DESIGN AND DEVELOPMENT OF A MIXER FOR THE EVALUATION OF

BEST ALTERNATIVE RETARDER CEMENT ADDITIVES FROM

AGRICULTURAL WASTES

A Project Study
Presented to the Faculty of Petroleum Engineering Department
College of Engineering, Architecture and Fine Arts
BATANGAS STATE UNIVERSITY
Gov. Pablo Borbon Campus II
Alangilan, Batangas City

In Partial Fulfillment of the Requirements for the

Degree in Bachelor of Science in
Petroleum Engineering

by:

ARIDA, KIM B.

LAZARTE, ARMAN JADE S.

PAGLICAWAN, ANN D.

October 2019
 APPROVAL SHEET
The project study “DESIGN AND DEVELOPMENT OF

A MIXER FOR THE EVALUATION OF BEST ALTERNATIVE RETARDER

CEMENTS ADDITIVES FROM AGRICULTURAL WASTES” prepared and

submitted by KIM B. ARIDA, ARMAN JADE S. LAZARTE and ANN D.

PAGLICAWAN in partial fulfillment of the requirements for the degree Bachelor of

Science in Petroleum Engineering has been examined and is recommended for

oral examination.

ENGR. MANILYN V. CALAPATIA

Adviser
Approved by the Committee on Oral Examination with the grade of .

PANEL OF EXAMINEES

ENGR. DONNALYN C. CABACES

Chairman

ENGR. JULIE PEARL F. MARASIGAN ENGR. ROXANNE R. NAVARRO

Member Member

Accepted and approved in partial fulfillment of the requirements for the degree

in Bachelor of Science in Petroleum Engineering.

October 2019 DR. ELISA D. GUTIERREZ

Date Dean, CEAFA

ii
 ACKNOWLEDGEMENT

Grateful acknowledgement is hereby expressed by the researchers to the

following people who helped them accomplish the study:

To the Society of Petroleum Engineering Student of Batangas State

University, especially the 5th year petroleum engineering students, for their

encouragement, friendship and inspiration;

To the faculty members of the Engineering Department for their generosity,

assistance and support;

To their dearest friends and classmates for the prayer and moral support to

the group;

To their adviser, Engr. Manilyn V. Calapatia, for sharing her knowledge and

ideas about the study, for the support, assistance, encouragement and guidance;

To their parents who were very supportive to them at all times and who

served as their inspiration throughout this project;

And above all these, to the Almighty God who enlightened their ways and

gave them strength and wisdom to finish this study.

iii
 ABSTRACT

Cementing is one of the vital processes in well completion in the oil and gas

industry. Drilling cement additives are mixed with the Portland cement to meet the

specifications required in borehole conditions. Controlling the setting time of the

slurry and increasing its strength is one of those specification. Utilizing retarders

as an additive to the slurry is the best solution in achieving the specifications.

Market demand and high economic costs of retarder additives and Portland

cement are becoming a problem for consumers. These chemical retarders also

poses as a threat to the environment due to their toxic chemical content. Another

problem is the quantity of agricultural waste has been rising rapidly all over the

world.

In order to address the problems, the main objective of this was to design

and develop a mixer for the evaluation of agricultural wastes specifically rice husk,

sawdust, sugarcane bagasse, and eggshells to determine the best alternative

retarder cement additive. The mixer was designed and fabricated considering

material specifications and system components. The following parameters were

established: using Froude’s Equation for dry powder cement mixing the mixing

speed was set to 9 RPM, the mixing time was set to 10 minutes as standard for

ribbon-shaped blenders by the powder mixing handbook, and an operating

capacity for the mixer of 10 kilograms as required by the lab cement testing center.

Most samples were not able to pass one or two properties as a retarder,

there are 4 out of the 14 samples, however, that have passed all laboratory testing

iv
requirements, namely: SCB1, SCB2, SCB3, and SCB4. These four samples have

achieved the standards set by the ASTM.

