Chemical Analysis And Quality Control

Vijay Bhan

Raw Material Used in PPC

Lime stone Iron ore Laterite

Grinded and burnt with coal

Gypsum

Clinker

Fly ash

Pozzolona Portland Cement

Quality Control Department

In quality department the chemical analysis of following material has been analyzed at certain intervals

Clinker ( 8 Hrs.) Raw Material Laterite (Batch Wise) Iron Ore (Batch Wise) Lime Stone (Hourly) Coal (4 Hrs.) Raw Meal (Hourly) Kiln Feed (Hourly) Fly Ash And Gypsum (Hourly)

Clinker analysis
The main components of clinker measured by XRF
Composition CaO Sio2 Al2o3 Fe2O3 MgO Range (% w/w) 60 63.0 19.7 - 23 4.5 - 6.0 3.5 - 4.50 < 5.5

TiO2
Mn2O3 SO3

0.21 - 0.52
0.03 - 0.68 0.20 - 0.80

K2O
P2O5 Na2O

0.31 - 1.34
0.02 - 0.27 0.03 - 0.33

Continued.
There are some moduli which are calculated on the basis of clinker composition:
Alumina Modulus or AM (% W/W) Al2o3/Fe2O3 Lime Saturation Factor or LSF (% W/W) CaO/ (2.8 Sio2+1.2 Al2o3 + 0.65 Fe2O3) Silica Modulus or SM (% W/W) Sio2/ (Al2o3+ Fe2O3)

LSF AM SM

= = =

0.85 0.95 1.3 - 1.6 2.3 2.5

Continued
The main clinker phases are as follows:
Clinker Phases Range (%w/w)

C3S (3CaO. Sio2)

C2S (2 CaO. Sio2) C3A (3CaO. Al2o3) C4AF (4CaO. Al2o3. Fe2O3) Free CaO

40 - 55
26 - 32 7.0 - 12 8.0 - 14 1.0 1.5

Litre Weight : 1250 +/- 50 Gram / Lt. it is the weight of the clinker in gram When sieved by -12mm , +6mm mesh and taken in one liter of container. % Free lime = < 1.5 % MgO = < 5.5

Continued
Calculation for the clinker phases: Bouges formula :

C3S =4.07 CaO ( 7.60 Sio2 + 6.71Al2o3. + 1.43 Fe2O3 +2.85 SO3) C2S = 2.867 Sio2 + 7.544 C3S C3A = 2.65 Al2o3 -1.692 Fe2O3 C4AF = 3.04 Fe2O3

Raw Material Analysis

S. No Moisture % Sio2 % Al2o3 % Fe2O3 % MgO LSF Lime Stone < 12 < 4.0 110 - 118 Laterite < 10 < 30 < 20 > 40 Iron Ore < 10 < 12 < 15 > 70 -

Raw Meal And Kiln Feed Analysis

S. No % MgO % Fe2O3 LSF AM SM Raw Meal 3.90 2.2 - 2.6 110 -115 1.0 -1.6 2.0 - 2.6 Kiln Feed < 3.8 112-114 1.0-1.8 2.0-2.6

Total Carbonate = 1.784 CaO + 2.09 MgO

Coal Analysis
With the help of proximate and ultimate analysis the composition of coal are as follows:
% Ash % Inherent Moisture 28 - 32 1.5 - 2.5

% Volatile Matter
Useful Heat Value (K Cal /Kg) Net Calorific Value (K Cal /Kg) % Residue ( + 90 ) % Residue ( +212 )

28-30
4000 4500

4500 - 4850 14 -16 0.4 - 0.6

Fly Ash And Gypsum Analysis

S.No Fly Ash

% Moisture % Loss on ignition Sio2 + Al2o3 + Fe2O3 Total Alkali

<5 <5 > 70 < 1.20

Total alkali = Na2O +0.658 K2O Ignition loss = 0.44CaCO3 + 0.524 MgCO3 + Combined H2O + Organic Matter

Thank You