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CEMENT INDUSTRY
Kelompok 5Maya Monica D (1105821)
Miftahul Jannah (1100545)
Ratnasari (1105339)
Siti Fatimah S (0900451)
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TABLE OF CONTENT
History of Cement
Types of Cement
Cement Making Process
Impact of Cement Industry
Definition of Cement
Prevention
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HISTORY OF CEMENT
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Cement was first used by Egypt in pyramid
building process.
Cement which made by Egypt is gypsumcalcinations, then Roman make cement
from lime stone calcinations and Greek
make it from volcanic soil.
History of Cement
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DEFINITION OF CEMENT
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Cement comes from word
Caementum which means
a substance which has thefunction as an adhesive
between two or more
ingredients become a part
of a cohesive or adhesivematerial between the rocks
of building construction
Definition of Cement
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TYPES OF CEMENT
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Types of Cement
No. SNI Nama
SNI 15-0129-2004 Semen portland putih
SNI 15-0302-2004 Semen portland pozolan / Portland Pozzolan
Cement (PPC)
SNI 15-2049-2004 Semen portland / Ordinary Portland Cement
(OPC)SNI 15-3500-2004 Semen portland campur
SNI 15-3758-2004 Semen masonry
SNI 15-7064-2004 Semen portland komposit
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Cement
Making
Process
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1. Limestone
2. Clay
Materials of Cement Making
Process
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3. Iron sand
4. Silica
Material of Cement Making Process
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How Cement is Made
Extracting Raw Materials Crushing and Transportation
Raw Material Preparation I: Storage and Homogenisation
Raw Material Preparation II: Drying and Raw Grinding
Burning
Cement Grinding
Loading and Shipping
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Extracting raw materials
Crushing and transportation
The most important rawmaterials for makingcement are limestone,silica, clay and iron sand.
These are extracted fromquarries by blasting or byripping using heavymachinery. Wheelloaders and dumpertrucks transport the raw
materials to the crushinginstallations. There therock is broken down toroughly the size used inroad metalling.
1.
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Raw material preparation I:
Storage and homogenisation
The crushed materialis transported into theraw material storage
of the cement plant byconveyor-belts,cableways or railwaysand also inexceptional caseswith trucks. Oncethere it is stored inblending beds andhomogenised.
2.
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Raw material preparation II:
Drying and raw grinding
The desired raw mix ofcrushed raw materialand the additionalcomponents required for
the type of cement, e.g.silica sand and iron ore,is prepared usingmetering devices. Rollergrinding mills and ballmills grind the mixture to
a fine powder at thesame time as drying it,before it is conveyed tothe raw meal silos forfurther homogenisation.
3.
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Burning
The burning of the rawmeal at approx. 1,450Cis carried out in Lepol orpreheater kilns that work
by varying methods, themain difference being inthe preparation andpreheating of the kilnfeed. By chemicalconversion, a process
known as sintering, anew product is formed:clinker.
4.
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The making of clinker is based on this
reactions:
+ + +
C3S C2S C3A C4AF
Reaction on Cement Making
Process
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Those reactions have six steps, they are:
1. Water Evaporation
This process working at temperature 100 - 200 oC.
2. Extrication of Absorban Water
This process working at temperature 100400 oC.
3. Decomposition of Clay
The product from this process is Al2O3.2SiO2,working at
temperature 400 - 750 oC. This is the reaction:
Al4(OH)8.Si4O10 2( Al2O3.2SiO2 ) + 4 H2O
Reaction on Cement Making
Process
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4. Decomposition of Metakaolinit
The product from this process are Al2O3 and SiO2,
working at temperature 600 - 900 oC. This is the reaction:
Al2O3.2SiO2 Al2O3. + 2SiO2
5. Decomposition of Carbonat
The product are C3S and C3A, working at
temperature 600 - 1000 oC. This is the reaction:
CaCO3 CaO + CO2
3CaO + 2SiO2 +Al2O3 2( CaO .SiO2) +
CaO.Al2O3
Reaction on Cement Making
Process
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6. Reaction of Solid Phase
This reaction working at temperature 800 - 1300 oC,
and the product is the main components in clinker,
they are C3A, C2S dan C4AF, this is the reaction:
CaO.Al2O3+ 2CaO 3CaO.Al2O3
CaO.Al2O3 + 3CaO + Fe2O3 4CaO.Al2O3.Fe2O3
CaO .SiO2 + CaO 2CaO .SiO2
Reaction on Cement Making
Process
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Tricalcium silicate (C3S). Hydrates and hardens rapidly and is largelyresponsible for initial set and early strength. Portland cements with higher
percentages of C3S will exhibit higher early strength.
