REPORT WORK

ON
CEMENT AND CEMENT INDUSTRIES OF NEPAL.

A SHORT REPORT WORK SUBMITTED FOR PARTIAL FULFILLMENT OF THE

REQUIREMENT FOR CHEMISTRY IN GRADE XII NEB.

SUBMITTED BY:
Poshan Rijal
ROLL NO :
REG. NO. :

SUBMITTED TO:
Department of Chemistry
GORKHA UNITED PUBLIC SECONDARY SCHOOL
KOHALPUR-2, BANKE,NEPAL
December 2024.
 BOARD OF EXAMINER AND CERTIFICATE OF APPROVAL

This dissertation entitled, “Cement and Cement Industries in Nepal” by Poshan Rijal under
the Supervision of Mr. Ajay Kumar Bajgai, Chemistry lecturer, Gorkha United Public
Secondary School, Kohalpur-2, Banke, Nepal and under co-supervision of Mr. Roshan
Shrestha, Chemistry Lecturer, Gorkha United Public Secondary School, Kohalpur-2, Banke,
Nepal hereby submitted has been approved for the intenal evaluation of Grade XII, 2081.
This dissertation has not been submitted to any other institution previously.

…………………….. ……………………..

Supervisor Co-Supervisor
Mr. Ajay Kumar Bajgain Mr. Roshan Shrestha
GUPSS, Kohalpur-2, GUPSS, Kohalpur-2,
Banke, Nepal Banke, Nepal

…………………… …………………….

Principal Academic Advisor

Mrs. Sadhana Thapa Mr. Rajendra B. Gurung
GUPSS, Kohalpur-2, GUPSS, Kohalpur-2,
Banke, Nepal Banke, Nepal

Date: December 27, 2024

II
III
 Subject Teacher’s Letter of Recommendation

The project work report entitled ‘Cement and Cement Industries In Nepal’, submitted by
Poshan Rijal, of Gorkha United Public Secondary School Kohalpur-2, Banke, Nepal is
prepared under my supervision as per the procedure and format requirements laid by the
Department of Chemistry, Gorkha United Public Secondary School, as the partial fulfillment
of the requirements of the internal evaluation of grade XII. I, therefore, recommend the
report for evaluation.

…………………

Supervisor
Mr. Ajay Kumar Bajgai
GUPSS, Kohalpur-2,
Banke, Nepal

IV
Date: December 27, 2024

Declaration
I hereby declare that the report presented in this project report has been done by myself under
the Supervision of Mr. Ajay Bajgain and Mr. Roshan Shrestha has not been submitted
elsewhere for any examination.
All sources of information have been specifically acknowledged by
references to authors or institutions.

Signature:………………..
Name: Poshan Rijal
Stream: Science
Grade: XII ‘A’
Roll No: 26

V
Date: December 27, 2024

Acknowledgement

I would like to express my special thanks of gratitude to my teachers Mr. Ajay Kumar
Bajgai and Mr. Roshan Shrestha who gave me the golden opportunity to do this wonderful
project on the topic on ‘Cement and Cement Industries In Nepal’ which also helped me in
doing a lot of Research and I came to know about so many new things I am really thankful to
him. Secondly, I would also like to thank my parents and friends who helped me a lot in
finalizing
this project within the limited time frame. Additionally, this endeavor would not have been
possible without their support. Words cannot express my gratitude to all of them. Thanks also
goes to those who impacted and inspired me.

Signature:
Name: Poshan Rijal
Stream: Science
Grade: XII’B’
Roll no: 15

VI
Date: December 27, 2024

List of Figures

Fig 1: Raw materials for cement production............................................................................1

Fig 2: Some of the recognized industries of Nepal...................................................................4
Fig 3:Flowsheet diagram of cement production by wet process.............................................14
Fig 4: Flowsheet diagram of cement production by dry process............................................15

List of table
List of abbreviations like ppc opc gci ………..
1.
Table of Content

VII
 s

BOARD OF EXAMINER AND CERTIFICATE OF APPROVAL.....................................................II

Subject Teacher’s Recommendation..................................................................................III

Declaration.......................................................................................................................IV

Acknowledgement.............................................................................................................V

List of Figures...................................................................................................................VI

CHAPTER-1, INTRODUCTION..............................................................................................1

1.1 BACKGROUND INTRODUCTION OF CEMENT...........................................................1

1.2 IMPORTANCE OF CEMENT...........................................................................................2

1.3 HISTORY OF CEMENT INDUSTRY IN NEPAL.............................................................3

1.4 OBJECTIVES OF THE STUDY.........................................................................................5

To visit one of the commercial cement industry of Nepal............................................................................5
To Study the working of plant......................................................................................................................6
To know different grade of cements and their composition.........................................................................8
To know the material collection and marketing strategy of industry..........................................................10

