Evaluation of The Effectiveness of Quality Control in Dangote Cement Plc

   v  ABSTRACT 

The project evaluates the effectiveness of quality control  in Dangote Cement PLC, Ibese  Ogun  State,  Nigeria.  Limestone,  shale  and  laterite  samples  were  from  the  mines  to determine their right grade as well as their mixing proportion. Also samples were taken from kiln feed and the final stage of cement production. The compressive strength of the cubes is determined according to the ages of the cubes which is 2 days, 7 days and 28 days while the degree of lime content in raw materials, clinker, cement, limestone in relation to other oxides were  determined  using  XRF  and  setting  time  and  residue  determination  values  were  also estimated. The results show that the compressive strength for 2 days is between 16 – 33, for 7 days is between 28 – 47 and for 28 days is between 33 – 53. Meanwhile, percentages of CaO, C3S, C2S and MgO in clinker are 53.57 %, 56 %, 16.47 %, 2.14 % and 62 %, 58 %, 19 %, 0 % in  cement.  The  amounts  of  residue  retained  by  different  sieves  were  within  the  standard specification of 10 – 22 gm. The study therefore concluded that the quality control in Dangote Cement Company is effective and cement produce meets international standard requirements and characteristics which dependable and satisfactory.           

   vi  

TABLE OF CONTENT

 CERTIFICATION  ii ACKNOWLEDGEMENTS  iii DEDICATION  iv ABSTRACT  v TABLE OF CONTENTS  vi LIST OF TABLES  ix LIST OF FIGURES  x 

CHAPTER ONE  11     INTRODUCTION  11 

1.1   Background of the Study  11     

1.2    Scope of the Study                                                                                                         2     

1.3    Aim and Objectives of the Study                                                                                    2    

 1.4    Geology of the Ibese Limestone Deposit                                                                        2 

CHAPTER TWO  14 LITERATURE REVIEW  14 

2.1  CEMENT                        6

 2.2  TYPES OF CEMENT                     7 

2.3  Portland Cement                      8      

2.3.1   Types of Portland cement                  9         

2.3.2  Raw Mix Preparation                 12        

 2.3.3  Raw mix blending                  13 

   vii          2.3.4  Formation of Clinker                  14             

 2.3.4.1     The burning process               14             

 2.3.4.2     Suspension preheaters and calciners          16      

  2.3.5  Cement Grinding and addition of Gypsum            17        

2.3.6  Cement Kiln Dust                  18    

2.4  Raw Materials                     19 

2.5  Properties of the Major Cement Minerals              19    

2.6  Control Ratios                     23 

2.7   Mineral and oxide composition of Portland cement            24 

2.7.1  The Bogue calculation of cement mineral composition        26 

2.7.2  Modified Bogue calculation based on actual mineral compositions      27 

2.8  The Fineness and Particle size distribution of Portland Cement        28 

CHAPTER THREE  32    RESEARCH METHODOLOGY  32 

3.1  Data Collection                    32 

3.2  Sample Collection and Preparation                32 #

3.3  Quality Control of Limestone and Additives             32   

3.4   Quality Control Processes / Laboratory Procedures            32   

3.5  The ROBO/QCX Lab                   33

 3.5.1   ROBO- lab                    33 

3.5.2  XRF                      34 

3.5.3  Online analyzers                  34 

3.6  Compressive Strength Test Lab                34 

   viii  3.7  Fineness Test                      38 

3.8  Moisture Test                      38 

3.9  The Setting Time Determination                38 

CHAPTER FOUR  40 RESULTS AND DISCUSSION  40 

4.1  Compressive Strength Test Results                40

 4.2    Chemical Analysis in the ROBO-LAB              41

 4.3    Setting Time and Residue Determination              41 

4.4    Discussion of Result                    42 

CHAPTER FIVE  45 CONCLUSION AND RECOMMENDATION  55 

5.1  Conclusion                      45 5.2  Recommendations                    45 REFERENCES                       46