(Quality Assurance of Cement

-
jfrom Production to Construction j—

T
PResented by : K.K. Choi
14th February 2006
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Content

# Cement Standard in HK
# Cement Manufacturing Process
# Quality Assurance Planning
# Quality Control Schemes
Quality Planning

National Standards QUALITY PLANS:

• Product Specification
• Process Specification
Customer Requirements • Procedures
• Sampling & Testing Plans
• Work Instruction/Records
Market Positioning • Testing Data QA

Raw Material Constrain

Process Constrains
 Cement Sstandard M
^igratio: n
J

]Portland Cement Standard i- HK Adoption year

BS12 :1989 1992

BS12:1991 -

BS12 :1996 2003

BSEN197-1:2000 ) 2005
 Major Changes since BS12:1991
&-

BS12:1989 Since BS12:1991

Test method Mortar and Concrete cube Mortar prism test to EN196
tests to BS4550

By Fineness and early

Classification 4 major Strength Classes in BS,
strength, into CFPC, OPC
and 3 major strength classes
and RHPC
in BSEN197:2000
Not permitted Up to 5%
Minor constituents

Compliance Based on single sample Employs statistical method in

and single test. strength class classification,
Compliance based on and Single Sample Acceptance
absolute limits based on deviations.
 Conformity Criteria
n Arithmetic Mean
Vj Population

Measured Value
Limi LLSS LLAutoControl ULAutoControl

t s
F^orclass 52.5N 18.0 20.0 KA is no. of test dependent
2 days strength S is standard Deviation
50.0 52.5
2 days strength
8
Target 28 days’ Strength
—

1.
SD 2. 5 SD= 8 1

f-

V/ •
— f j
r

P k
=o
1 oo 57.00 55.74
= •

oh/
f- =55,
Reduce SD = Reduce target 28 d strengthV/
v_/ •
nf f o c i —
✓ """■= Reduce production cost X
~T_i—t~T~i= Improve operation stability
P k =2.07 57.68 56.23
=
What is Cement ?

Cement - A finely ground powder which has

hydraulic properties when mix with water
# It is the most essential element in concrete for civil
structures Cement
18%

C40 Water
7%
Aggregates Admixture
75%
0%
Typical C40 Concrete Composition
What’s Inside the Cement
Additives
•Such as Flyash, Limestone
Clinker
•Performance modifier
Inter-grinding

Additives
Gypsum

Cement Clinker Gypsum

•Major strength contributor •Regulate the setting properties
Typical Type I Cement Clinker

C2S
Such as free lime,
MgO, Alkali, sulphates

C3S & C2S C A & C AF

•Calcium Silicates, xCaO.SiO2 93Ca0.Al203,
•Amount up to 72-78 % *4CaO. Al203. Fe203
•Strength contributor *Flux for the pyroprocess
Composition
Type I cement clinker Composition
C3S 45 - 65 % CaO 63 66 %
CxS 72 -78 % , SiO2
K
20 23 %
C3A 8 - 12 % Al2O3 4 6 %
C4AF 10 -11 % Fe2O3 3 4 %
Bogue’s formulas for calculating potential composition
*3
CJa Sno 2 Al2C Fe *3
2

o C
- -
+4.071 -7.602 6 >.719 1 .430
C3S
C2S - .0 / 0 +8.602 +5.068 + 1.079
3
C3A -
+2.650 1 .692
Cement Plant Schematic Process Flow

Cfay/Sh Li.C
lica
rf l
dt
LM STON
CRUSHER
RA
on voal

Qlj
Feed
COAL
MILL
1MESTONE STCCKPiL
NDING
LINK OS
KILN
S OS ..

C h n K er
yp
dditiv

n'-sn
CzM N T M L !

CEMEN
SILOS r*

SHIPPING
Quarrying
i—i— j—j—i—i—
#■ Most limestone quarry are not uniform
#■ Origin from organisms like corals, algae in “Shallow
marine carbonate platform”
#■ Complex structure due to formation mechanism,
faults, foldings.

■ Resource conservation - Overburdens, Low Ca layers,

High MgO layers, Gypsum
■ Controls of harmful elements, such as Alkali, Chloride,
MgO
 INITIAL QUARRY
LIMESTONE QUARRY DEVELOPMENT
1
Sisoo
FACE

0,5 and 15 years after opening

t 1
284
i
1 i Ci |1
0 )
ST OCK OF

if /
/}.
1 90 / ' HIGHE R GRADE

/ iL
i LIME ST ONE

f!
i
pm
( i
!
in ooo itij
\
\J
j_

m 21)
0 O.
..—Si' -—te-

S0

~* I

LIMESTONE QUARRY LAYOUT

_____T RACE OF MOBILE CRUSHE R

___BE LT CONVE YOR

i— \, JO 5 from- ^oriion
j.o_ QUARRY FACE AFT E R 3 YE ARS OPE RAT ION Vert ical <• niijg*fa 1 iflni 1.4
C DRILLHOLE LOCAT ION
1J3
 Pre-blending & Homogenizing
■ST-

