Silo 9 Boulders Investigation Report

03.10.16 - 05.10.16
Team Members Present :
1. Raphael Dianga Packing plant foreman
2. Grace Tunje - Quality Chemist
3. Joel Mbuvi - Process Technician
4. Joseph Muasya - Packing plant maitenance foreman
 Problem Statement

Silo 9 boulders experienced from 29.09.16 todate.

The lumps are easy to break with one s hands.

Investigations approach;
Sampled silo 9 cement and analysed chemical and physical parameters.
Trended process parameters for CM4 for September 2016.
 Results- CEM I 42.5 Chemical analysis

Targets 2900 150 2.80 0.10 3.0 0.5 < 0.8

Sample ID Blaine (Cm2/g) % S03 % LOI % Moisture
Fine Cement 3603 2.89 3.4 0.1
Boulders only 3740 2.96 3.0 0.1
Fine cement + 3714 2.94 2.9 0.1
boulders

From the above analysis, the cement is within the required targets for all parameters except
for blaine which is high.

The high blaine can be explained by the formation of lumps in the silo .
 Results- CEM I 42.5 Physical analysis
Targets 130- 180 600 26- 27 > 10
Initial setting Final setting Water demand 1 day
time (minutes) time (minutes) compressive
strengths(
mpa)
Fine Cement 222 314 27.2 15

From the above analysis the initial setting time is higher than our target but the other
parameters are ok

The long initial setting time could be due to dehydration of gypsum.

A false set test was done to confirm the dehydration of gypsum.

 Results- CEM I 42.5 False Set Analysis

Target length from base 0mm 0mm 0mm 0mm

of mould

Time 0 mins 5mins 10mins 15mins

Length from base of 0.0mm 1.0mm 6.0mm 8.0mm

mould

From the above analysis, the cement has false set characteristics which confirms
dehydration of gypsum.
Results- CM4 Cement and Clinker Temperature Sept.2016

Target mill outlet temperature is 105 5 degrees

Celsius as per DCR for 15.05.15.

Mill outlet temperature H1 105 and H2 110.

At 110, the mill has 10mins before it can stop the

Main drive.

From the trends , 2 major incidents of temperature >

110 were observed on 02.09.16 1750hrs- 1930hrs ,
16.09.16 1420hrs -1620hrs and 16.09.16 1950hrs to
2220hrs.

On 02.09.16 and 16.09.16 1950hrs to 2220hrs , the

high cement temperature coincided with an increase in
clinker temperature.

On 16.09.16 1420hrs to 1620hrs , there were

incidents of mill filling up due to prolonged limestone
feedcut.

For the rest of the month the mill outlet temperature

was within the recommended range.
Results- CM4 Water Injection Volumes Sept.2016

Target water injection volume is 1800 ltr /hr

On most times of the month the water
injection levels are within the expected range <
1800 ltr/hr.

On the incidents where water injection is above

this range the clinker temperature is also high
(>60 degrees Celsius)
Incident on 02.09.16 100hrs to 1300hrs

High cement temperature

coincides with high clinker
temperature and water dosage
Incident on 02.09.16 1600hrs to 1900hrs

High cement temperature

coincides with high clinker
temperature and water dosage
Incident on 07.09.16 1100hrs to 1300hrs

High cement temperature

coincides with high clinker
temperature but low water
dosage
Incident on 09.09.16 2300hrs to 0000hrs

High cement temperature

coincides with high clinker
temperature and high water
dosage
Incident on 16.09.16 1800hrs to 0100hrs

High cement temperature

coincides with high clinker
temperature and high water
dosage
 Conclusion
The boulders in the silo is due to false set of cement in the silo resulting from dehydration of
gypsum. Leakage of water into the silo would have resulted in formation of hard lumps.

The dehydration of gypsum is due to high cement temperature but false set has not be
observed since milling and extraction from the silo has been simultaneous.

The false set phenomena leading to boulders formation is pronounced due to stocking the
cement in the silo for long.

Recommendations:
Revise the target mill outlet temperature to 95 5 degrees Celsius.
CM3 to mill fresh cement into silo 9 as we dispatch the current stock.
Observe the high cement temperature interlocks.
Analyse dispatch samples for false set .
Bring mbaraki dispatch samples for testing.
Annex
High Cement Temperature Incidents
High Cement Temperature Incidents Contd
High Clinker Temperature Incidents
High Clinker Temperature Incidents Contd
High Water Dosage Incidents
High Water Dosage Incidents Contd