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Raw Materials and Manufacturing Process for Portland Cement
- 3. Raw Materials Necessary forRaw Materials Necessary for Portland Cement ManufacturePortland Cement Manufacture Must Provide the FollowingMust Provide the Following CalciumCalcium SilicaSilica AluminaAlumina IronIron
- 4. CalciumCalcium IronIron SilicaSilica AluminaAlumina SulfateSulfate Alkali wasteAlkali waste AragoniteAragonite CalciteCalcite Cement-kilnCement-kiln dustdust Cement rockCement rock ChalkChalk ClayClay Fuller’s earthFuller’s earth LimestoneLimestone MarbleMarble MarlMarl SeashellsSeashells ShaleShale SlagSlag Blast-furnaceBlast-furnace flue dustflue dust ClayClay Iron oreIron ore Mill scaleMill scale Ore washingsOre washings Pyrite cindersPyrite cinders ShaleShale Calcium silicateCalcium silicate Cement rockCement rock ClayClay Fly ashFly ash Fuller’s earthFuller’s earth LimestoneLimestone LoessLoess MarlMarl Ore washingsOre washings QuartziteQuartzite Rice-hull ashRice-hull ash SandSand SandstoneSandstone ShaleShale SlagSlag TraprockTraprock Aluminum-oreAluminum-ore refuserefuse BauxiteBauxite Cement rockCement rock ClayClay Copper slagCopper slag FlyFly ashash Fuller’s earthFuller’s earth GranodioriteGranodiorite LimestoneLimestone LoessLoess Ore washingsOre washings ShaleShale SlagSlag StauroliteStaurolite AnhydriteAnhydrite CalciumCalcium sulfatesulfate GypsumGypsum Source: PCA, 2003
- 5. Traditional Manufacture ofTraditional Manufacture of Portland CementPortland Cement 1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.), and stored.Source: PCA, 2003
- 7. 2. Raw materials are ground to powder and blended. or 2. Raw materials are ground, mixed with water to form slurry, and blended. Source: PCA, 2003
- 8. 3. Burning changes raw mix chemically into cement clinker. Source: PCA, 2003
- 12. 4. Clinker is ground with gypsum into portland cement and shipped. Source: PCA, 2003
- 13. ClinkerClinker Gypsum Source: PCA, 2003
- 14. GrindingGrinding Clinker is ground withClinker is ground with gypsum (calcium sulfate) togypsum (calcium sulfate) to produce portland cementproduce portland cement Fine grinding is necessaryFine grinding is necessary for high early strengthfor high early strength – 85-95% -325 mesh (4585-95% -325 mesh (45 microns)microns) – ~ 7 trillion particles per~ 7 trillion particles per poundpound Gypsum absorbs water andGypsum absorbs water and prevents setting of Cprevents setting of C33AA during shipmentduring shipment
- 15. Source: van Oss and Padovani, 2002
- 16. Process of Clinker ProductionProcess of Clinker Production Source: PCA, 2003
- 20. Source: MacLaren and White, 2003
- 21. Source: MacLaren and White, 2003
- 22. Clinker PhasesClinker Phases AliteAlite oror 3CaO•SiO3CaO•SiO22 oror CC33SS – Hydrates & hardens quicklyHydrates & hardens quickly – High early strengthHigh early strength – Higher heat of hydrationHigher heat of hydration (setting)(setting) BeliteBelite oror 2CaO• SiO2CaO• SiO22 oror CC22SS – Hydrates & hardens slowerHydrates & hardens slower than alitethan alite – Gives off less heatGives off less heat – High late strength (> 7 days)High late strength (> 7 days) Modern cements areModern cements are manufactured to be higher inmanufactured to be higher in alite for early strengthalite for early strength
- 23. Clinker PhasesClinker Phases AluminateAluminate oror 3CaO• Al3CaO• Al22OO33 oror CC33AA – Very high heat of hydrationVery high heat of hydration – Some contribution to earlySome contribution to early strengthstrength – Low CLow C33A for sulfateA for sulfate resistanceresistance FerriteFerrite oror 4CaO4CaO•• AlAl22OO33 •• FeFe22OO33 oror CC44AFAF – Little contribution to strengthLittle contribution to strength – Lowers clinkeringLowers clinkering temperaturetemperature – Controls the color of cementControls the color of cement
- 24. Microscopic Images of ClinkerMicroscopic Images of Clinker
- 25. Microscopic Images of ClinkerMicroscopic Images of Clinker Alite
- 26. Microscopic Images of ClinkerMicroscopic Images of Clinker Belite
- 27. Microscopic Images of ClinkerMicroscopic Images of Clinker Aluminate
- 28. Microscopic Images of ClinkerMicroscopic Images of Clinker Ferrite
- 29. Types of Portland CementTypes of Portland Cement II NormalNormal IIII Moderate sulfate resistanceModerate sulfate resistance IIIIII High early strengthHigh early strength IVIV Low heat of hydrationLow heat of hydration VV High sulfate resistanceHigh sulfate resistance ASTM C 150 (AASHTO M 85)
- 30. Source: Mindess, Young, and Darwin, 2004
- 31. Source: Mindess, Young, and Darwin, 2004
- 32. Source: Mindess, Young, and Darwin, 2004
- 33. Source: Mindess, Young, and Darwin, 2004
Editor's Notes
- Fig. 2-5. Aerial view of a cement plant. (70000)
- Table 2-1. Sources of Raw Materials Used in Manufacture of Portland Cement Sulfate, often in the form of gypsum, is added during the grinding of the clinker to regulate the setting time of the cement and to improve shrinkage and strength development properties.
- Fig. 2-3. Steps in the traditional manufacture of portland cement
- Natural Cement Rock Two Benches No Blasting only Ripping 5- 10 hour shifts Haul trucks 2 – 796C cat 1 – 35R Euclid 988 Cat Loaders
- Fig. 2-3. Steps in the traditional manufacture of portland cement
- Fig. 2-3. Steps in the traditional manufacture of portland cement
- Modernized in 1999 by HBZ and Fuller 1500 tpd to 2000 tpd Fuel Consumption decreased by 15% Modern – State of the Art Preheater / Precalciner System with down draft calciner/ & DeSox
- Kiln –2,000 stpd 12’ x 165’ 3.1 RPM
- Fig. 2-8. Rotary kiln (furnace) for manufacturing portland cement clinker. Inset view inside the kiln. (58927, 25139)
- Fig. 2-3. Steps in the traditional manufacture of portland cement
- Fig. 2-9. Portland cement clinker is formed by burning calcium and siliceous raw materials in a kiln. This particular clinker is about 20 mm (3¼4 in.) in diameter. (60504) Fig. 2-11. Gypsum, a source of sulfate, is interground with portland clinker to form portland cement. It helps control setting, drying shrinkage properties, and strength development. (60505)
- Fig. 2-10. Process of clinker production from raw feed to the final product (Hills 2000).
- Fig. 2-10. Process of clinker production from raw feed to the final product (Hills 2000).
- Fig. 2-10. Process of clinker production from raw feed to the final product (Hills 2000).