ABS BLENDED ABS BLENDED CEMENTCEMENT

We believeWe believewe are AT PAR WITH THE World's BESTwe are AT PAR WITH THE World's BEST http://cementconsultant.org/http://cementconsultant.org/

LOOKING BEYOND ORDINARY PORTLAND CEMENTLOOKING BEYOND ORDINARY PORTLAND CEMENT

The Cement Industry with annual The Cement Industry with annual worldwide production of around 1.5 worldwide production of around 1.5 billion tons is one of the largest billion tons is one of the largest users of high-grade limestone, users of high-grade limestone, coal, electricity & other minerals.coal, electricity & other minerals.

Each ton of cement requires 1.3 Each ton of cement requires 1.3 tons of limestone, 0.2 tons of coal tons of limestone, 0.2 tons of coal & around 100 kwh of electricity.& around 100 kwh of electricity.

Worldwide, cement production now Worldwide, cement production now accounts for more than 1.6 billion accounts for more than 1.6 billion tons of CO2, or over 8% of total tons of CO2, or over 8% of total CO2 emissions from all human CO2 emissions from all human activities (Wilson 1993).activities (Wilson 1993).

It was the oil crisis of the 70’s that It was the oil crisis of the 70’s that made the world understand the made the world understand the evils of prolificacy of natural evils of prolificacy of natural resourcesresources..

The French, the Germans, the The French, the Germans, the Japanese took the lead cause Japanese took the lead cause these were the countries blessed these were the countries blessed with little natural resources. with little natural resources.

VSK in operation

BLENDED CEMENTBLENDED CEMENT This led to the resurgence of This led to the resurgence of

blended cements. The thrust was blended cements. The thrust was clearly on clearly on conservance of natural conservance of natural resources, usage of waste resources, usage of waste materials & on the durability of materials & on the durability of concreteconcrete..

According to figures released by According to figures released by CembureauCembureau (the European Cement (the European Cement Association), blended cement Association), blended cement production in Europe during 1994 production in Europe during 1994 increased by 21 percentage points increased by 21 percentage points to 51% of total cementitious to 51% of total cementitious production (from 30% in 1992).production (from 30% in 1992).

Portland cement production during Portland cement production during the same period declined to 37% the same period declined to 37% (from 52% in 1992). In the period (from 52% in 1992). In the period from 1990 to 1995, from 1990 to 1995,

The average The average clinker factorclinker factor during during this period (worldwide average) this period (worldwide average) was reduced by more than 6%. was reduced by more than 6%.

Rotary Cement Plant

BLENDED CEMENT IN INDIABLENDED CEMENT IN INDIA Lafarge is the world leader in Lafarge is the world leader in

blended Cement technologyblended Cement technology Lafarge spends 5% of its turnover on Lafarge spends 5% of its turnover on

R&D R&D Lafarge introduced a 16MPa one day Lafarge introduced a 16MPa one day

strength cement with only 35% strength cement with only 35% clinker ratio in the Indian market in clinker ratio in the Indian market in 1999.1999.

Indian cement companies have been Indian cement companies have been unable to decrease the unable to decrease the clinker/cement ratio below 75% while clinker/cement ratio below 75% while maintaining the one day bench mark maintaining the one day bench mark strength of 16MPa.strength of 16MPa.

However blended cement production However blended cement production is up 15% points now totalling 35% in is up 15% points now totalling 35% in the last two years as the Indian the last two years as the Indian companies grapple to bring down companies grapple to bring down costs & improve cement quality in costs & improve cement quality in face of stiff competition from face of stiff competition from multinationals like CEMEX, multinationals like CEMEX, LAFARGE etcLAFARGE etc

Blending Silos

The NEEDThe NEED ABS Cement was set up at a cost ABS Cement was set up at a cost

of $ 4,00,000 in 1991, with a term of $ 4,00,000 in 1991, with a term loan of $ 2,50,000 to manufacture loan of $ 2,50,000 to manufacture 70 tpd OPC (Ordinary Portland 70 tpd OPC (Ordinary Portland Cement) using VSK technology.Cement) using VSK technology.

