Acknowledgement for Altamash

8/2/2019 Acknowledgement for Altamash

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ACKNOWLEDGEMENT

Words are indeed inadequate to convey my deep sense of

gratitude to all those who have helped me in completing this

project to the best of my ability. Being a part of this proejct has

containly been a unique and a very productive experience on my

part .

I am really thankful to Dr. Sumita Mukherjee, H.O.D of

chemistry department and Dr. Anupurna Kumari of jamshedpur

Womens College , Jamshedpur of making all arrangement to help

me carry out the project successfully.

SUBMITTED BY

Shaista Nikhat


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CONTENT

1.Introuduction of cement industry

Current scenarioTop ten players in cement industry

2.Commodity cement profileCementComposition of cementVarities of cementProperties of cementManufacture of cement

3.Analysis of cementCollege laboratory analysis

4.Conclusion5.Biblography


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INTRODUCTION OF CEMENT

INDUSTRY


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CURRENT SCENARIO OF CEMENT INDUSTRY

The cement industry is one of the main beneficiaries of the

infrastructure boom with robust demand and adequate supply,

the industry has bright future. The indian cement industry has a

total capacity of 165 million tones and is the second larges cement

producer after china.

Cement industry in India has

made tremendous strides in technological upgradation and

assimilation of latest technology . recently 93% of the total

capacity in the cement industry in based on modern and

evironmental frindly process technology .


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TOP TEN PLAYERS OF CEMENT INDUSTRY

Acc/ambuja / holciumUltera tech cementJayvee groupThe india cements ltd.Shree cementCentury industry ltd.Birla corporation ltd.Madras cements ltd.Lafarge india pvt. Ltd.J.k. cement


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COMMODITY CEMENT

PROFILE


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CEMENT

Cement is one of the most important materials used in teh

construction of buildings, dams, bridges, road etc. In 1824, joseph

Asplin , a mason working in leeds (U.K) for the first time , heated a

mixture of limestones, clay and water and allowed the mass to

stand for some time when it hardened into a stone like mass. Itresembled porland rock which was an important naturally

occurring buliding stone used in eggland during those days . He

named it portland cement . in India, cement industry cane into

existence in 1914.

Cement is a grayish fine powder consisting of a mixture

of various silicates and aluminates of calcium such as tricalcium

(3CaO.SiO2), tricalcium aluminates (3CaO. AI203) and declaim

silicates (3CaO. Si02). On mixing with water , it sets into a hard

mass with a good strength.


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COMPOSITION OF CEMENTDifferent type of cement have different composition of metal

oxides. The average composition of different oxides found in

portland cement is

Lime (CaO) = 50-60 %Silica (SiO2)=20-25 %Aiumina (AL2O3)=5-10%Magnesia (MgO)=2-3%Ferric Oxide (Fe2O3)=1-2%Sulphur trioxide (SO3)=1-2%Sodium Oxide (Na2O)= 1.0%Potassium Oxide (K2O)=1.0%

The essential constituents of cement are lime (obtained from

limestone),silica and alumina (present in clay). Form the cement

of good quality , the oxides should be kept in the following ratio:

% SiO2/% AI203 =2.5 4.0.

%Ca0/%Si02+%AI203+%fe203=1.9-21.

Cement containing no iron is white , but hard to burn . if less lime

is present than is there, the cement cracks. Excess of silicaproduces a slow hardening cement , while excess of alumina

gives a quick setting product.


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VARITIES OF CEMENT ON INDIA

There are some varities in cement that always fine good demand

in market . to know their characteristics and in which area they

are most required it will be better take a look at some of the

details given below.

High Alumina Cement : High alumina cement is a rapidhardening cement made by fusing at 15,00 to 1,600 C (2,730

to 2,910 F) a mixture of bauxite and limestone in a

reverberatory or electric furnace or in a rotary kiln. It also

be made by sintering at about 1,250C (2,280F). Suitable

bauxites Contain 50 to 60 percent alumina , up to 25 percent

iron oxid . not more than 5 percent silica, and 10 to 30

percent water of hydration. The limestone must contain only

small amounts of silica and magnesia.The cement Contains

35 to 40 percent lime , 40 to ..........(100 of 4543 world)

Oil Well Cement : Made of Iron . coke , limestone and ironscrap, oil well cement is used in constructing of fixing oil

wells. This is applied on both the off shore and on shore of

the wells.

White cement : It is a Kind of Ordinary Portland Cement .the ingrredients of this cement are inclusive of Clinker, fuel


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oil and iron oxide. The content of iron oxide is maintained

below 0.4% to secure whiteness . white cement is largely

used to increase the aesthetic value of a construction . It is

perferred for tiles and flooring works. This cement cost morethan grey cement .

Portland pozolona cement (PPC): As it prevents creaks, itis useful in the casting work of huge volumes of concrete . the

rate of hydration heat is lower in this cement type. Fly ash,

coal waste or burnt clay is used in the production of this

category of cement. It can be availed at low cost in

comparison to OPC.

