Basic of cement-Amit Payal

RK GROUP
The RK Group had started their
business journey in the year 1989
from Marble business, RK Marble.
The Group achieved great heights in a
very short span of time and got its
name registered in the “Guinness
Book of World Records” as the
World's Largest Marble Producer.
The Group’s corporate culture is
built on the values of Quality,
Trust and Transparency.
Wonder Cement is a part of
RK Group.

WONDER CEMENT
We are expanding our current
capacity to 12.00 MTPA by
setting up a 3rd production line
at Nimbahera and split grinding
units in Maharashtra (Dhule) &
Madhya Pradesh (Badnawar).
Wonder Cement is committed
towards providing quality products to
consumers and is known for its
reliability and consistency.
Our plant is located at Nimbahera,
Chittorgarh in Rajasthan and has a
capacity to produce 8.0 MTPA cement.
Our plant was established in technical
collaboration with ThyssenKrupp and
Pfeiffer Ltd., Germany, the world
leaders in cement technology.

WONDER CEMENT
Cement Manufacturing Capacity
Description Started Clinker Capacity Cement Capacity
Line I Plant 2012 3.00 Million Tons 4.0 Million Tons
Line II Plant 2015 3.00 Million Tons 4.0 Million Tons
Dhule GU 2018 --- 2.0 Million Tons
Line III Plant Mid-2019 3.50 Million Tons ---
Badnawar GU Oct – 2019 --- 2.0 Million Tons
The Wonder Cement Ltd. (A Division of R. K. Marble Pvt. Ltd.) is having their
registered office in R K House, City Road, Madanganj-Kishangarh, Dist. Ajmer (Raj.)
and integrated Cement Plants are located at R. K. Nagar, Nimbahera, District
Chittorgarh, Rajasthan, near Villages Sangaria, Borakheri, Peerkhera and Rasulpura,
Tehsil Nimbahera, Chittorgarh (Rajasthan).

What is Cement?
Material having adhesive and cohesive
properties capable of bonding mineral
fragments into a compact mass.
OR
Simply Binding material made out of
Calcareous and Argillaceous material.

History of Cement
• Lime and Clay have been used as
cementing material in constructions
through many centuries.
• Romans are commonly given the credit
for the development of hydraulic
cement.
• Roman’s significant contribution - was
the use of pozzolan-lime cement by
mixing volcanic ash from the Mt.
Vesuvius with lime.
Pantheon in Rome

History of Cement
3000 BC – Egyptian civilization
• Mortar made of Gypsum and Lime - to build Pyramids.
300 BC - 476 AD—Roman Architecture
• Developed the Hydraulic cement.
• Used Volcanic ash and tuff mixed with lime and sand to
make Mortar.
• Used Animal products as early form of Admixtures.
• Colosseum and Pantheon stand as example.
1824 – Invention of Portland Cement.
• Joseph Aspidin, a brick layer invented Portland Cement at
UK.
1848 – Commercially Produced.

History of Cement
Invention of Modern Cement
Joseph Aspidin of Leeds, England, an English
inventor and manufacturer of Portland Cement.
Received patent in the year 1824.
The name ‘Portland’ was given to cement owing to the resemblance of
hardened cement to a natural stone available at Portland in England

History of Cement in India
Indus Valley Civilization – Use of some kind of cementing materials
• Portland cement was first manufactured
near Madras, which ultimately ceased
operations in 1912.
1904 - 1912
• India Cement Co. Ltd installed
uninterrupted cement production at
Porbander, Gujarat – 20 MT / Day
• 1940 – 1946 – No production. By 1948,
Capacity reached to 3 MMT / Annum
1914 - 1948
• Installed Capacity reached 22
MTPA
1948 - 1978
• Installed capacity reached
380 MTPA
FY15-16

Growth of Indian Cement
Industry
1914
20 MT/Day
1920
50 MT/ Day
1925
0.5 MTPA
1930
0.6 MTPA
Imports from
England & Japan.
Setting up of
Cement
Manufacturing
Organization
1936
Joining of 4 out
of 5
Manufactures

Growth of Indian Cement
Industry
1938
2 MTPA
1940 -
1946
II World
war
No New
cement
factories were
set up.
1948
3 MTPA
1978
22 MTPA
Increase in
capacity over
a period of 30
years
2015-16
380 MTPA
2018-19
502 MTPA
In 2020
it will Cross
550 MTPA

Raw Materials
Raw Materials Minerals Sources
CALCAREOUS Calcium carbonate
Limestone, Chalk, Marl, Sea
shells
ARGILLACEOUS
Alumina, Silica,
Iron, Magnesia
Bauxite, Laterite, Red ochre &
Iron sludge
GYPSUM Calcium Sulphate
Gypsum in the form of Chemical
or Mineral Gypsum
COAL/ Pet coke Used as Fuel
Coal mines/ Pet coke waste of
petroleum refineries
INDUSTRIAL BY-
PRODUCTS
Fly ash Thermal power plants
SECONDARY
TERTIARY
PRIMARY

Raw Materials
Oxides basically required in Limestone:
• Lime (44-47%)
• Silica (10-14%)
• Alumina (2-4%)
• Iron (1-3%)
• Magnesium (1-3%)

Raw Materials
 Lime Stone:
Quarried from open cast limestone mines which is rich in Calcium carbonate
 Shale:
Quarried from same lime stone mine. It is only inferior quality limestone rich in
silica & alumina.
 Bauxite / Laterite / Red ochre:
Procured from different mineral suppliers.
 Gypsum: Calcium sulphate (CaSO42H2O)
Mineral Gypsum, Chemical Gypsum.
 Coal /Pet coke :
High calorific value & low ash content is preferred.

