1. CONCH CEMENT----YINGDE PLANT
Yingde Conch Cement Company Co. Ltd. has 4 clinker & cement product lines with each capacity of 5000t/d clinker output. It has 6 sets ¦µ4.2x14.5m cement mill and 2 sets power generation systems by waste heat. The clinker output is about 7.2 million tones and cement output is about 4.8 million tones. The main products are ¡°conch cement¡± P.II52.5, P.O42.4, P.O42.5R and P.C32.5. Clinker and the product is mainly sold to Shaoguan, Guangzhou, Foshan, Dongguan and Shenzhen etc.and broadly used, but not limited, on Buildings, Express ways and Bridges such as Wu-Guang railway, Guang-Zhu city to city railway and Guang-He express way etc. 500 million tones product is sold to Hong Kong and Macao area every year.
TH-3 cement grinding aid is applied to the No.1 and No.2 cement mills in this plant. The result is compared as following:
TABLE 1 -- THE COMPARISON OF USING TH-3 CEMENT grinding AID
Item
|
1# TH-3
230g/t |
2# TH-3
230g/t |
1#
No aid |
2#
No aid |
Result |
Capacity (t/h) |
115.6 |
120.1 |
112.1 |
113.8 |
Increased by 4.8t/h |
Power Consumption (kwh/t) |
40.7 |
40.7 |
41.8 |
41.8 |
Reduced by 1.1kwh/t |
3d strength (Mpa) |
29.6 |
29.6 |
29.0 |
29.0 |
Increased by 0.6Mpa |
28d strength (Mpa) |
51.2 |
52.0 |
51.0 |
51.6 |
Approx. Same |
Additives(%) |
12.7 |
12.7 |
8.7 |
8.7 |
Increased by 4% |
Normal consistence(%) |
28.5 |
28.5 |
27.7 |
27.8 |
Increased by 0.75% |
Specific area (m2/kg) |
370 |
370 |
356 |
354 |
Increased by 15m2/kg |
Spec. area eligibility ratio(%) |
99.2 |
99.6 |
91.1 |
90.3 |
Increased by 8.7% |
L.O.I(%) |
4.28 |
4.26 |
4.03 |
4.08 |
Increased by 0.23% |
L.O.I eligibility ratio(%) |
92.8 |
92.6 |
94.5 |
94.9 |
Reduced by 2.1% |
Conclusion from the table above:
- 4% more additives can be added after cement grinding aid used, which means clinker consumption reduced by 4%.
- 3d average strength is 29.6MPa, and 28d average strength is 51.6MPa, the strength performance is increased after cement grinding aid.
- The average specific area is 370m2/kg, it increased 15m2/kg after cement grinding aid used.
- Normal consistence increased to 28.5% from 27.75%
1.2 CONCH CEMENT----ZHONGGUO CEMENT PLANT CO.
At year 2002, Conch Cement merged with Zhongguo Cement Plant and reformed it to Zhongguo Cement Plant Co. After the new company came into existence, Conch Cement invested to erect two 5000t/d product lines. The fist line has been taken over at July 2004, and the second line put into production at February 2005. All the two lines passed the environment test and the total capacity of the plant increased to 500 million tones from 110 million tones.
In order to improve cement quality and lower the produce cost and increase the using volume of additives, the company tested the P.O42.5 cement through experimentation to prove the adaptability of high effective retarder and cement grinding aid.
1.2.1 Equipments And Material For Test
- Clinker,
- 0.0235% TianHeng® TH-3 cement grinding aid,
- 1.1~1.2% naphthalene JM-9 high effective retarder,
- 1.0% hydroxyl acid PCA admixture,
- CaSO4-2H2O,
- Additives: limestone, pozzolana, flyash. and
- ¦µ4.2X11m cement ball mill with roller press.
1.2.2 Test Program
The test program is stipulated as following: Keeping the specific area and the gypsum proportion, test the cement performance after using cement grinding aid through changing the additives proportion.
Table 2 -- test program
| Test No |
Duration |
SO3 (%) |
CaO |
Spec. area (m2/kg) |
Limestone |
Pozzolana |
flyash |
| 0 |
8h |
2.3¡À0.3 |
¡Ý55% |
360 |
8% |
0% |
6% |
| 1 |
48h |
2.3¡À0.3 |
¡Ý54% |
360 |
10% |
0% |
6% |
| 2 |
48h |
2.3¡À0.3 |
¡Ý53% |
360 |
11% |
0% |
7% |
| 3 |
24h |
2.3¡À0.3 |
¡Ý53% |
360 |
6% |
6% |
6% |
1.2.2.1 Sample Physical Performance Resulted From Analyzing
Table 3 ¨CSample physical performance resulted from analyzing
Test No |
0 |
1-1 |
1-2 |
2-1 |
2-2 |
3-1 |
3-2 |
TH-3 (g/t) |
/ |
235 |
235 |
235 |
235 |
235 |
235 |
additives |
14% |
16% |
16% |
18% |
18% |
18% |
18% |
0.08 mm,% |
0.2 |
0.3 |
0.3 |
0.5 |
0.9 |
0.6 |
0.6 |
0.045mm,% |
2.2 |
3.2 |
2.5 |
4.2 |
6.8 |
6.8 |
6.1 |
Spec.area (m2/kg) |
365 |
371 |
387 |
376 |
394 |
391 |
380 |
Normal consistence (%) |
30.4 |
28.9 |
29.9 |
29.6 |
29.1 |
29.3 |
28.6 |
Initial setting (h:min) |
2:36 |
2:32 |
2:22 |
2:22 |
2:34 |
2:21 |
2:26 |
Final setting (h:min) |
3:30 |
3:28 |
3:18 |
3:17 |
3:30 |
3:18 |
3:21 |
1d Non Mpa |
15.6 |
17.0 |
17.5 |
17.0 |
17.2 |
16.4 |
16.5 |
1d SteamingMpa |
31.0 |
30.8 |
30.5 |
29.2 |
30.0 |
29.8 |
29.1 |
3d rupture strengthMpa |
6.0 |
6.5 |
6.4 |
6.1 |
6.4 |
6.0 |
6.1 |
3d compressive strength Mpa |
29.9 |
31.2 |
30.2 |
30.2 |
30.7 |
30.0 |
29.7 |
Note:
1d Non: The strength after drying curing 24 hours in 20¡æ atmosphere
1d Steaming: Curing 24 hours in 55¡æ humidity circumstance
1.2.2.2 The adaptability of naphthalene JM-9 admixture and sizegrade distribution resulted from test.
We can get a conclusion from the sizegrade distribution analyzing to tested sample using laser analyzer: the quantity of the 3~30¦Ìm grade is increased observably. And the adaptability of the cement grinding aid and concrete admixture is good.
Table 4 ¨C the adaptability of the sizegrade distribution and JM-9 admixture (net paste)
| Test No. |
TH-3
(g/t) |
Additives |
Paste fluidity (mm/mm) |
Lost ratio
(%) |
Xav
(¦Ìm) |
¡Ü3
(¦Ìm) |
¡Ü30
(¦Ìm) |
D50
(¦Ìm) |
X(5%)
(¦Ìm) |
X(95%)
(¦Ìm) |
0 |
/ |
14% |
193/164 |
15.0 |
20.49 |
18.28 |
69.52 |
11.63 |
1.44 |
56.69 |
1 |
235 |
16% |
197/181 |
7.8 |
19.75 |
26.12 |
72.50 |
12.97 |
1.19 |
57.87 |
2 |
235 |
18% |
193/166 |
13.8 |
19.7 |
25.06 |
72.56 |
47.18 |
1.23 |
56.70 |
3 |
235 |
18% |
194/166 |
14.4 |
22.42 |
22.21 |
65.56 |
17.03 |
1.30 |
58.44 |
Note:
Xav: Tthe average size of cement sample.
D50: Average size of the 50% accumulated particles of the total sample.
X(5%): 5% of the total sample particles less than some grade.
X(95%): 95% of the total sample particles less than some grade.
1.2.2.3 The chemical analyzing result told us: along with the additives increase, all the oxide contents changed a little except the LOI increased.
1.2.2.4 The mill capacity variety after using cement grinding aid
Table 5 -- The mill capacity variety after using cement grinding aid
|
Test No. |
TH-3
(g/t) |
Capacity
(t/h) |
Total additives
(t) |
Limestone
(t) |
Flyash
(t) |
Pozzolana
(t) |
Power consumption
(kwh/t) |
0 |
/ |
101.5 |
14.1 |
6.7 |
7.4 |
/ |
37.3 |
1 |
235 |
115.5 |
16.24 |
9.64 |
6.60 |
/ |
35.93 |
2 |
235 |
114.3 |
18.45 |
11.08 |
7.37 |
/ |
34.0 |
3 |
235 |
112.9 |
18.06 |
6.05 |
6.00 |
6.01 |
35.41 |
1.2.2.5 The cement and concrete admixture adaptability comparison of using cement grinding aid. (keeping the time of agitating and other conditions, only using different cement.)
W: The water consumption of 1m3 concrete.
C: The cement consumption of 1m3 concrete.
S: The normal size sand consumption of 1m3 concrete.
FA:The flyash consumption of 1m3 concrete.
G: The small stone (5~31.5mm) consumption of 1m3 concrete.
JM-9: Naphthalene concrete admixture.
PCA: Hydroxyl acid concrete retarder.
SL0: Concrete initial slump.
SL1h: Concrete slump of 1 hour later.
Air: The air content in the concrete just made.
R: The value of the concrete strength.
Table 6 -- The cement and concrete admixture adaptability comparison
|
Cement |
W
kg/m3 |
C
kg/m3 |
FA
kg/m3 |
S
kg/m3 |
G
kg/m3 |
JM-9
kg/m3 |
PCA
kg/m3 |
SL0
mm |
SL1h
mm |
Air
% |
R7d
Mpa |
R28d
Mpa |
0 |
178 |
300 |
60 |
790 |
1072 |
4.3 |
/ |
220 |
150 |
2.8 |
30.2 |
39.8 |
TH-3(
235g /t) |
178 |
300 |
60 |
790 |
1072 |
4.3 |
/ |
220 |
155 |
2.7 |
31.5 |
41.9 |
00 |
148 |
340 |
60 |
810 |
1070 |
/ |
4.0 |
220 |
210 |
3.5 |
43.4 |
52.7 |
TH-3(235g/t) |
148 |
340 |
60 |
810 |
1070 |
/ |
4.0 |
220 |
210 |
3.8 |
45.2 |
55.8 |
Analyzing of the test result
- When 0.235¡ë TianHeng® cement grinding aid is used and keeping the mill capacity, 4% more additives can be added and the cement specific area increased by 20m2/g. And at the same time, the 3d strength is almost not changed.
- The water consumption has increase intent along with the additives increase when cement grinding aid is used.
- The adaptability of the cement used grinding aid mixing with naphthalene and hydroxyl acid retarder is good.
- After using the cement aid, the mill capacity has increase intent and the power consumption has decrease intent.
- According to table 5, the economic benefit forecast after the cement grinding aid used is listed as following.
|
Cement Grinding Aid 