Ordinary portland cement: Also referred to as grey cementOPC, it is of much use in ordinary concete construction . in

the production of this type of cement in india, Iron (Fe203),

magnesium (MgO), Silica (SiO2), Alumina (Al203), and Suphur

Trioxide (S03) Components are Used.

Clinker cement : Produced at the temponrature of about1400 to 1450 degree Celsius, Clinke Cement is needed in the

construction work of complexes , houses and bridges. The

ingredients for this cement comprise iron , quartz, clay,

limestone and bauxite.


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PROPERTIES OF CEMENT

QUALITY: The quality of cement is expressed in terms of silica and

alumina modules

Silicon module (n) =( %Sio2) ( % Al2 O3 + Fe2 O3).

SETTING TIME-when cement is brought in contact with water it

starts setting. the initial setting is gained within 24hrs, through

hydration and crystallization of tricalcium aluminates and siphon

aluminates ,followed by setting of declaim silicate is over within

28days declaim silicate and tricalcium silicate provide full

strength at one year .

SHRINKAGE - Cement surface considerable shrinkage causing

fine cracks in the surface of concrete. The volume shrinkage

depend upon water/ cement ratio during period and time

fluctuation.

SOUNDNESS - The capacity of the set cement to resist this

integration all alternative exposure to wet and dry condition is

called soundness.


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STRENGTH - The quality of hardening of cement is best judges by

tensile strength and compressive strength of the cement through

setting for a particular prior.

HEAT OF SETTING OR HARDENING - The process of hard ration

in cement is exothermic and the heat evolved is the resultant of

the heats evolved during hydrolysis of various cement

constituents. this is known as heat of setting or hardening.

COLOUR - Thegreenish grey color of ordinary Portland cement

is due to the presence of iron in it.

ACID CORROSION - Cement construction are attached by all

types of acids.

DISSOVED CO2 CORROSION - Cement structure is greatlyaffected by water containing dissolvedCo2because it dissolves the

free lime present in the cement to calcium bicarbonate.

SULPHATE CORROSION - The hardened cement surface is

attached by water containing dissolved sulphate such as Mugs4

and Nabs4 and thus reduces the strength of the set cement.


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MANUFACTURING OF CEMENT

The cement manufacturing process involves four distinct

stages, and these are outlined below.

STEP 1 QUARRYING

The raw material for cement manufacture is a rock mixture

which is about 80% limestone (which is rich in CaCO3) and20% clay or shale ( a source of silica, alumina and

fe2O3).These are quarried and stored separately. The lime

and silica provide the main strength of the cement, while the

iron reduces the reaction temperature and gives the cement

its characteristics grey colour.

STEP 2 RAW METERIAL PREPARATION

The steps involved here depend on the process used. There

are two main cement manufacturing processes currently

used in New Zealand: the dry process (used by Golden Bay)

and the wet process (used by Milburn). The dry process uses

more energy in grinding but less in the kiln, and the wet

process has lower overheads than the dry process. The two

processes are discussed separately below.


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THE DRY PROCESS

The quarried clay and limestone are crushed separately

until nothing bigger than a tennis ball remains. Samples of

both rocks are then sent off to the laboratory for mineral

analysis. If necessary, minerals are then added to either the

clay or the limestones to ensure that the correct amounts of

alumiium , iron etc. are present . The clay and limestones

are then fed IX Materials B Cement 5.

Together into a mill where the rock is ground until more

than 85 % of the material is less than 90Um in diameter.

THE WET PROCESS

The clay is mixed to a paste in a washmill a tank in which

the clay is pulverised in the presence of water. Crushed lime

is then added and the whole mixture further ground . Any

material which is too coarse is extracted and reground . The

slurry is then tested to ensure that it contains the correct

balance of minerals , and any extra ingredients blended in as

necessary.

Reaction taking place in the rotary kiln can be divided into

the following three parts :

1.Reaction taking place in moderate temperature zone . Inthis zone the temperatures is upto 800c . In this zone ,

free moisture is removed and clay

(AL2O3.2SiO2.Fe2O2.2H2O) is broken into Al2O3, SiO2 and

Fe2O3.

Al2O3.2SiO2.Fe2O2.2H2O Al2O3 + SiO2 + Fe2O3 +

2H2O


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2.Reaction taking place in average temperature zone . Herethe temperature is 800 1000C . This zone , limestone

(CaCo3) decomposes into lime (CaO) and CO2

CaCo3 CaO + CO2

3.Reaction taking place in maximum temperature zone . Inthis zone , where the temperature is 1000 1500 C , the

oxide viz., Cao, SiO2.Al2O3 and Fe2O3combine together and

form calcium silicates viz, 2CaO.SiO2; calcium aluminates

viz, 2 CaO. Al2O3 ; 3CaO.Al2O3 and tetracalcium alumino

ferrite, 4CaO.Al2O3.Fe2O3.

