Clinkerisation

Clinker formation Clinker formation

Page B-1

The formation of cement clinker minerals and agglomeration into nodules is enhanced by the presence of a melted liquid phase. The melted phase mainly consists of the aluminium-, iron- and magnesium oxides but the alkalis and sulphates also contribute to the melted phase. The wetting by the melt enables the transport and contact of reactants and increasing the speed of reaction. The liquid phase also plays an important role in the nodulisation and formation of coating in the kiln. The clinker granulometry (bypassing the crusher) expresses the result of nodulisation (in N1). The main part of the melt phase consisting of aluminates and ferrites appear from 1250C to ~1400C. A small liquid phase starts to appear already from 750-1000C. It consists of minor components mainly alkalies as hydroxides, chlorides or sulphates. This melt often participates in undesirable coatings and build-ups in the lower preheater, kiln inlet area and cooler inlet(snowmen). The melt percentage at 1450 C can be estimated using the formula below: 0,2 < MA < 5,0 %LIQ (1450 o C ) = 3,00 A + 2,25 F + = MgO + K 2 O + Na 2 O + SO 3 The calculations do not compensate for solid solution of melt components in the cement clinker minerals and therefore the real values will be lower particularly with low liquid amounts.

The normal range of the melt phase is 22-25%. The relation between melt phase, nodulisation, coating and dusty operation is complex. Too much melt may give a coarse and lumpy clinker product. Too little melt, too little burning, too much burning, too much early melt (voltiles), too hard burnability all tend to give a dusty clinker product. (Keep checks on clinker granulometry and observe if it is affected by changes in chemistry).
FLSmidth 01.09.2003