**DERA GHAZI KHAN CEMENT INDUSTRY**

(Nishat Group Of Industries)

 INTERNSHIP REPORT
Submitted By :

 Muhammad Hamza Raheel

Sp07-Bec-025

Submiited To:

Sr. Manager Production DG CEMENT

Mr. Mohammad Shafique

*DEPARTMENT OF CHEMICAL ENGINEERING*

**COMSATS INSTITUTE OF INFORMATION TECHNOLOGY**

( LAHORE)
CEMENT

 Cement can be defined as any substance which can join or unite two or more pieces of some
other substance together to form a unit mass.

Introduction
D.G Cements is a project of NISHAT GROUP OF INDUSTRIES . It is the one of largest cement
manufacturing plant in Pakistan having record production in Asia .

It is established in 1978.

Site of D.G cement plant lies near to Dera Ghazi Khan city about 40 K.m away .

The site have many Geographical advantages . This area is rich in basic raw materials required
for cement production . Only small amount of Iron is taken from other areas .

The site also facilitates its employe and ensure their safety, also meeting their basic needs .

The environmental conditions of the site are also very suitable for processes .

For continuous and smooth operations of the plant uninterrupted power supply is very crucial.

The plant have its own production of electricity using furnace oil . Recentally Heat Recovery plant is
installed which also contribute to the production of electricity with the help of Japanese company
KAWASAKI.

DG CEMENT lies in the centr of three provinces.PUNJAB,SINDH AND KHBER PAKHTHUN KHAN.

DG CEMENT meet the WORLDS BANK ENVIRONMENTAL STANDARDS.

The first and only cement company have both ISO 14001 & ISO-9002 certification.

The installed generation capacity is 23.84 MW.

UNITS
There are two Units working simultaneously .

 UNIT 1
FUJI ( Installed by japan in 1984)
Production capacity = 2700 tons/day
 UNIT 2
FLS ( installed by Denmark in 1997)
Production capacity = 4000 tons/day

Raw Materials
 Limestone ( 70% - 75%)

It is the basic raw material for cement.

 Clay /Shale (15%-20%)

Shale is the 2nd major raw material used for the cement production.

 Iron Ore (2 %)

Iron ore as the name indicates is the iron rich material containing substantial amount of
silica together with certain amount of alumina and calcium carbonate.

 Silica Sand (1 %)

Silica sand is also used in cement making process especially when the shale/clay is
deficient in silica contents.
  Gypsum (4% - 5%)
Gypsum is used as an additive with clinker. Its contains sulphate, calcium carbonate,
alumina, etc. as impurities.

 Water

Gypsum is added with clinker as corrective additives for producing cement .

Gypsum is used to increase the settling time of cement.

MANUFACTURING PROCESSES OF CEMENTS

There are two manufacturing processes of cements.

1. DRY PROCESS
2. WET PROCESS

CHOICE OF DRY OR WET PROCESS

It depends upon the following factors

I. Physical condition of raw material.

II. Local climate condition of the factory.
III. Price of fuel.

DRY PROCESS
 This process needs excessive grinding and it is suitable for harder material .
 Grinding is difficult as compared to wet process.

WET PROCESS
 In the wet process grinding is done in the presence of water.
 Wet process is free from dust.
 Grinding is easier.
 Composition of cement can be easily controlled.

 IN PAKISTAN MOST OF THE FACTORIES USE WET PROCESS.

 DG CEMENT ALSO USE DRY PROCESS

Type Of Cement Products In D.G Cements

Plant have following two types of cement production

 OPC ( Ordinary Portland Cement )

 SRC ( Sulphate Resisting Cement )

OPC (Odinary Portland Cement)

It is defined a material obtained by pulverizing and calcining the calcareous (lime) and
argillaceous (clay) materials.

SRC (SULPHATE RESISTING CEMENT)

For SRC limestone and clay similarly are used as basic raw materials where as iron ore and silica
are added as corrective additives . It is used in High Moisture areas to resist salts such as
sulphates ( e.g Dam Construction )

Manufacrturing
 Te manufacturing of cement involves the followimg major steps ;

 Grinding and mixing of raw mixture.

