CEMENT INDUSTRY

Kelompok 5
Maya Monica D (1105821)
Miftahul Jannah (1100545)
Ratnasari (1105339)
Siti Fatimah S (0900451)
TABLE OF CONTENT
History of Cement
Types of Cement
Cement Making Process
Impact of Cement Industry
Definition of Cement
Prevention
HISTORY OF CEMENT
Cement was first used by Egypt in pyramid
building process.
Cement which made by Egypt is gypsum
calcinations, then Roman make cement
from lime stone calcinations and Greek
make it from volcanic soil.

History of Cement
DEFINITION OF CEMENT
Cement comes from word
Caementum which means
a substance which has the
function as an adhesive
between two or more
ingredients become a part
of a cohesive or adhesive
material between the rocks
of building construction

Definition of Cement
TYPES OF CEMENT
Types of Cement
No. SNI Nama
SNI 15-0129-2004 Semen portland putih
SNI 15-0302-2004 Semen portland pozolan / Portland Pozzolan
Cement (PPC)
SNI 15-2049-2004 Semen portland / Ordinary Portland Cement
(OPC)
SNI 15-3500-2004 Semen portland campur
SNI 15-3758-2004 Semen masonry
SNI 15-7064-2004 Semen portland komposit
Cement
Making
Process
1. Limestone
2. Clay
Materials of Cement Making
Process
3. Iron sand

4. Silica
Material of Cement Making Process
How Cement is Made
Extracting Raw Materials Crushing and Transportation
Raw Material Preparation I: Storage and Homogenisation
Raw Material Preparation II: Drying and Raw Grinding
Burning
Cement Grinding
Loading and Shipping
Extracting raw materials
Crushing and transportation

The most important raw
materials for making
cement are limestone,
silica, clay and iron sand.
These are extracted from
quarries by blasting or by
ripping using heavy
machinery. Wheel
loaders and dumper
trucks transport the raw
materials to the crushing
installations. There the
rock is broken down to
roughly the size used in
road metalling.
1.
Raw material preparation I:
Storage and homogenisation

The crushed material
is transported into the
raw material storage
of the cement plant by
conveyor-belts,
cableways or railways
and also in
exceptional cases
with trucks. Once
there it is stored in
blending beds and
homogenised.
2.
Raw material preparation II:
Drying and raw grinding

The desired raw mix of
crushed raw material
and the additional
components required for
the type of cement, e.g.
silica sand and iron ore,
is prepared using
metering devices. Roller
grinding mills and ball
mills grind the mixture to
a fine powder at the
same time as drying it,
before it is conveyed to
the raw meal silos for
further homogenisation.
3.
Burning

The burning of the raw
meal at approx. 1,450C
is carried out in Lepol or
preheater kilns that work
by varying methods, the
main difference being in
the preparation and
preheating of the kiln
feed. By chemical
conversion, a process
known as sintering, a
new product is formed:
clinker.
4.
The making of clinker is based on this
reactions:

+ + +
C
3
S C
2
S C
3
A C
4
AF
Reaction on Cement Making
Process
Those reactions have six steps, they are:
1. Water Evaporation
This process working at temperature 100 - 200
o
C.

2. Extrication of Absorban Water
This process working at temperature 100 400
o
C.

3. Decomposition of Clay
The product from this process is Al
2
O
3.
2SiO
2,
working at
temperature 400 - 750
o
C. This is the reaction:
Al
4
(OH)
8.
Si
4
O
10
2( Al2O3.2SiO2 ) + 4 H2O




Reaction on Cement Making
Process
4. Decomposition of Metakaolinit
The product from this process are Al
2
O
3
and SiO
2,

working at temperature 600 - 900
o
C. This is the reaction:
Al
2
O
3.
2SiO
2
Al
2
O
3.
+ 2SiO
2

5. Decomposition of Carbonat
The product are C
3
S and C
3
A, working at
temperature 600 - 1000
o
C. This is the reaction:
CaCO
3
CaO + CO
2

3CaO + 2SiO
2
+

Al
2
O
3
2( CaO .SiO
2
) +
CaO.Al
2
O
3





Reaction on Cement Making
Process
6. Reaction of Solid Phase
This reaction working at temperature 800 - 1300
o
C,
and the product is the main components in clinker,
they are C
3
A, C
2
S dan C
4
AF, this is the reaction:
CaO.Al
2
O
3
+ 2CaO 3CaO.Al
2
O
3

CaO.Al
2
O
3
+ 3CaO + Fe
2
O
3
4CaO.Al
2
O
3
.Fe
2
O
3

CaO .SiO
2
+ CaO 2CaO .SiO
2



Reaction on Cement Making
Process
Tricalcium silicate (C
3
S). Hydrates and hardens rapidly and is largely
responsible for initial set and early strength. Portland cements with higher
percentages of C3S will exhibit higher early strength.

