NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS

Centre for Cement Research and Independent Testing

CEMENTS AND OTHER BINDERS

F Establishing Limestone Consumption Factor (LCF) F Optimization of raw mix design F Utilization of marginal / low grade raw materials in the manufacture of cement and building materials F Development of newer cements, composite formulations, alternate binding materials F Improving clinker/cement quality F Maximizing fly ash content in PPC F Investigations on lump formation in cement silos/bags and remedial measures F Effect of minor constituents on clinker/cement quality F Optimization of SO3 content in cement F Studies on use of mineralizers in clinkerization

Services Offered

Shotcreting of NCB-Quick set formulation inside tunnel at a dam site

Achievements
Meeting delivery schedules and targeted quality of delivered cement through minimizing/ eliminating lump formation in silos/bags for 6 cement plants. Utilizing flyash, low grade limestone and additives in cement manufacturing through optimization of raw mix design for 40 cement plants. Achieving desired setting time and early strength through optimization of clinker quality, PSD and SO3 content in two cement plants. Increasing flyash content in PPC by 5-10 percent through optimization studies. Carried out 117 LCF studies resulting in : Rationalization of limestone consumption Estimating royalty payable to State Government Internal material audit in cement plants
Optical Microscope for micro-structural evaluation of clinker and rocks

Fused belite cluster

Lath shaped alite grains

Perfect hexagonal shaped alite grains with inclusions of mineralizer and micro grains of belite

Optical Micrograph of control OPC clinker fired at 1450oC (50x)

Optical Micrograph of mineralized OPC clinker fired at 1400oC (50x)

Services Offered

WASTES UTILIZATION
F Techno-economic feasibility studies on utilization of industrial wastes/ supplementary materials in the manufacture of OPC and blended cements F Developmental studies on plaster coating, tiles, bricks, blocks, boards, etc. using industrial wastes such as marble slurry, fly ash, red mud, by-product gypsum, etc.

Achievements
Waste Materials Flyash from Thermal Power Plants Lead-Zinc Slag from Hindustan Zinc Ltd. Copper Slag from Sterlite Industries Ltd. Steel Slag from Tata Steel Ltd. Spent Pot Lining from NALCO E-cat from Oil Refinery Marble Dust from Marble Industries Benefits based on NCB Studies Increase in utilization up to 8% in PPC manufacture Utilization up to 6.0% as cement raw mix component

5% as performance improver in OPC

Utilization up to 2.5% as cement raw mix component 5% as performance improver in OPC 2.0% as cement raw mix component

Utilization up to Utilization up to Utilization Utilization

5% as performance improver in OPC

1.5% as cement raw mix component 10 to 15% in manufacture of blended cement 5 to 15% as cement raw mix component

Limestone Mine Site

Clinker drop test conducted during LCF studies

REFRACTORIES AND CERAMICS

F Diagnostic studies / investigations related to Premature refractory failures in cement rotary kilns Damage assessment during shipment of refractories Quality evaluation of fresh refractories lot at cement / refractory plant Kiln shell corrosion Loosening of brick rings in cement rotary kiln during operation Coating and build-up formation/ring formation

Brick sample from cement kiln at 24m indicated heavy discoloration due to infiltration of gases

Services Offered

F Refractory management studies and optimization of refractory lining performance F Development and technology transfer of refractory products F High temperature investigations Devitrification studies of slag, alumino silicates, etc. Refractory-raw mix interaction studies

F Technical suitability of industrial wastes in refractory and ceramic industries

Corroded rotary kiln shell

Achievements
Developed high performance refractory products for cement plants: - Alumina Zircon Refractory (AZR) Bricks for transition zone - Magnesia Spinelide Refractory Bricks for burning zone - High Strength Insulating Bricks for preheating zone - Coating Repellent Castables for build-up prone areas Light weight sintered aggregate based on 99.5% industrial wastes for construction industries. Use of NCB-AZR bricks in rotary kiln improved productivity by up to 10%. Trouble shooting services to 20 cement plants with following benefits: - Kiln uptime increase by up to 12% - Fuel consumption reduction by 2-3% - Lining performance synchronization for one year - Trouble free kiln operation

Crushed light weight sintered aggregate

Refractory kiln furniture utilizing spent catalyst from refinery

Ceramic pottery wares utilizing spent catalyst from refinery

FUNDAMENTAL AND BASIC RESEARCH

Areas of Research
F F F Exploratory studies related to materials science Application of nano technology for enhancing the cement quality Development of novel cement systems and additives

Services Offered

INDEPENDENT TESTING
F Complete physical, chemical, mineralogical and micro structural analyses of various types of cement, clinker, pozzolana, aggregate, concrete, admixtures, water, refractories, bricks, limestone and other raw materials, coal, lignite, etc as per national and international standards.

