FLY ASH USING CEMENT MANUFACTURING

Different varieties of cement can be produced by using the fly ash, each having unique
characteristics and benefits. Some of them are discussed here. Portland Pozzolana Cement
(PPC) It consists not less than 15-35% fly ash with respect to the % weight of cement, and the
presence of fly ash improves the durability of cement reduces the heat of hydration and also it
provides a better resistance to the chemical attack. Blended Cement. The other type is Blended
Cement, where fly ash not only blended. Fly ash is mixed with other supplementary cementitious
materials, it improves workability and long-term strength. And the last one is High-Volume Fly
Ash (HVFA) more than half of the High-Volume Fly Ash (HVFA) Cement can be formed by fly
ash which results in significant reductions in CO2 emission while providing a good long-term
performance. Such cements exploit the pozzolanic nature of Fly Ash, enabling sustainability,
economy, as well as high-performance construction practices.

METHODOLOGY FOR MAKING BLENDED CEMENT

Introduction
The first step in the procedure is selecting fly ash that meets particular requirements for chemical
composition, quality, and particle size. This ensures the fly ash is appropriate for use in the
manufacture of cement. After being chosen, the fly ash is often crushed to the appropriate particle
size and dried to remove moisture. These procedures enhance the fly ash's ability to be blended
with other components throughout the cement production process. Fly ash is mixed with
conventional ingredients like clinker and gypsum, and sometimes with slag, to create blended
cement. Carefully controlling the ratios of these constituents results in a cement with certain
performance characteristics, such enhanced workability, increased durability, and decreased heat
of hydration. These characteristics improve the quality and durability of the finished constructions
by making the cement appropriate for a range of construction applications. The carbon footprint
of the cement industry is also greatly decreased by using fly ash in the process. The method
becomes environmentally friendly by recycling this industrial residue and lowering the need on
clinker, which requires a lot of energy to create. Before being packed and delivered, the finished
blended cement product is subjected to stringent quality control measures to guarantee that it
satisfies strict requirements for environmentally friendly building supplies.

1.2. Quality Control of fly ash:

Screaning
Fly ash is screened by filtering it to get rid of contaminants and big particles. This procedure
guarantees that cement is made exclusively from acceptable, quality fly ash. The cement performs
better and has higher quality when these undesirable components are removed. This stage is
essential because it guarantees that the finished cement is uniform and satisfies the specifications
needed for use in building, producing cement that is stronger and more durable.
 .

A rotary screen is basically a fancy rolling sieve. As it

spins, it sorts things by size. Small stuff falls through
the holes, while bigger things tumble out the other
end. Used in construction, mining, and more to
separate stuff like rocks and sand The average cost
of a rolling sieve is $1000 [3].

Testing
Fly ash is tested to make sure it satisfies requirements for making cement. The fineness, specific
gravity, and chemical composition of the samples are examined, with an emphasis on silica,
alumina, iron oxide, and lime. These characteristics have an impact on the workability, strength,
and durability of fly ash in cement. Furthermore, pozzolanic activity is measured to make sure fly
ash and calcium hydroxide combine appropriately to generate strong molecules. Achieving
standards such as ASTM C618 ensures cement of superior quality, leading to reliable building
supplies.

2. Production of Blended Cement

2.1. Raw Material Preparation:
Clinker production
The most important step in the creation of typical Portland cement is clinker manufacturing. The
process starts with heating a mixture of raw materials and limestone to extremely high
temperatures—roughly 1400–1450°C—in a kiln. The extreme heat sets off a chemical process that
results in the formation of tiny, dark gray clusters known as clinker. Following creation, the clinker
is quickly chilled to maintain its characteristics before being finely powdered. When combined
with additional ingredients like gypsum, this powder, known as clinker, gives Portland cement its
distinctive strength and durability. Clinker is the major part of Portland cement its added 75 – 95%
by weight. The cost of clinker can be influenced by several factors including production costs, demand,
and import-export dynamics. The average cost of Clinker is $72.5 per ton.

