Analysis and Manufacturing of Cement
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ANALYSIS AND MANUFACTURING OF CEMENT Amardas C D Reg no :170021040555 This is hereby to certify that the original and genuine investigation work has been carried out to investigate about the subject matter and the relative data collection and investigation has been completed solely, sincerely and satisfactorily by Amardas C D , regarding his project titled ANALYSIS AND MANUFACTURING OF CEMENT " in partial fulfillment for the Bachelor of Science in Industrial Chemistry from St.Paul’s College, Kalamassery in the academic year 2017-20. Examiner Head of the Department Project Guide Date : Place : I hereby declare that the dissertation entitled “ANALYSIS AND MANUFACTURE OF CEMENT" is an authentic record of the project work done under the guidance and supervision Mr.Texin Joseph, Head of the Department, Department of Chemistry, and MRs.Reshma Raghavan, Assistant professor, St.Paul’s College Kalamassery. Amardas C D Name of candidate Signature of the candidate Register Number : 170021040568 The satisfaction that accompany the successful completion of any task would be incomplete without mentioning the people, whose constant guidance and encouragement have served as a beam of light & crowned my efforts with success. I would like to express my sincere thanks to Mr.Texin Joseph, Head of the Department, Department of Chemistry, St.Paul’s College Kalamassery who gave me an opportunity to carry out the thesis work in one of the most prestigious institute. My sincere thanks to MALABAR CEMENTS LTD Cherthala, for providing opportunity and guidance to do the project work in their esteemed concern. I express my sincere thanks and deep sense of gratitude to Mr. K.P Pradeep Kumar Dy. Manager (Q.C) Mr. Pradeep officer (QC). Mr. for their support to complete this project work successfully. Finally I would like to thank all the staff of MALABAR CEMENTS who have their support in this effort. For giving good guidance, encouragement and also suggest improvement, I like to give thanks to Mrs. Reshma Raghavan, my Project Guide. Above all, I thank the God almighty to give the unlimited support and encouragement for the successful completion of this project work. Amardas C D CONTENTS 1. INTRODUCTION 1.1 .About the company 1.2. Products 1.3 Types of cement 1.4 Quality parameters 2. REVIEW OF LITERATURE 3. AIM AND SCOPE OF THE PROJECT 4. MATERIALS AND METHODS 4.1 Raw materials 4.2 Manufacturing process 5. RESULTS AND DISCUSSION 5.1. Cement chemistry 5.2. Clinker 5.3 Setting of cement 5.4 Properties of cement 1. INTRODUCTION 1.1 ABOUT THE COMPANY Malabar Cements Limited, a fully owned Government of Kerala undertaking, is the only major integrated cement-manufacturing unit in the State. The Company was incorporated on 11th April 1978 and commenced production in April 1984 at its Walayar plant. The company has a paid up equity of Rs.26 crores and capital outlay of Rs.68 crores. It is rated to produce 4.2 lakh tons of cement per annum at its Walayar plant. As part of expansion programme it has commissioned a 2.0 lakh tons clinker-grinding unit at Cherthala in Alappuzha district in August 2003. Thus the total installed capacity of MCL is 6.2 lakh tons. This ISO 9001:2000 Company meets about 10% of total cement consumption in Kerala. Malabar Cements Ltd., the only Portland cement manufacturer in Kerala. The company incorporated in April 1978, commenced commercial production in 1984, with capital outlay of Rs. 680 million and paid up equity capital of Rs. 260 million, is owned fully by the Government of Kerala. The 1200 TPD plant at Walayar is continuously running in profit. The Geological Survey of India has identified a cement grade limestone deposit in the Walayar reserve forest way back in 1961-62. The Mineral Exploration Corporation Limited confirmed its efficacy. 1.2 PRODUCTS Malabar Cements uses the state of the art, dry process technology for the manufacturing of super quality cement and the quality is much ahead of the National Standards. For various applications, the Company is producing three brands — 1) Malabar Super (43 grade OPC conforming to IS 269:2015), 2) Malabar Classic (PPC conforming to IS 1489:2015 Part1) 3) Malabar Aiswarya (PSC conforming to IS 255:2015). 1.3 TYPES OF CEMENT A number of different types of cement are manufactured, by varying the ratio of the raw material and/or by adding some additional materials. CLASSIFICATION OF CEMENT 1. Ordinary Portland Cement. 2. Rapid hardening cement, 3. Ultra-rapid hardening cement. 4. Low heat cement, 5. Quick setting cement, 6. High alumina cement, 7. Blast furnace slag cement, 8. Pozzolana cement, 9. White cement, 10. Hydrophobic cement, 11. Super sulfate cement, 12. Low alkali cement, 13. Water proof cement, 14. Air entraining cement, 15. Expansive cement, 16. Colored cement. Types of Cement: Every type of cement has their own properties, advantages, and disadvantages. In this article, you are going to learn the most important properties of different types of cement in details. Following are the cement types. 