Internship Report On Chhatak Cement Comp

Internship Report
On
Chhatak Cement Company Limited
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Cement is the general term given to the powdered materials which initially have plastic flow
when mixed with water or other liquid but has property of setting to a hard solid structure in
several hours with varying degree of strength and bonding properties. Cement is one of the
most important building materials at the present time. In spite of modem concrete roads and
buildings, everywhere around us, it is difficult to realize the tremendous growth of cement
industry during the past century. In modern times one need only mentioned reinforced
concrete walls and grinders, tunnels, dams and roads to realize the dependence of present day
civilization upon these products, the convenience, cheapness, adaptability, strength, and
durability of cement products have been a foundation of these application.
1.2. A brief discussion of different types of cement
Cements are mainly of two types.

1) Hydraulic cement
2) Non-hydraulic cement
Hydraulic cement is one which requires water to attain adhesive properties, where as the
non-hydraulic cement does require water for getting adhesive properties e.g. araldite, fevicol
etc. hydraulic cements are also two types. They are natural and Portland cement.
Natural cement : A hydraulic cement produced by calcining a naturally occurring

argillaceous lime stone at a temperature below the sintering point and grinding to a fine
powder.
Portland cement : Hydraulic cement produced by pulverizing clinker consisting essentially

of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate
as an underground addition, hydraulic calcium silicates posses ability to harden without
drying or by reaction with atmospheric carbon dioxide. The reactions involved in the
hardening of cement are hydration and hydrolysis. Its hardening is due to chemical reaction
between the cement water.
The reactions are given below:
1. Reactions of tricalcium silicate (C3S) with H2O.

2(3CaO.SiO2) + 6H2O 3CaO.SiO2.3H2O + 3Ca(OH)2
2. Reactions of dicalcium silicates (C2S) with H2O.

2(2CaO.SiO2) + 4H2O 3Ca.2SiO2. 3H2O + Ca(OH)2
3. Reaction of tricalcium aluminate (C3A) with H2O.

3CaO. Al2O3 + 6H2O 3CaO.Al2O3. 6H2O
4. Reaction of tetra calcium aluminates ferrite (C4AF) with H2O.

4CaO.Al2O3. Fe2O3 + 2Ca (OH)2 + 10H2O 3CaO. Al2O3. 6H2O
+ 3CaO. Fe2O3. 6H2O
5. Reaction of tridicalcium aluminates (C3A), Gypsum with H2O.
6. Reaction of uncombined lime (CaO) magnesium oxide (MgO) with H2O.
a) CaO + 06. Reaction of uncombined lime (CaO) and Magnesium oxide (MgO)
with H2O.
b) CaO+H2O Ca(OH)2 c) MgO + H2O Mg(OH)2

7. Reaction of sodium and potassium oxide with H2O.
a) Na2O + H2O 2NaOH b) K2O + H2O 2KOH
This leads to the insoluble product. When used in concrete or mortar, it binds to the aggregate
together into a solid mass.
1.3. : Types of Portland cement
Portland cement is of various types depending upon the rate of setting, heat evolution and
strength characteristics. These properties may varied by varying the percentage of
constituents present in the cement. Five types of Portland cement are recognized, which
contain varying amounts of the clinker compounds C2S, C3S, C4AF and MgO. Normally
Portland cements are following types:-
1. Ordinary Portland cement

They are used products for general concrete constructions harden to fall strength in about 28-
30 days. They contain 40-60% C3S, 10-30% C3S and 7-13% C3A. White cement, oil well
cement, quick setting cement etc. also belong to this class.
2. Modified Portland cement

This cement is use where moderate hear of hydration is required or for the general concrete
construction exposed to moderate sulfate action.
3. High early strength Portland cement

These are made from raw materials with lime to silica ratio higher than that of type 2 cement
and are ground finer than type 1 cement.
4. Low heat Portland cement

The cement contains lower percentage of C2S and C3A thus lowering the heat evolution.
Addition of Fe2O3 to reduce the amount of C2S and increase the percentage of C4AF. These
cements are designed for massive structure work.
5. Sulfate resisting Portland cement

This cement can resist sulfate better than the other four types. This cements are lower in C3A
and than regular cement, the C4AF is higher.
The aim and objectives of this program are as follows:
1. To gain introductory knowledge on the industry of our country.
2. To gain work experience in chemical industry.
3. To identify specific problems of chemical industries.
4. To work on specific problems of industries.
5. To improve technical system in the field of chemical industry.
6. To find out the various chemical source and also to apply them in various aspects.
7. To make an option where cost reducing will be the main fact.
8. To solve the environment pollution caused by the chemical source.
Contents
Chapter One: General discussion about cement
1.0. General discussion about cement
1.1. What is Cement?
1.2. A brief discussion about different types of cement
1.3. Types of Portland Cement
Table No. 1.1: Chemical Speciation for Portland Cement
1.4. Major constitute of Portland cement
1.5. Methods of manufacturing cement
Chapter Two: Chhatak Cement Company Limited
2.0. Chhatak Cement Company Limited
2.1. Chhatak cement company at a glance
2.2. Socio Economic
2.3. Welfare Facilities
Chapter Three: Production of Cement
3.0. Production of Cement
3.1. Procedure of Cement preparation
3.1.1. The Process
3.1.2. Production process and flow diagram
3.2. Raw Materials & Production process
3.3. Principle Raw Material
3.4. Source & Collection of Raw Material
3.5. Types of Cement Produced
3.6. Process Description
3.6.1. Clinker preparation
3.6.2. Phase Formation
3.7. Typical Analysis of cement raw material
3.8. Typical Analysis of clinker, cement and mineralogical composition of

cement
3.9. Hard Mass formation with Water
3.10. Production of sulphate resisting cement (SRC)
3.11. Production of Rapid Hardening Portland Cement (RHCP)
Chapter Four: QUALITY CONTROL IN CHHATAK CEMENT CO. LTD.
4.0. QUALITY CONTROL IN CHHATAK CEMENT CO. LTD.
4.1. Introduction
4.2. Quality Control Branch
4.3. Analysis of chemical composition of clinker and cement
4.4. Physical Analysis
4.5. Fitness test
4.6. Water consistency test
4.7. Soundness test
4.8. Theory of rapid setting and hardening of cement
4.9. Water treatment of Chhatak Cement Company Ltd.
Chapter Five: Ropeway Department
5.0. Ropeway Department
Chapter Six: Mechanical Department
6.0. Mechanical Department
Chapter Seven: Commercial Department
7.0. Commercial Department
7.1. Production, sales, profit and loss
7.2. Contribution of national exchequer
Chapter Eight: Environmental pollution and control of the factory
8.0. Environmental pollution and control of the factory
8.1. Air Pollution
8.2. Noise Pollution
8.3. Hill cutting for collected clay
Conclusion
8
Table 1.1: Chemical specification for Portland Cement
Types of cement Type -1 Type -2 Type -3 Type -4 Type -5

Silicon dioxide (SiO2), Min% 20.0
Aluminum dioxide (Al2O3), Max% 6.0
Ferric oxide (Fe2O3), Max% 6.0 6.5
Magnesium oxide (MgO) Max% 5.0 6.0 6.0 6.0 6.0
Sulfur trioxide (SO3), Max%
When C3Al is 8% or less 2.5 3.0 3.5 2.3 2.3

When C3Al is 8% or more 3.0 4.5
Loss on ignition (LOI), Max% 3.0 3.0 3.0 2.5 3.0
Insoluble residue (IR), Max% 0.75 0.75 0.75 0.75 0.75

