8 FLSMIDTH Parts & Services Division CALCULATION OF RAW MIXcture Chemical Nomenclature In chemistry symbols are used to donate substances. Every element is described by one on two symbols and combinations of elements can thus be donated by a formula. In cement manufacture the most important substances are: Sio, Silicon Dioxide (quartz or sand) made up of Silicon (si) and Oxygen (0). A1,05 Aluminium Oxide (Aluminium + oxygen) Fe,0, Ferric Oxide (Fe = Iron) cao Calcium Oxide (the same as burnt lime) (Ca = Calcium). The above substance, together with the gas CO, (Carbon Dioxide) make Calcium Carbonate which is the principal”component of lime stone and chalk. Mgo Magnesium Oxide is made up of Magnesium (Mg) and Oxygen (0) Like CaO in Caco, it is a component of Magnesium Carbonate MgCo,, 50, Sulphur Trioxide (which together with water gives Sulphuric Acid), is a combination of Sulphur (S) and Oxygen. This substance combined with CaO gives CaSO, the useful component in gypsum. 11,0 Water, (H = Hydrogen) Na,o Sodium Oxide (Na = Sodium)” K,0 Potassium Oxide (K = Potassium) Sodium Oxide and Potassium Oxide are called Alkalies. co Carbon Monoxide co, Carbon DioxidePage 2 Atom: Weights The unit for atomic weights is 1.6604 x 10 7’kg. The atomic weights for above mentioned elements are as follows. Si 28.09 AL 26.98 Fe 55.85 ca 40.08 Mg 24.31 K 39.10 : Na 22.99 s 32.06 8 1.008 c 12.01 ° 16.00 Molecular Weights The molecular weights of above mentioned substances can be calcu- lated from the atomic weights as follows: sio si + 20 28.09 + 2 x 16.00 60.09 A40, GEUAN Se2Qeh ona amoensaeses zorerogtae, crake BP nego” oSdGind deaiee 28 Aprasstasis aiereiog a2! toarge cx8 cso 4otoa + 16.00 36108 30 ug +0 24l3i + 16:00 = a0.3 0 2 0 2) 39110 4 16.00 = 3420 Bo aha 1°0 2% 22.99 + 16.00 = toe 30 5+ 30 3206 +3 x 16:09 80.06 id aH +0 221.008 7 16.00 1e!o16 ©, oi 48 Latot #2 x 16:00 4401 Analysis of Clini An example of the chemical analysis of clinker, and limits within which the analysis is usually found are given here: Clinker Range of Clinker Composition Sats a a sic, mat 17-26 a0, aaiow nae fo} iar ons cab 65.1 62 - 69 to 220 on Rvaties 1115 jsaioise 2 nae oni Lots on magi on mis: 0-3 Total” 99534 Freecao 1.10 BE 2sOPERATION AND PRODUCTION COURSE. . Page 3 Modules The wide limits for the composition of clinker do not mean that composition is not important. On the contrary, there must be a certain relationship between the components, and no component may be changed independently of the others. In order to express the relationship between the components more clearly the clinker modules are calculated. The silica module Mg is the ratio between SiO, and (A1,0, + Fe,0,). Using theSabove analysis as examplé, we find: Si, oan Me een = 2.79 734 97 RI{0, + Fe,0, ~ 4.94 +2 The silica module is ‘normally between 1.80 and 3.50. The alumina module M, is the ratio between Al,0, and auc a 2°3 eo 0as Z The alumina module is normally between 1-50 and 2.50. The lime saturation factor LSF is the ratio between CaO and the maximum amount of lime with which the acid components (SiO 41,0, and Fe,0,) combine. 2 ‘i cao cao SUSE = 100°X ta0,,,, 1°4 S0zgheceeio, + 1.10% Alj0, caUc65 x FEQ0, max 2 2 23 = 100 x Sud Tox WTF le x 4-90 F 0.65 x 2,57. 