FINALCEMENT

Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology

Department of Chemical Engineering
PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 1

TABLE OF CONTENTS
Introduction 3
History of Cement 4
Chemical Composition of Portland cement 5
Properties of Portland cement 7
Types of cement 7
Types of Portland cement 10
Uses of Portland cement 13
Raw materials 13
Companies in the Philippines 16
Manufacturing process (wet and dry)
Portland cement (with plant layout) 19
Gypsum 30
Miscellaneous calcium compound 32
Miscellaneous magnesium compound 34
References 37

Cement Industry
Cement is a binder, a substance that sets and hardens independently, and can
bind other materials together. Cement is a very important material used in the
construction industry. Cement has replaced all other binding materials, for example,
clay and lime. Cement is the strongest binding material.
Cement is a fine, soft, powdery-type substance made from a

mixture of elements that are found in natural materials such as
limestone, clay, sand and/or shale. When cement is mixed with
water, it can bind sand and gravel into a hard, solid mass called
concrete. Cement mixed with water and sand, forms cement plaster.
Cement mixed with water, lime and sand, forms mortar.
Cement is used as one of the materials in making concrete buildings, roads,

bridges and other structures. It is one of the ingredients of concrete, the others being
gravel and sand.
Cement has been used as a binder of materiel for millenia. No one knows for
sure who first came up with the idea to use a cement substance to bind materials
together to make concrete, bricks, and other building materials. The process can be
traced back to Ancient Macedonia, but was more widely popularized during the Roman
Empire. Early forms of cement used things like lime and pozzolana, a type of volcanic
ash. The Romans were able to produce massive structures like the Pantheon and the
Roman aqueducts using this formula.
Currently, cement comes in two forms: Hydraulic and Non-Hydraulic. Hydraulic

cement refers to any cement that uses water to begin a chemical reaction that hardens
the mixture and, when fully formed, creates a water resistant product. This reaction is
independent of the water content of the mixture so allows for the material to harden
even underwater. This makes
It a very versatile construction material. Most all cements used today are hydraulic
cements. Non-hydraulic cement uses materials that do not harden when exposed to
water. While this type is much cheaper than hydraulic cement, the problems of long
drying times, combined with the inability to use it in wet environments makes it a poor
choice in most applications.
The most common type of modern cement is portland cement (sometimes

referred to as OPC for Ordinary Portland Cement). This type of cement is typically
made by grinding small rock-like bits of sintered limestone and aluminosilicate minerals
into a very fine powder. Its fast drying times combined with its higher compression
strength compared to other cements, makes it a great choice for use in concrete,
mortar, grout, and stucco.
Concrete and cement are not synonymous terms. Concrete is artificial stone
made from a carefully controlled mixture of cement, water, and fine and coarse
aggregate (usually sand and coarse rock).
History of Cement
3,000 BC The Egyptians used gypsum mortars and lime mortars to build the
pyramids.
800 BC Greeks and Cretans used lime mortars, which later became the base
of the famous Roman Mortar.
300 AD - 476 AD The Romans used lime and cementing pozzolan from Pozzuoli, Italy,
to build the Apian Way, the Roman baths, the Coliseum, and the
Pantheon in Rome. They used animal milk and blood as additives
when preparing the mixture of two parts of pozzolan and one part of
lime. These structures still exist nowadays.
1779 Bry Higgins promoted a patent for hydraulic cement (stucco) to be
used in exterior plasters.
1793 John Smeaton found that calcining limestone-containing clay formed
a lime that gets hardened under the water (hydraulic lime).
1796 Joseph Parker patented in England a natural hydraulic cement
produced by the calcination of coarse limestone nodules containing
clay which was called Parker Cement or Roman Cement.

1812 - 1813 The Frenchman Louis J. Vicat prepared an artificial hydraulic lime by
the calcination of a mixture of limestone and clay.
1822 James Frost prepared a hydraulic lime similar to that prepared by
Vicat and called it British Cement.
1824 Joseph Aspdin, a bricklayer and mason in Leeds, England, invented
the Portland cement by the calcination of a mixture of chalk and clay
finely divided. The senterized product was milled and denominated
Portland cement, for its similarity in high quality for construction to
that found in the stones quarried on the isle of Portland, England. His
Portland cement was called 'proto-Portland cement'
1853 William Aspdin made what could be called 'meso-Portland cement' (a
mix of Portland cement and hydraulic lime).
1854 Isaac Charles Johnson further refined the production of 'meso-
Portland cement' (middle stage of development) and claimed to be
the real father of Portland cement.
1858 The next development with the manufacture of Portland cement
was the introduction of the rotary kiln patented by German Friedrich
Hoffmann called a Hoffmann kiln for brick making
1860 The Hoffman "endless" kiln which gave "perfect control over
combustion" was tested and showed the process produced a better
grade of cement.
1875 The first Portland cement was produced by Coplay Cement Company
under the direction of David O. Saylor in Coplay, Pennsylvania.
1878 The Association of German Cement Manufacturers issued a standard
on Portland cement.
20th century American made Portland cement had displaced most of the imported
Portland cement.
Chemical Composition of Portland Cement
Portland cements are composed of four basic chemical compounds, shown with
their names, chemical formulas, and abbreviations:
1. Tricalcium silicate: 3CaO SiO2 = C3S

