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Grasim Cement, Raipur

India

Project No: 10-31017
Case No: 20100035
2010-05-14

Partial Report
FLSmidth A/S
R&D Centre Dania
Daniavej 49
DK-9550 Mariager, Denmark
Tel + 45 3618 1000
Fax + 45 3618 3599
Lab.DK@flsmidth.com

FLSmidth Private Limited
R&D Centre Chennai
34 Egattur, Kelambakkam
Tamil Nadu 603103, India
Tel +91 44 4748 1000
Fax +91 44 2747 0301
R&D.IN@flsmidth.com
LABORATORY REPORT


Grasim Cement, Raipur
India

Case No: 20100035 2010-05-14 Page 1 of 1
LABORATORY REPORT
Ordered by: DKS-IN
Copies to : BLO-IN, SNE-IN, SSA-IN


SAMPLE DESCRIPTION
SAMPLE NAME SAMPLE NUMBER WEIGHT, KG DATE RECEIVED
Limestone 01 1500 2010-01-29
Clay 02 500 2010-01-29
Shale 03 425 2010-01-29
Iron Ore 04 150 2010-01-29
Coal Grade B 05 25 2010-01-29
Coal Grade C 06 25 2010-01-29
Pet Coke 07 25 2010-02-09
Fly Ash 10 60 2010-03-09
Clinker 11 600 2010-03-09
Gypsum 12 35 2010-03-09
Slag 13 150 2010-03-09

CONTENTS OF REPORT (ANALYSES / TESTS)
ENCL. NO. ITEM
1. Material Description
2. Characterization of Materials
3. Analysis of Solid Fuel
4. Raw Mix Calculation
5. Burnability
6. Heat of Reaction
7. ATOX Vertical Roller Mill Test


Grasim Cement, Raipur
India
Encl.: 1.1
Material Description - Sample as received
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
01 Limestone Limestone 20100035-01
INSPECTION
Received: 2010-02-12
Container: 5 Drum, steel
Weight, kg:
1500
COLOR
Munsell Color: Gray
Color Code: Gley1 6/N
BULK MATERIAL PROPERTIES
PROPERTY OF SAMPLE
MATERIAL CRUSHABILITY
PROPORTION OF FINES GRAIN-SIZE SCALE (mm)
Boulders
Cobbles Top size (mm)
Pebbles 100x50x40

Granules
Sand Average size (mm)
Silt 60x30x30
Clay
MINOR COMPONENTS ADDITIONAL INFORMATION
LABORATORY SUGGESTIONS (MATERIAL CONSIDERATIONS)
Doubleclick here to insert picture
The material smells
Moist
Caking
Dry
Only Plastic/Soft materials
Both fines materials and hard specimen
Only hard specimen
Very Weak - The material can be scratched by thumbnail
Weak - Knife cuts material
Very Strong - Requires many blows by hammer to break into specimens
Strong - Hand held specimens broken by single blow of hammer
None
Low
Medium
High
> 256
64 - 256
4 - 64
2 - 4
0.1 - 2
0.004 - 0.1
< 0.004
Yes No
Flowability Max moisture Load strength Sample contains 10 or more specimens larger that 35 mm
Material wrapped up in Plastic
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 1.2
Material Description - Sample as received
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
02 Clay Clay 20100035-02
INSPECTION
Received: 2010-02-12
Container: 2 Drum, steel
Weight, kg:
500
COLOR
Munsell Color: Yellow
Color Code: 10 YR 7/8
BULK MATERIAL PROPERTIES
PROPERTY OF SAMPLE
MATERIAL CRUSHABILITY
PROPORTION OF FINES GRAIN-SIZE SCALE (mm)
Boulders
Cobbles Top size (mm)
Pebbles 95x80x45

