18 EnglishPart

CEMENT & BUILDING MATERIALS REVIEW
Issued by : ARAB UNION FOR CEMENT & BUILDING MATERIALS
No. 18 - December 2004
EDITOR IN CHIEF
CONTENTS
Foreword AUCBM Member Companies:
Eastern Province Cement Co. * Isothermal Calorimetry Study of Blended Cements and its Application in Numerical Simulations K. Van Breugel, X. Ciong \ Delft University and Technology \ The Netherlands * On-Line Quantification of Clinker: A Case Study Jairo Rueda, Henry Santamaria, Jorge Montana, Nestor Bernal and Renan Jaimes \ Cementos Paz del Rio S.A. \ Columbia Bertrand Jequier and Felix Torres \ Symtek \ Columbia * Condition Monitoring on Girth Gear units experience and developments Dr. E. Becker, K. Cools \ Flender Service GmbH \ Germany * Kiln Doctor Phillips Kiln Services (India) PVT. Ltd. \ India * Global Warming, Kyoto Protocol and Role of Cement Industry Tanmay Maitra \ Birla Corporation Limited - Cement Division \ India * Durability of Plain and Blended Cements in Marine Environments O. S. B. Al-Amoudi \ King Fahd University of Petroleum and Minerals \ Saudi Arabia
Eng. AHMAD AL-ROUSAN

Contribution
The Magazine editorial staff welcome the contribution of experts to enrich the contents of the magazine.
Arab News International News New Products and Media Articles:

* State of the Art of Lime Manufacture Dr. Laila Farag \ National Research Center \ Egypt * A Potential Process for Production of Gypsum Board via Recrystallization of Dihydrate Gypsum Stefan Follner, Heinz Follner \ Technische Universitat Clausthal \ Germany * Storage and reclaim of FGD
Articles are not to be returned to authors.
Points of view exressed in the Gypsum in Wallboard Production magazine do not necessarily express Aumund Frdertechnik GmbH / points of view of the AUCBM jor the Germany * Innovative Production process magazine itself. for cement bonded slabs, bricks it is rather to opinion of the auther. and tiles the AUCBM does not bear aby legal Dipl. Ing. Gunter Grimm, Dr. Alfred Kaiser / Laeis GmbH / Germany liability or resposability from any * Computer Based Training for article.
Cement Industries Eng. Adnan Obeidat \ Tabuk Cement Comapany \ Saudi Arabia
Diary Dates
The AUCBM is ready to translate any article from its original language upon request
CORRESPONDENCE correspondence should be addressed to the Editor in Chief at the following address: Syria, Damascus - P.O.Box 9015 Tel: (+963 11) 611 5412 - 611 8598 Fax: (+963 11) 612 1731 - 611 1318 E-mail: aucbm@net.sy / aucbm@scs-net.org Website: www.aucbm.org
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Foreword
The year 2004 has passed and demand on cement in Arab countries is still increasing dramatically, with consumption jumping to its highest level for many years, particularly in GCC countries, headed by Saudi Arabia. Countries which were for a while principal exporters have become either importers or have stopped exporting, excluding Egypt where the stability of consumption indicators and the accumulation of a large surplus of clinker and cement made the country a major exporter (7.8mt in 2003). This reality has created a problematical situation and formed a future image that pushed some investors, particularly in GCC countries, to consider seriously, and even start, investing in cement industry. This was represented by constructing new plants, benefiting of financial surplus and granted facilities as well as individual savings, pushed also by their desire to contribute to this important industry. If we would consider the current installed capacity in the Arab world of 140mta of cement and add the new planned projects and current expansions in most Arab cement plants, the expected installed capacity after three years from now will exceed 168mta. It is worth mentioning that actual production in 2003 stood at 108mt, representing 78 percent of the installed capacity, with consumption reaching 105mt in 2003. This is on the Arab level in general, but on the geographical (regional) level, cement industry is more complicated and problematical. For example, within three years from now, the installed capacity in the Mashreq region will reach 70mta as compared to the current 64mt. Installed capacity in the GCC countries will become 57mta as compared to the current 41mta; while in Maghreb countries installed capacity will reach 40mt compared to the current 35mt. I believe that this leap in raising capacities will create a complicated situation in future and will be negatively reflected on this industry, given the instable nature of building and construction industry . The question that remains Where are we heading for?
Eng. Ahmad Al-Rousan
AUCBM MEMBER COMPANIES
Eastern Province Cement Company Saudi Arabia
The Eastern Province Cement Company EPCC (previously Saudi-Kuwaiti Cement Company) was established in 1983 and its commercial production started in 1984. The Company name was modified in 1994 when Kuwait Cement Company sold its stake to Saudi shareholders and the Company became a wholly Saudi owned corporation. The factory lies in Kharasania area, at 70 km from Jubail Commercial Port. Production Capacity: Installed capacity is 2.1mta of clinker and 3.2mta of cement. Actual production in 2003 was 2.189mt of clinker and 2.7mt of cement. In 2003, the Company exported 663,000t of clinker and 542,000t of cement and the balance was marketed locally. Companys capital and shareholders: EPCCs capital is SR 645 million, with shareholders being General Establishment for Social Security at 10%, Retirement Fund at 10%, Public Investments Fund at 10%, and Saudi citizens at 70%. Future projects: the Company concluded a contract to construct an additional cement production line at 3,500tpd, which will raise the Companys annual capacity to 3.15mta or 10,500tpd of cement. Environment and ISO: The Company obtained the ISO certificate and the consent of the Saudi Arabian Standards Organization to use the Quality Mark as its products comply with international standards.
Company Address: Eastern Province Cement Company EPCC P.O. Box 4536 Dammam 31412 Saudi Arabia Tel.: (+966 3) 8262575 / 4655170 Fax: (+966 3) 8271923 E-mail: gmo@epcco.com http://www.eastern-cement.com.sa ARAB CEMENT INDUSTRY
Arab News
New Projects and Expansions Egypt
National Cement Company The Company is in the process of upgrading its existing production line with a view to raise installed capacity at 0.9mta of clinker. Execution will start during the first half of 2005 and commissioning will start by the end of 2006. Suez Cement Company The Company intends to upgrade its electrostatic precipitators and conditioning towers, which will allow it to add 150,000tpa of clinker to its installed capacity. The project will be completed during the second quarter of 2005. Egyptian Cement Company The Companys existing production lines are being upgraded with a view to add 0.8mta of clinker to its installed capacity. Execution started in November 2004 and the project is planned to be completed in July 2005. Misr Cement Company (Qena) The Company will add a new 1.35mta of clinker production line, with execution taking 30 months. Beni Suef Cement Company The Company is planning to build a new 2mta of clinker production line. At present, offers are being studied and execution will last 30 months. Furthermore, GCC is executing the project of 0.9mta of cement mill No. 4 which is planned to be commissioned in December 2004; further six cement silos will be also installed. The kiln capacity was gradually upgraded to reach 4,100tpd today as compared to 3,309tpd previously. With the completion of this new line, GCC will be able to produce 3.7mta of clinker and will become the top producer of clinker in the UAE.
ARAB CEMENT MARKETS

UAE Cement Producers agree to halt exports of their product Cement producers in the UAE reached an understanding to halt exports of their cement until prices stability returns to the local market. Such understanding was achieved during a joint meeting of cement producers in the country which took place at the headquarters of Sharjah Cement Company. Representatives of cement plants agreed to satisfy the UAE local market consumption of cement in a bid to stabilize prices. The gathering also discussed all marketing and cement production developments including activity in the contracting and construction sector and the needs of the local market of cement for the next few months up to the end of the year. It is expected that local demand on cement rose at 10%-15% to reach around 13mt to fulfill local construction demand. It is worth mentioning that total production of the UAE based cement plants accounts for 9mta; the remainder of demand is usually imported from abroad via cement factories, contracting companies and dealers. Source: Al Ghorfa Magazine, No.233 Annual growth rate of 9.5% in demand on cement in GCC during 20032006Demand in the GCC countries is forecast to grow at an annual rate of 9.5% during 20032006-. Prices are expected to stabilize at low levels due to higher imports and new capacities being executed. Mexico - Mexico Bans CDM to Import Cement from Russia Mexican customs authorities finally banned Mexican cement importer Comercio para el Desarrollo
Saudi Arabia
A new cement plant in Saudi Arabia It is reported that some investors in the cement sector have obtained approval to establish a new 1.35mta cement plant at a cost of SR 760 million.
UAE
Gulf Cement Company adds a new production line The Ras Al-Khaimah based Gulf Cement Company (GCC) of the UAE signed a contract with Thyssen Krupp Industries India Pvt. Ltd. and Polysius AG for the supply of machinery and equipment for a new clinker production line worth US$ 155 million. The capacity of the new line will be 7,500tpd of clinker and is planned to start production by mid 2006. GCC chairman confirmed the planning-based economy in the country with a view to cope with increasing development in the UAE.
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No. 18 DECEMBER 2004
Arab News
Mexicano (CDM), on November 25, 2004, from importing Russian cement into Mexico. CDM is a joint venture of Jordan-based CTI Group, Spain-based Tradeland Commodities and Mexican Businessmen. The embargo was imposed under the petition of Mexican cement producer Cemex. The Panamanian-flagged ship Mary Nour, operated by CDM, arrived at the port of Tampico, on the Mexican Atlantic coast, in July 2004, carrying 27,000 tonnes of Russian cement, but it was blocked by the Mexican authorities under Cemexs claim. Cemex claimed that CDMs import project would affect its operations at the port of Tampico. Cemex grounded the court injunction to block the Mary Nour ship on the fact that CDM does not have a proper permit to import the cement. Apart from that, Cemex operates a private terminal in El Prieto, Veracruz state, also on the Atlantic coast, and thus the ships transporting Cemex production pass through Tampico port. The operations of Mary Nour could block the operations of Cemex on Tampico port, according to Cemex. After this setback, Mary Nour set off for another Mexican port, arriving at the port of Altamira on July 29, 2004. The ship once again did not succeed in importing the product, because it was alleged to have made an error in the import procedure, Altamira customs administrator, Gerardo Zapien Pachec, said. Thus, the Mexican authorities imposed an embargo on the cargo. Source: Intercem E-line No. 223, 24.11.2004 Consumption and Sales Arabian Company for Manufacturing of Cement and Building Materials of Syria sold 241,000t of cement during the third quarter 2004. During 2003, Ciment de Gabes of Tunisia sold 982,000t of cement to local market. sales jumped to AED 183.7m as compared to AED 126.1m during the first nine months of 2003. Total assets at the end of September rose to AED 632.9m versus AED 608.5m at the end of December 2003. Total shareholders value increased from AED 401.6m to AED 470.9m. Union Cement Company profits exceed AED 80m Total net profits of Union Cement Company increased to AED 260.80m during the first nine months of 2004 as compared to AED 610.22m in the same period in 2003. As per the Companys financial data total sales rose to AED 6.234m as compared to AED 5.135m. Total assets increased to AED 592m as compared to AED 6.537m in 31 December 2003. Source: Al Ghorfa Magazine, No. 235
ARAB CEMENT PRODUCTION:

Egypt White cement production in Egypt During 2003 Egypt produced 574,718t of white cement from Sinai White Cement plant and Asec Cement. Iraq Iraqi Cement State Enterprise Total 2003 production of cement plants related to Iraqi Cement State Enterprise, namely Qaem, Karkouk and Kbeisa, registered 596.600t of clinker and 663,500t of cement. Falluja plant produced 37,000t of white cement and 54,000t of grey cement. Syria Arabian Company for Manufacturing of Cement and Building Materials Arabian Company for Manufacturing of Cement and Building Materials of Syria produced 233,000t of clinker and 250,000t of cement during the third quarter of 2004. It is worth mentioning that the Companys installed capacity is 960,000ta of clinker. Tunisia Ciment de Gabes During 2003, Ciment de Gabes of Tunisia produced 726,000t of clinker and 1.46mt of cement. It is worth mentioning that the Companys installed capacity is 1mta of clinker.
ARAB COMPANIES RESULTS

Ras Al Khaimah Cement Company profits exceed AED 96m in September Ras Al Khaimah Cement Company announced an increase in its total net profits during the first 9 months of 2004; net profits registered AED 69.3m as compared to AED 22.6m during the same period of 2003. The Companys financial data show that its
CEMENT PRICES (2004)
Arab News
Tunisia: Ciment de Gabes Local Price (ex-works) Cement type I US$ 43.47 per ton Cement HRS US$ 57.40 per ton Clinker US$ 27.08 per ton Export Price: US$ 80.37 per ton Source: Al Ghorfa Magazine, No. 235 Dolphin will supply gas to Ras Al Khaimah Gas Organization through a pipe linkage in Fujairah with the gas piping of Emirate Company originally used to supply the northern emirates. Supplies will continue for two years and five months, up till the end of July 2007.
BUILDING MATERIALS
Results of RAK Ceramics R.A.K. Ceramics witnessed an increase in its net profits, registering AED 81.8m at the end of 3Q04 as compared to AED 76.4m during the same period in 2003 and compared to AED 103.1m in December 2003. Total assets increased to AED 1.736b as compared to AED 1.356b on 30 September 2003 and AED 1.478b by the end of December 2003. Total fixed assets reached AED 532.4m as compared to AED 396.9m during the first nine months of 2003 and compared to AED 421.8m on 31 December 2003. Source: Al Ghorfa Magazine, No. 235 RAK Ceramics wins the Arabian Business Company 2004 year Award R.A.K. Ceramics, the Ras Al Khaimah based ceramic multinational was chosen as the winner of the Arabian Business Company of the Year Award for the year 2004. Dr. Khater Massaad, Chief Executive Officer of R.A.K. Ceramics received the award. The AUCBM seizes the opportunity to congratulate R.A.K. Ceramics for such prominent achievement which demonstrates the great success the Company accomplished. Source: Al Ghorfa Magazine, No. 234 RAK Ceramics installs a Power Station R.A.K. Ceramics announced that it will install a US$100 million power station with a view to cover its needs of electrical power. The stations capacity will be 120mW. This follows concluding an agreement between Ras Al Khaimah Gas Organization and Dolphin Power, under which Dolphin will sell supplies of natural gas to Ras Al Khaimah Emirate as of March 2005.
ENVIRONMENT
Syria Arabian Company for Manufacturing of Cement and Building Materials Within its environmental projects, Arabian Company for Manufacturing of Cement and Building Materials of Syria will execute comprehensive maintenance for the electrostatic precipitators of its cement mills and raw mills, as well as replacing and upgrading filters for the filling machines and bag filters at the cement mills. Gulf Cement Company works to improve environment Ras Al Khaimah based Gulf Cement Company (GCC) purchased state-of-the-art filters and automatic spraying system for raw materials to prevent dust. The Company also installed a 115,000t silo for clinker and two developed automatic mobile reclaimers. Green areas around the plant were also expanded. GCC obtained ISO 14001 in 1996, and it has endeavored to apply environmental safety in compliance with international standards of 50mg/m3 limits of dust emissions, with a view to reduce dust emissions to 10mg/m3 in future. Ras Al Khaimah Company for White Cement completes its environmental projects Ras Al Khaimah for White Cement and Construction Materials in the UAE established fast plans to preserve environment in its plants in Khor Kuwair region. The Company executed several projects to improve environmental conditions in its white cement and lime plants during the last two years, at a cost of AED 27 million.
Internatioal News HAZEMAG Compound Crusher for Qatar Cement Company

HAZEMAG & EPR GmbH in Duelmen/Germany has received an order from Messrs. FCB.Ciment in Villeneuve dAscq/France to supply a compound crusher for the comminution of limestone and marl/ clay as well as an order for a small gypsum crusher destined for the Qatar National Cement Company. Messrs. FCB are handling the turnkey contract on behalf of the customer to set up the whole production line of 4,000 tonnes/day. The Compound Crusher Type AP-CM 2022 is used for the primary crushing of the raw materials limestone and a marl/clay mixture. The different materials are processed separately. This double-rotor crusher effects two-stage crushing within one housing at a rate of 900 tons/hour. The feed materials have a max. size of 1.8 m edge length and are reduced to 93 95 % minus 25 mm, the optimum feed size for the further processing in the downstream ball mill. The 1st (primary) rotor is a rugged GSK-type rotor of welded cast steel construction, and is driven by a 900 kW motor. The 2nd (secondary) rotor is a QK-type rotor, which is of somewhat lighter construction and which has a 1,200 kW motor. The compact design of this crusher with its high crushing ratio has proved extremely successful world-wide, and is rated highly with customers on the Arabian Peninsula in particular. Further crushers of this type are operating successfully at the Oman Cement Company in Oman and at the Sharjah Cement Company in the United Arab Emirates.
Fig.: HAZEMAG Compound Crusher Type AP-CM 2022 The gypsum crusher Type AP-PMG 1310 being supplied can handle 70 tons/hour, and has been designed by HAZEMAG specifically for the processing of gypsum. For more information, please contact: Hazemag & EPR GmbH Brokweg 75 D-48249 Dlmen Tel.: +490-77 2594- Fax: +49400-77 2594Internet: www.HAZEMAG.de / www.EPR.de
New orders in Iran

KHD Humboldt Wedag AG has won two further contracts for new cement plant projects Sarouj Isfahan and Omran-e-Anarak Cement and confirms herewith its leading position in the Iranian market as partner of the cement industry. Cement production line for Sarouj Isfahan Co. Sarouj Isfahan Co. (SIC), a newcomer to the cement sector, contracted with KHD Humboldt Wedag AG to supply a cement production plant, with a designed capacity of 2,000 t/d clinker. The investors decision represents a further step towards the realisation of the countrys aim for a
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distinct increase of the capacities of cement factories. The new greenfield cement plant will be erected 90km from Isfahan south of Tehran, Islamic Republic of Iran. Scope of supply and services of KHD Humboldt Wedag covers engineering and supply of key components and mechanical and automation equipment for the cement production plant from the raw material crushing department to the cement packing and loading plants, e.g.: Pyroprocessing line, 2,000 t/d clinker:
5-stage preheater with PYROCLON-R calciner,

PYROTOP-compact mixing chamber and tertiary air duct with dust settling chamber,
Internatioal News
components for the clinker production line, e.g.: rotary kiln, diameter 4.0m x 54.0m length, with PYROCLON-R calciner, PYRO-JET kiln burner and burners for calciners, 5-stage preheater both for heavy fuel oil and natural gas firing, PYROSTEP clinker cooler fitted with a hammer- type clin ker crusher. Clinker grinding plant, 120 t/h cement at 3,000 cm2/ g acc. to Blaine: PYROTOP -compact mixing chamber and tertiary air duct with dust settling chamber, PYRORAPID rotary kiln on two piers, diameter 4.4m x 52.0m length,
PYRO-JET kiln burner and burners for calciners,

both for heavy fuel oil and natural gas firing. KHD is also responsible for supervision of local manufacturing, erection and commissioning.
ball mill in closed circuit mode, diameter 4.4m x

13.0m length,
high
efficiency dynamic SKS-separator, type SEPMASTER.
Automation systems: ROMIX quality control system system.
The following advantages result from the decision on KHDs PYRORAPID kiln on two piers:
PRODUX-PLUS process control and monitoring

3,300 t/d clinker production plant for Omran-eAnarak Cement Co. Omran-e-Anarak Cement, a newcomer to the cement sector, has decided to install a cement production plant, designed for a capacity of 3,300 t/d clinker. The new greenfield cement plant will be erected in Delijan, Markazi province of Islamic Republic of Iran. KHD Humboldt Wedag AG, Germany has won the contract for engineering and supply of core
less radiation losses, less heat and power consumption, higher operating life of brick lining due to the
statically defined system.
For more information, please contact: KHD Humboldt Wedag AG, D-51170 Cologne e-mail: info@khd-ag.de Contact person: Hans-Peter Klckner www.humboldt-wedag.de Tel. +491370-6504-221Fax. +491449-6504-221e-mail: kloeckner.hp@khd-ag.de
Wietersdorfer & Peggauer Zementwerke GmbH

The Lepol-kiln in the plant Wietersdorf/ Carinthia of Wietersdorfer & Peggauer Zementwerke GmbH will be upgraded to a modern preheater kiln with precalcination. Significant parts of the Lepol-kiln will persist and will be involved for the system of the new 5-step Cyclonpreheater with Calciner and tertiary air duct. The order for this project design and after receipt of legal UVP approval also execution has been awarded to the company PMT-Zyklontechnik GmbH (Austria) in the frame of works renewal and capacity extension of the w&p plant. Using the new preheater concept, the production in the first step will be increased from 1.000 to 1.400 t/ d. The new technical concept also includes a maximum flexibility for the use of different fuels. The start up of the new plant is scheduled for autumn 2005. The total investment cost for the project amount to approximately 13 millions.
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Internatioal News
More plants in the OMY A Group put their trust in FRITZ & MACZIOL
VAS 2004 dispatch system supports the quality strategy of Dammann KG lime works
VAS 2004 upgrades existing dispatch systems FRITZ & MACZIOL realises overall concept Increase in shipping quality along with reduction in working steps The Vereinigte Kreidewerke Dammann KG is in the process of modernising its existing dispatch system with the help of the VAS 2004 logistic and dispatch automation software scheduled to be completed in autumn 2004. The FRITZ & MACZIOL solution is being installed in the Shlde, Lgerdorf and Rgen plants. With the decision to use VAS 2004 as a uniform shipping system, the producer of fine and rough chalk fillers as well as fertilisation lime is resolutely continuing the implementation of its quality policy. The VAS modular standard software, developed by FRITZ & MACZIOL, The Ulm-based system and software provider, allows companies to control deliveries and loading as well as providing complete automation of raw materials shipping. This results in a noticeable increase in productivity from order entry and inventory control through to actual deliveries. This is also shown by the experience of long-term VAS users such as Anneliese Zement AG, Heidelberg Cement AG, Lafarge Perlmooser AG, Rheinkalk GmbH and other well-known companies. For Dammann, F&M realised a solution which amongst other things comprises of VAS IBM servers with matching terminal server technology (CITRIX) and corresponding self-service terminals, the proven VAS transponder identification system as well as the high-performing VAS VDX module for connecting to the Axapta invoicing system. In addition, FRITZ & MACZIOL is responsible for software and system maintenance, in line with its service concept, and offers a 24-hour hotline for the company. With this configuration, Dammann has achieved not only an immediate increase in the quality of its shipping processes but, at the same time, a reduction in the working steps. The independent systems in the three plants containing the master and transaction data were replaced with a centralized Microsoft
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Axapta system. Thus, all dispatch processes could be integrated in VAS. Three IBM xSeries servers with a MS SQL Server2000 database form the basis, and web-based VAS clients are used to ensure a simplified installation procedure and to guarantee an enhancement of the availability. They allow cross-plant access to all required information. VAS self-service terminals and transponder ID cards provide drivers with easy-to-use facilities at the loading stations. Mobile data acquisition equipment partly installed on fork-lifts and wheel loaders provide flexible processing through automatic information flow between the loading process and the dispatch system. With the decision in favour of VAS 2004, Dammanns aim was twofold: using this solution to guarantee the quality chain from production right through to delivery and to achieve an optimal support for the dispatch organization. Reliably supplying customers with high-quality and error-free products is an extremely important element in the companys quality assurance programme which has been pursued from the very beginning. At the same time, adapting processes to meet customer expectations and market requirements play a significant role. With the implementation of theVAS 2004 logistics and dispatch automation system, Dammann being a member of the worldwide OMYA Group, is taking another important step to improve the groupwide quality standards.
For more information please contact, Anette Hucker Press Information Officer FRITZ & MACZIOL Hrvelsinger Weg 17, 89081 Ulm, Germany Tel.: +49 - 731 - 1551634Fax: +49 - 731 - 1551555E-Mail: ahucker@fum.de www.fum.de
Internatioal News
Gebr. Pfeiffer AG wins repeat business from Turkish customer
Gebr. Pfeiffer AG recently received an order for the supply of a raw mill to Turkey.
Gebr. Pfeiffer AG to carry out modernisation of lime hydrating plant and supply new separating stage to Sweden
Gebr. Pfeiffer AG won an order for the supply of a lime hydrating plant from Nordkalk AB. The plant will have a capacity of 5 t/h of lime hydrate and is intended for the companys lime works in Lulea, Sweden. In this context an existing Pfeiffer lime hydrator, type 10001250/, will be completely overhauled and equipped with state-of-the-art technology comprising pre-mixer and bag filter system. After the modernisation, the further processing of the raw hydrate will take place in a new separating plant featuring an SLV 500 high-efficiency separator. The commissioning is scheduled to take place in spring 2005.
Cimento Sanayi ve Ticaret A.S., Mersin, Turkey, decided to invest in another MPS vertical roller mill from Gebr. Pfeiffer AG. This choice was determined by the years of reliable service the client obtained from mills of this type . An MPS 2900 raw mill and an MPS 2250 K coal mill have been operating at kiln line II of the Mersin works since 1989. They ordered another two mills for his kiln line II in 1998, namely an MPS 3350 B for raw meal grinding and an MPS 225 BK for the grinding of lignite, coal and/ or brown coal. The client has now placed a repeat order for an MPS 3350 B raw mill for his Kayseri works. The mill will boast a capacity of 160 t/h ground to a fineness of 9 % R 90 m. During the grinding process, the material will be dried from a feed moisture of 5 % to a residual moisture of 0.5 % with the use of process gases. The plants design takes into account the approximate erection altitude of 1300 m above sea level. Gebr. Pfeiffer AG will be in charge of the processrelated aspects of this project and is to supply the core components, that is the mill, the classifier and the feed unit as well as the complete mill fan. Moreover, the company will provide the customer with the manufacturing documents for components to be manufactured locally by the client such as the housing. The erection procedure will be supervised by specialist staff from Gebr. Pfeiffer AG, whose process specialists will also be in charge of the commissioning.
Gebr. Pfeiffer AG to supply lime hydrating plant to Belarus

