Kamyll Dawn Cocon | ChE 140 | MSU-IIT

The Builders of Pillars

Portland Cements, Calcium and Magnesium Compounds

Outline | Builders of Pillars | ChE 140

Portland Cements
Calcium Compounds
Magnesium Compounds

Introduction | Builders of Pillars | ChE

140

Concrete vs. Cement

Cement

Powder that hardens

when reacted with
water
Ingredient of concrete
Bind the aggregates
into a rock like mass

Concrete

Mixture of aggregates
and paste
Uses cement to bind
aggregates together

Brief History
3600 BC

1759

1824

1914

Egyptians:

John Smeaton:

Joseph Aspdin:

Ynchausti y Compaia :

Heated
Limestone
First hydraulic
cement

Portalnd
Cement

Set up the first cement

company in Philippines
Produces 600,000 bags per
300 days
Portland cement had not
reached the Philippines

Limestone
Lime
Diatomaceo
us earth

Portland Cement

Generic term for the type of cement used in virtually all concrete

A type of hydraulic cement

Most common type of cement in general use

Closer Look: Clinkers

Formula

(CaO)3SiO2

Shorthand
Notation

C3S

(CaO)2SiO2

C2S

(CaO)3Al2O3

C3A

(CaO)4Al2O3Fe2O3

C4AF

Description

Typical
Mineral Function
Percentage
Tricalcium silicate

Hydrates quickly
(alite)
50-70
and imparts early
strength and set
Dicalcium silicate

Hydrates slowly
(belite)
10-30
and imparts long

term strength

Hydrates almost

instantaneously

and very
Tricalcium
3-13
exothermically.
aluminate
Contributes to
(aluminate)
early strength and
set

Hydrates quickly.

Acts as a flux in
Tetracalcium
5-15
clinker
aluminoferrite
manufacture.
(ferrite)
Imparts gray color

Closer Look: Hydration

Dry
Cement

Wet
Hydraulic
Cement

Grinding and Blending

Kiln
Dry Process

Wet Process

Closer Look: Dry Process Kiln

Closer Look: Wet Process Kiln

Clinkering Reactions

Review: Dry vs. Wet Process

Wet Process

Dry Process

Moisture content of the slurry is

35-50%
Slurry enters into the kiln directly
at 20C
Dimensions of the kiln needed to
manufacture the cement is bigger
Less efficient heating process due
to surface area of slurry.

Moisture content of the pellets is 12%

Meal enters preheaters first then into

kiln at 900C
Dimensions of the kiln needed to
manufacture the cement is smaller
Heating process is efficient because of
very high surface area in relation to
the size of meal.
The amount of the heat required The amount of heat required is lower,
is higher, so the required fuel
so the required fuel amount is lower
amount is higher
More economical
Less economical
Original process adopted in early Used in modern day industry for
times
Portland cement manufacture
Blows raw mix in kiln out
Provides ideal mix for kiln

Types of Portland Cement

ASTM C-150
Cement Type

Classification

Type I

General purpose

Type II

Type III

Type IV

Moderate sulphate
resistance
High early strength

Type V

Applications
General construction (most
buildings, bridges,
pavements, precast units,
etc)
Rapid construction, cold
weather concreting
Rapid construction, cold
weather concreting

Low heat of hydration Massive structures such as

dams. Now rare.
(slow reacting)
High sulphate
Structures exposed to
resistance
high levels of sulphate
ions

Types of Portland Cement

Clinker Mineral Percent

ASTEM C-150
Cement Type

C3S

C2S

C3A

C4AF

I
II
III
IV
V

50-65
45-65
55-65
35-45
40-65

10-30
7-30
5-25
28-35
15-30

6-14
2-8
5-12
3-4
1-5

7-10
10-12
5-12
11-18
10-17

Outline | Builders of Pillars | ChE 140

Portland Cements
Calcium Compounds
Magnesium Compounds

Brief History: Lime

Discovery of
Lime

Caesar
Augustus
27 12 A.D

Marco Polio
Architect

Brief History | Lime | ChE 140

America

Dugout Kiln

Manufacturing process

Kiln reactions
For high calcium
lime:

CaCO3 + heat CO2 + CaO

For dolomitic
lime: CaCO3 MgCO3 + heat

2CO2 + CaO MgO

Quicklime
Classification
High Calcium Quicklime
High Calcium Quicklime

Description
Derived from limestone

Composition
0 5% MgCO3
35 46% MgCO3

Hydrated Lime
Classification

Description

Composition

High Calcium Hydrated

Lime
Dolomitic Hydrated Lime
(normal)
Dolomitic Hydrated Lime
(pressure)

Produced rapidly from high

calcium quicklime

72 74% CaO
23 24% H2O

Calcium oxide fraction hydrates

under
atmospheric hydrating conditions

Produced from dolomitic quicklime under

pressure
resulting to hydration of all MgO and
CaO

33-34 percent MgO

15-17 percent H2O
40-42 percent CaO
29-30 percent MgO
25-27 percent H2O

Gypsum

CaSO4 2H2O
CaSO4 2H2O + heat CaSO4 H2O + 1 H2O
Gypsum

Plaster of Paris

Manufacturing process

Beta Plaster Crystals

High Specific Surface
High Water Demand
High Porosity
Low Mechanical Property

Alpha Plaster Crystals

Low Specific Surface
Lower Water Demand
Low Porosity
High Mechanical Property

Dry Process
Steam vapour is injected
during calcination

Wet Process
Calcination of a gypsum
slurry under pressure

Rehydration

CaSO4 H2O + 1 H2O CaSO4 2H2O

Plaster of Paris

Gypsum

Outline | Builders of Pillars | ChE 140

Portland Cements
Calcium Compounds
Magnesium Compounds

Magnesium
One if the most abundant element in the earths
crust

Element
Oxygen
Silicon
Aluminum
Iron
Calcium
Sodium
Potassium
Magnesium
Hydrogen
Titanium

Percent of total mass

49.2
25.7
7.50
4.71
3.39
2.63
2.40
1.93
0.87
0.58

Magnesium Hydroxide
John Callen patented Magnesium Hydroxide
1818 Used for alleviation of digestive disorders
Sir James Murray used his own fluid magnesia formula to treat the Lord
of Ireland, Marquis Anglesey, of stomach pain
1829 Appointed as resident physician and knighted
Charles Henry Phillips formulated 8% w/v
1872 Sold under the brand name Philips Milk of Magnesia

Magnesium Hydroxide Uses

Antacid

Neutralizer

Manufacturing process

Magnesium Oxide Uses

Wall Board

Book
Preservation

Cables

Magnesium Chloride
Production Process

Uses

Melting of Snow

Food Coagulant

END