Types of Production Processes
• Mixing, Blending, Grinding
done with water.WET
• Blending and Grinding with
water – Nodulising – burning.SEMI DRY
• Mixing, Grinding, Blending,
Feeding to the kiln in dry
condition.
DRY

CEMENT MANUFACTURING PROCESS
FLOW CHART

LIMESTONE MINES
The prime raw material limestone after blasting in mines is broken into big
boulders. Then it is transported by dumpers and tipples it to limestone
crusher.

LIMESTONE CRUSHER
Limestone of maximum feed size of 1.1x1.0x1.0 m3 is dumped in crusher dump
hopper. The undersize material of -80 mm goes to the screening plant and +80
mm material is fed to impactor having the total capacity of 1600 TPH. After
crushing, this material is fed to limestone stacker through belt conveyors.

ELECON STACKER & RECLAIMER
STACKER RECLAIMER
➢ For better blending after crushing, the crushed limestone is piled longitudinally by an
equipment called Stacker. The pile is normally 250 to 300 m long and 8-10 m height.
➢ The Reclaimer cuts the pile vertically, simultaneously from top to bottom to ensure
homogenization of limestone

WEIGH FEEDER
➢ The crushed limestone from pile is transported through belt conveyor to hopper.
➢ Similarly, other raw materials like, Bauxite, Laterite & Red ochre etc. are also
transported by belt conveyor from storage yard to respective hoppers.
➢ All raw materials are proportioned in requisite quantity through weigh feeders.

RAW MIX PREPARATION DIAGRAM
Limestone Bauxite Laterite
CaCO3 Al2O3 Fe2O3
CF Silo

VERTICLE ROLLER MILL
The proportioned raw materials are transported by belt conveyor to Raw Mill for
grinding into powder form.

RAW MEAL SILO
➢ After grinding, the powdered Raw mix, is stored in
a raw meal-silo where blending takes place.
➢ Blending is done by injecting compressed air.
➢ This powder material (Raw meal) is fed to the kiln
for burning.

STACKER / RECLAIMER FOR COAL
Coal also requires homogenization as it contains different ash percentages.
The coal is homogenized by Stacker & Reclaimer before entering into kiln for
burning.

PRE-HEATER
➢ The powder raw mix is fed into 6
stage Pre-Heater from top and the hot
gases from kiln enters Pre-heater from
bottom.
➢ Powdered raw mix which travels from
top to bottom, comes in contact with hot
air in the Cyclones.
➢ Utilization of all waste hot gases from
Kiln and Cooler, taking place through
modern age Waste Heat Recovery
System.

PRE-HEATER
POLYSIUS THYSSENKRUPP
GERMANY TECHNOLOGY

ROTARY KILN
➢ Rotary kiln is 75 meters long, 5.5 meter diameter tube.
➢ This is placed horizontally with some inclination to facilitate the raw mix movement
inside the kiln. Powdered raw mix enters the kiln at one end and firing of Pet coke is
taking place from opposite end through burner. The rotary kiln rotates at the speed of 1
to 6 revolution per minute (RPM).
➢ The raw mix in the kiln melts first into liquid form and then transforms into nodules due
to the effect of the rotation of the kiln.
Internal view of Kiln

➢ The hot clinker from kiln discharge is cooled
very quickly/ quenched in air with the help of
efficient coolers. The temp. of clinker is
brought down to 80 - 90oC from 1350oC.
➢ Fast cooling is very essential to get good
quality clinker . If cooling is not quick, the
compound stability in clinker will be adversely
affected resulting in lower strength of cement
after grinding.
POLYTRACK CLINKER COOLER
FOR HIGH THERMAL EFFICIENCY BETTER COOLING

CENTRAL CONTROL ROOM
➢ Operations of Raw mill, Coal mill, Kiln & cooler and Cement mills is through fuzzy logic /
computer control.
➢ These operations are controlled from Central Control Room (CCR) which is the nerve center
for any cement plant.