Gebr. Pfeiffer AG received an order for the supply of a lime hydrating plant from the Belorussian company Krasnoselskstroimaterialy. The plant will boast a capacity of 10 t/h and is intended for the companys Krasnoselsk-based works. The equipment to be supplied comprises the metering unit for quicklime and water, a KLV 8005-6.3/ lime hydrator with pre-mixer and a bag filter. The commissioning of the plant is scheduled for spring 2005.
Gebr. Pfeiffer AG to supply another mill to China

Gebr. Pfeiffer AG has received a follow-up order from GMG Tendering Co. Ltd., China, to supply an MPS 5300 B vertical roller mill complete with ancillary equipment. The mill is intended for grinding cement raw material at the Tapai Group-owned Huizhou Longmen cement works located in the Chinese province of Guangdong. With a driving power of 3,700 kW, the raw mill will boast a guaranteed production rate of 400 tph. The material will be ground to a fineness of 12 % R 80 m and is intended as feed material for a new rotary kiln with pre-heater. The Nanjing Cement Design & Research Institute (NCDRI) is in charge of the planning of the new production line whose production rate will amount to 5000 tpd.
Gebr. Pfeiffer AG receives an order from Hungarian Omya Eger Kft, Eger
Gebr. Pfeiffer AG won an order from Hungarian Omya Eger Kft, Eger, for an MPS 2800C vertical roller mill together with the main plant components for a second production line at its Eger works. In terms of design, the second line will be identical to the first one, which was commissioned in 1999. The same guaranteed values, that is a finished product rate of 45 t/h ground to a fineness of 8 % R 0.090 mm, will apply to the two grinding plants. The second line is scheduled go into operation as early as 1st July 2005.
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Internatioal News
LAFARGE CEMENT CHOOSE DOME VALVES FROM CLYDE MATERIALS HANDLING
Throughout 2001, Lafarge Cement UKs Northfleet Works in Kent experienced numerous issues with knife gate valves. Dome Valves from Clyde Materials Handling, however, have since solved them. The knife gate valves in question formed a key part of the Cement Kiln Dust Lines, running from the kiln precipitators to a dust storage area. They were unreliable and frequently stuck, which could impact on production. During normal operation of the kiln, almost all of the cement kiln dust gets returned to the kiln by way of a scoop system, says Mark Mutter, production manager at the plant. In the event of the kiln stopping for whatever reason, the dust gets diverted away from it to the dust storage area. However, dust and material would regularly build up on the side of the gate valves and prevent them from moving, something that could impact on the whole production process. On top of that, any leaks could be uncontained, with potential to cause unwanted and unnecessary pollution. Lafarge approached Doncaster-based Clyde Materials Handling in order to find a solution and consequently purchased 12 six-inch Dome Valves that were installed between the scoop system and the dust storage area towards the end of 2001. To date, these valves have worked successfully under extreme conditions. Whats more, they also ensure that any kind of leak is contained within the system, rather than being allowed to escape into the atmosphere. The Dome Valves have made a huge difference to our performance, adds Mark. They are environmentally friendly and require far less maintenance, besides of course being far more reliable than their predecessors. For more information on Clyde Dome Valves, contact Alan Edge at Clyde Materials Handling, Tel: +44321313 1302-, email:aedge@clydematerials.co.uk or visit the website www.clydematerials.co.uk
secondary extraction systems, while degradation and segregation are considerably reduced. This patented chute has applications in ship, barge, truck, railcar, and silo loading as well as conveyor-to-conveyor transfer. PEBCO Incorporated of Paducah, Kentucky has entered into an agreement with Cleveland Potash of England to manufacture and sell the CLEVELAND CASCADE Chute in North and South America. As part of this agreement, PEBCO has purchased the patent rights to the CLEVELAND CASCADE Chute in these territories.
PEBCO was selected for the design and manufacture of a CCC-Mark 463- design Cleveland Cascade Chute for loading calcined petroleum coke into ships. This chute features lightweight fiberglass cones with abrasion resistant steel liners and a heavy duty shroud. A specially designed collapsible speed reducer capable of supporting both the Cleveland Cascade Chute and shroud assembly is attached to the bottom of the chute which allows ship trimming with minimal dusting. The Cleveland Cascade Chute requires minimum maintenance and operates free of product spillage and dust leakage. This design chute has successfully handled a diverse range of dry bulk solids from finished cement and alumina to calcined petroleum coke, calcined lime, wheat, soda ash, potash, phosphate, lead oxide, etc. The truncated, oppositely-inclined cones, supported by straps and covered by a wind shroud, enable material to be loaded in mass flow at low velocity. In this way, the bulk particles remain tightly packed together; thereby minimizing the release of small dust particles. Operating on the principle of mass flow at low velocity, dust emission is minimized without recourse to
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CLEVELAND CASCADE CHUTE PORT OF LONG BEACH
For further information, please contact: PEBCO, INC. W. Edward Barker Phone: (+1 270) 4421996- Ext. 211 Fax: (+1 270) 4425214E-mail: barker@pebco.com Web Address: www.pebco.com
Internatioal News
TEREX artic trucks in major road building projects
Scottish manufacturer Terex Equipment Limiteds current range of articulated trucks has been specially developed to provide an efficient solution to the most demanding job applications. The trucks technical features and versatility make them suited to varied projects, including major road building operations. Here are a few of the main sites where TEREX trucks are used. In the West of Scotland, a large fleet of forty-two Terex articulated dumptrucks has been working extensively on the largest single construction project Terex have ever been involved with in their home market. This 130m project involves the up-grading of a 15 km stretch of the A77 to motorway status and the extension of the M77 Ayr Road route to dual carriageway. The trucks, ranging from 23 mt to 36.5 mt payload, have been shifting tons of rock and clay for several months. Designed for easy operation and low maintenance costs, they have proved a success with the operators working on this project. They are particularly impressed by the TA25 and TA27s increased horsepower and load capacity, as well as by the spacious ergonomic cab. The TA40s have also been praised by the operators for their oil-cooled disk brakes which substantially reduce downtime and maintenance costs. The low-end torque has proved to be a highly successful feature, which has ensured that the trucks superior level of performance is maintained even in the hostile Scottish terrain. Two TA30s are working in a major motorway project in the western part of Hungary. The development, which started at the beginning of November 2004, involves the construction of the new M7 motorway link between Budapest and Zagreb. Part of the motorway is to be built over a dried lake bed, therefore working conditions are extremely hard - hence the choice of TEREX trucks. The 28 t Generation 7 articulated trucks are fitted with 350HP 10.8 L engines for class-leading performance. With a powerto-weight ratio of 4.92 kW/t, the trucks have the ability to go where others cannot follow. They are equipped with heavy-duty transmissions with built-in reserve for long life and reliability and dual caliper brakes ensure excellent stopping power with added safety and cost efficiency. The powerful traction makes the TA30s the ideal choice for operation on the soft and slippery terrain of the dried up lake. The biggest truck shipment to Germany, consisting of 20 Terex TA40 articulated dumptrucks, has been recently delivered to company Bickhardt Bau in Kirchheim from TEREXs manufacturing plant in Motherwell, Scotland. The fleet of brand-new 36-ton trucks are working approximately 200 hours each a month on a motorway project region involving the construction of the A73 stretch which runs across the Thuringian forest. During the course of this expansion, which is expected to last between 18 and 24 months, the trucks are estimated to shift several millions cubic metres of earth, rock and natural stones. Equipped with high-capacity Detroit Diesel engines, the heavy-duty, high-power trucks offer outstanding performance, reliability and durability. Each axle is fitted with automatic limited slip differentials and sealed oilcooled disc brake for superior traction and excellent braking power. The operators have been particularly impressed by the trucks smooth ride thanks to their 6 x 6 all-wheel drive with ground-following suspensions and to the large and spacious cab. In Spain, several Generation 7 trucks operate in various road building projects. Excavaciones Hermanos Saldaa have recently purchased three TA30s, which have been working in a tunnel project since August 04. The trucks are estimated to shift over 200 000 cubic metres of material during the duration of this project, which involves the construction of a tunnel and a 1.5 km road stretch in Formigal in the Pyrenees. Mr Domingo Saldaa, the company director, is impressed by the trucks reduced radius and outstanding traction in the harsh working environment. Four TA27s and three TA30s work in a major motorway project in Barcelona. A 28 km road stretch will be built to join the towns of Igualada and Manresa. The trucks, working for company Gruas Usabiaga, operate in extremely harsh conditions on steep slopes with gradients ranging between 15 and 20% - in the middle of thick forests. The trucks shift soil and overburden material along a 3 km road. The operators have praised the trucks for their ease of use and maintenance, their excellent traction and power and their comfortable and spacious cabs. The TEREX articulated line consists of the flagship Generation 7 range, which includes the 23 t TA25, 25 t TA27 and 28 t TA30, and the larger models, the 32 t TA35 and 36.5 t TA40. The trucks are all designed and manufactured by Terex Equipment Limited based in Motherwell, Scotland. The company is a leading manufacturer of articulated trucks, off-highway dumptrucks and motor scrapers and is part of the $4 billion Terex Corporation the worlds third heavy construction, mining and quarrying equipment manufacturer. For additional information please contact: Michelle Lansdowne Terex Equipment Limited Tel: +44 (0) 1698 503170 Fax: +44 (0) 1698 503200 e-mail: michelle.lansdowne@terex.co.uk www.terex.com
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Internatioal News
WORLD-CLASS GENERATION OF OLYMPIC ATHLETES
Over 80 TEREX rigid trucks have been operating for two decades in the land where the Olympic games were born. And like true Olympic athletes, the trucks excel in extreme conditions all over Greece. TEREX trucks have been the first choice of several leading Greek companies. The countrys biggest truck user, Public Power Corporation a major sponsor in the Athens 2004 Olympic Games - own a large fleet of thirty 50-t 3308E rigid trucks, fourteen 85-t 3311E mining trucks and two R35 rigid trucks, as well as several 90Cs and 7271- front loaders. The trucks have been operating alongside six Unit Rig MT3300 and an O&K RH170 excavator in the companys lignite mines all over Greece since the early 90s. The trucks are estimated to shift over 250 million cubic metres of overburden annually, contributing to the total lignite production of 70 million tons per year at Public Power Corporations mines in Drama, Western Macedonia and Megalopolis in the next years. Quarrying contractor Tsokani S.A., a TEREX user since 2001, currently operate eight 91-t TR100s mining trucks for the transport of overburden in their aggregate quarries. Powered by the world-class Cummins KTA38-C engine with overhaul intervals between 15000 and 20000 hours, the TR100s have over 11000 hours on their clock and operate 3000 hours a year in average, shifting over 7.5 millions tons of material annually. Among the reasons why the company chose these trucks over other competition models are the TR100s versatility and the unique Dual Retardation System. This model has excellent traction on soft terrain - where competitors trucks have difficulty - and the Dual Retardation System, with transmission or oil-cooled disc brakes, offers the operator the option of using the Hydronamic Retarder in slippery conditions for safety and faster haul cycles. The body is made of thick steel plates for added durability, making this truck the ideal choice in heavy mining and quarrying operations. Another lignite mining contractor, AKMI S.A., purchased two TR60s rigid trucks in 2002. The trucks are used to shift overburden and operated approximately 5500 hours per year. The TR60s, which
CEMENT & BUILDING MATERIALS REVIEW No. 18 DECEMBER 2004
work alongside six 3310 rigid trucks and two 3308 quarry trucks, are highly versatile trucks which can be used in mining and quarrying operations as well as in dam excavation projects. These 55-t dumpers are fitted with a heavy-duty transmission with built-in reserve for long life and durability. They also have two reverse gears which allow the operator to manoeuvre the trucks in elevated dumping and loading areas with added confidence and safety. Like the TR100, the TR60 model is equipped with the Dual Retardation System for maximum control and safety in wet and slippery conditions. The TR60 and TR100 rigid trucks are very popular among our customers because of their versatility and their highly competitive technical features, stated Alekos Argyris. We have several other customers who own some 25-year-old TEREX rigid trucks which are still operating with the same stamina and efficiency as when they were purchased. This shows what strong, reliable and durable trucks TEREX produce. Petros Petropoulos, with head quarters in Athens, are responsible for the sale and support of TEREX articulated and rigid trucks in Greece. Their team of fully-trained service engineers ensure prompt local assistance and the companys close working relationship with TEREXs head office in Scotland guarantees a fast and efficient spare part supply service.
For additional information please contact: Michelle Lansdowne Terex Equipment Limited Tel: +44 (0) 1698 503170 Fax: +44 (0) 1698 503200 e-mail: michelle.lansdowne@terex.co.uk www.terex.com
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Internatioal News
Gaiotto: the art of robotized glazing at Tecnargilla 2004 Kemacs new Cross Cut machine previewed at Tecnargilla
At Rimini the Sacmi Group presented an automatic A new glazing line with kiln car loading presented by abrasive water-jet tile/decoration cutting machine, in Cremona-based Gaiotto at the Rimini fair addition to ultra-innovative, reliable technology for the Robotized de-moulding and glazing: combining absolute working of ceramic and other materials. technical perfection with first-rate production efficiency. An absolute first the abrasive water-jet Cross Cut This is what Gaiotto a Cremona-based company belonging system plus all the latest equipment for working to the Sacmi Groups Whiteware division presented at the ceramic tiles as well as other innovative materials, latest edition of Tecnargilla; more specifically, visitors had intaglio and mosaic. This is the technology that Kemac the opportunity to see a glazing line with kiln car loading, a Sacmi Group company specialising in the production a robotized de-moulding machine based on a system of kilns, trims and ceramic cornices put on show at the developed by Niv and pre-drying finishing systems for the last edition of Tecnargilla. complete unfired piece. For the very first time, Sacmi exhibited Cross Cut: In Rimini, our finishing demonstration used high-quality this automatic machine uses an abrasive water-jet to tools and innovative technology, the result of a close R&D cut trims, strips, rosettes, mosaics, inlays, logos and partnership between Gaiotto and Sacmi. In addition to patterns of any type or form up to 150 mm thick. Also the traditional self-learning programmes used on glazing on show was another machine for trims, the KTDSrobots, visitors to Tecnargilla also had the opportunity to see innovative off-line programming, achieved by 7003/T, launched in 2004: this is an automatic machine digitalising the piece to be machined and modelling the for the cutting and bevelling of strip tiles, inserts and work programme on it. This system allows users to simulate other trims (triangular, diamond-shaped pieces etc.) and and set every aspect of the programme and so optimise also performs edge-grinding and calibration to produce working conditions. The six robot axes plus the seventh a rounded profile. turret axis are coordinated to optimise robot movement by Tecnargilla was also the showcase for some of the using trajectories that are as fluid and linear as possible, most reliable and innovative machines ever designed thus reducing cycle and overspray times. by Kemac. For example, Roll Box (model KDCS) is a The production island at Rimini also included the new mechanised structure that loads/unloads storage roller kiln loading/unloading system, a system that is already racks using a vertical-axis roller unit with a chuck used successfully by some customers. The key advantage of this solution is that everything can be done automatically, bar for roller movement. Then there is the GKE 1.6, without any need for workers in the loading and unloading an electric kiln for fast, uniform firing of glass which zones. Another key feature of the Gaiotto system is features casket-like gas piston opening (with automatic flexibility; note that the specially developed picker can locking), high density ceramic fibre insulation and quartz tube heating. The EKS is a roller module designed for perform fully automatic handling of glazed pieces. Gaiotto Automation offers the sanitaryware industry use with single-layer ceramic tile gas kilns: it features more than forty innovative automated glazing solutions. PC-controlled gas and combustion air modulation, Since joining the Sacmi Group it has been able to draw gear drive, A.P.G. burners with silicon carbide cones, on a vast amount of experience and innovative ceramic an effective load width of 1600 mm and a maximum manufacturing technology and has consequently achieved temperature of 1250 C. excellent results in the glaze application and piece handling fields.
17
Lime
Equilibrium pressure , atm.
temperature , oC Fig. ( 1 ) Equilibrium pressure of Co2 against temperature

o
The ring kiln is charged with stones larger than 200 mm in diamter ,can produce homogenuous soft burnt lime . However in modern times it is not used for its complexity of operation and the required high costs for its modernization for charging and discharging. The rotary kiln is specified for limestone particles of diamter less than 50 mm. It is used however only in special cases referring to its high heat consumption in comparison with shaft kiln. The shaft kiln is the most used kiln type for lime burning allover the world. The charge particles size lies between 50 and 200 mm. It is the kiln type of lowest construction costs and its operation can also be easily automized with fulfilling relative low labor demand . Besides, many technical developments have been introduced to the lime shaft kiln to achieve homogeneous soft burnt lime product at the same time with high thermal efficiency of the kiln. However, such developments could not be achieved without recognizing various scientific and technical problems relating to lime burning as will be clarified in the next section.
shown in fig (1). When a piece of limestone is burnt at its calcination temperature or at higher temperature it will loose about 44% of its weight through the evolved carbon dioxide while keeping its outer form . The resulting body will have higher porosity. The product is not compact; it consists of calcium oxide crystals with pores inbetween. The diamter of those crystals and the vlume of the pores depend on the height of the firing temperature and the firing time, especially in the first calcination hours. With higher calcination temperature or with prolonged heating time , calcium oxide crystallites increase in volume accompanied by changes of the lime product such as: shrinkage , increase of the specific gravity and decrease of both pore volume and inner specific surface . The soft burnt lime is that fine crystals fine pores product with high inner specific surface. That explains its high rate of slaking with water Which may need few minutes. On the other hand, hard (dead) burnt lime is characterized by large CaO crystals, large pores and small inner surface area with small slaking rate which may need few hours. According to Wuhrer(2), the crytical limestone temperature above which dead burnt lime is produced attains -1150 C. The best possible soft burnt lime can be obtained at firing temperature of 800 C or nearly at the calcination beginn temperature. With prolonged calcination times, the solid temperature should not exceed about 900 C.
2- Calcination degree of lime , effect of temperature and time:

The calcination temperature of pure calcium carbonate in dependence of the pressure of CO2 has been
19
Lime
Calcination time in h
heat flow in 10^3 kcal/m^2.h

Fig. ( 2 ) Changes of temperature and CO2 parial pressure across Lime Layer of a spherical particle
Fig. ( 3 ) admissible heat flow density in sphere lumpof lime of 125 mm diamter
3- Mechanism of calcination of limestone particle in surrounding hot gases flow:

The operations that occur in each particle during calcination are shown in fig (2), with assuming limestone particle as a sphere. Calcination reaction begins at the particle surface at a front that moves towards the particle inner surface with progress of the reaction. Heat is transferred from the hot gases to the sphere surface by convection and radiation then conducted through the formed lime layer by conduction , the chemical reaction takes place at the reaction front with evolution of CO2 that diffuses backwards through the lime layer then by mass transfer to the surrounding gas stream. The kinetics of the calcination reaction is controlled then by 5 different operations : two of them are heat transfer and one chemical reaction and two mass transfer. For calcination of the particle core, the needed calcination heat is transferred through the isolating burnt lime layer to particle innen by conduction; the particle surface must be heated then to a temperature higher than 900 C. For production of soft burnt lime, the particle surface temperature should not exceed 1100 bis 1150 C , otherwise recrysta-llization of CaO with densification and loss of activity occurs. Fig(3) shows the permissible heat gained amount by sphere formed lime piece, 125 mm diamter against firing time in order that the surface temperature doesnt exceed 1100 C. As clear from fig(3), at calcination beginn relative large heat amounts can be transferred to the raw stone without hard burning danger, while towards the calcination end the allowed to be transferred heat strongly decreases. In fact ,such principle could be simply fulfilled through co-current flow of hot gases and stone
20
particles in the calcination zone. As the limestone charge is not homogeneous in particle sizes, and in order to avoid dead burning of smaller particles, the allowed heat flow for larger particles will be smaller than that calculated in fig(3). In order to produce soft burnt lime,it is then recommended to expose limestone particles to the hottest gases ( larger available heat amount) at calcination beginn, then gases temperature (or its heat amount) should decrease with progress of the reaction according to the heat requirements of the limestone particle. Many designs and developments of lime shaft kilns have been achieved in order to fulfill such optimum heat dozing. . Example of such designs are: -Regenerative Co-Current lime shaft kiln. -Counter Current Lime Shaft Kiln With Gas Re cycle (from the Kiln top or from the base of the pre heating zone). -Double Inclined Lime Shaft Kiln. -Multiple Chamber Lime Shaft Kiln . Brief note about few designs of lime shaft kilns and their operation characteristics will be clarified in the next part.
4- Lime Shaft Kilns:

