transformation process, qa/qc

8/9/2019 transformation process, QA/QC

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ChE427N

1. Transformation process of Lafarge cement

Step 1: Raw Materials reparationThe raw materials nee!e! to pro!"ce cement #calci"m car$onate% silica%al"mina an! iron ore& are generall' e(tracte! from limestone roc)% chal)%shale or cla'. These raw materials are won from the *"arr' either $'e(traction or thro"gh $lasting. These nat"rall' occ"rring minerals are thencr"she! thro"gh a milling process. +t this stage% a!!itional minerals area!!e! to ens"re the correct chemical composition to ma)e cement is in

place. ,t is then !rie! an! gro"n! to the correct chemical composition an!store! in silos for the ne(t process. Lafarge recogni-e! that s"ch rawmaterials are nonrenewa$le reso"rces an! as s"ch% the mining an!processes are f"ll' in line with Lafarge/s s"staina$ilit' actions an!commitments. 0hereer possi$le% we wo"l! s"$stit"te nat"ral reso"rceswith $'pro!"cts from other in!"stries.

Step 2: Raw rin!ing an! 3"rningrin!ing pro!"ces a ne pow!er% )nown as raw meal% which is preheate!an! then sent to the )iln. The )iln is at the heart of the man"fact"ringprocess. 5nce insi!e the )iln% the raw meal is heate! to aro"n! 1%68C it

is of a similar temperat"re to molten laa. +t this temperat"re% chemicalreactions ta)e place to form cement clin)er% containing h'!ra"lic calci"msilicates.,n or!er to heat the materials to this er' high temperat"re% a 2%8C 9ameis re*"ire!% which can $e pro!"ce! thro"gh the "se of fossil an! waste!erie! f"els. The )iln itself is angle! $' 8 to the hori-ontal to allow thematerial to pass thro"gh it% oer a perio! of $etween 2 min"tes.


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;pon e(iting% the clin)er is coole! an! store! rea!' for grin!ing to pro!"cecement.Step : Cement rin!ing an! Shipping

+ small amo"nt of g'ps"m #6"ring this phase% !i?erent mineral materials% calle! =a!!itions/%ma' $e a!!e! alongsi!e the g'ps"m. ;se! in ar'ing proportions% thesea!!itions% which are of nat"ral or in!"strial origin% gie the cement specicproperties s"ch as re!"ce! permea$ilit'% greater resistance to s"lfates an!aggressie enironments% improe! wor)a$ilit'% or higher*"alit' nishes.

@inall'% the cement is store! in silos $efore $eing shippe! in $"l) or in $agsto the sites where it will $e "se!.

2. CompareAcontrast *"alit' control an! *"alit' ass"rance. Bow to improeCA+D

"alit' control is a s'stem of maintaining stan!ar!s in man"fact"re!pro!"cts $' testing a sample of the o"tp"t against the specication. "alit'ass"rance is the maintenance of a !esire! leel of *"alit' in a serice orpro!"ct% especiall' $' means of attention to eer' stage of the process of!elier' or pro!"ction.

3asicall'% the !i?erence $etween the two is that *"alit' control foc"ses on

the pro!"cts while *"alit' ass"rance refers to the process in ma)ing s"chpro!"cts.

"alit' ass"rance ma)es s"re 'o" are !oing the right things% the right wa'.

The p"rpose of + is to preent !efects from entering into the sol"tion in the

rst place."alit' control ma)es s"re the res"lts of what 'o"/e !one are

what 'o" e(pecte!. ,t is a reactie means $' which *"alit' is ga"ge! an!

monitore!.F

QC is detection. QA is prevention.

. 0hat are the components of goo! man"fact"ring practices #M&D

There are man' important parts of M compliance. 5f these% the most

critical are:


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roper !oc"mentation an! recor!s /if it is not recor!e! it neer

happene!/ accor!ing to the inspectors. ,t is important that all actions%

eents an! !ecisions relating to the *"alit' of the pro!"ct m"st $e

recor!e! at the appropriate leel of !etail in a controlle! wa'.

Control of materials. This refers to ens"ring that all materials "se!%

whether the' $e the raw materials% components s"ch as $ottles or

stoppers% an! pac)aging materials% are of the s"Gcient *"alit' an! are

tracea$le.

Thoro"gh ho"se)eeping an! cleaning. M re*"ires that people wor)

in an or!erl' an! metho!ical wa' an! that wor) areas are neat% ti!'

an! there is segregation $etween tas)s where re*"ire!. This will

re!"ce the potential for errors an! mi("ps to occ"r

Responsi$le personnel $ehaior. This incl"!es s"ch areas as reporting

inci!ents an! errors imme!iatel'% $ehaing appropriatel' in controlle!

areas #e.g. minimi-ing particles an! micro$ial contamination in cleanrooms&

rocess control at all steps. This leel of control relates to ens"ring that

all parameters are in control thro"gho"t the man"fact"ring process

#e.g. time% temperat"re% pB& an! reporting imme!iatel' if there is a

noticea$le !rift or a!erse tren!.

Maintenance of e*"ipment. This inoles ens"ring all e*"ipment "se!

in the man"fact"re of pro!"ct is /t for p"rpose/ an! is cleane!%

maintaine!% cali$rate! an! erie! as appropriate an!

la$ele!Arecor!e! as s"ch. This is s"pporte! thro"gh initial an! ongoing

ali!ation. +n' e*"ipment not t for p"rpose sho"l! i!eall' $e

remoe! or clearl' la$ele!.

4. ie s"$stantial e(amples an! !enitions of statistical process techni*"es

"se! in *"alit' control.

>eeloping control charts + control chart #also calle! process chart or

*"alit' control chart& is a graph that shows whether a sample of !ata

falls within the common or normal range of ariation.

Chec) Sheets Chec) sheets are simpl' charts for gathering !ata. Bistograms + histogram is a snapshot of the ariation of a pro!"ct or

the res"lts of a process.

areto Charts The areto chart can $e "se! to !ispla' categories of

pro$lems graphicall' so the' can $e properl' prioriti-e!.


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Ca"se an! E?ect >iagrams of @ish$one >iagrams The sh$one chart

organi-es an! !ispla's the relationships $etween !i?erent ca"ses for

the e?ect that is $eing e(amine!.

transformation process, qa/qc

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