Tricalcium silicate (3CaO.SiO2) 35
Max%
Dicalcium silicate (2CaO.SiO2) 40

min%
Tricalcium aluminate 8 15 7 5
(3CaO.Al2O3), %
1.4 : Major constitute of Portland cement
CaO=C
SiO2=S
Al2O3=A
Tricalcium silicate, 3CaO.SiO3.C3S
Dicalcium silicate, 2CaO.SiO3.C2S
Tricalcium aluminate, 3CaO.Al2O3.C3A
Tetra calcium alumino ferrate, 4CaO.Al2O3.C3A.Fe2O3.C4AF
Gypsum, Calcium sulfate, CaSO4
Calcite, CaO.
1.5: Methods for manufacturing cement:
Cement is generally manufactured by the three processes given below:

a) Wet process
b) Dry process
c) Semidry process
a) Wet process: Wet Process is most common and is almost universally employed for the
manufacture of cement. In this process the raw materials are finely group blended in the
designed portion and the mix is brought to the condition of free flowing slurry containing
30-40% water. The slurry is thoroughly homogenized with the help of compressed air and
introduced into a rotary kiln. The change slowly moves down the kiln due to the rotary
motion while a blast of burning coal is blown up from the other end of the kiln.
b) Dry process: In this process, the calcareous argillaceous materials are crashed in gyratory
crushers to small pieces, dried and mixed in proper proportion, pulverized, the tube mills
and homogenized in mixing mill with the help of compressed air. This raw meal is
introduced into the upper of the rotary kiln while a blast of burning coal dust is blown
from the other end. The reaction taking place and the rest of the process is same as
described in wet process.
c) Semi dry process: in this process, the raw materials are good dry, but instead of feeding
as a powder the raw meal is nodulised with ID-40% water in pan or drum type
noduliser.
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CHAPTER TWO
CHHATAK CEMENT COMPANY LTD.
2.0. Chhatak Cement Company Limited, Chhatak Sunamganj
2.1 Chhatak cement company at a glance

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1. Year of establishment : 1973 as ASSAM BENGAL CEMENT COMPANY
2. a. commercial production : 1941 by M/s. Polysius AG, GERMANY

b. initial capacity : 60,000 TPY Ordinary Portland cement (OPC)
3. status of company : Public limited
4. Logo
5. Raw materials : Limestone, Clay, Gypsum
6. Process of manufacture : wet process
7. a. Establishment of 2nd line of the plant : 1958 by F.L. Smidth & co. DENMARK
b. capacity : 90,000 TPY (OPC)
8. a. BMRE Phase-I : 1987 by M/S. Heavy Engineering Corporation,

(Balancing Modernization India.
Rehabilitation and Extenuation
b. Cost (in core) : Total F.C L.C
32.51 7.09 25.42
9. Attainable capacity after BMRE : 1,35,000 MTPY

Phase-1
10. BMRE Phase-II
a. Feasibility Study : August, 1984 by STORCR CORPORATION, USA

b. Approval by ADB : December, 1985
12
d. Loan Agreement signed : March, 1987.
e. PP approved by ECNEC : 3rd, March, 1987.
f. Cost of BMRE-11 : Total F.C L.C (Lac Taka)
- Original approved ECNEC 4.3.1987 11537.40 6630.10 4907.30
- Revised approved P P ECNEC 2.12.3992 12656.66 8463.85 4392.81
- Current remised P P ECNEC 8.12.1999 5990.75 6031.07 9959.68
- Actual Cost 17928.3 17928.31
g. Mode of financing : Loan Equity Source Total
- Local currency (As per approved p.p) 2438.68 5731.83 8170.51
- Foreign Aid 6159.07 6159.07
h. Project period : July, 1986 to August,2000
i. Component of works - Cement Plant modification and expansion for

increase of production from 135,000 MT to
233000 M. TPY.
- Installation of a new 8 MW Power Generator.
- Renovation of Ropeway ( Capacity of 66 MT)
j. Cement Plant Modification & Expansion
- Consultant : M/S. Nihon Cement Co. Ltd. Japan.
- Turnkey Contractor : M/S. SAMSUNG and Korea Heavy Industries
- Execution Period : December 26, 1989 to June30, 1993
- Turnkey Contract Cost : Total F.C. L.C.(in lac taka)

6431.00 5218.00 1195.00
- Progress of Work : Physical work completed within June 1995
k. Procurement and installation of new power : Renovation work completed within August 2000
generator Total expenditure Tk. 5032.10 Lac
ADP Tk. 1412.18 Lac
Own source Tk. 3619.92
l. Renovation of ropeway : Renovation work completed within June, 2000

Total expenditure Tk. 670.34 Lac
ADP Tk. 477.00 Lac
Own source Tk. 193.34
13
11. Capacity after BMRE Phase-II : Attainable - 2,33,000MTPY
12. Name of Products : Ordinary Portland cement. Manufactured as per

BS- 12/1978 & BDS -232: 1993.
Rapid hardening cement. Manufactured as per
BS 12/1978 & BDS232: 1993.
Sulphate Resisting cement as per BSS 4027.
13. Standard of cement : British Standard 12:1978/BDS-232:1993
14. Usage of ratio : a. Limestone - 1.227 MT/MT of cement

b. Clay - 0.29 MT/MT of cement
c. Gypsum - 0.045 MT/MT of cement
15. Land area of Chhatak cement Co. Ltd. : a) Factory : 14.19 acres
b) Housing : 24.84 acres
c) Others : 215.81 acres
Total : 254.87 acres
Besides there is 193.64 acres land area owing this company used for transporting system
2.2. Socio-economic
Amenities: The factory also renders following facilities to its employees.
a) Welfare fund facility for easy loan, retirement grant and death grant.
b) Islamic library facility.
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c) Central sports committee to organize and promote sports activities of the factory.
d) Central Co-operative fund for different financial and social benefits like departmental
store, internal transport facility.
2.3. Welfare facilities
1. Medical: there is one medical center with 18 beds hospital where free medical
services are provided to employees.
2. Accommodation: Family quarter, Bachelor seat.
3. Club: Workers and employees club auditorium officers and ladies club.
4. School: High school up to S.S.C level.
5. Canteen-Subsidized canteen facilities for employees and
6. Family planning: A family planning center.
15
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CHAPTER THREE
PRODUCTION OF CEMENT
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3.0. Production of cement:
3.1. Procedure of cement preparation
3.1.1. The process
At present cement company produces cement is by wet process. It is low cost compare with
wet process. Chhatak Cement Company is only all in all cementing company in Bangladesh,
all process is in re within wet process and here production is good compare with other
cement.
3.1.2. Production process and description of the flow diagram
a) Raw material preparation
The basic raw materials for the production of cement are clay, limestone and gypsum. Clay is
collected from companys own hills washed in wash mill by mixing with water. Limestone
transported from Takerghat and imported from India is crushed to 25 mm size.
b) Preparation of slurry
Crushed limestone and washed clay in the proportion of 82:18 are fed to the ball mill and
converted to slurry having about 38% moisture. This slurry is fed kiln after correction in
blending silo.
c) Clinker preparation in the rotary kiln
Slurry is travelled through 120m long rotary kiln and is converted into clinker at about
14000C passing through the different stages of temperature zone.
d) Cement preparation in cement mill
Finally mixing 96% clinker with 4% gypsum. The mixture is then sent to a three
chambered ball mill containing balls of 90mm diameter in the first chamber 50mm
diameter in the second chamber of grinding into fine particles. It is then sent to cement
silos.
e) Storing and packing

