Cement Industry Expertise

Ask Dr Clark - Raw materials

Q: What is SO3 in linker i! SO3 in lime st"ne is #$3%&$ Sulphur in Petcoke is 6-6.5%.Petcoke is firing in kiln with a 40-45% of total coal consumption per hour.if any direct formula/calculation is there for getting S ! in clinker.Please suggest. A: 'he "ntri(uti"n t" the linker SO3 !r"m the limest"ne will (e )i*en (y #$3% x #$+ x ,$%%$ 'he "ntri(uti"n !r"m the !uel will (e )i*en (y SO3 "ntent "! !uel x k) !uel-k) linker$

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Q: new ement plant t" (e (uilt and needs expert ad*i e do you offer such a ser"ice in which you pro"ide expert advice for newly #uilt cement manufacturers$ A: Certainly$ 'hat is "ur main line "! (usiness$

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Q: /i)h 0)O limest"ne %e are in the process of doing sampling of limestone to check on their &uality #efore making a proposal to ac&uire the limestone hill for setting up an integrated cement plant.%e ha"e taken random surface samples co"ering a#out '0% of total hill area and found out that (a /)g reading as follows 55.!/0.**+

55.*/0.*5+5!.!/'.4,+5'.-/*..,+4'.!/''.0+!6.4/'!.,+54.'/'.!*+55.4/0.'.+4-.6/6.'6+55.5/0.*4.%e ha"e now used /ack hammer so that we can deeper sample at the high )g /ust to retest the &uality..0o u e1pect difference in )g areas again

le"el #etween surface sample and

sample at * feet depth$2s the limestone hill usa#le if we carefully mi1 it$%hat is the limit for )g at raw mi1 stage$(an we use the high )g limestone as additi"e for cement

grinding$ 3ppreciate your further ad"ice on our ne1t step. A: I kn"w n" reas"n t" expe t a di!!eren e in 0)O "ntent "! the limest"ne (etween sur!a e samples and th"se at 1 !eet depth$ .ased "n the in!"rmati"n pr"*ided s"me "! the limest"ne is hi)h purity and there!"re ertainly usea(le with are!ul (lendin)$ 3& 0)O in limest"ne is the maximum limit2 dependent t" s"me extent "n 0)O "ntent "! se "ndary materials and y"ur national standard !"r ement$ 'he hi)h 0)O limest"ne an (e used as an additi*e !"r ement )rindin)$

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Q: Whi h sla) is suita(le !"r pr"du in) 3"rtland sla) ement 4 %hich slag is suita#le for producing portland composite cement$ Air cooled slag or 4last furnace slag$ 5ahmid A: 5ranulated (last!urna e sla) that has (een 6uen hed in water when drawn "!! the (last!urna e$ Air- ""led sla) has little "r n" hydrauli pr"perties and is n"t suita(le$

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Q: /"w I an dete t sla) in 3"rtland C"mp"site Cement 0ear Sir+ 6ow 2 can detect Slag or &uantity of slag mi1ed in portland composite cement #y chemical method$ 5ahmid A: 'hat will (e di!!i ult (e ause the sla) will (e "mp"sed mainly "! lime2 sili a2 alumina and iron oxide there!"re undistin)uisha(le !r"m the linker minerals (y hemi al meth"ds$

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Q: Raw 0ill Residue 0ear Sir+ is there any effect of raw mill residue on the bag house #ags either we grind finer or coarser. A: 7"2 I d"n8t expe t the !ineness "! )rindin) the raw meal will ha*e any e!!e t "n the (a)h"use (a)s$

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Q: /"w I an estimate !lyash2sla)2limest"ne "ntent in p"rtland "mp"site ement 6ow 2 can estimate of 7ly ash+ slag +limestone in portland composite cement A: 'he (est way w"uld (e (y 9-ray di!!ra ti"n$

