total quality control in prism cement production

Title of the Project

content

1. Preface

2. introduction

3. company profile4. about the project5. Ppc grinding

6. Physical testing of cement

7. Uses of cement

8. Limitation

9. Suggestion

10. Conclusion

11. Bibliography12. questionnairePREFACE

I was highly obligated to the present with the golden opportunity of working with PRISM CEMENT. A company having huge infrastructure and networking with the lounch of prism cement brand, it has added a new weapon to its army.

My project titled quality control of PRISM CEMENT was undertaken for a period of 6 weeks.

In the first chapter titled COMPANY PROFILE, & quality control has been dealt in the next chapter, Comparative analysis by analyzing various ratios has been done on the basis of Balance Sheets.

Although the project was completed and completed using limited resources, I would be highly obligated if this proves beneficial to your

introduction

Quality control in the Cement industry forms an important aspect of the production process, because of the complexity of the process involved and the necessity of their lending themselves to proper clinker formation. Combinations of tools and techniques work together in the quality control process within the industry, and both physical inspection and automated quality control methodologies can have a place in the quality control done on the production of Cement.

"Total quality control", also called total quality management, is an approach that extends beyond ordinary statistical quality control techniques and quality improvement methods. It implies a complete overview and re-evaluation of the specification of a product, rather than just considering a more limited set of changeable features within an existing product. If the original specification does not reflect the correct quality requirements, quality cannot be inspected or manufactured into the product. For instance, the design of a pressure vessel should include not only the material and dimensions, but also operating, environmental, safety, reliability and maintainability requirements, and documentation of findings about these requirements. Total Quality Management (TQM) refers to management methods used to enhance quality and productivity in business organizations. TQM is a comprehensive management approach that works horizontally across an organization, involving all departments and employees and extending backward and forward to include both suppliers and clients/customers. TQM is only one of many acronyms used to label management systems that focus on quality. Other acronyms include CQI (continuous quality improvement), SQC (statistical quality control), QFD (quality function deployment), QIDW (quality in daily work), TQC (total quality control), etc. Like many of these other systems, TQM provides a framework for implementing effective quality and productivity initiatives that can increase the profitability and competitiveness of organizations

QUALITY CONTROL IN CEMENT PRODUCTION

Quality Control

Efficiency quality control is error prevention rather than error detection. Online reaction to special cause of variation will lead to progressive improvement in the process, performance and cost. Fundamental improvement in quality results from testing rational prediction about special process using statistical method. The effective pursuit of quality permanent commitment through out an organization.

Pitfall of quality control

Pitfall of the successful implantation of the permanent quality improvement culture are:-

1. Lack of top management support.

2. Lack of middle management support.

3. Commitment to only department.

4. Haphazard approach a little of this and that with no meaning change in the system.

5. Measurement of success and guidance program on the basis of short-term profile.

Cement :-

Cement is a word given to a powder material which initially has plastic flow when mixed with water but has the property of setting hard solid structure in the several hours with varying degree of strength and bonding properties.

Natural is a mixture of burnt silicate and lime. It was discovered by Joseph Aspdin an English brick layer in 1924. This Cement is called Portland Cement and now a day prepared artificially.

Properties of Cement

It gives strength to the masonry.

It is an excellent binding material.

It is easily workable.

It harden early.

Types of Cement

A. Ordinary Portland Cement (OPC)

It is of 3 types

1. 33G

2. 43G

3. 53G

B. Pozzolana Portland Cement (PPC)

COMPANY PROFILE

Introduction:

Prism Cement Limited is an ISO 9001:2000 certified professionally managed company promoted by the Rajan Raheja Group. The company operates one of the largest single kiln cement plants in the country at Satna, Madhya Pradesh. The company also has a packing unit at Allahabad, Uttar Pradesh. Equipped with machinery and technical support from world leaders, F. L. Smidth & Co. A/S, Denmark, Prism has created a niche for itself in the cement industry.

The company primarily caters to the demand in the Northem Region, mainly in the States of Uttar Pradesh, Bihar and Madhya Pradesh. The Companys plan for a five-fold increase in cement capacity from 2 MTPA to 10.0 MTPA by 2011 through Brownfield and Greenfield expansion is making steady headway. These expansions will establish the companys brand in the new markets and a larger customer base. A team of experienced engineers and dedicated workforce combined with a high level of automation and sophisticated control systems have placed the Companys products in the premium segments.

PRISM has successfully established a high brand performance among its customers through its excellent quality products and transparent policies. PRISM has truly taken cement production to global standards. PRISM is one of the most advanced concerns in the world indulged in manufacturing ordinary Portland cement of every grade e.g.53, 43 and 33 and pozzolana Portland cement.Initially, this company was incorporated under the name of RASI cement by DR.B.V. RAI, then it was took by RAJAN RAHEJA and the name of the company was changed to karan cement ,afterwards the name was again changed to prism cement ltd. Presently, the company is jointly promoted by Rajan Raheja group of Mumbai, f. l .smith &company A/S, Denmark (FLS and industrilization fund for developing countries, Denmark (IFU).

This plant is started its production from june1,1997 in village Mankahari, near Satna in M.P. with 2million tons per year , which can be translated in term s of 50 million bags of ordinary / pozolana Portland cement. Raw material assessment and finalization of the plant technical design has been carried out with the support of FLS and also the main equipment from the lime stone crusher to the electronic packers were supplied by FLS. With an objective of being an active participant in the dynamics of the nation march towards total industrialization prism cement limited has set up a state-the-art cement plant near satna in Madhya Pradesh.

