Centre for

Cement Research and

Independent Testing

NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS

Serv

ices

Off

ere

dCEMENTS AND OTHER BINDERS

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

Achievements

Establishing Limestone Consumption Factor (LCF)

Meeting delivery schedules and targeted quality

of delivered cement through minimizing/

eliminating lump formation in silos/bags for 6

cement plants.

Utilizing flyash, low grade limestone and additives

in cement manufacturing through optimization of

raw mix design for 40 cement plants.

Achieving desired setting time and early strength

through optimization of clinker quality, PSD and

SO content in two cement plants.

Increasing flyash content in PPC by 5-10 percent

through optimization studies.

Carried out 117 LCF studies resulting in :

- Rationalization of limestone consumption

- Estimating royalty payable to State Government

- Internal material audit in cement plants

Optimization of raw mix design

Utilization of marginal / low grade raw materials in

the manufacture of cement and building materials

Development of newer cements, composite

formulations, alternate binding materials

Improving clinker/cement quality

Maximizing fly ash content in PPC

Investigations on lump formation in cement silos/bags

and remedial measures

Effect of minor constituents on clinker/cement quality

Optimization of SO content in cement

Studies on use of mineralizers in clinkerization

3

3

CEMENTS AND OTHER BINDERS

Optical Microscope for micro-structural evaluation of clinker and rocks

Optical Micrograph of control OPC clinker fired at 1450 C(50x)o

Optical Micrograph of mineralized OPC clinker fired at 1400 C(50x)o

Shotcreting of NCB-Quick set formulation

inside tunnel at a dam site

Lath shapedalite grains

Fused belite

cluster

Perfect hexagonalshaped alite grains withinclusions of mineralizer

and micro grains of belite

Serv

ices

Off

ere

d WASTES UTILIZATION

�

�

Achievements

Techno-economic feasibility studies on utilization of industrial wastes/ supplementary materials

in the manufacture of OPC and blended cements

Developmental studies on plaster coating, tiles, bricks, blocks, boards, etc. using industrial

wastes such as marble slurry, fly ash, red mud, by-product gypsum, etc.

WASTES UTILIZATION

Waste Materials Benefits based on NCB Studies

Flyash from Thermal Power Plants Increase in utilization up to 8% in PPC manufacture

Lead-Zinc Slag from

Hindustan Zinc Ltd.

Utilization up to 6.0% as cement raw mix component

5% as performance improver in OPC

Copper Slag from

Sterlite Industries Ltd.

Utilization up to 2.5% as cement raw mix component

5% as performance improver in OPC

Steel Slag from Tata Steel Ltd. Utilization up to 2.0% as cement raw mix component

5% as performance improver in OPC

E-cat from il efineryO R Utilization 10 to 15% in manufacture of blended cement

Spent Pot Lining from NALCO Utilization up to 1.5% as cement raw mix component

Marble Dust from Marble Industries Utilization 5 to 15% as cement raw mix component

Limestone Mine Site

Clinker drop test conducted during LCF studies

Refractory kiln furniture utilizing spent catalyst from refinery Ceramic pottery wares spent catalyst from refineryutilizing

Serv

ices

Off

ere

d

REFRACTORIES AND CERAMICS�

�

�

�

�

�

�

�

�

�

�

�

�

Premature refractory failures in cement rotary kilns

Damage assessment during shipment of refractories

Quality evaluation of fresh refractories lot at cement / refractory plant

Kiln shell corrosion

Loosening of brick rings in cement rotary kiln during operation

Coating and build-up formation/ring formation

Devitrification studies of slag, alumino silicates, etc.

Refractory-raw mix interaction studies

Diagnostic studies / investigations related to

Refractory management studies and optimization of refractory

lining performance

Development and technology transfer of refractory products

High temperature investigations

Technical suitability of industrial wastes in refractory and ceramic

industries

Achievements

�

�

�

�

- Alumina Zircon Refractory (AZR) Bricks for transition zone

- Magnesia Spinelide Refractory Bricks for burning zone

- High Strength Insulating Bricks for preheating zone

- Coating Repellent Castables for build-up prone areas

.

- Kiln uptime increase by up to 12%

- Fuel consumption reduction by 2-3%

- Lining performance synchronization for one year

- Trouble free kiln operation

Developed high performance refractory products for cement plants:

Light weight sintered aggregate based on 99.5% industrial wastes for

construction industries

Use of NCB-AZR bricks in rotary kiln improved productivity

by up to 10%.

Trouble shooting services to 20 cement plants with following

benefits:

REFRACTORIES AND CERAMICS

Brick sample from cement kiln at 24m

indicated heavy discoloration due to

infiltration of gases

Corroded rotary kiln shell

Crushed light weight

sintered aggregate

Are

aso

fR

ese

arch

FUNDAMENTAL AND BASIC RESEARCH

�

�

�

Exploratory studies related to materials science

Application of nano technology for enhancing the cement quality

Development of novel cement systems and additives

FUNDAMENTAL AND BASIC RESEARCH

INDEPENDENT TESTINGINDEPENDENT TESTING

Serv

ices

Off

ere

d

�

�

�

�

�

Achievements

Facilities

- Performs coding of samples, generation of test reports and data storage and retrieval

- Facilitates smooth and efficient operations in Test House

Complete physical, chemical, mineralogical and micro structural analyses of various types of

cement, clinker, pozzolana, aggregate, concrete, admixtures, water, refractories, bricks,

limestone and other raw materials, coal, lignite, etc as per national and international

standards.

