Cement and Refractories

Cement and refractory's
By
Inderjit Singh
Cement and Refractory:

(Syllabus)
Introduction, Types of Portland cement, BIS specification of

cement Raw materials Manufacture, Reactions in the Kiln,
Mixing of Additives ,Introduction to various parameters for
testing of cement ,Brief introduction of acid resistant
cement ,waterproof cement ,white cement
Introduction
Cement may be described as a material
possessing adhesive and cohesive properties
and capable of binding materials like stones,
bricks, building block etc.
The principal elemental composition of
cement used for constructional purposes are
Ca, Al and Si.
Cement have the property of setting and
hardening under water by virtue of certain
chemical reaction.
Portland Cement
First invented in 1824 by Joseph Aspdin. It
resembles stones found near Portland.
It is greenish grey colored extremely finely
ground powder which turned into solid
material on reaction with water. It si obtained
by calcining an intimate & properly
proportional mixture of clay and limestone at
1500oC followed by addition of gypsum as
additive.
It is most important and reliable cementing
PORTLAND CEMENT:
PORTLAND CEMENT A cement is a
binder,
a substance that sets and hardens
independently, and can bind other
materials together.
Material with adhesive and cohesive
properties
Any material that binds or unites
essentially like glue
Cement Chemical Composition

Cement Chemical Composition Cement
Compound Weight Percentage Chemical
Formula Tricalcium silicate 50 % Ca 3 SiO
5 or 3CaO . SiO 2 Dicalcium silicate 25 %
Ca 2 SiO 4 or 2CaO . SiO 2 Tricalcium
aluminate 10 % Ca 3 Al 2 O 6 or 3CaO .
Al 2 O 3 Tetracalcium aluminoferrite 10 %
Ca 4 Al 2 Fe 2 O 10 or 4CaO . Al 2 O 3 . Fe
2 O 3 Gypsum 5 % CaSO 4 . 2H 2 O
Functions of the ingredients of cements:

Functions of the ingredients of cements Lime is the
principal constituent of cement. Its proportion must
be properly regulated. However excess of lime reduce
the strength of cement . On the other hand presence
of lesser amount of lime than required also reduce
the strength of cement and make it quick setting.
Silica imparts strength to cement. Alumina makes the
cement quick setting. (due to excess weakness of
cement increased) Gypsum helps to retard the setting
action of cement. It actually enhance the initial
setting time of cement. Iron oxide provides color,
strength and hardness to the cement
PRODUCTION STEPS:
PRODUCTION STEPS Raw materials are crushed,
screemed & stockpiled. Raw materials are mixed
with definite proportions to obtain raw mix. They
are mixed either dry (dry mixing) or by water (wet
mixing). Prepared raw mix is fed into the rotary
kiln. As the materials pass through the kiln their
temperature is rised upto 1300-1600 C. The
process of heating is named as burning. The
output is known as clinker which is 0.15-5 cm in
diameter . Clinker is cooled & stored. Clinker is
ground with gypsum (3-6%) to adjust setting time.
Packing & marketting.
REACTIONS IN THE KILN:

REACTIONS IN THE KILN ~ 100 C
free water evaporates. ~ 150-350C
loosely bound water is lost from
clay. ~ 350-650 C decomposition
of clay SiO 2 & Al 2 O 3 ~ 600 C
decomposition of MgCO 3 MgO &
CO 2 (evaporates) ~ 900 C
decomposition of CaCO 3 CaO& CO
2 (evaporates
SETTING AND HARDENING OF CEMENT:

SETTING AND HARDENING OF CEMENT INITIAL
SETTING : Hydration of C 3 A, C 2 S, C 3 S Gel
Formation of C 4 AF 3CaO.Al 2 O 3 + 6 H 2 O 3CaO.Al 2
O 3 .6H 2 O 2CaO.SiO 2 + 4 H 2 O 2CaO.SiO 2 .4H 2 O
3CaO.SiO 2 + 6 H 2 O 3CaO.SiO 2 .6H 2 O 4CaO.Al 2 O
3 .Fe 2 O 3 + 7 H 2 O 3CaO.Al 2 O 3 .6H 2 O + CaO.Fe 2
O 3 .H 2 O FINAL SETTING AND HARDENING : Hydrolysis
of C 3 S, C 2 S 2[3CaO.SiO 2 ] + 6H 2 O 3CaO.2SiO 2 .
3H 2 O + 3Ca(OH) 2 2[2CaO.SiO 2 ] + 4H 2 O
3CaO.2SiO 2 .6H 2 O + Ca(OH) 2 When cement is
mixed with water to a plastic mass called cement
paste, hydration reaction begin, resulting in the
formation of gel and crystalline products
ROLE OF CEMENTING MATERIALS

ROLE OF CEMENTING MATERIALS 1) GYPSUM :
INITIAL SETTING TIME RETARDER C 3 A + 6H 2 O
C 3 A.6H 2 O + HEAT C 3 A + x H 2 O + y CaSO 4
. z H 2 O C 3 A.yCaSO 4 .z H 2 O Insoluble
calcium sulphoaluminate Quick hardening
property Gypsum 2) Silica / CaO: Imparts
srengths 3) Alumina : Imparts strengths, Makes
the cement quick setting 4) Fe 2 O 3 : Imparts
Grey color , strength and hardness 5) SO 3 :
Imparts soundness 6) Alkalies (MgO, Na 2 O, K 2
O): Lower the clinkering temperature
Refractories
Firebricks for furnaces and ovens.
Have high Silicon or Aluminium oxide
content.
Brick products are used in the
manufacturing plant for iron and
steel, non-ferrous metals, glass,
cements, ceramics, energy
conversion, petroleum, and chemical
industries.
Refractories
Used to provide thermal protection of other
materials in very high temperature applications,
such as steel making (Tm=1500C), metal foundry
operations, etc.
They are usually composed of alumina
(Tm=2050C) and silica along with other oxides:
MgO (Tm=2850C), Fe2O3, TiO2, etc., and have
intrinsic porosity typically greater than 10% by
volume.
Specialized refractories, (those already mentioned)
and BeO, ZrO2, mullite, SiC, and graphite with low
porosity are also used.
Refractory Brick
Any material can be described as a refractory, if it can withstand the

action of abrasive or corrosive solids, liquids or gases at high
temperatures. The various combinations of operating conditions in
which refractories are used, make it necessary to manufacture a
range of refractory materials with different properties. Refractory
materials are made in varying combinations and shapes depending on
their applications. General requirements of a refractory material are:
Withstand high temperatures
Withstand sudden changes of temperatures
Withstand action of molten metal slag, glass, hot gases, etc
Withstand load at service conditions
Withstand load and abrasive forces
Conserve heat
Have low coefficient of thermal expansion
Should not contaminate the material with which it comes into contact
Fireclay Refractories
Firebrick is the most common form of refractory material. It is
used extensively in the iron and steel industry, nonferrous
metallurgy, glass industry, pottery kilns, cement industry,
and many others.
Fireclay refractories, such as firebricks, siliceous fireclays and
aluminous clay refractories consist of aluminum silicates with
varying silica (SiO2) content of up to 78 percent and Al2O3
content of up to 44 percent.
The table shows that the melting point (PCE) of fireclay brick
decreases with increasing impurity and decreasing Al2O3.
This material is often used in furnaces, kilns and stoves
because the materials are widely available and relatively
inexpensive.
High alumina refractories