ABS made profits since inception ABS made profits since inception & repaid almost 50% of the loan & repaid almost 50% of the loan by 1996.by 1996.

However ABS had to be shut However ABS had to be shut down for want of Limestone in down for want of Limestone in 1996 as the Dehradun Limestone 1996 as the Dehradun Limestone mines were closed following an mines were closed following an order of the honourable Supreme order of the honourable Supreme Court. Court.

New product lines were required New product lines were required for survival.for survival.

A need thus arose for the A need thus arose for the manufacture of Blended Cement.manufacture of Blended Cement.

Our VSK & RAW MILL were sold in 2001

The cost of the Rotary Clinker in The cost of the Rotary Clinker in India is $ 44 PMT almost India is $ 44 PMT almost equivalent to the selling price of equivalent to the selling price of Cement.Cement.

It is a well known fact that Clinker It is a well known fact that Clinker gives cement the early strength gives cement the early strength while the pozollan the later age while the pozollan the later age strength.strength.

In 1998 we re-commenced In 1998 we re-commenced production of Cement with 65% production of Cement with 65% clinker content balance being clinker content balance being locally available pozollans.locally available pozollans.

Our experiments to decrease the Our experiments to decrease the clinker content led to a cement clinker content led to a cement with low one/three day strength with low one/three day strength which was unacceptable in the which was unacceptable in the Indian Market.Indian Market.

Rotary Clinker received at ABS

Cement being packed

THE BEGINNING

ACI-Effect of fineness on cementACI-Effect of fineness on cement

The startling finding that the The startling finding that the one/three day strength increases one/three day strength increases almost three fold if the fineness of almost three fold if the fineness of cement goes up from 2500 blaines cement goes up from 2500 blaines to 4500 blaines( provided we to 4500 blaines( provided we maintain the desirable residue) maintain the desirable residue) was an important breakthroughwas an important breakthrough. .

““The effect of fineness on cement” The effect of fineness on cement” was published online by the was published online by the American Concrete Institute in American Concrete Institute in 1999.1999.

Cement FinenessCement Fineness As our cement mill is designed As our cement mill is designed

for manufacturing cement at a for manufacturing cement at a maximum fineness of 3500 maximum fineness of 3500 blaines further R&D was blaines further R&D was required.required.

With trial & error we achieved With trial & error we achieved our bench mark.our bench mark.

Eight major changes had to be Eight major changes had to be made to our cement mill to made to our cement mill to achieve the required fineness.achieve the required fineness.

These changes includedThese changes included 1.1. Installing an on line Jaw crusher,Installing an on line Jaw crusher,2.2. Tinkering with the RPM of the Tinkering with the RPM of the

cement mill,cement mill,3.3. Changing Grinding media Changing Grinding media

distribution etc etc.distribution etc etc.On Line Jaw Crusher at ABS

FLY ASHFLY ASH The only world class pozollan The only world class pozollan

available near us was Class F available near us was Class F Flyash containing less than 1% Flyash containing less than 1% CarbonCarbon

Fly is priced at a reasonable $8 Fly is priced at a reasonable $8 PMT.PMT.

This fly ash became the natural This fly ash became the natural ingredient around which our ingredient around which our research evolved.research evolved.

In1999 ABS trial marketed fly ash In1999 ABS trial marketed fly ash blended cement with 32% fly ash blended cement with 32% fly ash content. content.

Indian standard IS: 1489 permitted Indian standard IS: 1489 permitted a maximum of 25% fly ash content a maximum of 25% fly ash content in cement.in cement.

It was on our letter that the It was on our letter that the IS: IS: 1489 was AMMENDED to 1489 was AMMENDED to allow 35%allow 35% fly ash addition in fly ash addition in cement in 2001.cement in 2001.