 Burning of mixture to give Clinker.
 Grinding the clinker along with Gypsum

Section in D.G.Cement plant

 Quarry Area
 Utility and Water Treatment
 Raw Mill Area
 Coal Mill Area
 Kiln Area
 Cement Mill Area
 Packing Plant
 Quality Control

Quarry Area

First of all we visited Quarry Area of D.G.Cement Plant.

There is a massive quantity of basic raw materials necessarily required for cement production
(limestone and clay) available in KOH-E-SULEMAN lies near to industry.

Most impotant is that each deposit is nearly available to each other. Each material is crushed in
transported to industry through long Belt Conveyors.

These belts travel a distance of about 7 to 7.5 Km to transport raw materials .

 Interlocking
These Belts are specially designed based on interlocking system. The belts throughout the plant
are interlocked. Interlocking is actually helpfull when any belt or instrument is damaged due to
any reason ,all the previuous system of these belts along with instrument are locked(switched
off) .

MAJOR STEPS IN QUARRY AREA

Quaryy area involves following major steps.

 Limestone Crusher
 Clay Crusher
 Mining Section(Drilling/Blasting)
 Auto Section

 Limestone
Limestone is a available as hard rock of mountains . Blasting is done to break it from mountains .
Blasting is done by drilling holes of about 100mm in dia and 60ft depth using drilling machienes.
The holes are drilled by consulting mining engineers . Different explosive materials (Bombs) are
placed in these holes . Bombs are blasted to break hard rocks. Blasting is dangerous phenomena
so high quality precautions are used during this process.

Explosive in most cases ANFO is preferred due to its low price. It can be filled in the bore holes
as bulk material or pre-packed in cartridges.
Finally after blasting material is sent to Hammer crushers with the help of loader or dumpers.

In hammer crusher the particle are broken by sets of swing hammers pinned to a rotor disc.

This crushed material iis sent to industry through belts .

 Clay (Shale)
Blasting is not required for clay because it is soft material.

Produced shale is dumped into the feed hopper and fed to the roller crusher by the apron
feeder .

The speed of the feeder is controlled by the load cell on the roller motor.

After crushing it is sent to industry through belts.

 Gypsum

It is also soft material and requires in small quantity.

It is transported to industry through trucks.

Raw Mill Area

The materials came form quarry is stored separately in their respective storages.
The storage system consist of stacker and reclaimer.
It is a two piled system in which one is staked and other is reclaims.
Pile of every material is made with the help of stacker .
Reclaimer is used to transport limestone to belts which fed into the hoppers.
Side Scrappers are used for clay transport to hoppers.
 Similarly silica sand and iron ore are transport to hopper with similar method.
The material stored in separate hopper which is feed to Raw Mill Unit 1 and 2 by
dosimate feeder.
Load cell are use to weight the feed.
After weighing all th 4 raw materials are combining them on a single belt before entering
into raw mill.
Basic Working Principal for Unit 1 and 2 of Raw Mill is same .

MAGNETI SEPARATOR

MAGNETIC SEPARATOR is erected on the common belt on which all the raw
materials are combined to separate magnetic objects.

METAL DETECTORS

METAL DETECTORS is built for the metals which are not attracted by magnetic
separator to save raw mill.

PNEUMATIC OPERATED GATE

Whenever a metallic piece is detected the PNEUMATIC OPERATED GATE will be
operated for the discharge of metal piece.
It is also called as CHANGE OVER GATE.

 Working

 Milling is basic purpose of Raw Mill .

