CONTENT

1. PREFACE
2. INTRODUCTION
3. COMPANY PROFILE
4. ABOUT THE PROJECT
5. PPC GRINDING
6. PHYSICAL TESTING OF CEMENT
7. USES OF CEMENT
8. LIMITATION
9. SUGGESTION
10. CONCLUSION
11. BIBLIOGRAPHY
12. QUESTIONNAIRE

PREFACE
I was highly obligated to the present with the golden opportunity of working with PRISM
CEMENT. A company having huge infrastructure and networking with the lounch of prism
cement brand, it has added a new weapon to its army.

Page 1 of 67

My project titled QUALITY CONTROL OF PRISM CEMENT was undertaken for a

period of 6 weeks.
In the first chapter titled COMPANY PROFILE, & quality control has been dealt in the
next chapter, Comparative analysis by analyzing various ratios has been done on the basis of
Balance Sheets.
Although the project was completed and completed using limited resources, I would be
highly obligated if this proves beneficial to your

INTRODUCTION

Page 2 of 67

Quality control in the Cement industry forms an important aspect of the production
process, because of the complexity of the process involved and the necessity
of their lending themselves to proper clinker formation. Combinations of tools
and techniques work together in the quality control process within the
industry, and both physical inspection and automated quality control
methodologies can have a place in the quality control done on the production
of Cement.

Page 3 of 67

"Total quality control", also called total quality management, is an approach that
extends beyond ordinary statistical quality control techniques and quality
improvement methods. It implies a complete overview and re-evaluation of
the specification of a product, rather than just considering a more limited set
of changeable features within an existing product. If the original specification
does not reflect the correct quality requirements, quality cannot be inspected
or manufactured into the product. For instance, the design of a pressure vessel
should include not only the material and dimensions, but also operating,
environmental, safety, reliability and maintainability requirements, and
documentation of findings about these requirements. Total Quality
Management (TQM) refers to management methods used to enhance quality
and productivity in business organizations. TQM is a comprehensive
management approach that works horizontally across an organization,
involving all departments and employees and extending backward and
forward to include both suppliers and clients/customers. TQM is only one of
many acronyms used to label management systems that focus on quality.
Other acronyms include CQI (continuous quality improvement), SQC
(statistical quality control), QFD (quality function deployment), QIDW
(quality in daily work), TQC (total quality control), etc. Like many of these
other systems, TQM provides a framework for implementing effective quality

Page 4 of 67

and productivity initiatives that can increase the profitability and

competitiveness of organizations

QUALITY CONTROL IN CEMENT

PRODUCTION
Quality Control
Efficiency quality control is error prevention rather than error detection.
Online reaction to special cause of variation will lead to progressive
improvement in the process, performance and cost. Fundamental

Page 5 of 67

improvement in quality results from testing rational prediction about

special process using statistical method. The effective pursuit of quality
permanent commitment through out an organization.

Pitfall of quality control

Pitfall of the successful implantation of the permanent
improvement culture are:1.
2.
3.
4.
5.

quality

Lack of top management support.

Lack of middle management support.
Commitment to only department.
Haphazard approach a little of this and that with no meaning
change in the system.
Measurement of success and guidance program on the basis of
short-term profile.

Cement :Cement is a word given to a powder material which initially has plastic
flow when mixed with water but has the property of setting hard solid
structure in the several hours with varying degree of strength and
bonding properties.
Natural is a mixture of burnt silicate and lime. It was discovered by
Joseph Aspdin an English brick layer in 1924. This Cement is called
Portland Cement and now a day prepared artificially.

Page 6 of 67

Properties of Cement
It gives strength to the masonry.
It is an excellent binding material.
It is easily workable.
It harden early.

Types of Cement
A.

Ordinary Portland Cement (OPC)

It is of 3 types

1. 33G
2. 43G
3. 53G
B.

Pozzolana Portland Cement (PPC)

COMPANY PROFILE

Page 7 of 67

Introduction:
Prism Cement Limited is an ISO 9001:2000 certified professionally managed
company promoted by the Rajan Raheja Group. The company operates one of the
largest single kiln cement plants in the country at Satna, Madhya Pradesh. The
company also has a packing unit at Allahabad, Uttar Pradesh. Equipped with
machinery and technical support from world leaders, F. L. Smidth & Co. A/S,
Denmark, Prism has created a niche for itself in the cement industry.
The company primarily caters to the demand in the Northem Region, mainly in the
States of Uttar Pradesh, Bihar and Madhya Pradesh. The Companys plan for a
five-fold increase in cement capacity from 2 MTPA to 10.0 MTPA by 2011 through
Brownfield and Greenfield expansion is making steady headway. These expansions
will establish the companys brand in the new markets and a larger customer base.
Page 8 of 67

A team of experienced engineers and dedicated workforce combined with a high

level of automation and sophisticated control systems have placed the Companys
products in the premium segments.
PRISM has successfully established a high brand performance among its
customers through its excellent quality products and transparent policies. PRISM
has truly taken cement production to global standards. PRISM is one of the most
advanced concerns in the world indulged in manufacturing ordinary Portland
cement of every grade e.g.53, 43 and 33 and pozzolana Portland cement.
Initially, this company was incorporated under the name of RASI cement by
DR.B.V. RAI, then it was took by RAJAN RAHEJA and the name of the company
was changed to karan cement ,afterwards the name was again changed to prism
cement ltd. Presently, the company is jointly promoted by Rajan Raheja group of
Mumbai, f. l .smith &company A/S, Denmark (FLS and industrilization fund for
developing countries, Denmark (IFU).
This plant is started its production from june1,1997 in village Mankahari, near
Satna in M.P. with 2million tons per year , which can be translated in term s of 50
million bags of ordinary / pozolana Portland cement. Raw material assessment and
finalization of the plant technical design has been carried out with the support of
FLS and also the main equipment from the lime stone crusher to the electronic
packers were supplied by FLS. With an objective of being an active participant in
the dynamics of the nation march towards total industrialization prism cement
limited has set up a state-the-art cement plant near satna in Madhya Pradesh.

Page 9 of 67

The 2.51 million ton capacity ultra modern cement plant of prism is one of the
most advanced cement producers in the world with machinery and technology
imported from the world leaders, and state of art processes that lend it a futurist
environment. The company has set up a packing unit at Allahabad to cater to the
requirement of customer in eastern/central U.P.

The company is jointly promoted by RAJAN RAHEJA GROUP of Mumbai

F.L.SMITH and CO. A/S Denmark (FLS), world leaders in cement technology and
industrization fund for developing countries DENMARK (IFU). A team of
experienced engineers and a dedicated workforce, rich deposited of high quality
limestone, a high level of automation and sophisticated quality control system with
unbeatable facilities prism cement production to global standards. Prism
achievements have been made possible by our people people with vision, united
by shared values and there commitment to excellence in the world of contraction.
No wonder, on quality, strength and consistency, Prism cement is a world part.

GLOBAL SCENARIO:Cement is one of the key infrastructure industries. Price and distribution controls
were lifted on the 1st march 1989 and licensing was dispensed with since 25th July
1991. However, the performance of the industry and prices of cement are
monitored on a regular basis. The industry is subject to quality control order issued
on 17.02.2003 to ensure quality standards.