Tricalcium aluminate (C3A). Hydrates and hardens the quickest. Liberates a
large amount of heat almost immediately and contributes somewhat to early
strength. Gypsum is added to Portland cement to retard C3A hydration.
Without gypsum, C3A hydration would cause Portland cement to set almost
immediately after adding water.
Dicalcium silicate (C2S). Hydrates and hardens slowly and is largely
responsible for strength increases beyond one week.
Tetracalcium aluminoferrite (C4AF). Hydrates rapidly but contributes very little
to strength. Its use allows lower kiln temperatures in Portland cement
manufacturing. Most Portland cement color effects are due to C4AF.
About C3S, C3A, C2S and C4AF
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Cement grinding
After burning, the clinkeris cooled down andstored in clinker silos.
From there the clinker isconveyed to ball mills orroller presses, in which itis ground down to veryfine cement, with theaddition of gypsum and
anhydrite, as well asother additives,depending on the use towhich the cement is tobe put.
5.
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Loading and shipping
The finished cement isstored in separate silos,depending on type andstrength class. From thereit is mainly loaded in bulk
form from terminals ontorail or road vehicles as wellas onto ships. Only a smallproportion of the cementreaches the customer in theform of bags that have
been filled by rotarypackers and stacked byautomatic palletisingsystems.
6.
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Reactions of Hydration
2C3S + 6H = C3S2H3 + 3Ca(OH)2
(100 + 24 = 75 + 49 ) 2 C2S + 4H = C3S2H3 + Ca(OH)2
(100 + 21 = 99 + 22 )
C3A + 6H = C3AH6 [C3A + CaSO4 . 2H2O = 3Cao. Al2O3.
3CaSO4. 31H2O]
Calcium Sulfoaluminate
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Cement Manufacturing
Details:
1. Quarries (Limestone, Clay)
2. Drill
3. Dumper
4. Crushing
5. Prehomogenisation6. Grinding
7. Preheating
8. Filter
9. Rotary Kiln
10. Cooler
11. Clinker Storage12. Additions
13. Cement Grinding
14. Cement Silos, Dispatching
15. Grinding
16. Homogenisation
17. Filter
18. Kiln
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IMPACT OF CEMENT
INDUSTRY
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1. Declining Quality of Land
The decline of soil
fertility can be caused
by clay mining
process.
Clay is used as a
raw material for
cement industry.
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2. Declining Quality of Water
Declining quality of
water due to
wastewater fromcement industry are
dumped into the river
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3. Cause Air Pollution
Dust and smoke
that generated
during combustion
process and during
procurement of raw
materials can
cause respiratorysystem disorders
4 I i th A t f
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4. Increasing the Amount of
Greenhouse Gases
Gases that produced
from combustion of
petroleum fuels and coal
are CO2, CO andanother gases.
Increasing the amount
of Carbon dioxide in theair can cause increasing
of earth temperature.
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5. Noise Pollution
Noise pollution is a disruption in the
environment caused by the sound or
noise from industrial activities that cancause unrest for society.
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6. decreasing diversity of flora, change in
vegetation pattern and endemic species .
7. Decreasing diversity of flora, change invegetation pattern and endemic species
decreasing diversity of fauna (birds,
endangered animals). Changes in aquaticecosystems and ground ecosystems as a
place to live animals.
Continued
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PREVENTION
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PREVENTION
Implementing blended cementproduction
that can decrease CO2emission.
Replacing some of materials in cementmanufacture with more ecofriendly
materials.
Wate disposal industries that doesntdamage the environment.
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http://people.ce.gatech.edu/~kk92/scmkek.
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