93°5 ‘The lime saturation factor is usually between 85 and 98%. If the LSF of cement is calculated, one must also consider CaO in the form of gypsum (CaS0,). This is done be deducting 0-7 50, from Cao. Mineralogical Composition During burning, the clinker components are combined as more com- plex substances called minerals. These are built up of one or more of the acid components Si0,, Al,0,, Fe,0,, and the basic CaO. The minerals confer én cement it? Snique properties. The following are the four most important clinker minerals: norms! range Mite 2c20, si0, = 48 3e-co8 elite 2ea0, si02 = cis do-ase BSeiievecsnsee “sacier x00, ee Saiet Recitephive’ — 4cag'vnl02, (reco, ons rePage 4 ‘The abreviated form (C,S etc.) is widely used. Besides these minerals, clinker holds’ Free CaO and Free MgO (Magnesia) in lesser quantities. The molecular weights of the clinker min -rals are: 3ca0 + Sio. +510, "a x 56,08 + 60.09 228.33 2on0; elo dale uancesebammecoios tia demo + A108, 3 % seloas toivse 21.30 deeS Recetas 4 x 56.08 + 101.96 + 159.71 85.98 Equations for calculation of the mineral composition from the chemical analysis ‘of clinker may be derived by material balance as follows: coo = 0.7888 elev o1@s11 €,6 + 0.6225 c,h + 0.4816 car Sio, = 0.232 est 0.3409 E26 198, 0.3774 Cyn +.0,2098 car 3) 4) Fe303 0.3286 CAF by matrix inversion these equations are transformed to the following equations, from which the mineral composition can be calculated (Bogue): 4,07 C' = 7.60 S$ - 6.72 A- 1.43 F -3.07 C' + 8.60 S + 5.07 A+ 1.08 F 2.87 S - 0.754 Cs 2.65 A - 1.69 F 3.04 F where Ct = CaO - Free CaO in clinker. For cement C'' is used instead of c', where C'' = CaO - Free Cad - 0.7 S03. Example (clinker). ce = 65.1 ~ 1.10 = 64.0 C8 = 4.07 x 64.0 ~ 7.60 x 22.1 - 6.72 x 4.94 - 1.43 x 2.97 ©3s = = 3.07 x 64.0 + 8.60 x 22.1 + 5.07 x 4.94 + 1,08 x 2.97 2a 2165 x 4194 -.1169 x 2.97 cir = 3.04 x 2.97 55.1% 21.8% 8.07% 4 9.03%The above mentioned matrix inversion leading to the Bogue formu- las may be expressed as follows: c 0.7368 0.6511 0.6226 0.4616) {c,s Biles 0.2632 0.3489 0 0 Ic3s x ° ©, 0.3774 0.2098] Ic3a P. 0 ° ° 0.3286) |cjar) 3s 4.07 -7.60 -6.72 -1.43 re ejs|. |-3.07 8.60 5.07 1.08 s 3A 0. ° 2.65 -1.69 a c4ar] ° ° ° 3.04 F Inc ese of surplus CaO the clinker mineral CjA is substituted ay, “0.704 0.213 S9.082? 2 1 0.7368 0.5974 0.4616 cao 3 : 3 8 a 623806) | E2qz0440.213%0.002 Cc A, Ss }O Oo 3.05 1.95) A which leads to Cao = 2.805 + 1,18 A + 0.65 F (Lea & Parker 193592* Raw Mix The raw mix shall contain those components which, after allowance for the chemical changes during burning, will give the desired clinker composition. The chemical components are found in many different forms. The principal component CaO is normally found as CaCO,. On heating CaCO, carbon dioxide CO, is liberated leaving a desidue of burnt’ Lime (Cad). The CaGo, has a large loss on ignition. other components too contribute to the loss on ignition of the raw mix (water removed by heating to 100% is not considered). On ac- count of the loss on ignition raw mix analysis differs appreci- ably from the resulting clinker analysis.OPERATION AND PRODUCTION COURSE bage 6 Let us assume that the'raw material limestone, clay, sand and iron ore were represented by the minerals Calcite, Kaolinite, Quartz and Iron Oxide: caiglee traci iatigiilts oat 0:1 58 rormia Gaesearseerdtse,2H,0 ST6 Faso Rollweigne i0d.'12°3336 02 so e023 At : aes too ee ae ae 5:8 g a 3 ioo Be 56.0 es cae on ignition 44.0 14.0 - teat aoclat| fee 100.0 to0.0 A raw mix with a percentage composition of: Calcite (x,) 77.5% Kaolinite (x) 11.58 Quartz (x,) 2 8.5% Tron Oxide (xq) 2.5% will have the following analysis: s ° 46.5 100.0 0 (13.0475) Fy = ° ° 0 100 0.115| _ | 2.5000 Cc 56.0 oO oO o 0.085] ]43.4000 L 