CHAPTER-2, MATERIALS AND METHODS..........................................................................11

2.1 COMPOSITION OF CEMENT........................................................................................11

2.1 RAW MATERIALS REQUIRED FOR CEMENT PRODUCTION.................................11

2.3 METHODS FOR THE PRODUCTION OF CEMENT....................................................13

2.4 FIGURES/RESEARCH DIAGRAMS:..............................................................................14

CHAPTER-3, LIMITATION OF THE STUDY...........................................................................16

CHAPTER-4, RESULTS AND DISCUSSION............................................................................17

CHAPTER-5, BIBLIOGRAPHY..............................................................................................19

VIII
 CHAPTER-1 INTRODUCTION
1.1 BACKGROUND INTRODUCTION OF CEMENT
Cement is an inorganic material which has adhesive and cohesive properties. It has been used
to support human civilizations specially for development since many years and decades. With
the advancement of technology, cement and cement based materials were modified the roles
in our life. The main function of cement is to act as a binder which is capable of bonding the
construction materials like sand, stones, bricks, building rocks, iron etc.
The principle constituents of cement are the compounds of Calcium (Ca), Aluminum (Al) and
Silicon (Si). Cement constituent of calcium is called calcareous whereas the constituent of
Aluminum and Silicon are called argillaceous. The cement consists of a unique property of
setting and hardening of calcareous and argillaceous material under water by virtue of certain
chemical reactions within it. The resulted hard material thus obtained will have different
physical and mechanical properties than the initial one.

Raw Materials for Cement Production:

Starting materials for cement production are minerals which are mainly lime, silica, alumina,
iron oxide and gypsum which are shown in figure below. They can be classified as:
i. Calcareous materials (such as limestone, chalk, marl) also called lime component.
ii. Argillaceous materials (such as clay, shale, slate) also called clay component.
iii. Auxiliary components (other raw materials).

1
Fig 1: Raw materials for cement production

1.2 IMPORTANCE OF CEMENT

Cement is a vital construction material that plays a key role in infrastructure and building
development. Here are some important points about its significance:
1. Foundation for Construction
 Cement is the primary binding material in concrete and mortar, providing the strength
and stability required for buildings, bridges and other structures.
2. Durability and Longevity
 Structures made with cement-based materials can withstand environmental conditions
such as rain, heat, and freeze-thaw cycles, ensuring long-term durability.
3. Versatility
 Cement is used in a variety of construction applications, including roads, dams,
industrial plants, residential homes, and decorative architecture.
4. Economic Growth
 The production and use of cement contribute significantly to the construction
industry, driving economic development and creating employment opportunities.
5. Resistance to Fire and Water
 Cement-based materials have high fire resistance, making them suitable for fire-prone
areas, and are often used in waterproofing applications.
6. Ease of Application
 Cement can be easily mixed with aggregates and water to create concrete or mortar,
making it practical and widely usable in construction.
7. Support for Modern Infrastructure

2
  Advanced types of cement, such as high-performance and eco-friendly options,
support modern construction needs, including sustainable and energy-sufficient
designs.
8. Innovation in Design
 Cement enables the creation of diverse and complex architectural designs due to its
moldability and strength.

Its versatility and essential role in construction make cement a cornerstone of modern
infrastructure development.

3
1.3 HISTORY OF CEMENT INDUSTRY IN NEPAL
Nepal is a landlocked country lying between two big countries India and China. Though It is
surrounded by big countries, Nepal is almost independent of them in context of cement
production. Almost all raw materials used for cement production is found in Nepal. Nepal is
near to fulfill the internal cement demands (about 80%) and may be able to export in near
Future which may assist to achieve the goal of “Prosperous Nepal and Happy Nepali”, a
slogan of Government of Nepal.
Nepal in rich in limestone. The Department of Geology and Mines (DGM) has estimated
about 1.07 billion tons of limestone deposits, among that 540 million tons are proven, 110
million
tons are semi proven and 420 million tons are feasible deposits.
Based on the known cement grade limestone deposits, about 28 cement industries are already
introduction phase, few are under construction and some are in the pipeline for the operation.
Establishment of cement industries based on available limestones is rewarding our country
since demand for cement is increasing in Nepal, India, China and other nearby countries.
Preliminary studies shows that there is a possibility to find more the 2.5 billion tons of
cement grade limestone deposits only in the lower Himalayan region. Annual production of
limestone in 2018 was 6,621,614.96 metric tons. The cement industry has experienced a
sudden surge in demand due because of increasing demand of the construction taking place
these days. It is estimated that Nepal imports about 15-20% of the total cement consumed.
The total FDI in this sector till date is approximately NPR 4.1 billion (USD 40 million).
As of the 2020s, Nepal has around 50 active cement factories, producing over 10 million
metric tons annually. Domestic production now meets most of the country’s cement needs.
Some factories, such as Shivam Cement and Hongshi Cement, have started exploring export
opportunities to neighboring countries like India.
The cement industry has become a cornerstone of Nepal’s infrastructure development,
contributing significantly to the economy and supporting large-scale construction projects
like highways, hydropower plants and urban housing.