 After entering to raw mil the feed material drops on to the rotary grinding table.
 Due to the rotation of the table, the material is driven towards the edge of the grinding
table and forced under the rollers and ground.
 The rollers are thrust down against the grinding table by gravity and hydraulic
pressure.
 The grinding table is driven by the main motor.
 Unit 1 contain three vertical rollers and unit 2 contain four vertical rollers .
 The feed which is not properly crushed is recycled usind small BUCKET
ELEVATOR to DYNAMIC SEPARATOR & again into the mill.
 The mill is equipped with a VIBRATION SENSOR which stops the mill automatically
if too strong vibrations are measured.
 A number of oil pumps secure lubrication and cooling of the gear unit and bearings of
the grinding table and rollers.
 Temperature is important parameter used for milling which is maintained by hot
gasses coming from kiln .
 Induced draft(I.D) Fan is used to suck hot gasses from kiln to mill & separator.
 It is constant speed fan & stabalize the operatinal stability.
 These to ensure sufficient and constant gas flow through the mill.
 Nozzles are installed for water injection in front of the rollers and on the grinding
table to control the temperature.
 Raw meal ground to a fineness of 15% residue on the 90 micron sieve

The temperature of the supplied hot gas must be sufficient to provide the necessary
drying of the raw material when they leaving the mill.

The mill fan take the gas stream out of the mill / separator carries the fine fraction, the
product, the raw meal.

The raw meal is collected by cyclones due to gravity.

The raw meal produced is transported to the CF silo through buckets elevator and air
slides from cyclones.

When the mill is stopped, the collected kiln dust can be directed either to the kiln feed
system or to the CF silo.

COAL MILL AREA

There is a separate storage for coal.

Stacker is used to make the pile.

Reclaimer is used to transport it to the coal hoppers through belts.

From there it enters to coal mill and it is crushed there.

 Temperature is required for crushing & it is obtain from hot gases which is
obtained from kiln through I.D.FANS.

Coal which is not properly crushed is came out of the mill.and from there is again
put to the pile.

From the coal mill,crushed coal is entered into bag filter where hot air is separated
from the coal.

The powdered coal is then sent to pneumatic conveyoy through rotary valve.

With the help of conveyor,the coal is send to raw coal silo.

Load cells are placed to weigh the coal,when it is trasfered to calciner and kiln for
coal firing.

 Kiln Area
Then I visited Kiln Area .

Material that is stored in CF SILO act as a kiln feed.

The aim is to produce a homogeneous raw meal quality in order to facilities the kiln
operation.

Stable kiln operation is the basis for good clinker quality and consequently good cement
quality.

The kiln feed is extracted from the homogenizing silo & transported to the inlet of
preheater through air slides and bucket elevator.

The pre-heater is operating as a counter current heat exchanger with the raw meal
passing downwards through the pre-heater stages by gravity, and the gas moving
upwards drawn by the ID-fan.

Having passed 4 or 5 pre-heater stages – depending on to which unit the feed is directed.

From the preheaters Kiln feed is send to calciner for coal firing.

In the calciner vessel approximately 55-60% of the coal is burnt as a fuel.

The raw meal will be calcined to a degree of about 90-95%.

The calciner can be operated at high temperature of more than 1000°C, which increases
the combustion rate.
 The combustion gas used in the calciner is a mixture of hot atmospheric air and the kiln
gases from the proper rotary kiln.

From this last pre-heater stage the material slides to the rotary kiln inlet.

Due to the inclination and rotation of the kiln, the raw meal is transported downstream
through the kiln.

The raw meal is gradually heated and fully calcined by the heat supplied to the kiln by
the firing installation at the outlet end of the kiln.

KILN
ZONES IN KILN
There are four zones in kiln listed below

 Initiall Zone ( 350-850 degree celcius)

 Transition Zone (1400 degree celcius)
 Burning Zone (1800 degree celcius)
 Cooling Zone (150 degree celcius)

The length of kiln is 67.5 m & its diameter is 4.3 m & it is inclined to 4 degree.

It rotation is up to 4 rpm.

The capacity of kiln is 4000 ton/day.

 KILN LINING The temperatures in the kiln system are so high that most of the system
is protected by means of a lining consisting of bricks and concrete.

Calciner is placed before the kiln and it is very helpful in increasing the rpm of kiln
because most of the feed is heated due tocalciner.

Cooling shell fans are used to maintain the temperature of the metal surface.