44.0 14.0 07 Oo 0.025} [35.7100 On loss on ignition free tasis, the analysis can be calculated as follows: s, 13.8475 21.5391 Rel eel] 4-Sa2chee 7.0656 F°| “I-0.01235-71 ] 2/5000 3.8886 ee 35.7100 67.5066 = = 1.9663 = 1.8170 ine 100 x 67.5066 © ee MST Te Tess EOE a -aee = 24-847 cS) [-7-60 6.72 -1.43 4.07] (21.5391) [58.013 c3s |_| 8.60 5.07 1.08 -3.07| |.7.0656|_ }18.013 c3n ° 2.65 -1.69 0 3.e8a6[~ 112.152 cjar} [0 ° 3:04 0 67.5066} (11.821By making small changes in percentage composition for each of the raw materials Kaolinite, Quartz and Iron Oxide we can calculate the following coefficients: a(Mg) -0.044257 0.141995 ~0.2792 (My) 0.158 ° 0.7268 a(u8r)| | -4/8887 -7.0276 -2.5711 ‘a(xy) a(cys) =4-13.4417 15.7637 ~6.1665 (x3), a(cys) 11.9254 18.9277 4.2307 Clee) a(c3a) 1.57146 -0.083169 72.7119 a(Cyar 0.055163 -0.080906 4.6477 atxt) -1 -1 x =I i By matrix inversion of the first 3 rows, we find: (xy) 4.6506 2.1190 -0.093968 a(M,) a(x3) = 3.6051 -1.1392 -0.069454 (My) axa) 1.0110 -0.91525 -0.020428 a(t8P) For small changes in Mg, M, and LSP, £. ex. da(M,) alms) a(L8r) we find: Present change New raw mix raw mix 2 2 2 x 77.5 0.038 77.538 x als 0.035, 11.465 x2 8.5 0.018 8.518 = 25 01021 21479 Too a Too By making small changes in each of the modules we can calculate the following coefficients: d(c,s) 11.9175 -4.8807 2.4839 a (Me) (C38 )}.J-2.3172 3.2525 -2.3133 a(mMy) a(cta)||-4.8664 519067 -0.086403 a(n8r) a(cgar) [-4.7340 -4.2785 -0.084138): Page 8 For small changes. Mg, Ma and LSF, f.exs a(Mg) 0.01 (m8) = 0.01 atte) = 0.1 we find: Present Change New raw mix - raw mix (ignition-free) (ignition-free) a a a cs 58.013 0.319 58.332 c3s 18.014 0.222 -17.792 cla 12.152 0.002 12.154 cjar 11.821 -0.099 wee 722 Note that froma change in LSF alone, the change in C,S is approximately: 4 a(cjs) = 2.5 d(LsF). In words if the LSF is increased by 1% (f.ex. from 95 to 96%), the CS will increase by approximately 2.5% (f.ex. from 58 to 60.5%} in the completely fused raw mix (clinker)-Ais OPERATION AND PRODUCTION COURSE Page 1 Chemistry - Raw Materials . Raw Materials For the production of cement the following raw materials will be used: Limestone Shale Sand Pyrite which are all included in the raw mix. Additionally, coal ash is add- ed during the burning process and gypsum during the grinding of ce- ment. The four materials are kept separately until the raw mill. Limestone and shale are homogenised in two separate prehomogenising stores, whereas pyrite and sand are kept in silos. The coal is also homog- enised in a prehomogenising store. ‘The composition can vary for the individual raw materials, but typi- cal compositions may be the following: Material sio, A1,0, Fe,0, cao Lor Limestone 1 4.99 1.07 0.56 50.9 40.7 Shale 2) 54.5 21.4 7.04 1.40 9.34 Sand 3 90.1 4.61 1.17 0.28 1.14 Pyrite 4 20.1 2.43 74.6 0.94 1.56 Coal Ash 5 48.7 26.6 12.0 4.42 0.61 2. Composition of raw mix and clinker ‘The chemical composition of the clinker is expected to fulfil the following requirements: Lime saturation factor, LSF LSF =Fi5 pes werralnien Wien EPR nae la! 8 = 4.07 x CaQ - 7.60 x Sio, ~ 1.43 x F = 6.72 x,A (on loss-on-ignition free basis). The mineral C,S is formed during burning and is one of the principal components of*cement clinker, determining the strength properties of the final product. Normally cement clinker contains around 60% CS. With the raw materials mentioned above, it will not be difficult to create a raw mix which will produce clinker with this composition af- ter burning