2. Dicalcium silicate: 2CaO SiO2 = C2S
3. Tricalcium aluminate: 3CaO Al2O3 = C3A

4. Tetracalcium aluminoferrite: 4CaO Al2O3FeO3 = C4AFe
Tricalcium silicate hardens rapidly and is largely responsible for initial set and
early strength. In general, the early strength of Portland cement concretes will be higher
with increased percentage of C3S. Dicalcium silicate hardens slowly, and its effect on
strength increases occurs at ages beyond one week. Tricalcium aluminate contributes to
strength development in the first few days because it is the first compound to hydrate.
It is, however, the least desirable component because of its high heat generation and its
reactiveness with soils and water containing moderate-to-high sulfate concentrations.
Cements made with low C3A contents usually generate less heat, develop higher
strengths, and show greater resistance to sulfate attacks. Tetracalcium aluminoferrite
assists in the manufacture of Portland cement by allowing lower clinkering temperature.
C4AFe contributes very little to the strength of concrete even though it hydrates very
rapidly.

Properties of Portland Cement
1. Fineness
One factor which affects
the hydration of cement,
regardless of its chemical
composition, is its fineness. The
finer a cement is ground, the
higher the heat of hydration and
resulting accelerated strength gain.
2. Soundness
Soundness is the ability of a cement to maintain a stable volume
after setting. An unsound cement will exhibit cracking, disruption, and
eventual disintegration of the material mass. This delayed-destruction
expansion is caused by excessive amounts of free lime or magnesium.
3. Setting Time
A cement used in concrete must not set too fast, for then it would
be unworkable, that is, it would stiffen and become hard before it could
be placed or finished. When it sets too slowly, valuable construction time
is lost. Most Portland cements exhibit initial set in about 3 hours and final
set in about 7 hours. If gypsum were not added during final grinding of
normal Portland cement, the set would be very rapid.
4. Compressive Strength
The ability of a cement to develop compressive strength in a
concrete is an important property. Compressive strength is the ability of
the cement to resist squeezing (compressive) load without fracture.
Types of Cement
1. Portland Cements
It is the product obtained by

pulverizing clinker consisting
essentially of hydraulic calcium
silicates, to which no additions have
been made before calcinations
other than water or untreated
calcium sulfate, provided the
addition will not exceed 1.0%. it is the main raw material in the production of
concrete.
2. Pozzolans
Since the beginning of the Christian

era, the Italians have successfully
employed pozzolan cement, made by
grinding 2 to 4 parts of a pozzolan with 1
part of hydrated lime. A pozzolan is a
material which is not cementitious in itself
but which becomes so upon admixture
with lime. The early strength of such a
cement is lower than that of Portland
cement, but within a year the strengths are equal. The advantage of this cement
is that it resists the corrosive action of saline solutions and seawater much better
than does Portland cement.
3. Rapid Hardening Cement
As the name implies, it develops

strength rapidly and therefore can be
called as highearly strength cement. The
rate of setting is same as that of ordinary
Portlandcement.The increased rate of
gain of strength of RHC is achieved by a
higher C3S Content and by finer grinding
of clinker. The rapid gain of strength is
accomplished by a high rate of heat
development and hence it should not be used in mass concrete constructions
like concrete gravity dam, concrete retaining walls.The Use of RHC is
recommended in the following situations: In pre-fabricated concrete
construction, for road repair works, place where form-work is required to be
removed early for re-use elsewhere, in Cold weather concreting and in wall
sealing.

4. High Alumina Cements
High-alumina cement, essentially a

calcium aluminate cement is
manufactured by fusing a mixture of
limestone and bauxite, the latter usually
containing iron oxide, silica, magnesia,
and other impurities. It is characterized by
a very rapid rate of development of
strength and superior resistance to
seawater and sulfate-bearing water.
5. Silicate Cements
Silica-filled, chemically setting silicate

cements withstand all concentrations of
inorganic acids except hydrofluoric. They are
not suitable at pH values above 7 or in the
presence of crystal-forming systems. Usually 2
parts by weight of finely divided silica powder
is used to 1 part of sodium silicate. Two
typical applications are the joining of bricks in
chromic acid reaction tanks and in alum tanks.
6. Quick setting Cement
This cement sets very early but

does not gain strength early. The early
setting property is brought out by
reducing the gypsum content at the time
clinker grinding. Sometimes aluminum
sulphate is added to accelerate the
setting process. It contains higher
percentage of C3A. It is required to be
mixed, placed and compacted very early. The use of quick setting cement is
recommended under water construction and grouting operations.

