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

1. Cement

2. Presented By:
Md. Abdul Aziz Roky
Student ID: 131805
3rd Year , 2nd Term
Chemistry Discipline
Khulna University
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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
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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
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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
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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

13. Flow Diagram of Ball Mill
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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
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 Ball mill is mainly consisted of :
 Grinder
 Dust collector
 Hot air stove
 Feeder
 Hopper etc.

15. Flow Diagram of Vertical Roller Mill

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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22. THANKS
TO ALL
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