in the rotary kiln. Due to the amount of coal ash added during burning, the raw mix com- position will be different from the clinker composition. See later calculations For the first period of operation a raw mix composition which is easy to burn is chosen. This is primarily to protect the refractory lining of the kiln until a protective coating has been formed. As more ex- perience with kiln operation is gained, the chemical composition can be gradually changed to optimise operation with respect to fuel economy, clinker quality, etc.OPERATION AND PRODUCTION COURSE Page 3 ac as AA ac. Raw mix calculations For calculating the proportion in which the raw materials must be mixed to give a raw mix with the required set point values for LSF, MS, MA or the like, we use the so-called delta values: for a raw material is defined as the content of CaO in the raw material minus the CaO content it should have had to give an LSF in the raw material equal to the set point value for the LSF in the raw mix. Thus, + _ LSFsp BC. = Cao x(a - HBESBy where Cao and LSF is % CaO and LSF for the raw material in question, while LSFsp is the required set point value for the raw mix. * for a raw material is defined as the content of sio, in the raw material minus the S10, content it should have fad to give an MS in the raw matefial equal to the set point value for MS in the raw mix. Thus, As i ~ MSsp sio, (1 és) ’ where SiO, and MS are % SiO, and MS for the raw material in question, while MSsp is the*required set point value for the raw mix. for a raw material is defined as the content of Al,0, in the raw material minus the Al,0, content it should havé Rad to give an MA in the raw mat@rfal equal to the set point value for MA in the raw mix. Thus, e MAsp BAP = ALO esl it Red where A1,0, and MA are # A1,0, and MA for the raw material in question? @hile MAsp is the@sd point value for the raw mix. for a raw material is defined as the theoretical CS content in the raw material (loss on ignition-free basis), minus the required C,5 content in the clinker. Thus, AC S = 4.07 x Cad - 7.60 x S10) - 6.72 x A104 - 1.43 x Fe,0, - (C38)sp x (1 - 0.01 x Lor) where LOI is the loss on ignition in the raw material.AS OPERATION AND PRODUCTION COURSE Page 4 In other words, a positive AC means that the LSF value of the raw ma- terial is higher than the set point value for the raw mix, while a negative AC indicates that the LSF value of the raw material is lower than the set point value for the raw mix. If the sum of the AC contributions from the individual raw materials (which can be positive or negative) becomes 0, this corresponds to the condition that AC for the raw mix is equal to 0. Consequently, the LSF of the raw mix is equal to LSFsp. The same conclusions can be drawn with respect to 4S, AA andsc,S. : If we want to mix e.g. limestone (1) and shale (s) in the prehomog- enising store to a mixture with a given LSF, the following equations will apply? X, xAC, + K, xAC, =.0 Xy4 X, = 100 where X, and X, are the proportions of limestone and shale in the mixture The pfoportions can be found by solving the equations after having calculated the AC values. ‘The calculations are performed on dry material and therefore the X values must be converted to wet proportions based on the known water content of the raw materials. It appears from the equation system that the first equation expresses the requirement to the chemical composition, while the second equa- tion indicates that the sum of the proportions