Granules
Sand Average size (mm)
Silt 50x30x25
Clay
MINOR COMPONENTS ADDITIONAL INFORMATION
LABORATORY SUGGESTIONS (MATERIAL CONSIDERATIONS)
Doubleclick here to insert picture
The material smells
Moist
Caking
Dry
Only Plastic/Soft materials
Both fines materials and hard specimen
Only hard specimen
Very Weak - The material can be scratched by thumbnail
Weak - Knife cuts material
Very Strong - Requires many blows by hammer to break into specimens
Strong - Hand held specimens broken by single blow of hammer
None
Low
Medium
High
> 256
64 - 256
4 - 64
2 - 4
0.1 - 2
0.004 - 0.1
< 0.004
Yes No
Flowability Max moisture Load strength Sample contains 10 or more specimens larger that 35 mm
Material wrapped up in Plastic
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 1.3
Material Description - Sample as received
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
03 Shale Shale 20100035-03
INSPECTION
Received: 2010-02-12
Container: 2 Drum, steel
Weight, kg:
425
COLOR
Munsell Color: Pink
Color Code: 5YR 7/4
BULK MATERIAL PROPERTIES
PROPERTY OF SAMPLE
MATERIAL CRUSHABILITY
PROPORTION OF FINES GRAIN-SIZE SCALE (mm)
Boulders
Cobbles Top size (mm)
Pebbles 110x60x25

Granules
Sand Average size (mm)
Silt 60x30x15
Clay
MINOR COMPONENTS ADDITIONAL INFORMATION
LABORATORY SUGGESTIONS (MATERIAL CONSIDERATIONS)
We Observed 3 Types of color Material Pink ,Yellow &White
Doubleclick here to insert picture
The material smells
Moist
Caking
Dry
Only Plastic/Soft materials
Both fines materials and hard specimen
Only hard specimen
Very Weak - The material can be scratched by thumbnail
Weak - Knife cuts material
Very Strong - Requires many blows by hammer to break into specimens
Strong - Hand held specimens broken by single blow of hammer
None
Low
Medium
High
> 256
64 - 256
4 - 64
2 - 4
0.1 - 2
0.004 - 0.1
< 0.004
Yes No
Flowability Max moisture Load strength Sample contains 10 or more specimens larger that 35 mm
Material wrapped up in Plastic
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 1.4
Material Description - Sample as received
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
04 Iron Ore Iron Ore 20100035-04
INSPECTION
Received: 2010-02-12
Container: 4 Bag, plastic
Weight, kg:
150
COLOR
Munsell Color: Brown
Color Code: 7.5YR 4/3
BULK MATERIAL PROPERTIES
PROPERTY OF SAMPLE
MATERIAL CRUSHABILITY
PROPORTION OF FINES GRAIN-SIZE SCALE (mm)
Boulders
Cobbles Top size (mm)
Pebbles 50x25x15

Granules
Sand Average size (mm)
Silt 20x15x10
Clay
MINOR COMPONENTS ADDITIONAL INFORMATION
LABORATORY SUGGESTIONS (MATERIAL CONSIDERATIONS)
Doubleclick here to insert picture
The material smells
Moist
Caking
Dry
Only Plastic/Soft materials
Both fines materials and hard specimen
Only hard specimen
Very Weak - The material can be scratched by thumbnail
Weak - Knife cuts material
Very Strong - Requires many blows by hammer to break into specimens
Strong - Hand held specimens broken by single blow of hammer
None
Low
Medium
High
> 256
64 - 256
4 - 64
2 - 4
0.1 - 2
0.004 - 0.1
< 0.004
Yes No
Flowability Max moisture Load strength Sample contains 10 or more specimens larger that 35 mm
Material wrapped up in Plastic
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 1.5
Material Description - Sample as received
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
05 Coal Grade B Coal 20100035-05
INSPECTION
Received: 2010-02-12
Container: 1 Bag, plastic
Weight, kg:
25
COLOR
Munsell Color: Black
Color Code: 7.5YR 2.5/1
BULK MATERIAL PROPERTIES
PROPERTY OF SAMPLE
MATERIAL CRUSHABILITY
PROPORTION OF FINES GRAIN-SIZE SCALE (mm)
Boulders
Cobbles Top size (mm)
Pebbles 60x50x30

