ASSIGNMENT-2

Material- Cement

Criteria
no. 7

Criteria
no. 8

Group no. Group

Krushna 4 no.864
-Krushna
2016
Myatra -Myatra
2016 109
Madhav - 2016 110
Madhav
Rathi -2016 157
Rathi
Nikita
Nikita
INTRODUCTION :
Cement can be defined as the bonding material having cohesive & adhesive
properties which makes it capable to unite the different construction materials and
form the compacted assembly.

Portland cement is the most common type of cement in general use around the
world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. It
was developed from other types of hydraulic lime in England in the early 19th
century by Joseph Aspdin, and usually originates from limestone.

Ordinary Portland Cement (simply called ordinary cement) refers to the hydraulic

binding material ground by mixing Portland cement clinker, 6% ~ 15% blended
materials, and appropriate amount of gypsum, code-named P• O.

The maximum amount of active blended materials mixed in cement should not
exceed 15% of the total mass. They are allowed to be replaced by kiln ash and
inactive blended materials which should be no more than 5% and 10% of the cement
mass respectively. The maximum amount of inactive blended materials mixed in
cement should not exceed 10% of the total mass.

Today, Ordinary Portland cement is the most

widely used building material in the world with
about 1.56 billion tone produced each year.
Annual global production of Portland cement
concrete is around 3.8 million cubic meters
per year.

CEMENT PRODUCTION AND MANUFACTURING PROCESS:

Cement is the essential ingredient of concrete and mortars, and generally produced
from the limestone, clay and sand; which provide the four key ingredients required:
lime, silica, alumina and iron. Mixing these ingredients and exposing them to intense
heat causes chemical reactions that convert the partially molten raw materials into
pellets called “clinker.” After adding gypsum and other additional materials, the
mixture is ground to a fine grey powder called “Portland cement.

The process of cement production includes three main stages as can be seen
from Figure 1:

- Raw material preparation including quarrying raw materials, crushing, pre-

homogenization and raw meal grinding,
- Clinker burning which includes preheating, pre-calcining, clinker production in the
rotary kiln and cooling and storing,
- Cement preparation which includes blending, cement grinding, storing in the
cement silo.

Figure 1. The cement manufacturing process

1. In the first stage, the raw materials are crushed and mixed to produce a
homogenized raw mix for rotary kiln.
2. In the second stage of process, the raw mix is fed to the rotary kiln and heated to
a temperature of >1400 0C in a rotary kiln to produce clinker which is the main
component of cement.
3. In the final stage of process, clinker is ground with gypsum and other additives to
produce the powder called as “cement”.

Cements are divided into five main categories according to their contents of clinker
substitutes with an allowed range for their chemical composition. CEM I typically
contains 95% clinker. Blended cements can be manufactured with up to 65% of
slags or 35% of fly ash and used instead of Ordinary Portland Cement (CEM I) in
most applications.
There are two main cement production processes: wet and dry process. The wet
process consumes more energy because of the evaporation of the 30% plus slurry
water before heating the raw materials to the necessary temperature for calcinations.

Background system:

Electricity: Electricity is modelled according to the individual country-specific

situations. The country-specific modelling is achieved on multiple levels.

Firstly, individual energy carrier specific power plants and plants for renewable
energy sources are modelled according to the current national electricity grid mix.
Modelling the electricity consumption mix includes transmission / distribution losses
and the own use by energy producers (own consumption of power plants and "other"
own consumption e.g. due to pumped storage hydro power etc.), as well as imported
electricity.

Secondly, the national emission and efficiency standards of the power plants are
modelled as well as the share of electricity plants and combined heat and power
plants (CHP).

Thirdly, the country-specific energy carrier supply (share of imports and / or

domestic supply) including the country-specific energy carrier properties (e.g.
element and energy content) are accounted for.

Fourthly, the exploration, mining/production, processing and transport processes of

the energy carrier supply chains are modelled according to the specific situation of
each electricity producing country.