The 2.51 million ton capacity ultra modern cement plant of prism is one of the most advanced cement producers in the world with machinery and technology imported from the world leaders, and state of art processes that lend it a futurist environment. The company has set up a packing unit at Allahabad to cater to the requirement of customer in eastern/central U.P.

The company is jointly promoted by RAJAN RAHEJA GROUP of Mumbai F.L.SMITH and CO. A/S Denmark (FLS), world leaders in cement technology and industrization fund for developing countries DENMARK (IFU). A team of experienced engineers and a dedicated workforce, rich deposited of high quality limestone, a high level of automation and sophisticated quality control system with unbeatable facilities prism cement production to global standards. Prism achievements have been made possible by our people people with vision, united by shared values and there commitment to excellence in the world of contraction. No wonder, on quality, strength and consistency, Prism cement is a world part.

GLOBAL SCENARIO:-Cement is one of the key infrastructure industries. Price and distribution controls were lifted on the 1st march 1989 and licensing was dispensed with since 25th July 1991. However, the performance of the industry and prices of cement are monitored on a regular basis. The industry is subject to quality control order issued on 17.02.2003 to ensure quality standards.OVERVIEW OF THE PERFORMANCE OF THE CEMENT SECTOR:The Indian cement industry not only ranks second in the production of cement in the world but also produces quality cement, which meets global standards. However, the industry faces a number of constraints in terms of high cost of power, high railway tariff, high incidence of state and central levies and duties, lack of private and public investment in infrastructure project, poor quality coal and inadequate growth of related infrastructure like sea and rail transport , ports and bulk terminals .In order to utilize excess capacity available with the cement industry , the government has identified the following thrust areas for increasing demand for cement :

(i) Housing development programmers;(ii) Promotion of concrete highways and roads;(iii) Use of ready-mix concrete in large infrastructure projects(iv) Construction of roads in rural areas under prism ministers Gram Sadak Yojana.

INDIAN SCENARIO OF CEMENT INDUSTRY:Indian cement industry is modern and uses latest technology. Only a small segment of industry is using old technology based on wet and semidry process. Efforts are being made to recover waste heat and success in this area has been significant.

WHAT IS CEMENT AND HOW IS IT MADE?

Cement is a soft powdery-type substance. It is made from a mixture of element found in nature material such a limestone, clay and/or shale when cement mix with water it can bind sand and gravel into a hard solid mass called concrete.

Four essential elements are needed to make cement they are silicon, aluminum, iron, and calcium (which is the main ingredient) can be obtained from limestone, sand/clay.

For making cement mainly four Raw materials are required:-

1) Limestone

2) Gypsum

3) Laterite / Blue Dust

4) Fly Ash

Limestone is obtained by blasting in mines. In mines there are several layers of soil, hard rocks, etc. After 5-6 Layers Company gets limestone in the form of big rocks. By blasting these big rocks of limestone be get limestone in smaller form which are easier to transport. Now through conveyer belt these limestone are moved to plant. These limestone breaks up into smallest part by grinder. Now

This grinded lime stone transfer to kiln. The temperature of kiln approximately 1400C. In kiln limestone and other raw materials like Gypsum, Laterite and Fly Ash were mixed with each other. The high temperature of kiln melts all the raw materials. After kiln all these materials take a round shape which is generally known as Clinker. Clinker is a semi-finished product of company. After grinding these clinkers we get final cement which is used for domestic as well as construction purpose.

Cement product is very fine one kilo (2.2ibs) contains over 300 billion gram we havent actually counted them to see if that is completely accurate the powder will pass through a slave capable of holding water.

Applications:-

Suitable for all types of construction like building, roads, bridges, culverts and cement base products.

Mass concrete work like dam, machine foundation work.

Concrete works in environment involving chemicals in soil and water.

Sewage and effluent treatment plant.

All kinds of marine works, like jetty etc.

Suitable for all construction ensuring higher durability.

TYPES OF CEMENT:-

Prism cement ltd manufactured two types of cement-

1. PPC

2. OPC

PPC (Portland Pozzolona Cement) with the brand name Champion is general-purpose cement popular for all applications during house construction by individuals. It is finely ground blend of high quality clinker and carefully selected high quality Pozzolona material (Fly Ash) with high fineness an optimum range of chemical composition.

OPC (Ordinary Portland cement) is made in three grades i.e. 33 Grade, 43 Grade, and 53 Grade cement. Prism Cements OPC is in demand for specialized cement concrete applications like high-rise buildings, bridges, manufacturing AC sheets, pipes, poles etc.

43 Grades:-

Features:-

Achieve more than the specified strength as per the relevant IS code through proper adjustment in the chemical composition.

High quality limestone deposit result in:

Higher strength of cement.

Moderate sulphate resisting properties.

Lower level of chloride concentration

Efficient quality control and high level of process parameter results in reduced free lime, low insoluble residue and loss on ignition

Applications:-

Optimally higher strength of cement makes it suitable for:

All General and semi specialized construction works like plain and reinforced cement concrete works, brick and stone masonry, plastering and flooring.

Manufacturing of concrete pipes, blocks, tiles and poles.

Suitable for applications like pre-cast, pre stressed and slip form construction work.

Also suitable for all types of specialized concrete repair works like gunniting etc.

Grade 53:- Features:-

Higher strength than 43 Grade is achieved through further improvement in the raw meal chemical composition and also grinding finer than 43 Grade cement.

High quality limestone deposit result in

Higher strength of cement.

Moderate sulphate resisting properties.

Lower level of chloride concentration.

Efficient quality control and high level of process parameter results in reduced free lime, low insoluble residue and loss on ignition.

Optimally higher fineness results in early strength improvement.

Closed circuit cement grinding system using high efficiency separator controls the particle size distribution resulting proper hydration character.