Page 10 of 67

OVERVIEW OF THE PERFORMANCE OF THE CEMENT SECTOR:

The Indian cement industry not only ranks second in the production of cement in
the world but also produces quality cement, which meets global standards.
However, the industry faces a number of constraints in terms of high cost of power,
high railway tariff, high incidence of state and central levies and duties, lack of
private and public investment in infrastructure project, poor quality coal and
inadequate growth of related infrastructure like sea and rail transport , ports and
bulk terminals .In order to utilize excess capacity available with the cement
industry , the government has identified the following thrust areas for increasing
demand for cement :

(i)

Housing development programmers;

(ii)

Promotion of concrete highways and roads;

(iii) Use of ready-mix concrete in large infrastructure projects

(iv) Construction of roads in rural areas under prism ministers Gram Sadak
Yojana.
INDIAN SCENARIO OF CEMENT INDUSTRY:
Indian cement industry is modern and uses latest technology. Only a small segment
of industry is using old technology based on wet and semidry process. Efforts are
being made to recover waste heat and success in this area has been significant.

Page 11 of 67

WHAT IS CEMENT AND HOW IS IT MADE?

Cement is a soft powdery-type substance. It is made from a mixture
of element found in nature material such a limestone, clay and/or shale when
cement mix with water it can bind sand and gravel into a hard solid mass
called concrete.

Page 12 of 67

Four essential elements are needed to make cement they are silicon,
aluminum, iron, and calcium (which is the main ingredient) can be obtained
from limestone, sand/clay.
For making cement mainly four Raw materials are required:1)

Limestone

2)

Gypsum

3)

Laterite / Blue Dust

4)

Fly Ash

Limestone is obtained by blasting in mines. In mines there are several layers

of soil, hard rocks, etc. After 5-6 Layers Company gets limestone in the form
of big rocks. By blasting these big rocks of limestone be get limestone in
smaller form which are easier to transport. Now through conveyer belt these
limestone are moved to plant. These limestone breaks up into smallest part by
grinder. Now

This grinded lime stone transfer to kiln. The temperature of kiln approximately
1400C. In kiln limestone and other raw materials like Gypsum, Laterite and Fly
Ash were mixed with each other. The high temperature of kiln melts all the raw
materials. After kiln all these materials take a round shape which is generally
known as Clinker. Clinker is a semi-finished product of company. After
grinding these clinkers we get final cement which is used for domestic as well as
construction purpose.
Cement product is very fine one kilo (2.2ibs) contains over 300 billion gram we havent
actually counted them to see if that is completely accurate the powder will pass through a
slave capable of holding water.

Page 13 of 67

Applications:Suitable for all types of construction like building, roads,

bridges, culverts and

cement base products.

Mass concrete work like dam, machine foundation work.

Concrete works in environment involving chemicals in soil and water.

Sewage and effluent treatment plant.

All kinds of marine works, like jetty etc.

Suitable for all construction ensuring higher durability.

TYPES OF CEMENT:Prism cement ltd manufactured two types of cement1.

PPC

2.

OPC

PPC (Portland Pozzolona Cement) with the brand name Champion is general-purpose
cement popular for all applications during house construction by individuals. It is finely
ground blend of high quality clinker and carefully selected high quality Pozzolona material
(Fly Ash) with high fineness an optimum range of chemical composition.
OPC (Ordinary Portland cement) is made in three grades i.e. 33 Grade, 43 Grade, and
53 Grade cement. Prism Cements OPC is in demand for specialized cement concrete
applications like high-rise buildings, bridges, manufacturing AC sheets, pipes, poles etc.
43 Grades:Features:

Achieve more than the specified strength as per the relevant IS code

through proper adjustment in the chemical composition.

High quality limestone deposit result in:

Page 14 of 67

Higher strength of cement.

Moderate sulphate resisting properties.

Lower level of chloride concentration

Efficient quality control and high level of process parameter results in reduced free
lime, low insoluble residue and loss on ignition
Applications:Optimally higher strength of cement makes it suitable for:
All General and semi specialized construction works like plain and
reinforced cement concrete works, brick and stone masonry, plastering and
flooring.
Manufacturing of concrete pipes, blocks, tiles and poles.
Suitable for applications like pre-cast, pre stressed and slip form construction
work.
Also suitable for all types of specialized concrete repair works like gunniting
etc.
Grade 53:Features:

Higher strength than 43 Grade is achieved through further improvement in

the raw meal chemical composition and also grinding finer than 43 Grade cement.

High quality limestone deposit result in

Higher strength of cement.

Moderate sulphate resisting properties.

Lower level of chloride concentration.

Page 15 of 67

Efficient quality control and high level of process parameter results in

reduced free lime, low insoluble residue and loss on ignition.

Optimally higher fineness results in early strength improvement.

Closed circuit cement grinding system using high efficiency separator

controls the particle size distribution resulting proper hydration character.

Applications:

High strength of cement makes it suitable for:

Making high grade concrete with proper mix design.

Early form works removal due to high early strength development result in

quicker construction.
Optimally higher fineness gives better cohesiveness, improved workability
resulting denser concrete and superior surface finish.
Economical usage of cement due to high strength through proper concrete
mix design.
All type of plain and R.C.C., semi and specialized construction work, like
bridges, culverts, slip form work, pre-stressed pipe / poles etc.
Also suitable for all types of specialized concrete repair work like gunniting
etc.

REVIEW OF LITERATURE
Page 16 of 67

Financial ratios are important to analysts due to conquer the little meaning of
typically numbers. Thus, ratios are intended to provide meaningful relationship
between individual values in the financial statement (Reilly, Brown, 2006).
Because the major financial statement report numerous individual items, it is
possible to produce a vast number of potential ratios, many which will have little
value.
A single number from a financial statement is of little use, an individual
financial ratio has a little value except in relation to comparable ratios for other
entities. That is, only relative financial ratios are relevant. A firms performance
relative can be compared by the aggregate economy; or by its industries; or by its
past performance (Reilly, Brown, 2006).

Page 17 of 67

COMPANY VISION & MISSION

Page 18 of 67

VISION:- To be acknowledged as a leading player in the industry with the highest

level of integrity.

MISSION: State of the art cement plants

Transparent dealings with all stakeholders.
Committed to the principles of good corporate governance.

Page 19 of 67

Page 20 of 67

LIST OF BOARD OF DIRECTORS:-

Chairman

Mr. Rajesh Kapadia

Non-executive Directors

Mr. Rajan Raheja

Mr. Satish Raheja
Mr. S.Ramnath
Mr. James Arthur Brooks
Ms. Ameeta A. Parpia

Managing Directors

Mr. Manoj Chhabra

Mr. Vijay Aggarwal

Executive Director

Mr. Ganesh Kaskar

Page 21 of 67

Page 22 of 67

PRISM CHAMPION CEMENT is a finally ground blend of high quality clinker

and carefully selected high quality pozzolonic material (Fly ash) with high fineness
and optimum range of chemical composition.
Carefully selection of pozzolona is one of the crucial factor for the superiority of
PRISM CHAMPION CEMENT.
The other crucial factors are: Optimum dosage of pozzolona to ensure high level of 28 days strength.
Balancing the fineness and the reactivity of pozzolona to ensure proper
hydration character, thus ensuring sustained strength gain over long period
without sacrificing on the early age strength.
Low heat of hydration helps in prevention of cracks ensuring durability of
structure.
Also ensure durability of structure even in adverse environment condition.

QUALITY POLICY & CERTIFICATION

Quality Policy:National Accreditation Board for testing and Celebration Laboratories has
granted accreditation to our laboratory in accordance with ISO/IES 17025:2005 for
the chemical & mechanical testing.
We are committed to strive foe customer satisfaction by supplying consistent
quality cement and clinker as per mutually agreed product specifications.

