CEMENT
Under the guidance of
Dr. Bahurudeensir
Ajinkya Ingale
RITWIK CHAUHAN
2015H130062P
2015H130055P
O VERVIEW
INTRODUCTION
HISTORY OF CEMENT
PRODUCTION OF CEMENT
CEMENT AND ITS COMPOSITION
HYDRATION
HEAT OF HYDRATION
MISCELLANEOUS
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W hat is Cem ent?
Cement can be defined as any substance
Definition
C150:
which can by
joinASTM
or unite
two or more pieces of
some
substance
together
to form aby
unit
A other
hydraulic
cement
produced
mass
SOURCE: Technology of Portland and blended cementspulverizing
clinkers
consisting
[Link]
essentially of hydraulic calcium
Acementis abinder, a substance that sets
silicates,
and
a
small
amount
of
one
or
and hardens and can bind other materials
more formsSOURCE:[Link]
of calcium sulfate as an
together
interground addition
A powder of alumina, silica, lime, iron oxide,
and magnesium oxide burned together in a
kiln and finely pulverized and used as an
ingredient
of mortar and concrete
SOURCE: [Link]
CEMENT
Hydrated products are
resistant to water
Hydrated products are
not resistant to water
Applications ofCem ent
Mortar for plastering,masonry work,
pointing, etc.
Water tightness of structure, Making
joints for drains and pipes.
In concrete for laying floors, roofs and
constructing lintels, beams, stairs, pillars
etc.
For precast pipes manufacturing, piles,
fencing posts etc.
Construction of important engineering
structures such as bridges,
SOURCE:[Link]
PRODUCTION
Data in thousand metric tons
SOURCE: [Link]
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H ISTO RY
3000 BC - Egyptian Pyramids
(Mud + Straw + Gypsum + Lime)
300 BC - 476 AD-Roman Architecture
(Close to Modern Cement + Animal Products)
1756- Hydraulic lime was first developed
(John Smeaton erected theEddystone lighthouseoff
the coast of Plymouth, Devon, England)
1824-Portland Cement Invented
(Joseph Aspadin synthetic mixture of limestone
and clay)
H ISTO RY
1836-Strength Testing (Germany)
(Tensile and Compressive Strength Test of
concrete)
1845 First Modern Prototype of Portland
Cement
(Isaac Johnson- Chalk + Clay @ 14000 C
-15000C)
1889- Alvord Lake Bridge, San
Francisco, CA
1891- Concrete Street, Ohio
1903-The Ingalls Building, Ohio
SOURCE: [Link]
PRODUCTION
OF
CEMENT
Raw M aterials N ecessary for Portland
Cem ent M anufacture M ust Provide the
Follow ing
Calcium
Silica
Alumina
Iron
SOURCE:
[Link]
Cem ent M anufacturing
Processes
Wet Process
(mostly used now-a-days)
Dry Process
(almost updated)
THE CEMENT
MANUFACTURING PROCESS
1. Quarry
[Link]
[Link]
[Link],
[Link],
[Link],
[Link]
MANUFACTURING STEPS
1) Raw materials are crushed, screemed & stockpiled.
2) Raw materials are mixed with definite proportions to
obtain raw mix. They are mixed either dry (dry
mixing) or by water (wet mixing).
3) Prepared raw mix is fed into the rotary kiln.
4) As the materials pass through the kiln their temperature
is rised upto 1300-1600 C. The process of heating is
named as burning. The output is known as clinker
which is 0.15-5 cm in diameter.
5) Clinker is cooled & stored.
6) Clinker is ground with gypsum (3-6%) to adjust setting
time.
7) Packing & marketing.
THE CEMENT MANUFACTURING PROCESS
quarry
dumper
loader
Quarry face
1. BLASTING
2. TRANSPORT
crushing
conveyor
storage at
the
plant
3. CRUSHING & TRANSPORTATION
[Link] : The raw materials that are used to manufacture cement (mainly limestone
and clay) are blasted from the quarry
[Link]: The raw materials are loaded into a dumper
[Link] and Transportation : The raw materials after crushing, they are homogenized, and
transported to the plant by conveyor. The plant stores the materials
THE CEMENT MANUFACTURING PROCESS
Raw grinding and burning
storage at
the
plant
preheating
Raw mill
conveyor
Raw mix
1. RAW GRINDING
kiln
cooling
clinker
2. BURNING
[Link] GRINDING : The raw materials are very finely ground in order to produce the raw mix.
[Link] : The raw mix is preheated before it goes into the kiln, which is heated by a flame that
can be as hot as 2000 C. The raw mix burns at 1500 C producing clinker which, when it leaves the
kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material
needed to make cement.