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Q: Dear Sir2 we are usin) hi)h sulphur "al$ Clinker :t$ wt$ is ,3## -,3%#$ we want t" in rease C3S m"re than ;%&$ 3lease ad*i e !"r re6uired li6uid phase in the linker$ Our kiln !eed :S<= ,,12 S0= 1$1;2 Al1O3= 1$>2 <e1O3= 1$;$ Our linker SO3= 1$? t" 1$+ A: '" a hie*e a hi)her C3S "ntent in linker y"u need t" raise the lime saturati"n "! the linker$ @"ur kiln !eed lime saturati"n is hi)h (ut s" is y"ur linker SO3$ 'he !ull analysis "! kiln !eed2 "al ash and linker w"uld (e re6uired t" pr"perly adt*ise y"u this$

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Q: /"w t" !ix the raw mix rati" with !"ll"win) raw materials 0ear Sir+ 2 ha"e following composition of raw materials. 8 2 Si * 3l* ! 7e* ! (a 8imestone 4*.5- !.*4 0.., 0.!- 50.0' '.*4 (lay 5.-. .4.,- -.-0 6.*0 0.,- 0.*4 2ron )g re 4.65

,.'6 *.00 -!.04 0.06 0.4' 4y using of these raw materials 2 want to fi1 the raw mi1 with following modulus #ut 2 can9t success to get following target modulus in raw mi1 6):*.! S):*.5 2):'.5 6ere+ 2 am kindly asking what are the ratios of raw mi1 to get the a#o"e modulus of the raw mi1. 2f not+ what kind of correcting raw mat should 2 used to o#tain a#o"e target modulus in raw mi1$ ;our "alua#le suggestions will #e "ery apprecia#le for me <egard 0inesh =oirala A: 'Ahe hydrauli m"dulus is an "utdated "n ept$ .etter is t" use the lime saturati"n !a t"r$ In "rder t" "ntr"l 3 rati"ns in the mix y"u need !"ur raw materials$ @"u "nly ha*e 3 s" an "nly "ntr"l 3 rati"s$

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Q: .elite %hat is the ma/or difference #etween alpha-#elite and #eta-#elite $ 6igher content of which crystal form of #elite is prefera#le $ >1plain. A: 'hese are di!!erent rystal !"rms "! the (elite$ (eta-(elite has the m"st hydrauli rea tti*ity and this there!"re pre!erred$ It is what is n"rmally pr"du ed in an industrial ement kiln$

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Q: :aterite 6ello 0r.+ (an you suggest any material that would replace laterite and still produce high strength cement $ 2f possi#le +please state the chemical composition of such material. A: :aterite is n"rmally added t" ement raw mixes t" in rease the <e1O3 "ntent "! the mix$ 'here!"re any s"ur e "! ir"n "xide an (e used instead "! laterite$ Alternati*ely a hi)her alumina m"dulus mix an (e prepared whi h will redu e the am"unt "! laterite used and still pr"du e hi)h stren)th ement$ 'he <e1O3 "ntainin) linker mineral BC;A<C d"es n"t make a maD"r "ntri(uti"n t" ement stren)th$

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Q: C"atin) 6i Sir+ %hat is coating inde1 $ what is its significance $ A:

'he "atin) index is an indi at"r the likelih""d that a raw mix "! a parti ular hemistry will )i*e rise t" "atin) with the ement r"tary kiln$

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Q: Clinker .urnin) 6i Sir+ %hat is the general e1pression for calculating #urning temperature of clinker $ A: 'here is n" )eneral expressi"n !"r al ulatin) the (urnin) temperature "! linker$

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Q: C"al Ash 6ello 0r.+ 6ow do coal ash gets added to the kiln feed $ Please clarify with e1planation A: 'he !ine "al (urnt in the kiln "ntains s"me ash$ 'hat ash is pred"minatly sili a and alumina s" the ash "m(ines with the lime !r"m the limest"ne t" pr"du e the linker minerals C3S2 C1S2 C3A and C;A<$

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Q: E!!e t "! Ash %hat is the effect of ash on 8S7+ S)+ 3) of clinker $ A: C"al ash is mainly "mp"sed "! sili a2 alumina and ir"n "xide s" the :S< is redu ed$ 'he e!!e t "n sili a and alumina m"dulus depends "n the exa t "mp"siti"n "! the ash$

