PURKHOO CAMP, DOMANA, JAMMU

SESSION 2012-2013
A MINOR PROJECT REPORT ON

PORTLAND pozzolana CEMENT

(ITS MANUFACTURING AND ITS USES)

PROJECT INCHARGE:-

SUBMITTED BY:Vijay Deep Singh Pawar

recognized by j&k govt.

Manju Baloria

DEPARTMENT OF CIVIL ENGINEERING

affiliated to j&k state board of technical education council for technical education approved by all india (a.i.c.t.e)

PURKHOO CAMP, DOMANA, JAMMU

DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE Academic Session Nov-Dec 2012

This is to certify that Vijay Deep Singh Pawar of Vth semester, Civil Engineering of (N.P) Examination roll No. _______________ _________has successfully completed the minor project work entitled Baloria. PORTLAND POZZOLANA CEMENT (its Manju manufacturing and uses) under the guidance of

Manju Baloria
(H.O.D CIVIL ENGG.)

This project would never have been possible without the benign patronage of Manju Baloria (H.O.D civil) who boosted our morale at every step. We express our thanks to all who directly or indirectly helped in this project. The project work was very enterprising and hectic. It was very useful to all of us as we could make out all ambiguities about the actual operation involved in the manufacturing of cement. It was really a nice experience to interact with different workers of the factory. It made us feel like one amongst them. We also came to know the practical difficulties and challenges in the field work. This minor project helped us a lot to get respective and prepared to work at any major project pertaining to Civil Engineering in times to come.

Students of Vth sem

Group Associates

S.NO.

NAME

ROLL NO.

1. 2. 3. 4. 5.

Aamir Khan Vijay Deep Singh Pawar Kashish Bhogia Gagan Deep Singh Varun Parihar

1402 1562 1413 1398 1052

1. PREFACE 2. INTRODUCTION 3. SITE LOCATION OF CEMENT 4. SCOPE OF THE PROJECT 5. LAY OUT PLAN OF THE FACTORY 6. CEMENT 7 . RAW MATERIAL REQUIRED 8. MANUFACTURING OF PPC. 9. COLLECTION OF RAW MATERIALS 10. BURNING/CALCINATION 11. COOLING AND GRINDING OF CLINKERS 12. PROPERTIES OF CLINKERS 13. SETTING OF CEMENT 14. TESTING PORTLAND CEMENT 15. AVERAGE COMPOSITION OF PPC. 16. HISTORY, EARLU USES 17. TYPES OF MODERN CEMENT 18. ENVIRONMENTAL AND SOCIAL IMPACTS

1. 2. 3. 4. 5. 6. 7-8 9-10 11 12 13 14 15 16 17 18 21-25 26-28

Curriculum is the back bone of any academic structure. Curriculum decides the human development N.P, Jammu also has a mission in its curriculum to take its students to various sites of construction and industrial units to acquaint them with practical knowledge in their relenvant field. The students are assigned to frame a project report in order to make them conversant with the work they are expected to take after completion of their training from this institute. We as a group of seven students of 5th semester civil engineering were also assigned to work on the project PORTLAND POZZOLANA CEMENTITS MANUFACTURING AND ITS USES. During last week of September 2012, we were provided with an opportunity to pay a visit to a cement factory namely as SUDERSHAN CEMENT PLANT, at industrial area BARI BRAHMANA. Hence this report is submitted after making thorough study at site. It was a unique experience to see something being manufactured just before our eyes. It made us feel as one among the workers engaged in the job.

Cement is well known building material and has occupied an indispensable place in the construction works. There are verities of cement available in the market and each type is used under certain conditions due to its special properties. Among the different Cement, PPC (Portland Pozzolana Cement) is general purpose cement suitable for the construction of all engineering works. PPC is also commonly used in our state of Jammu & Kashmir. Thus it enhanced our curiosity and priority to know more about its manufacturing and uses in allied Civil Engineering works. Portland cement was a discovery of a brick layer of Leeds (U.K) know as Joseph Aspin. In 1824 he found that when a strongly heated mixture of limestone and clay was mixed with water and allowed to stand for some time, it hardened to a stone like mass which resembled with the stones quarried near Portland in England. Hence it was named Portland cement.

