Cement:
Cement sectors in Bangladesh:
40th largest market in the world
Currently capacity is about 20 million tons (MT)
At present , many cement factories are produced cement to fulfil the demand of their customers
Bashundhara Cement Industries Ltd. is one of them
Profile of Bashundhara Cement Factory
Definition of Cement
Raw materials of cement
Types of Portland cement & composition
Production processes
Quality Monitoring
Packaging & Delivery
Environmental Effects of Cement
2. Presented By:
Md. Abdul Aziz Roky
Student ID: 131805
3rd Year , 2nd Term
Chemistry Discipline
Khulna University
01
Course No.: CHEM-3210
3. Discussible Topics…
1. Cement sectors in Bangladesh
2. Profile of Bashundhara Cement Factory
3. Definition of Cement
4. Raw materials of cement
5. Types of Portland cement & composition
6. Production processes
7. Quality Monitoring
8. Packaging & Delivery
9. Environmental Effects of Cement
02
4. 40th largest market in the world
Currently capacity is about 20 million tons (MT)
At present , many cement factories are produced cement
to fulfil the demand of their customers
Bashundhara Cement Industries Ltd. is one of them
Cement sectors in
Bangladesh
03
5. Bashundhara Cement Factory
Fig.: Bashundhara Cement Factory , Mongla , Bagerhat
Established in 1993
Largest Cement Manufacturer in Bangladesh
Two most modern factories at Mongla and Madanganj (Narayanganj)
Production capacity is 5.05 million MT per year
Use VRM technology04 Reference: Bashundhara Cement Factory,Mongla
6. A fine powder obtained by grinding the clinker of a
clay and limestone mixture
Mixture calcined at high temperature by
calcinations
A binder, a substance that sets and hardens
And also can bind other materials together
Cement
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7. Different raw materials :
Limestone
Gypsum
Clinker
Slag
Fly ash
Reference: Wikipedia
Raw Materials
Fig.: Limestone Fig.: Gypsum
Fig.: Fly ashFig.: SlagFig.: Clinker06
8. Types of Portland
Cement
Ordinary Portland Cement (OPC)
Portland Composite Cement (PCC)
Portland Slag Cement (PSC)
Blast Furnace Portland Cement
Only OPC and PCC are manufactured
in Bashundhara cement industry
07
9. Ordinary Portland Cement
(OPC)
Compositions:
Clinker : 95-100%
Gypsum : 0-5%
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Characteristics:
Faster Setting time
Greater earlier & later strength
Reduces Construction time
Applications:
Bridges & Flyovers
Electric Pole
Any type of RCC constructions
10. Compositions:
Clinker : 65-79%
Slag, Fly Ash & Limestone : 21-35%
Gypsum : 0-5%
Portland Composite Cement
(PCC)
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Active ingredients:
Portland clinker
Applications:
Commercial, Industrial & Residential structures
High rise building
Pile, dam & deep foundation
Bridges & flyovers
Marine structures
11. Production Process
In Bashundhara cement industry, there are two types of
mill use for manufacturing cement:
Ball Mill ( BM )
Vertical Roller Mill ( VRM )
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12. Ball Mill ( BM )
Ball mill is a horizontal rotating devices
The ball mill has two warehouses
Ball mill is mainly consisted of :
Hopper
Feeder
Conveyor
Bucket elevator
Powder classifier
Dust collector
Fig.: Ball Mill
11 Reference: Bashundhara Cement Factory,Mongla
14. Vertical Roller Mill ( VRM )
Most advanced technology in cement production
VRM built with two pairs of roller
Each pair of rollers mounted on the same shaft,
rotating at different speeds
Fig.: Vertical Roller Mill
Reference: Bashundhara Cement Factory,Mongla
13
Ball mill is mainly consisted of :
Grinder
Dust collector
Hot air stove
Feeder
Hopper etc.
16. Between BM & VRM Method, which
is Better ?
Suitable grinding bed is easily obtained
High Fineness
Better Particle Size Distribution (PSD)
Faster Setting Time
Less Energy Consumption
Does not release fine particles to the air
Produces less than 85 dB sound while in
production
The grinding process of Ball mill & Vertical Roller Mill differs fundamentally.
The Vertical Roller Mill is better than Ball Mill because the Vertical Roller Mill has
some special criteria:
Fig.: Material & Grinding Movement
15 Reference: www.bashundharacement.com
17. Quality Monitoring
The several monitoring apparatus is :
X – ray Analyser : To test composition of raw materials like
limestone
Fig.: X – ray Analyser
Rapid analysis
High Accurate analysis
Easy qualitative analysis
Fig.: Particle Size Analyser
Particle Size Analyser:
Analyse particle size
16 Reference: Wikipedia and
www.bashundharacement.com
18. Fig.: Curing Tank
Fig.: Moisture Analyser
Curing Tank:
Control concreate testing
Hardening within (45-600) minutes
Moisture Analyser:
Test Moisture Balance
Detect dry
17 Reference: Wikipedia
19. Process Flow Test Parameters Frequency
Raw Materials
Quality Control
Physical Test Minimum 3 Samples per Ship or Vessel
Chemical Test
During unloading period, daily 3~4 nos of all samples is
collected, After Physical Test, one part of each collection is
stored & after 3~4 days, an average is prepared as sample for
Chemical Test.
Production Process
Control & Sampling in
both Ball Mill & VRM
Every Hour
Physical Test Hourly
Chemical Test Hourly
Physical Test Daily
Finished Products
(Packer 1&2)
Chemical Test Minimum 3 nos/Week
ENSURING THE BEST QUALITY
18Reference: www.bashundharacement.com
20. Packaging & Delivery
Bashundhara cement industry is usually
packing cement by using HAVER ROTO-
PACKER® - rotating packing system
Rotating packing machine designed for
packing loose
Fig.: HAVER ROTO-PACKER
After completing packaging process ,
• Prepared for delivery
• By river and road
Fig.: Bashundhara Cement19 Reference: Wikipedia and
www.bashundharacement.com
21. Environmental Effects of Cement
CO2 emissions
Heavy metal emissions in the air
Emissions of airborne pollution in the form
of dust, gases, noise and vibration when
operating machinery
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