4
SOME OF THE RECOGNIZED INDUSTRIES OF NEPAL ARE:
Name of the Industries Clinker(ton/year)

Hetauda Cement Ind. Ltd. 247,500

Udayapur Cement Ind. Ltd. 264,000

Maruti Cement Udhyog 150,000

Kanak Cement Pvt. Ltd. 120,000

Sagarmatha Cement Pvt. Ltd. 163,720

Shivam Cement Pvt. Ltd. 150,000

Pashupati Cement Pvt. Ltd. 132,000

Fig 2: Table Some of the recognized industries of Nepal

1.4 Types of cements

Depending on the hardening and setting behaviour, cement is mainly classified into two
types:
a) Hydraulic cement:
The cement which sets very quickly and hardens with addition of water to the finely
ground cement is called hydraulic cement. It is composed of mainly limestone and
gypsum clay. It is a non-corrosive, non-rusting and non-shrinkable substances widely
used in construction. For example, different brands of Portland cement are available
these days which are referred as hydraulic cement.
b) Non-hydraulic cement:
The cement which sets very slowly by the absorption of carbon dioxide from the
atmosphere and cannot harden while in contact with water is called non-hydraulic
cement. It is composed of lime, gypsum, plaster and oxychloride. For example,
gypsum and magnesium cement are referred to as non-hydraulic cement. Due to a
long drying period of its setting, use of this type of cement is less common. It’s still
used for making brick and mortar.

5
 Depending on the composition and characteristics, there are many types of cement.
Among them, the two commercially available important types of cement are:
1. Ordinary Portland Cement(OPC):
OPC is one of the most popular materials used all over the world for construction of
infrastructure. The name Portland was given by British cement manufacturer, Joseph
Aspdin in 1824 due to its resemblance to Portland stone, a type of white grey lime
stone found in the Isle of Portland. The chief chemical constituents of ordinary
Portland cement are calcium, silica, alumina and iron.
Portland cement clinker is a hydraulic material which consists of at least two-thirds by
mass of calcium silicates ([Link] 2 and 2CaO.SiO2), the remaining part consists of
clinker phases of aluminium and iron. The ratio of CaO to SiO 2 shall not be less than
2.0 and the magnesium oxide content should not exceed 5% by mass.
The cement available in the market has three grades namely OPC 33, OPC 43 and
OPC 53. These grades imply the maximum strength of the particular cement after 28
days.
Uses of OPC:
 It is used for general construction purposes.
 It is used for making grouts and mortars.
2. Portland Pozzolana Cement(PPC):
The Romans and Greeks knew that certain volcanic materials containing silica in the
reaction form when mixed with lime and sand could be used as building mortars of
good strength. The Roman builders used the red or purple volcanic tuff found in the
neighborhood of Pozzuoli for the construction purposes and hence the material is
known as pozzolana. The cement made from these pozzolanic materials is named as
Portland Pozzolana Cement(PPC).
PPC is a kind of blended cement which is produced by grinding the Portland clinker
with gypsum and pozzolanic materials (containing silica in a reactive form such as fly
ash) in measured proportions. PPC can also be produced by blending Ordinary
Portland Cement(OPC) with pozzolanic materials in certain proportions.
The composition of Portland Pozzolana Cement are:
 OPC clinker
 Gypsum
 Pozzolanic materials (fly ash, volcanic ash and calcined clay or silica fumes)

