IMR025 - The Portland cement industry in Ontario

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ONTARIO
DEPARTMENT OF MINES
THE PORTLAND CEMENT INDUSTRY IN ONTARIO
PROPERTY OF ONTARIO DEPT. OF MINES
GEOLOGICAL BRANCH
By
D. F. HEWITT
INDUSTRIAL MINERAL REPORT NO. 25
1968
Crown copyrights reserved.
This book may not be reproduced, in whole or
in part, without the permission of the Ontario Department of Mines
Publications of the Ontario Department of Mines
and pricelists
are obtainable through the
Publications Office, Ontario Department of Mines
Parliament Buildings, Queen's Park,
Toronto, Ontario, Canada.
Orders for publications should be accompanied by cheque, or money order,
payable in Canadian funds to Treasurer of Ontario.
Stamps are not acceptable.
TABLE OF CONTENTS
Page
Introduction ..........................................
l
Production of Portland Cement .........................
2
Uses of Portland Cement ...............................
4
Cement Raw Materials ..................................
5
History of Cement Production in Ontario ...............
8
Bibliography ..........................................
17
TABLES
Page
1.
Portland Cement Producers in Ontario, 1967 ........
l
2.
Production of Portland Cement in Ontario,
1950 to 1966 ...................................
3
Consumption of Raw Materials used in Portland
Cement in Ontario in 1966 ......................
6
Natural Hydraulic Cement Producers in Ontario,
1841-1907 ......................................
10
3.
4.
5.
6.
Marl-Using Portland Cement Producers in Ontario,
1886-1919 ....................................
Limestone-Using Portland Cement Producers in
Ontario, 1905-1967 .............................
- iii -
12,13
15
- l The Portland Cement Industry in Ontario
By
D. F. Hewitt1
There has been a large expansion of the portland cement
plant capacity in Ontario between 1950 and 1967.
In 1950
there were 3 cement plants in operation in Ontario, with 5
kilns having a total rated capacity of about 1,090,000 tons per
year.
In 1967 there were 6 cement plants with 16 kilns
having a total rated capacity of about 3,918,750 tons per
year.
(1)
These plants are listed in (1).
Portland Cement Producers in Ontario, 1967.
Company
Location
No.
Approx. Annual
Kilns Capacity in tons
Canada Cement Company
Belleville
3
770,000
Canada Cement Company
Port Colborne
l
210,000
Canada Cement Company
Woodstock
2
595,000
Lake Ontario Cement Company
Picton
3
900,000
St. Lawrence Cement Company Clarkson
2
700,000
St. Marys Cement Company
St. Marys
5
743,750
Total
16
3,918,750
^ Senior Geologist, Ontario Department of Mines, Toronto.
Manuscript received by the Director, Geological Branch,
7 Dec. 1967.
- 2 -
A new kiln is being installed at the Clarkson plant of
St. Lawrence Cement Company which should be in operation in
1968.
This will increase the plant capacity to approximately
1,750,000 tons per year and make it the largest cement plant
in Canada.
Canada Cement Company has announced plans for a
new kiln at their Woodstock plant.
In 1950 the three portland cement plants in operation
were St. Marys Cement Company at St. Marys, and the Port
Colborne and Belleville plants of Canada Cement Company.
Since
World War II the St. Marys Cement Company plant has been
expanded to 5 kilns, while the Belleville plant of Canada
Cement Company has been expanded to 3 kilns.
In 1956 and 1957
new plants were opened by St. Lawrence Cement Company at
Clarkson, and Canada Cement Company at Woodstock.
In 1958
production began at the new plant of Lake Ontario Cement
Company at Picton.
In 1965 this plant was expanded to 3 kilns
and is at present the largest cement plant in Ontario.
All the cement plants in Ontario with the exception of
Lake Ontario Cement Company at Picton are wet-process plants.
The kilns are fired with powdered coal or gas.
The plants are
described by Hewitt (1960, 1964).
Production of Portland Cement
The production of portland cement in Ontario from 1950 to
1966 is given in (2).
- 3 (2)
Production of Portland Cement in Ontario, 1950 to 1966.
Year
Tonnage
Value in $
1950
930,000
10,953,896
1951
950,000
12,494,677
1952
975,000
14,142,060
1953
1,228,000
18,497,744
1954
1,260,000
18,958,173
1955
1,359,000
20,309,648
1956
1,447,000
21,455,019
1957
2,184,000
33,516,000
1958
2,400,158
35,195,552
1959
2,386,334
31,731,767
1960
2,007,044
30,699,800
1961
2,226,923
35,671,569
1962
2,510,783
38,704,090
1963
2,552,665
39,551,719
1964
3,043,771
46,804,126
1965
3,145,873
50,055,554
1966
3,242,591
52,680,630
In 1966 the portland cement industry in Ontario was
operating at 83 percent of rated capacity.