Major components of Portland Cement Clinker

 Tricalcium silicate 3CaO Si02( Alite, C3S)

 Diacalcium silicate 2CaO Si02(Belite ,C2S)
 Tricalcium Aluminate 3CaO Al2O3 (C3A)
 Tetra Calcium Aluminiferrite 4CaO Al2O3 Fe2O3 (C4AF)

Major steps in clinkering

 Decarbonation of calite( Calcinations )

CaCO3 CaO+CO2 (Highly endothermic)

 Rapid Neutralization of free lime (Exothermic)

3CaO + Al2O3 C3A
2CaO + Fe2O3 C2F
2CaO + SiO2 C2S(belite)
  Formation of Alit (Slow Reaction)
CaO+ C2S C3S(alite)
(>1200*C)

Cooling (Cooler )
When fed enter the cooler its temperature decreased to 150 degree celcius.

Clinkerization – clinker formation – takes place when he raw meal passes through the
burning zone of the kiln to the cooler.

Cooler have 2 chambers.

To ensure effective cooling at the cooler inlet, it may as previously stated be necessary to start
the first fans of the cooler.

The cooler has horizontal grates consisting of movable and fixed rows of grate shoes.

Cooling fan are used to cool the feed by using air.

Afterr clinker formation,the clinker is moved towards the roller press for pre crushing after
leaving the coolers.

From the roller press, clinkers are entered to the CLINKER YARD through apron feeder.

CLINKER YARD are the storage of clinkers.

Clinker size should be 32-50 mm.

GAS CONDITIONING TOWER

Whenever the kiln is in normal operation,the mill is also in operation , part of the gases is
used for drying purposes in mill.

The remaining gases are used for in the gas conditioning tower, so this gas, and the gas from
the mill is conditioned to a temperature which is acceptable to the ESP-filter, where the gas
mixture is dedusted.

The entire exhaust gas flow passes through the conditioning tower, where the gases are
cooled down to 150°C, before they are dedusted in the filter installation
ELECTROSTATIC PRECIPITATOR (ESP)
The gases after cooled down from gas conditioning tower are entered to electrostatic
precipitator for dedusting.

The ESP has electrodes which have a charge on it & the gases containing dust have
charged by the electrodes & positive electrode captured the dust.

It is stick with the electrode and by continuous hammering in ESP the dust is collected and
sent to CF SILO.

The hot gases from the electrostatic seperator is send to heat recovery plant for power
generation.

Cement Mill
There are three cement mills . Unit 1 use cement mill 1 and Unit 2 use cement mill 2 and
three.
Material taken from clinker yard transported to hopper by the system of interlocking
belts .
There is also a conveyer for gypsum from where gypsum is pre crusher & stored to fed
hopper.
The fixed proportion of clinker and gypsum in the ratio 95 clinkers and 5 of gypsum
respectively.
The mixture of clinker and gypsum is fed via two weigh feeders & combine on one belt
conveyor.
At the end of the conveyor belt, just before the elevator, a metal detector and a magnetic
separator is installed.
If metal or a magnetic item is detected, then the changeover gate is used to remove them.

The elevator take the material to the feed bin which is placed above the roller press.

ROLLER PRESS

The feed bin is opened, and the mixture is flowing by gravity through the vertical the
roller press. .
The flow is controlled by adjustment of the speed of rollers of the roller press
The crushed material leaves the roller press and these flakes are divided into two
streams.
The material extracted by the feeder from the overflow box is weighed and transported to
the cement mill.
The feed bin is opened, and the mixture is flowing by gravity through the vertical the
roller press. .
The flow is controlled by adjustment of the speed of rollers of the roller press
The crushed material leaves the roller press and these flakes are divided into two
streams.
The material extracted by the feeder from the overflow box is weighed and transported to
the cement mill.

The rollers are pressed together by the hydraulic system.

The material passing through the roller gap is compressed / crushed, and the particle
size is considerably reduced. Most of the material leaving the roller press is pressed into
compressed flakes.
The material send to the mill is controlled by the mill capacity.

BALL MILL

This ball mill has two compartment s.