18
The cement is stored in cement silo and bagged in polypropylene bags in packing plant,
which is dispatched to customers by railway wagon and track as per customers demand.
From kiln
Rope way
Clay from hill India
TLMP
Clay wash Clay basin Lime

stone Limestone
crusher
River route
Storage
hall
Raw mill
Slurry silo Slurry

basin
Rotary kiln
Gypsum Finish mill

driver
Cement
silo
Clinker Packing
storage plant
hall
Dispatch
Dispatch
by bridge
by boat
Fig 1: Flow diagram of Chhatak Cement Co. Ltd.
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3.2. Raw materials & production process
Chhatak Cement Company limited is the only complete cement mill of the country. In this
mill limestone & clay slurry mixed and fed to the kiln for clinker preparation.
3.3. Principle raw material
The principle raw materials for production of cement are:
1. Limestone (CaCO3 92-96%; SiO2 1-2%; Oxides of Al & Fe 1-2%)
2. Clay (Al2O3 10-20%; SiO2 70-74%; Fe2O3 6~8%; CaO 0.5-1%; MgO 0.1-1.5%;
Oxides of Na & K 0.5-0.8%; LOI 5-6%; )
3. Gypsum (CaSO4.2H2O 90-96%; H2O 4%)
4. Water.
3.4. Source and collection of raw materials
Limestone
Source-1: Komra limestone mine project, Khasia/Jayntia hill, Meghalay, India.
Mode of collection: A 16 km long rope way is maintained by CCCL to carry limestone from
the source. About 360 buckets of carrying capacity 7000 kg each are in operation.
Source-2: Takergh at mining project, Tahirpur, Sunamganj, Bangladesh.
Mode of collection: CCCL has self mining project at Takerghat. A man power set up of 273
is maintained for limestone mining. The limestone is transported to the factory by country
boat through river surma.
Source-3: Chala/ T. alab/ Echamati mining project, Meghalay, India.
Mode of collection: limestone is also collected from this source by country boat through
contractors.
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Clay
Source: Hill adjacent to factory.
Mode of collection: The factory owns a big area of hilly land. The soils of these hills are
used as clay.
Gypsum
Source: Gypsum is available in TSPCL. Chittagong.
Mode of collection: The factory carries gypsum from TSPCL by truck, barge, and railway.
3.5. Types of cement produced:
Chhatak cement Co. ltd. Generally produces three types of cement:
a) Ordinary Portland cement
b) Rapid hardening Portland cement
c) Sulphate resisting cement
3.6. Process Description:
Chhatak cement factory produces cement through wet process. Though fuel cost is high but
raw materials are homogeneously mixed in this process.
The following are the major steps for clinker preparation
a) Clay slips preparation
b) Crushing of limestone
c) Mixture preparation
d) Clinker preparation
a)Clay slip preparation :
21
Clay from self owned adjacent hill cut by escalator labor and washes and carried to
wash mill by a dump truck. It is then fed to the wash mill. In the wash mill clay is
mixed with 50% water to make slurry called clay slip. Unwanted material from the
clay slip like stone beads, weeds & roots are separated and removed in the wash mill.
There are two wash mills for clay slip preparation.
b)Crushing of limestone:
The principle raw material is limestone. The limestone carried from different sources
is bigger in size. They are first crushed into smaller size in crusher. The crushed
limestone is stored in storage hall.
c)Mixture preparation:
There are limestone storage bins, clay storage bin in the mixture mill house. In the
mill house two ball mills namely raw mills are operation with modern control system.
The cylindrical ball mill with specially constructed lined for grinding of limestone
chips. Limestone chips from storage hall carried to mill bin through conveyer belt and
bucket elevator. Clay slip from the basin is carried to clay storage bin of mill house
through pump. Limestone chips are charged to the ball mills through one weighing
feed system. Clay slip and water are also fed to the ball mill by controlling their ratio
through flow meters. The collision of limestone chips with balls and liner due to the
continue rotation of ball mill grinds to the chips to dust producing thick slurry with
clay and water. This slurry is called mixture. This slurry is stored in slurry tank and
finally pumped to silo for storage. There are four silos for storing this slurry. Slurry is
tested periodically from ball mills and silo to ensure its quality. Tested slurry is sent to
slurry basin. There are agitators in the silos and slurry basin moving slowly, round the
clock with arrangement for regular air flow to prevent clogging of slurry. This slurry
is fed to the kiln from slurry basin for preparation of clinker.
d)Preparation of clinker:
Clinker is produced in the rotary kiln from slurry mixture. Wet process needs a longer
kiln. Different physical and chemical changes occur at different zones of the kiln.
22
CCCL has got two long rotary kilns namely 1) FLS rotary kiln and 2) HEC rotary
kiln.
The kiln may be divided into three major operations zone:
1) Evaporation zone 2) Calcining zone and 3) Burning zone
1)Evaporation zone: the temperature of this zone is generally 150-180C. As the kiln is
inclined at a 4% slope to the front, the slurry moves forward with rotation of the kiln.
Metallic chains are hanged inside kiln up to 30m from the rear end. These chains
regulate material flow, arrest dust and heat for proper reaction. In this zone the water
present in the slurry evaporates out. The slurry is changed into noodles and forward.
2)Calcining zone: the temperature of this zone is generally 500-800C. In this zone CC.
in this zone CO2 is removed from CaCO3 and MgCO3 producing CaO and MgO.
3)Sintering zone: the temperature of this zone is generally 850-1400C. In the C. in this
temperature CaO reacts with silica, alumina and iron to form the main mineralogical
complex of cement C2S & C3S, C3A & C4AF. The complex compound so formed
comes out from the front end of the kiln, is called clinker. The mineralogical
composition of clinker is as follows:
a) Tri calcium silicate (C3S) : 51-52%
b) Di-calcium silicate (C2S) : 25-28%
c) Tri calcium aluminate (C3A) : 8-9%
d) Tetra calcium silicate : 8-9%
Table 3.1: Reacton during clinker formaton
Temperature C Reaction Heat change
23
100 Evaporation of free water Endothermic
500 and above Evaporation of combined Endothermic

water from clay
900 and above Crystallization of amorphous Endothermic

dehydration products of clay
900 and above Evolution of carbon dioxide Endothermic