4.1 The operation principle of counter- current lime shaft kiln: (fig4) Counter- current lime shaft kilns represent a category of simple constructed shaft kilns having round or right-angled shaft in which limestone particles are brought , preheated, calcined and cooled through moving downwards countercurrently with hot gases and air along the preheating-, the firing and the cool-
Lime
4.2 Counter current lime shaft kiln with gas recycle:
In the simple counter current kiln, the burnt lime is exposed to relatively high temperature(at the base of the firing zone), which would affect disadvantageously the quality of the lime product. That is reflected in the difficulty of attaining soft burnt lime in such counter current kiln. A development of such kiln in order to avoid the exposure of burnt lime to high temperature is that : counter current lime shaft
Fig. ( 4 ) Schematic diagram of counter-current lime shaft kiln with and with out recycle
Fig. ( 5 ) Flow pattern in the regenerative co-current/ counter current kiln
ing zones respectively . Fuel with primary air are introduced at the lower end of the firing zone meeting the flowing air upwards from the cooling zone. The latter acts as secondary air for fuel combustion. Fuel combustion gases with evolved CO2 from calcination of limestone flow upwards through the firing zone ,to the preheating zone where limestone particles are heated to about 800 C, then to the kiln chimny.
kiln with gas recycle either from the kiln top (at - 400 C) or from the base of the firing zone ( at 900 C) to the fuel combustion chambers around the base of the firing zone. Such gas recycle lowers the fuel combustion temperature in the calcination zone (firing zone)through its effect on decreasing the O2 content of the combustion gases leading to increase of the
21
Lime
time of fuel combustion. In that way, soft burnt lime can be produced. From fuel economy point of view, recycle of gases from the base of the preheating zone(at 900 C) is more economic than gas recycle from the kiln top (at 400C), as in the latter case recycled gases have to be heated , on expence of fuel, to the gas outlet temperature from the firing zone (-900 C) . Fuel consumption of the kiln with gas recycle from the kiln top attains - 1400 kcal/kg lime ; its thermal efficiency attains about 53%. On the other hand , thermal efficiency of the kiln with gas recycle from the base of the preheating zone ( at 900 C) attains about 68% and its specific fuel consumption is about 1100 kcal/kg lime.
4-4 Modern multiple chamber lime shaft kiln :

It is a multiple chamber shaft kiln with 6 combustion chambers and counter current cooling zone. It is fired with natural gas heavy fuel oil, pulverized coal or small coal of 0 1 mm particle size and is built for capacities ranging from 50 to 225 t of lime per day. The fuel is supplied to six combustion chambers, each with two burners. The degree of burning of lime can be modified via the distribution of fuel. Heat consumption is about 3968 kJ/kg of lime ( 949.3 kcal /kg lime) for an output of 100 t/day,a CaCO3 content of 97.1% in the limestone and a residual CO2 content of 1%.
4.3- Parallel flow / counter flow regenerative lime shaft kiln (fig 5):
That kiln type has two special characteristics:
References:
1- Calcination of limestone occurs through counter- 1-L.M.Farag: Theoretical studies for optinization of current flow of hot gases and solids along the fir lime shaft kilns; Dr. Eng. Thesis, Clausthal ing zone, in order to allow optimum rate of heat Technical University , Germany, Februar 1979. flow to the stone particles to produce soft burnt lime. 2- J. Wuhrer : Scientific and technical problems of 2- Regenerative preheating of the combustion air limestone burning . Chemi-Ingenieur-Tech through its flow through the limestone pack nik 30 , 1958, page 19-30 ing in the preheating zone; the latter acts as a regenerator. 3- H.Eigen : Theory and Praxis of the oil fired The kiln , as shown in fig(5), consists of two symmetlime shaft kiln. Zement-Kalk_Gips 6/1957 rical shafts, each is divided into three equal zones: p.239-246 preheating, firing and cooling zones. The kiln operates periodically, combustion air flow downwards through shaft (1) and cooling air flow counter-cur- 4- H.Waldert:Uniflow regenerative kiln of the lime rently through burnt lime in the two shafts. Combusindustry.Gas warme international 23/ 1974 tion air is heated through limestone regenerator to p.430-434 . about 750 C to meet the fuel and combustion occurs. Combustion gases flow co-currently with the packed charge downwards. Combustion gases are mixed in 5- P.Zeisel : Operational capabilities of the ad the canal binding the two shafts with the two upvanced multiple chamber shaft kiln. Ze flowing cooling air streams from the cooling zones; ment-Kalk-Gips 1/1989 p. 46-51 the gas mixture flow then through the firing zone and preheating zone of the other shaft with heat gain and partial calcination of the limestone packing. At the end of the firing period, the process will be reversed , fuel combustion occurs in shaft 2 and counter current heating of the packing occurs in shaft 1, while new charge of limestone is introduced to the kiln. The kiln is characterized by its very high thermal efficiency that attains more than 83%
22
Gypsum
crystallites are intergrown with one another at the (0 1 0)/(010) and/or (010)/(010) surfaces. This results, theoretically, in six different intergrowth arrangements. Theory of formation calculations [4] make plausible the concept that penetration twins may occur as a result of isoepitaxial intergrowths of mirror-image (010) faces. This phenomenon is associated with the occurrence of lattice faults which have an effect on the properties of the pinacoidal faces of the crystals. Similar calculations have been performed for the intergrowths found by Russo and Petrov. The (040) layers in Figure 1 contain parallel (010) water-bearing (A) and ionic surfaces (B). the layers AA,AB,BA and A*A,A*B, and B*B result, corresponding to the (010)/(0 1 0) and (010)/(010) intergrowths observed, the asterisk signifying rotation of the layer by 180 about the "a" axis. Two (040) layers were displaced relative to one another along a grid, and one of the layers was rotated from 10 by 360 at each grid point. In all six different arrangements, maximum energy of attraction was found for practically every grid point at a specific position. A range of around 100 featuring "attracting" cohesive energy thus results for practically every grid point. The fact that tilting of (010) layers is also possible, is indicated by the occurrence of fibrous crystals with differing orientations as the fiber axis. The cause and mechanism of such dislocations have not
in gypsums obtained from -hemihydrate, are found in hard historical gypsums with Brinell hardnesses of up to 100 N/mm2. The [010] fiber axes run approximately parallel to the diagonals of a cube (fig. 4a and 4b in [1]). There are several variants of this texture. A subtype frequently observed is that in which only two opposing systems occur (convertible into one another by approx. 180). Gypsum specimens with these crystallite arrangements are harder than products obtained from -hemihydrate.
2. Intergrowth of gypsum crystallites

The generation of such textures is possible only if typical crystal intergrowths occur. These obviously only take place once certain dislocations are present in the crystals. The symmetrical intergrowths as per ( 1 01) (butterfly twin), (100) (Monometer-twin), (001) and ( 2 01), which can occur as contact or penetration twins, have long been known in this context. In their crystallization tests, Russo and Petrov [3] found individuals transversely intergrown with one another, the angle between the components being variable. The
yet been determined. Also still unknown are the

25
Gypsum
effects on order of structure of the incorporation of organic molecules such as eosin and hematoxylin, and of extraneous ions. The replacement of an SO4 row in a (040) layer by CO3 groups, for example, produces the mineral Rapidcreekite (CA2(SO4) (CO3). 4H2O) [5], Brushite (CaHPO4 . 2H2O) and Pharmacolite (CaHAsO4 . 2H2O) [6] also produce similar structures, like gypsum. It can be assumed that portions of these structures can also be incorporated into the gypsum structure. plastic ring (height: 5cm, diameter: 10cm) which was located on a glass plate over which domestic cling film had been stretched. The ring was removed after two days and the specimens dried in the air for four weeks. The term "Fluka" in the table indicates dehydrate produced by Fluka; "Natural Gypsum" (air-dried) indicates natural gypsum produced by maxit Baustoffe Nord (Dorste). A surplus of NH3 was present in Specimens F3 and N7. the quantity of suspended particles and of dissolved substances was low in case of the grass extract and was therefore ignored. The Brinell hardnesses stated were determined on the contact faces of the specimens (the values in parentheses indicate data for the interior of the specimens). Measurements of porosity were performed using the GeoPyc 1360 V 3.00 manufactured by Micrometrics GmbH. The pore volume of Specimens F1 and N4 was determined using cut bodies (pure density 2.31 g/cm3), due to the low strength of these specimens. The grass extract was obtained using the following procedure: Freshly mown grass was allowed to ferment in the open for period of seven days and then kept covered in water in glass vessels in the laboratory for four days. After pressing of the grass, the extract was coarsely stained off. Gypsums with Brinell hardnesses of up to 45 N/mm2 have been obtained in setting of -hemihydrate using similar extracts [1].
3. Gypsum hardening experiments

This work was intended to demonstrate, on the basis of hardening experiments performed on gypsum obtained from solutions in pure water and in the presence of additives, that new intergrowths occur between recrystallized gypsum, and also between the undissolved particles. Gypsum (dehydrate) produced by Fluka and air-dried natural gypsum produced by maxit Baustoffe Nord (Dorste) were used as the starting materials for these hardening experiments. As the X-ray diffraction diagram a) in Figure 2 shows, anhydrite and hemihydrate are still (just) detectable in the Fluka Gypsum. Marks H and A indicate the positions of the lines of greatest intensity in the diagrams for Hemihydrate and Anhydrate II. The product also contains small quantities of carbonate. X-ray diffraction diagram b), for the natural gypsum, does not differ with respect to the position of the lines from the diagram for Fluka gypsum, but no carbonate is detectable. The differences in intensity are attributable to structural dislocations and, essentially, to a texture produced during powder preparation. The integration of areadetector images makes it possible to largely eliminate the latter effect [4]. The specimens prepared in accordance with Table 1 where placed after agitation for two minutes into a
4. Texture and strength of the gypsum specimens

As already mentioned in the introduction, gypsums obtained from -hemihydrate manifest a more or less well formed fiber texture with a [010] principal component. Figure 3a shows the corresponding pole figure of the contact faces produced during preparation. The texture also continues in the interior of the specimens. In is apparent from the intensity ring at an angular distance of around 45 (face normal angle between (010) and (121) in the (121) pole figure
26
Gypsum
(Fig. 3b) that a practically static arrangement of the crystallites around the [010] fiber axis is present here. The (020), (121), (141) and (002) pole figures of all specimens were measured using CuKa radiation in the case of the contact faces and using AgK radiation for the interior (due to sulfur's high absorption of copper radiation). Pearshaped specimens with a diameter of around 5 mm were cut in the latter case. The specimens were orientated vis--vis the X-ray beam in such a way that the surfaces of the specimens
The pole figures of the two gypsum specimens F1 and N5, which were recrystallized in pure aqueous solutions (Fig. 4) exhibit the greatest deviations from the texture which occurs in gypsums obtained from -hemihydrate. This is also reflected in their low strength. A significant increase in order is also observable in the pole figures of the specimens prepared with additives (Fig. 5 and6). This is clearly apparent from a comparative assessment of the SEM images of the specimens without any additive (Fig.7) and the specimen prepared with citric acid (Fig. 8). The degree of crystallite intergrowth is thus increased, as is again reflected in higher strength. It is apparent in the marked zone of figure 8 that the recrystallized material creates the connection with the undissolved particles. In all these specimens, the Brinell hardness of the gypsum is significantly greater than that of a commercially available gypsum board. This is also demonstrated by the measured porosity data shown in Table 1. This texture continues in the interior of the specimens. Tilting of the [010] fiber axis occurs in some cases, a phenomenon possibly attributable to compaction during transfer to the plastic ring. Setting of hemihydrate with the addition of grass extract results in superimposition of the penetration texture found in the hard historical gypsums and the arrangement observed in gypsums from -hemihydrate (Fig. 6b in [1]). The penetration texture is lacking where gypsum (dehydrate) is the initial material (Fig 6). ODF calculations using a program developed by Baitz [7] were performed for all specimens. In addition to the principal components already mentioned, these calculations also contain a series of further order
corresponded to the contact faces produced during hardening of the gypsums on the substrate.
27
Gypsum
the cause of this behavior. On the basis of these tests, the recrystallization of dehydrate can also be cited as an explanation of the great hardness of historical gypsums. It is, in addition, also conceivable that the method described could be used for gypsum board production. Further tests and investigations will be necessary for the development of a cost-efficient process with the shortest possible production times, however.
Literature
1. Vogel, D.; Follner, H.; Jacobi, H.;Kulke, H.; Brokmeier, H.-G.: Charak-terisierung und Nachstellung historischer Gipse und Vergleich mit heute bekannten Praparaten. ZKG INTERNATIONAL 52 (1999) No. 11, PP.640648-. 2. Pedersen, B. F.; Semmingsen, D.: Neutron diffraction refinement of the structure of gypsum, CaSO4 . 2H2O.Acta Cryst. B 38 (1982), pp. 10741077. 3. Russo, G.V.; Petrov, T. G.: A new type of regular concretion of crystals. Sov. Phys. Crystallogr. 28 (1983), pp. 114116-. 4. Follner, S.; Wolter, A.; Helming K.; Silber, C.' Bartels, H.; Follner, H.: On the real structure of gypsum crystals. Cryst. Res. Technol. 37 (2002), pp. 207218-. 5. Cooper, M.A.; Hawthorne, F.C.: the crystal structure of rapidcreekite, Ca2(SO4)(CO3)(H2O)4, and its relation to the structure of gypsum. Cand. Mineralogist 34 (1996), pp. 99106-. 6. Heijnen, W.M.M.; Hartman, P.: Structural morphology of gypsum (CaSO4.2H2O), brusite (CaHPO4.2H2O) and pharmakolite (CaHAsO4.2H2O). J.Cryst. Growth 108 (1991), pp. 290300-. 7. Baitz, S.; Vogel, D.; Kulke, H.; Jacobi, H.; Follner, H.: Direction-dependent orientation distribution function of textures and consideration of twin formations. Application to copper and gypsum samples. Cryst. Res. Technol. 33 (1998), pp. 715755.
states, which are, however, incomplete. No systematic pattern is discernable.
5. Conclusions
The crystallization tests demonstrated that characteristic crystallite intergrowths which result in an order similar to that in set -hemihydrate occur irrespective of external conditions. This order obviously increase the strength of the recrystallized gypsum and can be influenced by certain co-solutes. It can be assumed that dislocations of the crystals are
28
Gypsum
Main properties of the FGD gypsum: bulk density ranging between 0.8 and 1.3 t/m particle size < 1mm moisture contents 15% max. The silo geometry featuring an enlarged bottom section allows the material to ease and to achieve the required mass flow. The same applies to the intermediate discharge chute. The respective negative wall slope angles prevent the FGD gypsum from sticking to the walls and avoid bridging. Plastic coating sprayed onto the silo wall surface in contact with the material reduces the wall friction and protects against corrosion. A CENTREX ensures material reclaim from the silo according to the principle first in / first out. The rotating discharge arm of the CENTREX with a diameter of 3.000 mm is driven by a hydraulic drive unit of 55 kW, located inside the inner cone of the discharge unit. The hydraulic drive allows to continuously adjust the discharge arms rotation to the actual bulk density of the FGD gypsum hence ensuring smooth mass flow even with considerable bulk density variations. Continuous adjustment of the reclaim volume is achieved with the discharge arm rotating at 0.3 and 3 rpm. Pressure limit sensors protect the machine against overload. The logarithmically shaped discharge arm moves the bulk material towards the central outlet underneath the inner cone where it is discharged into the transfer chute. The discharge arm reclaims the material from underneath the material column and reaches beyond the outlines of the silo wall through a built-in slot. Homogeneity of the stored material is maintained, thus avoiding segregation and bridging. Stiffening girders connect the inner cone with the silo wall. These girders with roof-shaped upper section serving as deflector plate, are hollow to allow access to the drive unit inside the inner cone.
Silo data : capacity 20 m diameter 2.25 / 3.0 m height 5.000 mm
31
Gypsum
The chute installed underneath the central discharge and fitted with a double paddle mixer transfers the material to the dryer. Material level sensors control the double paddle mixer to ensure an even material discharge flow even with large lumps of material and variations of the moisture contents. CENTREX data : Nominal diameter Drive Drive arrangement Reclaim capacity 3.000 mm hydraulic 55 kW inside the silo 7 70 t/h
Discharge arm speed 0.3 3.0 rpm The CENTREX with internal drive unit was chosen in this installation on account of its absolutely tight design with a fix and stationary discharge chute, a must to prevent loss of air in connection with the subsequent dryer. The equipment at the NORGIPS plant was commissioned in October 1997 and perfectly integrates into the production process.
Further details may be obtained from : Andr Tissen AUMUND Frdertechnik GmbH Saalhoffer Str. 17 47495 Rheinberg Germany Tel.: +49720-2843Fax: +4960270-2843tissen@aumund.de
Silo bottom with chute and transfer to dryer
32
Ceramic
concepts for a large variety of requirements and tasks (see figure 1):
An
automatic press with manual periphery offers a cost efficient access into the production of high quality products. Here, the weighing of additives and the product handling is done manually. next stage of extension is a semi-automatic plant, where the weighing of additives and the transport within the factory takes place automatically, while the handling of the products after pressing is still done manually. with a fully automatic material preparation (dosing, weighing, mixing and transport) followed by an automatic off-bearing and packing of the products. It is possible to provide individual intermediate stages adapted to the local conditions at site.
The
analysed and integrated into custom-made concepts. Alpha Ceramics at Aachen, a subsidiary of LAEIS GmbH provides the best conditions in their excellent laboratories and production facilities for performing of tests with the customers own materials, even on production scale. Thanks to the competent plant engineering division, the in-house production of the main plant components and the worldwide available
In the final stage of extension the plant is provided
Increasing the productivity of our customers and optimising the quality of their products
With this claim LAEIS offers a complete service package. From the time of evaluating the basic concept followed by designing of the plant up to installation and commissioning, including training of the operating staff, everything is supplied from one source. Special customer requirements and ideas are service and spare part supply, LAEIS is the perfect partner for investments in future-oriented products. Figure 2: High performance hydraulic press BETA 3000 for the production of various cement bonded products
Table 1:Performance data comparison of LAEIS presses for cement bonded products
35
Ceramic
Figure 1:Flow sheet examples for plants with different levels of automation
36
Management
industries environment where a complete range of subjects can be delivered from technical to managerial skills and knowledge. This is because it is a learner based method of training where in the learner is more active and involved in his learning, and to a greater or lesser extent learners can adjust the pace of learning to their individual capacities to absorb the training. As the name suggests computer based training courses are training materials, therefore the same systematic apprach of task analysis, writing aims, and objectives, criterion testing, content evaluation are required as for the production of any training materials.
Computer Industies
Based
Training
for
Cement
Training investment
At present, investment in cement manufactring equipments is increasing. The general demand for cements is expanding the cement industry world wide and therby creating a need for increased production capacity. New production equipment and the latest technology help to increase production and lower production costs through highly automated processes and reduce down time by means of better maintenance practices. The introduction of new technology has reduced manpower per produced unit of cement. The production results rely on the full utilisation of the equipments potential, and this can only be achieved by the human resources applying good operation and maintenance procedures. The decrease of manpower increase the demand for good qualifications. The cement industries are well aware of the need for ahighly qualified workforce. This in turn raises the demand for training. The problem facing the industry in general is to define what is required to ensure that the employees are able to utilise and maintain the equipment adequately. Unfortunately the cement industry is not always able to specify the exact training needs of the employees . The requisition for training from a cement plant is often formulated in general terms, refering to a general curriculum for cement manufacturing. Training manager for cement industries seek to assist their companies in specifying the exact staff training requirnients. This will ensure that the companys investment in training will be utilised to provide the exact required qualifications within the staff Training in cement industries in many circumstances is delivered through the traditional training methods with the help of standard training programmes format and the help of potential instructors, or through cement plant simulator trainer for operators. Still there are new methods of decentralized and individual education and instruction, one of them
is the computer based training which is considered as one of the main forms of open and continuous learning and also as an approach that allows people to learn at atime, pace and place to suit their needs and those of the organization. Through the medium of personal computer which has now become available to almost every one, computer based training offers an attractive means of teaching and learning for many application. The learning through it is achieved more successfuly than with other teaching methods specifically because of many combinations such as new low cost hard ware (PC) with education oriented author soft ware and with lessons prepared in accordance with the best possible teaching practice. It also has proved particularly successful in cement industries environment where a complete range of subjects can be delivered from technical to managerial skills and knowledge. This is because it is a learner based method of training where in the learner is more active and involved in his learning, and to a greater or lesser extent learners can adjust the pace of learning to their individual capacities to absorb the training. As the name suggests computer based training courses are training materials, therefore the same systematic approch of task analysis, writing aims, and objectives, criterion testing, content evaluation are required as for the production of any training materials. Development of cababitity in computer based training: (A) Identifying of training needs however as the power and flexibility of the personal computer (PC) is used as the delivery medium there is extra knowledge and skills needed for authors to acquire to fully utilise this medium. The requirements of a CBT author can be divided in to four main areas of expertise: 1. Computer literacy to aminimum level where they will be able to: (1) Safely operate au IBM or