- 4 Uses of Portland Cement
One of the major users of portland cement in Ontario in
the 1950 f s was the Hydro Electric Power Commission of Ontario
in its extensive hydro-electric power developments.
In twelve
power development projects completed by Ontario Hydro between
1950 and 1958, including the Robert H. Saunders power station
and dam on the St. Lawrence seaway, the Sir Adam Beck No. 2
generating station at Niagara Falls, and the Des Joachim power
plant and dam on the Ottawa River, over 16,000,000 barrels of
portland cement were used, amounting to about 23 percent of
the total Ontario production during the period.
The completion
of most of this hydro-electric expansion program releases more
cement for other markets.
The uses of portland cement have
been recently given by V.C. Hamilton of Canada Cement Company
in the May 1967 issue of Canadian Pit and Quarry as follows:
Uses of Portland Cement
Residential construction
2070
Non residential building
3070
Highways and streets
Power facilities
Subways, bridges and overpasses
Miscellaneous uses
10-1270
8-1070
1570
15-2070
- 5 Among the miscellaneous uses for portland cement is cement
stabilization of hydraulic mine tailings backfill which was
pioneered in Ontario by Inco and Falconbridge Nickel in
co-operation with Canada Cement Company in 1960.
There is an
increasing trend towards the use of cement for soil stabilization
for road bases.
V.C. Hamilton points out that a trend toward vertical
integration of cement companies and their markets began in
the late fifties.
He states that the cement industry in
Canada is far more vertically integrated than a few years ago
and in fact most of the large ready mix companies in Canada
are either directly controlled or indirectly connected with
cement companies.
The primary purpose of forward vertical
integration by cement manufacturers has been to secure
captive customers and thus protect market outlets for their
products.
Cement Raw Materials
Consumption of raw materials used in the manufacture of
portland cement in Ontario in 1966 is given in (3).
- 6 (3)
Consumption of Raw Materials used in Portland Cement in
Ontario in 1966.
Commodity
Tons
Limestone
4,283,727
Gypsum
150,081
Clay
822,369
Shale
47,136
Iron oxide
14,564
Sand
97,935
Limestone contains the lime necessary for portland cement.
Shale, clay or sand furnish the alumina and silica required.
Silica and lime together form the cementitious constituents,
tricalcium silicate (C3S)1 and dicalcium silicate (C2S).
Alumina
forms tricalcium aluminate (C3A) which causes the high heat of
hydration and contributes to early strength of concrete.
Alumina
acts as a flux, lowering the kiln cement clinker formation
temperature.
Iron oxide in the form of hematite or mill scale
or iron sulphide (pyrite) is added to produce tetracalcium
aluminoferrite (C4AF).
Iron oxide further lowers the reaction
temperature and lowers the heat of hydration in concrete.
Gypsum is added during grinding of the cement clinker in
the finish grinding process to act as a set regulator in the
cement in the proportion of about l to 6 percent.
Three to
five percent MgO can be held in solid solution in the glassy
phase of the clinker and in chemical composition.
If the MgO
crystallizes out in the clinker as periclase, due to improper
cooling, this is slow to hydrate and causes expansion of the
concrete.
Symbol used by Portland Cement Industry.
- 7 Excessive alkaline oxides, Na20 and K20, are deleterious
as they contribute to the reaction of concrete with such aggregates
as opal and chert, decreasing the resistance of concrete to
freezing and thawing, and the water soluble portion contributes
to concrete staining and masonry efflorescence.
The chemical requirements for the various types of portland
cement vary, but in general the limestone chosen should contain
less than 2.5 percent magnesia and preferably less than 2 percent
magnesia.
Silica should not exceed about 13 percent, and alumina
should not exceed about 3.7 percent.
The types of portland cement include normal portland
cement for use in general construction; cement for general
concrete construction exposed to moderate sulphate reaction and
where moderate heat of hydration is required; high early strength
cement; low heat cement; concrete products cement; sulphateresisting cement; oil well cement; and masonry cement.
Special properties are obtained by increasing or decreasing
one or another of the cement compounds in the clinker.
For
high early strength the C^S/02^ ratio is increased due to the
capacity of C^S to hydrate and set rapidly.
For lower heats of
hydration in massive concrete structures the percentage of 038
is decreased and more important the C3A is lowered.