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The factory is situated at Kartholi village industrial area SIDCO complex Bari Brahmana [jammu], which is almost 40 Kms from Jammu city. Sudershan Cement Plant Pvt. Ltd has large chunk of land under its occupation which envisages its bright future for any advanced technological installations. On reaching the factory during our first visit we got introduced to the Chief Executive Manager, Mr.Sukhvinder Singh who warmly received the students. He briefed us all about the precautions to be taken during the visit to the factory. Every student of our group was eager to know and record the related information`s regarding the cement manufacturing operations. The site fulfills almost all the requirements to be needed by the factory and eco-friendly. There is a regular supply of water and electricity to the factory.

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Sudershan Cement Pvt. Ltd was established in 1997. The design of the factory suits to the location and the various units have been raised in an articulated manner which speaks volumes of concern for futuristic prospects of the factory. It is basically a unit of SUDERSHAN cement. It has a potential to enhance its production much more than that of its present production which is about 1100 bags/ day.

OBJECTIVES OF THE PROJECT: To meet the rising demand of the cement in the State. To supply quality-controlled cement for important structure like dame, weirs, bridges, tunnels etc. To earn both name and fame for the product and the company. To supply freshly prepared cement for construction purposes in order to maintain its characteristic qualities. To help check the monopoly of other cement companies in the market.

NAME OF THE PRODUCT:The Cement is sold in the market under the trade mark, SUDERSHAN CEMENT with crushing strength of 43 MPa( Mega Pascal).

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AT BARI BRAHMANA
BALANCE

RAW MATERIAL

SUPPLY

MASTER HOPPER STORAGE RAW MILL/GRINDER PACKING MACHINE

ELEVATOR

BLENDING SILOS

HOPPER

STORAGE CELL

CEMENT MILL/GRINDER

STOCK SILOS

CRUSHER

NEUTRILIZER

KILN

CANOPY

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In the most general sense of the word, cement is a binding substance which sets and hardens independently, and can bind other materials together. The word cement traces to the Romans, who used the term A cement factory at Bari Brahmana OPUSCAEMENTICIUM to describe masonry which resembled concrete and was made from crushed rock with burnt lime stone as binder. The volcanic ash and pulverized brick additives which were added to the burnt lime to obtain a hydraulic binder were later referred to as cementum, cimentum, cament and cement. Cements used in construction are characterized as hydraulic or non- hydraulic. The most important use of cement is the production of mortar and concrete the bonding of natural or artificial aggregates to form a strong building material which is durable in the face of normal environmental effects. Concrete should not be confused with cement because the term cement refers only to the dry powder substance used to bind the aggregate materials of concrete. Upon the addition of water and/ or

additives the cement mixture is referred to as concrete, especially if aggregates have been added.
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The basic ingredients of Pozzolana Portland Cement are: Calcareous Materials The materials which contain calcium of lime as major constituent are called Calcareous materials. For example: lime stone, CaCo3, Marl, Chalk or shells etc. These materials provide the required proportion of Calcium Oxide (Cao) in the manufacturing of cement.

Lime stone

Argillaceous Material The material which contain Alumina (Al2O3) as their basic constituents are called argillaceous materials such as shale, laterite SILICA CLAY etc. These materials provide required proportion of Silica/Clay,Iron Oxide etc. in the manufacture of Cement. When asked about the procurement of the raw materials,

the Supervisor Incharge of the Cement factory informed us that the raw materials is brought from the various places.
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For example limestone is brought from Khrew area of Srinagar which has a high lime content i.e. more than 52%. Silica (Sio2) Clay is locally procured. Fuel of Petroleum coke and fly ash are bought from outside the J&K State. Trucks are conveniently used for transportation of raw materials.

FLY ASH

CARBON

Aluminium dust

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Generally the following methods are employed for manufacturing of cement: Dry Process. Wet Process. DRY PROCESS The process is adopted when the raw materials are very hard. In this method, the raw material are ground to powder in tube mills separately and then stored in separate storage bins. They are then mixed in proper proportions and a raw mix is prepared. The raw is fed into a Rotary Kiln in the form of a fine powder. The remaining process is same as that of the wet process. This process is commonly used in the state of J&K.

