QAULITY CONTROL REPORT

BY

ONWUKWE JUSTUS. C
 PURPOSE OF QUALITY CONTROL

Ensure finish product conformity at all standard

QUALITY CONTRO LABORATORY

- Sample preparation laboratory

- Physical laboratory
- Chemical Laboratory

Power Laboratory

- Robo laboratory

TEST CONDUCTED AT THE SAMPLE PREPARATION AND PHYSICAL LABORATORY

1, Determination of the Amount of Residue in the Raw Mill. It help to show how
fine the raw mill is grinded.

STEPS

- Weigh 10g of the sample

- Sieve the sample using 200um sieve for 3 minutes
- Weigh the residue
- Mass of residue=weight x 10

2,Determination of Mass of Residue in Cement. Sample is taken from each of

the four cement mill.

STEPS

-Weigh 5g of the sample

- sieve the sample using 45um sieve

- weigh the amount of residue

- determine the amount of residue (result x 20)

The above test is repeated using 10g of cement sample and 90um of sieve. The
result is multiplied by10 to get the actual value
 ALPINE SEIVE CONFIGURATION

TYPE WEIGHT TIME VACCUM

PRESSURE
90um 10g 3minute >1200pa
200um 10g 3minute 1200pa
45um 5g 3minute 1200pa

Kiln feed with high residue content will be very difficult to burn

DETERMINATION OF LITRE WEIGHT

This is the determination of the weight of one litre of clinker. Nodule clinker is for
this purpose. It help to know how far the clinker has been burnt

Apparatus; one litre measuring cup, analytical balance

Procedure;
- Weigh empty cup, m1
- Weigh cup and clinker m2
- Weight of clinker = m2 – m1
PRACTICAL TEST
Volume of clinker = 1 litre
Mass of clinker = 1204.8g
The litre weight = 1204.8g
IMPLICATION OF HIGH LITRE WEIGHT
- Waste of energy
- Clinker becomes hard to grind
- Decrease in the strength of the cement
- Affect the chemistry of the clink
High litre weight of the clinker can be corrected through the following
- Increase in kiln
-
 - Increase in the speed of the kiln so that the clinker will spend lesser time in
the kiln
IMPLICATION OF LOW LITRE WEIGHT
- Pressence of excess free lime in the clinker
- Decrease in the strength of the cement
Low litre weight of the cement can be prevented by the following
- Reduction in the speed of the kiln so that the material will spend more time
the kiln
- Increase in the temperature at the burning zone

TEST CONDUCTED AT THE CHEMICAL LABORATORY

FINENEES :This shows the specific area of the cement particles. It shows also
how coarse and fine the cement has been grinded. When the sample is coarse
the rate of air passage through the sample at the BLAINE APPARATUS will be
high (the liquid flows down faster at the blaine tube ). When the sample is fine,
the rate of air passage through the sample in the BLAINE APPARATUS will be
low.

IMPLICATION OF HIGH FINENESS

- Energy is wasted in crushing the cement

- Increase in strength of the cement
IMPLICATION OF LOW FINENESS
- Low strength of the cement
- Presence of free lime
TEST FOR FINENESS

Apparatus Required: Analytical Balance, Blaine Apparatus, Filter paper, Disc

Preparation of cement Bed: weigh accurately cement sample under testing to

0.0001g as per the calibration report and place it in the permeability cell having
perforated metal disc at the bottom and one filter paper on the top, take another
filter circle and place on the poured cement and applying plunger on prepared
cement bed and fit the permeability cell in socket of the manometer. Take care
not to disturb the cement bed.

Procedure; Check the lower meniscus of the dibutyl phthalate liquid filled in
manometer should touch the lower mark of the manometer. Open the valve of
the manometer with gentle aspiration raise the level of the manometer and close
the valve, now the liquid level start to fall down , then note down the time
nearest to one second by using stop watch from the top second mark of the
manometer to the next lower mark (distance in between the two marks is 55mm)
note down the time in seconds

Calculation; Ft = Tt x K

Where; Ft= fineness of the cement sample, cm2/gm or M2/ kg

Tt = time taken for testing the sample

K = apparatus constant

Practical Test Result

Mass of the sample = 2.59g

Time for testing the sample = 33.03s.

Apparatus Constant = 540
Blaine Fineness = 33.03 x 540

SOUNDNESS
This is the measure of degree of expansion of the cement. The degree of expansion of the
cement depends on the amount of free lime present in the cement (max 3%). The higher the
percentage of free lime the higher the rate of expansion. The maximum acceptable expansion
of cement is 10mm.