7. White Cement
It is more costly and is used in

architectural purposes such as facing panels and
terrazzo surface. The Grayish color of Portland is
due to the presence of Iron Oxide. The Process of
manufacturing of white cement is the same as
that of Portland cement but the amount of iron
oxide is limited to less than 1 %. The raw material
used are high purity lime stone (96 % CaCO3 and
less than 0.07 % iron oxide)
8. Colored Cement
It is widely used for decorative works

in floors. For manufacturing of various
colored cements either Grey Portland
Cement or White Cement is used as a Base.
With the use of Grey cement only red or
brown cement can be produced. Colored
cement consists of Portland Cement with 5 -
10 % of pigment. For proper mixing of
pigment, it is usual to grind pigment and
cement clinkers together.
Types of Portland cement ASTM C150
1. ASTM Type I
This type is a general concrete construction cement utilized when the
special properties of the other types are not required. It is used where the
concrete will not be subjected to sulfate attack from soil or water or be exposed
to severe weathering conditions. It is generally not used in large masses because
of heat generated due to hydration. Its uses include pavements and sidewalks,
reinforced concrete buildings, bridges, railway structures, tanks, reservoirs,
culverts, water pipes, masonry units.

2. ASTM type II (Moderate heat or Modified)

Type II cement is used where resistance to moderate sulfate attack is
important, as in areas where sulfate concentration in groundwater is higher than
normal but not severe. Type II cements produce less heat hydration than Type I,
hence their use in structures of mass such as piers, abutments, and retaining
walls. They are used in warm-weather concreting because of their low
temperature rise than Type I. The use of type II for highway pavements will give
the contractor more time to saw control joints because of the lower heat
generation and resulting slower setting and hardening.
3. ASTM Type III (High-Early-Strength)
Type III cements are used where an early strength gain is important and
heat generation is not a critical factor. When forms have to be removed for
reuse as soon as possible, Type III supplies the strength required in shorter
periods of time than the other types. In cold-weather concreting, Type III allows
a reduction in the heated curing time with no loss in strength.
4. ASTM Type IV (Low Heat)
Type IV cement is used where the rate and amount of heat generated
must be minimized. The strength development for Type IV is at a lower rate than
Type I. it is primarily used in large mass placements such as gravity dams where
the amount of concrete at any given time is so large that the temperature rise
resulting from heat generation during hardening becomes a critical factor.
5. ASTM Type V (Sulfate-Resisting)
Type V is primarily used where the soil or groundwater contains high
sulfate concentrations and the structure would be exposed to severe sulfate
attack.
6. Air Entraining Portland Cements
ASTM C175 governs the air-entraining cements, Types IA, IIA and IIIA. The
three cements correspond to Types I, II, and III, with the addition of small
quantities of air-entraining materials integrated with the clinker during the
manufacturing process.
These cements provide the concrete with improved resistance to freeze-
thaw action and to scaling caused by chemicals and salts used for ice and snow
removal. Concrete made with these cements contains microscopic air bubbles,
separated, uniformly distributed, and do small that there are many billions in a
cubic foot.

7. White Portland Cement

White Portland cement is a true Portland cement, its color being the
principal difference between it and normal Portland cement. The cement is
manufactured to meet ASTM C150 and C175 specifications. The selected raw
materials used in the manufacture of white cement have negligible amounts of
iron and manganese oxide, and the process of manufacture is controlled to
produce the white color. Its primary use is for architectural concrete products,
cement paints, tile grouts and decorative concrete.
8. Portland Blast-Furnace Slag Cements
In these cements, granulated blast-furnace slag of selected quality is
interground with Portland cement. The slag is obtained by rapidly chilling or
quenching molten slag in water, steam, or air. Portland blast-furnace slag
cements include two types; Type IS and Type IS-A, conforming to ASTM C595.
These cements can be used in general concrete construction when the specific
properties of other types are not required. However, moderate heat of
hydration (MH), moderate sulfate resistance (MS), or both are optional
provisions. Type IS has about the same rate of strength development as Type I
cement, and both have the same strength requirements.
9. Portland-Pozzolan Cements
IP, IP-A, and P-A designate the Portland-pozzolan cements with the A
denoting air-entraining additives as specified in C595. They are used principally
for large hydraulic structures such as bridge piers and dams. These cements are
manufactured by intergrinding Portland cement clinker with a suitable pozzolan
such as volcanic ash, fly ash from power plants, or diatomaceous earth, or by
blending the Portland cement or Portland blast-furnace slag cement and a
pozzolan.
10. Masonry Cements
Type I and type II masonry cements are manufactured to conform to
ASTM C91 and contain Portland cement, air-entraining additives, and materials
selected for their
ability to impart workability, plasticity, and water-retention properties to the
masonry mortars.
11. Special Portland cements
a. Oil well cement
Oil well cement is used for sealing oil wells. It is usually slow setting and
resistant to high pressures and temperatures. The American Petroleum