# Further reduce quality variation from quarry

# Applicable to limestone, clay, coal
ULIEfllALSCHlCKTEN
MAT E RIAL LAVLH3

nuMB N
FUNNEL

BCLUrrUNCSSEKTIONEN
fteflATEO SECTIONS

Stacking KLfiPPE
-f A LVfc

□05IEHSCHIE9EH
F_Ov^COHTROL-GArE

□REHKOtB€NG€8LASE
ROTARY Ain COMPRESSOR
ZEMTRALflEHALTcn

CENTRAL HOPPER

=NT5TAU0Ln
OUST COLLECTOR

2\3\4

Reclainning -7
Raw Meal Proportioning

#Raw Mix design

■ Clinker performance - Bogue’s formulas
■ Burnability - Free lime VS temperature
■ Coal ash correction
■ Cost
^Control parameters - LSF, S/R, A/R
#Material dosing, drying and grinding
Impact Flowmeter

Material Flow

Flowguide
Sensing Plate
Measurement is
made only in the
Horizontal Plane

Horizontal
Force

Total enclosure, ideal for powder

Less accurate
Belt Weight Feeder

Belt Scale Speed Sensor

Flow (tph) = Weight x Speed

Accuracy : Better than 1%
Suitable for very high flow rate
 Coriolis Flowmeter

JUL
Torque Load Cell
TZT

Feed in
▼

Tacho Speed Sensor /

a
i
Feed out

Flowrate * Angular speed * RadiusA2 = Torque

Totally enclosure, ideal for powder
Very accurate : For Coal, Cement Additives Dosing
Typical Close Circuit Raw Grinding with High Efficiency Separator

Or

High Efficiency
Separator

Main Components Correctives

Limestone Clay, Flyash Si Fe

Belt analyzer Product KilnFeed

Raw Mix Controller
v_ XRF analyzer
 Ra [/ A/Til 1 PAntrnl c
V
w
SJ

Processes Objectives

Raw Material # Ensure correct potential clinker chemistry

-w—^ •

heat transfer
Raw meal fineness # Ensure proper in Preheater

analvsi
Coal ash < # Provide data for ash correction
 Typical Precalciner-Kiln System
380oC
n
kj 100-400 C : Escape of adsorbed wa ter

600-900 C : Decomposition of clay, metakaolinites

& others with formation of reactive oxide mixture

800-1000 C : Decomposition

oJ of CaCO3, with formation of CS,CA,

850oC

1100oC
Kiln 1450oC
To Clinker
C2S + C => C3S Silo 110°C/
CA +3C +F => CAF
 Cement Kiln Controls
380oC Combustion air control
♦ Reduce excess air
♦ Prevent reducing atmosphere ( Fe2+ formation)

Precalciner temperature control

# Provide reactive oxide for sintering
# Reduce kiln thermal loading

850oC Clinker cooling rate

# Control crystal and glass formation
# Control of alite size
# Control periclase (MgO) crystal
1100oC
Kiln 1450oC
Cooler To Clinker'
Burning zone temperature control Silo 110°C/
^ Reduce residue free lime
Complete transform C2S to C3S
 Typical Close Circuit Finish Grinding
With High Efficiency Separator
High Efficiency Separator
❖Control particle size distribution
Gypsum dosing
♦ Control hydration reaction
♦ Obtain optimal dosing

Clinker Gypsum
Cement cooling
♦Control false setting during storage

Additives
88
-Q
ii 0>
Finish mil Cement Cement Silo
Additives dosing Cooler
# Reduce strength deviation Water spra y
# Regulate strength
Mill temperature control
^ Control false setting during grinding
 Comparison of Size distribution on Separator product

8.00

7.0
0

6.0
0
result in %

5.00

4.00 Over-grind Inert

3.00 Active

2.00

1.00
0.00
0.10 1.00 10.00 100.00 1000.00
size (u)

Conventional —H. Efficiency

 Comparison of Se.parato r
■< Specific
1Blaine A Sum Power
J residue,
. r\ . Consumption,
cm2/g %
kWh/t

t QQm 1ACL
t 1
Open Circui

4
1ACL 9 L
1
~r
y
Separator
H. E. 3200 0(17 4
1
 IE Separator
-fr

BS12:1989 Limits >00

2 Averagt
Test items 2
OPC RHPC
HK Japai 1
Fineness, m2/kg >275 >350
330 325
Mortar Strength >25 >25
3 days, MPa 35.5 34.0
>47
28 days, MPa >52
<67 69.0 68.5
|
Standards & Cement Process

#HE Separator drove the review of BS12:1989.

# Auto-Control scheme of BS12:1991 provides
incentives to reduce SD through QA.
# Provision of 5% additive enables better control of
strength variation and cost saving.
#■ End-users are benefit from the addition of 5%
pozzolanas.