from calcium carbonate
900-1200 Main reaction between lime Exothermic

and clay
1250-1280 Commencement of liquid Endothermic

formation
1280 and above Further formation of liquid Probably Endothermic on

and completion of formation balance
of cement compounds
Reaction in the rotary KILN
During the preparation of clinker in the rotary kiln many reaction occurs some important
reaction of them are given below.
Stage-1: At 150-200C free water of slurry is evaporated and forms a jelly like species that
passes through chain zone to inhibit aggregation.
Stage-2: At 600-700C combine water of clay is removed from slurry and forming
metakaolite structure, e.g.
Al4(OH)8Si4O10 2 (Al2O3.2SiO2) + 4H2O
Stage-3: At 700-900C species of clay is converted to reactive Oxide e.g.
Al2O3.2SiO2 Al2O3 + 2SiO2
Stage-4: At 900-1000C decomposition of limestone (CaCO3) and MgCO3 is occurred e.g.
CaCO3 CaO + CO2
24
MgCO3 MgO+ CO2
And simultaneous formation of calcium silicate and calcium acuminate with the reaction of
calcium oxide silica and alumina is occurred.
CaO + 2SiO2 + Al2O3 2 (CaO SiO2) + CaO. Al2O3
Stage-5: At 1000-1300C calcium silicate and calcium aluminate react with more calcium
oxide to form dicalcium silicate and tri calcium aluminate and tetera calcium alumino ferrite
with ferric oxide.
CaO SiO2 + CaO 2 CaO SiO2 (C2S)
2CaO + CaO. Al2O3 3CaO. Al2O3 (C3A)
2CaO + CaO. Al2O3 + Fe2O3 4Cao. Al2O3 + Fe2O3 (C4AF)
Stage-6: At 1250-1450C the slurry reaches at firing zone and ten some of the minerals also
reach at their melting point and this situation dicalcium silicate combines with more calcium
silicate and tricalcium silicate.
2 CaOSiO2 + CaO 3 CaO. SiO2 (C3S)
This tricalcium silicate is the most important compound of cement it helps cement to quick
hardening.
After the formation of clinker, this is then introduced into rapid cooling either the help of 12
cooler attached with the kiln.
If the clinker does not introduced into rapid cooling tricalcium silicate may undergo reverse
reaction and breaks down into dicalcium silicate and free calcium oxide and ultimately
declines cement quality.
3 CaO.SiO2 2 CaO.SiO + CaO
If magnesium oxide remains in free state in cement it is called percaies the free magnesium
react with water and form magnesium hydroxide, which may cause volumetric expansion.
There are 12 long tubes at the end of discharge point of the kiln, known as planetary cooler.
After crossing burning zone, when the clinker reaches planetary copier its temperature
25
remains around 700800C. Air is drawn through the planetary cooler by the IDF placed on
the other end of the kiln. This circulation of air in the planetary cooler drops the temperature
of the clinker to 200C.
The clinkers are then drawn to the secondary cooler by drag chain/apron bucket conveyer etc.
In the secondary cooler clinker is cooled through cooling fans. At this stage, temperature of
the clinker drops to 100C. It is then sent to clinker storage hall by bucket elevator.
The dust originated in the kiln are trapped in EP and again fed to the kiln. There are two EPs
for two-kilns.
3.6.2. Phase formations
The physical and chemical changes that occur at different zones of the kiln arc as
follows
Physical/ chemical changes Temperature, C
1. Evaporation of free water from the feed 100 & above
2. Evolution of the chemical chemically combined water in 500& above
3. Evolution of CO2 from Ca & Mg carbonates (Calcinations) 800 & above
4. Formation of interim phase (C2F) 850 & above
5. Formation of interim phase (CF) 900 & above
6. Formation of interim phase (C2S+C2AS+CF+C2F) 1000& above
7. Formation of interim phase (C2S+C5A3+C5A+C3S+CF+C2F) 1100 & above
8. Formation of interim phase (C2S+C3A+C2F+C3S) 1200 & above
9. Formation of (C3A+C3S+C2S+C4AF) 1300-1450
3.7. Typical Analysis of cement raw material
Table 3.2.: ingredients of cement raw material and their percentage
26
Compound Lime stone % Clay in % Slurry (blended in %)
SiO2 0.84 71.84 14.50
Al2O3 0.60 13.20 4.00
Fe2O3 0.32 7.68 1.2
MgO 0.50 0.32 0.65
Na2O 0.30 0.10 0.20
K2O 0.10 0.5 0.0
CaO 54.0 0.80 43.00
LOI (Loss of ignition) 42.80 5.40 35.50
TOTAL 99.26 99.49 99.57
3.8.Typical analysis of clinker, cement and mineralogical composition of cement.
Table 3.3.: Composition and percentage of cement, clinker and mineralogical species.
Clinker composition Cement composition Mineralogical composition of cement in

in % in % % (calculate)
IR-0.25 0.25 C3S-54.83
27
CaO-66.48 64.50 C2S-19.71
Si2O-23.30 12.30 C3A-10.34
Al2O3-5.04 5.50 C4AF-7.60
Fe2O3-2.80 2.50 ..
LOI-0.25 1.80 ..
MgO-0.40 1.20 MgO-0.29
Na2O-0.40 0.38 Na2O-0.38
K2O-0.15 0.12 K2O-0.18
CaO-0.58 0.50 CaO-0.50
SO3-0.30 0.86
3.9. Hard Mass Formation with water
When the fixed amount of limestone and clay are mixed at 1450C temperature at a result of
chemical reaction four chemical compounds are formed and clinker are formed. We find
magnesium as MgCO3 in clay and limestone. It breaks low temperature compare with
limestone.
MgCO3 MgO + CO2
It reacts with water i.e.
MgO + H2O Mg(OH)2
If MgCO3 excess in slurry then free MgO will be increase then the volume of cement will be
increase and will be break. The kiln is in oxidation state. The gas use in the kiln contains
CO2-16%, O2-4% CO-0-0.5% that the condition of the kiln is good.
28
3.10. Production of Sulphate Resistance Cement (SRC) and its uses
3.10.1 Introduction
Sulphate resistance cement is a spatial type of Portland cement. In the market several kinds of
Portland are found, among them only Chhatak Cement Co. produce the sulphate resistance
(SRC) and marketed.
3.10.2 Raw material
The following raw materials are use to produce sulphate resistance cement (SRC).
1. Limestone (CaCO3)
2. Clay.
3. Iron scale (Fe2O3) and
4. Gypsum (CaSO4)
3.10.3. Production
Chhatak Cement Co. Ltd. produces SRC by wet process
3.10.4. Slurry Preparation
1. Limestone: limestone is fed into the crusher and it is crushed into 0.5 inch down size
particle and stocks it in the storage hall.
2. Clay slip preparation: Red soil is collected from the company own hill. In the wash
mill, 50% water is added to the red soil to produce clay slip. Then it store in the slurry
basin.
3. Iron scale: Iron scale is that where above 90% Fe2O3.
Clinker preparation for SRPC is same as for OPC but some change for the raw material is
use. At first slurry preparation, alumina content soil is decrease and added 3%-5% iron scale
29
i.e. 3%-5% soil is decrease and 3%-5% iron scale with limestone and clay. The last step for
the preparation of SRPC same as OPC cement preparation.
3.10.6. Uses
At present, different types of slab or concrete block is made for the use in the river and costal
area of the sea. Now some municipal corporation use SRPC for better drainage system.
Because the water contain SO42- ion did not damage any structure that is made by SRPC.
3.11. Production of Rapid Hardening Portland Cement (RHPC) and its uses
3.11.1 Introduction
Rapid Hardening Portland Cement (RHPC) is a spatial type of Portland cement. In the market
several kinds of Portland are found, among them only Chhatak Cement Co. produce the
Rapid Portland Cement (RHPC) and marketed.
3.11.2 Raw material
The following raw materials are use to produce Rapid Hardening Portland Cement (RHPC):
1. Limestone (CaCO3)
2. Clay and
3. Gypsum (CaSO4)
3.11.3 Production
Chhatak Cement Co. Ltd. produces RHPC by wet process
3.11.4 Slurry preparation:
30
1. Limestone: limestone is fed into the crusher and it is crushed into 0.5 inch down size
particle and stocks it in the storage hall.
2. Clay slip preparation: crushed limestone and washed clay in the proportionof 82:18
are fed to the ball mill and converted to slurry having about 38% moisture. This slurry
is fed to the kiln after correction in blending silo.
3.11.5. Clinker preparation:
Clinker preparation for RHPC is same as for OPC but some change for the raw material is
use. At first slurry preparation, alumina content soil is decrease and increase lime. The last
step for the preparation of RHPC same as OPC cement preparation.
3.11.6 RHPC Cement preparation
Gypsum content is increase from 4% to 4.4-5.5%. So clinker is also decrease from 96%. The
last step for the preparation of RHPC same as OPC cement preparation.
3.11.7 Uses
At present railway slipper is made with the help of the special type of RHPC cement.
CHAPTER FOUR
31
QUALITY CONTROL
32
4.0. QUALITY CONTROL IN CHHATAK CEMENT CO.LTD.
4.1. Introduction
Technical department consists of three branches
Quality Control Branch

