A Presentation On Mongla Cement Factory.

1. A Presentation On Mongla Cement
Factory
Group C
Roll: 170524-170534
Presented To
Dr. S. M. Nur Alam
Associate Professor
&
Marzia Sultana
Lecturer
Dept. Of Chemical Engineering
Jashore University Of Science & Technology

2. Basic Information-24
Mongla Cement Factory is one of the biggest industrial units of
Sena Kalyan Sangstha, which was set up on the bank of the river
Pashure near Mongla Port, Bagerhat. It is one of the oldest
cement clinker grinding factories in the country with modern
technology of packing and delivery system also computerized
system including a well equipped laboratory. At present has got
two mills with two separate packing sections. The production
procedure is same in both the mills.

3. Basic Information-24
1. Name of industry : Mongla Cement Factory
2. Start production : 1994
3. Communication : Roads & Rivers
4. Plant Location : Burirdanga, Mongla, Bagerhat
5. Total Units : 3 unit
6. Major products : Portland cement
7. Raw Materials : Clinker and Gypsum
8. Production Rate : 100 M.ton per hour
9. Mill : Three
10. Packer Machine : Two mill(each capacity 100 M.ton per hour)
11. Storing capacity : Three silos(per silos 5000 M.ton)

4. Basic of cement-25
Cement is a generic name for powdered materials which initially have a
plastic flow when mixed with water or other liquid, form a solid structure
in several hours with verifying degree of strength and bounding
properties.
Raw Materials :
Portland Cement : Clinker, Gypsum
Portland Composite Cement : Clinker, Gypsum, Limestone, Granulated
Blast Furnace Slag (GBFS), Fly ash
Clinker Gypsum Limestone Fly ash

5. Manufacture process of Clinker-25
Clinker is a dark grey nodular material made by heating ground
limestone and clay at a temperature of about 1400 °C - 1500 °C.
Chemical Composition of Clinker
Tricalcium silicate (C3S) : 60% Above
Dicalcium silicate (C2S) : 12-18 %
Tricalcium aluminate (C3A) : 5.5-09 %
Free Lime : 1% Max
Insoluble Residue : 0.5 %
Chloride : 0.01% Max
Magnesium oxide : 03% Max

6. Manufacture process of Clinker :-26
Limestone(CaCO3+MgCO3) +
Clay(SiO2+Al2O3+Fe2O3+MgCO3) +
Bauxite(Al2O3) + Silica(SiO2)
Rotary
Kiln
Clinker
Clinker
Heat 1450° C

7. Gypsum-26
Gypsum is a soft sulfate mineral composed of calcium sulfate
dihydrate, with the chemical formula CaSO4·2H2O.
In grinding machine, 2-3% gypsum is added to cement because it
prevents the rapid setting of the cement and actually enhances the
initial setting time of cement.
Gypsum

8. Limestone-27
Limestone is a sedimentary rock composed primarily of calcium
carbonate (CaCO3) in the form of the mineral calcite.
Advantage
 Particle packing
 Improved particle size distribution
 It has been observed that initial compressive strength of the
concrete increase due to the porefilling effects.
Limestone

9. Blast Furnace Slag-27
Ground-granulated blast-furnace slag is obtained by quenching
molten iron slag from a blast furnace in water or steam, to produce a
glassy, granular product that is then dried and ground into a fine
powder.
Advantage :
 Higher long term strength
 Improved workability
 Lower heat of hydration
 Reduced permeability
 Resistance to sulphate attack
 Resistance to chloride attack Slag

10. Fly Ash-28
Fly ash is a pozzolan, a substance containing aluminous and
siliceous material that forms cement in the presence of water. When
mixed with lime and water, fly ash forms a compound similar to
Portland cement.
Advantage :
 Higher ultimate strength
 Reduced permeability
 Reduced bleeding and segregation
Fly Ash

11. Manufacture of Portland Cement-28
Basically they are producing Portland Composite Cement in three
stages-
1. Raw material(Clinker, Gypsum) handling operation
section
2. Grinding Operation section
3. Packing & Delivery section

12. Manufacture of Portland Cement-29
Clinker
Clinker
Additives
(slag/limestone/flyash)
Hop
per
Automated weightier
Air
separator
Grinding ball mill
Cement silo Packing
Hop
per
Hop
per

13. Characteristics of Elephant Brand Portland Cement-31
 Higher Long Term Strength
 Reduce Heat of Hydration
 Better Workability
 Sulfate Resistant
 Acid Resistant
 Carbonation & Chloride Resistant
 Reduced Leaching of Lime
 Reduce of Permeability

14. Difference Between PC & PCC-32
Portland Cement
(PC)
Portland Composite Cement
(PCC)
PC produced by grinding clinker and gypsum. PCC treated at clinker grinding stage by adding
certain additives such as fly ash, slag, gypsum
and lime.
PC is less durable comparing to PCC PCC has more durability than PC
Sulphate corrosion is higher than PCC Less sulfate corrosion
Less hardening time Take more time for hardening process
Affordable price Costly than PC

15. How Cement Works-33
When cement is mixed with water and allowed to stand, it sets to a
hard rigid mass by a series of complex reactions. Hydration reaction
begins a resulting in the formation of gel and crystalline products. The
process of solidification consists of setting and hardening. Setting is
regarded as stiffening of the original pest mass because of initial gel
formation and hardening is regarded as development of strength of
crystallization. In this industry, the setting time of produced cement is
28 days .

16. Testing of cement-33
Chemical Lab
 Chemical composition of raw materials are tested here.
X-ray fluorescence (XRF) Lab
 Chemical composition of raw materials can be tested here within 5 to
10 mins.
Physical Lab
 Vicut Apparatus (For determining setting period)
 Permeability Apparatus (For determining fineness of the cement)
 Jolting cabin (For compacting of cement)
 Humidity cabin (Dice kept here for 24h)
 Universal Testing Machine (For determining tensile & compressive
strength)

17. Uses of Portland Cement-34
Bridges & Flyovers.
Pre-stressed concrete Structures.
Electric Pole.
Any type of RCC constructions.

18. Environmental Effects-34
Machineries loud sound occur sound pollution.
Dust of cement industry is harmful for worker.
Cement raw materials is harmful for worker skin.

19. Thank you
Visit-Mongla Cement Factory