of the individual raw materials must always be equal to 1.00 (or 100%). Generally, this means that by calculating a mix of n components we can fulfil n - 1 requirements to the composition. Example It should be mentioned here that although the figures used in the example are based on raw materials from Zhu Jiang, the calculated mixes, etc. may not represent the actual situation The limestone is to be mixed with shale, sand, pyrite and - during the burning process - with coal ash to result in clinker with the following chemical modulei: LSFsp = 95 SIMsp = 2.4 ALMsp = 1.8 where sp stands for "set point” 4AS OPERATION AND PRODUCTION COURSE Page 5 Before we continue, the amount of coal ash absorbed by the clinker must be calculated. Heat consumption of kiln: 750 kenlyng | Net calorific value of coal: 6,435 keat/kg | Percentage of ash in coal: 11.88 Loss on ignition of coal ash (LOI): 0.61% Maximum absorbtion of coal ash in clinker (LOI-free): 750 (100 = 0.61) ee See As the first step in our calculation the raw material analyses are converted to clinker basis by dividing each component with the factor (1 = 0.01 x LOI) where LOI is the loss on ignition for each raw ma- terial: 1 2 3 4 5 sio, €.41 60,12. gad 20.42. 49/00 41,0, 1.80 23.60 4.66 2.47 26.76 Fe,0, 0.94 707 ag 75.78 12.07 cao 85.83 1.84 0.28 0.95 4.45 LSF 326.6 0.765. 0.108 0.869 2.52 sIM 3.07 1.92 “Mies: 43 0.261 1.26 ALM 1.91 3.04 3.95 0.033 2.22 In order to calculate the mix, the following equations can be made: X1 x AC, + X2 x AC) 4 X3 x AC, + K4 x AC, + X5 x Ac, = 0 XL x AS, + X2 x AS) + XB xAS, 4 X4 x AS, + X5 x AS, = 0 X1 x AA, + X2 x AA) + X3, x OA, + 4 x AAg + X5 x AAG = 0 : X14. X2 + X3 + X44 X5 = 1 where X1, X2, X3, X4, and X5 are the proportions of the raw materials (LOI-free) in the clinkerfis cea RTERIOR course Page 6 alculations of the values 1) Limestone: AC, = 85.83 x (1-- x22-¢) = 60.96 1 , 326.6 ; bs, = 1.835 1.8 Aa, = 1.80 x (1 - 8) = 0.104 (2) shaie: 95 AC, = 1.54 x (1 ~ 52355) =-189.7 AS, = 60S1ix (1 - 2-45) = - 18.03 2 2 1:92 ‘ AA, = 23.60 x (1.- 3:87) = 9.626 (3) Sand: 95 Oy = 0-28 x (1 ~ g23qg) = - 246.0 2 AS, = 90.14 x (1 - 7o"4q) = 76.12OPERATION AND PRODUCTION COURSE Page 7 As, = 20.42 x (1 - 5258 4 0.28L) | tee er 192.4 . 95 AC, = 4.45." (1 - $855) = - 163.3 AS, Aas Now the calculated A-values can be inserted into the equation system. The amount of coal ash, X5, is already known, namely, X5 = 1.37. X1(60.86) + X2(- 189.7) + X3(- 246.0) + X4(- 102.9) + X5(- 163.3) = 0 X1(1.835) + X2(- 15.03) + X3(76.12) + X4(- 167.4) + X5(- 44.33) = 0 X1(0.104) + X2(9.626) + X3(2.536) + X4(- 132.3) + X5(5.063) = 0 X1 + X24 X3 + -R4 + X5 =, 100AS OPERATION AND PRODUCTION COURSE Page 6 The corresponding matrix, 60.86 - 189.7 = 246.0 - 102.9 27ae 1.835 - 15.03 76.12 ~ 167.4 60.73 0,104 9.626 2,536 - 132.3 - 6.936 1 1 1 1 98.63 can, by means of multiple row operations, be brought to a form which makes it possible to solve the four equations above. Solution: 2 Xl = 76.248 Limestone X2 = 15.918 shale x3= 5.118 sand x4= 1.378 Pyrite RS = 1.37% Coal ash This solution is on clinker basis and must be converted to raw mix basis by dividing by the LOI factor (1 - 0.01 x LOI,) where LOZ, is the loss on ignition for each raw material. Clinker basis Raw mix basis x1 76.24 128.57 x2 15.91 17.55 x3) 5.11 5.17 x4 1.37 1.39 152.68 As can be seen, the sum of the new proportions is not equal to 100, so each proportion is divided by the sum (normalised)+ pyemi2e.57 x 100% 84.218 17.55 152.68 x 100% = 11.498AS