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Q: /ydrauli 0"dulus 6ello Sir+ %hat is the significance of hydraulic modulus in the present days $ A: 'he hydrauli m"dulus is the rati" "! CaO t" the sum "! SiO12 Al1O3 and <e1O3$ It was "!ten used hist"ri ally and !"r )""d ement 6uality2 it sh"uld (e (etween ,$E and 1$3$ /"we*er2 this is n"t a use!ul as the lime saturati"n !a t"r s" it d"es n"t ha*e maD"r si)ni!i an e t"day$

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Q: industrial waste in ement Sir+(an we use ?inc metallurgical waste+ /arosite in cement manufacturing process either as raw material for raw meal preparation or as set retarder #y partial replacement of gypsum$ any#ody in the world uses ha?ardous waste /arosite in cement manufacturing process$

A: I am n"t aware "! any"ne usin) Dar"site in the ement manu!a turin) pr" ess$ 'he !irst step w"uld (e t" kn"w the hemi al "mp"siti"n "! the Dar"site$

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Q: Online Analyser !"r Raw 0ix 6ello Sir+ (an you pro"ide some information a#out online analyser used for monitoring raw mi1 $ @owadays what are the online analysers cement manufacturer use for controlling the raw mi1 $ Please ad"ice. A: 'he m"st widely used w"uld (e 5ammametri s "r the S ante h analysers$

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Q: :ime Saturati"n <a t"r B:S<C 6ello Sir+ 2t is found that 8S7 of output of the <aw mill ABertical <oll )illC is ,4% whereas the 8S7 of =iln feed is ,5%. (an you pro"ide any possi#le reason for this change $ Please ad"ice. A: 'his mi)ht arise !r"m h"w the dust !r"m the kiln is handled$ 'he kiln !eed will "ntain the dust$ 'he raw mill pr"du t mi)ht n"t "ntain the dust$

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Q: kiln n"t )i*in) rated pr"du ti"n sir our kiln with capacity 600 tonns per day is not going on rated capicity.it is operating upto 60% of rated capacity.3s soon as feed rate is increased proper clinker formation does not take place also sometimes there is sudden feed surge.2t also accompanies decaoting and #all formation.%hat can #e the possi#le causes$ A: 'here "uld (e many auses$ A te hni al audt is re6uired t" ident!y the p"ssi(le auses$

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Q: what happend in kiln when latarite is n"t )"ne in rawmeal A: 'he laterite is presuma(ly added !"r it8s ir"n "xide "ntent$ 'here!"r i! has n"t )"ne int" the raw meal !"r whate*er reas"n there will (e a de!i ien y "! ir"n "xide in the meal in the kiln$ 'hat will mean less li6uid phase "r !lux and han)ed pr"perties "! the remainin) !lux$ 'he linker will (e m"re di!!i ult t" "m(ine there!"re !uel "nsumpti"n is likely t" (e hi)her$ C"atin) tenden y will han)e and perhaps the "atin) will (e stripped "ut "! the kiln$

3"tentially the linker will (e "*er ,##& lime saturated and there will (e hi)h le*els "! residual !ree lime$

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Q: Ex essi*e Dust in 3reheater Sir our (7 is '.-5 you said that it is caused #y e1cessi"e dust loss from the top stage of the preheater. So how do we reduce this dust loss from Pre 6eater Section$ A: 'hat depends "n the wider situati"n$ 'hin)s t" (e he ked are the "nditi"n "! the internal !ittin)s Bdip tu(es2 !eed distri(uti"n plates2 !eed !lapsC in the preheater$ Als" the dra!tin) "! the preheater2 ex ess air2 inleakin) air2 et $ Als" the !ineness "! the kiln !eed$ 'he )i*e m"re spe i!i ad*i e a te hni al audit w"uld (e re6uired$

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Q: Ex essi*e !ines in raw material 6i Sir 2 posted a &uestion on e1cessi"e fines in raw material for which you said that the fines can #e added directly to the B<) separator 5hanks for your answer. 2f we do the a#o"e e1ercise will our clinker factor come down$ Anow it is at '.-5C. 2s there any other plant where the a#o"e e1ercise is successfully followed. 5hanks A: 'here is n" reas"n why the raw mix t" linker !a t"r w"uld redu e !r"m it8s urrent *alue$ ,$+% is a *ery hi)h !a t"r whi h must (e aused (y ex essi*e dust l"ss !r"m the t"p sta)e "! the preheater$ /"w y"u handle the !ines in the raw millin) ir uit will n"t make any di!!eren e in the t"p sta)e "! the preheater$

