Northern Cement

Corporation

Lontok, Sophia Cortez, Patrick

Moriya, Yukari San Pedro, Lear Ver
1 INTRODUCTION
 VISION
We will shape a legacy of excellence in nation

“
building.

MISSION 3

We will pave the roads of progress in every cement

bag we produce.
CORPORATE PROFILE
Northern Cement Corporation is a cement 4

industry that offers the market a variety of

Portland cement products that are widely
used as general infrastructure material.
 Northern Cement Corporation is situated at the extreme south-
western flanks of Cordillera mountain range. The area is characterized
TECHNICAL
by low flat lying alluvial plains and eventually rises towards the north
DESCRIPTION
and east exhibiting a gently rolling to moderately rugged terrain. Rolling
hills occupy mostly the western and southern portion of the company
which is at the foothills of the Cordillera and sliced in between by the
Aloragat River. High relief starts from the cement plant abruptly rising to
the north and east reaching an elevation of about six hundred (600) 5
meters above sea level. Its strategic location offers ample limestone and
shale deposits that comprises bulk proportion of raw materials for the
manufacturing of cement, which makes the company live for the next
centuries and continuously giving livelihood for the next generations.
 ◎ Northern Cement Corporation was incorporated on February 10, 1967, on the same year, Mr.
Eduardo “Danding” Cojuangco, Jr., showed the first ray of hope and blessings to the people of
TECHNICAL barrio Labayug, Sison, Pangasinan by transforming this idle forested land into an industrialized
community. Under his leadership and guidance, the Atlantic Gulf & Pacific Company of Manila
DESCRIPTION (AG&P) was commissioned to construct what was to become the largest and the most modern
cement plant in the country during that time. A team of engineers arrived in Sison, Pangasinan
and taught the barrio folks whose only skills is to till the soil; the precious knowledge of cement
manufacturing that eventually gave them livelihood without leaving their home town. The year
1969 saw the rise of Northern Cement Corporation as the Country’s producer of quality cement.
On the 6th of December 1969, the first smoke was emitted from its chimney stack signifying the
firing of the Rotary Kiln. Twenty-one days later, the plant was blessed and inaugurated. The first 6
bag of cement was produced on January 28, 1970 and from then on, the domestic markets have
known Northern Cement as a household name in concrete construction. The company also
engaged in exporting its products from 1970 to the 80’s satisfying customers in India,
Bangladesh, Kuwait, Bahrain, Saudi Arabia, China and other countries in the region. An
undeniable proof that quality product defies distance. The company added to its mantle the
certification on ISO 9002:1994 on September 2, 1999 and on October 25, 2002, the ISO
9001:2000, in its commitment towards consistent product quality. On January 19, 2006,
Northern Cement Corporation focused on strengthening further its existing Quality
Management System by including ISO 14001:2004 and OHSAS 18001:1999 for environmental
protection and occupational safety & health, respectively.
 PLANT Impact Crusher Rotary Dryer
FACILITIES A machine A type of industrial dryer employed
designed to reduce to reduce or minimize the liquid
large rocks into moisture content of the material it is
smaller rocks, handling by bringing it into direct
gravel, or rock dust. contact with a heated gas.
7