Cement is ground in ball mills with roller press (M/s Thyssen Krupp) having
capacity 200 TPH to 270 TPH. All cement mills are equipped with high efficiency
latest generation separators.
CEMENT GRINDING

CEMENT MILL
BALL MILL VERTICLE ROLLER MILL

PP CEMENT BAGS
The benefits of Polypropylene (PP) Cement
Bags are:
➢ Non-toxic
➢ Non-staining
➢ 100% reusable and durable
➢ Easy to clean and anti bacterial
➢ Light in weight with lowest density
➢ Easy to produce, assembly and an economic material
➢ Excellent resistance to stress and high resistant to
cracking
➢ High operational temperatures with a melting point of
167°C
➢ Resistant to most alkalis and acid, organic solvents,
decreasing agents

PP CEMENT BAGS
TEST REPORT OF PP BAGS FOR PPC
Sr. No. Characteristic BIS requirement IS 11652:2017
1
Dimension, mm
A. Length of sack (mm) 710 ±10 mm
B. Width of sack (mm) 480 ±10 mm
C. Depth of sack (mm) 230 + 10 / - 5 mm
D. Width of sack (mm) 100 + 10 / - 5 mm
2 Ends per dm 40±2
3 Picks per dm 40±2
4 Mass of sack ( grams) 70± 6%
5
Average Breaking Strength of fabric (N)
A. Length and Widthwise (Min) 900 N
B. Top and Bottom Seam (Min) 400 N
6 Elongation at break of fabric, Length & widthwise (%) 15 to 25
7 Drop impact strength (Drop test) No failure

QUALITY CONTROL
AND
ASSURANCE SYSTEM

Key Process –
Quality Assurance Systems
• Close Monitoring ❖ Cross Belt analyzer
• Homogenization and
consistency
❖ Limestone Stacker-Reclaimer
❖ Microprocessor Controlled CF (Controlled
Flow) Raw Meal Silo
❖ Innovatively designed clinker storage.
• Right proportioning
❖ X-Ray & XRD Analyzer
❖ On-line AQC (Automatic Quality Control) Net
Computerized Feed Controls
• Homogeneous and Fine
grinding
❖ High efficiency latest generation – Closed
circuit Grinding

QUALITY & ADVANTAGES
OF
WONDER CEMENT

PRODUCTS
WONDER – PORTLAND
POZZOLANA CEMENT (PPC)
It is manufactured in combination of high
C3S Clinker with High Reactive
Pozzolanic material under controlled
quality parameters. By this process, we
are producing cement with high
compressive strength and low heat of
hydration, which further helps in
achieving better finish and durable
structure.

PRODUCTS
WONDER – ORDINARY PORTLAND
CEMENT (OPC 43 & 53 Grade)
• Intermediate product Clinker, which is
manufactured from required good quality
limestone along with the best available
raw materials Bauxite, Red-Ochre, Laterite
etc.
• OPC cement is produced from Clinker &
Gypsum which is ground at designated
fineness under the strict quality control
measures with the help of latest
technology and machineries like Roller
Press, High Efficiency Separators, On-
line Robotic Lab, X-ray Analyser &
Optimum Particle Size Distribution.

PRODUCT QUALITY
Sr.
No.
Physical Requirement
IS: 1489
Part-1
Wonder
PPC
IS: 269
OPC-43
Wonder
OPC-43
IS: 269
OPC-53
Wonder
OPC-53
1
Compressive Strength (MPa)
3 Days 16 31.50 23 33.50 27 37.00
7 Days 23 41.00 33 44.00 37 47.50
28 Days 33 57.50 43 Min
58 Max
55.00
53 63.00
2 Fineness (M2/Kg) 300 347 225 271 225 281
3
Setting Time (Minutes)
Initial Setting Time 30 165 30 155 30 145
Final Setting Time 600 220 600 210 600 200
4
Soundness
Autoclave Exp(%) 0.8 0.03 0.8 0.02 0.8 0.03
Le-Chatelier Exp(mm) 10 0.50 10 1.00 10 1.00
Comparison of Wonder Cement with Indian Standards (BIS)

PRODUCT QUALITY
Comparison of Wonder Cement with Indian Standards (BIS)
Sr No Chemical Requirement
IS : 1489
(Part-1)
Wonder
PPC
IS:269 OPC-
43
Wonder OPC
-43
IS:269 OPC-
53
Wonder
OPC -53
1 Loss on ignition (%) Max 5.0 1.55 Max 5.0 1.41 Max 4.0 1.06
2 Insoluble residue (%)
Max. X+4(100-X)
/ 100, Min. 0.6X
30.05 Max 5.0 2.38 Max 5.0 2.07
3 Sulphuric anhydride (%) Max 3.5 2.20 Max 3.5 2.23 Max 3.5 2.24
4 Magnesia (%) Max 6.0 0.99 Max 6.0 1.17 Max 6.0 1.16
5 Total Chloride (%) Max 0.1 0.01 Max 0.1 0.01 Max 0.1 0.01
6 Total Alkalies as Na2O (%) Not Specified 0.58 Not Specified 0.53 Not Specified 0.53
7 Lime Saturation Factor Ratio 0.66 to 1.02 0.86 0.80 to 1.02 0.87
8 Alumina Iron Ratio Min 0.66 1.18 Min 0.66 1.19
9 Performance Improvers Added
A. Limestone (%) 0.00 0.00
B. Fly Ash (%) 0.00 0.00