6
  The proportion of Pozzolana may vary from 15% to 35% by weight of
cement.
Uses of PPC:
 It is usually used in hydraulic structures, marine structures, dam constructions
etc.
 It is used in decorative and art structure.
Different types and grades of cement manufactured by Ghorahi Cement Industry Ltd. are
given below with their composition also:
1. Sagarmatha OPC – 43 Grade Sagarmatha remeve the word sagarmatha OPC
cement is higher strength cement made up of 95% clinker. This product is covered
under “Nepal Standard 49-2041(Ordinary Portland Cement: Specification)”. The
higher 28 days compressive strength of Sagarmatha OPC makes it suitable for all
general purpose as well as specialized works. Sagarmatha OPC is having very low
alkalis, which makes it more suitable for mass construction like dams, bridge etc.
Sagarmatha OPC Grade cement produced at Ghorahi (Dang) Plant has the most
modern Cement Manufacturing Technology, sophisticated and fast responsive Quality
Control equipment.
2. Sagarmatha OPC – 53 Grade
Sagarmatha 53 OPC is covered under “Nepal Standard 572(Ordinary Portland
Cement: Specification)”. Sagarmatha 53 OPC is manufactured by inter grinding of
high-grade clinker and right quality gypsum in appropriate ratio. It has high strength
and durability to structures because of its optimum particle size distribution and
superior crystallized structure. Sagarmatha 53 OPC sets quicker and has a quite low
initial setting time. It is used in paving of interlocking blocks, roads, runways and
industrial building, bridge pillars, precast concrete elements, lofty building etc.
3. Sagarmatha Gold PPC
The Sagarmatha Gold PPC is a Blended Cement which is produced by inter-grinding of
OPC clinker along with gypsum and pozzolanic materials (Fly Ash) in certain
proportions. The product is covered under “Nepal Standards No. 385-2054, Portland
Pozzolana Cement”, the quality of fly ash to be used in manufacturing of PPC is also
specified by “Nepal Standard No. 385-2054, Portland Pozzolana Cement”. The
Sagarmatha Gold (PPC) Portland Pozzolana Cement is ideally suited for Mass
Concreting Work, Masonry Mortaring and Plastering and can be used with all the other
applications where OPC is used.
7
 4. Sagarmatha Clinker
The primary raw material for Cement Manufacturing is Clinker. GCI owns a range of
Limestone-mines and Coal-mines, located in the Western region of Nepal, which is
mainly used to produce Clinker. GCI acts as a Self-Sustaining organization by
meeting its primary needs locally and by making its products truly authentic.

1.5 OBJECTIVES OF THE STUDY

To visit one of the commercial cement industry of Nepal
On Saturday 7th of December, 2024 we the students of Grade XII from Gorkha United
Public Secondary School went for our study visit to Ghorahi Cement Ltd. manufacturing
plant Ghorahi, Dang District, situated in Western Nepal. We boarded our college bus
around 7:00 am and reached the factory in between 12 pm to 12:30 pm.
Here, as we were preparing to enter the factory some mandatory safety tips and equipment
such as face masks were provided to the students. All set and prepared we now entered the
factory. At first we had no clue of the environment we were in, there were big machines and
infrastructures everywhere in different shapes and sizes. We were feeling like explorers
walking on a mini cement desert hidden from civilization, aloof from the city lights “and we
meant business”. Curiosity hit everyone hard and I could see most of us looking here and
there for answers. After a while of wandering the supervisor showed up and took charge of
the situation.
Write objectives points wiseTo know different grade of cements and their composition
To know the material collection and marketing strategy of industry
Established as a private limited company under the Company Act 2063 on 2064/04/21, Shree
Ghorahi Cement Industry Pvt. Ltd was converted into a public limited company on 2024/11/12
and has since been operating as Ghorahi Cement Industry Limited. The company’s major
objective is to produce and distribute cement clinkers of different types and grades within and
outside the country. Additionally, it intends to produce Portland cement, Portland Pozzolana,
and slag along with other types of cements and construction related products by establishing
cement factories with modern machinery and technology. Major products of the company
include Sagarmatha OPC – 43 Grade, Sagarmatha OPC – 53 Grade, Sagarmatha Gold PPC, and
Sagarmatha Clinker, among others. In order to ensure uninterrupted supply of raw materials
for its production process, the company has signed agreements with companies such as Shree
Bishwakarma Mines and Minerals Pvt. Ltd, Shree Rolpa Chundhunga Khaani Pvt. Ltd, and has

8
invested 100% in its subsidiary Shree Malaraani Mines and Minerals Pvt. Ltd. The company
uses modern Rotary Kiln and VRM along with Roller Press Grinding equipment made from
high-quality German technology for production. For the distribution of its products, the
company utilizes its network of distributors that expand throughout the country and also
directly supplies to large construction projects. The company has been able to establish itself
as a well-known brand in the country as a result of its production capacity, market share,
delivery system, and free of cost after-sales technical services.