Page 23 of 67

This shall achieve by:

Continual improvement in productivity levels and quality management
system
Enhancing employees skills.
Focusing on customers needs and creating awareness regarding proper use
of cement.
ENVIRONMENT CONSIDERATIONS
The Company is committed to mitigate potential environmental impacts associated
with cement plants. The Pyro processing and pollution control systems for Raw
Mills and all kiln, Cooler, Cement Mills and all Transfer points are designed to
meet the stringent requirements for Dust and NOx Emission. Green belt
development through large scale plantation of trees in and around the plant and
residential areas.
Social Welfare:A well established township provides facilities like School, Hospital,
Banks, Post and Telegraph office and Recreational facilities for employees and
their families.
Human Welfare:Company considers its human resources as one of its most
important assets. At every stage, concept of ownership is instilled in them to
ensure full commitment and dedications. Training of personnel is an integral part of
the Companys operation. Right from level of worker

Page 24 of 67

Health & Safety Policy:The Health & safety of our people is the prime concern of the Company. Our
commitment to create & maintain safe & healthy work environment against
hazards and risks shall be achieved by:

Continuously developing & maintaining safe work practices

Focusing on operational & occupational hazards & risks

Creating awareness about preventive health

Page 25 of 67

OBJECTIVES OF PRISM CEMENT LTD.:The main objective of Prism Cement is to continuously improve the quality
of its products and services in order to meet the customer satisfaction.
COMPETITORS OF PRISM CEMENT LTD:-

In intensive competition Prism Cement Ltd. has many competitors as

JP CEMENT, BIRLA CEMENT SAMRAT (Satna), BIRLA GOLD
(Maihar) CEMENT and ACC CEMENT.
The most competitor of Prism Champion is JPCement.in this
competition scenario Prism Champion is facing competition.
Increase discount structure provided by JP Cement there market
share.
JP Cement Ltd. is increasingly more wide open in the area of
advertisement comparing to Prism Cement.

Page 26 of 67

HEAD OFFICES OF THE COMPANY:Allahabad: 16/1/6-A Tagore Town,

Jawaharlal Nehru Road.
Allahabad -211002 (UP)
Ph. (0532) 2465228, 2467288.
REGIONAL OFFICE:Varanasi: Unit -1, C 19/40, VIP,
Fatiman Road Sigra
Behind the Kashi Gramin Bank
Varanasi 221002
Ph. (0542) 2227427, 2227428.
Kanpur: X-1/170- Krishna puram
Ph. (0512) 2404123, 2400932.
Lucknow : 3/113-Vivek khand
Gomati nagar Lucknow -2260110
Ph. (0552) 2396847, 2397589.
Bareli: C-77/3 in front of Tagore Park
Rajendra Nagar Bareli.
Ph. (0581) 2530089, 2530091.
Satna: Rajdeep Hotal, Near Rewa Road
Satna - 485002
Ph. (07672) 404400, 404403
Jabalpur: 4 HIG Residency Road
South civil line Jabalpur, 482001
Ph. (0761) 26200256, 2326907.

Page 27 of 67

Patna : 302 C- Abhishek Plaza

Exhibition Road Patna, 800001

ABOUT THE PROJECT

TESTING OF RAW MATERIAL

Iron ore
Loss of Ignition (LOI)
Take 1.0 gm of sample in a weighted crucible. Heat it in a constant
weight at 900 to 1000C. Coal weight.
%Loss of ignition = Loss weight x 100

Silica (SiO2)
Take a 0.2 gm of sample in dry beaker and add 400 ml Aquaregia
&digest with slow heat. Evaporate the solution at a low heat to dryness.
Cool it add 15 ml conc. H 2So4 and put the beaker at slow heat for 24
hours for digestion.
After 24 hours add 1:1 HCL 20 ml & just boil it in a 250 ml volumetric
flask. Wash it chloride free the filtrate. Char & ignite the residue in a
weight crucible (400 to 1200 C) treat the ignited residue thus obtained
which contain small amount of impurities with 1 or 2 ml of distilled
water + 10 ml HF and 2 drops of H 2So4 and evaporate to dryness.
Finally treat the small residue at 1050 to 1100 C for minute or two. Cool
in desicater & weight of ignited sample represented the amount of silica.
(keep it).
Silica % = (W1-W2) x 100
Where,
W1 = weight of silica + soluble impurities.
W2 = weight of impurities.
Now add 2.5 gm of sodium and potassium per sulphate to the crucible
heat in the Bunsen burner continuously till the small residue of
Page 28 of 67

impurities is dissolved in the melt. Cool dissolved the fused mass with
1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm
NH4CL and 2 drop of methyl indicator. Then boil and neutralize with
NH4OH (1:1) using drop wise till just yellow. Add on drop excess
NH4OH. Put this ppt. To settle and filter using 41 no. filter paper. Wash
with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite
the residue at 1050 to 1100C. keep the filtrate (A)
R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. volumetric flask. Boil and add few drop
of SnCl4 dropwise till sol. Decolorise. Add few drop of SnCl 4 in excess.
Cool it to room temperature. Rinse the beaker with H 2O add 15 ml of
HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate
with standard KMnO4 (0.05N) till permanent pink color is obtained.
Calculate iron and ferric Oxide.
R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)
Al2O3 : Fe2O3 % =
Weight of iron ore sample
R = Burette reading
N = Normality of KMnO4
AgO3 % = R2O3 Fe2O3

Calcium Oxide
Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of
ammonium oxalate sol. with NH 4OH (1:1) Allow to settle ppt. Filter
Page 29 of 67

using 40 no. filter paper and wash the residue free of oxalate with hot
water. Keep the filtrate feo MgO (B).
In the sample previous beaker take 10 % H 2SO4 100 ml and boil it.
Transfer filter paper with residue in the beaker and stir till the residue is
dissolved.
Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of
the beaker. At the end point pink color is obtained after taking in filter
paper.
R x 100 x 2.5 x N x 0.0285 (CaO Eq)
CaO% =
Weight of iron ore sample
Where,
R
N

= Burette Reading
= Normality of KMnO4

MgO
Acidify the above filtrate (B) (CaO free) with HCl till red color appear.
Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5%
diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch
the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in
excess and keep it 24 hours for settlement. Filter through 42 no. filter
paper and wash the ppt with NH4OH (1:1) and finally wash with cold
distilled water.
Take it in the crucible. Slowly char the paper and carefully burn the
resulting carbon. Ignite it at 1100C to 1200C calculate the ppt as MgO.
MgO % = W x 72.4
Where,
W
72.4

= gm of residue Mg2P2O7
= Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Page 30 of 67

Gypsum
Loss of ignition (LOI)
Take 1.0 gm of sample in a weighted crucible. Heat it in a constant
weight at 900 to 1000C. Coal weight.
%Loss of ignition = Loss weight x 100

Insoluble Residue (IR)

Take 1gm sample in a beaker add 50 ml water and stir it now add 5 ml
HCL and stir. Crush the lump with flattened end of the glass rod. Boil it
for 2 min. . Now filter it with whatman filter paper no. 40 wash the
residue with hot distilled water. Keep the filtrate for SO3 (A).
Residue is washed again with hot distilled water. Take out the filter
paper with 30 ml. Hot distill water and 30 ml 2N Na 2CO3 . For 15 min.
at temperature just below boiling point filter it b through whatman filter
paper no. 40. After transferring the sol. Treat the residue with 10 ml
(1:1) HCl and transfer the whole in previous filter paper.
Wash it with hot distilled water till it is chloride free. Take the filter
paper with residue in weighted crucible. Dry char and ignite at 100 C to
1100C for one hour. Cool and weight.
% of I.R. = Weight of residue x 100

Sulphuric Anhydride
Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5ml
conc. HCl and stir . crush the lump with flattened end of glass rod. Boil
it for 2 min. now filtered through whatman filter paper no. 40. wash the
residue with hot distilled water.
Page 31 of 67

Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for
another 1 min. digest it for 4-5 hours at 60 C. Now filter it with
whatman filter paper no. 40 wash the residue with hot distilled water.
Take the filter paper in weighted crucible.
Dry and ignite at 900-1000C. Cool in desicator and weight.
%SO3 = Wt. Of BaSO4 x 0.343 x 100
Where,
Molecular ratio of SO3 to BaSO4 = 0.343
CaSO4.2H2O = SO3 % x 2.15

Silica (SiO2)
Take a 0.2 gm of sample in dry beaker and add 400 ml Aquaregia
&digest with slow heat. Evaporate the solution at a low heat to dryness.
Cool it add 15 ml conc. H 2So4 and put the beaker at slow heat for 24
hours for digestion.
After 24 hours add 1:1 HCL 20 ml & just boil it in a 250 ml volumetric
flask. Wash it chloride free the filtrate. Char & ignite the residue in a
weight crucible (400 to 1200 C) treat the ignited residue thus obtained
which contain small amount of impurities with 1 or 2 ml of distilled
water + 10 ml HF and 2 drops of H 2So4 and evaporate to dryness.
Finally treat the small residue at 1050 to 1100 C for minute or two. Cool
in desicater & weight of ignited sample represented the amount of silica.
(keep it).
Silica % = (W1-W2) x 100
Where,
W1 = weight of silica + insoluble impurities.
W2 = weight of impurities.
Now add 2.5 gm of sodium and potassium per sulphate to the crucible
heat in the Bunsen burner continuously till the small residue of
Page 32 of 67

impurities is dissolved in the melt. Cool dissolved the fused mass with
1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm
NH4CL and 2 drop of methyl indicator. Then boil and neutralize with
NH4OH (1:1) using drop wise till just yellow. Add on drop excess
NH4OH. Put this ppt. To settle and filter using 41 no. filter paper. Wash
with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite
the residue at 1050 to 1100C. keep the filtrate (A)
R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop
of SnCl4 dropwise till sol. Decolorise. Add few drop of SnCl 4 in excess.
Cool it to room temperature. Rinse the beaker with H 2O add 15 ml of
HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate
with standard KMnO4 (0.05N) till permanent pink color is obtained.
Calculate iron and ferric Oxide.
R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)
Fe2O3 % =
Weight of iron ore sample
R = Burette reading
N = Normality of KMnO4
Alumina % = Al2O3 Fe2O3

Calcium Oxide
Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of
ammonium oxalate sol. with NH 4OH (1:1) Allow to settle ppt. Filter
Page 33 of 67

using 40 no. filter paper and wash the residue free of oxalate with hot
water. Keep the filtrate for MgO (B).
In the sample previous beaker take 10 % H 2SO4 100 ml and boil it.
Transfer filter paper with residue in the beaker and stir till the residue is
dissolved.
Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of
the beaker. At the end point pink color is obtained after taking in filter
paper.
R x 100 x 2.5 x N x 0.0285 (CaO Eq)
CaO% =
Weight of iron ore sample
Where,
R = Burette Reading
N = Normality of KMnO4 (0.12N)

MgO
Acidify the above filtrate (B) (CaO free) with HCl till red color appear.
Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5%
diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch
the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in
excess and keep it 24 hours for settlement. Filter through 42 no. filter
paper and wash the ppt with NH4OH (1:1) and finally wash with cold
distilled water.
Take it in the crucible. Slowly char the paper and carefully burn the
resulting carbon. Ignite it at 1100C to 1200C calculate the ppt as MgO.
MgO % = W x 72.4
Where,
W = gm of residue Mg2P2O7
72.4 = Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Page 34 of 67

Flyash
Loss of ignition (LOI)
Take 1.0 gm of sample in a weighted crucible. Heat it in a constant
weight at 900 to 1000C. Coal weight.
% Loss of ignition = Loss weight x 100

Sulphuric Anhydride
Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5ml
conc. HCl and stir . crush the lump with flattened end of glass rod. Boil
it for 2 min. now filtered through whatman filter paper no. 40. wash the
residue with hot distilled water.
Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for
another 1 min. digest it for 4-5 hours at 60 C. Now filter it with
whatman filter paper no. 40 wash the residue with hot distilled water.
Take the filter paper in weighted crucible.
Dry and ignite at 900-1000C. cool in desicator and weight.
%SO3 = Wt. Of BaSO4 x 0.343 x 100
Where,
Molecular ratio of SO3 to BaSO4 = 0.343

Silica (SiO2)
Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion
mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the
platinum crusible with led in a furnace for 1 hours at 1100 C. Cool it
and extract with HCl (1:1) and transfer all material in 500 ml beaker.
Add 2 to 3 drop of conc. HNO 3 with constant stirring. Digest at a slow
hear and agitate until the sample is completely dissolved. Evaporate the
sol. At a low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml
distilled water.
Page 35 of 67

Treat the ignited residue thus obtained which contain small amount of
impurities, with 1 or 2 ml of distill water + 10 ml of HF and 2 drops of
H2SO4 and evaporate to dryness. Finally heat the small residue at 1050
to 1100C for a min. Cool in desicater & weight of ignited sample
represented the amount of silica.
Silica % = (W1-W2) x 100
Where,
W1 = Weight of silica + insoluble impurities.
W2 = Weight of impurities.
Now add 2.5 gm of sodium and potassium per sulphate to the crucible
heat in the Bunsen burner continuously till the small residue of
impurities is dissolved in the melt. Cool dissolved the fused mass with
1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm
NH4CL and 2 drop of methyl indicator. Then boil and neutralize with
NH4OH (1:1) using drop wise till just yellow. Add on drop excess
NH4OH. Put this ppt. To settle and filter using 41 no. filter paper. Wash
with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite
the residue at 1050 to 1100C. keep the filtrate (A)
R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop
of SnCl4 dropwise till sol. Decolorise. Add few drop of SnCl 4 in excess.
Cool it to room temperature. Rinse the beaker with H 2O add 15 ml of
HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate
with standard KMnO4 (0.05N) till permanent pink color is obtained.
Calculate iron and ferric Oxide.
Page 36 of 67

R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)

Fe2O3 % =
Weight of iron ore sample
R
N

= Burette reading
= Normality of KMnO4
Alumina % = R2O3 Fe2O4

Calcium Oxide (CaO)

Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of
ammonium oxalate sol. with NH 4OH (1:1) Allow to settle ppt. Filter
using 40 no. filter paper and wash the residue free of oxalate with hot
water. Keep the filtrate for MgO (B).
In the sample previous beaker take 10 % H 2SO4 100 ml and boil it.
Transfer filter paper with residue in the beaker and stir till the residue is
dissolved.
Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of
the beaker. At the end point pink color is obtained after taking in filter
paper.
R x 100 x 2.5 x N x 0.0285 (CaO Eq)
CaO % =
Weight of iron ore sample
Where,
R
= Burette Reading
N
= Normality of KMnO4 (0.12N)

MgO

Page 37 of 67

Acidify the above filtrate (B) (CaO free) with HCl till red color appear.
Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5%
diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch
the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in
excess and keep it 24 hours for settlement. Filter through 42 no. filter
paper and wash the ppt with NH4OH (1:1) and finally wash with cold
distilled water.
Take it in the crucible. Slowly char the paper and carefully burn the
resulting carbon. Ignite it at 1100C to 1200C calculate the ppt as MgO.
MgO % = W x 72.4
Where,
W
72.4

= gm of residue Mg2P2O7
= Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Alkali
Take 0.5 gm sample in a platinum crucible moisture with H 2O and add
100 ml HF. Evaporate to dryness. After dryness add 1 ml HNO 3 and 10
ml per chloride acid (HClO 3) & 50 ml water & transfer all material to
250 ml beaker. Boil it and transfer all sol. In 250 ml measuring flask.
Add 10 ml cesium sol. Make up vol. upto a mark and stir well.