WET PROCESS This process is adopted when the raw materials are soft. This process is mostly used now-a-days. The wet process is carried out by the following operations. Collection of raw Material.

Mixing of preparation of Slurry. Calcination/ Burning. Cooling of Clinkers. Grading and Storing. (8)

CALIBRATING OF RAW MIX AS PER ACTUAL

Some Cao Clay Pet Coke Iron Dust TOTAL

76% 14% 8% 2% 100%

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The materials are transported from the quarry and collected at the factory site: MIXING The quarried lime store is first crushed upto 1 cm size pebbles by means of a jaw crusher and a hammer crusher. The capacity of the hopper is 25 tones. These are then stored in a stock yard by means of belt conveyers. Argillaceous materials are taken to wash mills. Here clay is broken up and intimately mixed with 30% water to form a thin fluid known as Clay Slurry. Mixing process consists of crushing, grinding, proportioning and blending (i.e. process of correcting the composition of slurry is called blending) of raw material to prepare Cement Slurry. BURNING/ CALCINATION -

Rotary Kiln is used for burning purpose to form Cement Clinkers. The Rotary Kiln consists of a cylindrical furnace made of sheet steel of 2.5 cm to 4 cm thick and 3 m to 4 m diameter. It has a length of 9m-12m and is mounted on rotating gears at a slope of 1 in 20m. It rotates at a speed of one revolution/ minute. Temperature at the lower end is 1500oc 1650oc while near the upper end it is 250oc
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ROTARY KILN HAS THREE ZONE 1. Evaporation Zone Here Water of the Slurry is evaporated. 2. Calcination Zone Due to rise in temperature, Carbon Dioxide is vaporized and small lumps called nodules are formed. 3. Burning Zone The nodules reach to the bottom zone (burning zone) where nodules are converted into small hard stones which are called as Clinkers.

COOLING & GRINDING OF CLINKERS:The clinkers leaving the kiln are very hot. They are therefore allowed to cool at room temperature or with the help of a blast of cold air.

The Clinkers are then subjected to grinding machine during grinding 23 % of mass of Gypsum is added to retard or slow down the initial setting action of cement. The fine products so obtained is stored in cylindrical silos from where cement is drawn from the bottom, weighed and packed in bags for dispatch.

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COMPOSITION OF CEMENT CLINKERS S.No. Compound 1 2 3 4 Tricalcium Dicalcium Silicate Tricalcium Aluminate Tetra Calcium Aluminium Ferrite Chemical Formula 3CaSio2 2CaoAl2O3 3CaoAl2O3 4CaoAl2O3 Fe2O3 Abbreviation C8S C2S C2A C4AF Common Ratio 40% 32% 10.5% 9%

Properties of Clinkers Tricalcium Silicate (C3S) It hydrates more rapidly. It develops strength.

It generates heat more rapidly. It is less resistant to chemical attacks. Dicalcium Silicate (C3S) It hydrates slowly. It hardens more rapidly. It provides ultimate strength to the cement. It has more resistance to chemical attacks.

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Tricalcium Aliminate (C3A) It hydrates slowly. It is weak against Sulphate attacks. It does not contribute to develop strength.

Tetra Calcium Aluminium fernite (C4AF) It is comparatively inactive. It has poor cementing value. It is slow in reaction with small heat generation.

CEMENT HYDRATION

The chemical reaction between cement and water is called hydration of cement of simply cement hydration. C3S +H2O = Hydrated Calcium Silicate + Ca (OH) 2 C2S +H2O = Hydrated Calcium Silicate + Ca (OH) 2 C3A +H2O = Hydrated Aluminate + Ca (OH) 2 C3S reacts slower than C3A, but faster than C2S and is responsible of first 28 days strength.

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SETTING OF CEMENT The phenomenon by virtue of which the plastic cement changes into a solid mass is called as Setting of Cement. The Setting of cement is due to immediate reaction between C2A & Water. For OPC initial setting time should not be less than 30 minutes and final setting time not more than 10 hours.