Institute Specifications for Oil Well Cements (API standard 10A) cover
requirements for six classes of cements. Each class is applicable for use at a
certain range of well depths.
b. Waterproof Portland cement
Waterproof Portland cement is manufactured by the addition of a small
amount of calcium, aluminum, or other stearate to the clinker during final
grinding. It is manufactured in either white or gray color and is used to
reduce water penetration through the concrete.
Uses of Portland cement
Portland Cement is used widely for the construction of various structures. Some
of them are listed below:
a. Used for filling cracks in concrete structures.

b. Used for masonry work, plastering and pointing.
c. Used for the construction of various structures like buildings, bridges. water
tanks, tunnels, docks, harhours etc.
d. Used to manufacture lamp posts, telephone posts, railway sleepers, piles etc.
e. For manufacturing cement pipes, garden seats, dust bins, flower pots etc. It
is useful for the construction of roads, footpaths, courts for various sports
etc.
Raw Materials
The main raw materials used in the cement manufacturing process are
limestone, sand, shale, clay, and iron ore.
OTHER RAW MATERIALS USED IN MANUFACTURING CEMENT:
Calcareous
Limestone (includes aragonite, marble, chalk)

Cement rock (include marl)
Oyster shell
Argillaceous
Clay
Shale

Others (includes Staurolite, bauxite, aluminum dross, pumice and volcanic

materials)
Siliceous
Sand
Sandstone and Quartz
Ferrous
Iron Ore, Pyrites, mill-scale and other iron-bearing material
Other
Gypsum and anhydrite

Blast furnace Slag
Fly ash
For its raw materials, cement uses minerals, containing the four essential elements for
its creation: calcium, silicon, aluminum and iron.
1. Volcanic Tuff
- Rock composed of the finer

or volcanic detritus usually
fused together through heat.

2. Limestone
- Rock that is formed chiefly by

accumulation of organic
remains (such as shells or
corals); consists mainly of
calcium carbonate. It yields
lime when burned.
3. Pyrite
- A common mineral that

consists of iron disulfide, FeS2
and has a pale brass-yellow
color and metallic luster. It is
being burned to make sulfur
dioxide and sulfuric acid.
4. Silica sand
- Impure silicon dioxide SiO2.

5. Gypsum
- A widely distributed mineral

CaSO4 2H2O consisting of
hydrated calcium sulfate.
COMPANIES IN THE PHILIPPINES
1. HOLCIM PHILIPPINES
Mailing Address: 7th Floor Two World Square McKinley Hill, Fort Bonifacio, Taguig City,
1634 Philippines Telephone No.: + (632) 459 3333
Website: www.holcim.ph
Plant Locations:
Holcim Philippines - La
Union Plant
Quirino, Bacnotan, La
Union (Region I)
Holcim Philippines -
Bulacan Plant
Barangay Matictic, Norzagaray, Bulacan (Region III)
Holcim Philippines - Lugait Plant
Lugait, Misamis Oriental (Region X)
Holcim Philippines - Davao Plant
Bo. Ilang, Davao (Region XI)

2. NORTHERN CEMENT CORPORATION
Mailing Address: 151 Epifanio Delos Santos

(EDSA), Brgy.Wack-Wack, Mandaluyong City,
Philippines Telephone Number: +(63 2) 667-5676
Fax Number: +(63 2) 320-3155
Website: www.ncc.com.ph
Plant Location: Bo. Labayug, Sison, Pangasinan
(Region I)
3. EAGLE CEMENT CORPORATION
Office Address: 153 EDSA, Mandaluyong City,

Philippines
Telephone No.: +(63 2) 727-4913 Fax No.: +(63 2)
723-9283
Website: www.eaglecement.com.ph
Plant Location: Brgy. Akle, San Idelfonso, Bulacan
4. SOLID CEMENT CORPORATION (CEMEX Philippines Group of Companies)
Office Address: 8th Floor, Petron Megaplaza, 358 Sen.

Gil J. Puyat Avenue, Makati City, 1200 Philippines
Telephone Number: +(63 2) 849-3585
Website: www.cemexphilippines.com
Plant Location: SitioTagbac, Brgy. San Jose, Antipolo City, Rizal (Region IV-A)
5. APO CEMENT CORPORATION (CEMEX Philippines Group of Companies)
Offices: 8th Floor Petron Megaplaza, 358 Sen. Gil J. Puyat

Avenue, Makati City, 1200 Philippines
Telephone Nos.: +(63 2) 489-3300
Website: www.cemexphilippines.com

Plant Location: APO Cement Plant Compound, Tina-an, Naga City, Cebu (Region VII)
6. LAFARGE REPUBLIC INCORPORATED
Office Address: 20th Floor, Salcedo Tower, 169