Applications:-

High strength of cement makes it suitable for:

Making high grade concrete with proper mix design.

Early form works removal due to high early strength development result in quicker construction.

Optimally higher fineness gives better cohesiveness, improved workability resulting denser concrete and superior surface finish.

Economical usage of cement due to high strength through proper concrete mix design.

All type of plain and R.C.C., semi and specialized construction work, like bridges, culverts, slip form work, pre-stressed pipe / poles etc.

Also suitable for all types of specialized concrete repair work like gunniting etc.

REVIEW OF LITERATUREFinancial ratios are important to analysts due to conquer the little meaning of

typically numbers. Thus, ratios are intended to provide meaningful relationship between individual values in the financial statement (Reilly, Brown, 2006). Because the major financial statement report numerous individual items, it is possible to produce a vast number of potential ratios, many which will have little value.

A single number from a financial statement is of little use, an individual

financial ratio has a little value except in relation to comparable ratios for other entities. That is, only relative financial ratios are relevant. A firms performance relative can be compared by the aggregate economy; or by its industries; or by its past performance (Reilly, Brown, 2006).

COMPANY VISION & MISSION

VISION:- To be acknowledged as a leading player in the industry with the highest level of integrity.

MISSION:- State of the art cement plants Transparent dealings with all stakeholders. Committed to the principles of good corporate governance.

LIST OF BOARD OF DIRECTORS:-

ChairmanMr. Rajesh Kapadia

Non-executive DirectorsMr. Rajan Raheja

Mr. Satish Raheja

Mr. S.Ramnath

Mr. James Arthur Brooks

Ms. Ameeta A. Parpia

Managing DirectorsMr. Manoj Chhabra

Mr. Vijay Aggarwal

Executive DirectorMr. Ganesh Kaskar

PRISM CHAMPION CEMENT is a finally ground blend of high quality clinker and carefully selected high quality pozzolonic material (Fly ash) with high fineness and optimum range of chemical composition.

Carefully selection of pozzolona is one of the crucial factor for the superiority of PRISM CHAMPION CEMENT.

The other crucial factors are:-

Optimum dosage of pozzolona to ensure high level of 28 days strength.

Balancing the fineness and the reactivity of pozzolona to ensure proper hydration character, thus ensuring sustained strength gain over long period without sacrificing on the early age strength.

Low heat of hydration helps in prevention of cracks ensuring durability of structure.

Also ensure durability of structure even in adverse environment condition.

QUALITY POLICY & CERTIFICATION

Quality Policy:-

National Accreditation Board for testing and Celebration Laboratories has granted accreditation to our laboratory in accordance with ISO/IES 17025:2005 for the chemical & mechanical testing.

We are committed to strive foe customer satisfaction by supplying consistent quality cement and clinker as per mutually agreed product specifications.

This shall achieve by:

Continual improvement in productivity levels and quality management system

Enhancing employees skills.

Focusing on customers needs and creating awareness regarding proper use of cement.

ENVIRONMENT CONSIDERATIONS

The Company is committed to mitigate potential environmental impacts associated with cement plants. The Pyro processing and pollution control systems for Raw Mills and all kiln, Cooler, Cement Mills and all Transfer points are designed to meet the stringent requirements for Dust and NOx Emission. Green belt development through large scale plantation of trees in and around the plant and residential areas.

Social Welfare:-

A well established township provides facilities like School, Hospital, Banks, Post and Telegraph office and Recreational facilities for employees and their families.

Human Welfare:-

Company considers its human resources as one of its most important assets. At every stage, concept of ownership is instilled in them to ensure full commitment and dedications. Training of personnel is an integral part of the Companys operation. Right from level of worker

Health & Safety Policy:-

The Health & safety of our people is the prime concern of the Company. Our commitment to create & maintain safe & healthy work environment against hazards and risks shall be achieved by:

Continuously developing & maintaining safe work practices

Focusing on operational & occupational hazards & risks

Creating awareness about preventive healthOBJECTIVES OF PRISM CEMENT LTD.:-

The main objective of Prism Cement is to continuously improve the quality of its products and services in order to meet the customer satisfaction.

COMPETITORS OF PRISM CEMENT LTD:-

In intensive competition Prism Cement Ltd. has many competitors as JP CEMENT, BIRLA CEMENT SAMRAT (Satna), BIRLA GOLD (Maihar) CEMENT and ACC CEMENT. The most competitor of Prism Champion is JPCement.in this competition scenario Prism Champion is facing competition.

Increase discount structure provided by JP Cement there market share.

JP Cement Ltd. is increasingly more wide open in the area of advertisement comparing to Prism Cement.

HEAD OFFICES OF THE COMPANY:-

Allahabad: 16/1/6-A Tagore Town,

Jawaharlal Nehru Road.

Allahabad -211002 (UP)

Ph. (0532) 2465228, 2467288.REGIONAL OFFICE:-

Varanasi: Unit -1, C 19/40, VIP, Fatiman Road Sigra

Behind the Kashi Gramin Bank

Varanasi 221002

Ph. (0542) 2227427, 2227428.

Kanpur: X-1/170- Krishna puram

Ph. (0512) 2404123, 2400932.

Lucknow : 3/113-Vivek khand

Gomati nagar Lucknow -2260110

Ph. (0552) 2396847, 2397589.

Bareli: C-77/3 in front of Tagore Park

Rajendra Nagar Bareli.

Ph. (0581) 2530089, 2530091.

Satna: Rajdeep Hotal, Near Rewa Road

Satna - 485002

Ph. (07672) 404400, 404403

Jabalpur: 4 HIG Residency Road

South civil line Jabalpur, 482001

Ph. (0761) 26200256, 2326907.