OPERATION AND PRODUCTION COURSE Page 9 xs = 3.398 x4 = —pgl:32 x 1008 = 0.918 E 100.00% This is the actual dry composition of the raw mix to be produced by the raw mill. The chemical composition of this raw mix will be: sio,, = 193708 A1,0,'= 3.54% Fe,0, = 2.00% cao = 43.04% Lor = 35.408 LSF = 98 SIM = 2.47 aM = 1.77 In order to calculate the actual wet proportions (i.e. feeder set points), we must know the water content. for each raw material. In this example the following data has been used: Limestone (1) = 5.0 Shale = 8.5 sand = 3.3% Pyrite =7.8% The wet proportions are calculated as follows: » Dry prop., wot Prop-; =] — 0,0LematlAa OPERATION AND PRODUCTION COURSE Page 10 where wet prop.; is an intermediate figure and and % H,0 is the water content for each raw material. The actual wet proportiéns are: wet prop.; wet prop. = ————+,- x 100 wet prop.; * gd.2n ‘i ce . 88.64 ido e xg = jee 12:56 3.39 T- 0.083 See * eS - oe 0.99 EX* = 105.70 88.64 a Si = = SUPOAE loge: = 83.86% Na =e eee es 11.88% sec sae SD ss va = 43:51,» 1008 = 3.328 nao : 0.94% z= 100.008 This is the actual feeder settings.AS OPERATION AND PRODUCTION ‘COURSE Page 11 Raw mill control When the raw mill is started, the raw material feeders are adjusted according to the wet X values calculated initially. This calculation is based on raw material analyses supposed toi be as representative as possible. But raw materials are seldom completely homogeneous, thus the analysis will vary with time. Although usually less impor- tant, it should also be mentioned that the feeders might not work as accurately as supposed. All in a11 this results in a raw meal which does not usually have the exact LSF, MS and MA required. Normally the first average sample of raw meal taken and analysed will cover the first hour's production after the mill has been started. As for the raw materials, the A-values for the raw meal are calcu- lated: 2 NX _ LSEsp AGaq i? C0,go01-" Pope As eee) S105 4.5) 0(:dir RM 20m MS iu & = Masp, a Bann = A203 ry (1 ma) RM If the first hour's production results in a positive ACpy, we wish to produce a raw meal with a negative SC,, during the subsSquent period, 50 that the overall SC, approaches zé¥o. We cannot, however, add up ACpy'S without weighing" them with the number of tonnes produced dur- inthe respective periods. For each hour (i.e. each sample) thesCay is multiplied by p, the production during that hour, divided by tno! standard monthly production, p,. For the first hour we get: el R CASAT = ACpy x For each subsequent hour (sample) the CASAT is updated, i.e. the new contribution is calculated and added to the old sum: CASAT (nen) = CAST (018) + AC py XB (new) h Similarly for MS and MA: SISAT (new) = SISAT (01d) +ASpy, x B (new) PhFa OPERATION AND PRODUCTION COURSE Page 12 ALSAT (new) = ALSAT (01d) +A Apy x B (new) h ‘The CASAT, SISAT and ALSAT are thus expregsions of how far off the ¢ desired set points the whole stock of raw meal is. Thus the CASAT in- dicates how much the next standard production should deviate in Cao contents if the average LSF of all the raw meal is to equal LSF,). > P Obviously, if this adjustment is to have any beneficial effect, the - new raw meal must be mixed with all the old raw meal. This takes place in the raw meal homogenising silo. When the silo is empty the CASAT is set at zero. During the filling of the silo the CASAT will change. Our control strategy is then aimed at keeping the CASAT around zero all the time, so that when raw meal extraction