PRODUCT CONSISTENCY
28.9 28.7 28.5
31.3
29.0 29.2 29.8 30.0 29.4 29.8 28.8 28.6
38.9 38.5 38.1
41.5
38.8 39.1
41.6
39.8 38.7 39.5 38.4 38.6
56.8 57.3 56.3
58.9
56.7 56.9 57.1 56.6 56.4 57.2
55.1 56.5
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
Jan-18 Feb-18 Mar-18 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18
COMPRESSIVE STRENGTH - PPC
3 Days 7 Days 28 Days

PRODUCT CONSISTENCY
34.4 33.8 34.4 34.8 34.7 34.7 34.8 34.3 34.5 34.3 34.3 34.3
44.4 43.8 44.2 44.4 44.6 44.6 44.5 44.4 44.6 44.4 44.3 44.1
55.8 55.6 56.0 55.9 55.7 56.0 55.6 55.7 55.4 55.4 55.7 55.8
0.0
10.0
20.0
30.0
40.0
50.0
60.0
COMPRESSIVE STRENGTH OPC-43

PRODUCT CONSISTENCY
37.0 36.3 36.8 36.6 37.6 37.4 38.1 37.1 37.0 37.1 36.9 36.7
48.2 46.8 47.2 47.2
48.9 48.6 49.9
48.0 47.7 47.9 47.5 47.4
63.1 63.7 63.4 64.1 64.2 64.1 64.0 63.8 63.8 64.4 63.1 63.2
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
COMPRESSIVE STRENGTH OPC-53

PRODUCT ADVANTAGES
1. LOW ALKALI CEMENT
Wonder Cement is low alkali cement, having alkali
content (0.48 to 0.50 % in OPC and 0.55% in PPC)
< 0.6 %.
Wonder Cement is useful specifically for (in addition to
normal constructions):
❖ Dam Construction
❖ Coastal Areas
❖ Areas with high silica content (To reduce the Alkali Silica
Reaction)
❖ When reactive aggregates are used ( to reduce the effect
of alkali-silica reaction.)
❖ Canal Lining

PRODUCT ADVANTAGES
2. LOW CHLORIDE CONTENT
In Wonder Cement (OPC & PPC) the chloride content is 0.01
% which very less than the maximum permissible limit of
chlorides (0.1 %) in cement.
The advantages of this low chloride content in wonder cement
leads to prevention from:
❖ Leaching as calcium hydroxide (White patches on surface of
concrete, plaster etc.)
❖ Loss of strength of cement & concrete
❖ Corrosion of steel reinforcement
❖ Due to low chloride content, wonder cement is also useful for
construction in coastal areas which are rich in Chlorides and
salts.

PRODUCT ADVANTAGES
3. LOW HEAT OF HYDRATION
Wonder Cement has very low heat of hydration due to low C3A
and addition of Fly Ash (in PPC). Therefore it is most suited in
mass concreting work like construction of dams etc., thereby it
prevents deterioration of concrete like thermal cracking etc.
4. MILD SULPHATE RESISTANT (Low C3A)
Tricalcium aluminate (C3A) is restricted to level of 6% and (2C3A + C4AF) is lower than 25%
where the concrete is exposed to the risk of deterioration due to sulphate attack.
❖ Underground and basements structures Works in coastal areas
❖ Piles and foundations
❖ Water and sewage treatment plants
❖ Sugar, chemical, and fertilizers factories Petrochemical and food
processing

5. RESIDUE ON 45 MICRON
LESS THAN 10 %
➢ Optimum water demand in Concrete
➢ No observation of segregation and
cracks
➢ More workability of concrete
➢ Less environmental impact on building
PRODUCT ADVANTAGES

PRODUCT PERFORMANCE
MIX PROPORTION
NAME OF CUSTOMER / PROJECT AND LOCATION
ITI,
Palanpur
RMC,
Ahmedabad
TPL,
Chittorgarh
MCC,
Baroda
MPRDC,
Dhar
MCC,
Baroda
RMC,
Jaipur
RMC,
Jaipur
Cement (Kgs) 388 324 345 348 415 385 340 400
Fly Ash (Kgs) 0 36 0 62 0 65 110 130
Fine Aggregate (Kgs) 754 870 831 775 666 772 762 609
Coarse Aggregate (Kgs) 1247 1118 1116 1153 1208 1146 1044 1047
Water (Litre) 178 173 155 160 170 171 160 187
Admixture (Kgs) 3.88 2.88 2.07 4.00 4.68 4.50 3.60 4.77
Grade of Concrete M25 M30 M30 M35 M35 M40 M40 M45
Compressive strength (MPa)
7 Days 22.89 31.90 30.77 36.25 32.84 37.85 47.60 46.80
28 Days 33.19 39.41 39.76 46.54 46.12 50.13 58.00 60.40