Patna : 302 C- Abhishek Plaza

Exhibition Road Patna, 800001

About the project Testing of Raw Material

Iron ore

Loss of Ignition (LOI)

Take 1.0 gm of sample in a weighted crucible. Heat it in a constant weight at 900 to 1000(C. Coal weight.

%Loss of ignition = Loss weight x 100

Silica (SiO2)

Take a 0.2 gm of sample in dry beaker and add 400 ml Aquaregia &digest with slow heat. Evaporate the solution at a low heat to dryness. Cool it add 15 ml conc. H2So4 and put the beaker at slow heat for 24 hours for digestion.

After 24 hours add 1:1 HCL 20 ml & just boil it in a 250 ml volumetric flask. Wash it chloride free the filtrate. Char & ignite the residue in a weight crucible (400 to 1200(C) treat the ignited residue thus obtained which contain small amount of impurities with 1 or 2 ml of distilled water + 10 ml HF and 2 drops of H2So4 and evaporate to dryness. Finally treat the small residue at 1050 to 1100(C for minute or two. Cool in desicater & weight of ignited sample represented the amount of silica. (keep it).

Silica % = (W1-W2) x 100

Where,

W1 = weight of silica + soluble impurities.

W2 = weight of impurities.

Now add 2.5 gm of sodium and potassium per sulphate to the crucible heat in the Bunsen burner continuously till the small residue of impurities is dissolved in the melt. Cool dissolved the fused mass with 1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm NH4CL and 2 drop of methyl indicator. Then boil and neutralize with NH4OH (1:1) using drop wise till just yellow. Add on drop excess NH4OH. Put this ppt. To settle and filter using 41 no. filter paper. Wash with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite the residue at 1050 to 1100(C. keep the filtrate (A)

R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. volumetric flask. Boil and add few drop of SnCl4 dropwise till sol. Decolorise. Add few drop of SnCl4 in excess. Cool it to room temperature. Rinse the beaker with H2O add 15 ml of HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate with standard KMnO4 (0.05N) till permanent pink color is obtained. Calculate iron and ferric Oxide.

R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)

Al2O3 : Fe2O3 % =

Weight of iron ore sample

R = Burette reading

N = Normality of KMnO4

AgO3 % = R2O3 Fe2O3Calcium Oxide

Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of ammonium oxalate sol. with NH4OH (1:1) Allow to settle ppt. Filter using 40 no. filter paper and wash the residue free of oxalate with hot water. Keep the filtrate feo MgO (B).

In the sample previous beaker take 10 % H2SO4 100 ml and boil it. Transfer filter paper with residue in the beaker and stir till the residue is dissolved.

Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of the beaker. At the end point pink color is obtained after taking in filter paper.

R x 100 x 2.5 x N x 0.0285 (CaO Eq)

CaO% =


Where,

R = Burette Reading


MgO

Acidify the above filtrate (B) (CaO free) with HCl till red color appear. Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5% diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in excess and keep it 24 hours for settlement. Filter through 42 no. filter paper and wash the ppt with NH4OH (1:1) and finally wash with cold distilled water.

Take it in the crucible. Slowly char the paper and carefully burn the resulting carbon. Ignite it at 1100(C to 1200(C calculate the ppt as MgO.

MgO % = W x 72.4

Where,

W

= gm of residue Mg2P2O772.4

= Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Gypsum

Loss of ignition (LOI)



Insoluble Residue (IR)

Take 1gm sample in a beaker add 50 ml water and stir it now add 5 ml HCL and stir. Crush the lump with flattened end of the glass rod. Boil it for 2 min. . Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Keep the filtrate for SO3 (A).

Residue is washed again with hot distilled water. Take out the filter paper with 30 ml. Hot distill water and 30 ml 2N Na2CO3 . For 15 min. at temperature just below boiling point filter it b through whatman filter paper no. 40. After transferring the sol. Treat the residue with 10 ml (1:1) HCl and transfer the whole in previous filter paper.

Wash it with hot distilled water till it is chloride free. Take the filter paper with residue in weighted crucible. Dry char and ignite at 100(C to 1100(C for one hour. Cool and weight.

% of I.R. = Weight of residue x 100

Sulphuric Anhydride

Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5ml conc. HCl and stir . crush the lump with flattened end of glass rod. Boil it for 2 min. now filtered through whatman filter paper no. 40. wash the residue with hot distilled water.

Boil the filtrate and add 50 ml hot BaCl2 sol. With stirring rod for another 1 min. digest it for 4-5 hours at 60(C. Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Take the filter paper in weighted crucible.

Dry and ignite at 900-1000(C. Cool in desicator and weight.

%SO3 = Wt. Of BaSO4 x 0.343 x 100

Where,

Molecular ratio of SO3 to BaSO4 = 0.343

CaSO4.2H2O = SO3 % x 2.15

Silica (SiO2)

Take a 0.2 gm of sample in dry beaker and add 400 ml Aquaregia &digest with slow heat. Evaporate the solution at a low heat to dryness. Cool it add 15 ml conc. H2So4 and put the beaker at slow heat for 24 hours for digestion.

After 24 hours add 1:1 HCL 20 ml & just boil it in a 250 ml volumetric flask. Wash it chloride free the filtrate. Char & ignite the residue in a weight crucible (400 to 1200(C) treat the ignited residue thus obtained which contain small amount of impurities with 1 or 2 ml of distilled water + 10 ml HF and 2 drops of H2So4 and evaporate to dryness. Finally treat the small residue at 1050 to 1100(C for minute or two. Cool in desicater & weight of ignited sample represented the amount of silica. (keep it).

Silica % = (W1-W2) x 100

Where,

W1 = weight of silica + insoluble impurities.

W2 = weight of impurities.





Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop of SnCl4 dropwise till sol. Decolorise. Add few drop of SnCl4 in excess. Cool it to room temperature. Rinse the beaker with H2O add 15 ml of HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate with standard KMnO4 (0.05N) till permanent pink color is obtained. Calculate iron and ferric Oxide.

R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)

Fe2O3 % =


R = Burette reading


Alumina % = Al2O3 Fe2O3Calcium Oxide

Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of ammonium oxalate sol. with NH4OH (1:1) Allow to settle ppt. Filter using 40 no. filter paper and wash the residue free of oxalate with hot water. Keep the filtrate for MgO (B).



R x 100 x 2.5 x N x 0.0285 (CaO Eq)

CaO% =


Where,

R = Burette Reading

N = Normality of KMnO4 (0.12N)

MgO



MgO % = W x 72.4

Where,

W = gm of residue Mg2P2O772.4 = Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Flyash



% Loss of ignition = Loss weight x 100

Sulphuric Anhydride



Dry and ignite at 900-1000(C. cool in desicator and weight.

%SO3 = Wt. Of BaSO4 x 0.343 x 100

Where,


Silica (SiO2)

Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the platinum crusible with led in a furnace for 1 hours at 1100(C. Cool it and extract with HCl (1:1) and transfer all material in 500 ml beaker. Add 2 to 3 drop of conc. HNO3 with constant stirring. Digest at a slow hear and agitate until the sample is completely dissolved. Evaporate the sol. At a low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml distilled water.

Treat the ignited residue thus obtained which contain small amount of impurities, with 1 or 2 ml of distill water + 10 ml of HF and 2 drops of H2SO4 and evaporate to dryness. Finally heat the small residue at 1050 to 1100(C for a min. Cool in desicater & weight of ignited sample represented the amount of silica.

Silica % = (W1-W2) x 100

Where,

W1 = Weight of silica + insoluble impurities.

W2 = Weight of impurities.





Iron Oxide (Fe2O3)


R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)

Fe2O3 % =


R = Burette reading


Alumina % = R2O3 Fe2O4

Calcium Oxide (CaO)




R x 100 x 2.5 x N x 0.0285 (CaO Eq)

CaO % =


Where,

R = Burette Reading


MgO



MgO % = W x 72.4

Where,

W



Alkali

Take 0.5 gm sample in a platinum crucible moisture with H2O and add 100 ml HF. Evaporate to dryness. After dryness add 1 ml HNO3 and 10 ml per chloride acid (HClO3) & 50 ml water & transfer all material to 250 ml beaker. Boil it and transfer all sol. In 250 ml measuring flask. Add 10 ml cesium sol. Make up vol. upto a mark and stir well.

Potassium Oxide (K2O)

Take 20 ml sol. From 250 ml measuring flask and transfer the solution in a 100 measuring flask. Make up the volume upto the mark by distilled water and see the reading for K2O by flame photometer.Sodium Oxide (Na2O)

In another case 50 ml solution from 250 ml flask and transfer the solution to 100 ml measuring flask. Make up the volume upto the mark by distilled water and see the reading for Na2O by flame photometer.

z x 250 x 100

z

{a}.Na2O % =

=

10 x 50 x 0.5 x 1000 10

y x 250 x 100

y

{b}.K2O % =

=

10 x 20 x 0.5 x 1000 10

LIMESTONE




Sulphuric Anhydride



Dry and ignite at 900-1000(C. cool in desicator and weight.

%SO3 = Wt. Of BaSO4 x 0.343 x 100

Where,


Silica (SiO2)

Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the platinum crucible with led in a furnace for 1 hours at 1100(C. Cool it and extract with HCl (1:1) and transfer all material in 500 ml beaker. Add 2 to 3 drop of conc. HNO3 with constant stirring. Digest at a slow hear and agitate until the sample is completely dissolved. Evaporate the sol. At a low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml distilled water.


Silica % = (W1-W2) x 100

Where,

W1

= Weight of silica + insoluble impurities.

W2 = Weight of impurities.





Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop of SnCl4 dropwise till sol. Decolorize. Add few drop of SnCl4 in excess. Cool it to room temperature. Rinse the beaker with H2O add 15 ml of HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate with standard KMnO4 (0.05N) till permanent pink color is obtained. Calculate iron and ferric Oxide.

R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)

Fe2O3 % =


R = Burette reading



Calcium Oxide




R x 100 x 2.5 x N x 0.0285 (CaO Eq)

CaO % =


Where,

R = Burette Reading


MgO



MgO % = W x 72.4

Where,

W

= gm of residue Mg2P2O772.4 = Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Testing of Cement & clinker

A- Chemical analysis of Cement and clinker

1. Clinker




Insoluable residue (IR & SO3)

Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5 ml conc. HCl and stir. Crush the lump with flattened end of glass rod. Boil it for 2 min. Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Keep the filtrate for SO3 (A).






%SO3 = Wt. Of BaSO4 x 0.343 x 100

Where,


Silica (SiO2)

Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the platinum crucible with led in a furnace for 1 hours at 1100C. Cool it and extract with HCl (1:1) and transfer all material in 500 ml beaker. Add 2 to 3 drop of conc. HNO3 with constant stirring. Digest at a slow hear and agitate until the sample is completely dissolved. Evaporate the sol. At a low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml distilled water.


Silica % = (W1-W2) x 100

Where,

W1


W2

= Weight of impurities.





Iron Oxide (Fe2O3)


R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)

Fe2O3 % =


R = Burette reading



Calcium Oxide




R x 100 x 2.5 x N x 0.0285 (CaO Eq)

CaO% =


Where,

R = Burette Reading


MgO

Acidify the above filtrate (B) (CaO free) with HCl till red color appear. Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5% diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in excess and keep it 24 hours for settlement. Filter through 42 no. filter paper and wash the ppt. with NH4OH (1:1) and finally wash with cold distilled water.

