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Engineering Chemistry: Cement

The document provides information on cement engineering chemistry. It discusses the composition and manufacturing process of Portland cement. Raw materials like limestone and clay are crushed, mixed, burned in a rotary kiln to form clinkers, and then ground with gypsum. The hydration process causes the cement to harden through reactions that form compounds like tobermorite gel and calcium hydroxide. Plaster of Paris is also discussed, noting that it is formed by heating gypsum and sets when mixed with water through re-forming gypsum.

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268 views

Engineering Chemistry: Cement

The document provides information on cement engineering chemistry. It discusses the composition and manufacturing process of Portland cement. Raw materials like limestone and clay are crushed, mixed, burned in a rotary kiln to form clinkers, and then ground with gypsum. The hydration process causes the cement to harden through reactions that form compounds like tobermorite gel and calcium hydroxide. Plaster of Paris is also discussed, noting that it is formed by heating gypsum and sets when mixed with water through re-forming gypsum.

Uploaded by

aryan jain
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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LECTURE NOTES

ON
CEMENT
ENGINEERING CHEMISTRY
B.Tech 1st year

By
Dr. Ranvijay Pratap Singh
Assistant Professor

Faculty of Engineering & Technology


University of Lucknow
Cement

Concrete is widely used as a non-metallic material in construction of buildings, dams,


bridges, high ways etc. In concrete, cement is a building material that possesses cohesive
and adhesive properties and capable of bonding with stones, bricks, building blocks etc.

Portland cement
The name Portland cement is used because this powder on mixing with water gives a
hard, stone like mass which resembles Portland rock (Leeds city UK). It is widely used as
a non-metallic material in construction. It is a composition of calcium silicates, calcium
aluminates and small amount of gypsum.

Composition of Portland cement:-

A sample of Portland cement contain following composition:

i) Calcium Oxide or lime (CaO) : 60-70%


ii) Silica (SiO2) : 20-24%
iii) Alumina (Al2O3) : 5-7.5%
iv) Magnesia (MgO) : 2-3%
v) Ferric Oxide (Fe2O3) : 1-2.5%
vi) Sulphur trioxide (SO3) : 1-1.5%
vii) Sulphur Oxide (Na2O) : 1%
viii) Potassium Oxide (K2O) : 1%

Manufacture of Portland Cement:

The steps involve in the manufacturing process are as follows:

i) Crushing
ii) Mixing
iii) Burning
iv) Grinding
i) Crushing:

In this step raw material of Portland cement lime, Silica, Alumina, Magnesia, Ferric
Oxide, Sulphur trioxide, Sulphur Oxide, Potassium Oxide are crushed and ground to
fine powder through ball mill.

ii) Mixing:

In this step raw ingredients or fine powder are mixed in presence (wet process) or
absence (dry process) of water to form slurry, then slurry is stored in storage tank.

iii) Burning:

The burning process is done in Rotary Kiln. The Rotary Kiln possesses three different
temperature zone like drying zone, calcinations zone and Clinkering zone.

Rotary Kiln

Drying zone:

It is the upper part of Rotary Kiln having temperature around 250 oC where the water
from the slurry evaporates.

Calcinations zone:

It is middle portion of Rotary Kiln where temperature ranges from 700 o-1200oC. in
this region limestone undergoes decomposition to form quick lime and carbon dioxide
(escape out).
Clinkering zone:

It is the lower part of Rotary Kiln where quick lime with clay to form calcium silicate,
aluminates and ferrite.

2CaO + SiO2 Ca2SiO4 (Ca2S)


Dicalcium silicate
3CaO + SiO2 Ca3SiO5 (Ca3S)
Tricalcium silicate
3CaO + Al2O3 Ca3Al2O6 (Ca3A)
Tricalcium aluminate
4CaO + Al2O3 + Fe2O3 4CaO.Al2O3.Fe2O3 (Ca4AF)
Tetracalcium alumino ferrite

The aluminates and silicates are mixed with CaO to form stone like structure, known
as clinkers.

iv) Grinding:

The cooled clinkers are ground to a fine powder in ball mill. At this time 2-3% of
gypsum is added to prevent the early setting of cement.

Setting and hardening of cement

When water mixed with Cement, form a plastic paste. The past is subjected to
hydration and gel and finally crystalline products are formed.

3CaO.Al2O3 + 6H2O → 3CaO.Al2O3.6H2O + Heat

2(2CaO.SiO2) + 4H2O → 3CaO.2SiO2.6H2O + Ca(OH)2 + Heat

4CaO.Al2O3.Fe2O3+7H2O → Ca3Al2O6.6H2O + CaO.Fe2O3.H2O + Heat

Tobermonite gel, calcium hydroxide crystallization and hydrated tricalcium aluminate


are responsible for final setting and hardening of cement.

2(2 CaO.SiO2) + 6H2O 3CaO.2SiO2.3H2O + 3Ca(OH)2 + Heat


3CaO.Al2O3 + 6H2O → 3CaO.Al2O3.6H2O + Heat

Role of gypsum:

2-3% of gypsum is added to prevent the early setting of cement.


3CaO.Al2O3 + xCaSO4.2H2O 3CaO.Al2O3. xCaSO4.2H2O
Tricalcium aluminate gypsum Tricalciumsulphoaluminate
Plaster of Paris (POP)

Plaster of Paris is Calcium sulphate hemihydrates having molecular formula 2CaSO4.H2O or


CaSO4.1/2H2O.

Preparation:

When gypsum is heated about at 150oC then plaster of Paris is formed.

CaSO4.2H2O 150o-160o 2CaSO4.H2O + 3H2O


Gypsum plaster of Paris

Properties:
i) When plaster of Paris reacts with water, large amount of heat is release. It absorbed
water and convert into gypsum. This process is known as setting of plaster of Paris.

2CaSO4.H2O + 3H2O CaSO4.2H2O


Plaster of Paris Gypsum
ii) Plaster of Paris is a fine white powder. When heated at 200oC it first convert into
gamma- CaSO4 and on further heating at 600oC it changes into beta-CaSO4.

When beta-CaSO4 is heated about 1100oC, then it converted into quick lime (CaO) and
SO3. The quick lime is used in formation of cement.

Uses of Plaster of Paris:

i) It is used in making casting and in surgical bandage.


ii) Used in making plaster wall and for making plaster boards
iii) Used in making statue, toy, models etc.
iv) Used in formation of gypsum and cement.
v) Used in the formation of calcium sulphate.

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