Alumina silicate refractories containing more
than 45 percent alumina are generally termed
as high alumina materials. The alumina
concentration ranges from 45 to 100 percent.
The refractoriness of high alumina refractories
increases with increase in alumina percentage.
The applications of high alumina refractories
include the hearth and shaft of blast furnaces,
ceramic kilns, cement kilns, glass tanks and
crucibles for melting a wide range of metals.
Silica brick
Silica brick (or Dinas) is a refractory that contains at least 93
percent SiO2. The raw material is quality rocks.
Various grades of silica brick have found extensive use in the
iron and steel melting furnaces and the glass industry.
Advantages are
The outstanding property of silica brick is that it does not begin to
soften under high loads until its fusion point is approached. This
behavior contrasts with that of many other refractories, for example
alumina silicate materials, which begin to fuse and creep at
temperatures considerably lower than their fusion points.
High resistance to thermal shock (spalling)
High refractoriness.
Flux and slag resistance
Volume stability
Magnesite
Magnesite refractories are chemically basic materials,
containing at least 85 percent magnesium oxide. They
are made from naturally occurring magnesite (MgCO3).
The properties of magnesite refractories depend on the
concentration of silicate bond at the operating
temperatures. Good quality magnesite usually results
from a CaO-SiO2 ratio of less than two with a minimum
ferrite concentration, particularly if the furnaces lined
with the refractory operate in oxidizing and reducing
conditions.
The slag resistance is very high particularly to lime and
iron rich slags.
Chromite refractories
Two types of chromite refractories are distinguished:
Chrome-magnesite refractories, which usually contain 15-35
percent Cr2O3 and 42-50 percent MgO. They are made in a
wide range of qualities and are used for building the critical
parts of high temperature furnaces. These materials can
withstand corrosive slags and gases and have high
refractoriness.
Magnesite-chromite refractories, which contain at least 60
percent MgO and 8-18 percent Cr2O3. They are suitable for
service at the highest temperatures and for contact with the
most basic slags used in steel melting. Magnesite-chromite
usually has a better spalling resistance than chromemagnesite.
Zirconia refractories
Zirconium dioxide (ZrO2) is a polymorphic material.
It is essential to stabilize it before application as a refractory, which is
achieved by incorporating small quantities of calcium, magnesium and
cerium oxide, etc. Its properties depend mainly on the degree of
stabilization, quantity of stabilizer and quality of the original raw material.
Zirconia refractories have a very high strength at room temperature,
which is maintained up to temperatures as high as 1500 oC. They are
therefore useful as high temperature construction materials in furnaces
and kilns.
The thermal conductivity of zirconium dioxide is much lower than that of
most other refractories and the material is therefore used as a high
temperature insulating refractory.
Zirconia exhibits very low thermal losses and does not react readily with
liquid metals, and is particularly useful for making refractory crucibles and
other vessels for metallurgical purposes. Glass furnaces use zirconia
because it is not easily wetted by molten glasses and does not react easily
with glass.
Oxide refractories (Alumina)

Alumina refractory materials that consist of aluminium
oxide with little traces of impurities are known as pure
alumina.
Alumina is one of the most chemically stable oxides known.
It is mechanically very strong, insoluble in water, super
heated steam, and most inorganic acids and alkalies.
Its properties make it suitable for the shaping of crucibles
for fusing sodium carbonate, sodium hydroxide and sodium
peroxide.
It has a high resistance in oxidizing and reducing
atmosphere. Alumina is extensively used in heat
processing industries. Highly porous alumina is used for
lining furnaces operating up to 1850oC
Monolithics
Monolithic refractories are single piece casts in the shape of equipment,
such as a ladle as shown in the figure. They are rapidly replacing the
conventional type fired refractories in many applications including industrial
furnaces. The main advantages of monolithics are:
Elimination of joints which is an inherent weakness
Faster application method
Special skill for installation not required
Ease of transportation and handling
Better scope to reduce downtime for repairs
Considerable scope to reduce inventory and eliminate special shapes
Heat savings
Better spalling resistance
Greater volume stability
Monolithics are put into place using various methods, such as ramming,
casting, gunniting, spraying, and sand slinging.

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Cement and Refractories

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Cement and refractory's

Cement and Refractory:

Introduction, Types of Portland cement, BIS specification of

Cement Chemical Composition

Functions of the ingredients of cements:

REACTIONS IN THE KILN:

SETTING AND HARDENING OF CEMENT:

ROLE OF CEMENTING MATERIALS

Any material can be described as a refractory, if it can withstand the

High alumina refractories

Oxide refractories (Alumina)

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