Gypsum Addition:
Gypsum is added to cement to control the setting time and avoid an excessively rapid hardening.
This makes cement more workable and convenient to utilize in building projects by giving workers
enough time to mix, transport, and install the material before it sets. The average sale price of
Gypsum is $65 per ton.
2.2. Blending Process:
Proportioning: The amount of fly ash in blended cement is chosen according to the required
qualities. It generally makes up 15% to 35% of the cementitious material in total. Higher
percentages, however, may be used if certain performance standards call for it. Ensuring that the
finished cement satisfies the necessary criteria for strength, durability, and workability involves
proportioning fly ash appropriately. By varying the fly ash concentration, producers may
customize the mixture to best suit the requirements of different building applications while making
the most use of an environmentally friendly industrial waste.

Mixing: The fly ash, clinker, and gypsum are thoroughly mixed in precise proportions to ensure a
homogeneous blend. This can be done in blending silos or by intergrading the materials in a ball
mill or vertical roller mill The average cost of Industrial blender is $10000 .

.
2.3. Grinding:
Intergrinding: In this method, clinker, fly ash, and gypsum are ground together in a mill. The
grinding process not only reduces the particle size but also ensures a uniform distribution of fly
ash within the cement.
Separate Grinding: Alternatively, fly ash can be ground separately and combined with the
ground gypsum and clinker after being mixed. This gives the fly ash better control over its
fineness, which can enhance its pozzolanic activity The average cost of grinding machine is
$80,000. [1]

.
.
Benefits of Using Fly Ash in Blended Cement
Enhanced Durability: Fly ash decreases permeability and prevents undesirable reactions like
alkali-silica reactivity (ASR), which improves cement's long-term strength and durability.
Reducing permeability shields the cement from internal damage by preventing the entry of harsh
chemicals and water. The pozzolanic reaction of fly ash and calcium hydroxide produces more
calcium silicate hydrate (C-S-H), which enhances the cement's microstructure. The resultant
material is denser and harder. Furthermore, fly ash lowers the danger of cracking and other
structural problems by interacting with alkalis to stop the production of expanding silica gels in
ASR.
Environmental Impact: The major source of CO2 emissions in the cement manufacturing
process, clinker, is used less often when fly ash is used in the process. A substantial quantity of
CO2 is released during the high temperatures used to produce clinker, which is made from
limestone and other elements. In order to reduce cement's overall carbon footprint, some of the
clinker can be replaced with fly ash, a byproduct of burning coal. Furthermore, by reducing the
demand for raw materials like limestone and other minerals, this strategy promotes
environmentally friendly and sustainable building techniques while also conserving natural
resources.

Cost Efficiency: Because fly ash is a byproduct of burning coal, it is easily available and lowers
the cost of raw materials, which is why it is frequently less expensive than Portland cement. Costs
associated with manufacturing are decreased overall when fly ash is used to the cement-making
process in place of more costly Portland cement. Construction projects become more cost-effective
as a result of this cost-efficiency, which benefits both manufacturers and customers. Furthermore,
by reusing a byproduct that would otherwise need to be disposed of, fly ash utilization helps in
waste management..

Improved Workability: Fly ash's spherical particles lower internal friction between the mix's
constituent parts, improving concrete's workability and pumpability. The concrete's softer texture
improves flowability without sacrificing strength, making it simpler to handle, mix, and position.
As a consequence, pumping and placing require less work and energy, and the finished product is
more consistent and of higher quality. This leads to more efficient building operations.