About 7000 samples are tested every year. The samples are mainly from cement

plants, builders and public sector organizations in India as well as from neighbouring

countries.

ISO 9001-2000 and NABL Accredited Laboratories

Laboratory Information Management System (LIMS)

State-of-the-art testing equipment

Flame Photometer Auto Titrator Orbital Shaker

X-RAY DIFFRACTOMETER (XRD)

X-RAY FLUORESCENCE SPECTROMETER (XRF)

FOURIER TRANSFORM IR SPECTROMETER

CHNS ANALYZER

ADIAB TIC BOMB CALORIMETER

U V - VISIBLE SPECTROPHOTOMETER

A

�

�

�

�

�

�

�

�

�

�

�

Mineralogical and phase analysis of raw materials, industrial

by-products, clinker, cement, aggregates and concrete.

Diagnostic studies on unstable kiln coating, ring formation, build-ups and

kiln shell corrosion.

Chemical characterization of raw materials, additives, clinker, cement,

pozzolanic materials, gypsum, etc.

Fully automatic, computerized and state-of-the-art equipment

Determination of functional groups such as carbonate, sulphate, silicate,

aluminate, etc.

Characterization of cements, admixtures and fuel

Ultimate analysis of various types of fuels for carbon, hydrogen, nitrogen

and sulphur

Computerized and fully automatic instrument

Determination of calorific value of coal and other fuels

Determination of major and minor constituents in cement and other

building materials

Fully automatic and rapid analysis of materials

Pulverizing Equipment Transverse Strength Testing Machine Hardgrove Grindability Test Apparatus

DIFFERENTIAL THERMAL ANALYZER

INDUCTIVELY COUPLED PLASMA SPECTROMETER

HIGH TEMPERATURE FURNACE

AUTOMATIC COMPRESSION TESTING MACHINES

�

�

�

�

�

�

�

�

�

�

�

�

Thermal behavior of raw materials, kiln feed and fuels up to 1450ºC

Polymorphism of clinker phases

Hydration characteristics of cement

Fully automatic computerized and state-of-the-art equipment

Estimation of toxic and non-toxic elements present in trace amounts in

cements, industrial wastes, water, effluents, etc.

Rapid simultaneous analysis of elements

Fully computerized furnace

Operation up to 1500ºC

Controlled heating and cooling system

Burnability studies and clinkerization

2000, 1000, 350, 100 & 50 kN capacities

Compressive strength determination of cement mortar and concrete

samples

OUR VALUED CUSTOMERS/BENEFICIARIES� � �

� �

� � �

� � �

� �

� �

� � �

Ministry of Environment and Forests, Govt. of India National Environmental Engineering Research Institute, Nagpur Central Pulp

and Paper Research Institute, Saharanpur Rajashan State Pollution Control Board, Jaipur Hindustan Zinc Limited, Udaipur

Central Pollution Control Board, New Delhi Rajasthan State Minerals Development Corporation, Jaipur State Directorates of

Mines and Geology Dhrangdhra Chemical Works, Dhrangdhra A. P. Government, Hyderabad National Mineral Development

Corporation, Hyderabad United Nations Industrial Development Organisation Indian Oil Corporation, R & D Centre, Faridabad

Thermal Power Plants - Nasik, Panki, Obra, Badarpur, Faridabad, Kota, Dhanu National Aluminium Company Ltd., Bhubaneswar

Reliance Industries Ltd. Sterlite Industries (India) Ltd., Tuticorin Tata Steel Limited, Jamshedpur

OUR VALUED CUSTOMERS/BENEFICIARIES

Mortar Cube Vibrator Flame Phtoto Meter PH / ION Meter

The Director General

NATIONAL COUNCIL FOR CEMENT AND BUILDING MATERIALS34 km Stone, Delhi-Mathura Road, (NH-2), Ballabgarh-121 004 (Haryana)

Tel : 91-129-2242051-56, 2246174, Fax : 91-129-2242100, 2246175

E-mail : nccbm@vsnl.com Website : www.ncbindia.com

Hyderabad UnitNCB Bhawan, Old Bombay Road, Hyderabad - 500 008 (Andhra Pradesh)

Tel : 91-40-23000344, 23000861, Fax : 91-40-23000343

E-mail : hyd2_ncbhyd@sancharnet.in

Published by S C Rastogi (GM-CIS) and Designed and Printed by Vinod Kumar (Programme Leader-Publication) for and on

behalf of National Council for Cement and Building Materials at Viba Press Pvt. Ltd. - New Delhi-110020

©JA

N2

00

9,N

CB

-CR

T-1