39
Management
compatible computer and peripherals (Printer,Scanner) (II)Use and understand Dos commands to manipulate computer files without loss of data The content of the training for the authors which relate to the specific knowledge I skills for CBT production may be divided in to modules containing the followings: I. BACKGROUND TO CBT
At the end of this module, the trainee will be able to: (III) Use of microsoft windows to the same level. - list the reasons for the development of CBT - describe the benefits of CBT over other forms 2. Authoring system usage i.e they are of training totally familiar with the capabilities - describe the components of multimedia. and limitations of the 2. Hardware and software authoring system to achieve the t the end of this module, the trainee will be able design and objectives of the to: training course. - operate the required hardware to produce CDT courses at an acceptable production rate 3. Training learning design i.e familiarity - operate the required software to produce CBT with training terminology and courses at an acceptable production rate techniques from training 3. Authoring workshop needs analysis , curriculam development designing, At the end of this module, the trainee will be able to: preparation and evaluation of training - use Ten CORE producer to create a fully operational material. CDT course. 4. Script writing i.e the ability to rewrite (This module usually takes a minimum of three working days) existing materials in to aformat suitable for computer 4. Training Records and Utilities based training and the target audience. At the end of this module, the trainee will be able to: (B) Resources needed: - design student performance measurement (I) Infrastructure and support services nwst be available routines that are valid and reliable to provide an excellent basis for the development of - record the correct score for a student the CBT production capability i.e multimedia room - feedback the correct score for a student large enough with information presentation platform 5. Training Design and computer based techniques which include amix At the end of this module, the trainee will be able to: of media, the use of digital technology and interaction - list the types of training for which CBT is for the users. appropriate (II) Computer hardware, software and accessories: - describe the component parts of training The main hardware components may include IBM objectives PS/1 personal computers with 30486 SX processors - list the benefits of a standard design running at 33MHZ, 4MB of RAM and SVGA graphic 6.Screen Design Layout - capability, Epson LQ-1 170 24 pin dot matrix printers At the end of this module, the trainee will be able to: and Hewlett-Packard scanjet llc desk top Scanners which allow the digitisation and incorporation of - demonstrate the ability to layout screens of CDT any colour or black and white image in to the CBT material consistently - produce fluent screen changes course. - describe simple graphic design rules The main soft ware may include Ten core producer - produce effective graphics/images/animation as an authoring system , publishers paintbrush as 7.Interaction Design the graphics package, Microsoft word as the wordprocessing package, Hijaak as graphics capture At the end of this module , the trainee will be able and conversion utility, and sidekick 2 as a utility to: - author variety of interactions programme - describe the uses of various types of interaction (C) Training needs to be provided - use interactions effectively.
40
Management
8. Script-writing ((Introduction - learning - practice - reinforcement testing))
At the end of this module the trainee will be able to: - write text, with emphasis on technical material, in Learning - practice - reinforcement are repeated for each segment of learning between the topic a format suitable for CBT usage introduction and test. - rewrite material from a variety of sources 9. Courseware Checking Maximum use is made of graphics which are always an aid to learning, to illustrate technical points and to maintain the interest of the trainees.
At the end of this module, the trainee will be able to - carry out quality control checking on their own and The training course may be divided in to integrated other authors courseware modules which are self containd, and these are furthur - produce courseware with a minimum number of subdivided in to topics . The topics may be arranged errors in to segments that are kept to aminimunl size to 10. Working with a Subject Matter Expert (SME) ensure interactivity of the learner. At the end this module, the trainee will be able to: The course structure may be arranged to allow - extract the required material from an SME maximum opportunity for learners to select their own - arrange for technical checking of courseware route or one suggested to them. - ensure that the finished course is agreed by the Each module containes a post test which is correlated SME. against the training objectives for that module. 11. Course Paperwork and files The content objectives and target audiences of the At the end of this module, the trainee will be able to: CBT course for cement industries may include the followings: - write pre-authoring design notes - keep records during production of a CDT course 1.Objectives of the CBT modules (Maintenance). - maintain a file of information on a CDT course * Longer working life of rollor bearings - produce text support material - refresh basic knowledge of anti-friction bearings 12. Production Scheduling - teach applications of major types of bearings At the end of this module, the trainee will be able to: - convey proper mounting and dismounting methods - provide an accurate estimate for the production to avoide failures * Trouble shooting on weighbelt feeders time for a CDT course - introduce concepts of electronic weighbelt feeders 13. Validation and Evaluation - explain the components of an electronic weighbelt At the end of this module, the trainee will be able to: feeder - validate and evaluate CDT courses produced in- - convey proper diagnosing methods house and externally - teach diagnosing skills 14. Production Issues At the end of this module, the trainee will be able to: - specify the required information before commencing production - describe the steps in a CDT course production - list the component staff roles in a CDT production unit. Contents and course design for cement industries computer based training The training programme objectives for cement industries are derived as a result of training needs establishment. The best planned procedure for the learning within the contents of the course is to proceed from the known to the unknown using the general principles of course structure based around the components: * Maintenance of conveyor belts - introduce concepts of conveyor belts - teach applications of the major belt types - convey proper maintenance and assembly methods - simulate correct load calclations * Compressors and pressuirized air - save costs through a better understanding of compressed air systems through: An introduction into the thermodynamics of compressing air An overview of the particularities of the major air compressors The teaching of the major applications of compressed air systems. * Systematic maintenance
41
Management
- - - - Describe what is meant by systematic maintenance and how it can be used to improve availability and productivity of plant. Outline the role of effective planning techniques in systematic maintenance Describe the reasons for using plant condition monitoring (PCM) and the factors to consider during application of this method. Describe the main techniques of PCM and the ways by which they can contribute to a monitoring system and be applied to common applications. * Maintenance of conveyor belts. components of conveyors belts. characteristic of conveyor belts mounting and maintaining conveyor belts. belts desing simulation * Compressors and pressurized air atmospheric air atomspheric pressure . density and .humidity of air. three phases of air. gas laws and compression.
- Explain the principles of vibration analysis and describe the features of different systems that can principles of themodynamics be used. working with compressed air. - Describe the role of systematic maintenance in compressed air systems dealing with environmental issues for the cement factory. preparation of compressed air. - Describe the role of systematic maintenance in distribution of compressed air. safeguarding and improving the health and safety application of compressed air of employees. * Plant condition monitoring. - Plant condition monitoring. to introduce principles of vibration terms and theory measurement and detection selection of machinery criteria vibration parameters - Lubrication care and maintenance of bearing transducers function and mounting provide aguide to the principles and the use of analysis terms associated with lubrication and common techniques trend anylsis amplitude v bearing care. day to day maintenance dealing. time amplitude v frequency amplitude v phase. - Basic hydraulics interpretaton identification of imbalance lack of security provide introduction to hydraulics for misalignment resoncance electrical problems those without format field training aerodynamic and hydrualic forces setting up but need basic appreciation abivration monitoring system consideration cost - Pneumatics resources and future trends introduction to all aspects of pneumtics in cement industries. * Lubrication care and maintenance of bearing: (2) Content of the cbt moducles { maintenance } principles of lubrication types of bearing * Longer working life of roller bearings type of friction mounting methods. purpose of lubrication dismounting methods. effects of lubrication dismounting methods for damaged bearing. ball and roller bearing ball bearing * Troubleshooting on weighbelt feeders. roller bearing principles of electronic weigbbelt feeders diametric clearnace components of electronic weighbelt feeders. interference fits strategy for effective troubleshooting. shoulder height enhancement of troubleshooting skills knowledge lubrication cleanliness fitting bank on important facts of weighbelt feeders. the concepts and benefits of condition based monitoring illustrations on setting monitoring programme for vibratin, opto electrical and thermography monitoring.
42
Management
removal inspection bearing failure storage plaing bearing friction bearing material bearing types alignment and bedding down scraping and running in oil grooving application of lubricants distribution within the bearing distribution to the bearing grease lubrication system oil lubrication system ciruclating system lubricant handling symptoms of bearing failure * Basic hydraulics introduction to basic hydraulics hydraulic pumps cetop symbols principles of power hydraulics and hydraulic fluids reservoirs and fluid conditioners fault finding subjects covers the lift and miss approach safety procedures line service instnitnentation, principles measuring instruments pressure gauges and installation flowmeters and installation machine faults malfunction procedure and block diagram system faults and malfunction procedures * Pneumatics compressed air theory air compressors compressed air production compressed air distribution compressed air quality symobols BS. 2917 and I.S.O. 1219. cylinders and actuators directional and control elements electrical interface and hydro - pneumatic elements introduction to circuits electro - pneumatic circuits and sensing systems multi - signal and logic circuits maintenance of fault finding circuit examples and application * Introduction to systemutic maintenance What is systematic maintenance type of maintenance benefits of systemtaic maintenance causes of failur principles of systematic inaintenace * Planning planning requirement job creation maintenance schedules manual of standard pre and post analysis bar charts * introduction to pcm maintenance management benefils of pcm where to apply pcm monitoring techniques system desing issues management implication * condition monitoring techiques vibration wear debris analysis non - destructive testing thermography common application * vibration analysis introduction fundamentals transducers portable data collectors hard wired systems singnal proccessing and analysis. * Target audience for CBT modules ( maintenance) maintenace supervisory personnel mechanics and apprentices production supervisory personnel. process engineer * Troubleshooting on weighbelt feeders maintenance supervisory personnel mechanics and apprentices production supervisory personnel process engineers * Maintenance of conveyor belts. maintenance supervisors mechanics and apprentices supervisory production personnel * Compressors and pressttrized air matntenace supervisory personnel mechanics and apprentices supervisory production personnel
43
Management
* Systematic maintenace. engineers inspectors implemcnters of systematic maintenance. * Plant conditon monitoring trainees instntctors maintenace and development staff associated with the installation and maintenace of vibration monitoring system. * Lubrication engineers technical persons responsible for lubrication system * Basic hydraulics engineers of other disciplines needing to gain abasic appreciation of hydraulics * Pneumatics plant engineers desing and maintenance staff 3 The objectives of the cbt modules { production * Controlling critical king condition. refresh knowledge of kiln control tinder various operating conditions improve kiln problems identification kills provide alternative solution to kiln problems identification skills provide alternative solutions to kiln distrubances and other kiln/cooler related problems. impart an attitude of rational energy consumption explain normal procedures for evaluating energy efficiency of kiln system offer solution for reducing energy consumption impart an understanding of the circulation phenomena learn the different circulating elements track down the circulating elements and solve the related problems provide decision support for solving specific problems establish the correlation between raw meal composition and other parameters with coating formation provide methods of ensuring proper coating for good kiln operation and control refresh knowledge of mill circuits , equipment and controls establish the relevance of proper mill maintenance emphasize the sole of quality control for good operation enhance the participants problems solving skills provide understanding of comminution enginnering establish the correlation betv~en the different system components explain the methods for reducing specific energy consumption
* cement mill operation
* Optimizing cement grinding systems
4 Contents of the cbt modules ( production * Controlling critical kiln conditions introductory refresher course on: kiln start up normal operation nomal shutdown condition
* dealing with problems for specific kiln cooler and preheater related cases * Saving energy from the control panel Energy efficiency in kiln systems advantages and disadvantages specific energy consumption break down of heat consumption * reducing specific energy consumption through operation through niaintenace through equipment modification * Reducing energy costs benefits of substituting hues using waste heat * circulation phenomena indication of circulation circulation phenomena effects of circulation tracing the problem elements solution to problems advanced topics multi element circulation
* Saving energy from the control panel
* circulation phenomena.
* Coating formation understand coating formation and the dangers of excess coating provide means to detec excess coating formation
44
Management
detailed circulation models * coating formating the necessity of coating formation of coating and rings ring detection operating akiln with aring - processing of cement - management of contractors - fire prevention - accident investigation - assessment - verification - control measures testing & maintaining - noise control - water treatment - slinging - instnimentation - programmable logic control - high voltage - basic electrical knowledge computer based training will provide the following main advantages over the traditianal training methods in cement industry. - increased accessibility to the training material at a time when it is required rather than waiting for a lecture - consistency and repeatability between all the trainees regardless of when the training is given. - reduced training time - flexibility , in that the trainee can be directed to the parts of the course that are most relevant to his level ofjob or training requirement - increased involvement of the trainee through the interactions built into the course Disadvantages include: - no tutor or lecturer available all the time during the course to answer technical questions, although the trainee should know of the support that is available. - inability to provide up-to-the-minute work related examples. Final word: Cement companies who invest in machines and dont care to invest in the persons running and maintaining these machines will face the problems of low productivity, high operating cost, and high accidents rate The machine it self is one any where in cement industries, but those who are operating, maintaining and managing in these industries are the real power for making a cost effective operation, adding value to the equipments and machines through proper use and handling. At this age of computer revolution, cement industries should put value to their owned desk top computers by making use of computer based training as apotential application in training and open learning.
* Cement mill operation from the control room to the grinding system closed vs. open cinicit problems to challenge participants skills start tip shut down and problems solving * Optimizing cement grindign systems optimizing through operation optimizing through quality control optimizing through maintenance optimizing through engineering 5. Target audience of the cbt modules controlling critical kiln conditons process engineers productions supervisors central control room operators - Circulation phenomena experienced CCR operators process engineers production supervisors quality control personel - coating formation process engineers central control room operators - cement mill operation central control room operators shift supervisors - Optimizing cement grinding systems process engineers experienced CCR operators other topics of interest may be identified and prepared as modules for future development and may include the followings: - use of personal computers - environmental protection awarness - quality control - safety measures - project management - kiln mechanical maintenance - kiln system operation and optimzation - cement grinding technologh - cost control - energy monitoring - engineerillg
45
Analysis
properties and by calorimetric methods. in this paper, the isothermal calorimetry method is used. Isothernial calorimetric measurement (was carried (out using Portland cement (CPC) and Pastes plast furnace slag cement (BFSC) cement pastes. Thereafter, apparent activation energy was calculated based (In the heat released during the hydration processes and was simplified into an easily opera ble expression and incorporated in the HYMOSTRUC model [1] to carry (out numerical simulation for concrete cured under adiabatic conditions. Comparison between measured adiabatic tempera ture raisend sinulated results shows that a better result is obtained using the simplified expres sum of apparent activation energy .
Figure 1. Exprimental setup,where1: isothermal calorimeter, 2: industerial computer, 3 :oven, 4 : Shaking machine,5 : mixer, 6 : electronic scale
2 - Experiment Description Experiment Instrument

The isothermal calorimeter used is the 31143236/ TAM Air isothermal calorimeter, Figure1 mannlactured by Thermometric AB, Sweden. It is an eight-channel calorimeter operating in the milliwatt region. the capacity chosen in this research was 60C mW. It can operate in the temperature range from 5 to 60C with a fluctuaion of only 0.02C. The calorimeter is located in a room where temperature was set to 20C and RH 75%. Atmeasure ment temperatures higher than the environment temperature, in order to prevent as much as ther mal shock to the calorimeter due to the temperature difference between the sample and calorime ter, both cement and water are kept in the over 24 hours at the desired mixing temperature befor mixing and isothermal measurement. Heat of hydration in the first 7 days was recorded by the industerial computer.
cou Her VS 230 and the result is shown in FIgure 2. The Blain number for PC Is found to 550 m2 / kg and that for BFSC is 440 m2 / kg
Cement Paste Composition

Table 2 shows the composition details of the
Table : 1 Chemical Composition of the cements
CEM I 52.5R wt% CEM III/B 42.5 LH wt%
Materials
The cements used are all manilaclured by FNCI B.V. The Netherlands and CEM /52.5R (referred as PC haterl) is produced in FNCI Maastricht and CFM Ill/ B 42.5 LH HS (referred as BFSC later) is produced in ENCI I JJmuiden. The oxide coniposition of the cement can he found from Table 1. The mineral content of CEM I 52.5R was calculated using Bogue equation as 60.57% C3S,11.37% C2S, 8.43%. C3A and 8.79% C4AF-. The content of blast furnace slag is 68%. and clinker 28%, fly ash 4% in CEM III/ B 42.5 LH HS. Particle size distribtion of the cement was also measured using laser diffraction, her equipment was
CaO SiO2 Al2O3 Fe2O3 K2O Na2O SO3 MgO TiO3 MnO P2O3 LOI
62.860 19.630 5.020 3.310 1.230 0.301 3.010 2.280 0.363 0.119 0.449 1.060
45.270 30.790 9.880 1.400 1.170 0.221 2.820 6.590 0.477 0.216 0.140 0.760
samples. The weight of the sample cement paste for the isothermal measurement is 10 0.01 gram. For each mixture composition, the measurement of the isothermal heat release was done at temperatures 20, 30 and 40C, respectively.
3 - Experiment Results
Thermal Power and Heat of Hydration Cement hydration is an exothermical process and an isothermal calorimeter recored the rate of the heat release or the thermal power. By integrating the thermal power with time, we can obtain the heat of hydration. Thereafter, the degree of hs dration at time
47
Analysis
Actiootiou Energy
From Eq.(1) and (2), taken the rate of hidration at two isothermal curing temperatures T1 and T2 (T1 > T2 ,absolutc temperature) as K1 and K2, the apparent actiration energy can be calculated using the formula below . Ea (T,Q) = - R*T1*T2/( T2 - T1)*In(K2 K1)
Figure 2 : Particl size distribution of the two cement
t can be defined as the heat released at time t dircded by the potential heat that can be released at complete hydration, viz . = Q(t) / Qpot It can be seen in Figure 3 Table : 2 Mixture Composition that the rate of hydration Code W/C of PC is quite fast and has R4I 0.40 two peaks. The first peak R6I 0.60 appears immediately R4H 0.40 after cement is mixed R6H 0.40 with water. The second peak appears generally at about 5 to 9 hours. The higher the temperature, the earlier the second peak is wll appear. However, BFSC exhibits another shoulder after the second peak. The higher the temperature, the shorter the interval between the second and third peak is. From the experimental data, a dependencs of E on was observed.. The higher the curing temperaure, the higher the degree of hydration is at early age while the final degree of hydration will he lower. For Portland cement, after 1 day, the degree of hydration at higher temperature is lower than that at lower temperature. However, for slag cement, lower values of degree of hydration are fonnd after about 2 to 3 days. The time of the lower value of the degree of hydration is also influen ced by the water cement ratio. At w/c=0.4, the time is shorter than that at w/c=0.6. If we have a lower at the experiment done with ultrasonic measurement of concrete [5], the ware speed is also lower at higher curing temperatures at later stage. In addition, lower 7 and 28 days compressive strength arc also bound for concrete cured at higher temperatures. Garcia and Sharp [2] also reported that higher curing temperature will decrease the degree of hydration both Portland cement and blended cement at the later stages.
The calculated F is shown in Figure 4 and in order to ose the obtained F in numerical simulation, a simplification similar to 141 was made and the following expression for E is obtained:
Ea((t),T=(44.92 - 0.043*T)*exp(0.00017*T)e-a(t) kg/mol
Water (gram)
2.86 3.75 2.86 3.75
Cement (gram)
7.14 6.25 7.14 6.25
Cement used
CEM I 52.5 R
CEM III/B 42.5 LH
Where a is the degree of hydration and T is temperature (K). a can be expressed as a function of time. Freieslehen et a). proposed a general be-linear apparent activation energy, which claims that Ea remain constant for temperature above 20 C [1, 6]. However, van Breugel [1] calculated the activa tion energy based on isothermal Calorimetry data on Portland cement carried out by Lerch and Ford and suggested that E is a function of temperature, degree of hydration and C3S. DAloia [3] confirmed that the E shows dependence on the degree of hydration based on isothermal calorimetry study, which is also found in our experiments.
4 - Application
In order to validate the effectiveness of Eq. (4), we used the equation in the HYMOSTRUC model and made several simulations using experimental data of [6], where adiabatic curing data was reported. It can he seen from Figure 5 that numerical simulation using KYMOSTRUC with Eq. (4) gives clo ser results to the measured adiabatic temperature raise. Figure 5 also shows that at the very begin ning of the hydration (<24 hours), FIYMOSTRUC with Eq. (4) predicts a
48
Analysis
In addition, the predicted adiabatic temperature raise at later periods (around 1000 hours) is also decreased in the direction of experimental data in comparison with the HYMOSTRUC, with its on ginally implemented expression of E
5 - Conclusions
Isothermal calorimeter measurements were done using Portland cement (PC) and blast furnace slag cement and the apparent activation energy was obtained and a simplified expression for E was found. Numerical simulation using HYMOSTRUC with this new form of activation energy agrees quite well with experiment adiabatic data, especially at early age. This is quite important for the calculation of thermal stress, control of thermal crack and associated durability. It is also found that E changes along with hydration and a significant change in the value of E may suggest a change in the mechanisms of the hydration processes. In order to get a more reliable numerical simulation result of cement blended with fly ash, silica fume, and limestone powder, a systematic isothermal calorimetry study of these pastes is needed and simulation results can be guaranteed by the better understanding of the apparent activation energy.
Figure 4 : Colcutated apparment actiuation energy for PC and BFSC using Eq. (3)
Figure 3. Thermal power of PC and BFSC at 20, 30 and 40 OC, W/C=0.4 and W/C=0.6 using isothermal calori meter, only first 50 hours are shown for a better view
quite acceptable adiabatic temperature raise, which is quite important because this provides the basis for more accurate calcu lation of the thermal stress in massive concrete at early age and has beneficial effect on the control of cracks and durability.
It has to be admitted that the exact value or expression of activation energy may be less important in the real engineering practice, for example, in the case of the calculation of risk of crack. However, it is quite necessary in the fundamental study, especially on the kinetics of cement hydration processes.
Acknowledgements
49
Analysis
This research is a part of the PCT 4.010 project financed by The Netherlands Science and lechnologv Foud (STW), whose support is gratefully appreciated. The authors would also like to thank Mr. E Horeweg, R. Molder and other colleagues in the Stevin Lab 11 of Delft University of technolog for their kind help in the experiment works.
References
I.Breugel, K. van, Siniulation of hydration and formation of structure in hardening cement-based materials, 2 Edition, 997 2.Escalante-Garcia, J.l., and Sharp, .JH., The microstructure and mechanical properties of blended cements hydrated at various temperatures, Cement and Concrete Research, Vol 31, No. 5, 2001, pp 695702- . 3.DAloia,L.., Determination de lenergie dactivation apparente du beton dans le cadre de / application de Ia methode du temps equivalent a Ia prevision de Ia resistance en compression au june age: approaches experimentales mecaniqne et calorimetrique, simulations numeriques, Ph.D thesis, LEcole Nationale des Travaux Publics de lEtat, 1998, 278 pp. in French) 4.Kim, J.K., et al., Estimation of compressive strength by a new apparent activation energy function, cem. Con. Res., Vol 31, No.2, pp 217225 5.Ye, G., Breugel, K. van., Eraaij, A.L.A., Experimental study on ultrasonic pulse velocity evaluation of the microstrueture of eementitious material at early age, HFRON, (Vol. 46, No. 3, pp. 161-I 67) 6.Krauss, M., Rostasy, FS., Gutsch, A.-W., Modelling of the Degree of Hydration on Basis of the Adiabatic Heat Release, IPACS BRPRCT-9786 ,0437- pp.
Figure 5 : Compaison among experimental valuse, where simulation using HYMOSTRUC with Eq.(4) are denoted as "New Ea" and simulation using HYMOSTRUC with the original implementation in HYMOSTRUC are dented as "Old Ea "
50
Analysis
Figure 1. Calibration curve for alite (C3S) in a series of industrial Figure 2. Calibration curve for aluminate (C3A) in a seoes of industrial clinker samples using the integrated XRD system. clinker samples using the Integrated XRD system.
being measured by the Total Cement Analyser. At the level of microscopic observation, the biggest limitation resides in the presence of a vitreous intersti tial phase which makes it difficult to differentiate the ferrite and the aluminium oxide. This is not the case with the samples in this study, since the clinker samples are cooled slowly allowing C3A crystallisation. On the other hand, the microscopically determined interstitial phase (alumina and ferrite) is always greater than that calculated by Bogue, as the after assumes that all of the A12O3 and Fe203 contributes to the formation of C3A and C4AF without considering the pos sibility that part of those oxides can form solid solutions with silicates. The total analysis time taken by the integrated XRD system for free lime and the four clinker phases is less than 4 mins. Peak intensities are used directly without any corrections
instrument. These concentrations are used to calculate the equivalent concentrations of clinker phases using Rogue formulae. It is clear that Rogues formulae do not produce accurate results, fundamentally due to the fact that the conditions of the process have not been taken into account. For example, the effects of very coarse raw mineral grains, temperature profile, time spent in the kiln, cooling speed etc. have a significant bearing on the formation of clinker phases. The microscopically determined concentrations have been used as nominal concentrations to establish a quantitative analysis program using the integrated XRD system. The peak intensities of C3S, C2S, C3A and C4AF are correlated with these concentrations to obtain calibra tion curves. Figures 1 and 2 show the calibration curve obtained for C3S and C3A respectively. Similar calibration curves have been obtained for C2S and C4AF phases as well. Table 2 compiles the results of the clinker phases obtained with the integrated XRD system within the ARt. Total Cement Analyser in comparison with the
RESULTS AND DISCUSSION

Table 1 shows the results of chemical analysis (total oxide concentration) obtained by the XRF part of the
53
Case Study
measurement for monitoring machines and processes One of the first DMGH girth gear units with a drive rating of 1600 kW went into operation in 1992 at a cement works in Duisburg, Germany. The gear unit was supplied with a vibration strength monitoring system. Velocity vibration sensors were mounted at the "on top" measuring point. A velocity vibration sensor consists of a coil suspended on springs which is excited into oscillations and induces electrodynamic voltages. These electrical voltages are processed in a separate box and are usually output as vibration strength in the frequency range from 10 to 1000 Hz. If certain vibration strengths are exceeded during operation then the plant is shut down. Operational experience has shown that although these velocity vibration sensors do supply a large electrical output signal, sensitive to magnetic fields, become fatigued after a certain operating time, and are not capable of measuring high-frequency roller bearing excitations. If malfunctions occur then expensive fault investigations are necessary or else cost-intensive servicing by the manufacturer of the measuring technology is required in order to re-adjust the electronics. F6110 acceleration sensors have now been introduced which work on the piezo principle; they are not sensitive to external influencing factors and use robust industrial cables. The required vibration strengths are determined in a VibController by integration and are processed as 4 to 20 mA signals with two alarm thresholds. A display can be included at the clients request so that the vibration values can also be read "on site". Fig. 2 shows a list from ISO 108163- which gives reference values for the vibration velocities for machines. According to the ISO the green and blue colours permit unrestricted long-term operation, yellow permits short-term operation and the ISO evaluates the red range as "vibration causes damage". Application of this list to girth gear units is only possible and appropriate with certain restrictions. During the operating and the running time of the machine the VibController checks whether the vibration values change and limit values are reached. It was found that this type of simple condition monitoring is in fact sufficient for general machine and process monitoring but is inadequate for monitoring the condition of a gear unit.
2.2 Frequency-selective vibration velocity monitoring