61
CLUSTER CEMENT QUALITY
COMPARISON

62
PPC - 2018
394
377
372
369
359
355
339
334
324
300 330 360 390 420
JK Platinum Dabok
UltraTech Sambhupura
Ambuja Rabriyawas
UltraTech Kotputli
Binani Pindwara
Wonder Nimbahera
JK sixer Sirohi
Duragaurd (Earlier Lafarge)
JK Nimbahera
Fineness
Blaine M2/Kg

63
PPC - 2018
26.3
19.6
12.6
11.3
9.2
7.8
6.7
6.5
5.6
0.0 5.0 10.0 15.0 20.0 25.0 30.0
JK sixer Sirohi
Binani Pindwara
Ambuja Rabriyawas
JK Nimbahera
UltraTech Kotputli
Wonder Nimbahera
JK Platinum Dabok
% Residue on 45 µm
Residue (%)

64
PPC - 2018
17.5
15.4
15.0
14.7
14.0
14.0
13.7
12.9
12.3
8.0 13.0 18.0
Wonder Nimbahera
UltraTech Kotputli
JK Platinum Dabok
Ambuja Rabriyawas
JK Nimbahera
Binani Pindwara
JK sixer Sirohi
1 Day Compressive Strength (MPa)
MPa

65
PPC - 2018
29.8
27.3
26.5
25.9
25.1
24.4
22.9
22.3
21.9
17.0 22.0 27.0 32.0
Wonder Nimbahera
UltraTech Kotputli
Binani Pindwara
Ambuja Rabriyawas
JK Platinum Dabok
JK Nimbahera
JK sixer Sirohi
3 Day’s Compressive Strength (MPa)
MPa

66
PPC - 2018
39.6
36.2
34.9
34.9
34.6
32.5
32.0
31.0
29.0
25.0 30.0 35.0 40.0
Wonder Nimbahera
UltraTech Kotputli
Binani Pindwara
JK Platinum Dabok
Ambuja Rabriyawas
JK Nimbahera
JK sixer Sirohi
7 Day’s Compressive Strength
MPa

67
PPC - 2018
56.6
54.3
53.3
53.1
50.8
50.2
49.7
48.7
42.0
40.0 46.0 52.0 58.0
Wonder Nimbahera
JK Platinum Dabok
UltraTech Kotputli
Binani Pindwara
JK Nimbahera
Ambuja Rabriyawas
JK sixer Sirohi
28 Day’s Compressive Strength
MPa

68
OPC 43 Grade - 2018
304
303
299
296
292
290
289
278
276
250 270 290 310
Shree cement
Birla Chetak Chanderiya
Binani Sirohi
JK Super Nimbahera
JK Platinum udaipur
JK Lakshmi Sirohi
Ultratech Kotputli
Wonder Nimbahera
UltraTech Shambhupura
Fineness
Blaine M2/Kg

69
OPC 43 Grade - 2018
25.8
25.7
23.9
20.4
18.3
18.1
17.3
17.2
11.4
8.0 13.0 18.0 23.0 28.0
JK Lakshmi Sirohi
Ultratech Kotputli
JK Super Nimbahera
JK Platinum udaipur
Shree cement
Binani Sirohi
Wonder Nimbahera
% Residue on 45 µm
Residue (%)

70
OPC 43 Grade - 2018
24.3
23.7
23.0
23.0
22.3
21.4
17.9
17.8
17.5
15.0 20.0 25.0
Shree cement
JK Lakshmi Sirohi
Ultratech Kotputli
Wonder Nimbahera
JK Super Nimbahera
Binani Sirohi
JK Platinum udaipur
1 Day Compressive Strength (MPa)
MPa

71
OPC 43 Grade - 2018
36.9
36.8
36.8
36.0
35.5
33.1
32.9
32.0
29.7
28.0 32.0 36.0 40.0
Wonder Nimbahera
Ultratech Kotputli
JK Lakshmi Sirohi
Shree cement
Binani Sirohi
JK Platinum udaipur
JK Super Nimbahera
MPa

72
OPC 43 Grade - 2018
46.9
45.6
44.9
44.8
44.0
43.1
41.7
40.6
40.6
37.0 41.0 45.0 49.0
Wonder Nimbahera
Ultratech Kotputli
JK Lakshmi Sirohi
JK Platinum udaipur
JK Super Nimbahera
Shree cement
Binani Sirohi
MPa

73
OPC 43 Grade - 2018
61.0
58.8
57.6
57.4
57.1
56.7
52.6
52.4
47.8
45.0 50.0 55.0 60.0 65.0
Wonder Nimbahera
JK Platinum udaipur
JK Super Nimbahera
Ultratech Kotputli
JK Lakshmi Sirohi
Binani Sirohi
Shree cement
MPa

ADVANCE CEMENT MANUFACTURING
TECHNOLOGY
WHICH PRODUCED
CONSISTENT QUALITY PRODUCTS

LIMESTONE MINES
Limestone cluster of Chittorgarh area in Rajasthan is known for its superior quality lime
stone deposits, possessing cement grade quality that gives high early strength and
ultimate long term strength. Additional characteristic features of lime stone is Low Alkali,
Low Magnesia and Low Chloride contents which are highly favorable constituents
required for durability of Concrete.

