ost cement manufacturers are aware of the vital contribution of the high temperature liquids of fines formed in the cement itn in keeping down the cost of clinker manufacture. Clinker is formed from the cement raw mix by a sequence of chemical reactions. The last and most important of these reactions is the final combination of the residual free lime, C20, liberated from the calcium carbonate, CaCO, with the dicalcium silicate, C25. The dicalcium si nt is a solid, as is the reac- tion product tricalcium sitcate, C35. Solid state reactions of this type rely on diffu- sion from the surface and are necessarily slox. However, the presence of the liquid fluxes in the kilt promotes this reaction and reduces the temperature which must be achieved, and therefore the fuel and refractory costs. The presence of flax is therefore of paramount importance in a cement ‘kiln The story does not end there however characteristics of the flux determine its effectiveness: ‘the temperature at which this flux first appears in the kiln of flux temperature formed asthe * the viscosity f the flux Flux First appears ia the Kila between the temperatures of 1250-1280°C dependent with industrial rew mixes containing lime silica, alumina, feric oxide, magnosia and soda. The Lea and Patker formulae for the amount of flux present at various tem- peratures are shown in Table 1. ‘These formulae can be used up to a maximum MgO coatent of two. per cent, arising from the maximum five to six per cont solubility of MgO Hn the func and Flux, volume or viscosity? Fluxes are of great importance in an industrial cement kiln to keep down the expense of clinker formation in terms of fuel and refractory costs. In this month's Technical Forum, Dr Clark discusses the relative benefits and disadvantages of various flux characteristics. These include the tempera- ture of the kiln when the flux enters, its quantity and viscocity. The article draws some interesting conclusions that seem to contradict actual cement The most important reaction in cliker formotion of fee tine plant practice. a typical flux content for cement clinker of 30 per cent. The formula for the flux pre- sent at 1338°C applies to raw mixes of alu ‘mina modulus greater than 2.38. Viscosity of the flux is important as its effectiveness depends on ‘wetting’ the sur- face ofthe satid C2S in the kiln, A mobile, low viscosity flux is more effective in wet- ting the (25 and promoting reaction with lime vie diffusion across the solid state phase boundary. Terrier, Endell and Hendrick have conducted studies into the viscosity of the flux and found that viscosity is signifi- ithe addition cantly increased with rising Sid, content and to a lesser extant ALO. . All these considerations point to the ferric oxide, Fe:0;, being a more effective flux than the alumina, ALO. The alumina oes not contribute to the fiux at the lower temperatures and also increases the viscosity of the flux. Both factors should be detrimental to the luxing of the Kiln, Jncreasing the temperature sequied for clinker formation and fuel consumption of the kiln. Why do cement companies in fect experience the opposite effect, with a fall in the alumina content at the expense of ferric oxide resulting fn lower kiln outputs and higher fuel consumption? Dr Stanistay Cheomy, the renowned clinker mineraogist from the Czech Republic has an explanation. Oue to the lower molecular weight of alumina in comparison with ferric oxide, Liquid phases rich in alumina are ‘much less dense than those richer in ferric oxide. The lower density means these Tunes ‘occupy a much greater volume jn the Kiln and are much more ‘effective in wetting the clinker ‘and promoting (3S formation. Mass percentage and viscosity are not the overriding considere- ‘ions - volume percentage ist