from the silo begins, the silo contains a large quantity of raw meal close to the right composition. The CASAT, SISAT and ALSAT are calculated by the QCX system after each sample has been analysed. The updated values are displayed to- gether with the analysis result. In this way the plant operators are kept informed about how well the raw material feed is regulated. For the QCX system's calculation of new raw material proportions in order to eliminate a CASAT, the length of the elimination period must be decided. Often a period of two to four hours is chosed. Sometimes too short a period will result in very drastic feeder adjustments, and too long a period might lead to inhomogeneous raw meal from the silo (for kiln feed), since the mixing cannot make up for the resulting slow changes in’ LSF. If a period of four hours is decided upon, we thus want to eliminate fone fourth of the CASAT during one hour. ‘The combined AC,,, for that hour must then equal one fourth of the CASAT with the opfUsite sign. The equation for the proportions wi11 be: Ky, AC, +X, KAC, +X, x AG, + x, x AC, = - The C values for the raw materials are the same that were used for the calculation of the initial proportions when the mill was started. Similarly for SISAT and ALSAT: X1, X08), +X) X AS, +X, x AS, +and again: Ky, tM, kg HK, = 1.00 The solution will then give the new dry set points for the feeders, which are,then converted to wet set points. The method shown here is the most simple proportioning calculation used by the QCX system. It will only succeed if the raw materials are fairly homogeneous, i.e. that they very around the same average analysis. If this is not the case, the QCX system can perform more complex Calculations better suited to more difficult conditions. In any case, the CASAT, SISAT and ALSAT are calculated and updated, enabling the operator to control the performance of the automatic raw mill control system. Based on the above-mentioned principles for raw mill control, also the mixture of limestone and shale fed to the prehomogenising store is controlled. The basis for this control is continuous registration of the limestone and shale feed to the storage and the average analy- sis taken from the automatic sample station.Aa OPERATION AND PRODUCTION COURSE Raw Mix Calculation If the analysis of each of the four raw materials M,, Mj. M, and M, are known, the percentage with desired modules ¥, total material balance’ SiO. and Al,0, as follows: composition of a raw mix ig Mp and LSF may be calculated by a S’and partial material balances on CaO, bi ” a ay + XD + x3 > 100 LSP LSP LSE © c,qal- tsF,)** +c, - [SF .)%2 ¥ cj. oe 1sF,)*3 +O, Mg My, M M, s,Q - iS dx, + 5,0 - aeeleoee (Gas x3 oP ong - 2 3 4 " M ¥ " Av = gh, + ald - pdx, +a; 2 pox, + ay - pox, = 0 Me h n in 2 3 4 Example M, M, Raw Mix co raca * Limestone clay s 2.87 48.5 ° A 0.87 11.9 FE 0.44 5.05 c 52.3 11.3 L 42.2 12.1 LSF 559.4421 7.3796 95Page 2 a es = 100 95 ‘ 95 “ 52.3 (1 - geg2egop) ee + 1263(2 - 333 5Q)x, =0 = 75.55078 = 2.44938 Check: Raw Mix LOI~free + My Raw Mix 75.55078 © 24.449387 s 14.0262 21.5261 a 3.5668 5.4739 FE 1.5671 2.4051, ic 42.2758 64.8807 L 34.8408 a a 4 ; 2.73 MS 2128 chs 60.2 os 16.3 cn 19.4 lar 7:31 Question: If blastfurnace slag and limestone with the analyses Blast furnace Limestone slag % a3 sio 2 29 5 a1,65 7 3 Fe203 ah 1 cad 55 51 Lor 3 40 were used as raw materials. In what proportion should the two raw materials be mixed in order to obtain LSF = 90%?fis OPERATION AND PRODUCTION COURSE ‘ Page 3 Answer: Raw Mix M, My M+ M, s 29 5 a 7 3 F 1 1 c 55 51 L 3 40 LSE 61.0365 280.3738 90 x + x) = 100 ao 90 55(1 - gO) Xe + SLD ogres x= jlo x, = 57.02318 x_ = 4297698 Check: Raw Mix LoI-free MUd+ oie Raw Mix 57.02318 . 