Granules
Sand Average size (mm)
Silt 30x15x10
Clay
MINOR COMPONENTS ADDITIONAL INFORMATION
LABORATORY SUGGESTIONS (MATERIAL CONSIDERATIONS)
Doubleclick here to insert picture
The material smells
Moist
Caking
Dry
Only Plastic/Soft materials
Both fines materials and hard specimen
Only hard specimen
Very Weak - The material can be scratched by thumbnail
Weak - Knife cuts material
Very Strong - Requires many blows by hammer to break into specimens
Strong - Hand held specimens broken by single blow of hammer
None
Low
Medium
High
> 256
64 - 256
4 - 64
2 - 4
0.1 - 2
0.004 - 0.1
< 0.004
Yes No
Flowability Max moisture Load strength Sample contains 10 or more specimens larger that 35 mm
Material wrapped up in Plastic
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 1.6
Material Description - Sample as received
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
06 Coal Grade C Coal 20100035-06
INSPECTION
Received: 2010-02-12
Container: 1 Bag, plastic
Weight, kg:
25
COLOR
Munsell Color: Black
Color Code: 7.5YR 2.5/1
BULK MATERIAL PROPERTIES
PROPERTY OF SAMPLE
MATERIAL CRUSHABILITY
PROPORTION OF FINES GRAIN-SIZE SCALE (mm)
Boulders
Cobbles Top size (mm)
Pebbles 70x50x25

Granules
Sand Average size (mm)
Silt 30x25x15
Clay
MINOR COMPONENTS ADDITIONAL INFORMATION
LABORATORY SUGGESTIONS (MATERIAL CONSIDERATIONS)
Doubleclick here to insert picture
The material smells
Moist
Caking
Dry
Only Plastic/Soft materials
Both fines materials and hard specimen
Only hard specimen
Very Weak - The material can be scratched by thumbnail
Weak - Knife cuts material
Very Strong - Requires many blows by hammer to break into specimens
Strong - Hand held specimens broken by single blow of hammer
None
Low
Medium
High
> 256
64 - 256
4 - 64
2 - 4
0.1 - 2
0.004 - 0.1
< 0.004
Yes No
Flowability Max moisture Load strength Sample contains 10 or more specimens larger that 35 mm
Material wrapped up in Plastic
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 1.7
Material Description - Sample as received
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
07 Pet Coke Petcoke 20100035-07
INSPECTION
Received: 2010-02-12
Container:
Weight, kg:
25
COLOR
Munsell Color: Black
Color Code: 7.5YR 2.5/1
BULK MATERIAL PROPERTIES
PROPERTY OF SAMPLE
MATERIAL CRUSHABILITY
PROPORTION OF FINES GRAIN-SIZE SCALE (mm)
Boulders
Cobbles Top size (mm)
Pebbles 45x40x20