HARDENING OF CEMENT

The phenomenon by virtue of which the cement paste which is finally set develops strength is known as hardening of Cement. The hardening of Cement is due to reaction between Tri-Calcium Silicate. C3S +C2S+C3A+Water.

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TESTING PORTLAND CEMENT The standardize the quality of Portland cement it should satisfy the tests before its use in any important engineering works. Following tests are performed: Finesses test by sieving. Consistency test.

 Initial & Final setting time test. Soundness test. Compressive Strength test. During our Project work, we happened to see the laboratory block of CEMENT CUBE IN WATER the Cement factory wherein various tests regarding the quality control are under taken. We came across with only one such test i.e. compressive strength test off cement. In order to verify the compressive strength in confirmation to the Indian Standard specifications ordinary sand (passing through 850 micron IS Sieve was used) was mixed with cement in the ratio1:3. A metallic cube mould is fitted on the table off vibration machine. The above mixed mortar is put into the cube and is compacted for two minutes. The mould is then removed. The cubes are cured for 3, 7 and 28 days and are turn by turn tested for compressive strength by compressive testing machine. The average compressive strength value of the value of cement was found to be 350-360 Kg/cm2.
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AVERAGE COMPOSITION OF PORTLAND CEMENT S.No. 1 2 3 4 5 6 7 8 INGREDIENT Lime Cao Silica Sio2 Alumina Al2O3 Magnesia Mgo Iron Oxide Fe2O3 Sulphur Trioxide SO3 Oxides of Na & K Loss of Ignition Total Percentage (in %) 63 22 6 2.5 3 1.5 1 1 100.00%

VARIOUS USES OF CEMENT It is used in mortars for masonry work, plastering pointing etc. It is used in Concrete, Lintels, beams etc. It is used for construction of dams, weirs, docks, bridges etc. It is used for construction water tanks, septic tanks, swimming pools. It is used for pre-cast pipes, poles, piles, garden seats etc. It is used for making manufacturing foundation in water.

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HISTORY, EARLY USES It is uncertain where it was first discovered that a combination of hydrated non-hydraulic lime and a pozzolan produces a hydraulic mixture (see also Pozzolanic reaction), but concrete made fro, such mixtures was first used on a large scale by Roman engineers. They used both natural pozzolans (trass or pumice) and artificial pozzolans (ground brick or pottery) in these concretes. Many excellent examples of structures made from theses concretes are still standing, notably the huge monolithic dome of the Pantheon in Rome and the massive Baths of Caracalla. The vast system of roman aqueducts also made

extensive use of hydraulic cement. The use of structural concrete disappeared in medieval Europe, although weak, Pozzolanic concretes continued to be used as a core fill in stone walls and columns. MODERN CEMENT Modern hydraulic cements began to be developed from the start of the Industrial revolution (around 1800), driven by three main needs: Hydraulic renders for finishing brick buildings in wet climates. Hydraulic mortars for masonry construction of harbor works etc. in contact with sea water. Development of strong concretes. In Britain particularly, good quality building stone became ever more expensive during a period of rapid growth and it became a common practice to construct prestige buildings from the new industrial bricks and to finish them with a stucco to imitate stone. Hydraulic limes were favoured for this, but the need for a fast set time encouraged the development of new cements.
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Most famous among these was Parker`s Roman Cement. This was developed by James Parker in the 1780s and finally patented in 1796. It was, in fact, nothing like any material used by the Romans, but was Natural Cement made by burning septaria nodules that are found in certain clay deposits and that contain both clay minerals and calcium carbonate. The burnt nodules were ground to a fine powder. This product made into a mortar with sand, set in 515 minutes. The success of Roman Cement led other manufacturers to develop rival products by burning artificial mixtures of clay and chalk. John Smeaton made an important contribution to the development of