Take it in the crucible. Slowly char the paper and carefully burn the resulting carbon. Ignite it at 1100(C to 1200(C calculate the ppt. as MgO.

MgO % = W x 72.4

Where,

W = gm of residue Mg2P2O772.4 = Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Free lime

Take 1 gm powder sample in dry corked conical flask. Add to in 50cc ethylene glycol. Keep it 60 70(C. Shake the flask vigorously every 5 min. to prevent the clinker from forming lump. After half an hours filter it in a dry & clean conical flask using filter paper no. 40. the filtrate add 2 to 3 drop of bromocresol green indicator and titrate against 0.1N HCl sol. At the end light yellow color will be obtained.

Free lime % = R x 100 x N x 0.02804

Where,

R = Burette Reading

N = Normality of HCl

Chloride (Cl -)

Take 20 gm of sample in 250 cc conical flask. Add 30 cc distilled water & 10 cc conc. HNO3. boil for 5 min. filter through whatman filter paper no. 41. Wash with hot distilled water 4 times. The filtrate adds 5 ml of silver nitrate sol. of 0.05N cool it.

Add 5ml nitrobenzene sol. Then filtrate against 0.025N NH4SCN sol. Using ferric Alum (Ferric Ammonium Sulphate) as a indicator.

R x N

% of Cl = A-x 0.3546 x 100

Strength of AgNO3Where

A = Amount of AgNO3R = Burette Reading

N = Strength of NH4SCN

2. Ordinary Portland Cement

(Grade - 43)




Insoluble residue (IR & SO3)

Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5 ml conc. HCl and stir. Crush the lump with flattened end of glass rod. Boil it for 2 min. Now filter it with whatman filter paper no. 40 wash the residue with hot distilled water. Keep the filtrate for SO3 (A).






% SO3 = Wt. Of BaSO4 x 0.343 x 100

Where,


Silica (SiO2)

Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the platinum crucible with led in a furnace for 1 hours at 1100C. Cool it and extract with HCl (1:1) and transfer all material in 500 ml beaker. Add 2 to 3 drop of conc. HNO3 with constant stirring. Digest at a slow hear and agitate until the sample is completely dissolved. Evaporate the sol. At a low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml distilled water.


Silica % = (W1-W2) x 100

Where,

W1


W2

= Weight of impurities.



Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm NH4CL and 2 drop of methyl indicator. Then boil and neutralize with NH4OH (1:1) using drop wise till just yellow. Add on drop excess NH4OH. Put this ppt. To settle and filter using 41 no. Filter paper. Wash with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite the residue at 1050 to 1100(C. keep the filtrate (A)


Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop of SnCl4 dropwise till sol. Decolorize. Add few drop of SnCl4 in excess. Cool it to room temperature. Rinse the beaker with H2O add 15 ml of HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate with standard KMnO4 (0.05N) till permanent pink color is obtained. Calculate iron and ferric Oxide.

R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)

Fe2O3 % =


R = Burette reading



Calcium Oxide




R x 100 x 2.5 x N x 0.0285 (CaO Eq)

CaO % =


Where,

R = Burette Reading


MgO

Acidify the above filtrate (B) (CaO free) with HCl till red color appear. Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5% diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in excess and keep it 24 hours for settlement. Filter through 42 no. filter paper and wash the ppt. with NH4OH (1:1) and finally wash with cold distilled water.

Take it in the crucible. Slowly char the paper and carefully burn the resulting carbon. Ignite it at 1100(C to 1200(C calculate the ppt. as MgO.

MgO % = W x 72.4

Where,

W



Free lime

Take 1 gm powder sample in dry corked conical flask. Add to in 50cc ethylene glycol. Keep it 60 70(C. Shake the flask vigorously every 5 min. to prevent the clinker from forming lump. After half an hours filter it in a dry & clean conical flask using filter paper no. 40. the filtrate add 2 to 3 drop of bromocresol green indicator and titrate against 0.1N HCl sol. At the end light yellow color will be obtained.

Free lime % = R x 100 x N x 0.02804

Where,

R = Burette Reading

N = Normality of HCl

Chloride (Cl -)

Take 20 gm of sample in 250 cc conical flask. Add 30 cc distilled water & 10 cc conc. HNO3. boil for 5 min. filter through whatman filter paper no. 41. Wash with hot distilled water 4 times. The filtrate adds 5 ml of silver nitrate sol. of 0.05N cool it.

Add 5ml nitrobenzene sol. Then filtrate against 0.025N NH4SCN sol. Using ferric Alum (Ferric Ammonium Sulphate) as a indicator.

R x N

% of Cl = A - x 0.3546 x 100

Strength of AgNO3Where

A = Amount of AgNO3R = Burette Reading , N = Strength of NH4SCN

S. No.Characteristics to be testedSpecified Requirement

33 G43 G53 G

1.Fineness (in m2/kg) 225 240 320

2.Setting time min. 60 300 60 300 60 300

3.Soundness

(a) Le-Chat

After Areation 10 mm 5 mm 10 mm 5 mm 10 mm 5 mm

(b) Auto Clave

After Areation 0.8 mm % 0.6 mm % 0.8 mm % 0.6 mm % 0.8 mm % 0.6 mm %

4.Compressive Strength (Mpa)

3 Days 16 23 27

7 Days 22 33 37

28 days 33 43 53

5.LOI 5 % 5 % 4 %

6.IR 4 % 3 % 3 %

7.SO3 3 % 3 % 3 %

8.MgO 6 % 6 % 6 %

9.LSF0.66-1.020.66-1.020.88-1.02

10.AM (Al2O3/Fe2O3)> 0.66> 0.66> 0.66

11.CaO> 0.66> 0.66> 0.66

12.SiO2> 0.66> 0.66> 0.66

13.Al2O3> 0.66> 0.66> 0.66

14.Fe2O3> 0.66> 0.66> 0.66

4. Pozzolana Portland Cement

The pozzolona is a powdery volcanic powder. It is found near Italy near Vesuvius. It resembles surkhi which is prepared by burning brick made from original soils. It can also be processed from shale and certain type of clays. The percentage of pozzuolona material should be between 10 to 30.