H. V. Dela Costa Street, Salcedo Village, Makati
City, Philippines
Telephone No.: +(63 2) 885-4599
Fax No.: +(63 2) 815-2668
Website: www.lafarge.com.ph
Plant Locations:
Lafarge Republic Bulacan Plant
Barrio Minuyan, Norzagaray, Bulacan (Region III)
Lafarge Republic Norzagaray Plant
Barrio Bige, Norzagaray, Bulacan (Region III)
Lafarge Republic Teresa Plant
Brgy.Dulumbayan, Teresa, Rizal (Region IVA)
Lafarge Republic Batangas Plant
Brgy.Mapulo, Taysan, Batangas (Region IVA)
Lafarge Republic Danao Plant
Brgy.Dungo-an, Danao City, Cebu

Lafarge Iligan Plant
Brgy.Kiwalan, Iligan City
7. TAIHEIYO CEMENT PHILIPPINES, INC.
Office Address: 11th Floor, Insular Life Cebu Business

Centre, Cebu Business Park Cebu City, 6000 Philippines
Plant Location: South Poblacion, San Fernando, Cebu
Telephone No.: +(63 32) 230-7333
Fax No.: +(63 32) 230-7300
Website: www.taiheiyo-cement.com.ph

8. GOODFOUND CEMENT CORPORATION, PHILIPPINES
Office Address: Palanog, Camalig, Albay (Region v)

Plant Location: Palanog, Camalig, Albay
Telephone Nos.: +(63 52) 484-1322
9. PACIFIC CEMENT PHILIPPINES, INC.
Plant Location: Km. 11, Surigao City, Surigaodel Norte

(Region xiIII)
Telephone No.: +(63 86) 826-1416
Manufacturing Process
A. Manufacturing process of Portland cement with equipment
TWO PROCESSS INVOLVED IN THE MANUFACTRUE OF PORTLAND CEMENT
1. Wet Process
The original rotary cement kilns were

called 'wet process' kilns. In their basic
form they were relatively simple
compared with modern developments.
The raw meal was supplied at ambient
temperature in the form of a slurry.
A wet process kiln may be up to 200m long

and 6m in diameter. It has to be long
because a lot of water has to be
evaporated and the process of heat
transfer is not very efficient. Basic principle of a wet-process kiln.
The slurry may contain about 40% water. This takes a lot of energy to evaporate and
various developments of the wet process were aimed at reducing the water content
of the raw meal. An example of this is the 'filter press' (imagine a musical accordion
10-20 metres long and several metres across) - such adaptions were described as
'semi-wet' processes.
The wet process has survived for over a century because many raw materials are
suited to blending as a slurry. Also, for many years, it was technically difficult to get
dry powders to blend adequately.
Quite a few wet process kilns are still in operation, usually now with higher-tech bits
bolted on. However, new cement kilns are of the 'dry process' type.
2. Dry process
In a modern works, the blended raw material

enters the kiln via the pre-heater tower. Here,
hot gases from the kiln, and probably the
cooled clinker at the far end of the kiln, are
used to heat the raw meal. As a result, the raw
meal is already hot before it enters the kiln.
The dry process is much more thermally

efficient than the wet process.
Basic
Firstly, and most obviously, this is because the meal principle
is a dry powderof and
a precalciner cement
there is little or
no water that has to be evaporated. kiln.
Secondly, and less obviously, the process of transferring heat is much more efficient in a
dry process kiln.
An integral part of the process is a heat exchanger called a 'suspension preheater'. This
is a tower with a series of cyclones in which fast-moving hot gases keep the meal
powder suspended in air. All the time, the meal gets hotter and the gas gets cooler until
the meal is at almost the same temperature as the gas.
The basic dry process system consists of the kiln and a suspension preheater. The raw
materials, limestone and shale for example, are ground finely and blended to produce
the raw meal. The raw meal is fed in at the top of the preheater tower and passes
through the series of cyclones in the tower. Hot gas from the kiln and, often, hot air

from the clinker cooler are blown through the cyclones. Heat is transferred efficiently
from the hot gases to the raw meal.
The heating process is efficient because the meal particles have a very high surface area
in relation to their size and because of the large difference in temperature between the
hot gas and the cooler meal. Typically, 30%-40% of the meal is decarbonated before
entering the kiln.
EQUIPMENT UNIT OPERATIONS AND PROCESSES

Excavator QUARRYING
Limestone and shale are extracted from the

quarry by open pit method, through drilling and
blasting techniques. For safety, the workers
must maintain a distance of at least 50 meters
from the area theyll blast.

Dump Truck TRANSPORTING THE RAW MATERIALS
Raw materials extracted from the quarry are

delivered to the plant by the use of dump
trucks.
Gyratory Mill CRUSHING
The bulk of limestone and shale would be

reduced into smaller pieces approximately 3.8 in
size by gyratory mill. There is a constant spray of
water to keep dust from billowing up.