Granules
Sand Average size (mm)
Silt 4mm
Clay
MINOR COMPONENTS ADDITIONAL INFORMATION
LABORATORY SUGGESTIONS (MATERIAL CONSIDERATIONS)
Doubleclick here to insert picture
1 Drum, steel small
The material smells
Moist
Caking
Dry
Only Plastic/Soft materials
Both fines materials and hard specimen
Only hard specimen
Very Weak - The material can be scratched by thumbnail
Weak - Knife cuts material
Very Strong - Requires many blows by hammer to break into specimens
Strong - Hand held specimens broken by single blow of hammer
None
Low
Medium
High
> 256
64 - 256
4 - 64
2 - 4
0.1 - 2
0.004 - 0.1
< 0.004
Yes No
Flowability Max moisture Load strength Sample contains 10 or more specimens larger that 35 mm
Material wrapped up in Plastic
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 2.1
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
01 Limestone Limestone 20100035-01
02 Clay Clay 20100035-02
03 Shale Shale 20100035-03
04 Iron Ore Iron Ore 20100035-04
PARAMETER METHOD UNIT 01 02 03 04
Moisture Content (105C) FLS-B21 % 0.1 5.1 1.0 1.8
SiO
2
FLS-D03 % 11.47 40.76 61.85 5.07
Al
2
O
3
FLS-D03 % 2.68 15.17 14.43 5.74
Fe
2
O
3
FLS-D03 % 1.25 28.47 7.02 82.66
CaO FLS-D03 % 45.24 4.12 2.98 0.55
MgO FLS-D03 % 1.13 0.79 2.42 0.17
Mn
2
O
3
FLS-D03 % 0.03 0.23 0.02 0.06
TiO
2
FLS-D03 % 0.17 0.82 0.90 0.36
P
2
O
5
FLS-D03 % 0.04 0.05 0.11 0.20
K
2
O FLS-D03 % 0.67 1.57 3.79 0.10
Na
2
O FLS-D03 % 0.16 0.63
SrO FLS-D03 % 0.01 0.01
LOI, 975 C FLS-D00 % 36.72 10.30 5.28 6.10
TOTAL FLS-D03 % 99.57 102.28 99.44 101.01
Sulphur, total FLS-D08 % 0.02 0.01 0.26 0.04
Organic Carbon FLS-D27 % 0.05 0.23 0.08 0.10
Chloride FLS-D07 % 0.006 0.001 0.002 0.002
Lime saturation factor (LSF) FLS-D03 % 125 3 2 1
Silica modulus (MS) FLS-D03 - 2.9 0.9 2.9 0.1
Iron modulus (MA) FLS-D03 - 2.1 0.5 2.1 0.1
Characterization of Materials
SAMPLE DESCRIPTION
Moisture
Chemical analyses
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 3.1
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
05 Coal Grade B Coal 20100035-05
05.01 Coal Ash Coal Ash 20100035-05.01
PARAMETER METHOD UNIT
As analysed
(air dried)
As received Dry
Dry,
ash free
Dry, mineral
matter free
Analysis
Free moisture FLS-B21BS
% 0.3
Moisture in air-dried sample FLS-E03BS
% 6.6
Total moisture CALC-BS
% 6.9
Volatile matter FLS-E03BS
% 30.2 30.1 32.3 46.5 42.8
Ash FLS-E03BS
% 28.5 28.4 30.5
Fixed Carbon CALC-BS
% 34.7 34.6 37.2 53.5 57.2
Carbon FLS-E10
% 51.5 51.3 55.1 79.4 82.6
Hydrogen FLS-E10
% 3.11 3.10 3.33 4.79 4.36
Sulphur FLS-E09BS
% 0.48 0.48 0.51 0.74 0.86
Nitrogen FLS-E10
% 1.14
Oxygen CALC
% 8.67
CO
2
FLS-D27