Compartment 1 has length of 3.30 meters .
It is containing an equilibrium grinding media charge of 66.4 – 72.4 tons of steel
balls .
The size is vayring from 50-75 mm.
The partition between the first and second compartment is done with the help of
diaphragm.
Compartment 2 has an effective length of 8.91 meters .
It is containing a grinding media charge of 194.8 -212.5 tons of steel .
The sizi is varying from 20-30 mm.
The ball mill fan, which ventilates the ball mill, draws the dedusting air from the mill to
the bag filter dedusting this airflow
The water injection equipment is installed in both the inlet and the outlet end of the ball
mill.
Water vapours developed when the cement is cooled by water injection are removed from
the mill by this air flow.
The water injection ensure that the cement leave the ball mill has a temperature of 115-
120 degree C.
 The material leaving the cement mill is transported by an inclined air slide, n elevator
and another air slide to the inlet of the separator.

In this separator the material is dispersed and the fines are separated from the course.

The course material is returned via a weighing unit to the ball mill inlet for further
grinding in the ball mill.
The fines passing the separator is collected in the large bag filter, from where the
collected material is transported to the cement silos.

Cement silos

At this point , cleaned air is recycled and circulating in a closed system as it is necessary foe
separation.

The excess air containing some very fine dust is escaping via the chimney.

The material than send to cement silos.

Packing Unit:

After visiting the cement mill we went to packing unit where .

There are four packers in the packing unit.

 Cement comes from silos through air slide to the bucket elevator throws the
cement to screen then after screening it cement bin and then to rotary packer
where it is weighed and packed in 50 Kg bags.
 Each packer has two conveyer belts. Bags come through the belts conveyer to the
loading trucks etc.

Two different products are:

1. DG brand and elephant brand ordinary port land cement.

2. DG brand sulphate resistance cement.
WATER TREATMENT PLANT
Industry takes the water from the canal which is very closed to the industries.

Then took the water from there & pumped the water to the storage tanks with the help of
centrifugal pumps.

Water is stored in thestorage tanks.

Water filtration is done before using in the process.The impure water can cause scaling and
corrosion.

Water is send to softening tank to remove the hardness.

Softening Tank:
 The raw water is pumped from the storage in to the softening thanks where it
softened.
 During regeneration, brine is led into the softening tank.
 During regeneration of one softening tank the other tanks can operate.
 For regeneration 72 kgs of salt (98% NaCL) is used.
 The regeneration of softening tanks is completed automatically controlled by a
water meter.

Cooling towers:
 The hot water is pumped from the hot sump to the cooling tower.
 In the cooling tower the water is sprayed and blower blow air on the water.
 The water is cooled evaporation.
 From the cooling tower the water runs to the tank for cooling water.

Than water is send to the procees.

After using water in a process water again come to the water treatment plan for
softening and cooling.

Softened water is used at:

1. Compressor (To cool the compressor hot air)
2. Raw mill (To control the temperature of mill)
3. Cement mill (To control the temperature of bearing)
4. Kiln bearing
Quality Controll

In the quality control, chemists are worked and they maintain the
quality of the feed by examined them in hourly basis by taking samples.

Sampling of raw material

Sample of raw mixture(in raw mill)
Control the raw mixture through(Raw mill)
Sample from CF SILO/BLENDING SILO(Intermediate storage)
Sampling of kiln feed
Final processing
 Sampling from clinke
They take the samples of all the materials from different unit and
analyse it by using QCXs(Quality Control by X-Ray analysis) technique.
It is a machine and software is installed in the machine according to the
standard composition.
Unlss the quality control not pass the finished cement product it cannot
be loaded onto the truck.

Followin parameters are under consideration for raw mixture composition

Lime saturation factor (LSF)

CaO x 100

2.8xSiO2 + 1.18xAl2O3 + 0.65xFe2O3

Silica Modulus (SM)

SiO2

Al2O3 + Fe2O3

Alumina Modulus (AM)

Al2O3

Fe2O3
Hydraulic Modulus (HM)

CaO
=

SiO2 + Al2O3 + Fe2O3

FORMULAE FOR CLINKER

Tricalcium Silicate (C3S)

= (4.071xCaO – 7.60xSiO2 – 1.430xFe2O3 – 6.718xAl2O3 / LOIFAC.