THE CEMENT MANUFACTURING PROCESS
Grinding, storage, packing, dispatch
Gypsum and the secondary additives are added
to the clinker.
clinker
storage
Finish grinding
1. GRINDING
silos
dispatch
bags
2. STORAGE, PACKING, DISPATCH
[Link] : The clinker and the gypsum are very finely ground giving a pure cement.
Other secondary additives and cementitious materials can also be added to make a blended
cement.
[Link], PACKING, DISPATCH :The cement is stored in silos before being dispatched either
in bulk or in bags to its final destination.
Quarry
1. Stone is first reduced to 125 mm (5 in.)
size, then to 20 mm (3/4 in.), and stored.
Raw
mill
4 materials
225tph limestone
88%,
sandstone 5%,
kaolin/clay 5%,
mill scale 2%
2. Raw materials are ground to powder and blended.
Or 2. Raw materials are ground, mixed with water to form
slurry, and blended.
Kiln
3. Burning changes raw mix chemically into cement clinker.
4. Clinker is ground with gypsum into portland
cement and shipped.
Reactions in Kiln
REACTIONS IN THE KILN
~100C free water evaporates.
~150-350C loosely bound water is lost from clay.
~350-650Cdecomposition of claySiO2&Al2O3
~600Cdecomposition of MgCO3MgO&CO2 (evaporates)
~900Cdecomposition of CaCO3CaO&CO2 (evaporates)
~1250-1280Cliquid formation & start of compound formation.
~1280Cclinkering begins.
~1400-1500Cclinkering
~100Cclinker leaves the kiln & falls into a cooler.
Sometimes the burning process of raw materials is performed in two stages:
Clinker + G ypsum = Portland Cem ent
Clinker
Formed by burning calcium
and siliceous raw materials
in a kiln.
Size: About 20 mm (34
in.) in diameter.
Gypsum
A source of sulfate, is
PCA
interground with portland
clinker to form portland
cement.
It helps control setting,
drying shrinkage
properties, and strength
development.
Intergrinding with gypsum
Final step in cement manufacture
Gypsum added as a set regulator
(absence flash set)
Strict control on temperature required
Done in ball mills; vertical roller presses are
now used for better efficiency
Cement of required fineness produced
For m ore about cem ent
m anufacturing process .
[Link]
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O xide Com position ofP.C.
Oxide
Approx.
Amount (%)
Common Name
Abbreviation
CaO
Lime
60-65
SiO2
Silica
17-25
Al2O3
Alumina
3-8
Fe2O3
Iron-oxide
0.5-6
MgO
Magnesia
0.5-4
Na2O
Soda
K2 O
Potassa
SO3
Sulfuric
Anhydride
0.5-1.3
1-2
BASIC PRO PERTIES IN TERM S O F OXID E
Sr.
No
.
Oxide
Properties
1.
Lime(CaO)
Strength-giving properties, increases
setting time
2.
Silica(SiO2)
Higher setting time, Higher strength
3.
Alumina(Al2O3)
Decreases setting time, Reacts quickly
with water
4.
Iron Oxide(Fe2O3) Acts as Catalyst and helps burning
temperature
5.
Magnesia (MgO)
Affects Colour and Hardness of cement
6.
Sulphur
Trioxide(SO3)
Increases setting time, causes
unsoundness
7.
Alkalis
If present in excess, they may react
with aggregate, cause efflorescence
CEMENT COMPOSITION
Bogue Com pound Com position
Name
Tri Calcium
Silicate
10%
Di Calcium
Silicate
Chemical
5% Formula
Abbreviati
ons
Alternate
Name
3CaO.SiO2
C3S
C3S
Allite
C2S
C3A
Bellite
C4AF
Gypsum
10%
Tri Calcium
Aluminate
25%
Tetra Calcium
Alumino
Ferrite
2CaO.SiO2
3CaO.Al2O3
4CaO.Al2O3.Fe2O
3
50%
C2S
C3A
Cellite
C4AF
Brownmillerite
SOURCE:[Link]
BASIC PRO PERTIES IN
CO M PO U N D S
Sr.
No.
Compounds
Properties
1.
Calcium
silicates(C3S,C2S)
Strength, controls setting time
2.
Tricalcium
Aluminate (C3A)
Reacts faster with water
3.