%
Mineral matter CALC-BS
% 31.0 31.0
Gross calorific value FLS-E08ISO
kJ/kg 20559 20497 22012 31678 32994
FLS-E08ISO
kcal/kg 4910 4896 5257 7566 7881
Net calorific value FLS-E08ISO
kJ/kg 19731 19665 21298 30651
FLS-E08ISO
kcal/kg 4713 4697 5087 7321
K
2
O FLS-D13
% 0.31
Na
2
O FLS-D13
% 0.02
Chloride FLS-D07BS
% 0.007
Hardgrove grindability index FLS-I08ISO
Wear Index FLS-I12BS
mg/kg
(total hydrogen - hidden) % 3.85
Safety index CALC 1
PARAMETER METHOD UNIT PARAMETER METHOD UNIT
Fineness (sieve openings) Analyses of ash
Residue on 40 mm Machine %
SiO
2 XRF % 65.06
Residue on 25 mm Machine %
Al
2
O
3 XRF % 23.09
Residue on 16 mm Machine %
Fe
2
O
3 XRF % 4.84
Residue on 8 mm Machine % CaO XRF % 1.54
Residue on 4 mm Machine % MgO XRF % 0.68
Residue on 2 mm Machine %
Mn
2
O
3 XRF % 0.07
Residue on 1 mm Machine %
TiO
2 XRF % 1.65
Residue on 500 m Machine %
P
2
O
5 XRF % 0.16
Residue on 250 m Alpine % SrO XRF % 0.02
Residue on 200 m Alpine % LOI, 975 C % 0.74
Residue on 90 m Alpine % TOTAL % 99.06
Residue on 45 m Alpine %
1.07
1
1.54
1.6
Analysis of solid fuel
SAMPLE DESCRIPTION
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 3.2
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
06 Coal Grade C Coal 20100035-06
06.01 Coal Ash Coal Ash 20100035-06.01
PARAMETER METHOD UNIT
As analysed
(air dried)
As received Dry
Dry,
ash free
Dry, mineral
matter free
Analysis
Free moisture FLS-B21BS
% 0.3
Moisture in air-dried sample FLS-E03BS
% 6.1
Total moisture CALC-BS
% 6.4
Volatile matter FLS-E03BS
% 29.2 29.1 31.1 45.7 41.7
Ash FLS-E03BS
% 30.0 29.9 31.9
Fixed Carbon CALC-BS
% 34.7 34.6 37.0 54.3 58.3
Carbon FLS-E10
% 52.5 52.3 55.9 82.2 85.7
Hydrogen FLS-E10
% 3.19 3.18 3.39 4.99 4.53
Sulphur FLS-E09BS
% 0.47 0.47 0.50 0.74 0.86
Nitrogen FLS-E10
% 1.16
Oxygen CALC
% 6.58
CO
2
FLS-D27
%
Mineral matter CALC-BS
% 32.7 32.6
Gross calorific value FLS-E08ISO
kJ/kg 20520 20458 21853 32113 33533
FLS-E08ISO
kcal/kg 4901 4886 5220 7670 8009
Net calorific value FLS-E08ISO
kJ/kg 19690 19623 21128 31047
FLS-E08ISO
kcal/kg 4703 4687 5046 7415
K
2
O FLS-D13
% 0.39
Na
2
O FLS-D13
% 0.03
Chloride FLS-D07BS
% 0.011
Hardgrove grindability index FLS-I08ISO
Wear Index FLS-I12BS
mg/kg
(total hydrogen - hidden) % 3.87
Safety index CALC 1
PARAMETER METHOD UNIT PARAMETER METHOD UNIT
Fineness (sieve openings) Analyses of ash
Residue on 40 mm Machine %
SiO
2 XRF % 65.26
Residue on 25 mm Machine %
Al
2
O
3 XRF % 22.93
Residue on 16 mm Machine %
Fe
2
O
3 XRF % 4.92
Residue on 8 mm Machine % CaO XRF % 1.29
Residue on 4 mm Machine % MgO XRF % 0.69
Residue on 2 mm Machine %