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Q: Ex essi*e !ines in Raw 0aterial 6i Sir %e are ha"ing e1cessi"e fines in our raw material. this is directly grinded #y 2mapct type crusher and is carried to stacker reclaimer. )y dou#ts are '. Since e1cessi"e fines are there it reduces the capacity of crusher and when it comes to raw mill it is grinded e1cessi"ely. *. ur cooler has 2=@ =20S and we also are faced with <ed ri"er formation and ur suggestion is to pro"ide

spillage in cooler due to which stoppages happen often.

screen in crusher area to remo"e e1cessi"e fines there#y impro"ing the capacity of crusher. 2 ha"e a dou#t on where can the fines #e supplied either to raw mill or after raw mill #ased on the si?e. Please suggest your "alua#le inputs on how to get rid of this pro#lem.
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A:

Certainly a s reen t" s alp the !eed t" the rusher seems t" (e a )""d idea$ Whether the !ines an (e added (a k t" the raw mill !eed "r pr"du t will depend "n the sie*e residues "! the !ines$ One s"luti"n w"uld (e t" add the !ines t" the separat"r "! the raw mill$ 'hen any material already !ine en"u)h will )" strai)ht t" the pr"du t while the "arser material will (e returned t" the mill !"r re)rindin)$

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Q: meth"d "! raw mix pile a*) al ulati"n a A:

'his re6uires that the wei)hted a*era)e "! ea h "xide in the pile (e al ulated a!ter ea h new sample usin) the analysis "! the sample and the wie)ht "! material added t" the pile$ 'he "mp"siti"n t" "rre t the pile t" tar)et an then (e al ulated$

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Q: Sir2 Why we multiply with 1$+ t" Si"12 ,$,+ t" Al1O3 A #$?% t" <e1O3 in :S< !"rmula i$e$ CaO-B1$+SiO1F,$,+Al1O3F#$?%<e1O3C A: 'hese are the "e!!i ients in the :ea and 3arker !"rmula !"r the maximum "m(ina(le lime in 3"rtland ement linker$ 'hey are deri*ed !r"m the phase e6uili(ria "! the CaO-SiO1Al1O3-<e1O3 system$

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Q: /"w % "r m"re "mp"nents raw mix desi)n are al ulated 4 it is too important for me please answer it to me A: .y settin) up % simultane"us e6uati"ns with the ; tar)ets in the raw mix that y"u want t" "ntr"l$ 'hen s"l*n) th"se simultane"us e6uati"ns$

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Q: hemi al and physi al analysis !"r white ement B:S<- SI0 -A:0 A C3S - C1S - C3A C;A<C4 A: :S< = >%&2 S0 = ;F2 A0 = ,#F$ C3S = G?#&2 C1S = G1#&2 C3A = G,%&2 C;A< H,&$ Stren)ths hi)her than )rey ement due t" hi)her sili ate "ntent$

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Q: lime st"ne is pure ristaline al ite I +E& '$CO3 and in the same (en h it has *ery l"w '$CO3& as pe)matite "r )niees with ,? & 0)O 2 sir "ur raw mill is ,E# '3/ JR0 and is there any di!!i ulty "! raw mill !ine )rindin) "! this al ite and )niees

dear sir + good e"ening. here in kenya we are going to instal !000 5P0 clinker unit with '.0 5P6 B<) for raw mi1 and is there any difficult to get fine grinding like *'* mic residue up to *% and ,0 mic residue up to '-% with this lime stone pure calcite crystalline and #ottom layer is "ery low phlegmatic or genies with * to '6% mgo. one place we find low cao stone with 56 silica and i came to know that this stone silica should not #e good reacti"e as it formed from calcite washed with water and cao is eliminated. i think that in #all mill we can maintain finesse as we re&uired. please gi"e me reply at the earliest thanking you <3 S @352 @38 (>)>@5 ( . 850 @32< 42 - =>@;3 A: 'here is n" reas"n t" supp"se that a JR0 w"uld n"t (e a(le t" )rind this material while a (all mill w"uld$ .;.

