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David, Kimberly Joyce Illuscupides, Dianne Mallari, Rose Marie Padilla, Raisa Sih, Allen James

The Philippine cement industry is labor intensive and utilizes the country's abundant limestone reserves estimated at 4 billion metric tons. Cement is used widely in construction and is made through a process involving grinding limestone and clay, burning the mixture in a kiln to form clinker, and then grinding the clinker. The industry contributes to the economy through jobs and exports. Holcim is a major cement producer in the Philippines. Cement production requires significant energy and emits large amounts of carbon dioxide, though kilns can safely burn hazardous waste and efforts are underway to improve energy efficiency.

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159 views34 pages

David, Kimberly Joyce Illuscupides, Dianne Mallari, Rose Marie Padilla, Raisa Sih, Allen James

The Philippine cement industry is labor intensive and utilizes the country's abundant limestone reserves estimated at 4 billion metric tons. Cement is used widely in construction and is made through a process involving grinding limestone and clay, burning the mixture in a kiln to form clinker, and then grinding the clinker. The industry contributes to the economy through jobs and exports. Holcim is a major cement producer in the Philippines. Cement production requires significant energy and emits large amounts of carbon dioxide, though kilns can safely burn hazardous waste and efforts are underway to improve energy efficiency.

Uploaded by

xpthatsme
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© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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David, Kimberly Joyce

Illuscupides, Dianne
Mallari, Rose Marie
Padilla, Raisa
Sih, Allen James
Philippine Cement Industry
• Labor Intensive industry (Construction Industry)

• The Philippines has an abundant supply of cement raw materials


such as limestone, shale/sandstone, siliceous sand, lime, diorite,
calcite, and probably gypsum.

• The availability of limestone for cement production, per record of


the Mines and Geosciences Bureau (MGB) is estimated in l992 at
around 4 billion metric tons

• The expected life is around 260 years

(source : www.boi.gov.ph , 2009)


What is Cement?
A binding agent that holds sand and other aggregates
together in a hard, stone-like mass.

A building material made by grinding calcined limestone and


clay to a fine powder, which can be mixed with water and
poured to set as a solid mass or used as an ingredient in
making mortar or concrete.
Where is cement used?
 Cement is used in civil engineering works

Cement is used in the construction of structures like


bridges, buildings, etc.

Cement is a binding material in concrete


Contribution to the economy
Employment

Growth rate-export

Creates opportunity
Cost and Types of Cement

A bag of cement cost


Php 205-220

(source : www.magkano.com2010)
Types of Cement
1. Gray Portland cement
 Is a high-quality, cost-effective building material

 It is comprised of at least 95% clinker and 0-5% of a minor


component (usually calcium sulfate)

 It meets all applicable chemical and physical requirements


and is used in virtually all forms of construction, from
hospitals and homes to schools, tunnels, and airports

 Manufactured with limestone, kaolin and gypsum.

(source : Cemex, 2010)


Types of Cement
2. Masonry or Mortar

• Is a Portland cement that we mix with finely ground inert


matter (limestone)

• This type of cement is used for multiple purposes,


including concrete blocks, templates, road surfaces,
finishes, plasters, and pasting over baked red brick

(source : Cemex, 2010)


Types of Cement
3. Pozzolana Portland

Is a variety of cement made by grinding clinker,


gypsum, and natural pozzolana —a raw material of
volcanic rocks and ash

 Consumers use pozzolana Portland cement for all kinds


of construction; however, its optimum use is for
construction projects that are in constant contact with
water or are built in humid or saltpeter ground

(source : Cemex, 2010)


Types of Cement
4. Oil-well cement

• Is a specially designed variety of


hydraulic cement produced with gray
Portland clinker
• It usually forges slowly and is manageable at high
temperatures and pressures
• Produced in classes from A to H and J, our oil-well
cement is applicable for each depth, chemical
aggression, or pressure
(source : Cemex, 2010)
Production of Cement
The cement industry is said to be an energy-intensive industry
together with steel, paper and petrochemical industries.

The percentage of energy cost in (Portland) cement production


cost is 20 to 30%. If the energy cost is reduced, the
manufacturing cost is lowered, resulting in increasing the
company’s profits.

(source: unido.org, 2009)


Annual
production
of Cement in
billion of
metric tons

Source: USGS 2006 report (PDF) and the USGS 2008 report (PDF).
Production of Cement
A cement production plant consists of the following
three processes:

1. Raw material process 


2. Clinker burning process
3. Finish grinding process
Production of Cement
Raw Material Process
• Requires a source of calcium (usually limestone) and a
source of silicon (such as clay or sand).
• Small amounts of bauxite and iron ore are added to
provide specific properties.

