This document provides an overview of concrete technology and the Portland cement manufacturing process. It discusses that Portland cement is produced by grinding raw materials like limestone, sand, shale and clay then burning them in a kiln at high temperatures to form clinker. The clinker is then ground with gypsum to produce Portland cement. It also describes the hydration process where cement hardens after mixing with water through a chemical reaction. The hydration releases heat and results in the formation of compounds that give concrete its strength.
This document provides an overview of concrete technology and the Portland cement manufacturing process. It discusses that Portland cement is produced by grinding raw materials like limestone, sand, shale and clay then burning them in a kiln at high temperatures to form clinker. The clinker is then ground with gypsum to produce Portland cement. It also describes the hydration process where cement hardens after mixing with water through a chemical reaction. The hydration releases heat and results in the formation of compounds that give concrete its strength.
This document provides an overview of concrete technology and the Portland cement manufacturing process. It discusses that Portland cement is produced by grinding raw materials like limestone, sand, shale and clay then burning them in a kiln at high temperatures to form clinker. The clinker is then ground with gypsum to produce Portland cement. It also describes the hydration process where cement hardens after mixing with water through a chemical reaction. The hydration releases heat and results in the formation of compounds that give concrete its strength.
This document provides an overview of concrete technology and the Portland cement manufacturing process. It discusses that Portland cement is produced by grinding raw materials like limestone, sand, shale and clay then burning them in a kiln at high temperatures to form clinker. The clinker is then ground with gypsum to produce Portland cement. It also describes the hydration process where cement hardens after mixing with water through a chemical reaction. The hydration releases heat and results in the formation of compounds that give concrete its strength.
Lecture 2 Engr. Usama Ali Contents Introduction Raw Materials of Portland Cement Manufacturing of Portland Cement Composition of Portland Cement Hydration and heat of hydration Structure of Hydrated Cement Introduction Cement is a finely ground inorganic powder that sets, hardens and adheres to other materials, binding them together The most important types of cement are used in the production of mortar in masonry, and of concrete, which is a combination of cement and an aggregate to form a strong building material. Cements used in construction are usually inorganic, often lime or calcium silicate based, and can be characterized as being either hydraulic or non-hydraulic, depending upon the ability of the cement to set in the presence of water Hydraulic cements (e.g., Portland cement) harden because of hydration, a chemical reaction between the anhydrous cement powder and water. Introduction (Cont’d) Non-hydraulic cements do not harden underwater; for example, slaked limes harden by reaction with atmospheric carbon dioxide (Carbonation) First calcium oxide (lime) is produced from calcium carbonate (limestone or chalk) by calcination at temperatures above 825 °C (1,517 °F) for about 10 hours at atmospheric pressure: CaCO3 → CaO + CO2 The calcium oxide is then spent (slaked) mixing it with water to make slaked lime (calcium hydroxide): CaO + H2O → Ca(OH)2 Once the excess water is completely evaporated (this process is technically called setting), the carbonation starts: Ca(OH)2 + CO2 → CaCO3 + H2O This reaction takes a significant amount of time because the partial pressure of carbon dioxide in the air is low. The carbonation reaction requires the dry cement to be exposed to air, and for this reason the slaked lime is a non- hydraulic cement and cannot be used under water. This whole process is called the lime cycle Raw Materials for Manufacturing of Portland Cement Basic Chemical Components of Portland Cement • Calcium (60-67%) • Silica (17-25%) • Alumina (3-8%) • Iron (0.5-6%)
The common Raw materials
• Limestone • Sand • Shale, Clay • Iron ore • Gypsum Manufacturing of Portland Cement The process of manufacture of cement consists of grinding of raw materials, mixing them intimately at certain proportions and burning them in a kiln at about 1300 to 1500ºC temperature, at which the material partially fuses to form nodular shaped clinker. The clinker is cooled and ground to fine powder with addition of 3 to 5% gypsum. The product formed by using this procedure is called Portland cement. Manufacturing of Portland Cement
1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm
(3/4 in.), and stored. 2. Raw materials are ground to powder and blended. (Dry process)
or 2. Raw materials are ground, mixed with water to form slurry, and blended. (Wet Process) 3. Burning changes raw mix chemically into cement clinker. 4. Clinker is ground with gypsum into portland cement and shipped. Clinker Gypsum
Portland cement clinker is formed
by burning calcium and siliceous Gypsum, a source of sulfate, is inter- ground with Portland clinker to form raw materials in a kiln. This Portland cement. It helps control particular clinker is about 3mm to setting, drying shrinkage properties, 20 mm (3¼4 in.) in diameter and strength development Chemical Composition of Cement Properties of main chemical compounds Tri-calcium silicate: is responsible for early strength. Cement with high content of C3S is favored in regions of cold climate.
Di-calcium silicate: Contributes to later age strength (after one
week). High percentage of C2S is recommended in hydraulic structures.
Tri-calcium Aluminate: Reacts immediately with water and
defines set. In the absence of gypsum, it causes flash set. Generates high heat and is more reactive with soils and water containing moderate to high Sulphate concentrations and is thus the least desirable compound.
Tetra-calcium Alumino-ferrite: Lowers clinkering temperature
and contributes very little to strength of concrete even though it hydrates very rapidly. Development of Strength of Pure Compounds Hydration Cement acquires binding properties when mixed with water The chemical reaction that takes place between water and cement is referred to as hydration of cement The reaction of cement with water is exothermic. This liberation of heat is called heat of hydration. Although simple hydrates such as C-H are formed, process of hydration is a complex one and results in reorganization of the constituents of original compounds to form new hydrated compounds 5 Stages of Hydration Hydration Reactions Characteristics of Hydration cement compound Heat of Hydration Heat of hydration at given age (cal/g) Compound 3 days 90 days 13 years CS 58 104 122 C2S 12 42 59 C3A 212 311 324 C4AF 69 98 102
Normal cement produces 89-89cal/g in 7 days and 90-100cal/g in 28 days.
Heat of Hydration The reaction of cement with water is exothermic The reaction results in the release of considerable amount of heat known as heat of hydration Minimum water requirement for complete hydration is 38% by weight. Heat of Hydration (Cont’d) Structure of Hydrated Cement Hydrated cement paste consists of • Hydration Products • Un-hydrated Clinker Grain • Water • Air Hydration Products are • Calcium Silicate Hydrate (C-S-H) • Calcium Hydroxide (C-H) • Calcium Sulfo-aluminates (ettringite) Structure of Hydrated Cement ( Cont’d) Relative volume of major compounds in hydrated pastes
at of Hydration References Concrete Technology by A.M Neville, J.J Brooks. Concrete Technology by M.S Shetty. THE END