Hammer Mill PRE-HOMOGENIZATION
Reduces the crushed limestone and shale or clay

to a finer powder; allows limestone and shale to
mix better.
Vertical roller mill RAW MATERIAL MILLING
The pre-homogenized materials (limestone and

shale/clay) and two other raw materials (silica
sand and pyrite) are proportioned, milled and
dried, producing raw meal.

Raw Meal Silos HOMOGENIZATION
This process takes place in silos equipped for

obtaining a homogeneous mix of the materials.
Preheating tower PREHEATING
The raw mix enters the pre-heater at a

temperature from 900C to 1000C.Within 40
seconds, this begins the process of bonding the
minerals together, so theyll later harden when
hydrated with water. In about 5 seconds, it
removes about 95% of the carbon dioxide of
powder through a chemical reaction, which
isolates the lime the most important
component of cement.
3 = + 2()

Rotary kilns
CALCINATION
Lime reacts with silica in stages and

clinker minerals are finally formed at
1450C.
Clinker produced are 3 to 20 mm in size.
The kiln is slightly inclined so that the
materials fed in the upper end travel
slowly to the lower firing end.
Portland cement clinker mainly consists
of CaO, 2, 2 3 and 2 3; are
accounting for more than 95%. Theminor
components in total less than 3% are
MgO, 2, 2 5 and alkalis.
Clinker Formation:
Length: 45m CaO = C; 2= S; 2 3= A; 2 3= F

Internal diameter: 2.5 to 6 m
Rotational speed: 0.5 to 2 rpm Composition of Portland Cement:
Rotation period: 1 to 3 h 1. Belite (2 ) constitutes 15-30%. It is dicalcium
Heat sources: mined coal, fuel oil, natural silicate (2 4).
gas and alternative fuel resources (like rice 2. Alite (3 ) is the most important constituent,
husk) 50-70%. It is tricalcium silicate (3 5 ).
3. Aluminate (3 ) constitutes 5-10%. It is
Tricalcium aluminate (3 2 6).
4. Ferrite (4 AF) makes up 5-15%. It is a
tetrcalciumaluminoferrite(4 5).

Clinker cooler
COOLING
Clinker is discharged from rotary kiln into the

air-quenching coolers, which quickly bring its
temperature down to approximately 100 to
200C.
Steel silos STORING
After the molten clinker is quickly air- cooled, it

is transported by bucket conveyors to the
shaded storage.

CEMENT MILLING
Tube Mill
Clinker, together with about 4-5% gypsum(help
regulate the setting time when the cement is
mixed with other materials and becomes
concrete), is finely ground at the tube mill. The
powder product is now called cement.
Packaging machine PACKAGING AND SHIPPING
The final product is shipped either in bulk (ships,

barges, tanker trucks, railroad cars, etc.) or in
strong paper bags which are filled by machine.

DUSTING BAG FILTER

The entire process of cement making creates a
lot of dust, so a Continuous Emission Monitoring
System (CEMS) is applied. This way, we can be
sure there is no pollution in the air. So,
everything is environment-friendly.

Plant layout: Cement

A. Gypsum Process
1 1
CaSO4 2H2O(c) CaSO2 2H2O(c) +12H2O(g)
A mineral occurs in large deposits throughout the world. It is the second
softest mineral following after talc in Mohrs Hardest Scale. It is hydrated calcium
sulfate, the formula CaSO4.(2H2O).
If heating is at a higher temperature, gypsum loses all its water and
becomes anhydrous sulfate or anhydrite. It is hydraulic and hardens under
water, but is also slightly soluble in water.
EQUIPMENT UNIT OPERATIONS AND

PROCESSES
Calciners Calcination of gypsum
The usual method of calcination of

gypsum consists of grinding the
mineral and placing it in large
calciners holding 9 to 22 tons. The
temperature is raised to about 120
-150 , with constant agitation to
maintain a uniform temperature.
The material in the kettle known to
the public as plaster of paris and to
the manufacturer as first-kettle
plaster, may be withdrawn and sold
at this point, or it may be heated
further to 190 to give a material
known as secondsettle plaster.
First-settle plaster is approximately
1
the half hydrate CaSO4 2H2O, and
the second form is anhydrous.
Practically all gypsum plaster sold is
in this form of first-settle plaster
mixed with sand or wood pulp. The
second form is used in the
manufacture of plasterboard and
other gypsum products.
Gypsum may also be calcined in
rotary kilns similar to those used
for limestone.