The different production and processing techniques (emissions and efficiencies) in

the different energy producing countries are considered, e.g. different crude oil
production technologies or different flaring rates at the oil platforms. Thermal energy,
process steam: The thermal energy and process steam supply is modelled according
to the individual country-specific situation with regard to emission standards and
considered energy carriers. The thermal energy and process steam are produced at
heat plants. Efficiencies for thermal energy production are by definition 100% in
relation to the corresponding energy carrier input. For process steam the efficiency
ranges from 85%, 90% to 95%.
 The energy carriers used for the generation of thermal energy and process steam
are modelled according to the specific import situation (see electricity above).

Transports: All relevant and known transport processes are included. Ocean-going
and inland ship transport as well as rail, truck and pipeline transport of bulk
commodities are considered. Energy carriers: The energy carriers are modelled
according to the specific supply situation (see electricity above). Refinery products:
Diesel fuel, gasoline, technical gases, fuel oils, lubricants and residues such as
bitumen are modelled with a parameterised country-specific refinery model. The
refinery model represents the current national standard in refining techniques (e.g.
emission level, internal energy consumption, etc.) as well as the individual country-
specific product output spectrum, which can be quite different from country to
country. The supply of crude oil is modelled, again, according to the country-specific
situation with the respective properties of the resources.

Emission of CO2 and Energy consumption

MANUFACTURING:
Manufacturing of cement involves various raw materials and processes. Each
process is explained chemical reactions for manufacture of Portland Cement.

Cement is a greenish grey colored powder, made of calcined mixtures of clay and
limestone. When mixed with water becomes a hard and strong building material.
Top Cement Manufacturers 2020

Total Cement Production Capacity

Company Name
(MTA)
 UltraTech Cement 117.35
 Shree Cement 37.90
 ACC Cement 33.40
 Ambuja Cement 29.65
 Ramco Cement 16.45
 India Cements 15.50
 JSW Cement 12.80
 Wonder Cement 11
 Binani Cement 6.25
 Mycem Cement 5.40

Graph representing market share of

MANUFACTURERS IN INDIA: manufacturers
UltraTech Cement: Ultratech Cement was incorporated in 2000 as Larsen &
Toubro. Later it was demerged and acquired by Grasim and was renamed as Ultra
Tech Cement in 2004. Today Ultatech cement  is a part of Aditya Birla group, is the
country’s largest exporter of cement clinker. It manufactures and markets Ordinary
Portland Cement, Portland Blast Furnace Slag Cement and Portland Pozzalana
Cement. It also manufactures ready mix concrete (RMC). It has annual capacity of
64 million tones. This company has been awarded as the Super Brand Status.

Ambuja Cements: Ambuja Cements Ltd, a part of Holcim, is an India-based cement

manufacturing company. Holcim is a supplier of cement and aggregates (crushed
stone, gravel and sand). Its activities include the manufacture and distribution of
cement, and the production, processing and distribution of aggregates, ready-mix
concrete and asphalt. It also offers consulting, research, trading, engineering and
other services. The Company has five integrated cement manufacturing plants and
eight cement grinding units. Its cement capacity is approximately 27.25 million tons.

ACC Cement: ACC Limited is India’s foremost manufacturer of cement and ready

mixed concrete with a countrywide network of factories and sales offices.
Established in 1936, ACC is acknowledged as a pioneer and trendsetter in cement
and concrete technology. The ACC Company manufactures cement, cement plant
and refractoriness and other heavy machinery including structural and mid
fabrications. ACC Cement is India’s largest and oldest cement company belonging to
the Tata group. ACC Cement Company was incorporated at Mumbai.

Birla Corporation Limited: Birla Corporation Limited is the flagship Company of the
M.P. Birla Group. Incorporated as Birla Jute Manufacturing Company Limited in
1919, it was Mr. Madhav Prasad Birla who gave shape to its present form. In 1890’s,
Birla Corporation was a jute manufacturing company, but over the time, they have
grown to operate four major divisions, like auto trim, vinoleum, jute and cement.
Formerly known as Birla Jute Manufacturing Company Limited, with the expansion of
divisions, the company changed their name in 1998 to Birla Corporation Limited.

