotary kiln or in
some cases, to a long kiln equipped with internal cross
preheaters.
Semi-wet process: Raw slurry is first dewatered in filter
presses. The resulting filter cake is either extruded into pellets
and fed to a travelling grate preheater or fed directly to a filter
cake drier for (dry) raw meal production prior to a
preheater/precalciner kiln.
Wet process: The raw slurry is fed either directly to a long
rotary kiln equipped with an internal drying/preheating system
(conventional wet process) or to a slurry drier prior to a
preheater/precalciner kiln (modern wet process).
Dry process: modern technology
Wet process allowed for an easier handling and
homogenisation of the raw materials, especially in cases
when the raw materials are wet and sticky or exhibit large
fluctuations in the chemical composition of the individual
raw mix components.
With more advanced modern technology however, it is
possible to prepare a homogeneous raw meal using the
dry process, i.e. without addition of water to prepare a
raw slurry. The main advantage of a modern dry process
over a traditional wet system is the far lower fuel
consumption and thus, lower fuel cost.
Today, the selection of the wet process is only feasible
under very specific raw material and process conditions.
27
Thermodynamics of Clinker Formation
Heat balance of wet and dry kiln
(kJ/kg clinker; approximate values)
Dry kiln Wet kiln
Evaporation of H2O 20 (0.6%) 2100 (38%)
(0.4 % dry kiln and 35 % wet kiln)
Heat of reaction 1765 (54%) 1765 (32%)
Heat losses through 840 (26%) 1250 (23%)
gas, clinker, dust, etc.
Heat losses by radiation 650 (20%) 360 (7%)
and convection
3275 kJ/kg 5475kJ/kg
Cement Manufacturing Process
https://www.youtube.com/watch?v=m8U76Bm8kDY
5 parts
1. Raw material
2. Raw meal preparation
3. Clinker production
4. Cement production
5. Cement design
30
1. RAW MATERIAL
1. Raw material
Materials Limestone, marl Ca
Clay, shale, iron ore Si, Al, Fe
Mining Blasting
Excavation
Selective exploitation
Preparation / Chemical control of composition of
Homogenization mix bed, e.g. online analyzer
PGNA
Pre-blending bed
Addition of correctives
Key issues:
Homogeneity of deposit
Control of critical minor
elements
Color
Raw material longitudinal pre-
blending bed
stacking
reclaiming
Raw material circular pre-
blending bed
Raw material chemical composition
Example:
Dosage of correctives
2. Drying and grinding kiln feed
with ball mill
Drying and grinding kiln feed
with vertical roller mill
42
Dust Collection (To clean gas streams)
Bagfilter
Out
HS
Bypass
GKA GKJ
Active Inactive
GAS
3. CLINKER PRODUCTION
Process of Clinker Production
(1)
Process of Clinker Production
(2)
Process of Clinker Production
(3)
Sequence of Reactions Occurring
in a Rotary Kiln
20 - 100C Evaporation of free H2O
100 - 300C Loss of physically adsorbed water
400 - 900C Removal of structural H2O from clay minerals
>500C Structural changes in silicate minerals
600 - 900C Dissociation of carbonates
>800C Formation of C2S
~1450C Completion of
reaction and re-crystallization
of C3S and C2S
DRYING
COOLING
PREHEATING
PREHEATING
SINTERING
Clinker Production Line
80 340 C; to raw mill
C and / or EP
Pre heater
900 C
Calciner
57
Grate cooler
Clinker production
Combustibles
Clinker storage
Outdoor storage causes
prehydration
Short storage time might lead to
high grinding temperature
CLINKER STORAGE (1)
Burn-ability
2. Meal Fineness
Ball mill
Note Composite
Cements contain >
5% mineral
components as a
clinker replacement
Jan 2009
Cement grinding
Vertical roller mill
(VRM)
Weigh
feeder
Cement grinding
Ball mill
(BM)
Vertical pre-grinder
Roller
press
(RP)
Cement storage, packaging & dispatch
Layout of dispatch / shipping station
Cement Cement
Silo Silo
Dispatch/Transport
Packing & Loading
5. CEMENT DESIGN
Cement design
Usually most reactive component
Clinker High uniformity required
Properties can directly be influenced
by the plant
Influence on
Setting time
Fineness Water demand
Strength development
Workability
Shrinkage
CEMBUREAU - the European Cement Association, Best available techniques for the cement
industry, December 1999
The positive impacts
When water is added to cement,
what happens?
Dissolution of cement grains
Growing ionic concentration in water (now a solution)
Formation of compounds in solution
After reaching a saturation concentration, compounds
precipitate out as solids (hydration products)
In later stages, products form on or very near the surface
of the anhydrous cement
Setting and Hardening
Setting: Solidification of the plastic cement paste
Initial Set: Beginning of solidification (point in time
when the paste has become unworkable) (>45 min.)
Final Set: Final solidification (< 375 min.)
10min 1h
85
3h 10h
Hydration of C3A and C4AF
(ettringite)
ettringite
Ca(OH)2
C-S-H
87
Dimensional range of solod and
pores in a hydrated cement paste
QUESTIONS
Silicate glasses
THANK YOU