Dicalcium Silicate (C2S)

= (2.867x–SiO2) / (LOIFAC – 0.7544xC3S)

Trcalcium Aluminate (C3A)

= (2.65xAl2O3 - 1.692xFe2O3)

Tetracalcium Aluminoferrite (C4AF)

= 3.04x Fe2O3 / LOIFAC

Liquid Phase

= (3.00xAl2O3) + (2.25xFe2O3) + MgO + K2O + Na2O + SO3

But if AM < 0.64, then

Tricalcium Silicate (C3S)

= (4.071xCaO – 7.60xSiO2 – 2.859xFe2O3 – 6.718xAl2O3 / LOIFAC.

C4AF + C2F

= (2.100xAl2O3 + 1.702xFe2O3) / LOIFAC.

ANALYSIS TECHNIQUES AND QC EQUIPMENT

In QC laboratories, generally dry as well as wet testing is done to control the product at different
stages.
a) X-ray Analyzer (XRF Spectrometer) is the main and most important equipment used in the
cement industry. On XRF, usually powder samples are analyzed to determine different
elements in the various materials. Powder press or fused bead is prepared as per prescribed
procedure and then analyzed on the XRF.
b) Blaine apparatus is usually used for the cement fineness (specific surface). A known weight
of cement sample is taken in a cell and its time flow is measured. Then the Blaine is
calculated with reference to some standard sample of known Blaine.
c) The residue (particle size) is determined on different micro sieves. A known quantity of
sample is taken on the sieve and the sieve is placed in the apparatus under vacuum. The
passing particles are sucked with vacuum cleaner.
d) Liter weight is determined by passing the clinker from 10 mm sieve and retaining on 5 mm
sieve. This sample is taken in one-liter vessel and weighed.
e) Free Lime of clinker is determined by solvent extraction method with Monoethylene Glycol
at a specific temperature for specific time and then titrating against Hydrochloric Acid
solution. This hydrochloric acid has already been used for the titration of standard lime to
calculate the factor.
f) Moisture and Loss on ignition are determined by keeping the material at certain temperature
for a specific time in oven or furnace.
g) Compressive strength of cement is determined by preparing cement-sand moulds, placing the
moulds in water and then breaking the moulds on compressive strength machine.
CEMENT LOADING (DISPATCH)
Cement being loaded to customer from the packing plant is actually the same that had come out
of the cement mill but even then the material being dispatched is also analyzed with respect to
Blaine and chemical analysis. However, sampling frequency is reduced for dispatched cement.
Generally, two samples of loading cement are collected in a shift if there is continuous dispatch.
PHYSICAL TESTING OF CEMENT
The quality of cement is evaluated by carrying out following tests under standard conditions.
 Short Time Strength of cement (03 Days)
 Long Time Strength of cement (28 Days)
 Initial Setting Time
 Final Setting Time
 Cement Expansion
 Water Consistency

FORMULAE FOR CEMENT

Lime saturation factor (LSF)

(CaO x 100) – (0.70 x SO3)

2.8xSiO2 + 1.18xAl2O3 + 0.65xFe2O3

Silica Modulus (SM)

SiO2

Al2O3 + Fe2O3

Alumina Modulus (AM)

Al2O3

Fe2O3

LOIFAC
= 1.0 – 0.01xLOI

Tricalcium Silicate (C3S)

= (4.071xCaO – 7.60xSiO2 – 1.43xFe2O3 – 6.718xAl2O3 – 2.852xSO3) / LOIFAC.

Dicalcium Silicate (C2S)

= (2.867x–SiO2) / (LOIFAC – 0.7544xC3S)

Trcalcium Aluminate (C3A)

= (2.65xAl2O3 - 1.692xFe2O3)

Tetracalcium Aluminoferrite (C4AF)

= 3.04x Fe2O3 / LOIFAC

But if AM < 0.64, then

Tricalcium Silicate (C3S)

= (4.071xCaO – 7.60xSiO2 – 2.859xFe2O3 – 6.718xAl2O3 – 2.852xSO3) / LOIFAC.

C4AF + C2F

= (2.100xAl2O3 + 1.702xFe2O3) / LOIFAC.