42.97698 s 18.6855 23.0405 a 512809 6.5117 F 1! 0000 122331 c 53.2809 65.6990 L 1819015 LSP 90.0 My 2.97 ay 5.28 gta 16.8 Ca 30.8 ca 1s.2 Char 3.75Raw Mix Composition L c 34, T, . = L = Limestone (tonnes) nites © = clay (tonnes) ~ S = Sandstone (tonnes) | T = Titration (4caco, ) a= c/s Basis: L + C + S = 100 tonnes (dry) | aco, ~ balance: i c s tm het) + 585M) + 7S5(t5) ar) 100-1, 100!) * Too ‘c/s? where: = 4 is Toys = Tylte) + halts) Numerical example: i 62.16 Cc =iaal "see ge7a 92:9 T= 0-55... Tom 11.8 T = (0,6216)(92.9) + (0.1411) (0.55) + (0.0373)(11-8) = 76.84 14.11 = _3-78 1 = = 3.78 and = 255) + 1.8) = 2.90 ie eee ee (0.8216)(92.9) + (1- 0.8216)(2.90) = 76.84 3 A‘The CacO,-balance may be rearranged to give the following: L (Ty, - Toys) = 100 (7 = Tro/s) Using this equation for the following two situations and assuming constant Ty - Toy a) From n~ 1 hours to n hours (past hour): L,, (7, nahn ~ Tejada Ua Peper b) From n hours to n+ 1 hours (coming hour): Trl gy tege) F200 (Tues toys) + yields the relationship: Trey - Ty are Ee (1) Uaeays eee ed The desired raw mix titration T,,; for the coming hour may be : determined from the following efpression: saldo, ee n (2) eae aes PP o wher T, = target for raw mix titration n = hours f = hours to bring saldo to zero production in tonnes per hour P P, = standard production ) p saldo, = EP(T - T,) = saldo,, + P,(T, ~ To) iCombining (1) and (2), the desired composition for the coming hour may thus be determined as: Numerical example: To 77-0 q= 3-78 n= 4 Por 7s ems 2.9 7,7 77.6 Lb, = 83.0 saldo, = 200 200 77.0 - (4)(75) ~ 2.9 byt” [perce Fy esse) 81.68 Pa = = j Cpe = 3y78,-(200 - 81.6) 14.5% = 1 ~ = Sy = —pppcqg- (200 - 81-6) 3.98If the chemical analysis of each of the three raw materials limestone, clay and sandstone is known, the percentage composition of a raw mix with desired characteristics LSF and Me may be calculated fram the total material balance, and the partial material balance on CaO and Sio,. L, C, and S are found as solution to the following three equa- s tions: L +c +S = 100 ise: ise LSF, %ca0, (1 L + ¥cadg Og (1 ~ s=0 yl = FE) (1. - Bye + acaog(a - ESE) he mS Yai tsioz, (1 - |S)L + asioac(i - |S)e + ssioasia - |8)s = 0 cr 4, Le Numerical example: Limestone Clay Sandstone Raw Mix asio. 3.74 55.5 66.4 si 2a1,0, 0.91 21.5 10.4% ' 2Fe703 0.88 7.80 2.59 cal 50.9 0.41 5.39 SLor 41.8 8.14 7.38 aLsF 420.04 0.22062 2.6969 96 Mg 2.0894 1.8942 5.1116 2.2 i +¢ +s = [100 page Y eee. Erte Gat) ow 50.9(1 Fiecog TE + 0-410 Soer)o + 5-390 = a 85eq)8 70 2.2 a . 5.) eee faa = sos 3.740. YL + 55.5(2 pasar C+ 66-46 5 ) ° ' s Solution: 82.18OFERATICS AN. PRUDICTIUN COUWSE Page 8 The percentage composition (L', C', and S') on wet basis can be calculated from the percentage composition (L, C, and S) on dry basis as follows: pees 100-W, Lt = —,—_, + —_,—. (100) a + loo-w! —100-W&—-100-nE. ' 100-W, ie cle. (100) a; 100-w? —-100-Wg st = —{~———, §&___.—- (100) where: Wi = % moisture of limestone on wet basis WA = 8 moisture of clay on wet basis =~ Wg = & moisture of sandstone on wet basis Numerical exampli L wt Lt c 61.6 @tGiee 1455) Geu= 3,9 2 We = 10 81.6 we tts peg ne Too=2 * Too-i0 * To0-5- 14.5 Too=10 (100) 1.6 , 14.5 35 Too=2z * Too-10 * To0-5 ee ade Te? Too-2 * Too-i0 * To0-5 0 a