2CaO + SiO2 2CaO.SiO2 (Dicalcium silicate)

3CaO + SiO2 3CaO.SiO2 (Dicalcium silicate)

2CaO + Al2O3 2CaO.Al2O3 (Dicalcium aluminate)

3CaO + Al2O3 3CaO. Al2O3 (Tricalcium Aluminate)


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ANALYSIS OF

CEMENT


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COLLEGE LABORATORY ANALYSIS

1.Purpose To estimate lime in the cement samples.

2.ApparatusBalance , weight box, dessicator , Crucible , pipette, Burette,

Conical Flask, Beaker, Glass rod.

3.Chemical RequiredCement, NH4Cl, Conc. Hai, Methyl indicator , H2SO4,

Ammonium Oxalate , 1 : 10 ammonia, 1 ; 9 Hal , AgNO3.

4.Procedure 1 gm sample was weighted out accurate and 1gm of NH4Cl was added to the mixture . The mixture was

stirred & any lunges produced were broken up with a glass

rod . It was then heated on a boiling H2O bath & beaker was

covered with a watch glass. It was heated for about 30 min ,

after removing the beaker from the water bath it was filtered

through at man filter paper no. 41. Then the residue was

taken in a beaker & 1 gm NH4Cl was added & same process

was repeated . The filtrate was acidified with dil. HCl using

methyl red indicator.


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The solution was evaporated by adding to 250 cc & 1 cc of

conc. HCl was added then CA was precipitated by adding

50cc of hot 4 % ammonium oxalate solution slowly to the

boiling solution. Then 1 : 10 ammonium solution was added

until the solution became neutral or slightly alkalaine.

Now the ppt. was allowed to settle for an hour. It was then

filtered & dissolved in H2SO4. Them solution was made up to

250cc.

25cc of the solution was taken in a conical flask , to this 25cc

of water and 40cc of dilute H2SO4 was added . Then warmed

up to 50 60 C to liberate oxalic acid. It was then titrated

against N/10 KMnO4 solution . The first pink colour which

remains for about 15 second was the end point.


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OBSERVATION TABLE1 ) Sample of ACC Cement

S.No. Vol. of

Solution

in cc

Burete reading in ml Concurrent

reading in

ml

Initial

Burette

Final

Burette

reading

Difference

1 25cc 0 23.0 23.0

2 25cc 0 22.2 22.2 22.2

3 25cc 0 22.2 22.2

1 ) Sample of LAFARGE CEMENT

S.No. Vol. ofSolution

in cc

Burete reading in ml Concurrentreading in

ml

Initial

Burette

Final

Burette

reading

Difference

1 25cc 0 21.0 21.0

2 25cc 0 20.2 20.2 20.7

3 25cc 0 20.7 20.7


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CALCULATION OF LIME PRESENT IN THE SAMPLE :

SAMPLE OF ACC CEMENT

Strength of KmnO4 solution is 1.2 (N/10)

25 cc of the KMnO4 solution = 22.2 * 1.02 (N/10)

= 2.26 (N) KMnO4 solution

Since , 1 cc (N) KMnO4 solution reacts with 0.0284 gm CaO

Therefore 2.26 (N) KMnO4 solution reacts with 0.0284 * 2.26 g

= 0.0641 gm CaO

Therefore 1 gm of sample contain = 0.0641

= 0.0641 gm of CaO

= 0.0641 * 100

= 6.418 gm of CaO

SAMPLE OF LAFARGE CEMENT

Strength of KmnO4 solution is 1.2 (N/10)

25 cc of the KMnO4 solution = 20.7 * 1.02 (N/10)

= 2.11 (N) KMnO4 solution

Since , 1 cc (N) KMnO4 solution reacts with 0.0284 gm CaO

Therefore 2.26 (N) KMnO4 solution reacts with 0.0284 * 2.11 g


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= 0.05996 gm CaO

Therefore 1 gm of sample contain = 0.05996 gm of CaO

= 0.05996 gm of CaO

= 0.05996 * 100

= 5.996 gm of CaO

Result 100 gm of ACC cement contains 6.418 gm of Lime 100 gm

of Lafarge cement sample contains 5.996 gm of Lime present in it.Our college lab.Analysis reveals greater % of Lime in ACC cement

seems to be of better quality than Lafarge cement.


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CONCLUSION

Practice makes more perfect

Thus we conclude that this projection on cement analysis is

reliable and of consistent quality. TheACC Cementproves to be of

better quality , durability and better compressive strength than

LAFARGE CEMENT. Thus

ACC

ACC Limited

Rightly says

BUILD WITH CONFIDENCE!!


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BIBLIOGRAPHY

The research Books Authors

Engineering Materials S.C. Ranghwala

Industrial Chemistry B.K. Sharma

Cement Industry of India Kumar Bardas

Cement Age Dr. Eddy

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