Alternative Raw Material Sources For Cement Production
In cement production, diversifying raw material sources emerges as a critical strategy to bolster sustainability and mitigate environmental impacts. Cement manufacturers are increasingly turning towards alternative materials such as fly ash, slag, and limestone substitutes to reduce reliance on traditional resources like limestone and clay. This strategic shift not only addresses concerns regarding resource depletion but also contributes to the circular economy by repurposing industrial by-products. Embracing alternative raw materials not only fosters resilience against supply chain disruptions but also enhances the environmental footprint of cement production by curbing greenhouse gas emissions and reducing energy consumption. Moreover, this paradigmatic transition aligns with regulatory frameworks promoting sustainable practices, thereby positioning cement manufacturers favorably in the competitive market landscape. By leveraging diverse raw material sources, cement production can achieve heightened sustainability, resilience, and environmental stewardship while meeting the demands of a rapidly evolving construction industry.
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.
Title page
Letter of transmittal
Approval page
Dedication
Acknowledgement
Abstract
Definition of terms
Table of content
CHAPTER ONE
INTRODUCTION
1.1 Background of the study
1.2 Purpose of the study
1.3 Scope of the project
1.4 Significance of the study
1.5 Limitation of study
CHAPTER TWO
LITERATURE REVIEW
2.1 LIME AND ITS USES
2.2 CONVERSION OF RICH HUSK TO ASH
2.3 BASIC CEMENT RAW MATERIALS
2.4 TYPES OF CEMENT
2.5 CEMENT CHEMISTRY
CHAPTER THREE
3.0 EXPENRIMENTAL WORK
3.1 PYROPROCESSING OF THE RICE HUSK
3.2 TERATMENT AND ANALYSIS OF THE LIME
3.3 COMPOUNDING OF THE RAWMIX
3.4 MANAUFACTURING PROCESS
CHAPTER FOUR
ANALYSIS AND DISCUSSION OF RESULT
CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
RECOMMENDATION
REFERENCES
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.
1.5 LIMITATION TO STUDY
Many factors limited the progress of this study, these include
a) Lack of high temperature furnace up to 16000c. we could only get one (15000) at federal science equipment manufacturing center (FSEMC).This one could only attain a temperature of 13000c and we4 had no alternative other than to stop there.
b) The cost of chemical analysis by PRODA is very high N300 per sample. Only few sample were therefore analyzed.
c) Another constraint was unavailability of plastering or graphite crucible that would with stand high temperature especially during the burning. This reason made it impossible for us to have enough burnt samples for physical test.
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Alternative Raw Material Sources For Cement Production:
Cement production typically relies on traditional raw materials like limestone, clay, and shale. However, there is a growing interest in finding alternative raw material sources for cement production due to concerns about the environmental impact of traditional mining and the need to reduce carbon emissions associated with cement manufacturing. Here are some alternative raw material sources for cement production:
Fly Ash: Fly ash is a waste product generated from coal combustion in power plants. It contains silica and alumina, which are key ingredients in cement production. Using fly ash as a supplementary cementitious material can reduce the need for traditional raw materials and lower greenhouse gas emissions.
Blast Furnace Slag: Blast furnace slag is a byproduct of iron and steel production. It has cementitious properties and can be ground into a fine powder to replace a portion of the clinker in cement production. This reduces the carbon footprint of cement.
Rice Husk Ash: Rice husk ash is an agricultural waste product that can be used as a supplementary cementitious material. It contains silica and can partially replace traditional raw materials in cement production.
Calcined Clays: Certain types of clays, when calcined at high temperatures, become pozzolanic and can be used as a substitute for some of the clinker in cement production. Metakaolin, for example, is a calcined clay often used in this way.
Natural Pozzolans: Natural pozzolans, such as volcanic ash, are naturally occurring materials with pozzolanic properties. They can be blended with traditional raw materials to reduce clinker content and improve sustainability.
Recycled Concrete Aggregates: Crushed concrete from demolished buildings and structures can be used as aggregates in cement production. This reduces the demand for virgin aggregates like sand and gravel.
Alkaline Activators: Some researchers are exploring the use of alkaline activators, such as sodium silicate and sodium hydroxide, to create alkali-activated cements that do not rely on traditional raw materials like limestone.
Alternative Binder Systems: Researchers are also investigating alternative binder systems, such as geopolymer cements, which use materials like fly ash, slag, and natural pozzolans combined with alkaline activators to create a cement-like material.
Industrial Waste Materials: Various industrial waste materials, such as silica fume, can be used as supplementary materials in cement production, reducing the need for traditional raw materials.
Bio-cement: Some research is being conducted on bio-cement, which involves using bacteria to precipitate calcium carbonate, forming a cementitious material. This approach has the potential to reduce the environmental impact of cement production significantly.
It’s worth noting that the feasibility of using these alternative raw materials can vary depending on local availability, regulatory requirements, and the specific properties required for the cement product. Additionally, the use of alternative raw materials may require adjustments to the cement production process and testing to ensure product quality and consistency.