Tricalcium aluminate (C
3
A). Hydrates and hardens the quickest. Liberates a
large amount of heat almost immediately and contributes somewhat to early
strength. Gypsum is added to Portland cement to retard C3A hydration.
Without gypsum, C3A hydration would cause Portland cement to set almost
immediately after adding water.

Dicalcium silicate (C
2
S). Hydrates and hardens slowly and is largely
responsible for strength increases beyond one week.

Tetracalcium aluminoferrite (C
4
AF). Hydrates rapidly but contributes very little
to strength. Its use allows lower kiln temperatures in Portland cement
manufacturing. Most Portland cement color effects are due to C4AF.
About C
3
S, C
3
A, C
2
S and C
4
AF
Cement grinding


After burning, the clinker
is cooled down and
stored in clinker silos.
From there the clinker is
conveyed to ball mills or
roller presses, in which it
is ground down to very
fine cement, with the
addition of gypsum and
anhydrite, as well as
other additives,
depending on the use to
which the cement is to
be put.
5.
Loading and shipping

The finished cement is
stored in separate silos,
depending on type and
strength class. From there
it is mainly loaded in bulk
form from terminals onto
rail or road vehicles as well
as onto ships. Only a small
proportion of the cement
reaches the customer in the
form of bags that have
been filled by rotary
packers and stacked by
automatic palletising
systems.
6.
Reactions of Hydration
2C3S + 6H = C3S2H3 + 3Ca(OH)2
(100 + 24 = 75 + 49 )
2 C2S + 4H = C3S2H3 + Ca(OH)2
(100 + 21 = 99 + 22 )
C3A + 6H = C3AH6
[C3A + CaSO4 . 2H2O = 3Cao. Al2O3.
3CaSO4. 31H2O]
Calcium Sulfoaluminate
Cement Manufacturing
Details:
1. Quarries (Limestone, Clay)
2. Drill
3. Dumper
4. Crushing
5. Prehomogenisation
6. Grinding
7. Preheating
8. Filter
9. Rotary Kiln
10. Cooler
11. Clinker Storage
12. Additions
13. Cement Grinding
14. Cement Silos, Dispatching
15. Grinding
16. Homogenisation
17. Filter
18. Kiln

IMPACT OF CEMENT
INDUSTRY
1. Declining Quality of Land
The decline of soil
fertility can be caused
by clay mining
process.
Clay is used as a
raw material for
cement industry.
2. Declining Quality of Water
Declining quality of
water due to
wastewater from
cement industry are
dumped into the river
3. Cause Air Pollution
Dust and smoke
that generated
during combustion
process and during
procurement of raw
materials can
cause respiratory
system disorders
4. Increasing the Amount of
Greenhouse Gases
Gases that produced
from combustion of
petroleum fuels and coal
are CO2, CO and
another gases.
Increasing the amount
of Carbon dioxide in the
air can cause increasing
of earth temperature.

5. Noise Pollution
Noise pollution is a disruption in the
environment caused by the sound or
noise from industrial activities that can
cause unrest for society.
6. decreasing diversity of flora, change in
vegetation pattern and endemic species .
7. Decreasing diversity of flora, change in
vegetation pattern and endemic species
decreasing diversity of fauna (birds,
endangered animals). Changes in aquatic
ecosystems and ground ecosystems as a
place to live animals.
Continued
PREVENTION
PREVENTION
Implementing blended cement production
that can decrease CO
2
emission.
Replacing some of materials in cement
manufacture with more ecofriendly
materials.
Wate disposal industries that doesnt
damage the environment.

http://people.ce.gatech.edu/~kk92/scmkek.
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