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ALTERNATIVE
RAW MATERIAL SOURCES FOR CEMENT PRODUCTION
ABSTRACT
It is generally known that cement id
produced from limestone, mar/clay and gypsum by the following three basic
process- wet semi- wet aid dry process.
The cost of exploiting the limestone:
the major raw material constitute about 50% of the production cost which
results in the high cost of cement. It therefore becomes imperative to
bring down the cost of cement by investigating into alternative source of raw
material for cement production and hence this project.
From literature, rice husk ash, Ukpo
day,& Nsu day contain the basic mineral constituents which limestone
has. Rice husk was burnt temperatures of 5000c,
6000c, 7000c, and 8000c. The
best ash was obtained at a temperature of 7000c,. the above
material were also analyzed to determine their mineral constituents. The
result shown that rice husk contains little aluminum (Al203)
and no lime (Ca0). To make up for these mineral constituents,
Upo day which is rich in aluming was blended with lime(Ca0)-a bye
product from gas plant and the three minerals were blended using the method of
lime saturation factor. A blending ratio of 70% lime 20% PHA and 10%
Alumina mixture (Ukpo day) was used. The mixture was mixed dry by
dry process and burnt in a furnace at a temperature of 12000c.
the resulting mass known as dinker was ground with 5% gypsum.
The cement obtained gave a comprehensive strength of 2N/mr2.
DEFINITION OF TERMS
OPC
- Ordinary Portland
cement
LSF
- Lime saturation
factor
Quicklime
- Calcium oxide Ca0
Raw
meal
- Secondary raw
material that is fed into the kiln for burning
Raw
mill
- A tube like
machinery where the grinding of raw material
takes
place.
ASTM
- American society
for testing materials.
Hydraulic
modulus
- The ration of
lime (Ca0) to silica, Alumina and ferric
oxides.
Clinker
- Intermediate raw
material and the product from the kiln.
C3S
- Tricalcimn
silicate
C2S
- Dicalcium
silicate
C3A
- Tricalcium
Aluminate
C4AF
- Tetra calcium
Alumiroferite
CHAPTER ONE
INTRODUCTION
1.1
BACKGROUND OF THE STUDY
Cement is a complete mixture of mineral
substances that gradually harden when mixed with water. It is the product
of the reaction of lime with the oxides of silica alumina and iron. It is
used in the construction of industry as a blending material. Some
builders regard it as the key engineering material for construction
purposes. many allied construction materials such as asbestos, culverts
concrete seals, concrete poles, cement blocks etc are derived from cement and
they also play very important roles in the construction industry.
For the average Nigeria, a major life
ambition is to own a living house cement, a key raw material has ruined to
‘Gold’ as has become a topical issue. Just like iron, steel and
petrochemical, cement is equally a major spring board for
industrialization. This quest for industrialization has resulted to
increase in demand with the consequent increase in the cost of cement.
One of the reasons adduced for the
exorbitant cost of cement is the scarcity of raw material. This situation
arises as a result of its fast depletion which is not replaced.
Another reason adduced for the
exorbitant cost of cement is the high cost of the exploration and exploitation
of the raw material. To mine the chief raw material for the manufacture
of cement- limestone requires a lot of machines, plants and explosives. A
lot of money is also paid as compensation to the communities that own the
land. All these expenditures lead to the high cost of cement. This
study was therefore to investigate alternative source of raw material for the
production of cement.
These investigation was geared towards
industrial waste and Agricultural residues. Agricultural residues are
composed of organic constituents such as cellulose, lignin, fibre and small
amounts of crude protein and fat. In addition, they contain a rage of
minerals which silica, Alumina and iron oxide. The residue itself cannot
be used as cement replacement and it is the ash that is obtained form the
preprocessing that is of interest. Two factors require for constituents
of the ash. The ash content is important because it indicates the amount
of reside which need to be burnt; that is the yield. D..J COOK (1980) states
that rice husk have shown by far the greater yieled of ash than other plants like
sorghum, corn leaf blade, Bamboo nodes, (Inner portion) bangasse, lantana leaf
and stem and rice straw.
For every 1000kg of rice husk burnt,
200kg of ash are produced. Hence it is not surprising that rice husk
emerged as the agricultural that with the greatest potential as cement
replacement material.
One the other hand, lime is a by
product of gas companies. It is readily available at no cost.
The utilization of these raw material
for cement product production is very altercative in developing countries like
ours. This is because it does not only reduce demand on Portland cement
but it also provides cement in rural areas of the country especially in rice
growing areas which rice husk is found in large quantities and constitute
environmental nuisance.
1.2
PURPOSE OF THE STUDY
The present high cost of cement and the
exorbitant cost of residential house occasioned by high cost of raw material
exploitation, energy, population explosion and development have necessitated
intensification into the search for alternative raw material for the production
of this product. The aim of this project therefore was to bring down the
cost of cement by the use of alternative raw materials form industrial and
agricultural waste.
1.3
SCOPE OF THE PROJECT
The intention was to
1)
Source and analyze the following raw materials rice husk lime (waste product
from Niger gas company) Ukpo clay, Nsu clay and pulverized fuel Ash (PEA)
2)
Obtain the best condition for preprocessing.
3)
Compounding the raw mix.
4)
Burning
5)
Peterning the physical characteristics.
1.4
SIGNIFICANCE OF THE STUDY
On completion of the study, the result
would be of importance to the Government and Entrepreneurs who may wish
to go into the production of cement. The increased investments in this
area will bridge the gap between demand and supply and bring down the cost of
cement the reduced price of cement will catalyze infrastructure development and
majority will be able to own a living house.
Another importance of the project is
that it will serve as the starting point for the production of other types of
cement known as blend cement. The study will also help to provide cement
in rural areas typically of those traditionally deprived of cement. In
this way small-scale businesses possible.
Since the industrial and agricultural
waste are waste which causes environmental pollution and create problem with
disposal its utilization would not only control environmental employment
opportunities to our young school leaver.
The research would also be of immerse
benefit to future researchers and student who would have the interest of
studying similar subjects.
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