Processes and Characteristics of product

Cement production consists of the following three processes.

1. Raw material process
2. Clinker burning process
3. Finish grinding process
Basic Raw Materials
The raw materials of Portland Cement are limestone, shale and gypsum. These materials are
rocks or soils and exist naturally in Jamaica in great abundance. Coal is deployed as the fuel used
in the process for the generation of heat. It is crushed into a powder.
Limestone
The limestone used in the process of manufacturing cement in Jamaica contains between 85%
and 95% calcium carbonate ( CaCO3), and small amounts of magnesium carbonate ( MgCO 3),
silica, alumina ( Al2 O3) and iron (Fe). It is obtained from the quarry which is located in close
proximity to the manufacturing plant.
The extraction of limestone is carried out by the processes of ripping and blasting and is then
transported to the crushing plant by rear- dump trucks. The limestone is then deposited onto a
wobbler feeder which separates the fine particles from the coarse and feeds the coarse rock
particles into a hammer mill. Here the limestone is reduced to minute 11/2 size particles. The
crushed limestone together with the fine particles from the wobbler is transferred to the
limestone storage silos.

Gypsum
Gypsum is extracted from deposits in Bull Bay, St. Thomas. These mines are owned by
Caribbean Cement Companys subsidiary Jamaica Gypsum and Quarries and it provides all the
gypsum for the manufacture of cement in Jamaica. It also exports gypsum to several countries in
the Caribbean.
Shale
Shale is crushed in the same way as the limestone. At this stage 2% of red mud is added to enrich
the iron content of the raw mixture.

The raw material process and the clinker burning process are each classified into the wet process
and the dry process.
Wet Process
The partially crushed limestone and shale are concurrently introduced in regulated quantities into
the slurry grinding mills in a 3:1 ratio. Water is then added to the mixture to adjust it to a thick
slurry with an appropriate density. This allows the mixture to be pumped into the storage silos for
homogenization, chemical analysis and blending. The materials can then be sent to a rotary kiln
for clinker burning,
Production of Clinker

The kilns are the main and heaviest pieces of moving machinery in the cement factory. (define
kilns)They are set above ground, sloping gradually down from the feeding end to the firing zone
and revolving slowly at a rate of 1 to 1.33 revolutions per minute. The interior of the kiln is lined
with special types of heat resistant bricks. The required heat is 1400 0C and this is generated by
the burning of coal.
The materials then passes through a series of chains which are overhanging the core of the klin
where heat is passed through it. The heat transforms the raw materials into clinker. The clinker is
cooled by wafting air through it as it leaves the klin by a cooler.
This is the most important phases of the cement manufacturing process
Dry Process
In the dry process, the limestone and shale/red mud are crushed in a Roller Mill by passing the
material under the heavy rollers which are on a fixed shaft. Here the mixture is called raw meal.
A current of air is passed all the way through the mill which takes the crushed raw meal into a
separator where a centrifugal force is in function. The coarse particles are forced out of the air
current and fall back on the rotating table to be re-crushed. The finer particles flow out with the
air

current.

The raw meal is then blended in a silo to allow homogeneity of the raw meal and it is the passed
into a storage silo.
A four stage cyclone system allows the raw meal to be preheated as it descends into the klin, here
the mixture is heated as in the wet process to become klinker. The inside of the klin is lined with
heat resistant brick as in the wet process and the material is burned at approximately the same
temperature; that is 14000 C.

Coal is the fuel utilized when making cement. It is crushed into a powder and used in the klin for
heating. The raw meal is pumped to the kiln by a weight feeder for constant measurement. It then
leaves the kiln as red hot clinker. The clinker is cooled by passing air through the clinker in a
clinker cooler.
The material now referred to as cooled clinker is mixed with a small portion of gypsum is
transferred to grinding mills. These mills have three sections and carry charges of assorted sizes
of steel grinding media (balls) weighing about 100 tons for the smaller chamber and 600 tons in
the larger chamber.
Gypsum is used to adjust the setting time of the cement which would otherwise set almost
immediately when mixed with water.
The cement is ground to a fineness of about than 3000 square cm per gram as determined by
measurement of the specific surface.
The dry process is different from the wet process in that it involves a pneumatic transport
medium instead of the water. It therefore uses less energy since evaporation of water is not
necessary.

Production of Cement
The Clinker and gypsum are ground together in ball mills resembling the slurry grinding mills.
These mills have three compartments and carry charges of assorted sizes of steel grinding media
(balls) weighing about 100 tons for the smaller chamber and 600 tons in the larger chamber.

Gypsum is also added in order to regulate the setting time of the cement which would otherwise
set almost immediately when mixed with water. The cement is ground to a fineness of not less
than 3000 square cm Per gram as determined by measurement of the specific surface.
Storage and Packaging
The cement from the mills is pumped by pneumatic conveyors into storage silos, which is then
packaging. Bagging is done by automatic packers which will automatically fill each bag of
cement to its 42.5 kg weight limit. Cement is also delivered in bulk form by means of a bulk
loading system to special trucks and to ships for export.
Quality Control
Routine checks and tests are carried out by Laboratory Technicians at each phase of the
production process so as to ensure that a consistent high quality is maintained. Cement quality is
monitored by the Jamaica Bureau of Standards to ascertain that the cement conforms to the
Jamaican Standard (JS32 1974).

New Trends
In February 2005 Caribbean Cement Company introduced an environmentally friendly new
product Carib Cement Plus or Type 1P cement. This is a combination of the regular Portland
cement with Pozzolan. Pozzolan is a fine, sandy volcanic ash which is mined locally in St
Thomas. In the process some of the clinker used in the original product is replaced with
Pozzolan.
Pozzolan does not have any inbound cementing properties , however when it is ground with
lime (Calcium Oxide) and water, a gel with cementing properties is achieved.
Carib Cement Plus is more environmentally friendly cement. It requires less electricity in the
production process and in turn a reduced green house effect. This product shows increased
durability in seaside, marine and harsh environments and can be used in most applications in
Jamaica.
Caribbean Cement Company began manufacturing this Type 1P cement because it:

Lowers production cost. Lower operating costs over time will result in savings, which
will be passed on to the end users resulting in both saving to the company and to
customers.

More environmentally friendly, as replacing clinker with Pozzolan results in lower energy
consumption resulting in lower emission of green house gases and less damage to the
environment.

Carib Cement Plus also have superior qualities, these include:

Higher strengths over time. Due to the presence of Pozzolan in cement, concrete made
with Carib Cement Plus will continue to gain strength at a greater rate than previously
achievable, resulting in higher than normal late strengths.

Increased durability over time the concrete increases in density thus keeping the harmful
compounds like sea water and mild acids on the surface and away from the steel in the
concrete.This property makes Carib Cement Plus ideal for this tropical market and
suitable for structures erected near the sea. Concrete made with Carib Cement Plus offers
greater protection to reinforced steel from Chloride attack.

Reduce heat of hydration the reaction between Pozzolan and lime generates less heat and
as such less cracking due to heat. Depending on the amount of concrete being poured,
their is a reduction in the amount of heat generated during the hydration process.

The product has received the approval of the Jamaica Manufacturers Association and the
Incorporated Masterbuilders Association. Carib Cement Plus is approved by the Jamaica Bureau
of standards and meets the ASTM C 595 designation.

Environment

Carib Cement Company is commited to

Prevention of pollution;

Continual improvement of our environmental performance; and

Compliance with applicable legal requirements and any other requirements to

which CCCL subscribes that relate to its environmental aspects.