Mn
2
O
3 XRF % 0.07
Residue on 1 mm Machine %
TiO
2 XRF % 1.51
Residue on 500 m Machine %
P
2
O
5 XRF % 0.16
Residue on 250 m Alpine % SrO XRF % 0.03
Residue on 200 m Alpine % LOI, 975 C % 0.74
Residue on 90 m Alpine % TOTAL % 99.05
Residue on 45 m Alpine %
1.06
1
1.56
1.63
Analysis of solid fuel
SAMPLE DESCRIPTION
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 3.3
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
07 Pet Coke Petcoke 20100035-07
PARAMETER METHOD UNIT
As analysed
(air dried)
As received Dry
Dry,
ash free
Dry, mineral
matter free
Analysis
Free moisture FLS-B21BS
% 0.6
Moisture in air-dried sample FLS-E03BS
% 0.9
Total moisture CALC-BS
% 1.5
Volatile matter FLS-E03BS
% 10.7 10.6 10.8 10.8 10.4
Ash FLS-E03BS
% 0.2 0.2 0.2
Fixed Carbon CALC-BS
% 88.2 87.7 89.0 89.2 89.6
Carbon FLS-E10
% 87.2 86.7 88.0 88.2 90.6
Hydrogen FLS-E10
% 3.65 3.63 3.68 3.69 3.86
Sulphur FLS-E09BS
% 4.87 4.84 4.91 4.92 1.43
Nitrogen FLS-E10
% 1.79
Oxygen CALC
% 1.39
CO
2
FLS-D27
%
Mineral matter CALC-BS
% 2.9 2.9
Gross calorific value FLS-E08ISO
kJ/kg 35483 35270 35805 35878 36451
FLS-E08ISO
kcal/kg 8475 8424 8552 8569 8706
Net calorific value FLS-E08ISO
kJ/kg 34686 34463 35023 35094
FLS-E08ISO
kcal/kg 8285 8231 8365 8382
K
2
O FLS-D13
%
Na
2
O FLS-D13
%
Chloride FLS-D07BS
% 0.001
Hardgrove grindability index FLS-I08ISO
Wear Index FLS-I12BS
mg/kg
(total hydrogen - hidden) % 3.75
Safety index CALC 8
PARAMETER METHOD UNIT PARAMETER METHOD UNIT
Fineness (sieve openings) Analyses of ash
Residue on 40 mm Machine %
SiO
2 XRF %
Residue on 25 mm Machine %
Al
2
O
3 XRF %
Residue on 16 mm Machine %
Fe
2
O
3 XRF %
Residue on 8 mm Machine % CaO XRF %
Residue on 4 mm Machine % MgO XRF %
Residue on 2 mm Machine %
Mn
2
O
3 XRF %
Residue on 1 mm Machine %
TiO
2 XRF %
Residue on 500 m Machine %
P
2
O
5 XRF %
Residue on 250 m Alpine % SrO XRF %
Residue on 200 m Alpine % LOI, 975 C %
Residue on 90 m Alpine % TOTAL %
Residue on 45 m Alpine %
1.01
0.99
1.01
1.04
Analysis of solid fuel
SAMPLE DESCRIPTION
Case No: 20100035 2010-05-14 Page 1 of 1
RAW MIX CALCULATION
PLANT: Grasim Cement, Raipur Encl.: 4.1
CASE.NO.: Date:
Raw Mix Calculation Mix 1
Ed. 1, 29-03-2010 by DKS Clinker Mix M01 M02 M03 M04 F01 A01 F02 A02
Mix [% dry] 100.00 96.29 1.00 1.61 1.10 100.00 0.00 100.00
Mix [as analysed % wet] 100.00 96.29 1.00 1.61 1.10 100.00 0.00 100.00
Mix [as fired % wet] 100.00 0.00 100.00
H
2
O (analysed) [% (wb)]
0.00 0.00 0.00 0.00 0.00 6.10 6.60 6.10
H
2
O (as fired) [% (wb)]
1.00 1.00 1.00
SiO
2
[%]
21.44 12.51 11.47 40.76 61.85 5.07 65.26 65.06 65.26
Al
2
O
3
[%]
