SUMMARY Cement is among the most important building materials.

It is a fine, grey powder mixed with water and materials such as sand, gravel, and crushed stone to make concrete. The ancient Romans developed cement similar to the kinds used today. Their cement had such great durability that some of their buildings, roads, and bridges still exist. To make cement, the Romans mixed slaked lime (lime to which water has been added) with a volcanic ash called pozzuolana. The ash produced hydraulic cement that hardened under water. Cement Industry was introduced in the Philippines during the early 1900s. Historical reminiscences point to rich limestone deposits in Montalban and Binangonan. The Philippines undoubtedly teemed with limestone and shale the essential raw materials in cement manufacture. Because of the abundance of these rich mineral resources, an enterprising group of Augustinian Recollects have taken interest in doing business in the country. With foreign investors in their fold, local cement manufacturers found themselves enjoying the best of both worlds. The multinational partnerships not only bailed them out of indebtedness, it also brought into the Philippines some of the worlds leading technologies and international best practices that would help the cement industry evolve into a globally competitive business. Four global cement leaders took interest in the Philippine cement business and took significant holdings among the embattled local firms. These cement conglomerates are Financiere Lafarge S.A. (France), Blue Circle PLC (UK), Cemex S.A. de C.V. (Mexico)Holcim Ltd. And (Switzerland) During the last quarter of 1997, Cemex forged an alliance with the Madrigal family, paving the way for the Mexican companys investment into Solid Cement and into the Rizal Group of Companies. Two years later, Cemex also acquired Apo Cement in Cebu which, at the time, was coming out fresh from rehabilitation and the conversion of its wet process under the management of the Gokongweis. In 1999, Lafarge entered the picture and acquired Republic Cement one of the oldest in the country. In 2001, following

its acquisition of Blue Circle, Lafarge became the worlds leading cement producer and the Philippines largest cement conglomerate in terms of capacity and sales. Holcim currently operates two plants in Luzon (Norzagaray in Bulacan and Bacnotan in La Union) and another two in Mindanao (Lugait in Misamis Oriental and Davao City. Other companies like Pacific Cement (established in 1967) and Taiheiyo Cement (which acquired Grand Cement in 2001) continued to provide a vibrant competition for the growing domestic cement market. All Portland cement is mainly similar but there are eight types of cement that are manufactured to meet various physical and chemical requirements for specific applications: Type I is a general purpose Portland cement that is suitable for most uses. Type II is used for constructions in water or soil that contains moderate amounts of sulphate, or when heat build-up is a concern. Type III cement provides and supplies high strength at an early state, usually in a week or less. Type IV moderates heat produced by hydration that is used for massive concrete surfaces such as dams. Type V cement resists chemical attack by soil and water high in sulfates. Type IA, IIA and IIIA are cements used to make air-entrained concrete. They have the same properties as types I, II, and III, but with the exception of possessing small quantities of airentrained materials shared and combined with them. The raw materials in the cement production are: Limestone it is a very common sedimentary rock which is composed mainly of calcite. It is formed mostly out of the remains of clams, shells, brachiopods, crinoids and corals. Chalk is a soft, fine-grained, easily pulverized, white-to-grayish variety of limestone. Mudstone - is a clastic sedimentary rock. As it sounds, a mudstone is hardened mud (silts and clays) and is mostly composed of very fine particles. Clay - is a clastic sedimentary rock. It is composed of very fine particles (clay sized, less than 1/256 mm) which have become cemented into a hard rock. Shale - is a fine-grained, clastic sedimentary rock composed of mud that is a mix of flakes of clay minerals and tiny fragments (silt-sized particles) of other