Water demand
Amount of water necessary to form a cement paste of normal consistency. This means that the
water demand of a cement paste will be, for example, different considering its chemical nature
and fineness. This study compares the water requirement of blended cements (in 5%,
10%,15%,20 % and 25%f ly ash substitutions) with pure cement. The graph showed that the
water requirements of blended cements were greater than those for neat cement, increasing by
between 1% and 5% at various levels of fly ash substitution [2].
Volume Expansion
the expansion of the cement paste caused on by the cement's high concentrations of SO3, MgO,
and CaO. The concrete may get damaged and crack as a result of these expansions. Measuring
volume expansion is essential because it provides insight into the likelihood of cracking and
durability problems in the concrete construction. In order to evaluate the long-term performance
and durability of the concrete, it is crucial to understand how the graph illustrates how varying
degrees of fly ash replacement impact the volume expansion of the cement paste [2].
Setting time
When compared to pure cement, the addition of fly ash to cement paste lengthens the initial and
final setting durations. Setting times increase in parallel with an increase in the fly ash
replacement %, suggesting a delay in the hardening process. For concrete to be properly
workable, handled, and cured and to acquire the appropriate strength and durability, setting
periods must be observed [2].

Cost Analysis
Identify Fixed Costs

Fixed costs are expenses that do not change with the level of production. For a cement
manufacturing project, these could include:

➢ Equipment Costs: Purchase or lease of grinding machines, blending machines, and rotary
screens.
➢ Grinding Machine: $80,000
➢ Industrial Blender: $10,000
➢ Rotary Screen: $1,000

Identify Variable Costs

Variable costs change with the level of production. In this project, variable costs would include:

Raw Materials:

➢ Clinker: $72.5 per ton

➢ Gypsum: $65 per ton
3. Identify Indirect Costs

Indirect costs are expenses not directly tied to production but necessary for overall operations.
These include:

➢ Administrative Expenses: Salaries for administrative staff, office supplies, and other
overheads.
➢ Maintenance Costs: Regular maintenance of equipment and infrastructure.
➢ Regulatory Compliance: Costs associated with meeting environmental and safety
regulations.

Cost Breakdown and Analysis

Fixed Costs

➢ Total Equipment Cost: Grinding Machine +Industrial Blender +Rotary Screen

= $80,000+$10,000+$1,000 =$ 91,000

Variable Costs (per ton of cement)

➢ Clinker: $72.5
➢ Gypsum: $65
➢ Fly Ash: Assume $30 (for calculation purposes)
➢ Utilities and Labor: Assume $50 (for calculation purposes)
➢ Total Variable Cost per Ton: Clinker +Gypsum +Fly Ash+ Utilities and Labor
= $72.5+$65+$30+$50 = $217.5

Indirect Costs

• Administrative and Overhead: Assume $10,000 annually

• Maintenance: Assume $5,000 annually
• Regulatory Compliance: Assume $2,000 annually
• Total Indirect Costs: $10,000+$5,000+$2,000=$17,000 annually

Total Cost Analysis

Assuming the plant produces 1,000 tons of blended cement annually:

➢ Annual Variable Costs:

Variable Cost per Ton × Annual Production = $217.5 × 1,000=$217,500

➢ Total Annual Costs:

Fixed Costs +Annual Variable Costs +Indirect Costs = $91,000+$217,500+$17,000 = $325,500

Summary

➢ Total Fixed Costs: $91,000 (one-time)

➢ Total Variable Costs: $217.5 per ton
➢ Total Indirect Costs: $17,000 annually
➢ Total Annual Costs: $325,500 for 1,000 tons of production

Conclusion
The use of fly ash in manufacturing blended cement involves careful selection and processing of
fly ash, precise blending with clinker and gypsum, and rigorous quality control to ensure the final
product meets performance standards. This process not only enhances the properties of cement but
also offers significant environmental and economic benefits.
References

[1] "2 Major Roles of Limestone in Cement Manufacturing," FTM. [Online].

[2] Y. Kocak and S. Nas, "The effect of using fly ash on the strength and hydration characteristics of
blended cements," Construction and Building Materials, 2014.

[3] "https://www.galaxysivtek.com/products/tumbler-screen/," Galaxy Sivtek. [Online].