cements when he was planning the construction of the third Eddystone Lighthouse (1755-59) in the English Channel. He needed a hydraulic mortar that would set and develop some strength in the twelve hour period between successive high tides. He performed an exhaustive market research on the available hydraulic lines, visiting their production sites and noted that the Hydraulicity of the lime was directly related to the clay content of the limestone from which it was made. Smeaton was a Civil Engineer by profession and took the idea so further. Apparently unaware of Smeaton`s work, the same principle was identified by Louis Vicat in the first decade of the nineteenth century. Vicat went on to devise a method of combining chalk and clay into an intimate mixture and burning this produced an Artificial cement in 1817. James frost working in Britain produced what he called British Cement in a similar manner around the same time but did into obtain a patent until -1822. In 1824, Joseph Aspdin patented a similar material which he called Portland cement because the render made from it was in color similar to the prestigious Portland stone.
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All the above products could not compete with lime/ pozzolan concretes because of fast-setting (giving insufficient time for placement) and low early strengths (requiring a delay of many weeks before formwork could be removed). Hydraulic limes natural cements all rely upon their belite content for strength development. Belite develops strength slowly because they were burned at temperatures below 1250oc, they contained no alite which is responsible for early strength in modern cements. The first cement to consistently contain alite was made by Joseph Aspdin`s son William in

the early 1840s. This was what we call today modern Portland cement. Because of the air of mystery with which William Aspdin surrounded his product, Others (e.g. Vicat and I C Johnson) have claimed precedence in this invention but recent analysis of both his concrete and raw cement have shown that William Aspdin`s product made at Northifleet, Kent was a true alite based cement. However, Aspdin`s methods were rule of thumb. Vicat is responsible for established the importance of sintering the mix in the kiln. William Aspdin`s innovation was counter-intuitive for manufacturers of artificial cements because they required more lime in the mix problem for his father because they required a much higher kiln temperature and therefore more fuel because the resulting clinker was very hard and rapidly wore down the millstones which were the only available grinding technology of the time. Manufacturing costs were therefore considerably higher, but the product set reasonably slowly and developed strength quickly thus opening up a market for use in concrete. The use of concrete in construction grew rapidly from 1850 onwards and as soon the dominant use for cements. Thus Portland cement began its predominant role.
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Types of modern cement 1. Portland cementCement is made by heating limestone (calcium carbonate) with small quantities of other materials (such as clay) to 1450 C in a kiln, in a process known as calcination, whereby a molecule of carbon dioxide is liberated from the calcium carbonate to form calcium oxide, or quicklime, which is then blended with the other materials that have been included in the mix. The resulting hard substance, called 'clinker', is then ground with a small amount of gypsum into a powder to make 'Ordinary

Portland Cement', the most commonly used type of cement (often referred to as OPC). Portland cement is a basic ingredient of concrete, mortar and most non-speciality grout. The most common use for Portland cement is in the production of concrete. Concrete is a composite material consisting of aggregate (gravel and sand), cement, and water. As a construction material, concrete can be cast in almost any shape desired, and once hardened, can become a structural (load bearing) element. Portland cement may be grey or white. Portland cement blends Portland cement blends are often available as inter-ground mixtures from cement manufacturers, but similar formulations are often also mixed from the ground components at the concrete mixing plant. 2. Portland blastfurnace cement contains up to 70 % ground granulated blast furnace slag, with the rest Portland clinker and a little gypsum. All compositions produce high ultimate strength, but as slag content is increased, early strength is reduced, while sulfate resistance increasesand heat evolution diminishes.
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3. Portland flyash cement contains up to 30 % fly ash. The fly ash is pozzolanic, so that ultimate strength is maintained. Because fly ash addition allows a lower concrete water content, early strength can also be maintained. Where good quality cheap fly ash is available, this can be an economic alternative to ordinary Portland cement. 4. Portland pozzolana cement includes fly ash cement, since fly ash is a pozzolan, but also includes cements made from other natural or artificial pozzolans. In countries where volcanic ashes

are available (e.g. Italy, Chile, Mexico, the Philippines) these cements are often the most common form in use. 5. Portland silica fume cement. Addition of silica fume can yield exceptionally high strengths, and cements containing 520 % silica fume are occasionally produced. However, silica fume is more usually added to Portland cement at the concrete mixer. 6. Masonry cements are used for preparing bricklaying mortars and stuccos, and must not be used in concrete. They are usually complex proprietary formulations containing Portland clinker and a number of other ingredients that may include limestone, hydrated lime, air entrainers, retarders, waterproofers and coloring agents. They are formulated to yield workable mortars that allow rapid and consistent masonry work. Subtle variations of Masonry cement in the US are Plastic Cements and Stucco Cements. These are designed to produce controlled bond with masonry blocks. 7. Expansive cements contain, in addition to Portland clinker, expansive clinkers (usually sulfoaluminate clinkers), and are designed to offset the effects of drying shrinkage that is normally encountered with hydraulic cements.