DETERMINATION OF SOUNDNESS OF CEMENT

Apparatus required: Le – chatelier’s apparatus, Water bath, Graduated glass
cylinder, Balance, Measuring scale.

Laboratory room temperature: 27±5

STEPS

- Form a mortar of normal consistency

- Measure the initial length of the la – chatelier mold on a measuring scale
- Put the mortar on the la chatelier mold
- Allow to solidify in a humidity chamber
- Put the la-chateleir mold containing the sample in a beaker containing
water and heat for about 3hours
- Remove the sample from the beaker of hot water and allow to cool to a
room temperature
- Determine the finial length of the la-chatelier mold in a measuring scale
- Expansion = Final length – Initial Length

LOSS OF IGNITION(LOI)
This is the amount of the kiln feed lost during conversion to clinker by pyro-
processing. The lost on ignition recorded in the OPC plant is between 33-
35% of the total kiln feed.
DETERMINATION OF % LOST ON IGNITION
Apparatus required: Dry and clean glass wear, Analytical balance, muffle
furnace, platinum crucible
STEPS
- Weigh a dry empty clean porcelain crucible….W1 gms
- Weigh 1.0gms of cement sample nearest to 0.0001 gmsin to the same
weighed crucible above…..W2 gms
- Ignite the cement in the muffle furnace set between 950 oc to 100oc for 15
minutes. Remove from the furnace and leave the crucible to cool it in a
decicator after cooling and weigh. Repeat by reheating for 5 minutes,
cooling and weighing until constant weight is achieved nearest to
0.0001gms….. W3.
 Calculation; % of loss of ignition= loss in weight/ weight of the sample x 100

a, weight of empty dry crucible = W1 gms

b, weight of crucible + sample = W2 gms
Before ignition
Weight of sample = (W2 – W1) gms
After Ignition
Weight of ignited sample = (W3 – W1) gms
Loss in weight = wt of sample before ignition – wt of sample after ignition
Therefore , loss in weight = (W2 – W3) gms
(W3 – W1)gms
% of loss of ignition = x 100
(W2 – W1)gms

DETERMINATION OF LOAD STRENGHT OF THE CEMENT SAMPLE

This is carried out using COMPRESSIVE FLEXURAL MACHINE. The cement sample is
formed into prism [block] of dimension of 40 x 40 x 60mm. The sample is kept at
the curing tank for some days before the strength is determined. The first part of
the machine, does the breaking to determine the compressive strength and the
second part is used to determine the flexural strength.

MATERIAL PROPORTION FOR PRISM OR BLOCK FORMATION

MATERIAL MASS RATIO

Cement 450g 2

Water 225g 1

Sand 1350g 6

COMPREHENSIVE STRENGHT AT DIFFERENT STAGES

STAGES TARGET N/MM2 NIS STANDARD N/MM2

2 days 14.0 Not specified

7 days 22.0 ≥16.0

28 days 35.0 ≥ 32.5

FACTORS AFFECTING THE STRENGHT OF THE CEMENT

1, Pressence o high excess free lime

2, Fineness of the cement

3, Low percentage of C2S and C3S

BLOCK FORMATION FOR TESTING OF THE STRENGHT OF THE CEMENT

Mass of the cement = 450g

Mass of the sand = 1350kg

Volume of water = 225ml

Mixing time = 5 minutes

Formation of bricks is done using the compacting machine and the mold. The
compacting machine help to remove air burbles from the sample.

Three [3] bricks each is made for both sample from the parking plant and
cement mill.

The mold containing the brick in the molten form is kept at the humidity cabinet
to solidify before taken to the curing tank. The brick is kept in the curing tank to
enable it attain its maximum strength. Among the three [3] bricks , one each is
kept in the curing tank for 2-days, 7-days and 28-days. The strength for each
sample is determined after the expiration of the specified days and compared
with the specified standard.

T
 BIESEL TEST
Properties tested for
 Density [acceptable range < 1g/cm3 for diesel and 0.9 g/cm3 LPFO]
 Moisture content
 Particulate matter

DENSITY

Density of the diesel =Mass of the diesel / Volume of the diesel

The volume of the diesel is determined using volumetric flask. The mass is
determined using a weighing balance

PARTICULATE MATTER

This is done using BUCKNER FUNNEL and FILTER PAPER. The filter paper is put
inside the buckner funnel. The funnel is attached on the sunction pump. The
sunction pump sucks the oil, leaving the particulate matter on the filter paper .
The filter paper is dried and weighed.