What is the effect of just monitoring vibration strength? Like machine noise, vibration strengths are composed of individual, frequency-related vibration excitations. The overall value is determined by the dominant components. If, for example, the motor vibrations are dominant it is the motor and not the gear unit which is monitored during vibration strength monitoring. Fig. 3 shows two examples of frequency analyses which were measured at the "on top" measuring point and at the input bearing of a DMGH gear unit. At the "on top" measuring point the dominant component is the double meshing frequency between the gear unit output pinion and the mill girth gear. The input stage has a meshing frequency of 410 Hz and the intermediate stage has a meshing frequency of 130 Hz. If the vibration strength is now monitored only the dominant component will be monitored. If, as a result of bearing damage, the vibration behaviour changes in the intermediate stage, the excitations at the "on top " measuring point at the meshing frequency must first rise to 1.0 mm/s before they cause any increase in the vibration strength. However, the damage occurs before this an aspect which is often forgotten with a gear unit and can lead to unexpected stoppages. As an alternative it would be possible to use several VibControllers with bandpass filters set up so that first the input stage, then the intermediate stage and then the output stage are monitored with adjacent VibControllers. However, this technology was overtaken some time ago by the rapid developments in measurement technology and in condition monitoring.
2.3 Routine mobile vibration analyses

Routine mobile vibration analyses represent another option for monitoring any changes which occur over periods of weeks, months or even years in the frequency spectra as shown in example in Fig. 3. Operators are increasingly carrying out routine
FIGURE 2: Recommended vibration values for machines in accordance with ISO Standard
56
Case Study
should take place with a frequency resolution of at least 3600 lines to ensure reliable resolution of sidebands. The rule at Flender Service is 8100 lines. f) For successive measurements it is necessary to guarantee that the vibration analyzer is parameterized in the same way and that, for example, Hanning filters are not confused with square-wave filters. g) The filter frequencies for the calculation of the envelope spectra must be adjusted to suit the rotational speed of the gear unit and the gear unit impedance in order to avoid incorrect diagnoses. Fig. 5 shows an inner ring crack that could only be measured with modified envelope spectra parameters. Diagnostic experience also shows that in grinding plants with very high availability requirements it is not sufficient just to carry out mobile measurements every six or even twelve months. Roller bearing cracks occur suddenly and initial damage which has been diagnosed can also grow quite rapidly. On the other hand self-aligning roller bearings lead to excitation of roller bearing frequencies which require no action. On-line vibration measurements systems ensure more information and greater diagnostic reliability although they have to work on the basis of frequency analysis and must be remotely programmable.FIGURE 5: Envelope frequency spectrum with excitations caused by a roller bearing inner ring crack and photograph of the roller bearing inner ring with crack 2.4 On-line machine monitoring systems and expert software
mobile vibration analyses on girth gear units or having the analyses sub-contracted. Unfortunately, experience has also shown that the external service providers in particular do not pay sufficient attention to the specific characteristics of the gear unit type when the measurements are carried out and/or they perform measurements which are incomplete, or with measuring times which are too short. This significantly reduces the diagnostic reliability. Measuring requirements for mobile vibration analyses are stated below: a) Acceleration sensors with adequately strong adhesive magnets should be used. Measurements with probe tips are not permitted. b) Fig. 4 shows some measuring points which are used, for example, during measurements by Flender Service. When a service employee or diagnostic engineer flies to a client the measurements are carried out at these measuring points with a GearController data collector. c) Before the measurements, the kinematics and gear unit specific excitation frequencies, including bearing frequencies, must be known. At the same time the vibration analyzer must be programmed so that the effective measuring time is sufficient to measure at least 100 revolutions. Effective measuring times of at least 60 seconds must be used the output gear stage for DMGH gear units, even when calculating envelope spectras. d) In addition to the velocity vibration measurements it is also necessary to measure the acceleration up to 10 kHz and calculate envelope spectras with variable filter frequencies in order to detect roller bearing damage. e) Frequency analyses in high-performance gear units
57
Case Study
therefore developed its own condition monitoring and comprehensive measuring techniques for vibration analysis and for automatic remote diagnosis. Experience with vibration diagnosis has been systematically accumulated and developed for more than 5 years at the diagnostic centre.
2.5 Autonomous remote diagnostic systems and expert networks

It is more reliable if an autonomous diagnostic system without separate diagnostic computer records the actual vibration conditions, preferably daily, as a function of operating conditions, automatically analyses any deviations in the frequency spectra and reports damage at an early stage, and if the system technology makes it possible to build up worldwide expert networks. At the same time it must also be possible to record noise, displacements, shaft vibrations, temperatures, loadings and other operation variables. If the operator requires access he should be able to connect into the system at any time. This experience and clients requirements resulted in the development of GearControllers using Internet technology [14-]. As is shown in Fig. 6 they are mounted in the immediate vicinity of the gear unit. The GearControllers are integral measuring, analyzing and checking systems which use software to unite the functions of an intelligent measurement acquisition unit, an event recorder, a classifying unit and an analysis and diagnostic computer. A realtime multi-tasking operating system coordinates the parallel processing of data acquisition, triggering, control, preliminary data processing, analysis, storage and communication. When connected to the GearController the HTML pages of the GearController webserver is automatically loaded into the users browser where it is implemented. Since TCP/IP also the standard is of the intranet and of the local area networks (LAN) in the company network, so a GearController can also be incorporated in the company network at a later date or measurement results can be mailed automatically as e-mails to the diagnostic centre. If early damage is indicated the drive specialists have access from any part of the world via Virtual Private Network Technology (VPN) to estimate the growth of the damage. In order to manage worldwide installations and offer remote diagnostic service at favourable cost, a service webserver was developed which automatically recognizes, identifies, distributes and unpacks incoming e-mails, and relays alarms in accordance with the programming in the incoming mail system.
On-line machine monitoring means in most cases that vibration sensors are installed permanently on the machine and that measuring, diagnostic and interface modules are mounted close to the drive. Computationally intensive diagnostic algorithms are performed on a central diagnostic computer and the measured data are held in databases. The condition diagnosis is undertaken by "expert software". In reality, however, the situation is rather different. The data from the measurements to be analyzed must be transferred without interference from the recording unit to the diagnostic computer where it is stored. Data volumes of the order of 100 Mbytes per month accumulate rapidly. Competent personnel in the factory are then necessary to manage the flow of data. Experience shows that in spite of expert software trained personnel must be on the site for the condition diagnosis in order to detect possible damage at an early stage. However, the local diagnostic engineer does not have many opportunities to accumulate valuable diagnostic experience with high-performance gear units. The expert software does not take sufficient account of the specific characteristics of the gear unit and damage can occur suddenly. As an alternative, some producers of measuring technology therefore also offer remote diagnostic services. A member of the service staff dials into the diagnostic computer by telephone modem, copies all the data and starts to diagnose machine conditions. Personnel and telephone costs rise rapidly with worldwide projects as large quantities of data require considerable time for transmission over traditional telephone connections. Service experience indicates that unexplainable vibration phenomena are often attributed to the drive. Test printouts are then sent to the manufacturer or gear unit specialist and rapid diagnosis is required. As the rule it is then necessary for a service and/or diagnostic specialist to visit the plant, carry out additional measurements, diagnose possible faults and initiate repair measures. Flender Service has
58
Case Study
Preliminary alarms raise diagnostic priorities. In the same way it is also possible to make use of worldwide machine and servicing experience and to operate a service management and expert network between operator, company, plant manufacturer and component manufacturer.
c) Recording the housing vibrations at the input stage with a second acceleration sensor, the signals from which are also evaluated multifunctionally with respect to the roller bearings, gear tooth system and rotational frequency vibrations in the gear unit. d) Installation of a high-sensitivity inductive proximity sensor to measure the axial vibrations and axial displacements of an intermediate shaft. This sensor also monitors running, load distribution and cracks in the gear unit and in the large mill girth gear. An interchangeable bearing cover or adapter is supplied to mount the sensor. Fig. 7 shows the part of the gear unit to which the non-contact displacement sensors are bolted. The acceleration sensors are also mounted with bolts. Through consistent use of frequency spectra and variable envelope filters it is also possible to reach gear unit components and roller bearings conditions in positions where sensors cannot be mounted. The vibration levels evaluated are therefore lower. If double drives are to be monitored or extensions to include motor bearings are required then the number of measuring channels is increased. In one application the torques have also been continuously monitored for about 2 years. There are also extended configurations for new gear units. The installation can be carried out by the technicians and plant electricians themselves so that there are no travel costs for servicing staff. A telephone connection, the mains voltage, the additional measured variables and an Internet access similar to that for a Hobby Surfer have to be provided. Data and warning messages are then transmitted by e-mail. As a rule the connection into the company network is made later as a three-month commissioning period is part
3. Practical experience with girth gear units 3.1 GearController remote diagnostic system retrofitted for DMGH drives
Diagnostically relevant measuring points for the girth gear unit were defined on the basis of mobile measurements and servicing experience, and tailormade software modules for continuous condition and vibration monitoring were programmed and activated in GearController remote diagnostic sys-tems. Not only structure-born vibrations but also shaft displacements and shaft vibrations in the intermediate gear shaft were measured in the girth gear unit and monitored for changes. Remote diagnostic systems with the following measured variables and measuring functions were implemented for DMGH drives: a) Measurement of the power consumption of the motor to obtain the actual operating loadings and for interpreting unsteady-state operating conditions. The motor current signal is also usedas a trigger for initiating the automatic diagnostic routines. b) Recording the housing vibrations in the upper part of the gear unit at the "on top" measuring point with an acceleration sensor. High-resolution frequency spectra of the vibration velocity, acceleration and calculated envelope spectra are evaluated.
59
Case Study
of the service provided by Flender Service condition monitoring. During this period the drive specifics are learnt, taken into account and documented for the client in a diagnostic report. Information is provided immediately, along with recommended actions, if deviations occur. An HTML visual display system and a traffic light frequency spectrum from a DMGH gear unit in South Africa are shown in Fig. 8. The alarm values set at specific frequencies were established during the commissioning period and form the basis for the automatic condition diagnosis. If one of the characteristic frequencies in the traffic light spectra is exceeded, an e-mail signal is sent by the network and/or via the Internet. Roller bearing monitoring by envelope frequency spectra is are also carried out in a similar manner. Several diagnostic characteristics are linked with one another by mathematical logic so that clear diagnoses can be generated. A diagnostic specialist working on-site would use the same approach. If new experience is available it is simply reprogrammed into the existing applications and activated by data remote transfer. The hardware remains up-to-date and can be developed further in line with diagnostic experience.
the first installations it was found that not only gear unit conditions but also the condition of the motor, coupling, mill and process can be diagnosed at a distance. Why is the diagnostic technique not just limited to the gear unit? Changes in the operating conditions of a grinding plant also affect the behaviour of the gear unit in the DMGH drive because of its compact design. It is therefore also in the interests of the gear unit supplier to identify additional stresses at an early stage and shield the gear unit from them. Costs have been saved by the use of the Gear-Controller in the following applications: Remote commissioning of a ball mill in North America During the commissioning were increased vibrations and repeated plant shutdowns because of excessive vibrations in a double drive. The GearController analyzed and diagnosed the condition of the gear unit, and it was established that there were no problems with the condition of the gear unit. This meant that the machine could be kept in operation for longer. The problem lay elsewhere.
Remote diagnosis of a loosened girth gear in southern Europe

The measurements showed unusual axial displacements in the floating shaft of the DMGH gear unit at every mill revolution. An inspection showed that bolts had become loose in the girth gear.
3.2 Remote diagnostic experience

The remote diagnostic technology can also include a remote diagnostic service, which permanently monitors the drive conditions and activates diagnostic algorithms daily whenever, for example, the tube mill has been in operation for at least 3 hours. Simple diagnostic and monitoring functions take place automatically in the GearController. After
Condition monitoring of a girth gear with local damage

A machine developed localized tooth damage on the
60
Case Study
girth gear. The drive was monitored with the GearController and the growth of damage was analyzed. There was no increase in the pitting and the mill has run for three years without any changes.
Diagnosis of an alignment error in South America

Increased rotational frequency vibrations occurred even during the commissioning. The machine had an axial alignment error.
monitor traffic light frequency spectra and send warning messages by e-mail if there is a risk. This makes drive conditions transparent and the service technicians are informed of any possible danger in good time. Condition-oriented maintenance can now be achieved, servicing costs remain low through consistent use of the Internet, while increasing use is being made of expert networks.
Diagnosis of motor damage

Motor damage was detected by additional acceleration sensors installed at the motor. Shaft keys had come loose.
/1/ C.Jaufmann, E.Becker: Remote Plant Monitoring based on autonomous diagnostic systems 6.NCB International Seminar on Cement and Building Materials, 1998, New Delhi /2/ Becker,E. Dahlhaus,N. : Fernberwachung von Getrieben ber das Internet, Z.antriebstechnik 0701/ /3/ Becker, E.: Weltweiter Telediagnoseservice fr Groantriebe im Zementwerk, ZKG 0797/ /4/ Becker, E.: Der E-Mail sendende Diagnoseroboter an Vertikalmhlen, ZKG 0500/ /5/ GearController: http\\:www.flender-cm.de
Defective vibration strength monitoring

A mill shut down repeatedly because of excessively high vibrations. The GearController showed that the acceleration sensor gave normal vibration strengths and that there was no operational risk. In fact the installed vibration velocity sensor was giving false indications of increased vibrations.
4. Summary and outlook

Greater reliability and availability can be achieved by using condition monitoring. Autonomous remote diagnostic techniques have been developed at Flender Service so that condition-related servicing can be offered and repair measures can be initiated in the case of an impending irregularity. The Gear-Controllers
61
Invironment
work says that a 2.5 4.9 0 C rise in temperature could cut rice yield by 1542%- and wheat production between 2542%-. Increased rain in form of torrential downpour Can cause shorter monsoon season, intense rainfall, increase in number of serious floods. Increase in frequency of extreme events such as droughts, floods & cyclone. In 1992 (Rio Summit), it was decided that since the developed countries had created the problem, they would take the first step to solve it by cutting down emissions. In 1997 Kyoto Protocol came into being to combat Global Warming, which sets specific emission target for developed countries. The Kyoto Protocol enjoins on industrialized (Signatory) countries to reduce their GHGs by 8% of the 1990 level between 20082012-. The Protocol provides for three mechanisms to enable developed countries to get emission reduction credits from outside their own countries. The three mechanisms are Emission trading, Joint Implementation among developed countries and Clean Development Mechanism. Under the clean development mechanism a developed country may take up GHGs reduction activities in developing countries and developing countries will benefit from the investment required for environmentally safe and sound technologies. 55 countries have ratified the treaty but to become effective it still needs ratification of other countries so that together account for 55% of Global GHGs, which is presently 36%. Russia and US abstained from the treaty while India has signed the Protocol.
Role of Cement Industries in GHGs reduction activity.

The 1997 Protocol first established reduction commitments binding in international law for the signatory states. In addition to project related flexible mechanisms as mentioned above, there is provision for part of these reduction commitments to be satisfied by trading of emission certificates. This applies in particular to manufacturing industries with high CO2 intensity and low value added. Buying emission certificates will significantly increase the production cost. If cement industry has to buy all these certificates, production costs will roughly double. This will distort competition to the extent of closing down production, the reason being high price anticipated for CO2 emission rights. For Cement industry, emission reduction targets could be achieved without buying certificates. Presently cement manufacturing units are offensive to drive up margins and shifting customer preferences, consumption of Blended Cement has witnessed a sharp increase in recent years. The share of Blended cement which includes PPC and PSC shoot up to 48 % in 2002. Now ordinary Portland cement accounts for 52% of total cement production. Manufacturing Blended Cement not only driven up margins of profitability but also contributes in Emission reduction
Trends in Variety wise Cement Production (Large Plants ) in Million Tons
65
Invironment
and Mineral Conservation.
Basis of Calculation : To produce 53 million

tons of blended cement out of total 110 million tons cement there is saving of clinker due to addition of Fly ash and Slag . Considering 20 % addition of fly ash and slag total savings of clinker is 53 x 0.2 =10.6 million tons ( 11.0 M.T say). Due to savings of clinker the benefits are many fold which are listed below:
Electrical
Thus saving of lime stone due to savings

of 11.0 million ton clinker is 11.0 x 1.54 = 17 million tons lime stone .
Savings in year =17 x 100 = Rs 1700

million
Environmental impact Calculation Basis :
energy savings
A. Calculation of CO2 generated /T coal

Considering Fixed carbon in indigenous coal 50.0 C + O2 = CO2 12 32 44 CO2 generation in ton per ton of coal = 44 x .51.8 = 12/
Electrical energy consumed to produce

4/units
1ton of clinker is 62 units on average basis considering various plants operating today.
Cost of power is variable and assume Rs Thus saving of electrical energy due to Savings in year = 657x 4= Rs 2628
million savings of 11.0 million ton clinker is 11.0 x 62 = 657 million units.
B. Calculation of CO2 generated /unit power generation

The amount coal required/unit power generation is variable and considered as 0.75kg coal / unit power generation Kg CO2 generated / unit power generation = 0.75 x 1.8 =1.35
Thermal
Thermal energy consumed to produce
energy savings
C. Calculation of CO2 generated /Ton lime stone

Taking total carbonate in lime stone 77.0 CaCO3 = CaO + CO2 100 56 44 Tons CO2/Ton lime stone 44 x 770.34=100/ Ts
1ton of clinker is 750 kcal/kg clinker on average basis considering various plants operating today.
Considering heat value of indigenous coal

5300 kcal/ kg coal
Saving of CO2 on different heads :
Landed cost of coal is variable component

and assume Rs 2000/t coal
Thus saving of thermal energy due to Savings in year =1.55x2000= Rs 3100

million
savings of 11.0 million ton clinker is 750x111.55 = 5300/ million tons of coal .
Saving of electrical energy 657 million units. Savings of CO2 in a year = 657x 1.35 /1000=
0.89 million Ts
CO2
CO2 savings due to Electrical energy savings
savings due to Thermal energy savings
Lime stone savings
Considering loss on ignition 35.0 Lime stone to clinker factor 1/ (10.35-)

=1.54
Total Coal savings 1.55 million tons per year Savings of CO2 in a year = 1.55x 1.8 =
2.79 million Ts
CO2
savings due to savings of lime stone
Cost of lime stone is variable and

considered as Rs 100 /t lime stone
66
Total lime stone savings 17.0 million tons per