1.3 About Ghorahi Cement Industry:

Ghorahi Cement Industry is a subsidiary of Triveni Group. The company was established in
the year 2009, set amidst the largest valley of Asia, in the city of Ghorahi, Dang District,
situated in Western Nepal. Mr. Purshotam Lal Sanghai is the current chairman of the
company along with 4 other members in Board of Directors. It is the largest cement factory in
Nepal with the area of 122 Bigha. It has the valuation of 2200 crores. It has employed about
450 to 500 manpower from people with no skill to people with highly skilled. GCI is an
integrated unit, which started as a green field project, with humble capacities. With strong
vision, and leadership, the company, in the last decade, has expanded its footprint
exponentially in the local market, and has established itself a reputed company within the
Nepalese Construction market.
The Journey of Ghorahi Cement Industry:
 In 2009, GCI started production of its Clinker Unit, with an annual capacity of
7,26,000 metric tons per year.
 In the quarter of 2013, GCI introduced its flagship brand of cement “Sagarmatha OPC
& Sagarmatha Gold PPC”, with an annual capacity of 2,50,000 metric tons annually.
 In 2015, based on the demand for its product, GCI expanded its annual capacity to
7,30,000 metric tons.
 In 2020, GCI expanded its production capacity by establishing a parallel
clinkerization unit, in the same location, with an additional capacity of 1.45 million
metric tons annually.
In the year 2020, GCI further boosted its production capacity, keeping in mind the
growing market, and its vision to be the market leaders.

9
 As of 2020, GCI’s total annual cement production capacity stands at 1.25 million
metric tons, also as one of the highest producers of OPC and PPC cement in the
country.
 In totality as of 2021, GCI stands as one of the largest clinker manufacturers in the
country with an aggregate capacity of over 2 million metric tons annually.
GCI invested substantially, in ensuring that its capacity is supported by state of the art
technology, which minimizes environmental impacts, and reduces energy
consumption and increases productivity, to match the best industrial practices
globally.

10
 CHAPTER-2, MATERIALS AND METHODS
2.1 COMPOSITION OF CEMENT
There are two primary cement manufacturing components that form the distinctive properties of
cement:
1. Calcareous materials: These materials are rich in calcium and magnesium and
typically include limestone, chalk, marl, shells, and other sources abundant in calcium
carbonate. These are the primary sources of calcium, which undergoes a calcination
process during cement production to form quicklime or calcium oxide that has
binding properties of the cement.
2. Argillaceous materials: Complementing the calcareous materials, argillaceous
components enrich cement’s composition. The argillaceous materials including silica,
alumina, iron oxide and more are added to the mix. This blend of elements adds to the
cement’s strength, durability, and binding characteristics.
2.2 RAW MATERIALS REQUIRED FOR CEMENT PRODUCTION
Here are the essential raw materials used for cement manufacturing:
 Limestone: It is the primary source of calcareous compounds. Limestone is a
sedimentary rock abundant in nature with high calcium content. It is quarried from
natural reserves which then undergo a series of processes including crushing,
grinding, and calcination to make quicklime.
 Clay or Shale: These materials are sourced from clay pits or shale deposits to
supplement the cement-making process. Their high silica and alumina content aids in
enhancing the binding properties of the final product.
 Pozzolans: These include volcanic ash, silica fumes, and certain industrial by-
products. The addition of pozzolans in cement enhances its strength, durability, and
resistance to chemical attacks. It makes it more resistant to harsh environmental
conditions. These are used to manufacture Portland Pozzolana Cement (PPC), a
popular choice for many construction projects.
 Iron Ore: It is used to add iron oxide to the mix to enrich the cement’s colour while
contributing to the fusion of raw materials for cement production and the strength of
the final product.