Achievements
About 7000 samples are tested every year. The samples are mainly from cement plants, builders and public sector organizations in India as well as from neighbouring countries.

Facilities
ISO 9001-2000 and NABL Accredited Laboratories Laboratory Information Management System (LIMS) Performs coding of samples, generation of test reports and data storage and retrieval Facilitates smooth and efficient operations in Test House

State-of-the-art testing equipment

Flame Photometer

Auto Titrator

Orbital Shaker

X-RAY DIFFRACTOMETER (XRD) Mineralogical and phase analysis of raw materials, industrial by-products, clinker, cement, aggregates and concrete. Diagnostic studies on unstable kiln coating, ring formation, build-ups and kiln shell corrosion. X-RAY FLUORESCENCE SPECTROMETER (XRF) Chemical characterization of raw materials, additives, clinker, cement, pozzolanic materials, gypsum, etc.

FOURIER TRANSFORM IR SPECTROMETER Fully automatic, computerized and state-of-the-art equipment Determination of functional groups such as carbonate, sulphate, silicate, aluminate, etc. Characterization of cements, admixtures and fuel CHNS ANALYZER Ultimate analysis of various types of fuels for carbon, hydrogen, nitrogen and sulphur

ADIABATIC BOMB CALORIMETER Computerized and fully automatic instrument Determination of calorific value of coal and other fuels

U V - VISIBLE SPECTROPHOTOMETER Determination of major and minor constituents in cement and other building materials Fully automatic and rapid analysis of materials

Pulverizing Equipment

Transverse Strength Testing Machine

Hardgrove Grindability Test Apparatus

DIFFERENTIAL THERMAL ANALYZER Thermal behavior of raw materials, kiln feed and fuels up to 1450C Polymorphism of clinker phases Hydration characteristics of cement

INDUCTIVELY COUPLED PLASMA SPECTROMETER Fully automatic computerized and state-of-the-art equipment Estimation of toxic and non-toxic elements present in trace amounts in cements, industrial wastes, water, effluents, etc. Rapid simultaneous analysis of elements HIGH TEMPERATURE FURNACE Fully computerized furnace Operation up to 1500C Controlled heating and cooling system Burnability studies and clinkerization AUTOMATIC COMPRESSION TESTING MACHINES 2000, 1000, 350, 100 & 50 kN capacities Compressive strength determination of cement mortar and concrete samples

OUR VALUED CUSTOMERS/BENEFICIARIES

Ministry of Environment and Forests, Govt. of India National Environmental Engineering Research Institute, Nagpur Central Pulp and Paper Research Institute, Saharanpur Rajashan State Pollution Control Board, Jaipur Hindustan Zinc Limited, Udaipur Central Pollution Control Board, New Delhi Rajasthan State Minerals Development Corporation, Jaipur State Directorates of Mines and Geology Dhrangdhra Chemical Works, Dhrangdhra A. P Government, Hyderabad National Mineral Development . Corporation, Hyderabad United Nations Industrial Development Organisation Indian Oil Corporation, R & D Centre, Faridabad Thermal Power Plants - Nasik, Panki, Obra, Badarpur, Faridabad, Kota, Dhanu National Aluminium Company Ltd., Bhubaneswar Reliance Industries Ltd. Sterlite Industries (India) Ltd., Tuticorin Tata Steel Limited, Jamshedpur

Mortar Cube Vibrator

Flame Phtoto Meter

PH / ION Meter

The Director General

NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS

34 km Stone, Delhi-Mathura Road, (NH-2), Ballabgarh-121 004 (Haryana) Tel : 91-129-2242051-56, 2246174, Fax : 91-129-2242100, 2246175 E-mail : nccbm@vsnl.com Website : www.ncbindia.com

Hyderabad Unit
JAN 2009, NCB-CRT-1
NCB Bhawan, Old Bombay Road, Hyderabad - 500 008 (Andhra Pradesh) Tel : 91-40-23000344, 23000861, Fax : 91-40-23000343 E-mail : hyd2_ncbhyd@sancharnet.in

Published by S C Rastogi (GM-CIS) and Designed and Printed by Vinod Kumar (Programme Leader-Publication) for and on behalf of National Council for Cement and Building Materials at Viba Press Pvt. Ltd. - New Delhi-110020