Tehran Cement, One Of The First Cement Factories In Iran Since 1954
Iran Cement History
Historical studies indicate that the Iranians as the Phoenicians, the Greeks, and Romans were able to produce cement that was able to withstand the pressure, and also its strength had been maintained in the presence of water.
The remaining works such as great dams and bridges in different areas of Iran, as Izadkhast dam that is the first arch dam in the world, also Karkheh and Shadorvan dam. This shows that Iranians have always known the properties of hydraulic lime. Ethnic groups residing in the northern Gulf used such a Concrete (sarooj) that has Interestingly hydraulic properties and high resistance. The most famous of this Concrete was Concrete paste that was prepared in Khamir Port and still, the Port facilities are built with this type of mortar In places like Lengeh and Bushehr are stable.
The Iranian cement sector traces its origins back to 1933, when the first plant, of the just 100t / day, was built to the south of Tehran by Denmark’s FLSmidth.
The cement factory in Iran started about 5 years after Japan, 60 years after America, 70 years after Germany, and 100 years after England. Capacity hit nearly 80Mt/year in 2015 in the Iran Cement Factory (Rey). (Rey area is in the southern section of Tehran)
The First Cement Factory in IRAN
In 1933/ 100 Ton per Day
On December 29, 1933, the first Iranian cement kiln with a capacity of 100 tons per day came in the operation in seven kilometers south of Tehran (Shar-e-ray area-Bibi Shahrbanu Mountain) by Denmark’s FLSmidth.
With the passage of time and an increase in the demands for this product, new factories were needed. Therefore, in 1935 another factory with a capacity of 200 tons was bought, built-in 1936, and put into use in 1937.
The Largest Cement producer in Iran
Iranian largest Cement producer
The largest Iranian cement producers are:
Fars & Khuzestan Cement:
Founded in 1950 as Fars Cement Company, Fars & Khuzestan Cement is the largest producer of cement operating in the Iranian market. It has grown substantially from a capacity of just 200t/day in 1955, when production began. In 2017 the company has 18 subsidiaries and, together with its partner Ta’min Cement Investment Company, which has a further five cement plants, it operates nearly 32% of Iranian cement production capacity.
Founded in 1954, Tehran Cement produced its first cement, from a 300t/day (0.1Mt/yr) kiln, in 1957. It launched numerous other lines over the next 30 years, bringing capacity to 3.1Mt/yr by 1987. In 2007 it replaced three of its older lines with a single line of the 3400t / day (1.1Mt/yr), bringing its capacity to 4Mt/yr. Further capacity has since come online, bringing capacity up to 6.1Mt/yr. This gives it around 7% of Iranian capacity.
Tehran Cement Factory in IRAN
Tehran Cement Co.
Tehran Cement Company registered in 1954 in Tehran-IRAN as license Number 4503. Its first production unit started operating in 1954 with a nominal capacity of 300 tons per day.
During the years 1956 to 1958, with the construction of 5 more production units, the nominal production capacity of the company reached 7600 tons per day.
From 1979 onwards, 8700 tons were added to the nominal capacity of the company. About 900 tons of nominal capacity related to the old lines of wet units 1, 2, and 5 were taken out of production due to equipment wear, air pollution, and high fuel consumption.
Currently, Tehran Cement Company has 5 active production lines with a nominal production capacity of 13,400 tons per day.
Tehran Cement CEO
Mr. Seyed Abbas Hosseini is Tehran Cement CEO. He introduced to this position in April 2020.
Tehran Cement Factory Products
Products produced in Tehran Cement
Tehran Cement has nine production lines and the types of cement products of this factory are as follows:
Portland cement type 1-325:
This cement is produced in accordance with Iranian National Standard No. 389 and is used in all reinforced and unreinforced concrete structures, bridges, water tanks, concrete silos, building mortars, flooring, and the manufacture of ordinary concrete parts.
Note: It is better not to use this cement in cases where the special properties of other types of cement are required, especially in corrosive environments containing concrete ions.
Portland cement type 1-425:
This cement is produced according to the national standard of Iran No. 389 ISIRI, which has the chemical and physical characteristics of 1-325 cement.
However, it has an initial pressure resistance (2 days) of at least 100 kg / cm2 and a final strength (28 days) of at least 425 kg / cm2 and a maximum of 625 kg / cm2, which is a fast-setting cement and It can be used in all reinforced and non-reinforced concrete structures that need more initial and final strength. Use in ordinary concretes, as described above, instead of 1-325 cement, all columns, roofs, bridge slabs, structures that need to be opened quickly, and concreting in cold weather are the areas of application of this cement.
Note: Due to faster hardening, it is better to use cement 1-425 with caution in tropical areas where there is a risk of increasing the temperature of concrete to more than 32 degrees Celsius and bulk concreting to more than 15 degrees Celsius.
Portland cement type 1-525:
Portland cement type 1-525 according to the national standard of Iran No. 389 ISIRI is produced and has chemical and physical characteristics like Portland cement type 1-325, but has an initial compressive strength (2 days) of at least 200 kg / cm2 and a final strength. (28 days) is at least 525 kg per square centimeter.