We realized that We realized that if our technique if our technique was adopted the world can was adopted the world can gainfully utilize 400 million tonsgainfully utilize 400 million tons of of fly ash per year in cement alone.fly ash per year in cement alone.

Class F Fly Ash with 1% Carbon Note the colour is off-white

Introduction of a pozollan is a time Introduction of a pozollan is a time consuming affair as any material consuming affair as any material requires at least 6 months of extensive requires at least 6 months of extensive laboratory testing & field trials.laboratory testing & field trials.

Emboldened we extended our Emboldened we extended our research to calcined clay, & low grade research to calcined clay, & low grade limestone & their usage in cement.limestone & their usage in cement.

Our discussions with Bureau of Indian Our discussions with Bureau of Indian Standards (BIS), National Council For Standards (BIS), National Council For Cement & Building Materials Cement & Building Materials (NCCBM), & the FLY ASH MISSION (NCCBM), & the FLY ASH MISSION also paved way for the allowance of also paved way for the allowance of addition of addition of low-grade raw limestone up low-grade raw limestone up to 5% in OPC cementto 5% in OPC cement..

Further amendments including the Further amendments including the allowance of more performance allowance of more performance improvers in cement are under improvers in cement are under

consideration.consideration.

Crushed Brick bats

Crushed Limestone

Calcined Clay & Limestone

Cement Manufacture is all about Cement Manufacture is all about incoming & outgoing freight.incoming & outgoing freight. Cement being an inexpensive Cement being an inexpensive commodity. commodity.

Addition of GGBFS was out of Addition of GGBFS was out of question as the landed price was question as the landed price was $32 PMT.$32 PMT.

We settled on air cooled slag from We settled on air cooled slag from a local mini steel plant that was a local mini steel plant that was free excepting for the freight of $5 free excepting for the freight of $5 PMT.PMT.

Although worldwide research on Although worldwide research on Air Cooled Slag-for usage in Air Cooled Slag-for usage in cement is not documented, we cement is not documented, we realized we were on the right realized we were on the right track.track.

AIR COOLED SLAG

Air Cooled SLAG

Alkali Activated Slag & AdditivesAlkali Activated Slag & Additives

To increase the one day strength To increase the one day strength we activated the slag by lime we activated the slag by lime sludge etc.sludge etc.

Further activators/accelerators Further activators/accelerators were added.were added.

The Clinker/Cement ratio in 2002 The Clinker/Cement ratio in 2002 stands at 52%.down from 65% stands at 52%.down from 65% three year ago.three year ago.

Research being a continuous Research being a continuous process we hope to bring down the process we hope to bring down the ratio by four percentage point this ratio by four percentage point this year to 48% by Sept this year.year to 48% by Sept this year.

Thanks to Thanks to Blended Cement, ABS Blended Cement, ABS has since repaidhas since repaid all outstanding all outstanding loans to financial institutions.loans to financial institutions.

The The 500 tpd Nirmaan Cement 500 tpd Nirmaan Cement appointed us consultantsappointed us consultants to to improve cement quality & decrease improve cement quality & decrease their clinker ratio in 2001.their clinker ratio in 2001.

Lime sludge

Additives & Accelerators being added

Consistency in CementConsistency in Cement

ABS cement now had 7-8 ABS cement now had 7-8 pozollan/additives.pozollan/additives.

We introduced the We introduced the weighbridge system so that weighbridge system so that each ingredient could now be each ingredient could now be weighed for producing a weighed for producing a cement consistent in quality.cement consistent in quality.

CEMENT INDIACEMENT INDIA The Journal Cement The Journal Cement

India showcased our India showcased our cement for two years cement for two years running on its website running on its website www.cementindia.netwww.cementindia.net

Several articles on Several articles on blended cement and fly blended cement and fly ash of ours were ash of ours were published by Cement published by Cement India.India.

At ABS our At ABS our quest to quest to produce better cement produce better cement has just started…….has just started…….