Design Library & Fire Service
Training Branch
4.2. Quality Control Branch:
This branch consists of two parts-
i. Analysis of chemical composition of clinker and cement.

ii. Physical analysis
4.3. Analysis of chemical composition of clinker & cement:
A. Analysis of silica (SiO2):
a. It was taken 0.5 gm of sample in a 50 ml dry beaker and about 0.5 gm NH4Cl
was added to it. The beaker was covered with a watch glass and mixed thoroughly
with gentle swirling.
b. 5.0 ml of concentrate HCl was added to it and the acid was allowed to run down the
leaf of the beaker. After the chemical action subsided the cover was lift and two drops
of concentrate HNO3 acid was also added to it. Then the solution was stirred with a
glass rod and the lumps was broken if any.
c. The beaker was covered with a watch glass and placed it on a water bath for
30 min. Then the mixture was stirred 4 or 5 times during the period of 5 of 6 min
interval.
33
d. The jelly like mass was filtered through Whatmarm-41 filter paper and the solution
was lift to drain completely. The beaker was washed 2 or 3 times with hot HCl (1:99)
and scrubbed the beaker in a polish manner with a piece of filter paper and was
transferred the contents of the beaker to the filter paper. The residue remained above
the filter paper was washed 3 to 4 times with small proportion of hot HCl (1:99)
e. The content of the filter paper was washed 10 to 12 rimes with hot distilled water and
the portion was allowed to drain out completely. The filtrate was reserved in another
500 ml beaker for R2O3 determination. The filter paper with residue was transferred in
an electric oven for removal of moisture. Then it was taken in a previously weight
platinum or porcelain crucible and was kept it at the entrance of carbolated furnace to
smoke off the filter paper and was ignited slowly at first and then strongly it was dept
again inside the same at 1050C about 30min. After the crucible as burnt, it was out
from the furnace.
f. Then the crucible was cooled in a desiccators and weight of was taken it in an
electric balance.
B: Analysis for R2O3 (Al2O3+Fe2O3)
a. It was filtrate (obtained from SiO2), to which 6 ml of concentrate HCl was added.
b. The nitrate was boiled on a heater for 5 min and a piece of filter paper no-42 was
placed at the bottom of the beaker and pressed with glass rod before heating the
solution.
c. Then 2 or 3 drops of methyl red indicator was added to it and NH 4Cl (1:1) was added
drop wise until the color of solution became distinctly yellow and 1 or 2 drops of
excess NH4Cl was also added. The precipitation of R 2O3 was appeared and it was
boiled continue for 2 min.
d. Then the beaker was kept on asbestos sheet and the precipitation was allowed to settle
down and then filtered through Whatmann-41 filter paper. After then the precipitation
was washed with hot NH4Cl solution (20gm/5liter) for 10-12 times.
e. The filter paper with precipitation (after drying the paper with precipitation) was
placed in a dry porcelain/ platinum crucible, which weight should be taken previously.
The crucible was smoked off at the entrance of the furnace and after then it was
ignited strongly at 1050C. after ignition, the crucible was cooled in a desiccators and
the weight of it was taken.
34
C. Analysis for Fe2O3,
a. It was taken 1 gm of sample (cement) into a 25o ml beaker and 25-30 ml distilled
water was added to it. Then the solution was stirred with a glass rod and 10 ml of
concentrated HCl was added to it.
b. During addition of water and HCl, the solution was stirred and grinds the un-dissolved
particles with a glass rod gently.
c. Boiled the solution in an electric heater. During boiling (about 5-10 min) stannous
chloride (SnCl2) was added to it drop wise until the solution became colorless and 1
drop of excess was added.
d. The whole mixture contained in a beaker was cooled down under tap water. Then 10
ml of 50% mercuric chloride (HgCl2) and 10 ml of 50% phosphoric acid (H3PO4) was
added to it and diphenylamine indicator (1 gm in 100 ml concentrated H 2SO4) was
also added to it.
e. Then the mixture was titrated against 0.00N potassium dichromate solution (dry 2.457
gm/liter) and the end point was marked.
D. Analysis for CaO
a. Filtrate (obtained from R2O3 separation) was taken in a 600 ml beaker and it was
boiled in an eclectic heater until the solution became natural (color slightly pink) then
hot ammonium oxalate (50 gm/liter) was added to it, while precipitate was appeared.
The solution was boiled for 15 min and then the whole solution was filtered through
Whatmann-40 filter paper. The residue above the filter paper was washed about 10-12
to times with got distilled water.
b. The precipitate was taken back into original beaker and it was washed with hot
distilled water. Added to it 10 ml (50%) H2SO4 solution and mixed well the solution.
c. The solution was heated up to 70-80C on an asbestos sheet of electric heater and then
it was titrated against KMnO4 (0.18N) solution and the end point was marked.
35
E. Analysis for MgO
a. The filtrate (obtained from calcium precipitate separation) was taken in a 600 ml
beaker and it was cooled, and 60 ml of 50% ammonium hydroxide solution and 10 ml
10% ammonium biphosphate solution was added to it. Then the mixture was stirred in
a magnetic stirrer for 15 min. Then precipitate was appeared.
b. After 12 hrs or next day the precipitate or residue was filtered through Whatmann-42
filter paper and the precipitate with NH4NO3 solution (100gm NH4NO3+200ml NH3
solution + 800ml distilled water) was washed for 12-15 times.
c. After drying the filter paper was placed in a dry and previously weight porcelain
crucible.
d. The filter paper was smoked off at the entrance of the furnace and was ignited
strongly at 950C. after ignition, the crucible was cooled in a desiccators and weight
of it was taken,
F. Analysis for free Lime
1 gm of cement was taken in dry conical flask and one gm dry coarse sand and 25 ml
ethanediol was added to it. Then it was heated to about 80C for 30 minutes, with occasional
stirring and it was filtered through whatmann-40 filter paper and the filtrate was titrated with
0.1N HCl to straw color using a mixed indicator.
Mixed indicator: A mixed of Thymol blue (3 parts of a 0.1% aqueous solution of the sodium
salt) and cresol red (1 part of a 0.17% aqueous solution of the sodium) changes from yellow
to violet at pH= 8.3.
G. Analysis for insoluble materials
a. It was taken 1 gm of cement sample into a 400 ml beaker.