Advantages of this Cement: -

1. It attains compressive strength with age.

2. It can resist action of sulphate.

3. It evolves less heat during setting.

4. It imparts high degree of water tightness.

5. It possesses higher tensile strength.

6. It impart plasticity and workability to the mortar and concrete prepared from it .

7. It offers great resistance to the expansion.

Following are the disadvantages of this Cement: -

1. Its compressive strength in early days is less.

2. It possesses less resistance to erosion and weathering action.

This Cement is used to prepare mass concrete of lean mix and of marine structures. It is also used for sewage works and for laying concrete under water.

PPC Grinding

S. No.Characteristics

To be testedSpecified Requirement

1.Fineness (in m2/kg) 300

2.Setting time min. 60

300

3.Soundness

(a) Le-Chat

After Areation 10 mm

5 mm

(b)Auto Clave

After Areation 0.8%

0.6%

4.Compressive Strength (Mpa)

3 Days 16

7 Days 22

28 days 33

5.LOI 5%

6.SO3 3%

7.MgO3%

8.IR z + 4(100-z)

100

z = % of Pozz.

B - Physical Testing of Cement

Consistency Measurement of Cement

Take 300 gm of Cement one mint. Dry mixing adds appx. Distil water (85 cc) and gauging 3 to 5 mints. Then poured into a 300 gm vicat mould then checks the plunger reading in the Vicat Apparatus. Reading shouls come between 5 to 7 mm.

Suppose

300gm Cement used 85 cc water

Therefore 100 gm Cement

85 x 100= 28 %

300

IST & FST (Setting Time)

Take 300 gm of Cement one mint. Dry mixing adds appx. Distil water (85 cc) and gauging 3 to 5 mints. Then poured into a 300 gm vicat mould then check the initial setting time by the help of vicat Apparatus, initial setting needle. Reading comes 5 0.5 mm. After that check final setting time by another needle, where outer needle ring disappear only dot point appears.

Compressive strength (Hydraulic Cement)

Temp of gauging room 27 2C.

Relative humidity of physical lab 65 5%.

Moist closet or moist room temp. 27 2C.

Relative humidity of moist closet not less than 90 %.

Curing tank fresh water temp. 27 2C.

Nine cubes to be prepared of each variety of Cements (three each for 3 days, 7 days & 28 days)

Preparation of Cube

Cement and 3 Std. Variety of sand is mixed in a ratio 1:3

Cement = 200 gm

Std. Sand three variety 200 gm each

Total = 800 gm

Water calculation: - P/4 + 3 where P is standard consistency.

Suppose p = 28 %

Then 28/4 + 3 = 10 cc water for 100 gm Cement.

100 gm Cement required 10 cc of water

800 gm Cement requires (800 x 10) / 100 = 80 cc water

Dry mixture with the help of trowel for one mint. Then add distil water and gauge 2 4 mints. After that pour into the vibration machine 50 % material poured then pock then rest of the material pour in the mould then vibrate for 2 min. at the rpm 12000 400. After that cube is ready, then cube put into the moist closet for 24 hours after that demould the cube put into the curing tank for rest of the days. Then cube is kept in curing tank for 3 days after which strength is checked. Than strength is again checked after 7 days and 28 days.

1 kgf force = 9.8065 N

1 N = 1/9.8065 kgf

1 KN = 1000/9.8065 kgf = 101.97 kgf

Cube size = 50 cm2 or 25 cm2 (length = 5 cm, width = 5 cm)

(Area (50 cm2 cube) = Length 70.6 x width 70.6 = 4984 mm2 = 4984/100 = 49.84 Cm2, approx 50 cm2Therefore 1 KN = 2.0394 kgf

1 Kg/Cm2 = 1/10 Mpa

Therefore = 2.0394/20 Mpa

Sound ness (Expansion)

(A) By Le- chatelier Method

Water calculation: - P x 0.78 = ------------ for 100 gm Cement.

Where P is Std. Consistency.

100 gm Cement adds water and gauge 3-5 mints. Then poured into Le- chate mould after that covered with glass sheet then put into a curing tank for 24 hours. After that check the initial reading with the help of scale in mm. Then boil the mould for 3 hours at the boiling point and cool at room temperature and again check the reading by scale. Difference between the initial and final reading is the expansion in mm.

(B) Auto Clave Test

Water calculation: - Std. Consistency x quantity of Cement = --------cc H2O use

The test specimen shall be in the form of rectangular bars 25 x 25 mm in section of 250 mm long.

700 gm Cement adds distil water and gauge 3-5 min. then pour in the autoclave bar and put in the moist closet for 24 hours. After that demould the bar and measure the length in length comparator in mm. After that bar put into the auto clave machine where water is taken 7 10 % of the volume of the cylinder, pressure 21 1 Kg/Cm2 and temperature 214 1.8(C for 3 hours. After release the pressure in 1 hours. Then cool the bar at room temperature then measure the length by length comparator in mm.

Scale of length comparator.