CROSS BELT ANALYZER
Online quality control by Cross Belt Analyzer, which is having world’s best
Combi CBA with CNA (Continuous Neutron Activation) Technology,
which is first time introduced in India.

CROSS-BELT X-RAY ANALYZER (CBA)

Fully Automatic POLAB Lab
First Time In India - with Germen Technology

ON LINE SAMPLING STATION FOR PROCESS CONTROL

High Efficiency Separator Installed
In Cement Grinding System

CLOSE CIRCUIT GRINDING
TECHNOLOGY
Closed circuit systems for ball mills
The closed-circuit grinding system, all ground materials
are led into a separator and classified into refined powder
(Cement) and coarse powder (return powder). The
coarse powder is returned to the ball mill and ground
again with newly-fed raw materials.
Following benefits can be realized with this technology:
➢ Grinding capacity increases.
➢ Optimum Particle size distribution of cement.
➢ The abrasion of liners and balls is suppressed
➢ Particle size distribution of products can be adjusted
by changing the circulation ratio.

WCL- JOURNEY TOWARDS EXCELLENCE
ISO CERTIFICATION TILL MAY 2020

OXIDE & COMPOUND
COMPOSITION OF CEMENT

TYPICAL OXIDE COMPOSITION
OF CEMENT
Sr. No. Oxides % by weight
1. Lime CaO 60 – 65
2. Silica SiO₂ 20 – 25
3. Alumina Al₂O₃ 3 – 8
4. Iron Fe₂O₃ 2 – 4
5. Magnesium MgO 1 – 4
6. Sulphur SO₃ 1 – 3
7. Alkalies (Na₂O, K₂O etc.) 0.2 – 1.3

OXIDES OF CEMENT - FUNCTIONS
➢ LIME (60 - 65%): A sufficient quantity of lime is required for its reaction which
imparts strength. Too little lime reduces the strength of cement. Free lime making
cement unsound, which leads to expansion and disintegration.
➢ SILICA (20 - 25%): Silica compounds along with lime imparts strength to cement and
thereby adequate percentage of silica is desirable.
➢ ALUMINA (3 - 8%): It lowers clinkerising temperature. This boost one day strength
and reflects in early setting of cement.
➢ MAGNESIA (1- 4%): Magnesia makes cement unsoundness, if it is over 5%.
➢ IRON OXIDE (2- 4%): It imparts the grey color and acts as a flux.
➢ GYPSUM (3 - 6%): It regulates the setting time, thus providing workability.

COMPOUND COMPOSITION OF
CEMENT
Compounds
Empirical
Formula
Reaction
rate
Heat liberated
(cal. / gram )
Contribution to
Strength
Development
C₃S
(Alite)
3CaO*SiO2 Moderate High (120)
✓First 4 weeks
✓Early strength
C₂S
(Belite)
2CaO*SiO2 Slow Low (62)
✓Long term
✓After 28days
C₃A
(Aluminate)
3CaO*Al2O3 Fast
Very High
(207)
✓1-3 days
✓Early strength
C₄AF
(Ferrite)
4CaO*Al2O3
*Fe2O3
Moderate
Moderate
(100)
✓Practically No
contribution

COMPOUNDS COMPOSITION OF
CEMENT - FUNCTIONS
➢ TRICALCIUM SILICATE – C₃S (45-55%): It imparts strength to the concrete
from inception and attains greater part of its strength in seven days. But this
evolves more heat generation than C₂S.
➢ DICALCIUM SILICATE – C₂S (20-27%): It gives negligible strength to the
concrete in the first seven days and gains steadily in strength at later ages and
attains greater part of its strength in 28 days.
➢ TRICALCIUM ALUMINATE - C₃A (4-7%): This contributes in development of
one day strength. C₃A and gypsum content in cement interact to form Calcium
Sulpho-Aluminate, which decides the setting time. With low C₃A the heat of
hydration is low and resists sulphate attack on concrete.
➢ TETRA CALCIUM ALUMINO FERRITE – C₄AF (14-16%): It acts as a flux and
helps to bring down clinkerising temperature. It imparts color to cement.

COMPOUND COMPOSITION OF
CEMENT

CEMENT HYDRATION
The reaction between water and cement is called Hydration of
Cement. This reaction is exothermic i.e., heat is evolved during the
course of hydration. It is called heat of hydration.
Solid Products Calcium Hydroxide
Hydration Heat
WaterCement
Reaction
+

HYDRATION OF BLENDED CEMENT
PRIMARY HYDRATION: in OPC
2C3S + 6H → C3S2H3 + 3 Ca(OH)2
2C2S + 4H → C3S2H3 + Ca(OH)2
SECONDARY HYDRATION: additional in PPC
3Ca(OH)2 + 2S → C3S2H3
As more of C-S-H gels are produced, the matrix becomes more dense
impervious and resistant to external effects. Also Ca(OH)2 gets depleted in
the process and is not available to chlorides / sulphates / moistures to form
expansive salts and create distress. Lower heat of hydration further prevents
plastic & drying shrinkage cracks thereby increasing durability.