b. 5 ml concentrated HCl and 5 ml distilled water was added to it.
36
c. It was slightly heated for 5-10 minutes and was filtered with whatmann-40 filter paper
and washed with distilled water.
d. The filter paper with residue was taken into the original same beaker and 50 ml 10%
NaOH was added to it and then the beaker was kept on hot plate for 10-15 minutes.
e. 3-4 drops of Methyl red indicator and concentrated HCl was added drop wise to it.
After neutralization 4-5 drops of excess concentrated HCl should be added.
f. Then the solution was filtered through whatmann-42 filter paper and it was washed
with hot NH4NO3 solution. Then the filter paper was put into a crucible and ignited up
to 950C (1hr) and after cooling in a desecrators the weight of the crucible was taken.
H. Analysis for SO3
a. 1 gm sample (cement) was taken into a 250ml beaker and about 25-30 ml distilled
water adder to it and it was stirred with a glass rod and 10 ml concentrated HCl was
also added to it.
b. During addition of water and HCl the solution was well and finally grinded to
dissolve the undissolved particles with a glass rod gently.
c. The solution was boiled on an electric heater (about 5-10min). After 2-3 min. the
contents of the beaker were filtered through Whatmann-40 filter paper and the beaker
was washed 10-12 times hot distilled water.
d. Filtrate was taken into a 400 ml beaker and then it was heated to boil on a heater for
5-10 min and a piece of filter paper whatmann-42 were placed at the bottom of the
beaker and it was pressed with a glass rod before hating the solution.
e. 10 ml of BaCl2 (10%) was added to the solution and it was boiled continuously for 15
min. (BaCl2 contents beaker should be at the same boiling point before mixing).
Precipitate was appeared as BaSO4.
f. After 2-3 min, the contents of the beaker were filtered through whatmann-42 filter
paper and was washed the content of the beaker and filter paper with hot distilled.
Water. The filter paper with precipitate was placed in dry and previously weight
porcelain or platinum crucible. The crucible was smoked off at the entrance of the
furnace and then it ignited strongly at 850C. After ignition it was cooled in a
desiccators and the weight of ix was taken.
37
I. Analysis of Na and K by flame photometer
a. 0.5 gm cement sample was taken in a 250 ml beaker and 25 ml distilled water was
added to it and was swirled.
b. 5 ml HNO3 was added to it and then it was simmered for 10 min and further 100 ml of
hot water was added.
c. The whole solution was cooled and transferred quantitatively to a volumetric flask
and the beaker was washed at several times and the washing was also transferred to
the volumetric flask.
d. Then 50 ml of Al(NO3) solutions was added to it.
e. After then 50 ml Ca solution was added and it was made exactly to 500 ml.
f. Then Na* and K* were measured in the flame photometer in usual way.
4.4. Physical analysis

38
A. Fineness test by measuring cement residue
Procedure
In this process 100 g cement was passed on 170-mesh sieve for the time of 15 minutes. After
sieving the cement the remaining pan was called cement residue. Standard value of cement
residue could not more than S 0%. Our observed value was 6%
B. fineness test by using Blein apparatus (By determination of specific surface)
In this experiment specific surface is expressed as total surface area in square centimeter per
gram of cement. The number and size of the pores in a prepared cement bed of definite
porosity is a function of the size of the particles and determines the rate of airflow through
the cement bed.
Procedure
First 2.84g sample was taken in a bed preparing metal disk (having sieve for airflow)
containing apparatus. A filter paper of appropriate mesh size was taken before and after the
sample fed then with the help of a plunger, the cement bed was prepared after plunging. After
then the cement bed containing apparatus was taken at the top of the manometer tube. Then
with the help of a pump the manometer liquid (dibutyl phtalate) was pumped into a desired
level, above A and the side cork, C was stopped and the time was counted with the help of a
stopped and the time was counted with the help of a stopwatch as the liquid touched at level
A and counting was continued up to level B.
Specific surface = SsT/Ts
= T393
Where, SsTs=393, standard value for standard sample. Standard value of specific
surface of OPC of Chhatak could not less than 3400cm/g. but our observed time was,
T= 77sec.
So, our observed value of specific surface was =77393=3448cm2/gm
Fineness depends on
39
1. Cement residue
2. Specific surface.
4.5. Water Consistence Test:
Using of Vicat Apparatus:
After plunging on (cement + water) pest by using Vicat apparatus, we had an idea about the
amount of water required for 400g of cement.
Procedure:
Initially Vicat apparatus scale was set up at 0 reading. After mixing cement (400g) with
considerable amount of water (122-318C.C), the mixture was set up under the plunger and
operated plunging was operated. Then we found that the reading was in between 5-7 mm, and
then we could say that the considerable amount of water that.
Our observed value of plunging was 5.7 mm.
4.6. Setting time test
1. Initial setting time must not be less than 45 minutes for ordinary Portland
cement. But, initial setting time of OPC of Chhatak cement was 120-150
minutes. Our observed value was 140 minutes.
2. Final setting time must not be more than 600 minutes for ordinary Portland
cement. But, final setting time of OPC of Chhatak Cement Company is 200-
250 minutes. Our observed value was 235 minutes.
4.7. Soundness test
The capacity of the set or hardened cement to reset disintegration either on fixation in marshy
areas or alternative exposure to wet and dry conditions is called soundness.
40
By using Le. Chatalier expansion test we had an idea about soundness of cement, ft was
nothing but the volumetric expansion test of cement at specific temperature and time.
Standard expansion value must not more than 10 mm. but expansion value OPC of Chhatak
Cement Company was in between (1-2) mm. Our observed value was 1.55mm.
Procedure:
After taking cement with 22.5% water and mixing thoroughly, it was kept on expansion
apparatus and was laced in water bath for 24hr. After picking up, it was placed on a hot water
bath and boiled it up to 1.5 hr and then it was cooled, and expansion of it was measured.
4.8. Theory of setting & hardening of cement
Although many theories have been proposed to explain the setting and hardening of cement,
it is generally agreed that hydration and hydrolysis are involved. The hydration products have
very low solubility in water. Concrete in contact water would be rapidly attacked, the various
compound contribute to the heat of hardening after 28 days as follows.
C3A> C3S> C4AF > C2S
Table4.1: Heat of hydration in joule per gram.
COMPOUND 3 DAYS 7 DAYS 28 DAYS 90 DAYS 365 DAYS
C4AF 290 495 435 416 377
C4AF 888 1557 1378 1302 1168
C2S 50 42 105 176 222
Strength contribution of various compounds in Portland cement (the relative strength are
the apparent relative contributions of equal weights of the compounds listed)
41
Table4.2: Function of cement compounds various setting times
1 day C3A> C3S> C4AF > C2S
3 days C3A> C3S> C4AF > C2S
7 days C3A> C3S> C4AF > C2S
28days C3A> C3S> C4AF > C2S
3 months C2S> C3S> C3A> C4AF
1 year C2S> C3S> C3A> C4AF
2 year C2S> C3S> C4AF > C2A
Table no 4.3.: Function of compounds
Compound Function
C3A Causes setting but needs retard; 3.tion (by gypsum)
C3S Responsible for early strength (at 7 or 8 days)
C2S & C3S Responsible for final strength (at 1 year)
Fe2O3 Al2O3, Mg and alkalis Lower clinkering temperature.
The setting and hardening of cement to hold up the flash set caused by C3A, the gypsum
added as a retarded cause the formation of C 3A.3CaSO4.3H2O. Calcium nitrite may be added
to inhibit the corrosion of steel reinforcing bars in concrete.
Sampling
Sampling is the most important step in testing sequence, should be realized that variations in
compositions and properties concrete and concrete making materials are basic and can only
be reduced but never completely eliminated. The degree of homogeneity that can be attained
in practice depends on the cost of reducing variability as compared with the benefits derived
from there.
42
Samples are taken from quantities or numbers in order that on examining the sample certain
information pertaining to the whole may be obtained. The process of sampling requires a
sampling plan that will be satisfactory sources or error at an acceptance cost.
Standard can provide better guidance and detailed instructions. British Standard Specification
(ESS)-12:1978 and Bangladesh Specification BDS-232: 1993 and BSS-4027.
Deal with cement and raw materials, better qualified and trained personal, under proper
supervision are a necessity to achieve maximum reliability with minimum sampling as a basis
for final important economic and safety decisions. This would improve the present sampling
situation immensely.
Concrete is the term that is used to describe an aqueous mix of cement with sand and
aggregates (with or without admixture). The properties of concrete are influenced by the
properties of the constituent materials. Hence it is essential to know about the quality of
constituent materials.
The properties of finished cement depend primarily on four factors:
1. Chemical composition of the mix.

