Controlling Cement Quality, Raw Materials and Products

Introduction

The course content will be suitable for a wide range of personnel within a cement manufacturing company including junior/middle management, technicians, production and control room staff, etc. and also for others who wish to gain a comprehensive understanding of the complete cement manufacturing process. This course exploring the quality control of cement manufacture, including the different quality control challenges faced by different cement factories around the world, plus the philosophies, testing, tools, and equipment used to address those quality control challenges. Also, this course is intended for structural and civil engineers who are interested in quality control and QA with the most recent non-destructive testing for concrete and steel structure.

Objectives

This course exploring the quality control of cement manufacture, including the different quality control challenges faced by different cement factories around the world, plus the philosophies, testing, tools, and equipment used to address those quality control challenges. Also, this course is intended for structural and civil engineers who are interested in quality control and QA with the most recent non-destructive testing for concrete and steel structure.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

The course content will be suitable for a wide range of personnel within a cement manufacturing company including junior/middle management, technicians, production and control room staff, etc. and also for others who wish to gain a comprehensive understanding of the complete cement manufacturing process.

Course Outline

Brief Introduction to Cement Manufacturing:

• What is meant by Cement?
• Binders.
• Types of binders.
• Hydraulic & non-Hydraulic Binders.
• Examples for Hydraulic and non-Hydraulic Binders.
• Gypsum.
• The Three modifications of Gypsum.
• Role of Gypsum.
• False & Flash set of Cement.
• Calcareous components.
• Types of Calcareous components.
• Argillaceous components.
• Types of Argillaceous components.
• Factors Favoring Rate of reaction between calcareous & argillaceous components.
• Corrective materials.
• Additives.
• The determining factors for the choice of raw materials.
• Importance of the Mineralogical composition of raw materials.
• Factors that are affected by the Mineralogical structure of raw materials.
• Raw mix ratios.
• Definition & explanation of SM, AM , LSF, Lime Deficiency & Delta.
• Clinker main phases.

Quality Assurance of Raw Materials & Raw Meal.

• Mining Plan of the Quarries.
• Physical properties and the importance of raw materials.
• Chemical composition of raw materials.
• Chemical analysis of the bore-hole dust.
• Chemical analysis of samples after blasting.
• Major oxides of raw materials.
• Minor oxides or troubles maker elements.
• Total carbonates or titration value.
• Raw mix ratios design.
• Cross-belt analyzer.
• Hourly sample from Raw mill product.
  • Sieve analysis on 90 & 212 um.
  • Complete chemical analysis by XRF.
  • Main oxides.
  • Minor oxides ( MgO, Na₂O, K₂O, SO₃, Cl).
  • Intensive attention on Volatile elements.
  • Lime Deficiency LD, LSD, SM & AM.
  • Sulphate / Alkalis ratio.
  • Total Alkalis equation.

Quality Assurance on Kiln Feed & Hot Meal.

• Samples every TWO hours from Kiln Feed & Hot Meal.
• Complete chemical analysis of Kiln Feed by XRF.
• Sieve analysis on 90 & 212 um. For Kiln Feed.
• Major and minor oxides in Kiln Feed.
• LOI for both Kiln Feed & Hot meal.
• Calcination Degree calculation.
• Na₂O, K₂O, SO₃, Cl % in a hot meal.

Quality Assurance on Clinker.

• Clinker sample every TWO hours.
• Liter-weight ( in-between 1 & 0.5 cm).
• Free-Lime content.
• Complete Chemical analysis of Clinker.
• C₃S, C₂S , C₃A & C₄AF.
• Volatility factor calculation for volatile elements.
• Liquid Phase equations.
• Burnability factor.
• Burnability index.
• Circulation phenomenon.
• Circulating load.
• Effects of Alkalis on production & product.
• Sulphate Ring formation.
• Oxidizing & Reducing conditions.
• How to make control on volatile oxides.
• Quenching of Clinker to avoid MgO expansion.

Control of Gypsum.

• Free Water%.
• Combined water %.
• Gypsum Dihydrate %.
• SO₃ content.
• Insoluble matter %.

Quality Control of Cement Cement Mill.

• Cement sample every TWO hours.
• Complete chemical analysis by XRF.
• Sieve analysis on 90 & 45 um.
• Measuring cement temperature.
• Free Lime by X-Ray diffraction & wet analysis.
• Sieve analysis by Blaine test.
• For Composite 24 hrs. Cement Sample:
  • Complete chemical analysis.
  • Free-Lime wet.
  • Sieve by both Blaine & 90, 45 um.
  • Water Consistency.
  • Setting Time by Vicat.
  • Compressive Strength test by prisms.
  • Expansion test by Le Chatelier & Auto-Clave.

​​Quality ControlofDispatched Cement

• A composite sample of 24 hrs.
• Chemical & Physical tests as with Cement of Mills.