The document discusses the raw materials and manufacturing process for Portland cement. Key raw materials include limestone, silica, alumina, and iron which are ground and blended. The blended raw mix is then burned at high temperatures in a kiln to form cement clinker in a chemical reaction. The clinker is then ground with gypsum to produce Portland cement, which is stored and delivered. Modern dry processing uses a preheater and precalciner to burn the raw mix more efficiently in a shorter kiln.

1. CON 123
Cementitious Materials
Session 2
Raw Materials & Manufacturing

2. Rotary kiln (furnace) for manufacturing Portland cement clinker.
Inset view inside the kiln.

3. Raw Materials and Grinding
 Raw materials
preparation
 Kiln systems
 Fuels
 Natural gas
 Coal
 Coke
 Syn-fuels

4. Primary Components of Raw Materials
Necessary for Portland Clinker Production
Materials used in the manufacture of Portland
cement must contain appropriate proportions:
 Calcium
 Silica
 Alumina
 Iron

5. Sources of Raw Materials Used in
Manufacture of Portland Cement
Calcium Iron Silica Alumina Sulfate
· Aragonite · Blast-furnace · Calcium · Aluminum-ore · Anhydrite
· Calcite flue dust silicate refuse · Calcium
· Cement-kiln · Clay · Cement rock · Bauxite sulfate
dust · Iron ore · Clay · Cement rock · Gypsum
· Cement rock · Mill scale · Fly ash · Clay
· Chalk · Ore washings · Limestone · Copper slag
· Clay · Pyrite cinders · Marl · Fly ash
· Limestone · Shale · Ore washings · Limestone
· Marble · Quartzite · Ore washings
· Marl · Rice-hull ash · Shale
· Shale · Sand · Slag
· Slag · Sandstone
· Shale
· Slag

6. Quarry
Limestone, a primary raw material providing calcium in making cement,
is quarried near the cement plant. 25,50, 0r 100 ton trucks.

7. Quarry
Quarry face may vary
depending on limestone
deposit.
10ft-40ft quarry face.

8. Steps in the Traditional Manufacture of
Hydraulic Portland Clinker
1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.),
and stored.

9. Crusher located at quarry pit

10. Automatic measurement of chemical composition

11. Raw material storage

12. 2. Raw materials are ground to powder and blended.
or
2. Raw materials are ground, mixed with water to form
slurry, and blended.

13. Raw Mill grinding

14. Raw Mix Chemistry
Bogue Potential Compounds
Tricalcium silicate C3S
Dicalcium silicate C2S
Tricalcium aluminates C3A
Tetracalcium Aluminoferrite C4AF

15. Bogue Equations
(C3S) = (4.071*%CaO) - (7.600*%SiO2) - (6.718*%Al2O3)
- (1.430*%Fe2O3)
(C2S) = (2.867*%SiO2) - 0.7455*%C3S)
(C3A) = (2.650*%Al2O3) - (1.692*%Fe2O3)
(C4AF) = (3.043*%Fe2O3)

16. Moduli for Burning
 Lime Saturation (LSF)
 Ca/(2.85Si + 1.18Al +0.65Fe)
 Silica Ratio (S/R)
 Si/(Al +Fe)
 Alumina Ratio (A/F)
 Al/Fe

17. Pyro-Processing Systems
 Wet Process
 Dry Process
 Dry Pre-heater
 Dry Precalciner

18. Steps in the traditional manufacture
of Portland cement (continued)
3. Burning changes raw mix chemically into cement clinker.

19. Slurry tank storage

20. Slurry tank storage

21. Clinker Cooler. Cools clinker from discharge of 2700 degrees F to 200 degrees F.

22. 2. Raw materials are
ground, to powder and
blended.
Steps in the modern dry-process
manufacture of Portland cement.

25. Dry raw mix typically labeled Dry Kiln
Feed

26. Steps in the modern dry-process manufacture of
Portland cement (Continued)
3. Burning changes raw mix chemically into clinker. Note
four stage preheater, flash furnaces, and shorter kiln.

28. Combustion
 Limestone + Heat = CaO + CO2 (0.50
tons)
 Fuel Contribution = CO2 (0.50 tons)
 Total CO2 Contribution of 1 ton per
clinker ton
Contribution of CO2 emissions during
Portland clinker production.

29. Clinker & Gypsum
Clinker Gypsum
Portland cement clinker is formed by burning calcium and siliceous raw
materials in a kiln. This particular clinker is about 20 mm (3¼ - 4 in.) in
diameter.
Gypsum, a source of sulfate, is interground with Portland clinker to form
Portland cement. It helps control setting, drying shrinkage properties, and
strength development.

30. Steps in the modern dry-process manufacture of
Portland cement (Continued)
4. Clinker with gypsum is ground into portland cement and
shipped

31. Finish mill grinding

33. Storage of Cement
Right click to
play

34. Delivery of Cement
Right click to
play

35. Hydraulic Portland Cement
By definition:
“a hydraulic cement produced by pulverizing
clinker consisting essentially of hydraulic calcium
silicates, usually containing one or more of the
forms of calcium sulfate as an interground
addition, and up to 5% limestone.”

36. Raw Materials and Grinding
Please return to Blackboard and watch the
following video:
 Video 1: Storage