Mass of the particulate matter = mass of dried filter paper and particulate matter

─ mass of the filter paper x a factor

MOISTURE CONTENT

The equipment used is centrifuge together with dripping flask [50ml]. The oil is
poured in the centrifuge. Centrifuging of the sample is done for about 3 minutes.
The level of water in the dripping tank is taken which is equivalent to the volume
of water.

% quantity of the water vapour = volume of water / volume of oil x 100

WATER TEST
Test on water is carried out to determine the following;
1, PH
2, CONDUCTIVTY 3, TOTAL HARDNESS
 The calibration of the probe of the ph meter is done using a buffer solution
of 4.0, 7.0 and 9.0 every morning.
 The probe of the PH meter is stored is stored in the buffer solution of ph of
4.0
 The PH of the water sample is determined using a Ph meter.
 Conductivity Meter is used to determine the conductivity of the water
sample and the total dissolve solid [TDS]
 Conductivity meter calibration is done using 0.01HCL buffer solution
 The probe of the conductivity meter is stored or preserved in distilled
water.
 One capsule + 100ml of water = Buffer of 4
 Pillos are added to the water sample to mask other component of the
solution sample except the one to be measured. One pillo to 10ml of water
sample
 SPEC equipment can be used to determine the elemental composition of a
sample. The reading gotten from SPEC equipment must be added to a factor of 10
to obtain the actual value of the elemental component. There is specific pillos for
specific elemental component

ELEMENTAL COMPOSITION OF KILN FEED

Elemental composition in the raw mix is classified into major and minor oxides.

The major oxides are CaO, Fe2O3, SiO2, Al2O3, The minor oxides are MgO2, K2O, Na2O,
SO3. Practical representation of the percentage oxide of the raw mix is as follows:

OXIDES % COMPOSITION IN THE CEMENT

CaO 42.7
Al2O3 3.4
Fe2O3 2.4
SiO2 14.4
MgO 1.14

Na2O 0.07
SO3 0.08
LOI 34.8
LSF 95
SIM 2.4
ALM 1.4

The above percentage elemental composition of the kiln feed can be determined
Quality Control by computer and X-ray or by weight analysis

MODULES
Modules determines the proportion of the raw mix for good clinker production.
The three modules are:

SILICA MODULUS (SM)= SI / AL +Fe

ALUMINA MODULES (AL) = SI / Fe

%CaO 1

LSF 2.8(Si)+1.18(AL) + 0.65(Fe) 100

WATER TREATMENT PROCESS

RAW WATER STILLING CHAMBER MIXING CHAMBER CLARIFIER

COLLECTING TROUGH PRE-SEDIMENTATION TANK SAND FILTER

INTERMEDIATE TANK CLEAN WATER

The raw water for water treatment plant comes from the dam. The treatment is
done to produce safe water for both industrial and domestic purpose. Parts of the
plant where water is used in the plant are raw mill , kiln , cement mill,power plant
and colony.

COMPONENT OF THE WATER TREATMENT PLANT

STILLING CHAMBER : This is the first place where the raw water from the dam
enters. Sedimentation of solid impurities start from this compartment. The
capacity of the stilling tank is 450 cubic meter per hour.

MIXING CHAMBER : This is also called flash chamber. This is the point where
NaOH and ALUM are added to the water. Alum is use for the coagulation of
impurities in the water. NaOH is added to neutralize the acidity of the water.

CLARIFIER : This is the point at which the polyelectrolyte is added to the water.
Clarification of the water occurs at this point. The sludge which are sedimented at
this point is trap are trapped beneath the turbine chamber

COLLECTING TROUGH: This the channel trough which the clarified water leaves
turbine chamber into the pre- sedimentation tank.

PRE-SEDIMENTATION TANK : This the point at which clean water is collected for
on-ward distribution to various part of the plant. The water has to filtered again
through sand filter before distributed throughout the plant. Capacity is 1125m 3
SAND FILTER : this is used for the filtration of the water. The dirt accumulated in
the filter is removed by backwashing

USED IN THE INHIBITORS WATER TREATMENT PLANT

Inhibitors are added to the water to enhance the performance of the water
treatment processes, prevent scalling and corrosion of the water pipe. Some of
the inhibitors used are as follows:

1, FLORIS CS 96. Added to the water monthly in TK100. The monthly dosage is
75kg.

2, FLORIS CS 141. Added to the water daily [TK 100]. Dosage is 11kg

3, PERFORMANCE 400. Added daily in the water [TK100]. Dosage is 13 litres daily