year
Savings of CO2 in a year = 17 x 0.34 = 5.8

million T
Invironment
Total CO2 savings due to production of blended cement = 0.899.48 = 5.8+2.79+ million tons per year.
Cost of CO2 at present level @ $5/Ton CO2 Hence savings due to CO2 = 9.48 x 5 x 45 = Rs 2133 million /year
to save our prime land for the future. Moreover, blended cement has lesser heat of hydration and offer greater resistance to the attack of aggressive weather than normal OPC. Blended cement also reduces the leaching of calcium hydroxide liberation during setting and hydration of cement. It is particularly useful in marine , hydraulic and other mass construction work. Blended cement can be used very conveniently wherever OPC is usable under normal conditions.
Intangible gains:
Currently 90 million tones of fly ash are generated per annum which is likely to touch the figure of 200 million tones by 2012. Disposal of fly ash is of great concern of the government and more importance and encouragement to be incorporated for the Cement industry for producing more blended cement, as we are the largest user of the national waste. As per thumb rule calculation, 0.68 hectares of land is required per MW installed capacity for ash pond 10 meter deep to last 25 Year. Hence use of 100% blended cement is the only way
Conclusion:
To reduce the GHG`s , cement industry is always concern and participating voluntary commitments to reduce the specific energy consumption , using more and more slag and fly ash , reducing GHG emission level and mineral conservation which add to the saving of Rs. 9558 million per year at the present level of production . Like cement Industry, all other industries and energy users should come forward and save energy and save this beautiful planet for our next generation.
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Cements
sulphate ions, as shown in Table 1. (e) the duration of the exposure period; (f) the specimen type (cement paste, mortar or concrete); (g) the large number of deterioration me chanisms that simultaneously operate, as is explained below; and (h) the usage of small specimens to predict the behaviour of structural concrete. Due to the extensive spread of seas all over the world, as compared with thc continental land available for human beings, marine structures and offshore oil facilities will grow and will continue to be made of concrete. This is because concrete is not only the most economical structural material for construction of such structures, but also the most durable. The performance of concrete structures in sea water is of great impor tance because the durability of these strucures is the most complicated system to investigate, where concrete deterioration is caused by freezing and thawing, by corrosion of the reinforcing steel, and by chemical constituents of the sea. There are other possible causes of concrete deterioration, such as erosion and wave action, crystallisation of salts due to the increase in salt concentration by capillary action and evaporation, particularly in and above the tidal zone.3 In the Arabian Gulf, concrete deterioration in marine structures mainly in the form of reinforcement corrosion, is aided by the high ambient temperature and salinity of the sea water. The interaction of all of these chemical and physical agents will lead to a maze of interwoven factors causing deterioration. The situation will be worse if premature cracking or micro-cracking by any means does exist.
Seawater may convey the impression of a constant chemical composition, and it is true that the relative proportions of dissolved salts are generally invariant; but the total concentration varies with the geographical and geomorphological location11. For example, the Arabian Gulf seawater is about 58% more saline than the Mediterranean seawater, as vividly noted in Table1. If these ions are to be presented as salts (i.e. compounds), the theoretical combinations will always be dominated by sodium chloride (82.70), followed by magnesium chloride (9.9%), magnesium sulphate (4.3%) and calcium sulphate (3.l%)11 in addition to traces of other compounds. Whereas the chloride ions in seawater have considerable influence on corrosion of steel in concrete, it is the magnesium salts, particularly those associated with sulphate and chloride ions, which exercise the most deleterious effect on the hydration products of Portland cement Research on durability of reinforced concrete in seawater is mostly concerned with two deteriorating actions; chloride-induced corrosion of reinforcing steel and sulphate attack on concrete. The need for continued research on these aspects stems from the fact that there have been considerable changes in the physico chemical characteristics of Portland cement in the past century. It is noteworthy to mention that the relevant cement phase that locks chloride ions into an insoluble compound of calcium chloro-aluminate hydrate (Friedels salt), thereby removing from it the hazardous role of corrosion promotion, is tricalcium aluminate (C3A). This is the same phase of cement, which in excess of a certain critical level, reacts with sulphate ions to form ettringite and gypsum, thereby leading to degradation of concrete into a noncohesive granular mass and to disruptive expansion
69
Cements
more than the former, the often recom mended usage of Type V cement in marine environ ments has been questioned. Moreover, the usage of supplementary cementing materials, such as fly ash, silica fume and blast furnace slag in Portland cement has significantly increased. This paper summarises the investigations conducted to assess the durability of plain and blended cements exposed to marine environ ments. between them. The sea water was obtained from the Arabian Gulf and its chemical composition is included in Table I. The sea water was changed every month during the first year and every three months thereafter.
Specimens and tests
Experimental programme
Materials used ASTM C 150 Type I and Type V Portland cements were used in preparing plain paste, mortar and concrete specimens. ASTM C 618 Class F fly ash, silica fume and blast-furnace slag were used at 20, 10 and 60% replacements by weight of Type I cement, respectively, to prepare fly ash, silica fume and blastfurnace slag cements. Table 2 details the chemical composition of the plain cements and blending materials used in this investigation. An effective water to cementitious mat erials (water to binder) ratio of 050 was kept invariant in all the paste, mortar and concrete specimens. In the mortar specimens, the sand to binder ratio was maintained at 2.75. In the concrete specimens, a cementitious materials content of 356 kg/m2 (600 lb/yd3) and a coarse-to-fine aggregate ratio of 2.0 by weight were kept constant in all the concrete mixtures. The coarse aizCrecate was 19 mm maximum size crushed limestone, of bulk specific eravitv 242. and water absorption 3.77%. while the fine aggregate was dune sand with a specific eravitv of 264 and water absorption of 0.23% . After casttne. all paste. mortar and concrete sped mens were covered with wet burlap for 24 h before demouldine. Thereafter, they were cured in potable water for a further period of 14 days. They were then air-dried in the laboratory (23 20C) for one day. and the initial weights of the concrete specimens were recorded before they were placed in the sea water. All the specimens were stored in plastic containers filled with sea water such that there was ample space
Table 2 : Chemical composition cements and blending materials
Cement paste cube specimens of 12.5 mm size were used to study the effect of seawater on the morphology of plain and blended cements using Xray diffraction (XRD) technique. These specimens were also chemi cal lv analysed to assess the chloride, sulphate and hydroxyl concentrations26,27The XRD and chemical analyses were conducted after 24 months of exposure to sea water. Mortar specimens were used to determine the strength reduction and expansion due to sulphate attack. The strength tests were conducted on 25 mm cube specimens using a compression machine espe cially suited for testing small cubes according to ASTM C39. Companion specimens, cured in potable water, were also tested and the reduction in compressive strength was evaluated as follows:
Reduction in compressive strength (%)
where A and B are average compressive strength (MPa) of five specimens cured in potable water and sea water, respectively. The expansion measurements were conducted on two 25 X 25 X 285 mm prismatic mortar specimens in ac cordance with ASTM C 441. The mean readings taken on three samples and the average value was used to plot the expansion--time curve for each cement type. Three concrete cylinders, 76 mm in diameter and 152mm high. with a centrally embedded 12mm dia meter reinforcing steel bar, were used to study the effect of sea water on the weight loss of concrete and corrosion of reinforcing steel. The change in weight was evaluated periodically, whereby the specimens were retrieved, air-dried for one day in the laboratory environment (23 20C) and weiehed. The weieht change (WL was determined using the following relationship where W, is the average initial weight of three
* Blast Fumace Slag
70
Cements
and cracking. Further, there have been controversial reports on the performance of Type I versus Type V cements in marine environments.17 Since the cost of the latter cement is more than the former, the often recom mended usage of Type V cement in marine environ ments has been questioned. Moreover, the usage of supplementary cementing materials, such as fly ash, silica fume and blast furnace slag in Portland cement has significantly increased. This paper summarises the investigations conducted to assess the durability of plain and blended cements exposed to marine environ ments. a cementitious materials content of 356 kg/m3 (600 lb/yd3) and a coarse-to-fine aggregate ratio of 2.0 by weight were kept constant in all the concrete mixtures. The coarse aggregate was 19 mm maximum size crushed limestone, of bulk specific gravitv 2.42. and water absorption 3.77%. while the fine aggregate was dune sand with a specific gravitv of 2.64 and water absorption of 0.23% . After casting, all paste, mortar and concrete speciments were covered with wet burlap for 24 h before demouldine. Thereafter, they were cured in potable water for a further period of 14 days. They were then air-dried in the laboratory (23 20C) for one day. and the initial weights of the concrete specimens were recorded before they were placed in the sea water. All the specimens were stored in plastic containers filled with sea water such that there was ample space between them. The sea water was obtained from the Arabian Gulf and its chemical composition is included in Table I. The sea water was changed every month during the first year and every three months thereafter.
Experimental programme
Materials used ASTM C 150 Type I and Type V Portland cements were used in preparing plain paste, mortar and concrete specimens. ASTM C 618 Class F fly ash, silica fume and blast-furnace slag were used at 20, 10 and 60% replacements by weight of Type I cement, respectively, to prepare fly ash, silica fume and blastfurnace slag cements. Table 2 details the chemical composition of the plain cements and blending materials used in this investigation. An effective
Specimens and tests

Cement paste cube specimens of 12.5 mm size were used to study the effect of seawater on the morphology of plain and blended cements using X-ray diffraction (XRD) technique. These specimens were also chemi callv analysed to assess the chloride, sulphate and hydroxyl concentrations 26,27 The XRD and chemical analyses were conducted after 24 months of exposure to sea water. Mortar specimens were used to determine the strength reduction and expansion due to sulphate attack. The strength tests were conducted on 25 mm cube specimens using a compression machine espe cially suited for testing small cubes according to ASTM C39. Companion specimens, cured in potable water, were also tested and the reduction in compressive strength was evaluated as follows:
water to cementitious mat erials (water to binder) ratio of 050- was kept invariant in all the paste, mortar and concrete specimens. In the mortar specimens, the sand to binder ratio was maintained at 2.75. In the concrete specimens,
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Cements
Reduction in compressive strength (%)
where A and B are average compressive strength (MPa) of five specimens cured in potable water and sea water, respectively. The expansion measurements were conducted on two 25 X 25 X 285 mm prismatic mortar specimens in ac cordance with ASTM C 441. The mean readings taken on three samples and the average value was used to plot the expansion--time curve for each cement type. Three concrete cylinders, 76 mm in diameter and 152mm high. with a centrally embedded 12mm dia meter reinforcing steel bar, were used to study the effect of sea water on the weight loss of concrete and corrosion of reinforcing steel. The change in weight was evaluated periodically, whereby the specimens were retrieved, air-dried for one day in the laboratory environment (23 20C) and weieght. The weight change (WL was determined using the following relationship where W, is the average initial weight of three speci mens. and Wt is the average weight of three specimens after a prescribed exposure period. Reinforcement corrosion of the three reinforced con crete specimens was monitored by measuring the corrosion potentials and corrosion current density at regular intervals. All the reinforced concrete
specimens were partially submerged to their midheight in the sea water solution. The corrosion potentials were measured using a high impedance voltmeter and recording the potentials with reference to a saturated calomel refer ence electrode (SCE). The linear polarisation resistance technique was used to measure the polarisation resis tance (Rp), and a positive feedback technique was used to compensate for the Ohmic drop between the refer ence electrode and the reinforcing bar. This technique was implemented to assess the corrosion current den sity on steel. Details of the measurement procedure and analysis are reported elsewhere.28
Results
Reduction in compressive strength The compressive strength development in plain and blended cement mortar specimens placed in potable water is depicted in Figs I and 2, respectively. All the cements exhibited somewhat similar strength after 14 days of water curing, except the blast furnace slag (BFS) cement. After 180 days of curing, the maximum compressive strength was observed in the silica fume (SF) and fly ash (FA) cements. The strength develop ment in BFS cement specimens, however, was lower than that of all the other cements at all curing periods. The lower streneth of BFS cement specimens may be ascribed to the high quantity of BFS (60%) in this cement. The reduction in strength in plain and blended cement mortar specimens exposed to seawater is plotted in
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Cements
Expansion
The expansion of plain and blended cement mortar specimens exposed to sea water is presented in Figs 5 and 6. respectively. After 540 days of exposure to sea water, the expansion in plain cements was more than that in all the blended cements. The better performance of blended cements could be ascribed to the dilution of C3A in the parent cement due to its replacement by pozzolanic materials. The maximum expansion of 0.8% was noted in Type I cement after 18 months, followed by Type V cement. The marginal improvement of Type V cement. as
Figs 3 and 4, respectively. The strength reduction was less than 20% in both plain and blended cements after 1 year of exposure. After 2 years of exposure. the reduction in streneth was in the range of 2226%in all the cements except in the BFS cement which was 13%. The lower reduction in strength in BFS may he partly attributed to their initially low strength as was stated earlier.
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Cements
compared with Type I cement. might be ascribed to its relatively low C3A. Among blended cements, BFS cement exhibited distinctly the lowest expansion of 0.56%. After 18 months of exposure to the marine environment, the expansion was about 0.067% in both FA and SF cements. The expansion in Type V Portland cement was about 0.070%. are reported against the exposure period in Figs 9 and 10, respectively. The corrosion potentials became more negative with time in plain, FA and SF cement concrete specimens. However, the corrosion potentials in the BFS cement concrete specimens did not change significantly with time. The corrosion potential-time curves were utilised to evaluate the time to initiation of reinforcement corrosion based on the ASTM C 876 criterion of 270 mV SCE. This information is summarised in Table 3. The time to corrosion initiation in Type I cement concrete was 114 days as compared with 71 days in Type V cement concrete. Therefore, the performance ratio of Type V cement concrete was 0.62. The better performance of Type I cement concrete specimens may be ascribed its higher C3A content, as shown in Table 2. Fly ash cement concrete displayed better performance than Type I cement concrete with a time to corrosion initiation of 148 days. The best performance was attained by silica fume cement con crete with the longest time to corrosion initiation of 648 days. The performance ratios of FA and SF cement concretes were 1.3 and 5.7, respectively. The superior performance of SF cement concrete specimens in chloride-sulphate exposures in particular, 23,28 and in seawater in general is well documented in the literature 7,12,17. It is worth mentioning that the corrosion potentials on steel in BFS cement concrete specimens were more negative than the -270 mV SCE. even before place ment in the sea water, indicating that the ASTM C 876 criterion is not applicable for evaluating the rein forcement corrosion in the these cement concrete specimens. 28,29 The higher potentials in BFS cement concrete specimens may be attributed to the reducing constituents if BFS, primarily the soluble sulphides, which tend to impede the early formation of the passive layer on steel.30
Weigh Change
The data on weight change in plain and blended cement concrete specimens exposed to sea water are plotted in Figs 7 and 8, respectively. Surprisinly, an increase, rather than a decrease, in the weight was noted in all the concrete specimens, even after 24 months of exposure to the sea water. In fact, the concrete specimens prepared with all the cements ex hibited a consistent increase in weight during the whole period of exposure. Though the highest weight gain was noted in the fly ash cement, the increase in weight in Type I and Type V cements was more than that in BFS and SF cements. The minimum weight gain of l.3l%, after two years of exposure, was noted in the SF cement concrete specimens. Visual inspection of the concrete specimens did not reveal any type of deterioration below or above the sea water level, as was observed in other sulphatechloride exposures.1,24.25 Only salt deposition was noted on the specimens in a way exactly similar to that observed on the specimens placed in sabkha brines (i.e. high chloride-sulphate media).23 The salt precipitation in creased in proportion to the increase in weight. In fact, salt precipitation was noted even on the portions of specimens above the sea water level
Corrosion current density

As the corrosion potential technique provides probable and qualitative information on the reinforcement corrosion activity, quantitative data were developed by determining the corrosion current density using the linear polarisation resistance technique after 10, 15 and 24 months of exposure to sea water. The corrosion current density (Icorr) on steel in plain and blended cement concretes is depicted in Figs 11 and 12. respectively. The (Icorr) increased with the period of exposure in all the concrete specimens. The Icorr On steel in Type I cement concrete was less than that in Type V cement concrete. However, the (Icorr) on steel in plain cements was more than that on steel
though to a less extent.
Corrosion potentials
The corrosion potentials on steel in plain and blended cement concrete specimens exposed to the sea water
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Cements
in blended cements. Among blended cements, the minimumIcorr was noted on steel in the SF cement concrete. A summary of the (Icorr) and performance ratio data is presented in Table 4. The (Icorr) data in Table 4 concur with that on the time to initiation of reinforcement corrosion presented in Table 3 in that SF cement concrete displayed the best performance and Type I cement concrete performed better than Type V cement concrete.
Chemical analysis
The results of chemical analysis of the 12.5 mm cubic cement paste specimens after 2 years of exposure to sea water are presented in Table 5. The water-soluble chloride concentration in all the cements was almost constant. though the chloride concentration in Type I cement was the lowest. The 0H- concentration varied with the type of cement. The averaege OHconcentra lion in the plain cements was 0.6% by dry weight of cement, while a significant reduction in the 0H- concentration was noted in the blended cements prob ably due to the replacement of part of the parent cement by the pozzolanic materials and the consumption of Ca(OH)2 in the pozzolanic reaction.
The 0H concentration in the 10% SF cement was 0.38% compared to 0.29% in the 20% FA cement. The lowest OH concentration of 0.13% was noted in the 60% BFS cement. As expected, these results indicate that the 0H concentration decreases with the increase in the replacement dosage of the pozzolanic material. The SO42- concentration was also higher in the plain cements. The average SO42- concentration in the plain cements was 3.30% as compared to 2.50% in the blended cements. Again, the lowest tion of 2.34% was noted in the SO42- concentra BFS cement. The lower SO42- concentration in the blended cements indicates that these cements are able to retard the diffusion of sulphate ions compared to plain cements.
Mineralogical analysis
The X-ray diffractograms (XRDs) for the plain and blended cement pastes cured in water are shown in Fig. 13. where C = calcite, E secondary ettringite, PSA = primary sulphoaluminate hydrate and P = port landite. As discussed elsewhere25 the common feature in the X-ray peaks is the presence of a broad peak between
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Cements
9 and 10.5o 2, indicating the presence of primary sulphoalominate phase, which may comprise primary ettringite (C6AH32), having its major peak at 9.1o 2, and monosulphate (C4AH12), which is generated from the partial conversion of ettringite. In addition to the broadband peaks of primary sulphoaluminate C-SH, being a poorly crystallised or a nearly amorphous compound, is indicated by the diffuse band between 29.5o and 31.5o 2.25 The XRDs of both Type I and Type V cement indicate significant precipitation of portlandite (calcium hydroxide), as shown by the well-defined peaks at 17.9o and 34.5o 2 The diffractograms for FA and SF cements, shown in Fig. 13 display reduced portland ite content compared to that in the plain parent Portland cement. In BFS cement, the portlandite peaks almost totally disappeared indicating their absence after two years of curing in potable water. The reduced and/or disappearance of portlandite peaks in blended cement is primarily ascribed to the pozzolanic reaction.25 However, the formation of calcite due to the reaction of portlandite and atmospheric carbon dioxide (i.e. nation reaction) might have contributed to the reduction of portlandite in blended cements. This is evidenced by the presence of calcite peaks in all the cements (see Fig. 14). In BFS cement, a primary ettringite peak is noted at 22.8o 2 (Fig. 13), indicating the formt of more primary trisulphoaluminate during the hydration of this cement25: The XRDs for plain and blended cements exposed the sea water for a period of 24 months are depicated in Fig. 14, where B = brucite, C = calcite, CCA calcium chloro-aluminate. G = gypsum and PSA = primary sulphoaluminate hydrate. A comparison of these diffractograms with those in Fig. 13 indicates that the portlandite peaks noted in the specimens cured in watere were either totally eliminated or significantly cured in water. Most of the noticeable peaks in Fig. 14 are very small; either the remnants of portlandite (at 17.9o and 34.5o 2), or gypsum (at 11.7o, 20.7o and 28.9o 2), or the calcium chloro-aluminate. known as Freidels salt (at 11.2o, 22.8o and 30.9o 2), or the magnesium hydroxide ( at 32.4o, 26.2o and 18.5o 2)31.32. These peaks are small and cannot be easily identified, as was noted previously in the case of the specimens exposed to a high sulphate-chloride environment.24 However formation of calcite due to carbonation of cement was noted in both the specimens cured in water or exposed to sea water. on concrete deterioration and the efficiency of cement type in resisting reinforcement corrosion in marine environments. The data on strength reduction expansion, weight change, visual inspection and the chemical and mineralogical an analyses can be utilised to discuss the effect of sea water on concrete deteriora tion. The second category can he related to the results of the corrosion potentials and corrosion current den sity and chemical analysis. These data can be utilised to assess the efficiency of cement type in resisting reinforcement corrosion in marine environments.
Concrete deterioration
The maximum strength reduction was about 25% in Type I and FA cements after two years of exposure to the marine media, as shown in Figs 3 and 4. Such a reduction can be considered as small for the following reasons: (a) the duration of the exposure was relatively very long (24 months); (b) the specimen size was to designed to be small (25 mm cubes) so as to have high surface area thereby accelerating the deterioration due its to sea water: and (c) the sea water had a sulphate (SO42-) concentration of 5120 ppm, which is consid edered as severe. according to the Canadian and Amercan Standards CAN3-A23.IM7733 and ACI 3l834.The strength reduction in, all the plain and blended cement mortars was less than 30% that is generally specified as the threshold value for failure due to in sulphate attack on small specimens like those utilised to in this investigation1,35 . The expansion data also support the results of strength reduction whereby the expansion of both plain and blended cements was vividly low. The expansion of both plain and blended cements during the 18-month exposure to sea water did not exceed the 0.1% that is generally considered as the failure criterion for ex pansion.35,36 The relatively mild attack of seawater on plain and blended cements is further supported by the weight change data generated by exposing reinforced concrete specimens to sea water. As stated earlier, an increase in the weight of these specimens, rather than weight loss, was noted thereby confirming the absence of noticeable concrete deterioration afier 2 years of exposure to sea water. The increase in weight may be ascribed to the salt penetration and precipitation that was visually noted on all the concrete specimens, both below and above the sea water level, as was discussed previously. Similar observation was noted when 15 different con crete mixtures were exposed to a very high chloride-sulphate sabkha solution.23
Discussion
The data reported in this paper can be discussed under two broad categories, namely the effect water
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Cements
Two forms of concrete deterioration are ascribed to sulphate attack. The first mode of deterioration is akin to the eating away of the hydrated cement paste and its progressive reduction to a cohesionless granular mass leaving the aggregate exposed and leading to loss of strength and reduction in weight. This mode is attrib uted mainly to the formation of gypsum, and is known as the acidic type of sulphate attack. The second mode of deterioration, which is normally characterised by expansion and cracking, takes place when the reactive hydrated alurninate phases. present in sufficient quantities are attacked by sulphate ions, thereby forming calcium aluminate trisulphate hydrate, also called ettrengite. This expansive type of reaction is ascribable to the formation of a colloidal form of ettringite in the presence of high concentrations of Ca(OH)2 in the pore solutions.21 Visual inspection of the specimens exposed to sea water did not reveal any of the above two forms of deterioration during the two year exposure period. Previous studies in the l950s and 1970s had reported excessive expansion and extensive deterioration in concrete structures exposed to sea water 3,8,3740 .The reason for the increased proneness of old cements to expansion and spalling by sea water is probably ascribable to the high C3A content of old Type I cements that were manufactured during the l930s to 1950s. When the C3A content is more than 11%, the susceptibility of concrete to expansion and cracking is significantly increased 32,33,37,39. On the contrary, the present-day Type I cements often have a maximum C3A content of about 9%. Accordingly, the expansion of Type I Port land cement when exposed to sulphate media is much mitigated. The expansion characteristics are further mitigated by the conjoint presence of chlorides with the sulphate salts in seawater.40,41 Even if ettringite or gypsum is formed, the expansive stresses will be much reduced owing to the concomitant presence of chloride ions24,32. Considering the long-term (i.e. more than 20 years) performance of concrete in sea water, some researchers37 reported that all Portland cements, includ ing Type V cements with C3A of up to 3%, will be significantly affected by sea water. The reason may be attributed to the first acidic type of sulphate attack, which is ascribable to the portlandite produced by the hydration of C3S and C2S phases. In fact, the portlan dite content is proportional to the C3S/C2S ratio of the cement and this ratio is responsible for the early strength development of the cement. Since the manu facturers of modem cements do care a lot about the high early strength. the C3S/C2S ratio of present ce ments is extremely high thereby increasing the portlan dite content. It is. therefore, expected that these cements will readily deteriorate after long exposure periods. The principal form of deterioration will be the gypsum type, whereby the portlandite produced by the hydration of calcium silicate phases will react with the sulphate ions of sea water to produce gypsum according to the following reaction To mitigate the inferior role of portlandite. it is re commended to use pozzolanic admixtures to consume this portlandite as shown in the following pozzolanic reaction: In addition to consuming the portlandite. the pozzo lanic reaction produces secondary C-S-H. Ca (OH)2 + SO42- 2H2O CaSO4.2H20 + 20H-
which re duces the permeability of concrete thereby improving the sulphate resistance of blended cements. Therefore, the long-term performance of blended cements, particu larly those incorporating silica fume and blast furnace slag, is expected to be much 3Ca (OH)2 + 2SiO 2 3CaO.2SiO2.3H2O
better than plain Portland cements exposed to marine environment, particularly when the concrete mixture is to be prepared at low water to binder ratio, similar to what is being used in the offshore structures.12,35,42 Reinforcement corrosion It is well known that the major durability problem in marine environments is corrosion of reinforcing steel.2,10,12,37,42 This phenomenon is ascribed to the higher rate of diffusion of chloride ions compared to that of sulphate ions thereby destroying the protective film on the steel surface.28.29 The corrosion potential data depicted in Figs 9 and 10 indicate that the performance of SF cement concrete specimens was significantly superior to FA and port land cement concretes. In fact, SF cement concrete performed 5.7 times better than Type I cement con crete, as is evident from the data in Table 3. Similarly, the performance of FA cement concrete was 30% better than that of Type I cement concrete. However, Type I cement concrete performed 16 times better than Type V cement concrete. The corrosion current density data, summarised in
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Cements
Table 4, also indicate the superior performance of silica fume cement concrete specimens in a way similar to the corrosion potential data. The performance ratio of SF concrete in terms of Icorr ranged from 23 to 32 times that of Type I cement concrete. The Icorr steel in BFS and FA cement concrete specimens was, respectively. 11 to 18 and 2.5 to 3.7 times lower than that on steel in Type I cement concrete specimens. The performance of Type V cement concrete was 1.1 times inferior to that of Type I cement concrete. The corrosion data show that SF cement is the best pozzolanic material to mitigate the corrosion of reinfor cing steel in concrete exposed to the marine environ ment. The superior performance of silica fume concrete is ascribed to the beneficial impact of silica fume on the impermeability of concrete. Such an impermeable nature of SF cement concrete may reduce the chloride diffusion by 10 times as compared with an equivalent concrete without SF. The effect of SF on water per meability and chloride diffusion in concrete is sum marised elsewhere.28,43 As shown in Table 5. the chloride concentration in all plain and blended cements was more than the allowable value of 0.15% proposed by the ACI Com mittee 31834 to avoid reinforcement corrosion in re inforced concrete structures exposed to Cl- bearing solutions. Furthermore. according to Hausmann44 the risk of corrosion is high when the Cl-/0H- ratio is above 0.6. The Cl-/0H- data in Table 5 indicate higher chances of reinforcement corrosion in concrete structures prepared with both plain and blended ce ments exposed to sea water. Lambert et al.45 investigeated the relationships between Cl-/0H- ratio and corrosion current density in various cements. Their investigation indicated that the passive condition of steel in concrete. tial lower than characterised by Icorr values substan 0.1A/cm2 was maintained until a threshold Cl-/0Hratio of approximately 3 was exceeded. However, there was a considerable scatter in the values of Icorrat Cl-/0H- ratios in excess of 3 and even at Cl-/0Hratios of as high as 15 to 20. there were instances of bars sufferinc no sienificant corrosion. Mangat and Gurusamy46 indicated that for steel fibres in concrete under conditions of a similar marine exposure. no visible signs of reinforcement corrosion were visible at a Cl-/ 0H- ratio as hiuh as320. The minimal reinforcement corrosion observed in blended cements. particularly in SF and BFS cements (as elaborated in Tables 3 and 4). in spite of the high Cl-/0H- ratio summarised in Table 5. indicates that other factors, such as the electrical resistivity of con crete, also influence the kinetics of
reinforcement corrosion. While the Cl-/0H- ratio may influence the corrosion initiation, its propagation is primarily depen dent on both the electrical resistivity of concrete and the availability of oxygen and moisture. The physical structure of the high profile blended cements, such as those prepared with silica fume and blast furnace slag, is characterised by a dense and highly impermeable matrix formed due to the refinement and segmentation42 of the capillary pores. This dense micro-structure not only retards the mobility and diffusion of chloride ions from the external environment to the steel-concrete interface, but also tremendously increases the electrical resistivity of concrete thereby retarding the flow of corrosion current.47 Lambert et al.45 attributed the commendable corrosion-resisting characteristics of the high profile blended cements to the formation of an interfacial layer of cement hydration products, formed in close proximity to the y-Fe203 passive film, on the embedded steel surface which acts as a buffer to resist the process of localised corrosion. In reinforced concrete construction, the time to initiation and time to propagation are the two compo nents that govern the service life of these structures. The initiation period is the time for diffusion of the aggressive substances, particularly the chlorides. through concrete to the steel surface to cause activation of the corrosion process. The propagation time repre sents the period before an unacceptable corrosion damage occurs. The data developed in this investigation indicate that the time to initiation of reinforcement corrosion was much more in blended cements, especially in silica fume cement, than in plain cements. Also, the lower corrosion rate observed in blended cements indicates that the time for corrosion propaga tion and the subsequent deterioration, marked by con crete cracking and spalling. will be longer in structures built with blended cements exposed to marine environment than those prepared with plain cements.
Conclusions
Cement paste. mortar and reinforced concrete speci mens prepared using Type I and Type V cements and Type I cement blended with fly ash, silica fume and blast furnace slag were exposed to sea water for a period of 720 days. The performance of these cements was evaluated through visual inspection, measuring the reduction in compressive strength. expansion and weight chance. X-ray diffraction and chemical analyses of the cement paste specimens were used to study the mineralogical changes and pore solution characteristics of the plain and blended
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Cements
cement pastes exposed to the marine environment. Electrochemical techniques were utilised to assess reinforcement corrosion. Based on data developed in this investigation, the following con clusions can be drawn. The reduction in compressive strength and expansion data indicated better performance by blended cements particularly the BFS cement. The performance of Type V cement was marginally better than that of Type I cements. An increase, rather than a decrease, in weight was noted in all the cement concrete specimens. The lowest increase in weight of about 1.5% was noted in SF and BFS after two years of exposure. The weight change was I.85% in plain and FA cements. No signs of deterioration were observed on plain and blended cements. even though the sulphate concentra tion in the sea water was high. The weight loss, expansion and reduction in compressive strength were less than the threshold values reported in the literature, even after two years of exposure. The time to initiation of reinforcement corrosion and corrosion current density values vividly revealed the superior performance of blended cements, particularly the silica fume and BFS. After 720 days of exposure to the sea water, the Icorr data indicated that the SF. BFS and FA cements performed 23. 11 and 2.5 times better than Type I cement. The performance of Type V cement was marginally inferior to that of Type I cement. Though the Cl- concentration and Cl-/0H- ratio were more than the threshold values, the reinforcement corrosion in SF and BFS cement concretes was less than that in plain cements. This could be ascribed to the dense micro-structure of these cements resulting in higher electrical resistivity. For a long-term durable performance of concrete in marine and offshore structures, SF or BFS cement can used at low water to binder ratio. To further enhance the resistance against deterioration by sulphate ions and or salt crystallisation, additional protective meas uresm such as the application of a water-resistant epoxy- based coating, may be considered.
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Acknowledgements
The support provided by King Fahd University of Petroleum and Minerals, Dhahran. Saudi Arabia. is appreciated. Thanks are extended to Dr Mohammed
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N, and MASLEHUDDIN M. Magnesium-sodium sulfate attack in plain and blended cements. ASCE Journal of Materials in Civil Engineering, 1994, 6, No. 2, 201222-.
Inc. New Jersey. 1981. 34.AMERICAN CONCRETE INSTITUTE. Building Code Requirements for Structural Concrete (A CI 318- 95) and Commentary (ACI 3 l8R- 95), American Concrete Institute. Farmington. 1 995. 35.AL-AMOUDI 0. S. B and MASLFHLDDIN M. Concrete protection in aggressive media, in Concrete in the Service of Mankind: Concrete Repair Rehabilitation and Protection (R.K. Dhir and M.. R. Jones (Eds), E & FN Spon. London. 1996 Pp. 139154-. 36. AL-AMOUDI 0. S. B Attack on plain and blended cements exposed to aggressive sulfate environments. Cement and concrete composites. Special Issue on Sulfate Attack. 2002. in press 37.MEHTA P. K and HAYNES H. H. Durability of concrete in seawater, ASCE Journal of the Structural Division,1975,101, No ST8 I6791686-. 38.KALOUSEK 6. L. and BENTON F. J. Mechanisms of seawater attack on cement pastes. AC! Journal, 1970, February, 187- 192. 39.RASHEEDIJZZAFAR. AL-SAADOUN S. S., AL-GAHTANI A. S., DAKHIL F 11. and BADER M. A. A repair strategy for corrosion damaged concrete. Proceedings, 3rd International Repair of Reinforced Concrete in The Arabian Gulf, Bahrain, 1989, Vol. 1, pp. 3557-. 40.FIGG J. W Chemical attack on hardened concrete, effect of sulphates and chlorides. Bulletin of the institution of Corrosion Science and Technology, 1979, 75, 1223-. 41.HARRISON W. H. Effect of chloride in mix ingredients on sulphate resistance of concrete. Magazine of Concrete Re search. 1990, 42, No. 152. 1 l3-l26. 42.MEITA P. K. Concrete in the Marine Environment, Elsevier Applied Science. London and New York, 1991. 43.AL-AMOUDI O. S. B. MASLEHUDDIN M. and BADER M. A. Characteristics of silica fume and its impact on concrete in the Arabian Gulf Concrete, 2001, 35. No. 2, 4550-. 44.HAUSMANN D. A. Steel corrosion in concrete, how does it occur Materials Protection, 1967, 6. No. 11. 1923-. 45.LAMBERT P., P.AGE C. L. and VASSIE P. R. W. Investigations of reinforcement corrosion. 2. Electrochemical monitoring a of steel in chloride-contaminated concrete. Materials and .Structures, 1991. 24. 351358-. 46.MANGAT P. S. and GURUSAMY K. Corrosion resistance of steel fibres in concrete under marine exposure. Cement and Concrete Research. 1988. 18. No. I. 4454-. 47.HUSSAIN S. E., Mechanisms of high durability performance of plain and blended cements, PhD thesis. Kina Fahd University of Petroleum and Minerals. Dhahran. Saudi Arabia. 1991 48.TUTUI K. Service life of structures with regard to corrosion of embedded steel, in Performance of C Concrete in Marine Environment, ACI SP-65, American Concrete Institute. Detroit, 1980.
26.VOGEL A. 1. A Textbook of Quantitative Inorganic Analysis.4th edn. Longman, London. 1978. 27.AMERICAN PUBLIC HEALTH ASSOCIATION. Standard Methods for the Examination of Water and wastewater. 16th edn, American Public Health Association. Washington. 1985. 28.AL-AMOUDI 0. S. B. RASHEEDUZZAFAR. MASLEHUDDIN M. and ABDULJAUWAD S. N. influence of sulfate ions on chloride-induced reinforcement corrosion in plain and blended cement concretes. .A4STM Journal of Cement, Concrete, and Aggre gates. 1994. 16, No. 1, 311-. 29.ARU P H. Mechanism of the protection of steel by concrete, in Corrosion of Reinforcement in Concrete Structures (A. P. Grane (Ed.)). Ellis Horwood, London. 1985. pp. 151157-. 30.MACPHEE D. E. and C.AO H. T. Theoretical description of blast furnace slag (BFS) on steel passivation in concrete. Magazine of Concrete Research. 1993. 45. No. 162. 6369-. 31 .HIGHWAY RESEARCH BOARD. Guide to Compounds of Interest in Cement and Concrete Research. High way Research Board. Special Report 127. Washington. DC. 1972. 32.LEA F. M. The Chemistry of Cement and Concrete. 3rd edn. Edward Arnold Ltd. London, 1970. 33.MINDNESS S. and YOUNG .J. F. Concrete. Prentice-Hall.
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New Products & Media