1 div. = 0.002 mm

250 mm length of the bar measure 0.002 mm length comparator

1000 mm length of a bar measure (100 x 0.002) / 250 = 0.0008

Suppose

Initial reading = 1400 mm

Final reading = 1500 mm

Difference

= 100 mm

Therefore expansion = 100 x 0.0008 = 0.08 %

C. Pozzolanic Material Physical Test

Lime Reactivity (L/R)

Procedure for determining the reactivity of pozzolanic material with hydrated lime.

Material required

Hydrated lime

Pozzolonic Material

3 variety of Std. Sand

1

:

2M

:

9

75 gm

150 x 1.2

225 x 3 = 675 gm

Where,

Specific gravity of Pozzolanic Materia 2.73

M =

=

=1.20

Specific gravity of hydrated lime 2.28

Water calculation: -

(Hydrated lime 75 gm + Pozzolonic material 180 gm) = A

225 x 3 = 675 gm (three variety of Std. Sand) = B

Suppose 170 cc water taken

Firstly water taken in mixing bowl then start stop watch and mixture machine in slow speed within 30 sec. Mixture A mix in the water after that machine moves another 30 sec. After that mixture B is added and run for 30 sec. (total time 1.30 mints). Stop the machine and screech the material with spatula and covered with plate for 1.30 min. total movement in slow speed. After completed 3 min. machine moves another 1.00 min. in the fast speed (total time 4.00 min.)

After that material transfer into the flow table mould during transferring two times pocking will be done by the help of poker (26 times in 6 sec.) then remove the cup 10 times tamping given by the flow table machine. And then measure the flow in all 4 directions that should come 70 5 mm (by scale 16.5 17.05 mm, 10 cm in the diameter of the cube). If it is ok pour the material in the 3 cubes of 25 cm2 area and put in a moist closet for 48 hrs. After 2 days cube transfer to the L/R oven for 8 days where temperature 50 2( C and humidity more than 90 %. After that break the cube by compressive machine 50 KN.

Drying shrinkages in Pozzolona Cement

Procedure for calculating of dry shrinkage of PPC Cement.

Material ratio = (1 Cement PPC : 3 Std. Sand ( all 3 variety equal quantity)

300 gm PPC Cement + 900 gm Std. Sand

Mixing procedure same as in L/R. calculate the water approx 170-180 cc by flow table, the flow between 100-115 mm i.e. by scale 20-21.5 with 25 drop in 15 sec. Fill up in the 250 mm bar and kept for 24 hours in the moist closet for 1 days. After demould and keeping in curing tank for 7 days and take initial reading by length comparator then kept for 28 days in the humidity control oven where temperature 27 2(C and humidity 55 5 % and then take final reading by length comparator.

Initial Reading = --------mm

Final Reading = --------mm

Difference

mm x 0.0008 = -------%

Replacement test and Blank testWe are comparing strength against plane Cement with addition of pozzolonic material. Cement how many strength replaced. It will be 80 % minimum.

Material Required : Suppose 250 gm material taken total quantity of material approx 1 Kg

Pozzolona

Plane Cement

3 variety of Std. Sand

0.2 N

:

0.8

:

3

250 x 0.2 = 50N 250 x 0.8 = 200gm 250 x 3 = 675 gm

Where,

Specific gravity of Pozzolana Material 2.73

M =

=

=0.87

Specific gravity of Cement 3.18

Plane Cement and Pozzolona mixture --------- = A

Standard Sand

--------- = B

Uses of Cement

At present the cement is widely used in the construction of various engineering structure. It has proved to be one of the leading engineering materials of modern time and has no rival in production and application. Following are possible uses of cement:-

1. Cement mortal for masonry work, plaster etc.

2. Concrete for layering floor, roof, construction lanters, beams weather shed stairs pillars.

3. Construction of important engineering structure such as bridges, culverts, dams, tunnels, storage reservoir, light houses, dock etc.

4. Construction of water tanks, well, tennis court, septic tank, lamp post, roads, telephone cabins etc .

5. Making joints for drain and pipes.

6. Manufacturing of present pipes, piles, garden seats, artistically design urns, flower pots, dustbin fencing post etc.

7. Preparation of foundation, watertight floor, footpaths etc.

LIMITATION There are limitation for primary data collection because of confidentiality. Company does not show their data because many things were confidential and cant be shown to everyone.

SUGGESTION

The company should publish and provide booklets to the users of Prism cement.

TO Provided the dividend.

To Debt should be reduces.

Prism cement holds good position owning to its price. It should be try to hold this position with continuous efforts by increasing promotional activities, SEMINARS AND VISIT CONSUMER SITES..

CONCLUSIONIt is the process of establishing and interpreting quantitative relationship between figures and groups of figures. With the help of ratios, the financial statements can be analyzed more clearly and decisions can be made more logically.

BIBLIOGRAPHY:-

Books:

Personal management: C.B. Mamoria

Research Methodology: C.R. Kothari

Human Resource Management: K Aswathappa

Designing and Managing Human Resource System: Udai Pareek and T. Rao

Websites:

www.google.com www.prismcement.com

www.hrcite.comOthers:

Training Records of PRISM CEMENT LIMITED.

QuestionnaireName:-

Designation:-

Q 1) Are you satisfied with your offer?

a) Yes b) No c) No comments

Q 2) why you joined B.C.L.?

a) For better opportunities of improvement?

b) For handsome salary?

c) For expected job profile?

d) Impressive brand image?

Q 3) Do you think, any improvement is required in Selection process?

a) Yes b) No c) No comments

If yes, please specify

Q 4) at which stage of the Selection process utmost attention is required?

a) Screening of resume b) Validation and scheduling c) Screening and interviewQ 5) what you dislike in complete procedure of your Selection & selection?

69

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