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Acid Proof KSC Cement

Introduction:
Acid Proof cement KSC is a potassium silicate based corrosion resisting cement. The basic distinction between Cement SSC & KSC is the use of Potassium silicate solution as the binding agent whereas in the case of acid proof cement SSC, sodium silicate solution is used.

Acid Proof Cement KSC being based on Potassium silicate has marked advantage over cement SSC based on Sodium silicate solution. Acid brick linings carried out with KSC Cement are not subject to crystal formation in the pores of the cement. Besides Bitumen mastic surface is joint-less hence there is no danger of Acids Or Alkalis percolating through the surface. Cement leaves behind no water of crystallization and as such, KSC cement do not expand as much as SSC Cement which sometimes lead to cracks in the lining carried out with Sodium silicate based cements, in case of extremely turbulent conditions.

Acid Proof Cement KSC has outstanding resistance to concentrate as well as dilute oxidizing acids, their salts and solvents and is principally used to prevent corrosion resulting from concentrated Acidic environments. Acid Proof Cement KSC however is not suitable for alkalis and therefore is not recommended in case of alternative Acidic or Alkaline conditions. One of the most important property which acid proof cement KSC possess is that the KSC Cement mortar, on its achieving final set, is very less impermeable to acidic water solutions as compared to Acid Proof cement SSC. This property of Acid Proof Cement KSC makes its use on a wider scale for plant linings.

Cement KSC is principally used for laying and jointing of Acid proof bricks or tiles for acid resistant plant linings. Mostly, it is used in conjunction with Acid proof brick for constructing Acid proof brick. Sheathing for chimneys, vent stacks, exhaust ducts, absorption towers, tank linings, H₂S0₄ storage tank linings etc. Unlike cement SSC Acid Proof Cement KSC is ideally suited for construction of fume chambers stacks handling hot dry acid fumes and is particularly suitable for linings that must resist the attack of S0₂ or gases containing S0₂ at higher temperature.

PROPERTIES OF BCPL'S ACID PROOF CEMENT: KSC

Chemical Properties: Acid proof cement KSC, when fully set, exhibits the following properties.
  (a) It is resistant to Chlorine, Bromine, Ammonia and Concentrated oxidizing acids.
  (b) It has very good resistance to concentrated oxidizing acids like Sulphuric Acid, Phosphoric Acid, Nitric Acid, Oxalic Acid etc.
  (c) It can also withstand hot concentrated glacial acetic acid.
  (d) It is not resistant to Hydroxides of Calcium, Potassium, Sodium, or Ammonium Hydroxide
  (e) It has marked resistance to dry and wet chlorine, Hydrogen Sulphide, Sulpur dioxide dry or wet and to organic solvents like Acetone, Methyl Alcohol, Benzene, Carbon tetrachloride, chloroform etc.

Physical Properties:

Characteristics	Values
Colour	White
Density (lbs/Cub.ft.)	130
Water Absorption	2-5%
Tensile Strength (Psi)	400
Compressive Strength (Psi)	2800
Bond Strength	180
Coefficient of thermal expansion	6.0 x 10-6

PREPARATION OF ACID PROOF CEMENT KSC:

KSC Acid Proof Cement mortar is prepared by mixing liquid and the powder components of KSC cement, so as to form a workable mix. The mixing ratio of KSC Cement is one part by weight of KSC solution to three parts by weight of KSC powder. The mixing ratio may vary slightly depending upon the temperature, workmen's preference and site conditions.

Acid proof cement KSC sets thoroughly by chemical as well as physical changes. We recommend the following procedure for the preparation of KSC Cement Mortar.

  1. Stir the contents of the KSC Liquid Container thoroughly, prior to its use. Draw ½ kilo of the solution from the container and place into a suitable mixing pan.
  2. Weigh 1½ kilos of the KSC powder component supplied and add gradually, while constant stirring powder into liquid and mix thoroughly. During the course of mixing please ascertain that no lumps are formed. Uniform mixing is very essential for preparation of the KSC cement mortar.
  3. KSC Cement mortar should be spread out into thin layers, so as to dissipate the heat of reaction and for lengthening the working life of the cement. Normally, KSC cement starts setting within half an hour and as such only that much of the cement mortar than can be consumed within half an hour should be prepared.
  4. Do not use KSC Cement once it starts setting. This is indicated by KSC mortar getting stiff and unworkable.
  5. Do not add KSC liquid, in order to make mortar usable. Water, also should not be used in order to make KSC mortar usable.
  6. Batch size for the preparation of KSC Cement can be varied, depending upon the requirements at site. However, larger the batch size, shorter is the working life of cement. In view of this factor, small batches should be mixed for lying of Acid Proof Bricks.
  7. Remove all the KSC cement mortar from the mixing pan, before another batch is mixed.
  8. In case of higher temperature at the site, where the KSC mortar is to be prepared, the same should be carried out under cold conditions. In this case, liquid container is kept under Ice-cold water bath and mixing carried out into pan kept in Ice-cold water bath. This will increase the working life of KSC CEMENT MORTAR.

APPLICATION OF KSC CEMENT:

Acid Proof potassium Silicate based KSC Cement is normally buttered on all sides of Acid Proof Bricks except the side facing the surface to be exposed to corrosives, and is placed into place. In case the service conditions demand the use of KSC cement both for the bedding as well as for pointing of Acid Proof Bricks, the bricks are slid into place and are squeezed, so as to form as small joint as possible. This is ascertained by observation of the KSC mortar exuding out of the vertical faces of the brick.

The exuding of KSC mortar from the brick surface indicates that a uniform joint is obtained.

The acid proof bricks to be laid should be free from moisture and should necessarily be dry and free of dust particles before being laid.

After the joints in between the acid proof bricks hardens, paint the same with 10% Hydrochloric or 20% Sulphuric acid. This treatment is essential in case of Silicate cements as this acts as a hardening agent.

During the course of installation of acid proof lining work, the area should be kept free from spillage of water, constructional dust. Portland cement. Moisture etc., as this interferes in the final setting of KSC cement.

Packing: 
BCPL'S ACID PRCOF CEMENT' KSC is supplied as two component system.
KSC Powder: 50 Kilos KSC Powder packed in Polythene lined Gunny Bags. .
KSC Solution: 25 Kilos KSC Solution in a Galvanized. M. S. Drum.

Storage: 
KSC Cement Powder as well as liquid does not deteriorate on storage. However, KSC liquid has a tendency to absorb moisture from air being Hygroscopic in nature. As such, the drum containing KSC liquid component should immediately be closed once the material is taken out. KSC Cement Powder as well as KSC liquid drums should be stored in a covered place, free from moisture or water and be kept away from direct sun light.