For the first time - determination of particle size distributions and particle shape recognition in a single process
In many sectors of industry, knowledge of the particle size distribution and particle shape of pulverised material or suspensions is a vital aspect of quality control. Measurement of these charac teristics also play a noteworthy role in production monitoring (e.g. of crushing plants). with those of the analysette 22 NanoTec except for the nano expansion. The measuring range is from 0.1 to 600 m for the measurement of particle size distributions of suspensions and emulsions as well as for dry powders.
FRITSCH with their vast experience in the particle

sizing field is now able to offer the FRITSCH analysette 22 Laser-Particle-Sizer in different versions and with complete new features.
Laser-Particle-Sizer analysette 22 COMPACT With the new COMPACT-model of the "analysette 22", FRITSCH is now providing those users the possibility to make use of the high tech laser tech nology, which had so far no sufficient budget avail able. The COMPACT-model can measure particle size distributions of any suspensions and emul-sions as well as of dry powders in the range of 0.3 to 300 microns - fast, rationally and efficiently.
All models of the analysette 22 Laser-ParticleSizer family use the laser diffraction technology with patented convergent laser beam and are therefore the only instruments in which the measuring cell is moved along the optical axis to adjust the measur ing range without the need to change the lens. The sample is therefore always measured with the greatest dynamic and optimal conditions. FRITSCH offers due to its equipment varieties for each special use and application a particle size measuring instrument with the most modern laser technology and this with an unbeatable price-toperformance ratio.
Here a glance of the different models: Laser-Particle-Sizer analysette 22 NanoTec

For fast automatic measurement of particle size distributions of suspensions, emulsions and dry powders.
Measuring range:
for suspensions + emulsions: for dry powders: 0.01 - 1000 microns 0.1 - 1000 microns
With the intelligent interpretation and further development of the FRITSCH patent for Inverse Fourier Optics (convergent laser beam), the NEW analysette 22 NanoTec achieves a measuring range down to the nanometer range. The revolutionary design along with the new optical, mechanical and electronic components and a new, modern, flexible analysis software makes the analysette 22 to an analysis instrument, which is on the most modern state of the art. As a unique feature, the NanoTec-version offers optionally the output of the elongation ratio for specific particle sizes and is therefore together with the MicroTec-Version of FRITSCH the only instru ment in the world that makes it possible to have information on the particle shape on the basis of light scattering.
Laser-Particle-Sizer analysette 22 MicroTec

The analysette 22 MicroTec is the measuring instrument for samples in the micron and sub micron range. The reduced optical bench allows a very compact and inexpensive design. The MicroTec is the little brother of the NanoTec. All hardware and software components are identi cal
Please for more information please contact: Fritsch GmbH Manufacturers of Laboratory Instruments Andrea Khler, Industriestrasse 8 D-55743 Idar-Oberstein, Germany Phone +49 67 84 70 146 Fax +49 67 84 7011 E-Mail: koehler@fritsch.de Internet: http://www.fritsch.de
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DISOBOX - The Key To A Digital Scale

Load cells with digital output are designed to offer additional applicability and to facilitate their use. Despite some improvements, previous solutions of this kind left much to be desired. As a consequence, none of these load cells really gained acceptance on the market. DISOBOX in contrast is visibly smarter! With the multi-channel analog-to-digital DISOBOX converter unit, Schenck specialists developed weighing electronics that add a whole variety of reasonable and useful features to the advantages of digital load cells. Equipped with the DISOBOX, a conventional analog scale is converted into a digital scale that proves its worth in both legal-for-trade and industrial process applications. Combined with weighing electronics of the DISOMAT family or the DISOVIEW-E PC software, highly precise multi-talented weighing systems emerge. The most vital feature of the new electronic unit is that the output signals of all connected load cells are digit ised one by one, so that the measuring voltage of the individual cells can be accessed at any time. Upon com missioning, this permits an exact analysis of de~dload distribution and convenient electronic corner comparison. During operation, the load distribution on the scale is analysed and, at the same time, every load cell is individually monitored. In case of faults, the affected component is detected in no time. In the end, this means a considerable savings in time, material and cost and distinctly improves process safety. Mounted in a rugged housing of protection type IP 65, the DISOBOX is directly connected to the scale. The unit comprises up to eight high-resolution signal channels measuring synchronously and additional binary inputs and outputs. Data acquisition is decentralized. They are directly transmitted to the host system using state-of-the-art communication modules, e.g. PROFIBUS DP, DeviceNet or Ethernet (MODBUS /TCP). DISOBOX is suited for use as data acquisition and control unit for almost any weighing system, whether combined with Schenck weighing electronics of the DISOMAT family or as extension of PC-based weighing systems. The integrated weighing functions permit its use as complete multi-channel scale, e.g. in conjunction with a PLC system. Thanks to the systems intelligent sealing concept (no plug-in jumpers), DISOBOX can be kept closed after installation/commissioning. The system is parameterised and calibrated via serial interface or Ethernet. The legal-for-trade part of the system is protected by an electronic modi fication counter monitoring the relevant adjustment parameters. Hence, there is no need any longer to open the DISOBOX for adjustment and calibration, thus eliminating the risk of grime and moisture entering during maintenance/adjustment. Universal usage Thanks to its virtually endless opportunities, the DISOBOX proves its worth whenever highest flexibility and fail-safe digital signal transmission is an important consideration. Typical applications are truck and train scales as well as crane and hopper scales. Used on systems where proper load distribution matters most, e.g. wheel-load scales, test systems, or scales designed for centre of gravity determination, the DISOBOX displays the entire spectrum of its strength. In industrial processes, too, the DISOBOX brilliantly masters the many and varied duties. Whether as weight transmitter for fill-level measure ment in hoppers and silos, as independent system for limit monitoring or simple feeding tasks. In any application, the DISOBOX replaces conven tional analog transmitters or PLC modules resp., and makes life easier for plant engineers and fitters. When used as 8-times converter, up to eight hopper scales can be acquired decentrally and interfaced with the existing host system via Profibus or Ethernet.
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Ethernet offers the additional possibility to access individual scales and -dependent on the configuration - individual load cells via the users intranet, so that remote diagnostics and maintenance can be effected quickly, easily and at any time, independent of the location. With conventional systems the user, up to now, has the restriction that all load cells of a scale must have identical rated capacities and electrical characteristics. Here, too, DISOBOX opens up new horizons: In asymmetrically structured systems, load cells of different rated capa cities can be combined to form a scale even in legal-for-trade applications. Maintenance, repair, and modernisation made easy The described DISOBOX properties facilitate the repair of systems where types or rated capacities of the existing load cells are no longer available. There is no need to equip the scale with new sensors as it used to be. The old summation box is simply replaced by a DISOBOX and the defective load cell is exchanged against a type with a different rated capacity. Inevitable repair work thus becomes an attractive modernisation that pays off. All advantages at a glance Local weighing electronics in lP 65 One measuring channel per load cell Monitoring of the individual load cells possible Electronic corner comparison Digital transmission of measured values Field bus connection All components exchangeable without readjustment/re-calibration Use in combination with Schenck weighing electronics, legal-for-trade PC programs, or standard PLC.
MULTICOOL D Highly Efficient Retrofit Solution to Increase Blown Film Output