5.51 3.03 2.68 15.17 14.43 5.74 22.93 23.09 22.93
Fe
2
O
3
[%]
3.94 2.51 1.25 28.47 7.02 82.66 4.92 4.84 4.92
CaO [%] 64.77 43.65 45.24 4.12 2.98 0.55 1.29 1.54 1.29
MgO [%] 1.72 1.14 1.13 0.79 2.42 0.17 0.69 0.68 0.69
Mn
2
O
3
[%]
0.05 0.03 0.03 0.23 0.02 0.06 0.07 0.07 0.07
TiO
2
[%]
0.35 0.19 0.17 0.82 0.90 0.36 1.51 1.65 1.51
P
2
O
5
[%]
0.07 0.04 0.04 0.05 0.11 0.20 0.16 0.16 0.16
K
2
O [%]
1.13 0.72 0.67 1.57 3.79 0.10 0.39 0.31 0.39
Na
2
O [%]
0.25 0.16 0.16 0.63 0.03 0.02 0.03
SrO [%] 0.02 0.01 0.01 0.01 0.03 0.02 0.03
SO
3
[%]
0.26 0.00
LOI [%] 35.61 36.72 10.30 5.28 6.10 0.74 0.74 0.74
Total [%] 99.51 99.61 99.57 102.28 99.44 101.01 97.60 97.85 97.60
S Total [%] 0.11 0.02 0.02 0.01 0.26 0.04 0.47 0.48 0.47
S Pyrite [%] 0.00
Cl
-
[%] 0.010 0.006 0.006 0.001 0.002 0.002 0.011 0.007 0.011
F
-
[%] 0.00 0.00 0.00
Cr
2
O
3
[ppm]
0 0 0
Ash [%] 4.55 30.00 28.50 30.00
Hi (analysed) [kcal/kg] 4703 4713 4703
Exp. kiln heat cons. [kcal/kg] 702.0
LSF [%] 93.7 108.5 125.4 2.7 1.5 0.7
MS 2.27 2.26 2.92 0.93 2.88 0.06
MA 1.40 1.21 2.14 0.53 2.06 0.07
Na
2
O eq. [%]
0.99 0.64 0.60 1.03 3.12 0.07
K
2
O eq. [%]
1.51 0.97 0.91 1.57 4.75 0.10
C3S [%] 52.00 M01: Limestone
C2S [%] 22.24 M02: Clay
C3A [%] 7.93 M03: Shale
C4AF [%] 11.99 M04: Iron ore
C2F [%] 0.00 F01: Coal B
Free CaO [%] 1.50 F02: Coal C
Liq. Ph. 1450 C [%] 28.75
Liq. Ph. 1338 C [%] 27.96
M SO
3 0.23
Exc. SO
3
[g/100 kg]
0
Calc. rev. 08-01 / May 29, 2008 / CBMI
20100035
Total fuel+ash
2010-05-14
Case No.20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 5.1
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
09 Raw Mix for Burnability Raw Mix
06.01 Coal Ash Coal Ash
PARAMETER METHOD UNIT 09
SiO
2
FLS-D03 % 13.99
Al
2
O
3
FLS-D03 % 3.61
Fe
2
O
3
FLS-D03 % 2.59
CaO FLS-D03 % 42.42
MgO FLS-D03 % 1.12
Mn
2
O
3
FLS-D03 % 0.03
TiO
2
FLS-D03 % 0.23
P
2
O
5
FLS-D03 % 0.05
K
2
O FLS-D03 % 0.73
Na
2
O FLS-D03 % 0.10
SrO FLS-D03 % 0.01
LOI, 975 C FLS-D00 % 34.81
TOTAL FLS-D03 % 99.69
Fluoride FLS-D34 % 0.03
C
3
S in Clinker (Free CaO=0) FLS-D03 % 59
Lime saturation factor (LSF) FLS-D03 % 94
Silica modulus (MS) FLS-D03 - 2.3
Iron modulus (MA) FLS-D03 - 1.4
PARAMETER METHOD UNIT Coarse Medium Fine
Residue, 200 m, wet WET % 2.0 0.3 0.1
Residue, 125 m, wet WET % 3.0
Residue, 90 m, wet WET % 19.8 13.8 9.9
Residue, 90 m, alpine ALPINE % 20.2 14.3 10.0
Residue, 45 m, wet WET % 30.7
Free CaO after burning at 1400 C FLS-D23 % 1.1 0.8 0.7
Free CaO after burning at 1450 C FLS-D23 % 0.7 0.6 0.6
Free CaO after burning at 1500 C FLS-D23 % 0.5 0.5 0.5
Burnability Index FLS-D23 - 30 27 24