Potassium Oxide (K2O)

Take 20 ml sol. From 250 ml measuring flask and transfer the solution
in a 100 measuring flask. Make up the volume upto the mark by distilled
water and see the reading for K2O by flame photometer.

Page 38 of 67

Sodium Oxide (Na2O)

In another case 50 ml solution from 250 ml flask and transfer the
solution to 100 ml measuring flask. Make up the volume upto the mark
by distilled water and see the reading for Na2O by flame photometer.
z x 250 x 100
{a}. Na2O % =

z
=

10 x 50 x 0.5 x 1000

10

y x 250 x 100

{b}. K2O % =

=
10 x 20 x 0.5 x 1000

10

LIMESTONE

Loss of ignition (LOI)

Take 1.0 gm of sample in a weighted crucible. Heat it in a constant
weight at 900 to 1000C. Coal weight.
%Loss of ignition = Loss weight x 100

Sulphuric Anhydride
Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5ml
conc. HCl and stir . crush the lump with flattened end of glass rod. Boil
it for 2 min. now filtered through whatman filter paper no. 40. wash the
residue with hot distilled water.

Page 39 of 67

Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for
another 1 min. digest it for 4-5 hours at 60 C. Now filter it with
whatman filter paper no. 40 wash the residue with hot distilled water.
Take the filter paper in weighted crucible.
Dry and ignite at 900-1000C. cool in desicator and weight.
%SO3 = Wt. Of BaSO4 x 0.343 x 100
Where,
Molecular ratio of SO3 to BaSO4 = 0.343

Silica (SiO2)
Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion
mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the
platinum crucible with led in a furnace for 1 hours at 1100 C. Cool it
and extract with HCl (1:1) and transfer all material in 500 ml beaker.
Add 2 to 3 drop of conc. HNO 3 with constant stirring. Digest at a slow
hear and agitate until the sample is completely dissolved. Evaporate the
sol. At a low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml
distilled water.
Treat the ignited residue thus obtained which contain small amount of
impurities, with 1 or 2 ml of distill water + 10 ml of HF and 2 drops of
H2SO4 and evaporate to dryness. Finally heat the small residue at 1050
to 1100C for a min. Cool in desicater & weight of ignited sample
represented the amount of silica.
Silica % = (W1-W2) x 100
Where,
W1
W2

= Weight of silica + insoluble impurities.

= Weight of impurities.

Now add 2.5 gm of sodium and potassium per sulphate to the crucible
heat in the Bunsen burner continuously till the small residue of

Page 40 of 67

impurities is dissolved in the melt. Cool dissolved the fused mass with
1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm
NH4CL and 2 drop of methyl indicator. Then boil and neutralize with
NH4OH (1:1) using drop wise till just yellow. Add on drop excess
NH4OH. Put this ppt. To settle and filter using 41 no. filter paper. Wash
with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite
the residue at 1050 to 1100C. keep the filtrate (A)
R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop
of SnCl4 dropwise till sol. Decolorize. Add few drop of SnCl 4 in excess.
Cool it to room temperature. Rinse the beaker with H 2O add 15 ml of
HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate
with standard KMnO4 (0.05N) till permanent pink color is obtained.
Calculate iron and ferric Oxide.
R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)
Fe2O3 % =
Weight of iron ore sample
R = Burette reading
N = Normality of KMnO4
Alumina % = R2O3 Fe2O4

Page 41 of 67

Calcium Oxide
Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of
ammonium oxalate sol. with NH 4OH (1:1) Allow to settle ppt. Filter
using 40 no. filter paper and wash the residue free of oxalate with hot
water. Keep the filtrate for MgO (B).
In the sample previous beaker take 10 % H 2SO4 100 ml and boil it.
Transfer filter paper with residue in the beaker and stir till the residue is
dissolved.
Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of
the beaker. At the end point pink color is obtained after taking in filter
paper.
R x 100 x 2.5 x N x 0.0285 (CaO Eq)
CaO % =
Weight of iron ore sample
Where,
R = Burette Reading
N = Normality of KMnO4 (0.12N)

MgO
Acidify the above filtrate (B) (CaO free) with HCl till red color appear.
Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5%
diammonium hydrogen orthophosphate and add NH4OH (1:1) Scratch
the side of the beaker till the ppt appears. Add 50 ml NH4OH (1:1) in
excess and keep it 24 hours for settlement. Filter through 42 no. filter
paper and wash the ppt with NH4OH (1:1) and finally wash with cold
distilled water.
Take it in the crucible. Slowly char the paper and carefully burn the
resulting carbon. Ignite it at 1100C to 1200C calculate the ppt as MgO.
MgO % = W x 72.4
Where,

Page 42 of 67

W
72.4

= gm of residue Mg2P2O7
= Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Testing of Cement & clinker

A- Chemical analysis of Cement and clinker

1. Clinker
Loss of ignition (LOI)
Take 1.0 gm of sample in a weighted crucible. Heat it in a constant
weight at 900 to 1000C. Coal weight.
%Loss of ignition = Loss weight x 100

Insoluable residue (IR & SO3)

Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5
ml conc. HCl and stir. Crush the lump with flattened end of glass rod.
Boil it for 2 min. Now filter it with whatman filter paper no. 40 wash the
residue with hot distilled water. Keep the filtrate for SO3 (A).
Residue is washed again with hot distilled water. Take out the filter
paper with 30 ml. Hot distill water and 30 ml 2N Na 2CO3 . For 15 min.
at temperature just below boiling point filter it b through whatman filter
paper no. 40. After transferring the sol. Treat the residue with 10 ml
(1:1) HCl and transfer the whole in previous filter paper.
Wash it with hot distilled water till it is chloride free. Take the filter
paper with residue in weighted crucible. Dry char and ignite at 100 C to
1100C for one hour. Cool and weight.
% of I.R. = Weight of residue x 100
Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for
another 1 min. digest it for 4-5 hours at 60 C. Now filter it with

Page 43 of 67

whatman filter paper no. 40 wash the residue with hot distilled water.
Take the filter paper in weighted crucible.
Dry and ignite at 900-1000C. Cool in desicator and weight.
%SO3 = Wt. Of BaSO4 x 0.343 x 100
Where,
Molecular ratio of SO3 to BaSO4 = 0.343

Silica (SiO2)
Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion
mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the
platinum crucible with led in a furnace for 1 hours at 1100C. Cool it and
extract with HCl (1:1) and transfer all material in 500 ml beaker. Add 2
to 3 drop of conc. HNO 3 with constant stirring. Digest at a slow hear and
agitate until the sample is completely dissolved. Evaporate the sol. At a
low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml distilled
water.
Treat the ignited residue thus obtained which contain small amount of
impurities, with 1 or 2 ml of distill water + 10 ml of HF and 2 drops of
H2SO4 and evaporate to dryness. Finally heat the small residue at 1050
to 1100C for a min. Cool in desicater & weight of ignited sample
represented the amount of silica.
Silica % = (W1-W2) x 100
Where,
W1
W2

= Weight of silica + insoluble impurities.

= Weight of impurities.

