2.

0 FORMATION OF PORTLAND CEMENT

According to ASTM C-150, portland cement is a hydraulic cement produced by pulverizing

clinker consisting essentially of hydraulic calcium silicates, usually containing one or more
types of calcium sulfate, as an interground addition.

The raw materials for the manufacture of portland cement contain, in suitable proportions,
silica, aluminum oxide, calcium oxide, and ferric oxide. The source of lime is provided by
calcareous ingredients such as limestone or chalk and the source of silica and aluminum oxide
are shales, clays or slates. The iron bearing materials are iron and pyrites. Ferric oxide not only
serves as a flux, but also forms compounds with lime and alumina. The raw materials also
contain small amounts of other com- pounds such as magnesia, alkalis, phosphates, fluorine
compounds, zinc oxide, and sulfides. The cement clinker is produced by feeding the crushed,
ground, and screened raw mix into a rotary kiln and heating to a temperature of about 1300–
1450°C. Approximately 1100–1400 kcal/g of energy is consumed in the formation of clinker.
The sequence of reactions is as follows: At a temperature of about 100°C (drying zone) free
water is expelled. In the preheating zone (750°C) firmly bound water from the clay is lost. In
the calcining zone (750–1000°C) calcium carbonate is dissociated. In the burning zone (1000–
1450°C) partial fusion of the mix occurs,

with the formation of C3S, C2S and clinker. In the cooling zone (1450– 1300°C) crystallization
of melt occurs with the formation of calcium aluminate and calcium aluminoferrite. After firing
the raw materials for the required period, the resultant clinker is cooled and ground with about
4–5% gypsum to a specified degree of fineness. Grinding aids, generally polar compounds, are
added to facilitate grinding.