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Q: Di!!eren e .etween :imest"ne A Shale 6ow to 0istinguish #etween 8imestone D Shale with chemical compostion. A: :imest"ne is a !"rm "! al ium ar("nate$ 3ure limest"ne has %?& CaO$ Shale is )e"l")i ally altered lay s" "mp"sed "! alumin" sili ate minerals$ 'he CaO "ntent "! shale is *ery l"w$ It8s sili a "ntent is likely t" (e ar"und %#-?#&$

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Q: Why we set ar("nates EE "r E? per in pile !"rmati"n 4 what happened when we increase the car#onates or decrease in pile like .0 or -0$ why we set -0 or .0 per car#onates in pile formation$ A: .e ause that le*el "! ar("nate will )i*e y"u the re6uired am"unt "! CaO in the pile$ I! y"u set l"wer then y"u will need t" add hi)h )rade limest"ne at the raw mill t" (rin) the kiln !eed :S< up t" tar)et$ I! y"u set hi)her then y"u will ha*e t" add sili a2 alumina "r ir"n "xide at the raw mill t" (rin) the :S< d"wn t" tar)et$

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Q: rusher !"r ka"lin 6i sir %hat is the #est crusher for 4reaking kaolin$ 3lso in our factory for kaolin 4reaking use of /aw crusher D Eyratory crusher.%hat do you think a#out using impact crusher$ 4est regards A: Impa t rushers are n"rmally used !"r (rittle materials$ Ka"lin is n"rmally 6uite s"!t$ 'he "nly pr"(lems that mi)ht arise are i! the kal"in is wet and sti ky$

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Q: l"w liter wei)ht linker and de rease pr"du t 8S7 F- <3; G ,0-,* S2) G *.!-*.4 38) G'.!-'.4 8S7 (6>)2(38 G---,0 S2) G*.4 38) '.! A: Well2 it seems that y"u 9-ray is readin) hi)h "n CaO2 i! the hemi al analyses are "rre t$ 'hat d"es n"t explain the de reased pr"du ti*ity$ 0y suspi i"n that there is s"me "ther pr"(lem$

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Q: /"w t" al ualate "r simulate the alkali enri hment in the preheater when alkali ri h material is used as additi*e4 2 am su#stituting 5rass for Sand to get silica in the raw mi1. 5he trass contains '.*% =* and !.*% @a* . (onse&uently+ the total alkalies in the raw meal inceases from 0.!4 % to 0.56%. 6ow calculate or simulate the alkali enrichment in the preheater circulation material$ A: It is "! "urse p"ssi(le t" d" this with an Ex el (ased m"del "! the alkali y les2 as I dem"nstrated at Cemte h in Du(ai and Lakarta$ /"we*er2 it is n"t Dust a 6uesti"n "! al ulatin)$ 'hat depends "n yhe *"latility "! the 7a1O and K1O2 whi h is dependent "n the am"unt "! hl"ride and sulphate present$ It is t"" "mpli ated !"r a simple al ulati"n and depends "n a m"del$ /"we*er at #$%?& t"tal alkali there sh"uld (e n" pr"(lems$

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Q: what is sili a m"dules A alumina m"dules )i*e me de!inati"n$ A: Sili a m"dulus is the rati"n "! the &sili a t" the sum "! the &alumin and &ir"n "xide$ Alumina m"dulus is the rati"n "! the &alumina t" &ir"n "xide$

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Q: :S< <OR0M:A 0ear sir+kiln feed isG (ao:4*.!%+ )go:*..% +sio*:'*.,0%+ 3l*o!:!.!.%+ 7e*0!:*.*!% .some plants do not consider )go in calculation of 8S7 and they use the formula 8S7:'00Hcao/A*.-Hsio*I'.'-H3l*0!I0.65H7e*o!Cis it right$or they should add 0..5H)go in numerator. if we want to announce kiln feed 8S7 with a#o"e analysis what should we say a#out 8S7$ 8S7:'0*Awithout )goCor 8S7:'05Awith considering )goC. A: 7"rmally !"r kiln !eed :S< the 0)O is n"t in luded$

