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    Chemical Technology Subject Code: CH2001

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    U SANKAR TEJO
    Portland cement is produced by heating limestone, clay, and other materials in a kiln to form clinker, which is then ground with gypsum. The major compounds formed are tricalcium silicate, dicalcium silicate, tricalcium aluminate, and tetracalcium aluminoferrite. The proportions of these compounds affect the cement's properties. Gypsum is added to control the setting time of concrete.

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    Chemical Technology Subject Code: CH2001

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    U SANKAR TEJO
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    Portland cement is produced by heating limestone, clay, and other materials in a kiln to form clinker, which is then ground with gypsum. The major compounds formed are tricalcium silicate, dicalcium silicate, tricalcium aluminate, and tetracalcium aluminoferrite. The proportions of these compounds affect the cement's properties. Gypsum is added to control the setting time of concrete.

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    Portland cement is produced by heating limestone, clay, and other materials in a kiln to form clinker, which is then ground with gypsum. The major compounds formed are tricalcium silicate, dicalcium silicate, tricalcium aluminate, and tetracalcium aluminoferrite. The proportions of these compounds affect the cement's properties. Gypsum is added to control the setting time of concrete.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    94 views13 pages

    Chemical Technology Subject Code: CH2001

    Uploaded by

    U SANKAR TEJO
    Portland cement is produced by heating limestone, clay, and other materials in a kiln to form clinker, which is then ground with gypsum. The major compounds formed are tricalcium silicate, dicalcium silicate, tricalcium aluminate, and tetracalcium aluminoferrite. The proportions of these compounds affect the cement's properties. Gypsum is added to control the setting time of concrete.

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    of 13

    Chemical Technology

    Subject Code: CH2001


    Lecture 8

    1
    PORTLAND CEMENT
    Portland Cement → Gypsum + Portland
    Cement Clinker (pulverizing)

    Portland Cement Clinker → Calcareous &


    Clay Materials (burning)

    Paste → P.C. + Water

    Mortar → P.C. + Water + Sand

    Concrete → P.C. + Water + Sand + Gravel


    RAW MATERIALS
    1) Calcareous Rocks (CaCO3 > 75%)
    • Limestone
    • Marl
    • Chalk
    • Marine shell deposits

    2) Argillocalcareous Rocks (40%<CaCO3<75%)


    • Cement rock
    • Clayey limestone
    • Clayey marl
    • Clayey chalk
    3) Argillaceous Rocks (CaCO3 < 40%)
    • Clays
    • Shales
    • Slates

     Portland cement is made by mixing substances containing


    CaCO3 with substances containing SiO2, Al2O3, Fe2O3 and
    heating them to a clinker which is subsequently ground to
    powder and mixed with 2-6 % gypsum.
    CLINKER GYPSUM
    Process flow sheet

    6
    PRODUCTION STEPS
    1) Raw materials are crushed, screened & stockpiled.
    2) Raw materials are mixed with definite proportions to obtain “raw mix”.
    They are mixed either dry (dry mixing) or by water (wet mixing).
    3) Prepared raw mix is fed into the rotary kiln.
    4) As the materials pass through the kiln their temperature is rised upto
    1300-1600 °C. The process of heating is named as “burning”. The output
    is known as “clinker” which is 0.15-5 cm in diameter.
    5) Clinker is cooled & stored.
    6) Clinker is ground with gypsum (3-6%) to adjust setting time.
    7) Packing & marketting.
    REACTIONS IN THE KILN
    • ~100°C→ free water evaporates.
    • ~150-350C°→ loosely bound water is
    lost from clay.
    • ~350-650°C→decomposition of
    clay→SiO2&Al2O3
    • ~600°C→decomposition of
    MgCO3→MgO&CO2 (evaporates)
    • ~900°C→decomposition of
    CaCO3→CaO&CO2 (evaporates)
    • ~1250-1280°C→liquid formation & start
    of compound formation.
    • ~1280°C→clinkering begins.
    • ~1400-1500°C→clinkering
    • ~100°C→clinker leaves the kiln & falls
    into a cooler.
     Sometimes the burning process of raw
    materials is performed in two stages:
    preheating upto 900°C & rotary kiln
    CHEMICAL COMPOSITION OF P.C.

    Sometimes the burning process of raw materials is performed in two stages: preheating
    upto 900°C & rotary kiln.
    Portland cement is composed of four major oxides (CaO, SiO2, Al2O3, Fe2O3 ≥90%) & some
    minor oxides. Minor refers to the quantity not importance.
    Oxide Common Name Abbreviation Approx. Amount (%)

    CaO Lime C 60-67


    SiO2 Silica S 17-25
    • CaO→limestone Al2O3 Alumina A 3-8
    • SiO2-Al2O3→Clay Fe2O3 Iron-oxide F 0.5-6
    • Fe2O3→Impurity in Clays MgO Magnesia M 0.1-4

    • SO3→from gypsum→not Na2O Soda N


    0.2-1.3
    from the clinker K2O Potassa K
    SO3 Sulfuric Anhydride S 1-3

    9
     The amount of oxides in a P.C. Depend on the proportioning of C 63.6
    the raw materials and how well the burning is done in the kiln. S 20.7
    The chemical composition is found by chemical analysis.
     A typical analysis of O.P.C. A 6
     CaO (C), SiO2 (S), Al2O3 (A) & Fe2O3 are the major oxides that F 2.4
    interact in the kiln & form the major compounds.
    S 2.1
     The proportions of these oxides determine the proportions of
    the compounds which affect the performance of the cement. M 2.6
     SO3→comes largely from gypsum N 0.1
     P.C. alone sets quickly so some gypsum is ground with K 0.9
    clinker to retard the setting time.
    Free C 1.4
     If too much gypsum is included it leads to distruptive expansions
    of the hardened paste or concrete. Total 99.8

    10
    COMPOUND COMPOSITION OF P.C. (OR CLINKER)
     Oxides interact with each other in the kiln to form more complex
    products (compounds). Basically, the major compounds of P.C. can be
    listed as:

    Name Chemical Formula Abbreviations

    Tri Calcium Silicate 3CaO.SiO2 C3S

    Di Calcium Silicate 2CaO.SiO2 C2S

    Tri Calcium Aluminate 3CaO.Al2O3 C3A

    Tetra Calcium Alumino Ferrite 4CaO.Al2O3.Fe2O3 C4AF


     The degree to which the potential reactions can proceed to
    “equilibrium” depends on:

    1) Fineness of raw materials & their intermixing.


    2) The temperature & time that mix is held in the critical zone of the
    kiln.
    3) The grade of cooling of clinker may also be effective on the
    internal structure of major compounds.
     There are also some minor compounds which constitute few %, so
    they are usually negligible. Moreover, portland cement
    compounds are rarely pure.
    For example in C3S, MgO & Al2O3 replaces CaO randomly.
    C3S→ALITE & C2S→BELITE
    Ferrite Phase: C4AF is not a true compound. The ferrite
    phase ranges from C2AF to C6AF. *C4AF represents an
    average.

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