CEMENT STANDARDS

There are different cement standards that are followed during the cement manufacturing process and the
product cement must always comply with the said standard. Generally following standards are being
followed in cement industry.

Pakistan Standard (PS 232-1983 R) / British Standard (BS 12-1978)

This standard is applied to ordinary Portland cement and has following specifications.

ITEM MINIMUM LIMIT MAXIMUM LIMIT

LSF 0.66 1.02

L.O.I. Nil 3.00%
I.R. Nil 1.50%
 MgO Nil 4.00%
SO3 Nil 3.00
3-days strength 2200 PSI (15 N/mm2) Nil
28-days strength 5500 PSI (34.5 N/mm2) Nil
Initial S.T. 45 minutes Nil
Final S.T. Nil 10 Hours.
Expansion Nil 10 mm
Blaine 2250 cm2/g. Nil

Pakistan Standard (PS 612-1989 R)

This standard is applied to sulphate resistance cement and has following specifications.

ITEM MINIMUM LIMIT MAXIMUM LIMIT

LSF 0.66 1.02

L.O.I. Nil 3.00%
I.R. Nil 2.00%
MgO Nil 4.00%
SO3 Nil 2.50%
3-days strength 20 N/mm2 Nil
28-days strength 39 N/mm2 Nil
Initial S.T. 45 minutes Nil
Final S.T. Nil 10 Hours.
Expansion Nil 10 mm
Blaine 2500 cm2/g. Nil
C3A Nil 3.50%
FACTORS AFFECTING THE CEMENT QUALITY

Generally all the materials and ratios affect the cement quality. But there are some factors that, in
particular, affect the quality of cement. Some of those factors are already mentioned in the
standard limits. Following are the major items / factors that can make the cement quality below
standard limits:

Sulphurtrioxide (SO3)
SO3 is one of the important factors that affect the cement quality with reference to setting time.
Therefore, gypsum is added to the clinker to maintain the required initial and final setting time. If
SO3 in cement is greater than limit, setting time will be increased and vice versa.

Lime Saturation Factor (LSF)

LSF is also an important factor in cement quality. Greater LSF increases the cement strength.
But up to certain limit, there is no increase in cement strength. On the other hand, more LSF
requires more fuel to form the clinker. Therefore, usually LSF is kept from 90 to 98 to get a good
quality cement at reasonable cost.

Free Lime
As discussed in the clinker manufacturing stage, free lime is an important factor to verify the
burning factor of clinker. If free lime is more than 1.5%, it shows that clinker is not burnt
properly. The cement of this un-burnt clinker will give high expansion when applied. Therefore,
it is tried at best to minimize the free lime in clinker.

Chlorides
Chlorides also affect the cement quality. But there is no way to reduce the chloride at any stage if
it is in abundance in the raw materials. Usually cracks are developed on the applied cement if
chlorides percentage is high in the cement.
Blaine (Specific Surface)
Fineness of cement is also a major factor that plays a key role in the cement quality. High Blaine
cement gives high cement strength as compared to low Blaine cement. Like LSF, very high
Blaine (> 3500) has uncountable affect on cement strength, therefore, Blaine is always kept
below this. More Blaine will require more power consumption in cement mill.
Loss on Ignition (LOI)
If LOI in cement is on higher side, cement will set soon and ultimately its strength will be lost.
Reducing the cement mill outlet temperature can control LOI.
Magnesium Oxide (MgO)
MgO is also a factor that affects the cement quality.
Special Feature Of DG Cement

 Limestone and shale raised in mines through controlled

blasting , ripping and dosing .
 Conveying of limestone from mines to the limestone
stacker through entirely covered single over long belt
conveyer .
 Separate closed conveying system for additives
 All silos are equipped with closed mechanical or pneumatic
conveying system .
 All the transfer points and loading or unloading have
provided with Back Filter

Conclusion
Working and training in D.G cement is very helpful to us . people and all staff members
cooperated and treated us very well

In the end we will like to thanks the management for giving us the chance to visit and study
operation of D.G cement plant . We students of COMSATS would also like to thanx all the
senior members and engineers for giving us a lot of knowledge out of their experiences .
**THE END**