This cement is used for making concrete structures that need fast molding and loading of concrete, and in addition to being used in conventional concreting, it has a special application for conventional and bulky concreting in cold weather that requires maintaining the temperature. Concrete is more than 5 degrees Celsius.
Note: Due to the rapid hardening, the hydration heat produced by this cement is higher and therefore is not recommended for bulk concreting in summer and hot weather, and for normal concreting in hot weather with the maximum temperature of concrete up to 23 degrees Celsius is best consumed with caution.
Portland cement type 2:
Produced according to national standard number 389 ISIRI. Portland cement type 2 is used to make concretes in which moderate hydration temperature is required and sulfate attack is moderate. Due to the limitation of the aluminate phase and the lower phase of the three calcium silicate in this cement, which causes the above-mentioned special properties, the initial and the final pressure resistance of its standard mortar is less than that of Portland cement type 1.
This cement can be used in all concrete structures and in water and soil environments where the concentration of sulfate ions is moderate (according to the concrete regulations of Iran “Aba”, for moderate environmental conditions in the aqueous environment, the concentration of sulfate ions is less than 1200 ppm and in the environment Soil is less than. This cement is widely used for concreting in relatively hot weather where there is a risk of increasing the temperature of ordinary concrete to more than 32 degrees Celsius and bulk concrete to more than 15 degrees Celsius.
Note: For use in environments containing chlorine and sulfate ions simultaneously and in environments containing high concentrations of sulfate ions, as well as concreting in cold weather, the use of this cement is not recommended.
Portland cement type 3:
This cement is defined as Portland cement with high initial strength in the national standard of Iran No. 389 ISIRI and is used in structures that need high initial strength.
According to the Iranian Concrete Regulations (ABA), the use of Portland cement type 3 in concreting for cold environments (according to this regulation, a cold environment is an environment where the average daily temperature for 3 days is less than 5 degrees Celsius or In half a day less than 10 degrees Celsius) is recommended. Also, this cement has a special application for concreting in structures that need fast molding and loading.
Note: The heat of hydration of type 3 cement is higher than other cements and therefore its use in hot environments for normal concreting is associated with caution and is not recommended for bulk concreting. Although high 1-day and 3-day strength is a requirement for cement, there is no need for high 28-day strength for its standard mortar.
Portland cement type 4:
Produced according to the national standard of Iran, number 389 ISIRI. This cement has a special application in situations where low heat hydration in short and long term (up to 28 days) is required in concrete. 7-day hydration temperature less than 60 Cal / gr and 28 days less than 70 Cal / gr are the requirements of type 4 cement and its unique feature. This feature creates a wide range of applications in all concretes in hot weather and bulk concreting in all weather conditions.
Note: Due to the need to reduce the rate of hydration for this cement, its initial and final strength is less than Portland cements type 1, 2 and 3, and therefore for structures that require high strength of 7 and 28 days, has limited application. Be. Also, if there is a risk of lowering the concrete temperature to less than 5 degrees Celsius, it is better not to use type 4 cement for concreting.
Portland cement type 5:
Due to the low aluminate phase (<5%), Portland cement type 5 has high resistance to sulfate ions in water and soil environments. According to the Iranian Concrete Regulations (ABA), in severe sulfate aquatic environments, the concentration of sulfate ions is more than 1200 ppm and in heavy sulfate soil environments, more than 0.5%, is the weight of the soil. Concrete plants exposed to water and soil should be made with type 5 cement, and in any case, for very severe sulfate environments with a sulfate concentration of more than 2500 ppm in water and more than 1% in soil, type 5 cement must be used.
Note: Research has shown that type 5 cement concrete is vulnerable to chlorine-containing environments, so if it is accompanied by sulfate ions in the chlorine ion environment, the use of this cement should be done with caution and the necessary tests should be done beforehand. The 3, 7, 28-day strength limit for this cement is lower than other Portland cements and therefore it has limited application for structures that require higher strengths.
Pozzolani Portland Cement:
In order to modify some properties of Portland cements and achieve wider application specifications, according to the Iranian national standard No. 3432 ISIRI, Portland cement produces pozzolans containing up to 15% natural pozzolans with Portland cement clinker (types 1, 2 and 5). To be. Portland pozzolanic cements, in addition to having the clinker functional characteristics of the cements used, depending on the type and characteristics of the pozzolan, show unique properties in concrete structures.
Lower initial and final hydration temperatures, reduced concrete permeability and high durability in environments containing corrosive salts, adsorption of cement alkalis and the ability to maintain the properties of fresh concrete for longer periods, are among the special properties that are applicable. Many such as widespread use in the tropics and bulk concreting, use in combination with reactive aggregates with alkalis, use in aqueous and soil environments containing sulfate and chlorine ions, portability over long distances and overall more durability and reliability in Causes reinforced and unreinforced concrete.
Note: Due to having a lower share of clinker than similar Portland cement, this cement has a longer hardening and initial setting and therefore it is better to mold and load on the structures made of it, after more time. Also, due to water absorption and reduction of flow and drop of slump, it is better to avoid more water to increase the flow rate of fresh concrete of this cement and to use lubricants in concrete mix.