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Q: <iness "! raw meal in!luen ed sn"w man

6i 0r (larck+ (an raw meal finenessA*'*C influenced formation of snowman$ A: Only indire tly$ 'his will n"t (e the primary ause "! sn"wman !"rmati"n in a ement kiln linker ""ler$

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Q: what is the essential raw materials t" pr"du e white ement A: Raw materials whi h )i*e the re6uired CaO2 SiO1 and Al1O3 "ntent with the minimum "! <e1O3 "ntaminati"n$ 7" "ther !irst r"w transiti"n elements an (e t"lerated2 (ut they are rare "mp"nents "n ement raw materials "r !uels$

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Q: Raw mix desi)n "! ; "mp"nents 6ow 4 components raw mi1 design are calculated and what are the 8S7+S)+ and 3) for the mi1 design$ A: 3r"p"rti"nin) ; raw material "mp"nents t" :S<2 S0 and A0 tar)ets in*"l*es settin) up and s"l*in) ; simultane"us e6uati"ns$ 'he :S<2 S0 and A0 tar)ets are *aria(les within th"se simultane"us e6uati"ns$ I su))est that the enr"l "! the Cem7et Cement 0anu!a turin) 'e hn"l")y "urse$

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Q: Sweetner )rade B/i)h 5rade C :ime st"ne Sir+ Pls tell me+ is it possi#le that (a A: 'he maximum CaO "ntent in pure limest"ne B al ium ar("nateC is %?&$ % 5. in 6igh grade lime stone A2ts 8S7 apro1 '050C

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Q: 'he in)redients in AS'0 C,%#$$$$ 0ear 0r. (lark+ 2 ha"e some &uestions on 3S5) ('50/('50m-'' Standard Specification for Portland (ement re"ised in 3pril '+ *0''. 5here are se"eral ingredients specified in 2tem 5. 2ngredient of the specification+ 5.'.' Portland (ement (linker 5.'.* %ater or (alcium Sulfate 5.'.! 8imestone Anot more than 5 %C 5.'.4 2norganic Processing additions Anot more than 5 %C 5.'.5 rganic Processing additions Anot more than ' %C 5.'.6 3ir-entraining addition

%ould you #e more specific a#out the following aspects$ '. %hat9s the meaning of %ater of J5.'.' %ater or (alcium SulfateJ $ *. %hat9s the meaning of Processing additions $ %hat9s the difference #etween 5.'.! and 5.'.4 $ !. %hat9s the ma1imum addition rate $ @ot more than '0 %$ 4. %hat9s the meaning of 5.'.5 $ 0oes it mean grinding aids$ 5. %hat9s the

purpose the us go"ernment re"ised the specification like this$ 7or the reduction of ( * emission$ 2 really thank you for your help up to nowK 4est <egards. A: Dear O("n)2 'he sh"rt answer is I d"n8t knn"w exa tly$ I presume the re!eren e t" water "r al ium sulphate is sayin) that the al ium sulphate additi"n mi)ht (e )ypsum with 1 m"le ules "! water "! rystallisati"n$ I think in"r)ani pr" essin) additi"ns are p!a2 )(s2 et $ s" the same as limest"ne$ As !ar as I I am aware the t"tal additi"ns are ,#&2 in ludin) the )ypsum$ I think "r)ani pr" essin) additi"ns are )rindin) aids and "r)ani 6uality impr"*ers$ I d"n8t kn"w the m"ti*es "! AS'0 "r the MS 5"*ernment (ut this seems t" (e a m"*e t"wards E7,>E CE0 I ements$

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Q: Intensity "! kiln !eed 6i sir 6ow we can get the analy?e of material + from intensity of kiln feed$ 4est regard A: I presume y"u mean the intensi!y "! the !lu"res ent 9-radiati"n !r"m a kiln !eed sample in 9-ray !lu"res ense spe tr"meter$ 'hese are ali(rated s" that the SiO12 Al1O32 <e3O32 CaO2 et $ "ntent "! the kiln !eed is "rrelated with the 9-ray intensity$ Email: adminIwhiteh"pleman$ "m N Whiteh"pleman 1#,, O www$whiteh"pleman$ "m O Site (y 3synapsis