minerals, especially quartz and calcite. Sandstone - as the name implies, sandstone is composed of sand. It is formed in many environments. Iron ore are rocks and minerals from which metallic iron can be economically extracted. Gypsum - is a major rock forming mineral that produces massive beds, usually from precipitation out of highly saline waters. The different equipment used are: Limestone Quarry and Crushing Plant -A quarry is a type of strip mine from which rock or minerals are extracted. Limestone Stockpile- The raw material is stored at either the quarry or at the plant. Additive Hopper/Storage- Certain additives such as iron ore, bauxite, laterite, quartzite and flourspar are added in required quantities in order to get the required composition of raw material. Raw Mill Building- This grinding is done using either Ball Mills or Vertical Roller Mills (VRM). Blending and Storage Silo- As there are various sources of raw materials, it becomes necessary to blend and homogenize these different materials efficiently to counteract fluctuation in the chemical composition of the raw meal. PreheaterClinkering takes place in the kiln and the preheater system. Preheater systems offer heat transfer from the hot kiln gases. Gas Conditioning Tower and ESPThe Electrostatic Precipitators are used in cement plants particularly for removal of dust from the exit gases of cement kilns and from the exhaust air discharged by dryers, combined grinding and drying plants, finishing mills and raw mills through water injection. Kiln It is basically a long cylindrical-shaped pipe, and rotates in a horizontal position. Its internal surface is lined by refractory bricks. Cooler- In the cooler, cold air is blown to effect heat exchange between hot clinker and cold air. Deep Bucket Conveyor- The deep bucket conveyor is essentially an equipment to lift material vertically. Clinker/Gypsum Storage- The output of the kiln is stored before it is fed to the cement mill for conversion to cement. This storage is called clinker storage, if it is used for clinker storage purpose. Coal Mill Building- The coal mill building houses the mill for grinding lumpy coals. Cement Mill and Bag House- In a cement mill, there is a cylindrical shell lying horizontal which contains metallic balls and as it rotates, the crushing action of the balls helps in grinding the clinker to fine

powder. Cement Storage Silo- The cement storage silo is used for storing the finished product - cement. Packing and Dispatch -The cement is packed with the help of a rotary packer and finally dispatched to the market. Central Control Room- It is the nerve center of the cement plant since all equipment is controlled from this place. The different unit operations involved are: Quarrying- The raw material for cement manufacture is a rock mixture which is about 80% limestone(which is rich in CaCO3) and 20% clay or shale (a source of silica, alumina and Fe2O3). These are quarried and stored separately. The lime and silica provide the main strength of the cement, while the iron reduces the reaction temperature and gives the cement its characteristic gray color. Extensive quarry drilling and analysis are being undertaken to reduce the variability of the raw material quality. Proportioning, Pre-blending and Grinding- The crusher is responsible for the primary size reduction of the quarried materials. Boulders as big as 1 meter are being crushed to material sizes less than 80 mm. The crushed materials pass through an on-line analyzer to determine the pile composition. A stacker is then used to create different piles of materials and to reduce variation in material beds. It is the initial blending phase. A belt conveyor transports the pre-blended piles into individual bins where a weighing feeder proportions it according to the type of clinker to be produced. The materials are then ground into the desired fineness by the raw mill equipment. The powdered raw meal is then transported into a continuous blending storage silo where variations are further reduced by mixing using aeration. The pulverized material is stored and blended in the controlled flow silo. The Blending action is achieved by extracting the material from the 7 outlets at a different rate. The extracted material is conveyed to a weighing bin where it is further blended. Burning and Blending- The pre heater tower supports a series of vertical cyclone chambers through which the raw materials pass on their way to the kiln. To save energy, modern cement plants preheat the materials before they enter the kiln. Rising more than 200 feet, hot exit

gases from the kiln heat the raw materials as they swirl through the cyclones. The next step in the process is to heat the blended mixture of raw ingredients (the raw mix) to convert it into a granular material called cement clinker. This requires maximum temperatures that are high enough to partially melt the raw mix. Clinker Cooling and Finish Grinding- The clinker cooler cools the hot granular mass of clinker by quenching air into it bringing the temperature down to 100 C. Packing and Distribution- The packed bags are directly loaded into the trucks by belt conveyors. 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. There are two types of cement manufacturing process: wet process kilns and dry process kilns. Wet process kilns- 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. Dry process kilns- 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. For the waste water treatment, Water Management- Cement plants generate little or no water effluent. Wet process plants use a large volume of water in the grinding of the raw materials and that water evaporates in the kiln. A large amount of energy is required to accomplish this. For those reasons, cement manufacturers are closing wet process kilns and installing more energy efficient dry process plants. For both dry and wet process plants, some water is used in the non-contact cooling of machinery and when necessary water is sprayed into hot gas streams to be cooled. Combustion Emissions- The cement industry has an enviable record in reducing air pollutants. It is working closely with the Environmental Protection Agency and

state regulators to develop new standards and technology to manage air emissions. Solid Waste Production- As raw feed travels through the portland cement kiln system, particulates of the raw materials, partially processed feed, and components of the final product are entrained in the combustion gases flowing countercurrent to the feed. These particulates and combustion gas precipitates are collected in the particulate matter control device (PMCD) electrostatic precipitators and fabric filtersand are collectively referred to as cement kiln dust (CKD).