2. Physiochemical state of the raw components.
3. Temperature and duration of burning.
4. Clinker cooling rate.
4.9. Water treatment of Chhatak Cement Company
There are four number of intake pumps to lift water from river Surma. Two pumps run at a
time while the other two remain stand by, the average intake of water is 580 MT/H.
The water from the intake pump is primarily stored in a reservoir to settle its turbidity. It is
then pumped to overhead tank where from water is supplied to factory for process use.
Another part of the water is taken to clarifier for alum treatment. The alum treated water is
sent to colony for sanitary use & drinking purpose.Under BMRE project CCCL has installed
a package demi-water plant for its new 8 MW gas turbine generator ($TG). There are cation-
43
anion resin beds and de-gasifying unit in this demi plant. The capacity of this demis plant is
2.5 MT/h. A block diagram of water treatment process is given in figure.
Following are the sequential process for water treatment:
a) Screening: Passing the water a mixture or moving screens remove large quantities of
floating particle.
b) Skimming: Oil and grease removed by passing of the water through skimming takes
where oil and grease are removed by passing the water through skimming tanks where
oil and grease is skimmed off.
c) Degrading: Grits is removed by grit setting chamber by careful regulation of flow
velocity in the grit tusks.
d) Sedimentation: suspended matter can be removed efficiently and economically by
sedimentation. Finally divided suspended solids colloidal particlaes cannot be
removed by simple sedimentation by gravity. In such case mechanical flocculation
and chemical coagulation is employed.
e) Demineralization: Ion exchange resin is used demineralization water.
Ion exchange resins are two types-
i) Cation exchange resin and

ii) Anion exchange resin.
Cation exchange resin exchange the cation ( Na+, Mg2+, Ca2+) from water-
Resin + Water (NaCl , CaCl2, MgCl2) resin-(Na, Ca, Mg) + HCl
Regeneration: R-(Na, Ca,Mg)+ H2SO4 R-H + (Na2SO4 ,CaSO4 , MgSO4 )
Similarly, hydroxylation can be displaced from the anion exchange by some other type of
anions.
R-OH + HCl R-Cl +H++ OH
H++ OH H2O
Regeneration: R-(Cl-, SO42- , SiO3 ) + NaOH R-H + (NaCl, Na2SO4)
44
CHAPTER FIVE
ROPEWAY DEPARTMENT
45
5.0. Ropeway Department
Ropeway department collect limestone (major raw materials of cement) from three sources-
Source-1: Komra limestone mining project, Khasia/Jayntahill, Meghalay, India.

Mode of collection: A 16.8 km long ropeway is maintained by Ropeway Department to carry
limestone form the Komra mining project, India. This ropeway is divided into two sections;
one section is 11.4 km and the other section 4.6 km. Each section is running by two motors;
each motor capacity is 150 HP and 75 HP respectively. About 360 buckets carrying capacity
700 kg each are in operation. The total carrying capacity of this ropeway is 666 MT/day.
About 2.0 lac MT/year of limestone is procured through this ropeway.
Source-2: Takerghat mining project, Tahirpur, Sunamgonj, Bangladesh.

Mode of collection: CCCL has a self mining project at takergahat. A man power setup of 273
is maintained for limestone mining. About 0.7 lac MT of limestone is collected from this
source per year. The limestone is transported to factory through river Surma.
Source-3: Chala/Talab /Echamati mining project, Meghalay, India (near the border line of
Bangladesh)
Mode of collection: limestone is also collected from this source through contractors. They
carry limestone through country boat about 0.2 lac MT of limestone is collected from this
source per year.
46
CHAPTER SIX
MECHANICAL DEPARTMENT
47
6.0. MECHANICAL DEPARTMENT
Work of Maintenance and Technical Service Department (MTS)
Distribution of Work:
MTS
Work shop Plant Maintenance Transportaton
Kiln Raw mill Cement Mill General Maintenance Shift Maintenance
Rail Transport River Transport
Clay Transport Limestone Transport Wash Mill Transport
Cement
packing
&Transport River Transport
&Dispatch
48
CHAPTER SEVEN
COMMERCIAL DEPARTMENT
49
COMMERCIAL DEPARTMENT
Commercial department consists of two branches-
A. Buy Branch
B. Sell Branch
Present sales price of: Ordinary Portland Cement = Tk. 3,9200.00 per
Ton. (Including VAT) Rapid Hardening Cement = Tk. 6,600.00 per
Ton Suphate Resistant Cement = Tk. 7,200.00 per
Ton 7.1. PRODUCTION, SALES, PROFIT &LOSS
Sl. No. year Production Sales (M.Ton) Profit/Loss (Fig. in

(M.Ton) lac taka)
1 1996-97 50,550 35,817 562.77
2 1997-98 1,12,170 1,20,588 106.22
3 1998-99 1,47,020 1,45,707 46.00
4 1999-2000 1,53,275 1,45,352 254.75
5 2000-2001 1,68,010 1,74,683 476.02
6 2001-2002 1,62,010 1,56,171 358.69
7 2002-2003 1,51,200 1,50,580 340.95
8 2003-2004 1,68,276 1,,77,769 297.54
9 2004-2005 1,73,845 1,76,415 713.57
10 2005-2006 13,0280 1, 21,178 1536.32
11 2006-2007 12,5925 1,23,813 243927
12 20007-2008 12,9060 1,33,423 254837
13 2008-2009 (up to Nov) 2,5431 2,3423 44639 (Up to Oct)
50
7.2. CONTRIBUTION TO NATIONAL EXCHEQUER
SI No. Year Import Exdse Electric Interest Others Total

duty duty/VAT duty on Govt. Ll/tk.
Loan
1 1996-97 50.75 194.15 14.89 34.40 5.35 299.72
2 1997-98 129.70 632.85 27.70 23.59 1.84 815.68
3 1998-99 104.42 761.36 26.78 38.83 4.74 936.13
4 1999-00 113.77 851.37 31.15 37.67 3.60 1037.56
5 2000-01 224.00 1061.20 28.5 375.00 3.83 1691.91
6 2001-02 270.84 967.23 35.53 5.77 1269.37
7 2002-03 225.09 924.76 21.90 6.29 1178.04
8 2003-04 83.66 1087.84 9.80 17.79 1199.09
9 2004-05 61.81 1096.03 4.50 1135.34
10 2005-06 37.86 723.91 18.68 789.25
11 2006-07 75.92 692.58 24.90 793.20
12 2007-08 17.79 295.67 0.12 313.58