Since its premire at K 2001, the MULTICOOL D air ring system has been proven as a feature to dramatically increase the output of blown film lines and has since continued on the road of success also as a retrofit to existing blown film installations. The output increasing potential of MULTICOOL D can be fully exhausted especially when producing FFS film. For PE-LLD and PP films a 30% increase is achieved. The dual air ring concept has proved to be particularly effective when producing films between 100 and 160 microns and in addition has been successfully used also on existing extrusion systems for laminating films and films for automatic packaging applications. Having seen the advantages
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of MULTICOOL D while testing it on one of their extrusion lines, a European film converter made up his mind to order nine further systems straightaway. The recipe for success of this unique concept consists in using a notably increased cooling air volume resulting from the dual deck design as well as a threestage cooling process. The long neck of the bubble with relatively late inflation through the second air ring allows to optimally influence film characteristics such as, e.g. physical strength values. Compared with the dual lip air rings that are being used in the market place, MULTICOOL D allows you to start up your extrusion line considerably faster and trouble-free as a result of unobstructed access granted by the dual deck design, which makes it easier for the operator to draw the melt from the die. For this purpose an electric motor lifts off the upper air ring which is brought back to working position only after the film has been completely threaded through the line
PANalytical announces new version 3.0 software for MiniPal and MiniMate series of spectrometers
With its recently released version 3.0, PANalytical has significantly improved the software for their range of MiniPal and MiniMate EDXRF benchtop spectrometers. New features in the software make it easier to use and enable more versatile analysis. The new software includes recalibration, spectra comparison, extended database formatting possibilities and a variety of other enhancements and modifications. Additionally, a Quick Start Guide for the MiniPal simplifying installation and application set-up is now supplied as part of the package. What is new? Applications can now be copied to other systems of the same type with a minimum effort, making life a lot easier for multi-system and multi-department users. Another advantage with this extended recalibration is that one set of calibration data can be copied from a research lab to a quality control or process control machine. This feature also extends the lifetime of a calibration. With version 3.0 it is now possible to compare spectra of samples from the same application or from different applications. Up to 64 spectra can be displayed at the same time. Spectra can also be scaled and shown in 3D. This all means that materials identification is made much simpler, trends can be easily monitored, and contamination can be checked. There are also a lot of small, but useful features in this new software version making operation and use easier. A tiny, yet practical one, for example, is the extension of the character number for the unit-name from 4 to 8 digits
For more information please contact: PANalytical , Marketing Services Dept. Tel: +31 546 534444, Fax: +31 546 534592 E-mail: info@panalytical.com web: www.panalytical.com
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Diary Dates
CEMENT
8th International 'CemEnter' Cement and Concrete Conference and Exhibition Date : 25 27 January 2005 Venue: Odessa, Ukraine For more information please contact: Vladimir E-mail: leocem@leocem.kiev.ua The 3rd International Specialized Exhibition of Cement and Cocrete for Capital and Landscape Construction Date : 16 21 February 2005 Venue: Moscow, Russia For more information please contact: Tel.: +7 95 105 6416 Fax: +7 95 105 6416 E-mail: evs@mvk.ru http:// www.betonexpo.ru Intercem Dubai Date : 21 22 February 2005 Venue: Dubai, UAE For more information please contact: Conference Secretariat Tel.: +44 208 669 5222 http:// www.intercem.com Concrete Technology for Sustainable development Date : 27 February 3 March 2005 Venue: Hyderabad, India For more information please contact: Dr. (Mrs) N. Bhanumathidas Secretary - Treasurer Indian Advisory Committee (INSWAREB) 'Fal-G Mansion', 35, Venkateswara Colony Vishakapatnam 530 012 Tel.: +91 891 2516411 Fax: +91 891 2517429 E-mail: inswareb@md3.vsnl.net. in / inswareb@sify.com http:// www.bouw.tno.nl / www. microlab.citg.tudelft.nl 5th European Cement Conference Date : 14 15 March 2005 Venue: Krakow For more information please contact: http:// www.EuropeanCement. com Cemtech Spring Meeting 2005 New Directions in Cement Manufacture Conference and Workshops Date : Spring 2005 Venue: London, UK For more information please contact: http:// www.CemNet.com Concrete Microscopy Course Date : Spring 2005 Venue: Delft, The Netherlands For more information please contact: Microlab, Delft University of Technology P.O Box 5048 2600 GA Delft, The Netherlands Tel.: +31 15 276 3216 / 278 8078 E-mail: j.larbi@bouw.tno.nl / m.derooij@citg.tudelft.nl http:// www.bouw.tno.nl / www. microlab.citg.tudelft.nl Ready-Mixed Concrete Industry Fair Date : April 2005 Venue: Japan For more information please contact: E-mail: nishiyama@cement.co.jp Slag Cement Symposium Date : 1720 April 2005 Venue: New York, USA For more information please contact: Tel.: +1 248 848 3795 Fax: +1 248 848 3796 E-mail: conventions@concrete. org http:// www.concrete.org/events/ ev_conventins.htm International Concrete Qualification Course
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Date : May 2005 Venue: Mumbai, India For more information please contact: Mr. Narendra D. Patel ICI-MLC, 4311/, Tamarind Lane Rajabahadur Building Fort, Mumbai 400 001 Tel.: +91 22 22652550 / 51 Fax: +91 22 22652541 E-mail: narendradaptel2003@yahoo.co.in / ndpatel@athithibuilders.com Mechanisms and Modelling of Waste/Cement Interactions Date : 0812 May 2005 Venue: Meiringen, Switzerland For more information please contact: http:// www.empa.ch/cemnet 18th BIBM International Congress and Exhibition on Meet the Future of Precast Concrete BIBM 2005 Date : 1114 May 2005 Venue: Amsterdam, The Netherland For more information please contact: BIBM Congress Secretariat B.O. Box 194 3440 AD Woerden The Netherlands E-mail: info@bibm2005.com IEEE-IAS/PCA 47th Cement Industry Technical Conference Date : 1520 May 2005 Venue: Kansas City, USA For more information please contact: E-mail: www.ieeepca2005.org Keep Concrete Attractive Date : 22 25 May 2005 Venue: Budapest, Hungary For more information please contact: Tel.: +36 1 4634068 Fax: +36 1 463 3450 E-mail: fibSymp2005@eik.bme. hu http:// www.eat.bme.hu
Diary Dates
First International Symposium on Design, Performance and Use of Self-Consolidating Concrete Date : 26 - 28 May 2005 Venue: China For more information please contact: Tel.: +86 731 265 6568 Fax: +86 731 265 766 E-mail: scc2005@mail.csu.edu.cn http:// www.scc2005-csu.com 4th International ACI/CANMET Conference on Quality of Concrete Structure and Recent Advances in Concrete Materials and Testing Date : 01 03 June 2005 Venue: Golandi, Brazil For more information please contact: IV High Performance Concrete Structures Enio Pazini Figueiredo Moacir Alexandre Eletricas S.A Centro Techologico de Engenharia Civil Caiza Postal 57-Centro, Golania Goias Brazil E-mail: hpc2005@furnas.com.br 5th International Symposium on Concrete for Sustainable Agriculture Date : 05 08 June 2005 Venue: San Lorenzo del El Escorial, Spain For more information please contact: Tel.: +34 913 365 762 Fax: +34 913 365 766 E-mail: secretariat@eurosteel200 5.info Website: www.eurosteel2005. info/information.html XIX Symposium on Nordic Concrete Research & Development Date : 13 15 June 2005 Venue: Sandefjord, Norway For more information please contact: Tel.: +47 22 94 7564 Fax: +47 22 94 7502 E-mail: siri.engen@tekna.no Website: www.betong.net the 7th International Symposium on Utilization of High Strength / High Performance Concrete Date : 20 24 June 2005 Venue: Washington, USA For more information please contact: Tel.: +1 248 848 3742 Fax: +1 248 848 3740 E-mail: thomas.adams@concrete. org http:// www.aciconference.org International Congress on Global Construction: Ultimate Concrete Opportunities Date : 05 07 July 2005 Venue: Dundee, Scotland, UK For more information please contact: Tel.: +44 1382 344 347 Fax: +44 1382 345 524 E-mail: r.k.dhir@dundee.ac.uk http:// www.ctucongress.co.uk 8th International Conference on Concrete Pavement Date : 13 18 August 2005 Venue: Dundee, Scotland, UK For more information please contact: Tel.: +1 979 845 9918 Fax: +1 765 496 1364 E-mail: iscp8@ecn.purdue.edu http:// www.concretepavements. org 8th Singapore Concrete Week Date : 22 26 August 2005 Venue: Singapore For more information please contact: Tel.: +65 673 32922 Fax: +65 623 535304 E-mail: cipremie@signet.com.sg http:// www.cipremie.com 4th Conference and Exhibition for Markets Production and Processing Technology of Cement in North, Central and South America Date : 0809- September 2005 Venue: Cancun, Mexico For more information please contact: Tel.: +44 1372 743837 Fax: +44 1372 743838 E-mail: system@propubs.com http:// www.propubs.com/ns2005/ index.htm ACECON 2005 Date : 23 25 September 2005 Venue: Mumbai, India For more information please contact: Mr. Narendra D.Patel Principal Co-ordinator, ACECON 2005 4311/, Tamarind Lave, Rajabahadur Bldg, For, Mumbai 400 001 Tel.: +91 22 22652655 \ 22654835 Fax: +91 00 22652541 E-mail: vrk99@vsnl.com Cemtech Barcelona 2005 Date : 18 21 September 2005 Venue: Barcelona, Spain For more information please contact: E-mail: info@cemnet.co.uk Website: www.CemNet.com Self-Compactin Concrete Date : 31 October 2 November 2005 Venue: Chicago, USA For more information please contact: Mr. Richard Graza Centre for Adanced CementBased Materials Northwestern University 2145 Sheridan Road, Suite A130 Evanston, IL 60208 USA Tel.: +1 847 4913858 Fax: +1 847 4671078 E-mail: acbm@northwestern.edu
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Diary Dates
Fall 2005 ACI Convention / Historic Innovations in Prestressed Concrete Date : 06 10 November 2005 Venue: New Orleans, USA For more information please contact: Tel.: +1 610 519 5390 Fax: +1 610 519 6754 E-mail: shawn.gross@villanova. edu http:// www.concrete.org/events/ ev_cnvention.htm International Conference on Concrete Repair, Rehabilitation and Retrofitting ICCRRR 2005 Date : 21 23 November 2005 Venue: South Africa For more information please contact: Tel.: +27 21 6505181 Fax: +27 21 6897471 E-mail: ICCRRR@eng.uct.ac.za http:// www.civil.uctac.za/iccrrr 9th NCB International Seminar on Cement and Building Materials Date : 22 25 November 2005 Venue: New Delhi, India For more information please contact: The Organising Secretary Ninth NCB International Seminar on Cement and Building Materials 34 km Stone, Delhi Mathura Road (NH2) Ballabgarh 121 004, Haryana, India Tel.: +91 129 224205156- (six lines) \ 2246174 Fax: +91 129 22142100 \ 2246175 E-mail: nccbm@giasd101.vsnl. net.in contact: Tel.: +1 8008735-933http:// www.kbis.com Unitecr 2005 9th Unified Int'l Technical Conference on Refractories Date : 811 November 2005 Venue: Florida, USA For more information please contact: E-mail: jsmith@umr.edu Webmail: www.budma.pl Swiss Building Fair 2005 Date : 2529 January 2005 Venue: Basel, Switzerland For more information please contact: Tel: +41 58 200 2020 Fax: +41 58 206 2188 E-mail: info@swissbau.ch Webmail: www.swissbau.ch India Stonemart 2005 Date : 28 January 1 February 2005 Venue: Jaipur, India For more information please contact: Center for Development of Stones CDOS, RIICO Wing, Udyog Bhawan, Tilak Marg, India Tel: +91 141 380199 Fax: +91 141 404804 E-mail: cdosindia@cdos-india. com http:// www.cdos-india.com 1st International Indian Construction & Building Exhibition Date : February 2005 Venue: Bangalore, India For more information please contact: Tel: +44 20 7596 5000 Fax: +44 20 7596 5111 E-mail: building@ite-exhibitions. com http:// www.buildingshows.com Smopyc - International Show of Public Works, Construction and Mining Technology Date : 01 February 2005 Venue: Spain For more information please contact: Feria de Zaragoza Tel: +34976 330649 E-mail: pramos@feriazaragoza. com http:// www.feriazaragoza.com Ukraine International Building &
GENERAL
TRADECOM 2005 International Exhibition Date : 1517 January 2005 Venue: Dubai, UAE For more information please contact: Fax: +971 4 3969911 / 3599080 E-mail: info@tradecom.ae http:// www.tradecom.ae Building for sustainable development Date : 2122 January 2005 Venue: Ahmedabad, India For more information please contact: Mrs Reshma A. Shah Organising Secretary, NSSD School of uilding Science & Technology Centre for Environmental Planning & Technology Kasturbhai Campus, University Road, Navrangpura Ahmedabad 380 009 Tel: +91 79 26302470 / 26302740 Fax: +91 79 26302075 E-mail: nssd4@hotmail.com BUDMA / International Construction Fair Date : 2528 January 2005 Venue: Poznan, Poland For more information please contact: Tel: +48 61 8692000 Fax: +48 61 866 5827 E-mail: info@mtp.pl
CERAMIC
Kitchen/Bath Industry Show Date : 1012 May 2005 Venue: Las Vegas, USA For more information please
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Diary Dates
Construction Exhibition Date : 15 18 February 2005 Venue: Kiev, Ukraine For more information please contact: Tel: +44 20 7596 5000 Fax: +44 20 7596 5111 E-mail: building@ite-exhibitions. com http:// www.buildingshows.com 13th International Construction Week Date : 16 - 21 February 2005 Venue: Moscow, Russia For more information please contact: http:// www.stroytekh.ru/ defaulteng.stm BAUSCHAU / LIGNOMEC Trade Show for Building and Construction Date : 1821 February 2005 Venue: Bolzano, Italy For more information please contact: Tel: +93 0471 516000 Fax: +93 0471 516116 E-mail: info@fierabolzano.it http:// www.fierabolzano.it IBASE Conference on Role of Structural Engineers Towards Reduction of Poverty Date : 1922 February 2005 Venue: New Delhi, India For more information please contact: Tel: +91 11 23782923 Fax: +91 11 23388132 E-mail: ingiabse@nde.vsnl.net.in http:// www.iabse.org AustralAsian Oil & Gas (AOG) 2005 Date : 2325 February 2005 Venue: Perth, Australia For more information please contact: Swan Exhibitions Tel: +6189443 3400 Fax: +6189242 1811 E-mail: energy@energy-pubs. com.au http:// www.swanexhibitions.com. au Autralian Construction Equipment Expo Date : 2426 February 2005 Venue: Melbourne, Australia For more information please contact: Tel: +613 9567 4260 Fax: +613 9567 4361 E-mail: ace@etf.com.au http:// www.ace2005.com.au Uzbekistan Building Week 2005 Date : 0104 March 2005 Venue: Tashkent, Uzbekistan For more information please contact: Tel.: +49 40 235 240 Fax: +49 40 235 24400 E-mail: info@gima.de http:// www.gima.de NLA's International Building Lime Symposium Date : 0608 March 2005 Venue: Orlando, USA For more information please contact: http:// www.buildinglime.org Middle East Electricity Exhibition & Conference Date : 0609 March 2005 Venue: Dubai, UAE For more information please contact: http:// www.middleeastelectricity. com/trme05 FEICON / International Construction Industry Trade Date : 0812 March 2005 Venue: San Paulo, Brazil For more information please contact: Tel.: +55 11 3291 9118 Fax: +55 11 3291 9176 E-mail: international@alcantara. com.br http:// www.feicon.com.br Consteel India 2005 Date : 12 March 2005 Venue: Mumbai, India For more information please contact: Mr. Umesh Pandey Principal Co-ordinator & Organising Secretary Plot No. B-107, Sextor-23 Nerul, Navi Mumbai 400 706 Tel: +91 22 31099880 / 27700081 Fax: +91 22 27713534 E-mail: consteelindia_ 2005@rediffmail.com / umeshkp63@yahoo.co.in Pyrometallurgy 05 Date : 1415 March 2005 Venue: Cape Town, South Africa For more information please contact: Minerals Engineering International Tel: +441326 318352 Fax: +441326 318352 E-mail: amanda@min-eng.com http:// www.min-eng.com/ pyromet05/ 7th IFHS Conference on Multipurpose high-rise towers and tall buildings IFHS 2005 Date : 1416 March 2005 Venue: Dubai, UAE For more information please contact: IISM Abu Dhabi P.O. Box 6466 United Arab Emirates Tel.: +971 2 6773900 Fax: +971 2 6776130 E-mail: IFHS2005@hotmail.com ICON / India International Construction & Contracting Exhibition Date : 1517 March 2005 Venue: New Delhi, India For more information please contact: Tel: +971 4 331 9688 Fax: +971 4 331 94805489/ E-mail: dmg@emirates.net.ae http:// www.dmgdubai.com
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Diary Dates
International Construction Equipment Exposition Date : 1519 March 2005 Venue: Las Vegas, USA For more information please contact: Tel: +1 301 587 3140 Fax: +1 301 587 4260 E-mail: pvlahos@conexpoconagg. com http:// www.conexpoconagg.com 12th Construction Machinery Trade Fair Date : 1520 March 2005 Venue: Berne, Switzerland For more information please contact: Tel: +41 31 340 1111 Fax: +41 31 340 1110 E-mail: baumashinenmesse@beaexpo.ch http:// www.beaexpo.ch Bio & Hydrometallurgy 05 Date : 1618 March 2005 Venue: Cape Town, South Africa For more information please contact: Minerals Engineering International Tel: +441326 318352 Fax: +441326 318352 E-mail: amanda@min-eng.com http:// www.min-eng.com/ biohydromet05/ 11th International Conference on Fracture Date : 2025 March 2005 Venue: Turin, Italy For more information please contact: Tel: +39 011 2446911 Fax: +39 011 2446900 E-mail: info@congressiefiere.com http:// www.congressiefiere.com the 2nd International Specialized Exhibition of Technologies and Equipment for Tunnel Construction Date : 29 March 01 April 2005 Venue: Moscow, Russia
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For more information please contact: Tel: +7 95 105 6416 Fax: +7 95 105 6416 E-mail: evs@mvk.ru http:// www.gewexpo.ru APCOM 2005 Date : 30 March 01 April 2005 Venue: Arizona, USA For more information please contact: 2005 APCOM organizing committee Tel: +1520 621 2359 Fax: +1520 621 8330 E-mail: apcom@mge.arizona.edu http:// engr.arizona.edu/apcom/ index.htm Moscow International Building and Construction Exhibition Date : 05 - 08 April 2005 Venue: Moscow, Russia For more information please contact: Tel: +44 20 7596 5000 Fax: +44 20 7596 5111 E-mail: building@ite-exhibitions. com http:// www.ite-exhibitions.com 26th International Building and Construction Exhibition / CONECO Date : 06 - 09 April 2005 Venue: Bratislava, Slovakia For more information please contact: Tel: +421 2 672 72209 Fax: +421 2 672 72055 E-mail: building@ite-exhibitions. com http:// www.ite-exhibitions.com Expo Build China Date : 0609 April 2005 Venue: Shanghai, China For more information please contact: http:// www.cmpsinoexpo.com Hannover-Messe/INTERKAMA Date : 1115 April 2005 Venue: Hannover, Germany
For more information please contact: http:// www.hannovermesse.de 4th International Conference on Water Repellent Treatment of Building Materials Date : 1213 April 2005 Venue: Stockholm, Sweeden For more information please contact: Tel.: 46 8 696 1100 Fax: 46 8 24 3137 E-mail: cbi@cbi.se http:// www.cbi.se Saudi Building and Interior Exhibition Date : 1721 April 2005 Venue: Jiddah, Saudi Arabia For more information please contact: Tel.: +44 20 7223 3431 Fax: +44 20 7228 4229 E-mail: international@acexpos. com http:// www.acexpos.com 5th Global Gypsum Conference Date : 1819 April 2005 Venue: Prague, Czech Republic For more information please contact: http:// www.propubs.com/gg2005/ index.htm Interpack 2005 Date : 2127 April 2005 Venue: Dsseldorf, Germany For more information please contact: http:// www.hannovermesse.de / www.interpack.de CIM Tradex Mining Exhibition Canada 2005 Date : 2427 April 2005 Venue: Toronto, Ontario, Canada For more information please contact: Canadian Institute of Mining, Mettallurgy and Petroleum Tel: +1939 2710 ext 1303 Fax: +1939 2714 E-mail: jgaydos@cim.org
Diary Dates
http:// www.tradex.cim.org World Geothermal Congress -2005 / Geothermal Energy: The Domestic, Renewable, Green Option Date : 2429 April 2005 Venue: Antalya, Turkey For more information please contact: Fax: +1650 725 2099 http:// www.wgc2005.org 5th Global Gypsum Conference Date : 2829 April 2005 Venue: Prague, Czech Republic For more information please contact: http:// www.GlobalGypsum.com ME Build 2005 Date : 30 April 4 May 2005 Venue: Damascus, Syria For more information please contact: Syrian International Marketing Association E-mail: simafair@net.sy http:// www.simafairs.com 1st International Mongolian Construction & Building Exhibition Date : May 2005 Venue: Ulaanbaatar, Mongolia For more information please contact: Tel.: +44 20 7596 5000 Fax: +44 20 7596 5111 E-mail: building@ite-exhibitions. com http:// www.ite-exhibitions.com 18th BIBM International Congress and Exhibition Date : 1114 May 2005 Venue: Amsterdam, Netherlands For more information please contact: http:// www.cembureau.be/ Events/BIBM_folder_p_pag_ WEB.pdf Processing & Disposal of Mineral Industry Wastes '05 Date : 1315 May 2005 Venue: Cornwall, United Kingdom For more information please contact: Minerals Engineering International Tel: +447768 2341212 Fax: +441326 318352 E-mail: bwills@min-eng.com http:// www.min-eng.com/ pdmiw05/index.html Geological Society of Nevada Symposium 2005 Date : 1518 May 2005 Venue: Nevada, USA For more information please contact: Geological Society of Nevada Tel: +1775 323 4569 Fax: +1775 323 3599 E-mail: gsnsymp@unr.edu http:// www.gsn2005.org Processing of Industrial Minerals '05 Date : 1617 May 2005 Venue: Cornwall, United Kingdom For more information please contact: Minerals Engineering International Tel: +447768 234121 Fax: +441326 318352 E-mail: bwills@min-eng.com http:// www.min-eng.com/pim05/ index.html The fourth Middle East Symposium on Structural Composites for Infrastructure Applications 2005 Date : 2023 May 2005 Venue: Alexandria, Egypt For more information please contact: Tel: +20 2 795 7361 Fax: +20 2 795 6614 E-mail: MESC4Egypt2005@seven7s.net http:// www.mesc4-egypt2005.4t. com Korea Construction Equipment Exhibition 2005 Date : 2528 May 2005 Venue: Goyang, Korea For more information please contact: Tel: +82 2 849 5371 Fax: +82 2 849 5312 E-mail: kocema@kocema.org http:// www.kocema.org European Conference on Steel and Composite Structures Research Euro Codes - Practice Date : 0810 June 2005 Venue: Maastricht, Holland For more information please contact: Tel: +32 4 3669297 Fax: +32 4 3669192 E-mail: secretariat@eurosteel200 5.info http:// www.eurosteel2005.info/ information.html Ankomak 2005 Date : 0812 June 2005 Venue: Istanbul, Turkey For more information please contact: ITE Group Plc Tel: +4420 7596 5213 Fax: +4420 7596 5113 E-mail: oleg.netchaev@iteexhibitions.com http:// www.ite-exhibitions.com Processing of Industrial Minerals '05 Date : 1315 June 2005 Venue: Falmouth, United Kingdom For more information please contact: Minerals Engineering International Tel: +447768 2341212 Fax: +441326 318352 E-mail: bwills@min-eng.com http:// www.min-eng.com/ pdmiw05/index.html Processing of Mineral Industry Wastes '05 Date : 1617 June 2005
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Diary Dates
Venue: Cornwall, United Kingdom For more information please contact: Minerals Engineering International Tel: +447768 2341212 Fax: +441326 318352 E-mail: bwills@min-eng.com http:// www.min-eng.com/ pdmi05/index.html Hillhead 2005 Date : 2123 June 2005 Venue: Buxton, United Kingdom For more information please contact: Penny Lewin Tel.: +44 115 945 3890 E-mail: penny.lewin@qmj.co.uk Website: www.hillhead.com The 11th International Conference and Exhibition: Structural Faults & Repair Date : 0507 July 2005 Venue: Londra, UK For more information please contact: Tel: +44 131 4470447 Fax: +44 131 4528596 E-mail: info@structuralfaultsandr epair.com http:// www.geotechnicalseminars. com European Conference on Steel and Composite Structures Research Euro Codes - Practice Date : 0810 July 2005 Venue: Maastricht, Holland For more information please contact: Tel: +32 4 36 69 297 Fax: +32 4 36 69 192 E-mail: secretariat@eurosteel200 5.info http:// www.eurosteel2005.info/ information.html 1st International Conference o Advances in Experimental
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Structural Engineering Date : 1921 July 2005 Venue: Japan For more information please contact: Tel: +81 52 6837711 Fax: +81 52 6837777 E-mail: ncc@ncvb.or.jp http:// www.ncvb.or.jp/ncc_e/ 3rd International Conference on Construction Materials: Performance, Innovations, and Structural Implications Date : 2224 August 2005 Venue: Vancouver, Canada For more information please contact: Tel: +1 604 822 5984 Fax: +1 604 822 6901 E-mail: conmat05@civil.ubc.ca http:// www.civil.ubc.ca/conmat05 27th Peruvian Mining Convention - EXTEMIN 2005 Date : 1216 September 2005 Venue: Peru For more information please contact: Peruvian Institute of Mining Engineers Tel: +51349 4262 Fax: +51349 3721 E-mail: convencion@conv-min. com http:// www.conv-min.com IABSE Symposium "Structures and Extreme Events" Date : 1416 September 2005 Venue: Lisbon, Portugal For more information please contact: Tel: +351 21 844 3260 Fax: +351 21 844 3025 Email: labse.lisbon2005@lnec.pt http:// www.iabse.org/lisbon 3rd International Structural Engineering and Construction Conference Date : 2023 September 2005
Venue: Shunan, Japan For more information please contact: E-mail: t-hara@tokuyama.ac.jp http:// www.tokuyama.ac.jp/tcss1/ ISEC_03 Filtech 2005 / International Conference & Exhibition for Filtration and Separation Technology Date : 1113 October 2005 Venue: Wiesbaden, Germany For more information please contact: http:// www.filtechEuropa.com TREMTI 2005 / Treatment and Recycling of Materials for Transport Infrastructure Date : 2426 October 2005 Venue: Paris, France For more information please contact: Fax: +33 1 45 75 53 25 E-mail: tremti2005@clubinternet.fr http:// www.tremit.org UNITECR 2005 Date : 0811 November 2005 Venue: Florida, USA For more information please contact: http:// www.unitecr.org The 2nd FIB Congress 2006 Date : 0508 June 2006 Venue: Naples, Italy For more information please contact: E-mail: fib2006@unina.it Webmail: www.naples2006.com 16. ibausil Date : 2023 September 2006 Venue: Weimar, Germany For more information please contact: http:// www.ibausil.de

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CEMENT & BUILDING MATERIALS REVIEW

Issued by : ARAB UNION FOR CEMENT & BUILDING MATERIALS

No. 18 - December 2004

Eng. AHMAD AL-ROUSAN

Arab News International News New Products and Media Articles:

Articles are not to be returned to authors.

Eng. Ahmad Al-Rousan

AUCBM MEMBER COMPANIES

Eastern Province Cement Company Saudi Arabia

ARAB CEMENT MARKETS

No. 18 DECEMBER 2004

ARAB CEMENT PRODUCTION:

ARAB COMPANIES RESULTS

CEMENT PRICES (2004)

CEMENT & BUILDING MATERIALS REVIEW

No. 18 DECEMBER 2004

CEMENT & BUILDING MATERIALS REVIEW

No. 18 DECEMBER 2004

Internatioal News HAZEMAG Compound Crusher for Qatar Cement Company

New orders in Iran

5-stage preheater with PYROCLON-R calciner,

No. 18 DECEMBER 2004

PYRO-JET kiln burner and burners for calciners,

ball mill in closed circuit mode, diameter 4.4m x

efficiency dynamic SKS-separator, type SEPMASTER.

Automation systems: ROMIX quality control system system.

PRODUX-PLUS process control and monitoring

Wietersdorfer & Peggauer Zementwerke GmbH

CEMENT & BUILDING MATERIALS REVIEW

No. 18 DECEMBER 2004

No. 18 DECEMBER 2004

Gebr. Pfeiffer AG to supply lime hydrating plant to Belarus

Gebr. Pfeiffer AG to supply another mill to China

CEMENT & BUILDING MATERIALS REVIEW

CLEVELAND CASCADE CHUTE PORT OF LONG BEACH

No. 18 DECEMBER 2004

CEMENT & BUILDING MATERIALS REVIEW

No. 18 DECEMBER 2004

CEMENT & BUILDING MATERIALS REVIEW

No. 18 DECEMBER 2004

Equilibrium pressure , atm.

temperature , oC Fig. ( 1 ) Equilibrium pressure of Co2 against temperature

2- Calcination degree of lime , effect of temperature and time:

CEMENT & BUILDING MATERIALS REVIEW

heat flow in 10^3 kcal/m^2.h

3- Mechanism of calcination of limestone particle in surrounding hot gases flow:

4- Lime Shaft Kilns:

No. 18 DECEMBER 2004

Fig. ( 5 ) Flow pattern in the regenerative co-current/ counter current kiln

CEMENT & BUILDING MATERIALS REVIEW

4-4 Modern multiple chamber lime shaft kiln :

2. Intergrowth of gypsum crystallites

yet been determined. Also still unknown are the

CEMENT & BUILDING MATERIALS REVIEW

3. Gypsum hardening experiments

4. Texture and strength of the gypsum specimens

CEMENT & BUILDING MATERIALS REVIEW

No. 18 DECEMBER 2004

CEMENT & BUILDING MATERIALS REVIEW

states, which are, however, incomplete. No systematic pattern is discernable.

CEMENT & BUILDING MATERIALS REVIEW

No. 18 DECEMBER 2004