11
  Gypsum: It regulates the cement’s setting time. Its controlled addition helps in rapid
solidification which ensures workability and allows ample time for construction
processes.
 Fly ash: It is a by-product of coal combustion in power plants used in cement to
enhance the compressive strength of concrete while addressing environmental
concerns by reusing industrial waste. It also contributes to workability, reduces heat
evolution during cement hydration, and long-term strength and durability.
2.3 Main Steps in Cement Production:
1. Extraction:
 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. Some deposits are mined by underground methods. Softer
rocks such as chalk and clay can be dug directly by excavators.
2. Crushing and grinding:
 All except soft materials are first crushed, often in two stages, and then ground,
usually in a rotating, cylindrical ball, or tube mills containing a charge of
steel grinding balls. This grinding is done wet or dry, depending on the process in use,
but for dry grinding the raw materials first may need to be dried in cylindrical, rotary
dryers.
Soft materials are broken down by vigorous stirring with water in wash mills,
producing a fine slurry, which is passed through screens to remove oversize particles.
3. Blending:
 A first approximation of the chemical composition required for a particular cement is
obtained by selective quarrying and control of the raw material fed to the crushing and
grinding plant. Finer control is obtained by drawing material from two or more
batches containing raw mixes of slightly different composition. In the dry process
these mixes are stored in silos; slurry tanks are used in the wet process. Thorough
mixing of the dry materials in the silos is ensured by agitation and vigorous
circulation induced by compressed air. In the wet process the slurry tanks are stirred
by mechanical means or compressed air or both. The slurry, which contains 35 to 45
percent water, is sometimes filtered, reducing the water content to 20 to 30 percent,
and the filter cake is then fed to the kiln. This reduces the fuel consumption for
burning.
4. Burning:
12
  The earliest kilns in which cement was burned in batches were bottle kilns, followed
by chamber kilns and then by continuous shaft kilns. The shaft kiln in a modernized
form is still used in some countries, but the dominant means of burning is the rotary
kiln. These kilns—up to 200 metres (660 feet) long and six metres in diameter in wet
process plants but shorter for the dry process—consist of a steel, cylindrical shell
lined with refractory materials. They rotate slowly on an axis that is inclined a few
degrees to the horizontal. The raw material feed, introduced at the upper end, moves
slowly down the kiln to the lower, or firing, end. The fuel for firing may be pulverized
coal, oil, or natural gas injected through a pipe. The temperature at the firing end
ranges from about 1,350 to 1,550 °C (2,460 to 2,820 °F), depending on the raw
materials being burned. Some form of heat exchanger is commonly incorporated at
the back end of the kiln to increase heat transfer to the incoming raw materials and so
reduce the heat lost in the waste gases. The burned product emerges from the kiln as
small nodules of clinker. These pass into coolers, where the heat is transferred to
incoming air and the product cooled. The clinker may be immediately ground to
cement or stored in stockpiles for later use.
Modern cement plants are equipped with elaborate instrumentation for control of the
burning process. Raw materials in some plants are sampled automatically, and a
computer calculates and controls the raw mix composition. The largest rotary kilns
have outputs exceeding 5,000 tons per day.
5. Grinding:
 The clinker and the required amount of gypsum are ground to a fine powder in
horizontal mills similar to those used for grinding the raw materials. The material may
pass straight through the mill (open-circuit grinding), or coarser material may be
separated from the ground product and returned to the mill for further grinding
(closed-circuit grinding). Sometimes a small amount of a grinding aid is added to the
feed material. For air-entraining cements (discussed in the following section) the
addition of an air-entraining agent is similarly made.
Finished cement is pumped pneumatically to storage silos from which it is drawn for
packing in paper bags or for dispatch in bulk containers.
In this industrial visit we learned about various stages of production and the whole process of
manufacturing cement from raw materials like limestone, clay, clinker and gypsum to the
final product and the packaging process. Altogether it was a great experience to know the
insights of how a manufacturing plant functions.
13
2.4 Hydration of Cement
The hydration of cement is a chemical reaction between cement and water, resulting
in the formation of a hardened product called hydrated cement paste (HCP). This
process is essential for the setting and hardening of concrete and gives it its strength
and [Link] Steps in Cement Hydration:
1. Mixing:
When cement is mixed with water, the hydration process begins immediately. The
water reacts with the compounds in cement to form various hydration products.
2. Dissolution:
The soluble compounds in cement (like tricalcium silicate and dicalcium silicate)
dissolve in water, releasing calcium and hydroxide ions into the solution.
3. Formation of Hydration Products:
The dissolved ions recombine to form solid phases, such as:
 Calcium silicate hydrate (C-S-H): Responsible for most of the strength in
concrete.
 Calcium hydroxide (CH): A byproduct that helps maintain a high pH
environment, protecting embedded steel from corrosion.
 Other products like ettringite may form from sulfate compounds.
4. Setting:
The mixture begins to lose plasticity, transitioning from a fluid to a solid state. This
process is referred to as the initial and final setting.
5. Hardening:
Over time, the hydration products continue to develop, increasing the strength of the
concrete. The process can take years to fully complete, although most strength
development occurs within the first 28 days.