Calcining kettle
Hardening of plaster
1 1
CaSO4 2H2O +12H2O CaSO4
2H2O
This equation is the reverse of that
for the dehydration of gypsum.
The plaster sets and hardens

because the liquid water reacts to
form a solid, crystalline hydrate.
Hydration with liquid water takes
place at temperatures below 99
and thus gypsum must be heated
above 99 for practical
dehydration. Commercial plaster
usually contains some glue in the
water used or a material such as
hair or tankage from the stockyards
to retard the setting time in order
to give the plasterer opportunity to
apply the material.
MISCELLANEOUS CALCIUM COMPOUNDS
CALCIUM CARBONATE
Calcium carbonate is a very widely used industrial

chemical, in both its pure and its impure state. As marble
chips, it is sold in many sizes as a filler for artificial stone, for
the neutralization of acids, and for chicken grit. Marble dust
is employed in abrasives and in soaps. Crude, pulverized
limestone is used in agriculture to sweeten soils in large
tonnage. Some pulverized and levigated limestone, to
replace imported chalk and whiting, is manufactured quite
carefully from very pure raw material and is finding
acceptance. Whiting is pure, finely divided calcium carbonate prepared by wet grinding
and levigating natural chalk. Whiting mixed with 18% boiled linseed oil yields putty,
which sets by oxidation and by formation of the calcium salt. Much whiting also is
consumed in the ceramic industry. Precipitated, or artificial, whiting arises through
precipitation, e.g., from reacting a boiling solution of calcium chloride with a boiling
solution of sodium carbonate or passing carbon dioxide into a milk-of-lime suspension.
Most of the latter form is used in the paint, rubber, pharmaceutical, and paper
industries.
CALCIUM SULFIDE.
Calcium sulfide is made by reducing calcium

sulfate with coke. Its main use is as a depilatory in the
tanning industry and in cosmetics. In a finely divided
form it is employed in luminous paints. Polysulfides,
such as CaS2 and CaS5, made by heating sulfur and
calcium hydroxide, are consumed as fungicides.

HALIDE SALTS
Calcium chloride is obtained commercially as a by-

product of chemical manufacture and from natural brines
which contain more or less magnesium chloride. In 1980,
730,000 t was sold. Its main applications are to lay dust on
highways in winter, to thaw coal, in oil and gas well fluids,
and as an antifreeze for concrete.
Calcium bromide and iodide have properties similar to

those of the chloride. They are prepared by the action of the halogen acids on calcium
oxide or calcium carbonate. They are sold as hexahydrates for yse in medicine and
photography. Calcium fluoride occurs naturally as a fluorspar. Calcium hypochlorite
[Ca(OCl)2] is prepared by the action of chlorine on calcium hydroxide. Its primary use is
for swimming pool sanitation.
CALCIUM ARSENATE
Calcium arsenate is produced by the reaction of calcium

chloride, calcium hydroxide, and sodium arsenate or lime and
arsenic acid:
2CaCl2(aq) + Ca(OH)2(c) + 2Na2HAsO4(aq) Ca3(AsO4)2(c) + 4NaCl(aq)

+ 2H2O(l) H = -27.8 kJ
Some free lime is usually present. Calcium arsenate is used

extensively as an insecticide and as a fungicide.
CALCIUM ORGANIC COMPOUNDS
Calcium acetate and lactate are prepared by the

reaction of calcium carbonate or hydroxide with acetic or lactic
acid. The acetate was formerly pyrolyzed in large amounts to
produce acetone, but now it is employed largely in the dyeing
of textiles. The lactate is sold for use in medicines and in foods
as a source of calcium; it is an intermediate in the purification
of fermentation lactic acid. Calcium soaps such as stearate,
palmitate, and the abietate are made by the action of the
sodium salts of the acids on a soluble calcium salt such as the

chloride. These soaps are insoluble in water but are soluble in hydrocarbons. Many of
them form jellylike masses, which are constituents of greases. These soaps are used
mainly as waterproofing agents.
MAGNESIUM COMPOUNDS
Magnesium is one of the most widely distributed

elements, occupying 1.9 percent of the earths crust. It
occurs usually in the chloride, silicate, hydrated oxide,
sulfate or carbonate in either a complex or in simple salts.
Magnesium metal first became available commercially
shortly before 1914, when the Germans initiated
production using magnesium chloride from the Stassfurt
deposits as the raw material.
MAGNESIUM CARBONATES
These vary from dense MgCO3 used in magnesite bricks to

the very low density 4MgCO3Mg(OH)25H2O and
3MGCO3MG(OH)23H2O once employed for insulation. There are
also other basic carbonates on the market with variations in
adsorptive index and apparent density. Many of these are
employed as fillers in inks, paints, and varnishes.
OXIDES AND HYDROXIDE OF MAGNESIUM
On heating magnesium carbonate or hydroxide,

magnesium oxide (MgO) is formed. This oxide has many
uses, e.g., in the vulcanization of rubber, as a material for
making other magnesium compounds, as an insulating
material, as a refractory material, and as an abrasive. The
magnesium hydroxide is principally made directly from
seawater. The seawater is screened and pumped to a
battery of three 38-m diameter concrete hydrotreaters.
Here enough calcined dolomite is added