Wet process
Since raw materials can be homogenized and the
mixing ratio can be corrected after grinding, this process is
relatively simple.
• The first important reaction to occur is the calcining of limestone
(calcium carbonate) into lime (calcium oxide) and carbon dioxide,
which occurs in the lower-temperature portions of the kiln—up to
about 1650°F (900°C).

• The second reaction is the bonding of calcium oxide and silicates


to form dicalcium and tricalcium silicates. Small amounts of
tricalcium aluminate and tetracalcium aluminoferrite are also
formed.
Clinker Burning Process: Wet Process
• Wet process is a straight cylindrical type kiln having a
length of about 40 times of the shell’s inner diameter,
rotated slowly; raw material is slurry containing 38 – 40%
water and fed from the upper end of the kiln, while fuel is
blown in from the lower end of the kiln

• As the new compounds cool, they solidify into solid pellet


form called clinker. The clinker is then ground to a fine
powder, a small amount of gypsum is added,
Fresh air

Raw material Pellet

Kiln

In the shaft kiln, fuel is added in the pelletizing process. All processes
of drying, sintering and cooling are effected in the vertical movable bed. This
concept had been conducted before the rotary kiln was spread and, recently, as
shown in the figure, the shaft kiln with a continuous discharging function
installed at the furnace bottom is mainly used in India and China.
Dry Process

In the dry process, there are the dry long kiln, the short kiln
with boiler,
Finish Grinding Process
• Divided into: Open circuit and closed circuit
grinding system

• Tube mill or ball mill


Product
In the open circuit mill, the mill shell has a length of
about 4 to 5 times of its diameter to obtain a prescribed
fineness, and the shell outer wall is sprayed with water to
prevent the temperature of the product in the mill from rising.
Marketing
• Holcim established its presence in the Philippine cement industry in 1974

 Holcim is one of the world's leading suppliers of cement and aggregates

 It holds interests in more than 70 countries on all continents. Holcim Philippines is a


member of the Holcim Group. It is involved in the manufacture, sale and distribution
of cement and ready mix concrete

 It is committed to managing resources responsibly and working with communities to


develop sustainable options for their future.

(source:http://www.holcim.ph/PH/EN/id/1610654938/mod/2/page/editorial.html)
Marketing
The sites of existing and proposed cement plants are Regions 1, 3, 4,
5, 6, 7, 8, 9, 10, 11, and 12

The project must locate in an area where there is available power,


and accessibility to the source of raw materials and port facility

The abundance of raw materials, availability of skilled manpower


and the existence of a growing domestic market make the
Philippines a suitable site to base a cement manufacturing operation.

(source:http://www.holcim.ph/PH/EN/id/1610654938/mod/2/page/editorial.html)
Environmental Problems
Energy consumption
• is the biggest environmental concern with cement and
concrete production

• According to the Worldwatch Institute, cement production is


approximately ten times as energy intensive as
our economy in general. In some Third World
countries, cement production accounts for as
much as two-thirds of total energy use

Source: Feature from Environmental Building News


Environmental Problems
BUT, the very high temperatures used in a cement kiln have
at least one advantage: the potential for burning hazardous
waste as a fuel.

• Waste fuels that can be used in cement kilns include used motor
oil, spent solvents, printing inks, paint residues, cleaning fluids,
and scrap tires.
• It is safe because the extremely high temperatures
result in very complete combustion with very low
pollution emissions.
• Safest method of disposal

Source: Feature from Environmental Building News


Environmental Problems
CO2 Emissions

2 different sources of carbon dioxide emissions during cement


production:

• Combustion of fossil fuels to operate the rotary kiln is the


largest source: approximately 3⁄ 4 tons of CO 2 per ton of cement

• Chemical process of calcining limestone into lime in the cement


kiln

Source: Feature from Environmental Building News


Environmental Problems
CO2 Emissions

• In US, cement production accounts for approximately 100


million tons of CO 2 emissions, or just under 2%
of our total human activities

• Worldwide, cement production now accounts for


more than 1.6 billion tons of CO 2—over 8%
of total CO 2 emissions from all human activities

Source: Feature from Environmental Building News


Environmental Problems
Reduction CO2 Emissions

• The most significant way to reduce CO 2 emissions is


improving the energy efficiency of the cement kiln
operation

• Switching to lower-CO 2 fuels such as natural gas and


agricultural waste (peanut hull)

• Substitution of fly ash for some of the cement in concrete


can have a very large effect
Source: Feature from Environmental Building News
Environmental Problems
Water Pollution
• According to Richard Morris of the National Ready Mix Concrete
Association, “wash-out water” with high pH is the number one
environmental issue for the ready mix concrete industry

• As long as the pH of this wastewater is lower than 12.5, it is not


considered a hazardous material by U.S. law

Source: Feature from Environmental Building News


Health Problems
Workers in the concrete industry
who fail to wear the proper
protective clothing

• Protect your skin from the


high alkalinity
LET’S GREEN IT!

GREEN IT!

GREEN IT!

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