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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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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
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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
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Types of Cement
Ordinary Portland Cement BS EN 197-1 2000
General use
Grind to 2250 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