Raw Mill
Hammer Mill Control
Suited for size reduction. An Equipment used to grind raw
materials into "raw mix" during the
manufacture of cement
 Homogenizing Silos Rotary Packing Machines
PLANT designed for homogenization of ideal for a wide variety of bag styles and
FACILITIES material mixtures of similar ranges as well as offers quick changeovers.
properties and grainage.
Continuous and work with air- Rotary Kiln
agitation and with various a pyro processing device used to raise
extraction systems. The bottom materials to a high temperature (calcination)
consists of 12 segments (outer in a continuous process. Rotary kiln is
important for its calcination process is the key 8
ring), 4 quadrants (mixing
chamber) and final discharge impact to the product quality.
chamber (tunnel), all are
equipped with porous aeration
boxes which can be aerated
independently by air from
blower/s.
 PLANT Gas Conditioning Clinker Cooler Static V-Separator
FACILITIES Towers clinker has a
cyclone a simple
temperature of over
This equipment is found mechanical device
+1300 °C (+2372 °F)
above all in the cement commonly used in the
industry, where they are after leaving the rotary
grinding circuits to
used to cool hot process furnace and must be
remove relatively large
gases from the cooled down to a 9
particles from gas
preheating tower to a temperature of about
streams. It also
filter acceptable +200 °C (+392 °F) for
removes relatively
temperature.It is used to intermediate storage.
large particles from
to increase the moisture
level of the dusty exhaust gas streams.
gas from the kiln, before
it is passed through the
bag house.
 PLANT Cement Ball Mill
FACILITIES Cement clinker is usually ground
into fine grey powder (cement)
using a ball mill. This is essentially
a large rotating drum containing
grinding media - normally steel
balls. As the drum rotates, the
motion of the balls crushes the 10
clinker. The drum rotates
approximately once every couple of
seconds.
2 MANUFACTURING
PROCESS
 ◎ Portland cement is manufactured from lime-bearing
RAW materials, usually limestone, together with clays,
MATERIALS shale, or blast-furnace slag containing alumina and
silica, in the approximate proportions of 60% lime,
19% silica, and 8% alumina, 5% iron, 5% magnesia,
and 3% SO₃. Some rocks, called cement rocks, are 12
naturally composed of these elements in
approximately suitable proportions and can be made
into cement without the use of large quantities of
other raw materials. In general, however, cement
plants rely on mixed materials.
 ◎ In the manufacture of cement the raw materials are ground together, the
mixture is heated until it fuses into a clinker, and the clinker is ground into a
RAW fine powder. The heating is usually accomplished in rotary kilns more than 150
MATERIALS m (500 ft.) long and 3.7 m (12 ft.) or more in diameter. The kilns are slightly
tilted from the horizontal, and the raw material is introduced at the upper end,
either in the form of a dry rock powder or as a wet paste composed of ground-up
rock and water. As the charge progresses down through the kiln, it is dried and
heated by the hot gases from a flame at the lower end. As it comes nearer the
flame, carbon dioxide is driven off, and in the area of the flame itself the charge 13
is fused at temperatures between 1540° and 1600° C (2800° and 2900° F). The
material takes approximately 6 hours to pass from one end of the kiln to the
other. After it leaves the kiln, the clinker is cooled quickly and ground, and then
conveyed by a blower to packing machinery or storage silos. The amount thus
produced is so fine in texture that 90 % or more of its particles will pass through
a sieve with 6200 openings per sq. cm (40,000 per sq. in).
 ◎ In a modern kiln, 45 kg (about 100 lb.) of raw
RAW material will make 27 to 30 kg (about 59 to 66
MATERIALS
lb.) of cement. The weight lost is largely carbon
dioxide and water. Kilns usually burn coal in the
form of powder and consume about 450 g
14
(about 1 lb.) of coal for about every 900 g (about
2 lb.) of cement produced. Oil and gas are also
used.
PROCESS
FLOW
CHART

15
 ◎ The finished products are then subjected to special
FINISHED packaging according to what type of Portland cement
PRODUCT the company has to offer. Northern Cement
Corporation is producing 3 types of Portland cement
which is Type I (regular Portland cement), Type I-P
with Philippine tuff cement, and Type N (Master 16
palitada masonry cement). The packaging material
they mainly use is paper which also has special
specification due to where they are being sold, this
also is one of their marketing strategies.
3 QUALITY CONTROL
PROCEDURES
IN –PROCESS The limestone gathered in
TESTING their quarry area is being
tested according to its
purity at their Quality
Assurance lab, which are 18
done by their chemical
engineers. The more
impure the limestone is
the best raw material to
use.
 The finished product is then subjected to physical test
FINISHED and tests on cement. Physical test includes fineness of
PRODUCT the powdered form of cement, setting time, soundness of
the hardened cement, and compressive strength. On the
other hand, test on cement includes loss in ignition,
silicon dioxide content, ammonium hydroxide content, 19
calcium oxide content, magnesium oxide content, sulfur
trioxide content, ferric oxide content, aluminum oxide
content, and insolubility of residue. These tests are done
in their laboratory for safety measure and to keep track
of the quality of the products they are producing.
 WASTE WATER AND

4 WATER TREATMENT
Northern Cement Corporation doesn’t
have a waste water treatment because
the company uses dry process
PLANT VISIT LAST FEBRUARY 19, 2018