Tetracalcium
Alumino
Ferrite(C4AF)
Hydrates rapidly, individual
contribution to the strength is
insignificant
Bogues Com pound Com position
C3S =4.07(CaO)-7.6(SiO2)- 6.72(Al2O3)1.43(Fe2O3 ) 2.85(SO3 )
C2S= 2.87 (SiO2) - 0.75( 3Cao. SiO2)
C3A= 2.65(Al2O3) 1.69 (Fe2O3 )
C4AF = 3.04 (Fe2O3 )
HYDRATION PROCESS
H ydration:
It is the reaction (series of chemical
reactions) of cement with water to
form the binding material. In other
words, in the presence of water, the
silicates (C3S and C2S) and
aluminates (C3A and C4AF) form
products of hydration which in time
produce a firm and hard mass the
hydrated cement paste.
SOURCE: [Link]
Characteristics of H ydration ofthe
Cem ent Com pounds
Chemical
Reaction
Rate
Amount
liberated
Strength
Heat
Liberation
C3S
Moderate
Moderate
High
High
C2S
Slow
Low
Low
Low
Low initially,
Higher later
Very High
C3A
Fast
Very High
C4AF
Moderate
Moderate
Low
SOURCE:[Link]
Moderate
SOURCE: [Link]
Cem ent hydration process
SOURCE: Mindess and
MICROSTRUCTURE OF CEMENT PASTE
SOURCE:[Link]
C -S -H G EL M O D EL
Young et al., 1998
C -S -H G EL M O D EL
C -S -H G EL M O D EL
M IC R O S TR U C TU R E O F
C A LC IU M
SEttringite
U LFO A LU M IN ATES
Monosulfoalumina
te
AFt (first): Prismatic needles
AFm (later): Plane hexagonal crystals
low surface area 2 m2/g
Volume 15-20%
Mehta and Monteiro; Mindess and Young
M IC R O S TR U C TU R E O F
H Y D R ATED C EM EN T PA S TE
C-S-H:
Agglomerations of C-S-H
particles of 1-100 nm.
H:
Hexagonal crystals of
calcium hydroxide,
monosulfoaluminate and
calcium aluminohydrate
of about 1 m.
C:
Capillary pores and voids
of 10 nm to 1 m.
Mehta and Monteiro
M IC R O S TR U C TU R E O F
C A LC IU M H Y D R O X ID E O R
P O R TLA N D ITE
Large hexagonal crystals
Low surface area (0.5 m2/g)
Low Van der Waals forces
Volume 20-25%
Mehta and Monteiro
M O R P H O LO G Y O F H Y D R ATIO N
P R O D U C TS IN 7 D AY S
Large crystals of
calcium hydroxide
Platelets of
monosulfoalumina
te
Cement particle
coated with C-SH, which is
surrounded by
ettringite needles
Young et al., 1998
A M O U N T O F H Y D R ATIO N
P R O D U C TS FO R M ED
PCA, Young et al.
EV O LU TIO N A N D
V O LU M ES O F H Y D R ATIO N
P R O D U C TS
PCA: Kosmatka (2005)
TH E FA C TO R S A FFEC TIN G
TH E K IN ETIC S O F
[Link] of cement
H Y D R ATIO N
[Link] amount and form of gypsum in the cement:
[Link] of cement
4.w/c of mix
[Link] conditions
[Link] temperature
[Link] of chemical admixtures: For example, set
controllers, and plasticizers.
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H EAT O F H YD RATIO N
It is the quantity of heat (in joules) per gram
of un-hydrated cement evolved upon
complete hydration at a given temperature.
The heat of hydration can be determined by
ASTM C 186 or by a conduction calorimeter.
The temperature at which hydration occurs
greatly affects the rate of heat development.
Fineness of cement also affects the rate of
heat development but not the total amount
of heat librated
R ATE O F H EAT
EV O LU TIO N D U R IN G
H Y D R ATIO N
Stage I:
Rapid evolution of heat, lasts about 15 minutes (C 3A and
some C3S reaction).
Stage II:
Dormant period, lasts until initial set occurs in 2 to 4 hours
Stage III:
Rapid reaction of C3S during the acceleration period, with
the peak being reached at about 8-10 hours, much after final
set at 4-8 hours and hardening has begun
Mindess & Young
Heat of Hydration of Pure
Compounds
HEAT OF
HYDRATIO
N
(cal/gm)
C3S
120
C2S
62
C3A
207
C4AF
100
The am ount ofheat
liberated is aff
ected by
the fractions ofthe
com pounds ofthe
cem ent.
H eat of
H ydration(cal/gr)= 120*
(% C 3S)+ 62*(% C 2S)
+ 207*(% C 3A)
+ 100*(C 4AF)
H EAT O F H Y D R ATIO N
Cement hydration is an EXOTHERMIC reaction
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SOURCE: Building Materials- M L Gambhir, Neha Jamwal
PH YSICAL TESTS O N CEM EN T
FINENESS
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