8. White blended cements may be made using white clinker and white supplementary materials such as high-purity metakaolin. 9. Colored cements are used for decorative purposes. In some standards, the addition of pigments to produce "colored Portland cement" is allowed. In other standards pigments are not allowed constituents of Portland cement, and colored cements are sold as "blended hydraulic cements". 10. Very finely ground cements are made from mixtures of cement with sand or with slag or other pozzolan type minerals

that are extremely finely ground together. Such cements can have the same physical characteristics as normal cement but with 50% less cement particularly due to their increased surface area for the chemical reaction. Even with intensive grinding they can use up to 50% less energy to fabricate than ordinary Portland cements. Non-Portland hydraulic cements 1. Pozzolana-lime cements. Mixtures of ground pozzolan and lime are the cements used by the Romans, and can be found in Roman structures still standing (e.g. the Pantheon in Rome). They develop strength slowly, but their ultimate strength can be very high. The hydration products that produce strength are essentially the same as those produced by Portland cement. 2. Slag-lime cements. Ground granulated blast furnace slag is not hydraulic on its own, but is "activated" by addition of alkalis, most economically using lime. They are similar to pozzolan lime cements in their properties. Only granulated slag (i.e. waterquenched, glassy slag) is effective as a cement component.
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3. Supersulfated cements. These contain about 80% ground granulated blast furnace slag, 15 % gypsum or anhydrite and a little Portland clinker or lime as an activator. They produce strength by formation of ettringite, with strength growth similar to a slow Portland cement. They exhibit good resistance to aggressive agents, including sulfate. 4. Calcium aluminate cements are hydraulic cements made primarily from limestone and bauxite. The active ingredients are

monocalcium aluminate CaAl2O4 (CaO Al2O3 or CA in Cement chemist notation, CCN) and mayenite Ca12Al14O33 (12 CaO 7 Al2O3, or C12A7 in CCN). Strength forms by hydration to calcium aluminate hydrates. They are well-adapted for use in refractory (high-temperature resistant) concretes, e.g. for furnace linings.

5. Calcium sulfoaluminate cements are made from clinkers that include ye'elimite (Ca4(AlO2)6SO4 or C4A3 in Cement chemist's notation) as a primary phase. They are used in expansive cements, in ultra-high early strength cements, and in "lowenergy" cements. Hydration produces ettringite, and specialized physical properties (such as expansion or rapid reaction) are obtained by adjustment of the availability of calcium and sulfate ions. Their use as a low-energy alternative to Portland cement has been pioneered in China, where several million tonnes per year are produced.[17][18] Energy requirements are lower because of the lower kiln temperatures required for reaction, and the lower amount of limestone (which must be endothermically decarbonated) in the mix. In addition, the lower limestone content and lower fuel consumption leads to a CO2 emission

around half that associated with Portland clinker. However, SO2 emissions are usually significantly higher. 6. "Natural" cements correspond to certain cements of the prePortland era, produced by burning argillaceous limestones at moderate temperatures. The level of clay components in the limestone (around 3035 %) is such that large amounts of belite (the low-early strength, high-late strength mineral in Portland

cement) are formed without the formation of excessive amounts of free lime. As with any natural material, such cements have highly variable properties.

7. Geopolymer cements are made from mixtures of water-soluble alkali metal silicates and aluminosilicate mineral powders such as fly ash and metakaolin.