1. Ordinary Portland Cement. Portland cement is a product obtained by the calcination at a very high temperature, an intimate mixture of correctly proportioned calcareous and argillaceous materials. The calcined product which is called clinker. Clinker is then finally pulverized by grinding into a very fine powder and is finally mixed with calcium sulfate or gypsum to obtain cement. 2. Rapid Hardening Cement: Definition: It is also known as High-Early-Strength cement. It is manufactured with such adjustments in the proportion of raw materials. So that the cement produced attains maximum strength with-in 24-72 hours. Properties: Two essential properties of Rapid Hardening Cement are following. (i) It contains relatively more tri-calcium silicate. This is done by adding a greater proportion of limestone in the raw materials compared to that required for ordinary cement. (ii) It is more fine-grained ( Air permeability 3250 cm2/gm ) than the ordinary cement. This factors helps in quicker and complete hydration of cement particles during setting and helps in gaining early strength. Uses: It is a special purpose cement. It is used in that types of projects, where quick hardening is required. 3. Ultra High Strength Cement. In advanced countries, an Ultra-high early strength cement is produced by separating the finest fraction (above 700 m2/kg) from the rapid hardening cement at the manufacturing stage itself. This is achieved by using special devices called cyclone air elutriator. Such cement is used for very high early strength concrete. 4. Low Heat Cement: Definition: It is that type in which a very low amount of heat or hydration is liberated during setting and hardening. Mostly it is used in massive concrete structures like Dams etc. Properties: (i) The proportion of di-calcium silicate (C2S) is almost double than ordinary cement. (ii) The proportion of tetra calcium alumino-ferrite (C4AlFe) is also increased to one and one- half time. (iii) The proportion of tricalcium silicate (C3S) and tri-calcium aluminate (C3Al) is reduced by about 50 percent. This is because these compounds are known to liberate a very high amount of heat during hydration. Uses: It is mostly used in mega projects construction like DAMS. If we use ordinary Portland cement instead of low heat cement in such structures, Cracks will develop in such structures due to the great amount of heat liberated during setting and hardening. And a DAM with cracks is a useless structure. But when low heat cement is used, this danger (development of cracks) can be eliminated. 5. Quick Setting Cement: These Types of Cement are quite different than rapid hardening cement. Its quality is that it set into a stone-like mass within a period of fewer than 30 minutes. This property, of setting as quickly as possible is achieved by following controls in the manufacturing process: (i) The quantity of retarding agents like gypsum is reduced to a bare minimum. (ii) The quantity of alumina-rich compound is reduced. (iii) The clinker is ground to extreme fineness. Quick setting cement is used only in very specific situations such as while constructing piers for bridges and other structures in running or standing water. 6. High Alumina Cement: Definition: These Types of Cement contains alumina in considerably larger proportions (average 40 percent) than normal cement. High Alumina cement is manufactured by calcining a well-proportioned mixture of Limestone and Bauxite (Al2O3, n H2O). No other raw material is added, not even gypsum is mixed with the clinker during grinding. The total Alumina content is generally above 32 percent. Properties: The most important properties of high alumina cement are summarized below: (i) It is resistant to the corrosive action of acids and salts of seawater. (ii) The ratio of alumina to lime is kept between 0.85 and 1.30. (iii) It gains compressive strength of 400 kg/sq.cm within 24 hours and 500 kg/sq.cm after 72 hours. (iv) It evolves great heat during setting. Due to this, it is not suitable for use in mega projects like Dams. But at the same time, it gives an advantage to high alumina cement for use in frost forming areas. (v) They react quickly with lime. Therefore, it must not come in contact with lime. Uses: Unfortunately, it is more costly. Therefore it is used only in those situations where resistant against corrosion is required. It is commonly used in construction work near and along sea-shore. 7. Blast Furnace Slag Cement: Definition: It is a modified type of Portland cement which contains 25-65 percent (by weight) of blast furnace slag. It is manufactured by grinding clinker and specific amounts of blast furnace slag together.