This cement was produced for the first time in the Middle East in 1967 by Tehran Cement company and includes types A, B, D, E, G, all of which are produced according to the API standard.
It should be noted that the main consumption of these cements is in the oil industry of Iran and oil-rich countries in the region. Types and characteristics of these cements were presented as follows:
- Class A cement: for consumption up to a depth of 6,000 feet (1829 meters)
- Class B Cement: Sulfate resistant for consumption up to 6,000 feet (1829 m)
- Class D cement: for consumption up to a depth of 10,000-6,000 feet (3658 meters) sulfate resistant
- Class E Cement: Sulfate resistant for consumption up to 14,000 feet (4267 meters)
- Class G Cement: For consumption up to 8000 feet (2438 meters) Sulfate-resistant base cement
The company has operated 9 cement production lines since its establishment.
- Lines 1 and 2: Built in the 1950s with a capacity of 300 tons of cleaners per day and are now obsolete.
- Line 3: Built in 1966 with a capacity of 600 tons of cleaner per day and now continues to operate as the only producer of wet method drilling cement in Iran. Drilling cement produced by this unit has a unique quality due to the production method Is an individual.
- Line 4: It was built in 1972 with a capacity of 2100 tons of clinker per day.
- Line 5: It was constructed in 1994 with a capacity of 300 tons of clinker per day and was closed and collected in 2004 in order to comply with environmental issues.
- Line 6: in 1978 with a capacity of 4000 tons of clinker per day of construction and is currently in production.
- Line 7: It was built in 1985 with a capacity of 2000 tons of clinker per day.
- Line 8: in 2006 with a capacity of 3300 tons of clinker per day of construction and is currently under production.
- Line 9: with a capacity of 3300 tons of clinker per day and relying on the most advanced technology of the day is under construction and is currently in production.
At present, Tehran Cement, relying on production lines and the efforts of its experts and skilled workers, has the ability to produce 13,400 tons of clinker per day.
Since its establishment, the Tehran Cement Company has played a significant role in the growth and prosperity of this region by producing more than 114 million tons of cement.
Factory Location of Tehran Cement
The Geographical location of Tehran Cement Factory
Tehran Cement, Contact Information:
Ferdowsi St., Shahid Taghavi St. (Kushk), Shahid Anoshirvani St., No. 5, Tehran, Iran
Research and Developement in Tehran Cement Factory
Tehran Cement Company (established in 1954) with experience in setting up 9 production units in Tehran Cement Industrial Complex and different parts of the country (Gilan Sabz, Ilam, Hegmatan Hamedan, Loshan, Payvand Golestan, Nahavand) and even other countries such as Oman, always in charge of research The cement industry has been. However, the official license of Tehran Cement Research and Development Center is from 2007. In 2017, he succeeded in obtaining a research and development license from the Ministry of Industry, Mine and Trade.
Tehran Cement Research and Development Center includes the following units:
- Concrete laboratory (control of cement rheology in concrete and providing technical advice)
- Microscopic laboratory (minerals, kiln feed and clinker for continuous improvement of production process)
- Laboratory cementation workshop and related projects (product and process design and development)
According to the global roadmap for the cement industry, the main solutions proposed to reduce greenhouse gas emissions and protect the environment include:
1. Efficient energy consumption;
2. Alternative fuels (green or low pollution);
3. Clinker replacement;
4. CCS (carbon recovery and storage).
Tehran Cement Company, looking at this instruction, has prepared its technology roadmap document until 2050 for the first time in the country.
In general, the measures taken and future plans of the Tehran Cement Company in this regard include:
- Production and introduction of mixed cements;
- Controlling energy consumption and improving the efficiency of mills and furnaces;
- Examining alternative fuel consumption strategies or carbon recycling.
Currently, the most important recent activities and studies in Tehran Cement R&D Center include:
- Investigation of band index in raw materials used to control energy consumption;
- Investigation of special cement production (HPC);
- Evaluation of flammability of raw materials used to control energy consumption, production efficiency and optimal regulation of raw materials;
- Assessing the compatibility of concrete additives with Tehran cement to provide the necessary recommendations to consumers;
- Microscopic study of all stone facades of Tehran cement mines;
- Microscopic study of furnace feed of different units of Tehran Cement;
- Microscopic study of clinker produced by different units of Tehran Cement;
- Careful study of mixed cements (calcareous, pozzolanic, slag) to provide the necessary recommendations to consumers;
- Continuous quality monitoring of cements used in the Tehran concrete industry with the help of various experiments to optimally design products with the opinion of cement consumers;
Certificate of quality management system in Tehran Cement
In February 1998, Tehran Cement received ISO 9001-1994 certification from TUV Rheinland Germany.
Then, in May 2004, the standard was upgraded to ISO 9001-2000 and in February 2008 to ISO 9001-2008.
Since 2014, Tehran Cement has signed a contract with the Italian company IMQ and has received its ISO9001 certificate from this company. The external audits of this company are performed once a year by IMQ.
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We hope you find detailed information about Tehran Cement, one of the first cement factories in IRAN since 1954 in this article.
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