The results of the study have shown that the produced drilling cement

retarder from agricultural wastes were all potential retarder.

v
 TABLE OF CONTENTS

TITLE PAGE i

APPROVAL SHEET ii

ACKNOWLEDGMENT iii

ABSTRACT iv

TABLE OF CONTENTS vi

LIST OF TABLES x

LIST OF FIGURES xii

CHAPTER

I THE PROBLEM AND ITS BACKGROUOND

Sketch-Up 1

Objectives of the study 3

Significance of the study 4

Scope and Delimitation of the study 5

Conceptual Framework 7

Definition of Terms 9

II REVIEW OF RELATED LITERATURE AND STUDIES

Conceptual Literature 13

I. Well Parameters 14

II. Drilling Cement 15

vi
 Composition of Drilling Cement 16

III. Factors affecting the mixing of cement 25

IV. Cement Additives 28

V. Properties and Materials Used as Cement Additive 31

Wood 31

Sawdust or Wood Dust 34

Sawdust Ash 35

Rice Husk 37

Rice Husk Ash 39

Sugarcane Bagasse 41

Sugarcane Bagasse Ash 43

Eggshell 46

Operating Principle of Mixer 48

VI. Ratio and Proportion of Cement Additive 42

Research Literature 49

Synthesis 51

Mathematical Model 53

vii
III RESEARCH METHODS AND PROCEDURES

Research Design 54

Methods of Testing 55

Preparation of the Cement Powder considering 55

ratio and proportion

Method of Determining the Operating Capacity 57

Method of Determining the Mixing Time 57

Method of Determining the Mixing Speed 58

Evaluation of the Properties of the Product Cement 58

Method of Mathematical Modelling 60

IV DEVELOPMENT OF PROTOTYPE, EXPERIMENTAL

RESULTS AND DISCUSSION

Development of the Prototype 62

Schematic Diagram of the Machine 62

Mixing Time 63

System Components and Functions 64

Determining the Best Proportion of the Drilling Cement 67

Mixture

viii
 Mathematical Modelling 76

V SUMMARY OF FINDINGS, CONCLUSIONS AND

RECOMMENDATIONS

Summary of Findings 87

Conclusions 88

BIBLIOGRAPHY 89

APPENDICES 92

ix
 LIST OF TABLES

Table No. Title Page

1 Chemical Composition of Portland Cement 17

2 Chemical and Physical Composition of Wood 32

3 Chemical Composition of Sawdust Ash 36

4 Chemical and Physical composition of Rice Husk 38

5 Physical Properties of Rice Husks Ash 40

6 Chemical Properties of RHA 40

7 Chemical and Physical Composition of Sugarcane 42

Bagasse
8 Chemical Composition of Sugarcane Bagasse Ash (SCBA) 44

9 Physical Properties of Sugarcane Bagasse Ash (SCBA) 45

10 Chemical Composition of Eggshell 46

11 Matrix for OPC, Eggshells, and Ricehusk Ash 56

12 Matrix for OPC, Eggshells, and Sugarcane Bagasse Ash 56

13 Test Result for Autoclave Expansion 67

14 Test Result for Fineness of Hydraulic Cement 68

15 Test Result for 3-day Compressive Strength 69

x
16 Test Result for 7-day Compressive Strength 70

17 Test Result for Initial Setting Time using Vicat Needle 71

18 Test Result for Final Setting Time using Vicat Needle 72

19 Summary of the Results 73

20 Chemical Components of the Produced Samples 75

21 Data used in Mathematical Modelling using Ash Content 76

22 Data used in Additional Mathematical Models 82

 LIST OF FIGURES

Figure No. Title Page

1 Research Paradigm of the Study 9

2 Wood 31

3 Mahogany Wood 34

4 Sawdust 34

5 Sawdust Ash 35

6 Rice Husk 37

7 Rice Husk Ash 39

8 Sugarcane Bagasse 41

9 Sugarcane Bagasse Ash 43

10 Eggshell 46

11 Benford Concrete Mixer 48

12 Workflow for the Study 54

13 Mixer Controller 64

14 Impeller 64

15 Motor 65

16 Pillow Block 65

xii
17 Shaft 66

18 Body 66

19 Scatter Plot for Initial Setting Time vs. Ash Content 77

20 Scatter Plot for Final Setting Time vs. Ash Content 78

21 Scatter Plot Autoclave Expansion vs. Ash Content 79

22 Scatter Plot for 3-day Compressive Strength vs. Ash 80

Content
23 Scatter Plot for 7-day Compressive Strength vs. Ash 81
Content
24 Scatter Plot for Fineness vs. 3-day Compressive 83
Strength
25 Scatter Plot for Fineness vs. 7-day Compressive 84
Strength
26 Scatter Plot for Fineness vs. 7-day Compressive 85
Strength

xiii