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Cement

Raw Materials

Chalk or Limestone

Dug up at quarry face

Quarried by blasting

Stone crushed to approx 25mm

Fed into washmills

Raw materials

Clay

Dug by scrapper type excavators

Passed to washmills

Made into slurry by addition of water

Fed into tank

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Making Cement Slurry

Chalk or Clay + Water

Fed into washmillls

From slurry storage tanks fed to Rotary Kiln
 Dries
 Produces Cement Clinker

Clinker

Slurry fed in one end

Pulverised coal blown in at firing end

Dries

Decarbonises ( removes carbon)

Calcines slurry (subject to prolonged heat)

Drive off CO2

Heat at 1371oC

Slurry transformed to clinker

Clinker

Clinker conveyed to mills

Ground to form Portland Cement

5% gypsum added to prevent flash setting

Gypsum = hydrated calcium sulphate CaSO4

Cement

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Wet Process

Wet Process

Cement

Stored in silos

Transported by road /rail

Bulk

Palletised Packs

25kg bags

Process

CaCO3 CaO + CO2

Limestone Quicklime Carbon Dioxide

Slaking = mixing with water

CaO + H2O Ca(OH)2 + Heat (volume)

Quicklime Slaked lime ( Calcium hydroxide)

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Manufacturing Process

4 Key Variants

1. Wet Process

2. Semi Wet Process

3. Semi Dry Process

4. Dry Process

Manufacturing Process
Wet Process

Clay mixed With Water = slurry

Excess sand removed by settlement

Chalk mixed with Water = slurry

Slurries blended together

Resultant Slurry fed into kiln and dried

Resultant clinker ground and gypsum added

Manufacturing Process
Semi Wet

Chalk broken down in water

Blended with clay slurry

Water content reduced from 40% to 19% by
filter press

Resultant Filter Cake

Extruded on grate

Reduced to pellets

Heated at 900 1100oC pecalcine

Short kiln at 1450oC for clinkering

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Manufacturing Process
Semi Dry

Dry Shale and limestone is blended

12% water added

Nodularised ( made into nodules extrusion)

Precalcined

Clinkered as semi wet process

Manufacturing Process
Dry Process

Limestone 80%

Shale 17%

Sand 3%

Milled to fine powders

Blended to form Dry Meal

Manufacturing Process
Dry Process

Meal passed through cyclones

Preheated using recovered kiln gases

750oC

Added fuel precalcine at 900oC

Fast roasting kiln to clinker 1450oC

Clinker cooled ground and 5% gypsum added

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Types of Cement

Ordinary Portland Cement BS EN 197-1 2000

General use

Grind to 2250 cm2/gm

Rapid Hardening Cement

High early strength required

Grind to 3250 cm2/gm

Types of Cement

Low Heat Portland Cement BS EN 14216:2004

Large mass of concrete poured

Reduce amount of lime in the constituents

Sulphate Resisting Cement BRE Special Digest 1 :2005

Chemical attack

Sea water, Acid ground waters

Mix blast furnace slag with portland cement
clinker

Types of Cement

White Portland Cement

Visual effect white or coloured finish

Use china clay or high grade chalk free

Free of colour forming impurities

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Types of Cement

Masonry Cement BS EN 413-1: 2004

Make mortars

Additives

Add air entrained agent
 Increases adhesiveness

Fine inert mineral powder
 Assists water retention
 Limits strength development