HEAT OF HYDRATION OF
CEMENT COMPOUNDS
120
62
207
100
0
50
100
150
200
250
300
350
C3S C2S C3A C4AF
Cal/gm

Types of Cement – As Per Indian Standards
1. Ordinary Portland Cement. – (33 Grade, 43 Grade and 53 Grade)
2. Pozzolana Portland Cement – (Fly ash based and Calcined clay based).
3. Portland Slag Cement.
4. High Alumina Cement.
5. Rapid Hardening Cement.
6. Oil Well Cement.
7. Sulphate Resisting Cement.
8. Low Heat Portland Cement.
9. White Portland Cement.
10. Super sulphated Cement.
11. Hydrophobic Cement.
12. Masonry Cement.

Ordinary Portland Cement - OPC
Varieties as per BIS
Specifications
Recommended Applications
33 Grade - IS : 269-2015
• All kind of general construction works.
43 Grade - IS : 269-2015
• All kind of general construction works, precast
concrete, prestressed concrete and High
Strength concrete.
• Slip form constructions
• Cement based products such as pipes, tiles,
blocks etc.
53 Grade - IS : 269 - 2015
• All the above mentioned in 43 Grade.
• High performance Concrete.

BLENDED CEMENTS
Portland Pozzolana Cement
IS : 1489 – 2015 (Part 1)
• General construction works,
especially in aggressive environmental
conditions to counteract chloride and
sulphate attacks.
• Water retaining structures, marine
works, mass concreting such as dams,
sewage pipelines etc.
• Substructures in sulphatic soils.
• Structures in hot and humid climate.
Portland Slag Cement
IS : 455 - 2015
• General construction.
• Construction of marine structures and
in coastal areas, where excessive
amounts of chlorides and sulphates.
• Mass concrete works – because of its
low heat of hydration.

BLENDED CEMENTS
Cement in which certain percentage of
Pozzolanic materials or Mineral
admixtures are used as prescribed in
the relevant Indian Standards to
improve the rheology and durability
of Concrete.

❖ Enhanced concrete durability and performance.
❖ Improved concrete properties in plastic and hardened state.
❖ Conservation of non renewable resources and energy.
❖ Environmental friendly : Reduces pollution level, utilization of
industrial waste.
BLENDED CEMENTS
Advantages
 High degree of cohesion and smooth workability of concrete and
mortar .
 Prevention of thermal cracks.
 Resistance to wet cracking.
 Resistance to ingress of aggressive gases and chemicals present in
environment .

Types of Pozzolanic / Mineral
Admixtures
Natural Pozzolans:
➢ Volcanic tuff, Clay and shales etc.
Artificial Pozzolans:
➢ Fly ash
➢ Ground Granulates Blast furnace Slag
➢ Silica Fume
➢ Rice husk ash

BLENDED CEMENTS
Clinker
Gypsum
Flyash
15 – 35%
Clinker
Gypsum
Slag
25 – 75%
Grinding
Grinding
IS 1489 – 2015 (Part 1)
IS 455 - 2015

Chemical Reaction of Blended Cements
CEMENT + MINERAL ADMIXTURE + WATER
(OPC) (Flyash/Slag)
Cement + Water CSH Gel + Calcium hydroxide
(Strength giving compound) (Ca(OH)₂)
Ca(OH)₂ + Flyash/Slag CSH Gel*
More CSH gel is formed by converting the available Calcium
hydroxide. This makes the mortar / concrete more denser and
impervious.

OPC + FLY ASH = PPC
Constituents Cement (%) Fly Ash (%)
SiO2 22 57
CaO 64 3
Al2O3 6 36
Fe2O3 4.5 5
MgO 1.00 0.50
Both show synergy in chemical composition

OPC + GGBS = PSC
Oxides Granulated Slag
Portland
Cement
CaO 40% 65%
SiO₂ 37% 20%
Al₂O₃ 11% 6%
Fe₂O₃ 0.2% 2.5%
*GGBS contains the same principal oxides as Portland cement.