to pretreat or soften the seawater by precipitating carbonates, which are

removed by rakes. The softened seawater flows to two primary reactors 25 m in
diameter into which is fed the main addition of calcined dolomite to precipitate the
Mg(OH)2, which in a fine suspension overflows into three parallel-flow 76-m-diameter
thickeners, the overflow being returned to the sea. The underflow of the two primary
reactors is fed first into an 18-diameter secondary reactor and then into the tertiary
reactor, from which the three-times-reacted residue, now largely silicious material and
unreacted dolomite, is wasted. The thickened Mg(OH)2 slurry from the three 76-m
thickeners is united and washed with calcined-dolomite-softened fresh water in two 76-
m thickeners in series. The Mg(OH)2 underflow is conducted through storage to a 4- by
5.5-m rotary filter operating at about 26.7-kPa vacuum and delivering about 50%
Mg(OH)2. This is removed from the rotary filter and conveyed either to sale or to one of
three rotary kilns operating up to 1800C to give different grades of MgO. After
purification this is the well-known milk of magnesia used in medicine. Magnesium
peroxide is available from the reaction of magnesium sulfate and barium peroxide. It is
employed as an antiseptic and a bleaching agent.
MAGNESIUM SULFATE
Magnesium sulfate is prepared by the action

of sulfuric acid on magnesium carbonate or hydroxide.
It is sold in many forms, one of which is the hydrate
MgSO47H2O, long known as Epsom salts. The less
pure material is used extensively as sizing and as a
fireproofing agent.
MAGNESIUM CHLORIDE
Magnesium chloride is made from hydrochloric

acid and magnesium hydroxide as described above. The
compound itself much resembles calcium chloride and has
many of the same uses. In addition, it finds application in
ceramics, in the sizing of paper, and in the manufacture of

oxychloride cement. Its principal use is in the making of metallic magnesium.
MAGNESIUM SILICATES
A consideration of magnesium silicates includes

two widely used naturally occurring compounds, asbestos
and talc. Asbestos is a magnesium silicate mixed with
varying quantities of silicates of calcium and iron. It is a
fibrous, noncombustible mineral and is used in the
manufacture of many fireproof and insulating materials.
Because of the cancer-causing characteristics of its fibers,
government regulations have sharply reduced its use. Talc
is a rather pure magnesium silicate in the form of
3MgO4SiO2H2O, found naturally in soapstone. It is
employed as a filler in paper and plastics and in many
cosmetic and toilet preparations.

References
Austin, G. T. (1984). Shreves Chemical Process Industries 5th edition
Coffey, J.C., Lafeur, C.B., LaPlante,C., Marotta,T.W. (2011). Basic Construction

materials 8th edition
Cement. Retrieved from

http://iti.northwestern.edu/cement/monograph/Monograph3_8.html on
November 18, 2015
Uses of Cement. Retrieved fromhttp://www.civilengineeringx.com/traditional-

materials/uses-of-cement/ on November 18, 2015


FINALCEMENT

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FINALCEMENT

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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 1

Chemical Composition of Portland cement 5

Properties of Portland cement 7

Types of Portland cement 10

Uses of Portland cement 13

Companies in the Philippines 16

Manufacturing process (wet and dry)

Portland cement (with plant layout) 19

Miscellaneous calcium compound 32

Miscellaneous magnesium compound 34

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 2

Cement is a fine, soft, powdery-type substance made from a

Cement is used as one of the materials in making concrete buildings, roads,

Currently, cement comes in two forms: Hydraulic and Non-Hydraulic. Hydraulic

The most common type of modern cement is portland cement (sometimes

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 4

Chemical Composition of Portland Cement

1. Tricalcium silicate: 3CaO SiO2 = C3S

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 5

4. Tetracalcium aluminoferrite: 4CaO Al2O3FeO3 = C4AFe

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 6

Properties of Portland Cement

It is the product obtained by

Since the beginning of the Christian

3. Rapid Hardening Cement

As the name implies, it develops

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 8

4. High Alumina Cements

High-alumina cement, essentially a

Silica-filled, chemically setting silicate

6. Quick setting Cement

This cement sets very early but

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 9

It is more costly and is used in

It is widely used for decorative works

Types of Portland cement ASTM C150

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 10

2. ASTM type II (Moderate heat or Modified)

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 11

7. White Portland Cement

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 12

Uses of Portland cement

a. Used for filling cracks in concrete structures.

OTHER RAW MATERIALS USED IN MANUFACTURING CEMENT:

Limestone (includes aragonite, marble, chalk)

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 13

Others (includes Staurolite, bauxite, aluminum dross, pumice and volcanic

Iron Ore, Pyrites, mill-scale and other iron-bearing material

Gypsum and anhydrite

- Rock composed of the finer

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 14

- Rock that is formed chiefly by

- A common mineral that

- Impure silicon dioxide SiO2.

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 15

- A widely distributed mineral

COMPANIES IN THE PHILIPPINES

PORTLAND CEMENT AND MISCELLANEOUS CALCIUM AND MAGNESIUM COMPOUNDS 16

2. NORTHERN CEMENT CORPORATION

Mailing Address: 151 Epifanio Delos Santos

3. EAGLE CEMENT CORPORATION