UNIVERSITI MALAYSIA SABAH SCHOOL OF SCIENCE & TECHNOLOGY

INDUSTRIAL TRAINING REPORT SK30403

CEMENT INDUSTRIES (SABAH) SDN. BHD.

MUHAMMAD ARIFF ASRAF ZAINAL BS08110382 (HS07) INDUSTRIAL CHEMISTRY

2012

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ACKNOWLEDGEMENT Alhamdulillah, finally I was able to finish my industrial training at Cement Industries Sabah (CIS) with successfully. Firstly, I would like to thank Cement Industries (Sabah) Sdn. Bhd for the opportunity to undergo my industrial training. Special thank goes to Mrs Suhaila Thien and Mr. Alimat @ Anuar Hj Salam for their supervision and guidance along my industrial training at CIS. The cooperation is much indeed appreciated. Not forget, great appreciation go to the rest of CISs staff, especially the laboratory sections staff that help me from time to time during the project, a big contribution and hard worked from them during the ten weeks is very great indeed. All projects during the program would be nothing without the enthusiasm and imagination from them. Big thank also goes to my family and my friend who work together with me as intern at CIS. Their encouragement and assistance during the training period was really helping me. Last but not least, my appreciations go to Dr. Noumie Surugau for her visit during my industrial training and all the parties involved either directly or indirectly during this period. Your service and courtesy will be remembered. Thank you.

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CONTENTS Page ACKNOWLEDGEMENT CONTENT LIST LIST OF TABLE LIST OF FIGURE LIST OF PHOTO LIST OF UNIT, SYMBOL, ABBREVIATION AND FORMULA CHAPTER 1 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 Company Profile Company Mission Company Vision Organization structure CIS Milestone ii iii v vi vii viii 1 1 2 2 2 3 5 5 7 8 8 9 9 9 9 10 10 13 13 14 15 15 15

CHAPTER 2 TRAINING SCHEDULE 2.1 2.2 Industrial Training Activities Mill Section a. Ball Mill b. High Pressure Grinding Roll c. High Efficiency Separator d. Pneumatic Through Conveyer e. Bucket Elevator f. Bag Filter 2.2.1 2.3 2.4 2.5 2.6 2.7 Manufacturing Process Packing/Dispatch Section Store Section Workshop/Jetty Unloading Section Electrical Section Laboratory Section 2.7.1 Laboratory Physical Test of cement a. Flexural and Compressive Strength Test

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b. Setting Time Test c. Soundness Test d. Fineness Test 2.7.2 Laboratory Chemical Test of cement a. Determination of Loss on Ignition b. Determination of Sulfate c. Determination of Chloride d. Determination of Residue Insoluble In Hydrochloric Acid and Sodium Carbonate e. Determination of Sodium and Potassium Oxides 2.8 Assessment 2.8.1 2.8.2 2.8.3 Ball Mill Grinding Mini Project Chemical Test of Cement

16 17 17 18 18 18 19 20 21 22 22 23 26 28 29 30

CHAPTER 3 CONCLUSION REFERENCE APPENDIX

LIST OF TABLE

No. of Table 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Result for flexural and compressive strength test (Mortar Prism) of cement Result for standard consistence test & setting time test Result for determination of soundness of cement Blaine test result of sample cement blank, sample 1 and sample 2 for SikaGrind 700, 874 and 874MY Flexural test strength test result (mortar prism) of sample cement blank, sample 1 and sample 2 for SikaGrind 700, 874 and 874MY Compressive test strength test result (mortar prism) of sample cement blank, sample 1 and sample 2 for SikaGrind 700, 874 and 874MY Sieve test result (mortar prism) of sample cement blank, sample 1 and sample 2 for SikaGrind 700, 874 and 874MY Chemical analysis report of Portland Cement (mill)

Page

22 23 23 25 25 26 26 27

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LIST OF FIGURE

No. of Figure 1.1 2.1 2.2 2.3 The organization structure of Cement Industries (Sabah) Sdn. Bhd The Flow of Industrial Training Activities The manufacturing Process of Cement The Flow of Packing Process of Cement

Page 2 6 10 11

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LIST OF PHOTO No. of Photo 1.1 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 Cement Industries (Sabah) sdn. Bhd Control room at Mill Ball Mill The worker take sample from ball mill 50 kg bag cement loader The jumbo bag of cement Cement tank lorry The worker measured the weight of 50 kg bag cement Maintenance for oil cooler Maintenance for conveyer belts One of local substation One of the control room at local substation Mixing process of clinker, gypsum and limestone Page 4 7 8 8 12 12 12 12 13 13 15 15 21

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LIST OF UNIT, SYMBOL, ABBREVIATION AND FORMULA C cm CO2 g h kg kV min mL celcius centimeter Carbon dioxide gram Hour Kilogram kilovolts Minute mililiter

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mm MPa HCl Na2CO3 OPC rpm s V CIS DSM SAMM SESB SIRIM Chloride content, % Compressive Strength (MPa) Flexural Strength, (MPa) Insoluble Residue, %

milimeter Megapascal Hydrochloric acid sodium carbonate Ordinary Portland Cement Revolutions per minute seconds Volts Cement Industries (Sabah) Sdn. Bhd. Department of Standards Malaysia Malaysia Accreditation Council under Skim Akreditasi Makmal Malaysia Sabah Electricity Sdn. Bhd Standard and Industrial Research Institute of Malaysia Chloride content =

Rc = Rf = IR =

Loss on Ignition, LOI = % Sulfate content, SO % = 3 %