Now add 2.5 gm of sodium and potassium per sulphate to the crucible
heat in the Bunsen burner continuously till the small residue of
impurities is dissolved in the melt. Cool dissolved the fused mass with
1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.
Page 44 of 67

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm
NH4CL and 2 drop of methyl indicator. Then boil and neutralize with
NH4OH (1:1) using drop wise till just yellow. Add on drop excess
NH4OH. Put this ppt. To settle and filter using 41 no. filter paper. Wash
with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite
the residue at 1050 to 1100C. keep the filtrate (A)
R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop
of SnCl4 dropwise till sol. Decolorise. Add few drop of SnCl 4 in excess.
Cool it to room temperature. Rinse the beaker with H 2O add 15 ml of
HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate
with standard KMnO4 (0.05N) till permanent pink color is obtained.
Calculate iron and ferric Oxide.
R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)
Fe2O3 % =
Weight of iron ore sample
R
N

= Burette reading
= Normality of KMnO4
Alumina % = R2O3 Fe2O4

Calcium Oxide
Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of
ammonium oxalate sol. with NH 4OH (1:1) Allow to settle ppt. Filter
Page 45 of 67

using 40 no. filter paper and wash the residue free of oxalate with hot
water. Keep the filtrate for MgO (B).
In the sample previous beaker take 10 % H 2SO4 100 ml and boil it.
Transfer filter paper with residue in the beaker and stir till the residue is
dissolved.
Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of
the beaker. At the end point pink color is obtained after taking in filter
paper.
R x 100 x 2.5 x N x 0.0285 (CaO Eq)
CaO% =
Weight of iron ore sample
Where,
R = Burette Reading
N = Normality of KMnO4 (0.12N)

MgO
Acidify the above filtrate (B) (CaO free) with HCl till red color appear.
Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5%
diammonium hydrogen orthophosphate and add NH 4OH (1:1) Scratch
the side of the beaker till the ppt appears. Add 50 ml NH 4OH (1:1) in
excess and keep it 24 hours for settlement. Filter through 42 no. filter
paper and wash the ppt. with NH 4OH (1:1) and finally wash with cold
distilled water.
Take it in the crucible. Slowly char the paper and carefully burn the
resulting carbon. Ignite it at 1100C to 1200C calculate the ppt. as
MgO.
MgO % = W x 72.4
Where,
W = gm of residue Mg2P2O7
Page 46 of 67

72.4 = Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Free lime
Take 1 gm powder sample in dry corked conical flask. Add to in 50cc
ethylene glycol. Keep it 60 70 C. Shake the flask vigorously every 5
min. to prevent the clinker from forming lump. After half an hours filter
it in a dry & clean conical flask using filter paper no. 40. the filtrate add
2 to 3 drop of bromocresol green indicator and titrate against 0.1N HCl
sol. At the end light yellow color will be obtained.
Free lime % = R x 100 x N x 0.02804
Where,
R
= Burette Reading
N
= Normality of HCl

Chloride (Cl -)
Take 20 gm of sample in 250 cc conical flask. Add 30 cc distilled water
& 10 cc conc. HNO 3. boil for 5 min. filter through whatman filter paper
no. 41. Wash with hot distilled water 4 times. The filtrate adds 5 ml of
silver nitrate sol. of 0.05N cool it.
Add 5ml nitrobenzene sol. Then filtrate against 0.025N NH 4SCN sol.
Using ferric Alum (Ferric Ammonium Sulphate) as a indicator.

RxN
% of Cl =

A-

x 0.3546 x 100
Strength of AgNO3

Where
Page 47 of 67

A
R
N

= Amount of AgNO3
= Burette Reading
= Strength of NH4SCN

2. Ordinary Portland Cement

(Grade - 43)
Loss of ignition (LOI)
Take 1.0 gm of sample in a weighted crucible. Heat it in a constant
weight at 900 to 1000C. Coal weight.
%Loss of ignition = Loss weight x 100

Insoluble residue (IR & SO3)

Take 1 gm sample in a beaker. Add 50 ml water and stir it. Now add 5
ml conc. HCl and stir. Crush the lump with flattened end of glass rod.
Boil it for 2 min. Now filter it with whatman filter paper no. 40 wash the
residue with hot distilled water. Keep the filtrate for SO3 (A).
Residue is washed again with hot distilled water. Take out the filter
paper with 30 ml. Hot distill water and 30 ml 2N Na 2CO3 . For 15 min.
at temperature just below boiling point filter it b through whatman filter
paper no. 40. After transferring the sol. Treat the residue with 10 ml
(1:1) HCl and transfer the whole in previous filter paper.
Wash it with hot distilled water till it is chloride free. Take the filter
paper with residue in weighted crucible. Dry char and ignite at 100 C to
1100C for one hour. Cool and weight.
% of I.R. = Weight of residue x 100

Page 48 of 67

Boil the filtrate and add 50 ml hot BaCl 2 sol. With stirring rod for
another 1 min. digest it for 4-5 hours at 60 C. Now filter it with
whatman filter paper no. 40 wash the residue with hot distilled water.
Take the filter paper in weighted crucible.
Dry and ignite at 900-1000C. Cool in desicator and weight.
% SO3 = Wt. Of BaSO4 x 0.343 x 100
Where,
Molecular ratio of SO3 to BaSO4 = 0.343

Silica (SiO2)
Take 0.5 gm sample of platinum crucible and add approx 11.0 gm fusion
mixture and mix it properly. Add 3-4 gm fusion mixture more. Put the
platinum crucible with led in a furnace for 1 hours at 1100C. Cool it and
extract with HCl (1:1) and transfer all material in 500 ml beaker. Add 2
to 3 drop of conc. HNO 3 with constant stirring. Digest at a slow hear and
agitate until the sample is completely dissolved. Evaporate the sol. At a
low heat to dryness and cool it. Add 5-10 ml of HCl &10 ml distilled
water.
Treat the ignited residue thus obtained which contain small amount of
impurities, with 1 or 2 ml of distill water + 10 ml of HF and 2 drops of
H2SO4 and evaporate to dryness. Finally heat the small residue at 1050
to 1100C for a min. Cool in desicater & weight of ignited sample
represented the amount of silica.
Silica % = (W1-W2) x 100
Where,
W1
W2

= Weight of silica + insoluble impurities.

= Weight of impurities.

Now add 2.5 gm of sodium and potassium per sulphate to the crucible
heat in the Bunsen burner continuously till the small residue of

Page 49 of 67

impurities is dissolved in the melt. Cool dissolved the fused mass with
1:1 HCL and add into the filtrate. Make up volume upto 250 ml mark.

Ferric Oxide and Alumina

Take 100ml sol. From 250 ml volumetric flask (Mother sol.). add 1 gm
NH4CL and 2 drop of methyl indicator. Then boil and neutralize with
NH4OH (1:1) using drop wise till just yellow. Add on drop excess
NH4OH. Put this ppt. To settle and filter using 41 no. Filter paper. Wash
with 2% hot ammonium nitrate sol. Till chloride free. Char and ignite
the residue at 1050 to 1100C. keep the filtrate (A)
R2O3 % = Weight of Residue x 250

Iron Oxide (Fe2O3)

Take 100 ml sol. From 250 ml. Volumetric flask. Boil and add few drop
of SnCl4 dropwise till sol. Decolorize. Add few drop of SnCl 4 in excess.
Cool it to room temperature. Rinse the beaker with H 2O add 15 ml of
HgCl4 sol., stir and add 25 ml of manganese sulphate sol. And titrate
with standard KMnO4 (0.05N) till permanent pink color is obtained.
Calculate iron and ferric Oxide.
R x 100 x 2.5 x N x 0.7985 (Fe2O3 Eq)
Fe2O3 % =
Weight of iron ore sample
R = Burette reading
N = Normality of KMnO4
Alumina % = R2O3 Fe2O4

