v ABSTRACT
The project evaluates the effectiveness of quality control in Dangote Cement PLC, Ibese Ogun State, Nigeria. Limestone, shale and laterite samples were from the mines to determine their right grade as well as their mixing proportion. Also samples were taken from kiln feed and the final stage of cement production. The compressive strength of the cubes is determined according to the ages of the cubes which is 2 days, 7 days and 28 days while the degree of lime content in raw materials, clinker, cement, limestone in relation to other oxides were determined using XRF and setting time and residue determination values were also estimated. The results show that the compressive strength for 2 days is between 16 – 33, for 7 days is between 28 – 47 and for 28 days is between 33 – 53. Meanwhile, percentages of CaO, C3S, C2S and MgO in clinker are 53.57 %, 56 %, 16.47 %, 2.14 % and 62 %, 58 %, 19 %, 0 % in cement. The amounts of residue retained by different sieves were within the standard specification of 10 – 22 gm. The study therefore concluded that the quality control in Dangote Cement Company is effective and cement produce meets international standard requirements and characteristics which dependable and satisfactory.
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TABLE OF CONTENT
CERTIFICATION ii ACKNOWLEDGEMENTS iii DEDICATION iv ABSTRACT v TABLE OF CONTENTS vi LIST OF TABLES ix LIST OF FIGURES x
CHAPTER ONE 11 INTRODUCTION 11
1.1 Background of the Study 11
1.2 Scope of the Study 2
1.3 Aim and Objectives of the Study 2
1.4 Geology of the Ibese Limestone Deposit 2
CHAPTER TWO 14 LITERATURE REVIEW 14
2.1 CEMENT 6
2.2 TYPES OF CEMENT 7
2.3 Portland Cement 8
2.3.1 Types of Portland cement 9
2.3.2 Raw Mix Preparation 12
2.3.3 Raw mix blending 13
vii 2.3.4 Formation of Clinker 14
2.3.4.1 The burning process 14
2.3.4.2 Suspension preheaters and calciners 16
2.3.5 Cement Grinding and addition of Gypsum 17
2.3.6 Cement Kiln Dust 18
2.4 Raw Materials 19
2.5 Properties of the Major Cement Minerals 19
2.6 Control Ratios 23
2.7 Mineral and oxide composition of Portland cement 24
2.7.1 The Bogue calculation of cement mineral composition 26
2.7.2 Modified Bogue calculation based on actual mineral compositions 27
2.8 The Fineness and Particle size distribution of Portland Cement 28
CHAPTER THREE 32 RESEARCH METHODOLOGY 32
3.1 Data Collection 32
3.2 Sample Collection and Preparation 32 #
3.3 Quality Control of Limestone and Additives 32
3.4 Quality Control Processes / Laboratory Procedures 32
3.5 The ROBO/QCX Lab 33
3.5.1 ROBO- lab 33
3.5.2 XRF 34
3.5.3 Online analyzers 34
3.6 Compressive Strength Test Lab 34
viii 3.7 Fineness Test 38
3.8 Moisture Test 38
3.9 The Setting Time Determination 38
CHAPTER FOUR 40 RESULTS AND DISCUSSION 40
4.1 Compressive Strength Test Results 40
4.2 Chemical Analysis in the ROBO-LAB 41
4.3 Setting Time and Residue Determination 41
4.4 Discussion of Result 42
CHAPTER FIVE 45 CONCLUSION AND RECOMMENDATION 55
5.1 Conclusion 45 5.2 Recommendations 45 REFERENCES 46