Resistance
to sulphate waters increases with a decrease in C3A content.
Fineness of cement has great effect on early strength and heat
evolution during setting due to the increased hydration rate.
- 8 -
Typical analyses of raw mix for type cements is given by
Taggart (1947, 3A-17):
Percentages
ASTM
No.l
High
Earl;
Moderate
Heat
Low
Heat
Sulphate
Resistant
Si02
14.1
13.3
14.6
16.5
16.5
A1203
4.2
4.0
3.2
2.5
2.3
F6203
1.8
1.8
2.3
2.5
2.2
CaO
41.5
42.8
41.4
41.0
41.2
MgO
2.4
1.8
2.5
2.0
2.3
36.0
36.3
36.0
35.5
35.5
Ignition loss
Calculation of the mix is based on use of empirical formulae.
History of Cement Production in Ontario^
The first cement manufactured in Ontario was natural
hydraulic cement made from "cement rock" composed of lime,
magnesia and shale.
Production probably began in the 1840 f s
at Thorold at the quarry of John Battle opened in 1841 and
later called the Thorold Hydraulic Cement Works.
This works
closed in 1891, and operated under the name "Estate of John
Battle" until 1907.
There were five natural hydraulic cement
lAfter A.M. Blair (1965, p. 48-54, 213-217)
- 9 producers in Ontario.
In 1880 Rathbun and Company began
operations at Strathcona (then Napanee Mills) and operated
until 1897.
Between 1881 and 1891 the Toronto Lime Company
began production of natural hydraulic cement at Limehouse and
continued production until 1907.
Between 1881 and 1891 the
Queenston Cement Works of Isaac Usher 6e Sons began production
of natural hydraulic cement at Queenston and continued until
1907.
In 1894 F. Schwendiman began production of natural
hydraulic cement in Barton township near Hamilton and
continued until 1907.
In all there were five producers of
natural hydraulic cement in Ontario in the period from 1841 to
1907.
The list of natural hydraulic cement producers in Ontario
from 1841 to 1907 is given in (4).
- 10
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- 11 In 1824 Joseph Aspdin of Leeds, a stonemason, patented
the invention of portland cement.
The manufacture of portland
cement was begun in Ontario using marl as the essential raw
material in 1886 by Rathbun and Company at Strathcona.
During
the period when marl-using portland cement plants flourished
in Ontario, between 1886 and 1919, there were 14 plants active.
A list of the marl-using portland cement plants in Ontario,
after Blair (1965, p. 214-215), is given in (5).
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- 14 In 1905 the first lime s t one-us ing portland cement plant
was built in Ontario by the Belleville Portland Cement Company
at Point Anne near Belleville.
Table (6) lists the limestone-
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p. 216).
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- 16 The competition in the cement industry in Canada in 1909
caused a merger of a number of the cement companies to form
the Canada Cement Company.
The companies in Ontario merging
in 1909 to form the Canada Cement Company were four marlusing plants:
The Owen Sound Portland Cement Company at
Shallow Lake, the Canadian Portland Cement Company at
Marlbank, the Canadian Portland Cement Company at Strathcona
and the Lakefield Portland Cement Company at Lakefield; and
three limestone using cement plants:
The Belleville Portland
Cement Company at Point Anne, the Lehigh Portland Cement
Company at Point Anne, and the Canadian Portland Cement Company
at Port Colborne.
In addition the merger included two Quebec
plants at Hull and Montreal.
plants were closed by 1914.
The four Ontario marl-us ing
The Lakefield plant was converted
to a limestone base in 1927 and operated until 1933.
A good description of the cement industry of Ontario in
1905 is given by Gillespie (1905).
- 17 Bibliography
Blair, A.M.
1965:
Surface Extraction of Non-Metallic Minerals in
Ontario southwest of the Frontenac Axis; unpublished
Ph.D. Thesis, University of Illinois.
Gillespie, P
1905:
Cement Industry of Ontario, Ont. Bureau Mines,
Vol. XIV, p. 118-183.
Hamilton, V.C.
1967:
Cement in the Present; Canadian Pit and Quarry,
May, p. 32-35.
Hewitt, D.F.
1960:
The Limestone Industries of Ontario, Ontario Dept.
of Mines, Industrial Mineral Circular No. 5.
1964:
The Limestone Industries of Ontario, 1958-1963,
Ontario Dept. of Mines, Industrial Mineral Report
No. 13.
Taggart, A.F.
1947:
Handbook of Mineral Dressing, Wiley Handbook Series.