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The setting of cement Cement sets when mixed with water by way of a complex series of hydration chemical reactions still only partly understood. The different constituents slowly hydrate and crystallise while the interlocking of their crystals gives to cement its strength. After the initial setting, immersion in warm water will speed up setting. In Portland cement, gypsum is added as a compound preventing cement

flash setting. The time it takes for cement to set varies; and can take anywhere from twenty minutes for initial set, to twenty-four hours, or more, for final set. Safety issues Bags of cement routinely have health and safety warnings printed on them because not only is cement highly alkaline, but the setting process is exothermic. As a result, wet cement is strongly caustic and can easily cause severe skin burns if not promptly washed off with water. Similarly, dry cement powder in contact with mucous membranes can cause severe eye or respiratory irritation. Cement users should wear protective clothing Cement industry in the world In 2010 the world production of hydraulic cement was 3,300 million tonnes. The top three producers were China with 1,800, India with 220 and USA with 63.5 million tonnes for a combined total of over half the world total by the world's three most populated states.For the world capacity to produce cement in 2010 the situation was similar with the top three states (China, India and USA) accounting for just under half the world total capacity.
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Environmental impacts Cement manufacture causes environmental impacts at all stages of the process. These include emissions of airborne pollution in the form of dust, gases, noise and vibration when operating machinery and during blasting in quarries, and damage to countryside from quarrying. Equipment to reduce dust emissions during quarrying and

manufacture of cement is widely used, and equipment to trap and separate exhaust gases are coming into increased use. Environmental protection also includes the re-integration of quarries into the countryside after they have been closed down by returning them to nature or re-cultivating them. CO2 emissions Cement manufacturing releases CO2 in the atmosphere both directly when calcium carbonate is heated, producing lime and carbon dioxide,and also indirectly through the use of energy if its production involves the emission of CO2. The cement industry is the second largest CO2 emitting industry behind power generation. The cement industry produces about 5% of global man-made CO2 emissions, of which 50% is from the chemical process, and 40% from burning fuel. The amount of CO2 emitted by the cement industry is nearly 900 kg of CO2 for every 1000 kg of cement produced. The high proportion of carbon dioxide produced in the chemical reaction leads to large decrease in mass in the conversion from limestone to cement. So, to reduce the transport of heavier raw materials and to mimimize the associated costs, it is more economical for cement plants to be closer to the limestone quarries rather than to the consumer centers. In certain applications, lime mortar, reabsorbs the same amount of CO2
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as was released in its manufacture, and has a lower energy requirement in production than mainstream cement. Newly developed cement types from Novacem and Eco-cement can absorb carbon dioxide from ambient air during hardening.Use of the Kalina cycle during production can also increase energy efficiency. Heavy metal emissions in the air

In some circumstances, mainly depending on the origin and the composition of the raw materials used, the high-temperature calcination process of limestone and clay minerals can release in the atmosphere gases and dust rich in volatile heavy metals, a.o, thallium,cadmium and mercury are the most toxic. Heavy metals (Tl, Cd, Hg, ...) are often found as trace elements in common metal sulfides (pyrite (FeS2), zinc blende (ZnS), galena (PbS), ...) present as secondary minerals in most of the raw materials. Environmental regulations exist in many countries to limit these emissions. Heavy metals present in the clinker The presence of heavy metals in the clinker arises both from the natural raw materials and from the use of recycled by-products or alternative fuels. The high pH prevailing in the cement porewater (12.5 < pH < 13.5) limits the mobility of many heavy metals by decreasing their solubility and increasing their sorption onto the cement mineral phases. Nickel, zinc and lead are commonly found in cement in non-negligible concentrations.

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Use of alternative fuels and by-products materials A cement plant consumes 3 to 6 GJ of fuel per tonne of clinker produced, depending on the raw materials and the process used. Most cement kilns today use coal and petroleum coke as primary fuels, and to a lesser extent natural gas and fuel oil. Selected waste and byproducts with recoverable calorific value can be used as fuels in a

cement kiln, replacing a portion of conventional fossil fuels, like coal, if they meetstrict specifications. Selected waste and by-products containing useful minerals such as calcium, silica, alumina, and iron can be used as raw materials in the kiln, replacing raw materials such as clay, shale, and limestone. Because some materials have both useful mineral content and recoverable calorific value, the distinction between alternative fuels and raw materials is not always clear. For example, sewage sludge has a low but significant calorific value, and burns to give ash containing minerals useful in the clinker matrix.

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