(up to
Nov)
51
CHAPTER EIGHT
ENVIRONMENTAL POLLUTION & CONTROL OF
THE FACTORY
8.0. IN CHHATAK CEMETN CO. LTD.
52
Chhatak Cement Company Ltd. (CCCL), the only integrated cement plant of Bangladesh is
the oldest cement factory of the country. Where other cement factories of the country are
mainly grinding mills, CCCl produces, cement from the basic raw material limestone & clay.
The company falls under red project from the pollution point of view. Again with
promulgation of EPA95 and ECR96 DOE has imposed binding on this project to get
environmental clearance. Environmental clearance from GOB. Three several factor involved
in environmental pollution in Chhatak Cement Co.Ltd. This are-
1. Air pollution
2. Noise pollution
3. Hill cutting for collected clay.
8.1. AIR POLLUTION
Source
In the manufacture of cement CO2 and dust particles are evolved into the air which causes
tremendous suffocation problems. It is totally neglected here in the CCC Ltd. Dust is the
main pollutant that is liberated from kiln by chimney. The industry has already set up
electrolytic precipitator equipment. In this equipment several iron plates are arranged in a
series, and it is electrically negation in charge. Smoke and dust liberated from kiln are passed
through those iron plates. Dust is the fine particles of slurry that liberated form kiln along
with the pressure of smoke. These dust particles are positive in charge and attracted by the
negatively charged iron plate and finally fall through the lower side. Where screw conveyer
or an elevator into the kiln conveys them. In this recycling process production of clinker is
increased and kept environmental neat and clean.
Effect
Total suspended particles (TSP) are made up of particles with an aerodynamic diameter
between 0.0002 and 70 micrometer. Due to very small size, these particles any remain
suspended in air for a very long time and can get carried away hundreds of miles by air
currents. For human health impact, particles with diameter smaller than 10 micrometer
(PM10) range are of main interest. Larger particles are effectively removed in the upper
respiratory system. Finer particles may enter lungs and reside there for years causing
respiratory infection, cardiac disorder, bronchitis, asthma, pneumonia and emphysema High
TSP concentration is injurious to plants- particulate coating on leaves inhibit plant growth.
53
In terms of exposure to CO, cab drivers, police, street vendors fall in the high risk group. The
exposure is measured in %COHb (carboxyl-hemoglobin as a percent of saturation) in human
blood, where less than 2% is deemed tolerable. Symptoms at higher concentration include:
3.5%- impaired judgment, 5%- psychomotor response time affected, 10% -dizziness, severe
headache, 30%-coma and convulsions, and 50%-lethal. CO binds with hemoglobin in human
blood 200 times faster than oxygen. Residence time of CO in air may vary between two to
five months after which most of it gets converted to CO2.
Control
Neutral dust particle may be controlled by using fabric filter as air dust collector. In bagging
section fabric filter any also be used as dust collector. If it is not possible then ordinary gas
mask may be offered for workers.
8.2NOISE POLLUTION
Source
During operation the locality is affected by intense sound. Most heavily affected persons are
those who inside the factory.
Effect
It is found that they are short of hearing.
Control
In the interior of the industry noise pollution is occurred continuously in limestone
pulverizing, which is a usual phenomenon.
8.3. HIIL CUTTING FOR COLLECTID CLAY:
54
Source
Hill is adjacent to the factory. The factory owns a big area of hilly Sands. The soil of these
hills is suitable for cement production. The clay is cut from hills both mechanically &
manually and transported through truck/tractors.
Effect
Disturbs the micro-eco system of environment.
Deforestation, denudation of hills and killing of wildlife.
The rampant and leveling of beautiful hills has not only diminished the amazing natural
beauty of this historic city but also killed the great prospect of major source from revenue
earning from tourism.
It was observed that hill cutting is the major cause of frequent land slides.
That fills up citys canals and drains causing serious water logging.
It reduces the rate of rain and helps global warming.
Control
This process is continuous and slow process. So, its effect is not so much massive in
human life.
Finding out the other source of for collecting clay like river dredging.
CONCLUSION
55
Now a day, industrial assignment course has become essential for enhancing skill in industrial
field. There is no doubt about it that practical experience makes a man perfect to his
respective profession. So I think our industrial training will be helpful to improve our skill in
industrial profession. This assignment is, therefore, a professional feeling for us. During my
work in the Chhatak Cement Co. Limited I gained very good knowledge about the industrial
rule and regulations. R & D sections and its function. It was a very short tour in the industry,
but the outcome is very outstanding. Production and quality control department are very vital
for the chemist. This tour has broadened my thinking capacity, and encouraged me further
work or research or it. I know and believe that if were appointed in any industry what so ever
its type, I will prove my experience with excellence.
56

Internship Report On Chhatak Cement Comp

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Internship Report

Chhatak Cement Company Limited

1.2. A brief discussion of different types of cement

Cements are mainly of two types.

Natural cement : A hydraulic cement produced by calcining a naturally occurring

Portland cement : Hydraulic cement produced by pulverizing clinker consisting essentially

The reactions are given below:

1. Reactions of tricalcium silicate (C3S) with H2O.

2. Reactions of dicalcium silicates (C2S) with H2O.

3. Reaction of tricalcium aluminate (C3A) with H2O.

4. Reaction of tetra calcium aluminates ferrite (C4AF) with H2O.

6. Reaction of uncombined lime (CaO) magnesium oxide (MgO) with H2O.

b) CaO+H2O Ca(OH)2 c) MgO + H2O Mg(OH)2

1.3. : Types of Portland cement

1. Ordinary Portland cement

2. Modified Portland cement

3. High early strength Portland cement

4. Low heat Portland cement

5. Sulfate resisting Portland cement

The aim and objectives of this program are as follows:

1. To gain introductory knowledge on the industry of our country.

2. To gain work experience in chemical industry.

3. To identify specific problems of chemical industries.

5. To improve technical system in the field of chemical industry.

7. To make an option where cost reducing will be the main fact.

8. To solve the environment pollution caused by the chemical source.

Chapter One: General discussion about cement

1.0. General discussion about cement

1.1. What is Cement?

1.2. A brief discussion about different types of cement

1.3. Types of Portland Cement

1.4. Major constitute of Portland cement

1.5. Methods of manufacturing cement

Chapter Two: Chhatak Cement Company Limited

2.0. Chhatak Cement Company Limited

2.1. Chhatak cement company at a glance

2.2. Socio Economic

2.3. Welfare Facilities

Chapter Three: Production of Cement

3.0. Production of Cement

3.1. Procedure of Cement preparation

3.1.1. The Process

3.1.2. Production process and flow diagram

3.2. Raw Materials & Production process

3.3. Principle Raw Material

3.4. Source & Collection of Raw Material

3.5. Types of Cement Produced

3.6. Process Description

3.6.1. Clinker preparation

3.6.2. Phase Formation

3.7. Typical Analysis of cement raw material

3.8. Typical Analysis of clinker, cement and mineralogical composition of

3.9. Hard Mass formation with Water

3.10. Production of sulphate resisting cement (SRC)

3.11. Production of Rapid Hardening Portland Cement (RHCP)

Chapter Four: QUALITY CONTROL IN CHHATAK CEMENT CO. LTD.

4.0. QUALITY CONTROL IN CHHATAK CEMENT CO. LTD.

4.2. Quality Control Branch

4.3. Analysis of chemical composition of clinker and cement

4.4. Physical Analysis

4.5. Fitness test

4.6. Water consistency test

4.7. Soundness test