Calcium Oxide

Page 50 of 67

Take the filtrate add 2 3 ml. Of acetic acid & boil mix 25-30 ml. of
ammonium oxalate sol. with NH 4OH (1:1) Allow to settle ppt. Filter
using 40 no. filter paper and wash the residue free of oxalate with hot
water. Keep the filtrate for MgO (B).
In the sample previous beaker take 10 % H 2SO4 100 ml and boil it.
Transfer filter paper with residue in the beaker and stir till the residue is
dissolved.
Titrate against 0.12N KMnO4 sol. Keeping the filter paper at the side of
the beaker. At the end point pink color is obtained after taking in filter
paper.
R x 100 x 2.5 x N x 0.0285 (CaO Eq)
CaO % =
Weight of iron ore sample
Where,
R
= Burette Reading
N
= Normality of KMnO4 (0.12N)

MgO
Acidify the above filtrate (B) (CaO free) with HCl till red color appear.
Reduce the volume to 200 cc by evaporating the sol. Add 25 ml of 5%
diammonium hydrogen orthophosphate and add NH 4OH (1:1) Scratch
the side of the beaker till the ppt appears. Add 50 ml NH 4OH (1:1) in
excess and keep it 24 hours for settlement. Filter through 42 no. filter
paper and wash the ppt. with NH 4OH (1:1) and finally wash with cold
distilled water.
Take it in the crucible. Slowly char the paper and carefully burn the
resulting carbon. Ignite it at 1100C to 1200C calculate the ppt. as
MgO.
MgO % = W x 72.4
Where,
Page 51 of 67

W
72.4

= gm of residue Mg2P2O7
= Molecular ratio of 2 MgO to Mg2P2O7 (0.362)

Free lime
Take 1 gm powder sample in dry corked conical flask. Add to in 50cc
ethylene glycol. Keep it 60 70 C. Shake the flask vigorously every 5
min. to prevent the clinker from forming lump. After half an hours filter
it in a dry & clean conical flask using filter paper no. 40. the filtrate add
2 to 3 drop of bromocresol green indicator and titrate against 0.1N HCl
sol. At the end light yellow color will be obtained.
Free lime % = R x 100 x N x 0.02804
Where,
R = Burette Reading
N = Normality of HCl

Chloride (Cl -)
Take 20 gm of sample in 250 cc conical flask. Add 30 cc distilled water
& 10 cc conc. HNO 3. boil for 5 min. filter through whatman filter paper
no. 41. Wash with hot distilled water 4 times. The filtrate adds 5 ml of
silver nitrate sol. of 0.05N cool it.
Add 5ml nitrobenzene sol. Then filtrate against 0.025N NH 4SCN sol.
Using ferric Alum (Ferric Ammonium Sulphate) as a indicator.

RxN
% of Cl =

A-

x 0.3546 x 100
Strength of AgNO3

Page 52 of 67

Where
R = Burette Reading ,
S. No.

A = Amount of AgNO3
N = Strength of NH4SCN

Characteristics to be
tested

Specified Requirement
33 G
43 G

53 G

1.

Fineness (in m2/kg)

225

240

320

2.

Setting time min.

60
300

60
300

60
300

3.

Soundness
(a) Le-Chat
After Areation

10 mm
5 mm

10 mm
5 mm

10 mm
5 mm

(b) Auto Clave

0.8 mm %
0.6 mm %

0.8 mm %
0.6 mm %

0.8 mm %
0.6 mm %

3 Days

16

23

27

7 Days

22

33

37

28 days

33

43

53

5.

LOI

5%

5%

4%

6.

IR

4%

3%

3%

7.

SO3

3%

3%

3%

8.

MgO

6%

6%

6%

9.

LSF

0.66-1.02

0.66-1.02

0.88-1.02

10.

AM (Al2O3/Fe2O3)

> 0.66

> 0.66

> 0.66

11.

CaO

> 0.66

> 0.66

> 0.66

12.

SiO2

> 0.66

> 0.66

> 0.66

13.

Al2O3

> 0.66

> 0.66

> 0.66

14.

Fe2O3

> 0.66

> 0.66

> 0.66

After Areation
4.

Compressive Strength
(Mpa)

4. Pozzolana Portland Cement

Page 53 of 67

The pozzolona is a powdery volcanic powder. It is found near Italy near

Vesuvius. It resembles surkhi which is prepared by burning brick made
from original soils. It can also be processed from shale and certain type
of clays. The percentage of pozzuolona material should be between 10
to 30.
Advantages of this Cement: 1.
2.
3.
4.
5.
6.
7.

It attains compressive strength with age.

It can resist action of sulphate.
It evolves less heat during setting.
It imparts high degree of water tightness.
It possesses higher tensile strength.
It impart plasticity and workability to the mortar and concrete
prepared from it .
It offers great resistance to the expansion.

Following are the disadvantages of this Cement: 1.

2.

Its compressive strength in early days is less.

It possesses less resistance to erosion and weathering action.

This Cement is used to prepare mass concrete of lean mix and of marine
structures. It is also used for sewage works and for laying concrete
under water.

Page 54 of 67

PPC Grinding

S. No.

Characteristics
To be tested

Specified Requirement

1.

Fineness (in m2/kg)

300

2.

Setting time min.

60
300

3.

Soundness

4.

(a) Le-Chat
After Areation

10 mm
5 mm

(b)Auto Clave
After Areation

0.8%
0.6%

Compressive Strength (Mpa)

3 Days
7 Days

16
22

28 days

33

5.

LOI

5%

6.

SO3

3%

7.
8.

MgO
IR

3%
z + 4(100-z)

100
z = % of Pozz.

Page 55 of 67

B - Physical Testing of Cement

Consistency Measurement of Cement
Take 300 gm of Cement one mint. Dry mixing adds appx. Distil water
(85 cc) and gauging 3 to 5 mints. Then poured into a 300 gm vicat
mould then checks the plunger reading in the Vicat Apparatus. Reading
shouls come between 5 to 7 mm.
Suppose
300gm Cement used 85 cc water
Therefore 100 gm Cement

85 x 100
300

= 28 %

IST & FST (Setting Time)

Take 300 gm of Cement one mint. Dry mixing adds appx. Distil water
(85 cc) and gauging 3 to 5 mints. Then poured into a 300 gm vicat
mould then check the initial setting time by the help of vicat Apparatus,
initial setting needle. Reading comes 5 0.5 mm. After that check final
setting time by another needle, where outer needle ring disappear only
dot point appears.

Compressive strength (Hydraulic Cement)

Temp of gauging room 27 2C.
Relative humidity of physical lab 65 5%.
Moist closet or moist room temp. 27 2C.
Relative humidity of moist closet not less than 90 %.
Curing tank fresh water temp. 27 2C.
Nine cubes to be prepared of each variety of Cements (three each for 3
days, 7 days & 28 days)

Page 56 of 67

Preparation of Cube
Cement and 3 Std. Variety of sand is mixed in a ratio 1:3
Cement = 200 gm
Std. Sand three variety 200 gm each
Total = 800 gm
Water calculation: - P/4 + 3 where P is standard consistency.
Suppose p = 28 %
Then 28/4 + 3 = 10 cc water for 100 gm Cement.
100 gm Cement required 10 cc of water
800 gm Cement requires (800 x 10) / 100 = 80 cc water
Dry mixture with the help of trowel for one mint. Then add distil water
and gauge 2 4 mints. After that pour into the vibration machine 50 %
material poured then pock then rest of the material pour in the mould
then vibrate for 2 min. at the rpm 12000 400. After that cube is ready,
then cube put into the moist closet for 24 hours after that demould the
cube put into the curing tank for rest of the days. Then cube is kept in
curing tank for 3 days after which strength is checked. Than strength is
again checked after 7 days and 28 days.
1 kgf force = 9.8065 N
1 N = 1/9.8065 kgf
1 KN = 1000/9.8065 kgf = 101.97 kgf
Cube size = 50 cm2 or 25 cm2 (length = 5 cm, width = 5 cm)
(Area (50 cm2 cube) = Length 70.6 x width 70.6 = 4984 mm 2 =
4984/100 = 49.84 Cm2, approx 50 cm2
Therefore 1 KN = 2.0394 kgf
1 Kg/Cm2 = 1/10 Mpa
Therefore = 2.0394/20 Mpa

Sound ness (Expansion)

(A) By Le- chatelier Method
Water calculation: - P x 0.78 = ------------ for 100 gm Cement.
Where P is Std. Consistency.