Ramco Cements Limited: The Ramco Cements Limited is formerly Madras

Cements Ltd. Is the flagship company of the Ramco Group, a well known business
group of South India and it is head quartered at Chennai. The ramco’s main product
company is Portland cement it is manufactured in eight state of the art production
facilities that includes incorporated Grinding units and cement plants with present
total production capacity of 16.45 MTPA (out of which Satellite Grinding unit’s
capacity alone is 4 MTPA).Ramco cements is the fifth largest cement producer in the
country.

LIFE CYCLE ASSESSMENT:

Life cycle assessment of cement is a crucial for determining the environmental
impacts from cement production process, developing and preferring the alternative
technologies. Due to these reasons, life cycle assessment (LCA) studies are
performed to determine the environmental impacts.

Figure 2: Material flow and system boundaries of

cradle-to-gate LCA of cement production.

LIFE CYCLE ASSESSMENT OF TYPICAL CEMENTS IN THE INDIAN CONTEXT

• Ariyalur, Tamil Nadu, India, has rich limestone deposits. Consequently, many
cement plants are located there.

• It is considered that the plant has been leased limestone quarries adjacent to its
location. Since the limestone is soft in this region, it is extracted by excavation
without blasting. The material used has a composition with about 44% CaO, 12.5%
SiO2, 10% moisture and 35.5% loss on ignition.
 • It is considered that Class F Fly ash is transported from the Mettur Power Plant
(over 200 km), with a composition of 61% SiO2 , 27% Al2O3 and 4% Fe2O3.

• It is considered that waste phosphogypsum is transported from Tutticorin (385 km)

Impact Assessment - C

• Most of the energy required is obtained by burning coal and pet coke. 10% of the
energy in the cement kiln is produced by burning biomass and alternative fuels

• Most of the electricity (80%) is considered as generated by a captive thermal power

plant burning pet coke (88% contribution in terms of power produced) and lignite
(11%). The plant also produces some fly ash that is added to the limestone for the
raw meal

• Water consumption of the plant is about 0.2 m3 per ton of cement

CEMENT: CSI SYSTEM CALCULATIONS

 Only direct emissions are considered.

 Emissions and energy consumption during extraction and transportation of raw
materials and all fuels are excluded.
 Emissions and energy consumed due to the production of electricity (both
purchased and produced) is excluded.

Based on measurable quantities at the plant level and avoids almost all assumptions
that are not relevant to local conditions and materials.

CONCLUSION:
Portland cement is a complex product obtained from unprocessed common natural
materials: limestone and clay. Consequently, the characteristics of Portland cement
clinker may vary from one cement plant to another. To limit the variations of the
technological properties of Portland cement, acceptance standards have been
developed, but presently these standards are not satisfactory for the whole concrete
market. Low cements are increasingly used; these concretes are made using large
dosage of super plasticizers to disperse cement particles. It is therefore urgent for
the cement industry to produce a clinker that will facilitate the production of the low
concretes that are more sustainable than normal-strength concretes. The production
of the old Type I/II clinker must continue to satisfy the needs of this very profitable
market, because now that we know how to increase concrete compressive strength,
it is very important that we focus on how to improve the rheology of these concretes
in order to transform concrete into a quasi-liquid material that can be poured without
any problem.

BIBLIOGRAPHY:

https://theconstructor.org/concrete/ordinary-portland-cement/23181/

https://www.sciencedirect.com/topics/engineering/ordinary-portland-cement

https://www.researchgate.net/publication/299454703_IDENTIFYING_ENVIRONMEN
TAL_IMPACTS_OF_CEMENT_PRODUCTION_WITH_LIFE_CYCLE_ASSESSMEN
T_LITERATURE_REVIEW

https://www.academia.edu/8058978/A_life-
cycle_assessment_of_Portland_cement_manufacturing_comparing_the_traditional_
process_with_alternative_technologies

https://theconstructor.org/concrete/ordinary-portland-cement/23181/

https://www.lc3.ch/wp-content/uploads/2016/03/LCA-@Stakeholder-meeting-12-01-
2016-Mumbai.pdf

https://www.constructiontips.co.in/top-10-cement-companies-in-india/

https://www.infrabazaar.com/blog/Top-5-Cement-Industries-in-India/172