CEMENT INDUSTRY

The cement industry requires large amounts of energy in all its forms, being the main component in
the cost of cement manufacturing.

Cement is a basic component in emerging economies; In many countries, from Asia to Eastern
Europe, cement is the unifier of progress, a fundamental element for the construction of buildings
and roads. Which is why 80% of the cement made is used in developing countries. China alone uses
45% of world production and in Ukraine cement manufacturing doubles every four years.

1) PRODUCTS AND PROCESSES

1.1) Cement:
In construction, cement is called a binder, which
when mixed with water and aggregates such as
sand and stone forms a uniform and malleable
paste that, when left undisturbed, can set, forming
a material with stone-like characteristics by
forming an atomic structure based on in crystals.
Its use is very widespread in construction and
civil engineering.

Production process:

STAGE 1: EXTRACTION AND GRINDING OF THE RAW MATERIAL

The raw material for the production of cement ( limestone , clay , sand , iron ore and
gypsum ) is extracted from quarries or mines and, depending on the hardness and
location of the material, certain exploitation systems and equipment are applied. Once
the raw material has been extracted, it is reduced to sizes that can be processed by the
crude mills, which produce a material of great fineness, which is what grinding the raw
material consists of.
STAGE 2: HOMOGENIZATION OF THE RAW MATERIAL
After the limestone and clay is crushed in the quarries themselves and transported to the
processing plant, it is gradually mixed until the appropriate composition is reached
depending on the type of cement to be made.
The ground material must be homogenized to guarantee the effectiveness of the
clinkeration process through constant quality. This procedure is carried out in
homogenization silos.
STAGE 3: OBTAINING THE CLINKER
Once the raw powder is homogenized, it is calcined in ovens that operate at high
temperatures (up to 1450 degrees Celsius) so that its components melt and the chemical
composition of the mixture changes, transforming it into Clinker.

STAGE 4: TRANSFORMATION OF CLINKER INTO CEMENT

 Subsequently, the Clinker is cooled and stored under cover, and then it is taken to the
final grinding, mixing it with gypsum (setting retardant), pozzolana (volcanic material
that contributes to the strength of the cement) and limestone, among other additives, in
quantities which depend on the type of cement you want to obtain. The final result is
cement.

1.2) Quicklime:

Quicklime is characterized by its versatility since it can be used in

almost all industrial processes, whether as a neutralizer, flux, lubricant,
drying agent, cementitious, absorbent, precipitant, disinfectant,
waterproofing and as a raw material.

Quicklime production process at Cementos Pacasmayo:

1. LIMESTONE EXTRACTION
The industrial production process of CAL VIVA PRIME begins in
Tembladera, the Cementos Pacasmayo quarry, where the raw material is
found, limestone, which is extracted through controlled blasting and is
subsequently crushed and classified according to its granulometry for the manufacture of
lime.
2. CALCINATION
Calcination is the application of heat to decompose limestone (CaCO3) which is
“transformed” into quicklime (CaO). Cementos Pacasmayo has 2 horizontal calcination
ovens with a fully controlled and automated process.
3. GRINDING
Grinding is the process of crushing granulated quicklime to reach a granulometry
equivalent to 15 microns or 0.15 mm. Cementos Pacasmayo has two mills with a capacity
equivalent to 9,000 MT/month.
4. DISPATCH AND LOGISTICS
CAL VIVA PRIME is shipped in:
- Cylinders
- 1TM big bags
- Hopper
- 40 Kg bag

5. QA
Its leadership in the industrial market is supported by the guarantee of its products and the
assurance of the quality control system in its production.

1.3) Ready-mixed concrete

The Raw Materials used in the production of concrete are:

Cement, Water, Gravel, Sand and Additives.
 Cement, although it occupies approximately 15% of the mixture, is the most important
material because it is what provides resistance.
Production process:
1. Weighing
2. Mix
3. Discharge or pump

1.4) Dry Mortar

Mortar is a compound of inorganic binders ,
fine aggregates and water, and possible
additives that serve to glue construction
elements such as bricks , stones, concrete
blocks, etc. In addition, it is used to fill the
spaces left between the blocks and for wall
covering.

Productive process:
1. Main raw material silos (aggregates and cement)
2. Additive silos.
3. Material dosing and mixing system.
4. Expedition
5. Supply in Big-bag, sacks or bags.

1.5) Bricks
The brick is a mass of clay fired in the shape of a triangular
parallelepiped, of clay fired to build walls and walls.
Productive process:
1. Raw material extraction
2. Maturation
3. Previous mechanical treatment
4. Processed raw material warehouse
5. Humidification
6. Molded
7. Drying
8. Cooking
9. Storage

2) MACHINES AND EQUIPMENT

The different machines and equipment that are used for the production of the different products
mentioned above are as follows:
 Ovens
 roller presses
 bucket elevators
 Clinker Chillers
 Vertical grinding mills
 cement mills
 cement rotary kiln
 Vertical pre-heater
 Hammer crushers
 Raw materials ball mill
 Ball mill for coal grinding
 Dust filter
 rotary lime kiln
 Press
 Jaw Crushers
 Gyratory Crushers
 Impact Crushers
 Conical Crushers
 Roller crushers
 Computers
 conditioning tower
 Licker
 dust collector
 Disperser and Leveler
 Rotary dryer
 Apron Conveyor Belt
 Chain conveyor
 Hovercraft Transporter
 Fixed packaging machine

3) STRENGTHS AND WEAKNESSES

3.1) Strengths:
The cement industry has many strengths to consider. Cement is literally the block in the
construction sector, it is an essential element. Almost all buildings built are based on
concrete foundations. The cement business is a $10 billion industry, as measured by annual
cement shipments. There is also a strong reputation behind the cement industry. Cement is a
solid material and consumers rarely have complaints about the product. Regional
distribution teams have also made cement widely available to any type of buyer.

3.2) Weaknesses
The cement industry is not without its drawbacks. The cement industry relies on
construction jobs to create a profit. But the cement industry is highly dependent on the
weather. About two-thirds of cement production takes place between May and October.
 Cement manufacturers often use the winter months to produce and stockpile cement to meet
demand. Another weak point is the cost of transportation; The cost of transporting cement
is high and this keeps cement from being profitable over long distances. In other words,
shipping cement costs more than the profit from selling it.
Another weakness is that cement manufacturing is one of the most polluting industries and
also has a negative environmental impact on health since it generates noise pollution, air
pollution, among others.

4) CAPITAL GOODS
Among the capital goods in a cement industry we have:
 Heavy machinery
 Vehicles
 electronic equipment
 Computers
 Machines that intervene in production processes

5) NON-FINAL PRODUCTS

Every industry to produce its products requires raw materials, that is, the material that is
extracted from nature, and a cement company to produce its products such as cement, lime,
concrete, bricks, etc. uses the following raw materials:

For the production of cement:

 Limestone
 Clay
 Sand
 iron ore
 And so
 Water
 Shale
 loam

To make lime:

 Limestone rock, the most important raw material in the production of lime.

For the preparation of concrete:

 Water
 Additives (solid or liquid chemicals)
 Cement
 Aggregates (stones and sand)
 Air
To make the brick:

 Clay (which is composed of iron oxides and other alkaline materials, such as
calcium oxides and magnesium oxides).
 Water
 Among others.