INTRODUCTION PROCESS DESCRIPTION PROCESS FLOW SHEET MATERIAL BALANCE ENERGY BALANCE DESIGN OF EQUIPMENT COST ESTIMATION CONCLUSION

An insight into the world of concrete

Concrete is a mixture of portland cement, water, aggregates, and in some cases, admixtures. The cement and water form a paste that hardens and bonds the aggregates together. Concrete is often looked upon as man made rock. Concrete is a versatile construction material, adaptable to a wide variety of architectural and residential uses. It is the most used man- made material in the world.

CEMENT: Mainly Portland Cement is used to make reinforced concrete. Portland Cement is a mixture of two- thirds mass of calcium silicates and the remainder of aluminium and iron containing clinker phases. Purpose of cement is to act as binder. The type of cement used can also influence the uses of concrete: Blended Portland Cement is used for slabs and roads

AGGREGATES occupy three- quarters of the volume of concrete. Sand, natural gravel and crushed stones. CHEMICAL ADMIXTURES are powders or fluids which can be used as accelerators, retarders, plasticizers, pigments, etc GENERAL ADMIXTURES and BLENDED CEMENTS are other components REINFORCERS

Hydration Fineness Soundness Setting Time Strength Heat of Hydration

Workability Consistence Modulus of Elasticity Expansion and Shrinkage Low thermal conductivity Creep

Calcareous: Limestone Cement Rock Oyster shell

Argillaceous Clay Shale Staurolite Bauxite Aluminium dross Volcanic material

Ferrous: Iron ore Pyrites Mill scale Iron bearing material

Others: Gypsum Anhydrite Blast furnace Slag Fly ash

Aggregates: Unconsolidated rock Solid rock Recycled material

Siliceous: Sand Sandstone and quartz

An account of the method by which concrete is produced

CEMENT: Dry process is preferred over the wet process. It involves:

Quarrying: The raw material for cement is quarrierd and stored Raw material preparation: Clay and limestone are crushed and fed to a mill where the rock is ground Clinkering: The ground material is dried, heated and then cooled down again Cement milling: Gypsum is added and the cement is ground twice depending upon the specifications

CONCRETE: To the prepared cement, aggregates are added These can be unconsolidated rock, loose rock, recycled materials The rock is then extracted Crushing, grinding, screening of the aggregates followed by mixing with cement

The process flow diagram

Process equipment design

Steps followed:

Calculate capacity (Q= *d2*u*3600/(4*V*1000) In this equation only V and d are unknown. Through the equations occurring in the klin, and applying the principles of stoichiometry, we can know volume of gas per kg clinker. Adjust to kiln conditions. Thus d is got. d= 3.62 m Outer diameter D= d + 2t; D= 4.02 m L/D = 15 L= 60.3 m t = 11.2 * L/ (* D* s), all values known, t=18.6 min % loading = 1.5 *w* t *s/ (L * A), all values known, % loading 13.03% P= * L* (D/2)2/ 4.7, P= 162.4 kW

Qloss for flue gas= Qgain for water = mCpT Getting the values of Cp of gas in kcal/m3, and as the other values are known, Qloss =1.9 * 107 kcal/ hr Qgain includes phase change and latent heat, so mass of water to be sprayed is 31.28m3/hr. Using ideal gas law, the volume of gas and vapour leaving the tower at 423 K is 450817.5 m3/ hr Cross sectional area of tower= Volumetric flow rate/ velocity. Using the cross sectional area, we get the diameter as 7.5 m. H/D = 3.8; H = 28.50 m Residence time = ht of tower/ velocity of gas = 5.7 t= * Dp2* * (W2- W1)/ (12* K* T) As all values are known, t = 13.43 sec

The diameter of cyclone is calculated by, Area = volumetric flow rate/velocity , Dc = 7.4m The dimensions of the cyclone separator is calculated by
Dc= collector of hoper diameter= 7.4 m Jc= exit diameter of dust leaving (down)= Dc/4= 1.85m Lc= height of cylindrical section= 2Dc= 14.8 m Zc= height of the conical section= 2Dc= 14.8 m Hc= inlet gas pipe diameter= Dc/2= 3.7 m De= inlet gas pipe diameter (up)= Dc/2= 3.7 m Bc= inlet width= Dc/2= 3.7 m

The pressure drop is calculated by using the empirical formula,

P= g2/ (203)* {u12*2(1+ 2()2(2*rt/re/re- 1) + 2(u22)} And has been found out as P = 13.1 Efficiency of the cyclone separator is 97%

An estimation of the total expenses involved in the running of the plant

Fixed Costs: - Cost of Land for establishment - Plant & Machinery cost (Batching plant, transit mixers, concrete pumps, etc) - Operation cost (Drivers, operators, mechanics) - Salaries & Benefits of Employees Variable Costs: The variable costs shall include the following Cost of Basic Materials (Cement, Aggregates, etc) POL Cost of Plant & Machinery Labour charges towards pumping of concrete

ESTIMATION OF CAPITAL COST

Item Land and site development Building and structures Plant and machinery Miscellaneous fixed assets Preliminary and capital issue expenses Pre-operative expenses Provision for contingencies Margin money for working capital Total capital cost Total Cost (*50000 Rs) 7.67 134.83 306.67 15.00 0.67 57.33 20.00 19.53 561.70

Capital = 8.58 crores Operating Profit = 1.59 crores Payback period = Net investment / Gross Profit = 2.923

A look at the potential plant layout and detail

Manuals and other official documentation of Larson and Tubro Limited Manuals and other official documentation of Technip Pvt Limited Robert H Perry and Don Green- Perrys Chemical Engineers Handbook, 7th edition, McGraw Hill 1996 C E Dryden- Outlines of Chemical Technology, West Press Pvt ltd 1965 George T Austin- Shreves Chemical Process Industries Edition, McGraw Hill, 1985 F M Lea- The Chemistry of Cement and Concrete, 3rd edition, Edward Arnold Ltd 1970 http://www.colorado.edu/che/HrenyaGroup/Education/TextFiles/ProcessControlS yllabus.pdf http://www.scribd.com/doc/6460063/Hopper-Design M I Gopala Rao and Marshall Sittig- Outlines of Chemical Technology, Second edition, Affiliated East- West Press Pvt Ltd, 1965 Brownwell and Young- Process Equipment Aid Design, John Wiley and sons, 1959 Coulson and Richardson- Chemical engineering, Pergamont Press Ltd, Oxford, 1964 Francis A J- The Cement Industry- A history- 1977 A M Neville- Manufacture of Concrete- 6th Edition