2.3 METHODS FOR THE PRODUCTION OF CEMENT

After performing crushing, there are two processes for grinding and blending of raw materials
for the manufacturing of Portland cement:
I. Wet process:
The grinding and mixing of the raw materials are done in presence of water. When chalk is
used as raw material, the chalk and clay are separately broken up and dispersed in water in a

14
wash mill. The two mixtures are now pumped so as to form slurry and passed into storage
tank When lime stone is used as raw material, the lime stone is blasted then crushed into
initial and secondary crushers and then fed into a ball mill with clay dispersed in water and
the resultant slurry is pumped into storage tanks. The slurry is mixed mechanically in the
storage tank and the sedimentation of the suspended solids is prevented by bubbling
compressed air from bottom of the tank. The slurry with desired lime content is fed in at the
upper end while pulverized coal is blown in air blast at the lower end of the kiln at about
1450 0C The slurry in its movement down the kiln, encounters a progressively higher
temperature. Water and carbon dioxide are liberated and the dry material fuses into balls
known as clinker which drops into coolers.
II. Dry process:
The grinding and mixing of the raw materials are done in their dry state. The raw materials
are hard so they do not disintegrates by water. The raw materials are crushed in grinding mill
and reduced into a fine powder called raw meal which is then pumped to a blending silos
usually by means of compressed air. The blended meal is sieved and fed into a rotating dish
called a granulator, water weighing about 12 % of the meal being added at the same time and
hard pellets are formed. The pellets are baked hard in a preheating grate by means of hot
gases from the kiln. The pellets enter the kiln by the same operations as in the wet process.
During burning of raw materials, the formed clinker consists of four basic chemical
compounds named as tricalcium silicate ([Link] 2 or C3S), dicalcium silicate (2CaO.SiO2 or
C2S), tricalcium aluminate (3CaO.Al2O3 or C3A) and tetracalcium aluminoferrite
(4CaO.Al2O3.Fe2O3 or C4AFe).
The cooled clinkers are ground to a fine powder in ball mills or tube mills. During final
grinding, a small quantity (2-5%) of powdered gypsum is added which prevents from quick
setting of product when it comes to the contact with moister or water. Therefore, gypsum acts
as a retarding agent for early setting the Portland [Link] proper mixing with gypsum
powder, the fine particles being removed to the storage silos by an air current while the
coarser particles are passed through the mill once again. From silos, cement is fed to
automatic packing machine for market supply using bags containing 50 kgs of each.
2.4 FIGURES/RESEARCH DIAGRAMS:
1. Flow chart diagram of cement production (wet process):

15
 Try to make your self or
insert sharp image

Fig 3:Flowsheet diagram of cement production by wet process

2. FLOW CHART DIAGRAM OF CEMENT PRODUCTION (DRY PROCESS):

16
 Fig 4: Flowsheet diagram of cement production by dry process

17
 CHAPTER-3, LIMITATION OF THE STUDY
Even though the overall study visit and research went pretty smoothly, if the following
limitations could have been overcame it would have been even better:
1. Limited Scope of Study:
 The study focuses only on Ghorahi Cement Industry, which might not fully represent
the practices, challenges, or opportunities across the entire cement industry in Nepal
2. Single Visit Observation:
 Insights were based on a single industrial visit, which might not provide a complete
understanding of operational variability or long-term challenges faced by the company.
3. Lack of Comparative Analysis:
 The report does not compare Ghorahi Cement Industry’s processes, technologies, or
production efficiency with other cement manufacturers in Nepal or internationally.
4. Inadequate Coverage of Environmental Impact:
 While the report mentions sustainable practices, it does not provide detailed data or
analysis of the environmental impacts (e.g., emissions, resource usage) of cement
production.
5. Reliance on Secondary Information:
 Some of the data (e.g., market share, limestone reserves, and overall industry statistics)
are based on secondary sources, which could be outdated or inaccurate.
6. Technical Limitations:
 The study does not delve deeply into the technical details of production efficiency,
machinery performance, or quality control processes, limiting the technical depth of the
findings.
7. Lack of Consumer Insights:
 The study does not include perspectives from consumers, distributors, or contractors,
which could provide valuable insights into product perception and market dynamics.
8. Economic and Policy Constraints:
 The study does not address potential challenges from fluctuating cement demand, raw
material price volatility, or government policies affecting the cement industry.
9. Short Time Frame:

18
  The short time frame of the visit limits the ability to observe long-term trends or
challenges, such as maintenance issues, seasonal production variations, or supply chain
disruptions.
10. Absence of Sustainability Metrics:
 While mentioning sustainable practices, the study does not quantify the environmental
and social benefits, such as energy savings, waste reduction, or community impact.
These limitations suggest opportunities for more comprehensive research, including
longitudinal studies, broader industry comparisons, and deeper analysis of technical, economic,
and environmental factors.