FINENESS OF CEMENT
➢ Fineness of cement is sum total of surface area of all cement particles in one
kg of cement expressed in m2 (unit m2/kg). When expressed in CGS units it is
called as Blaines (1m2/kg = 10 Blaines)
➢ Fineness of cement has an important bearing on the rate of hydration and
hence on the rate of gain of strength at early ages (1 to 3 days)
➢ Fineness is measured by Air Permeability Method and Sieving on 45 micron
sieve (Residue should not be more than 10%)
❖ Wonder OPC 43 Grade 2600 - 2700
❖ Wonder OPC 53 Grade 2800 - 2900
❖ Wonder PPC 3400 - 3600

Soundness is the measure of dimensional stability of the hardened cement
mass.
Cement having excess free lime, magnesia or calcium sulphate will cause
expansion in hardened mass at a later date and such cements are referred as
unsound
Free lime in cement should be within 3%. Lower the value better is the
quality. High quality cements have free lime about 1%
Soundness is measured by two methods
- Le-Chatelier Test– For free lime 10 mm (In Wonder 0.5 to 1.0)
- Autoclave Test – For Magnesium & free lime, both 0.8% (In Wonder 0.02)
SOUNDNESS OF CEMENT

Initial Setting Time (IST): The time elapsed between the moment
water is added to cement, to the time the paste starts losing its plasticity.
During initial setting time, cement paste can be moulded as desired
without any adverse effect. Indian Standard specifies IST as not less than
30 minutes
Wonder OPC – 155-160 Minutes Wonder PPC – 170-175 Minutes
Final Setting Time (FST): The time elapsed between the moment
water is added to cement, and the time when the paste has completely lost
its plasticity and has attained sufficient stiffness/rigidity to resist certain
pressure. The cement paste completely converts to solid after FST. Indian
Standard specifies FST as not more than 600 minutes (10 hours)
Wonder OPC – 210-215 Minutes Wonder PPC – 230-235 Minutes
SETTING TIME OF CEMENT

❖ Compressive strength is an important quality parameter of cement.
❖ A cube specimen of size 7.06 cm (cross sectional area of 50 sq cm), with
cement sand ratio of 1:3 is prepared for testing.
❖ Sand specified by IS (Ennore, Tamil Nadu) should be used for testing.
❖ Room temperature for conducting the test shall be 27±2°C and at 90%
relative humidity. The other parameters like normal consistency,
compaction, rate of loading, etc. should be as tested per IS 4031
❖ Compressive strength is tested for 3 days, 7 days and 28 days
❖ Generally 3 days strength is 40% - 45% of 28 days strength and 7 days
strength is around 70% of 28 days strength (depending on the type of the
cement)
COMPRESSIVE STRENGTH OF
CEMENT

Time
COMPRESSIVE STRENGTH ( In Mpa or Kg / Cm2)
BIS Wonder PPC BIS Wonder OPC43 BIS Wonder OPC53
1 Day NA 16-17 NA 20-21 NA 22-24
3 Days 16 28 - 30 23 32-34 27 37 - 39
7 Days 22 37 - 39 33 43-45 37 48 - 50
28 Days 33 56 - 59 43 - 58 54 - 56 53 62 - 64
COMPRESSIVE STRENGTH OF
CEMENT
As per BIS in OPC 43, Compressive strength should not less than 43 Mpa and
can not be more than 58 Mpa

❖ It is the inactive part of the cement and refers to purity of cement.
❖ All the compounds (C3S, C2S, C3A, C4AF), MgO and gypsum present in
cement will completely dissolve in hydrochloric acid.
❖ The impurities in gypsum or any adulterants are insoluble.
❖ Maximum limit of IR as per BIS is 5% for OPC, in our case it is 2.30 -
2.6
❖ In case of PPC IR depends on amount of Fly Ash addition, BIS has
specified a formula to calculate IR.
Insoluble Residue

• Indicates the degree of freshness of cement.
• The cement may be hydrated somewhat during storage and the
water of hydration is removed only when the cement is heated to
500°C. Similarly the two molecules of water present in the gypsum
are also removed when the cement is ignited.
• Excessive loss on ignition indicates that the cement is not fresh
enough.
• Limit for LOI as per IS is 5% for OPC 43 & PPC and for OPC 53 is
4%.
• In our case LOI of PPC – 1.74, OPC 43 – 1.98 & OPC 53 – 1.69
Loss on Ignition (LOI)

MATERIAL TEST
CERTIFICATES (MTC)

EFFECT OF TIME OF STORAGE
ON STRENGTH OF CEMENT
Duration of
storage
Relative strength
at 28 days (%)
Fresh Cement 100
3 Months 80
6 Months 70
12 Months 60
24 Months 50

CALCULATION OF GODOWN STORAGE
CAPACITY
Height of each bag = 180 mm or 7 Inches, Each Bag occupies = 0.3sqm. or 3.23 sft. Area
Considering 15 Bag High Stack (Max.)
Area required to store 1000 MT of cement = 3.23 x 20000 / 15 = 4306 sq.ft.
Add 15% area requires for passage = 646 sq.ft.
Total area requires to store 1000 MT = 5000 sq.ft. approx.
4 bags per sq.ft. of area ( 15 bags high) i.e., 100MT requires an area of 500 sq ft. OR in an
area of 1000 sq ft, 200 MT can be stored.
5 x 5 Rule:
Area required in sq.ft. = Qty in MT x 5
Storage capacity in MT = Area in sq.ft. / 5

Basic of cement-Amit Payal

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