Page 57 of 67

100 gm Cement adds water and gauge 3-5 mints. Then poured into Lechate mould after that covered with glass sheet then put into a curing
tank for 24 hours. After that check the initial reading with the help of
scale in mm. Then boil the mould for 3 hours at the boiling point and
cool at room temperature and again check the reading by scale.
Difference between the initial and final reading is the expansion in mm.

(B) Auto Clave Test

Water calculation: - Std. Consistency x quantity of Cement = --------cc
H2O use
The test specimen shall be in the form of rectangular bars 25 x 25 mm in
section of 250 mm long.
700 gm Cement adds distil water and gauge 3-5 min. then pour in the
autoclave bar and put in the moist closet for 24 hours. After that
demould the bar and measure the length in length comparator in mm.
After that bar put into the auto clave machine where water is taken 7
10 % of the volume of the cylinder, pressure 21 1 Kg/Cm2 and
temperature 214 1.8C for 3 hours. After release the pressure in 1
hours. Then cool the bar at room temperature then measure the length by
length comparator in mm.
Scale of length comparator.
1 div. = 0.002 mm
250 mm length of the bar measure 0.002 mm length comparator
1000 mm length of a bar measure (100 x 0.002) / 250 = 0.0008
Suppose
Initial reading
= 1400 mm
Final reading
= 1500 mm
Difference
= 100 mm
Therefore expansion = 100 x 0.0008 = 0.08 %

Page 58 of 67

C. Pozzolanic Material Physical Test

Lime Reactivity (L/R)
Procedure for determining the reactivity of pozzolanic material with
hydrated lime.
Material required
Hydrated lime
Pozzolonic Material
3 variety of Std. Sand
1
:
2M
:
9
75 gm
150 x 1.2
225 x 3 = 675
gm
Where,
Specific gravity of Pozzolanic Materia
M=

2.73
=

Specific gravity of hydrated lime

=1.20
2.28

Water calculation: (Hydrated lime 75 gm + Pozzolonic material 180 gm) = A

225 x 3 = 675 gm (three variety of Std. Sand) = B
Suppose 170 cc water taken
Firstly water taken in mixing bowl then start stop watch and mixture
machine in slow speed within 30 sec. Mixture A mix in the water after
that machine moves another 30 sec. After that mixture B is added and
run for 30 sec. (total time 1.30 mints). Stop the machine and screech the
material with spatula and covered with plate for 1.30 min. total
movement in slow speed. After completed 3 min. machine moves
another 1.00 min. in the fast speed (total time 4.00 min.)
After that material transfer into the flow table mould during transferring
two times pocking will be done by the help of poker (26 times in 6 sec.)

Page 59 of 67

then remove the cup 10 times tamping given by the flow table machine.
And then measure the flow in all 4 directions that should come 70 5
mm (by scale 16.5 17.05 mm, 10 cm in the diameter of the cube). If it
is ok pour the material in the 3 cubes of 25 cm 2 area and put in a moist
closet for 48 hrs. After 2 days cube transfer to the L/R oven for 8 days
where temperature 50 2 C and humidity more than 90 %. After that
break the cube by compressive machine 50 KN.

Drying shrinkages in Pozzolona Cement

Procedure for calculating of dry shrinkage of PPC Cement.
Material ratio = (1 Cement PPC : 3 Std. Sand ( all 3 variety equal
quantity)
300 gm PPC Cement + 900 gm Std. Sand
Mixing procedure same as in L/R. calculate the water approx 170-180
cc by flow table, the flow between 100-115 mm i.e. by scale 20-21.5
with 25 drop in 15 sec. Fill up in the 250 mm bar and kept for 24 hours
in the moist closet for 1 days. After demould and keeping in curing tank
for 7 days and take initial reading by length comparator then kept for 28
days in the humidity control oven where temperature 27 2 C and
humidity 55 5 % and then take final reading by length comparator.
Initial Reading
Final Reading
Difference

= --------mm
= --------mm
mm x 0.0008 = -------%

Replacement test and Blank test

We are comparing strength against plane Cement with addition of
pozzolonic material. Cement how many strength replaced. It will be 80
% minimum.
Material Required : Suppose 250 gm material taken total quantity of
material approx 1 Kg
Pozzolona
Plane Cement
3 variety of Std. Sand
0.2 N
:
0.8
:
3
250 x 0.2 = 50N
250 x 0.8 = 200gm
250 x 3 = 675 gm
Page 60 of 67

Where,
Specific gravity of Pozzolana Material
M=

2.73
=

Specific gravity of Cement

=0.87
3.18

Plane Cement and Pozzolona mixture --------- = A

Standard Sand
--------- = B

Page 61 of 67

USES OF CEMENT
At present the cement is widely used in the construction of various
engineering structure. It has proved to be one of the leading engineering
materials of modern time and has no rival in production and application.
Following are possible uses of cement:1. Cement mortal for masonry work, plaster etc.
2. Concrete for layering floor, roof, construction lanters, beams
weather shed stairs pillars.
3. Construction of important engineering structure such as bridges,
culverts, dams, tunnels, storage reservoir, light houses, dock etc.
4. Construction of water tanks, well, tennis court, septic tank, lamp
post, roads, telephone cabins etc .
5. Making joints for drain and pipes.
6. Manufacturing of present pipes, piles, garden seats, artistically
design urns, flower pots, dustbin fencing post etc.
7. Preparation of foundation, watertight floor, footpaths etc.

Page 62 of 67

LIMITATION

There are limitation for primary data collection because of

confidentiality.
Company does not show their data because many things were
confidential and cant be shown to everyone.

Page 63 of 67

SUGGESTION
The company should publish and provide booklets to the users of
Prism cement.
TO Provided the dividend.
To Debt should be reduces.
Prism cement holds good position owning to its price. It should be try to
hold this position with continuous efforts by increasing promotional
activities, SEMINARS AND VISIT CONSUMER SITES..

Page 64 of 67

CONCLUSION
It is the process of establishing and interpreting quantitative relationship
between figures and groups of figures. With the help of ratios, the
financial statements can be analyzed more clearly and decisions can be
made more logically.

Page 65 of 67

BIBLIOGRAPHY:Books:
Personal management: C.B. Mamoria
Research Methodology: C.R. Kothari
Human Resource Management: K Aswathappa
Designing and Managing Human Resource System: Udai Pareek and T. Rao

Websites:
www.google.com
www.prismcement.com
www.hrcite.com
Others:
Training Records of PRISM CEMENT LIMITED.

Page 66 of 67

QUESTIONNAIRE
Name:Designation:Q 1) Are you satisfied with your offer?
a) Yes

b) No

c) No comments

Q 2) why you joined B.C.L.?

a) For better opportunities of improvement?
b) For handsome salary?
c) For expected job profile?
d) Impressive brand image?
Q 3) Do you think, any improvement is required in Selection process?
a) Yes

b) No

c) No comments

If yes, please specify

Q 4) at which stage of the Selection process utmost attention is required?
a) Screening of resume b) Validation and scheduling c) Screening and interview
Q 5) what you dislike in complete procedure of your Selection & selection?

69

Page 67 of 67