19
 CHAPTER-4, RESULTS AND DISCUSSION
4.1Overview of the Cement Industry in Nepal
Nepal’s cement industry has seen significant development due to its abundant limestone
reserves, a primary raw material for cement production. As of 2020, approximately 50 cement
factories operate in Nepal, meeting about 80% of domestic demand. Prominent players, such as
Shivam Cement and Hongshi Cement, are exploring export opportunities to countries like India.
The government’s emphasis on infrastructure development has catalyzed growth in this sector.

4.2 Observations from Ghorahi Cement Industry Visit

Production Capacity and Infrastructure:
Cement Industry (GCI), established in 2009, has rapidly expanded its production. It now boasts
an annual production capacity of over 2 million metric tons of clinker and 1.25 million metric
tons of cement. The state-of-the-art facilities and environmentally sustainable practices ensure
minimal ecological impact and enhanced efficiency.
 Production Process:
The cement manufacturing process at GCI involves several key stages:
o Extraction and Crushing: Limestone and clay are quarried and crushed.
o Blending: Precise mixing of raw materials ensures quality.
o Burning: The rotary kiln process produces clinker at high temperatures.
o Grinding: Clinker is finely ground with gypsum to produce cement.
 Technological Innovations:
GCI employs advanced German technology, including Rotary Kilns and Vertical Roller
Mills, to optimize energy consumption and productivity.
4.3 Grades and Types of Cement
 Not only Ghorahi All Cement industries produces several types of cement to meet
diverse construction needs:
o Sagarmatha OPC 43 and 53 Grades: Known for their strength and durability,
these are used in major infrastructure projects.
o Sagarmatha Gold PPC: Blended cement ideal for mass concreting and plastering.
o Clinker Production: Integral to cement manufacturing, GCI ensures high-quality
clinker through local limestone reserves.

20
 5. Economic and Environmental Contributions
 GCI has significantly contributed to Nepal’s economy by creating employment
opportunities for 450–500 individuals and supporting infrastructure projects.
Environmentally, GCI has adopted measures to reduce energy consumption and
minimize emissions.

6. Challenges and Future Prospects

 Despite domestic production meeting most of the demand, Nepal still imports 15–20%
of its cement. Expanding export capabilities and exploring untapped limestone deposits
could position Nepal as a competitive player in the international market.
The visit highlighted the cement industry's critical role in Nepal’s economic development and
infrastructure projects. GCI serves as a model for other industries, balancing production
demands with environmental sustainability. Future efforts could focus on enhancing
technological advancements, scaling up production capacities, and reducing import dependency
to achieve self-sufficiency in cement production.

21
Bibliography
1. Gautam D. R., Pant H. R., Bhatt B. D., Mukhiya T., Bhattarai D. P., Modern
Chemistry, Reprint 2080, Asmita Books Publisher & Distributors (P) Ltd., 2081
2. Gewali M. B., Tiwari R., Acharya S., Ghimire C., Principles of Chemistry, Revised
Edition 2024, Buddha Publications Pvt. Ltd., 2024
3. Wagley P., Khadka N. M., Gautam S. D., Adhikari N. R., Pandey B. R.,
Comprehensive Chemistry, Revised Edition 2024, Heritage Publishers & Distributors
Pvt. Ltd., 2024
4. Mishra A. D., Kalauni S. K., Joshi R. D., Pal K. B., Pandey A., Pioneer Chemistry,
Revised Edition 2023, Dreamland Publicatiion Pvt. Ltd., 2023

Web References:
Chatgpt: [Link]
Wikipedia: [Link] Wikipedia is accepted here but these are not proper ways
for citation.
Ghorahi Cement Industry: [Link]
Y

22
Appendix

Pic : Group photo of XII 'B' students (2081 Batch) of GUPSS in Ghorahi Cement Industry

Pic 1: Quality check points of GCI

Pic 2: Cement Manufacturing Process

23
 Pic 3: Certificate of Accreditation of GCI

Pic 4: Nepal Standard Specification of Cements

Pic 5: GCIPL cement quality against Nepal standard

24