Burnability Classification FLS-D23 - EASY EASY EASY
Burnability test on Raw Mix with Coal Ash
Burnability Test
SAMPLE DESCRIPTION
Characterization of Raw Mix with Coal Ash (Coal Grade C)
Fineness on Raw Mix
20100035-06.01
20100035-09
Case No: 20100035 2010-05-14 Page 1 of 1
Grasim Cement, Raipur
India
Encl.: 6.1
SAMPLE DESCRIPTION
ID SAMPLE NAME MATERIAL TYPE SAMPLE NUMBER
09 Raw Mix
06 Coal
06.01 Coal Ash
PARAMETER UNIT * RESULT PARAMETER UNIT RESULT
Raw mix Fuel: Coal
SiO
2
% 12.51 Fuel in percentage of clinker % 14.9
Al
2
O
3
% 3.03 Sulphur, total % 0.47
Fe
2
O
3
% 2.51 Ash in percentage of fuel % 30.0
CaO % 43.65 Net calorific value ( Q
net,p
) kJ/kg 19690
MgO % 1.14 kcal/kg 4703
SO
3
% * 0.01 Heat consumption, clinker kJ/kg 2939
Loss on ignition (LOI) % 35.61 kcal/kg 702
TOTAL % 98.46 Analysis of ash
CO
2
% * 34.86 SiO
2
% 65.26
K
2
O % 0.72 Al
2
O
3
% 22.93
Na
2
O % 0.16 Fe
2
O
3
% 4.92
Sulphur, total % 0.02 CaO % 1.29
Water of crystallisation % * 0.86 MgO % 0.69
Carbon
1)
% * 0.05 K
2
O
2)
% 1.30
Na
2
O
2)
% 0.10
CaCO
3
% 77.93 CaSO
4
% 0.02
MgCO
3
% 1.09 Silica-combined CaO % 0.00
Sulphur in pyrites % 0.02
RAW MIX ADJ USTMENT
PARAMETER UNIT RAW MIX ADJUSTMENT FUEL
SiO
2
% 12.51 1.97 14.48
Al
2
O
3
% 3.03 0.69 3.72
Fe
2
O
3
% 2.51 0.15 2.66
CaO % 43.65 0.04 43.69
MgO % 1.14 0.02 1.16
SO
3
(total) % 0.05 0.12 0.17
K
2
O % 0.72 0.04 0.76
Na
2
O % 0.16 0.00 0.16
TOTAL % 63.77 3.03 T = 66.80
SULPHUR BALANCE AND RAW MIX / CLINKER RATIO
Adjusted raw mix, total : T : 66.80
Volatilised : U = 50 U : 0.02
SO
3
in clinker (calculated) : 0.22
Raw mix / clinker ratio F : 1.50
Remarks:
* Analytical results
1) Carbon as CO
2
is not included. 2) Calculated from analysis of solid fuel.
(loss of dust = 0 %) : F = 100 / ( T U ) :
% of sulphur in pyrites as SO
3
CALCULATED VALUES
Heat of reaction
ADJUSTED RAW MIX
20100035-09 Raw Mix for Burnability
Coal Grade C
Coal Ash
20100035-06
20100035-06.01
Case No: 20100035 2010-05-14 Page 1 of 2
Grasim Cement, Raipur
India
CALCULATIONS
Content
%
Conversion factors
kJ / kg / %
RAWMIX
kJ / kg
CLINKER
kJ / kg
RAWMIX
CaCO
3
77.93 -17.78 -1386
MgCO
3
1.09 -15.10 -16
Water of crystallisation 0.86 -42.70 -37
Silica-combined CaO 0.00 -17.00 0
Alkali silicates (K
2
O + Na
2
O) 0.88 -14.80 -13
-1452 xF: -2174
Heat of formation
Property Component Adj. RAWMIX
C
3
S CaO
43.69 -0.46 -20
C
2
S SiO
2 14.48 21.43 310
C
3
A Al
2
O
3 3.72 1.21 5
C
4
AF Fe
2
O
3 2.66 2.46 7
SO
3
from fuel and pyrites 0.14 59.60 8
309 xF: 463
Heat of combustion
Carbon 0.05 327.86 16
Sulphur in pyrites 0.02 129.14 2
18 xF: 28
Heat of reaction
HEAT OF REACTION (A + B + C): -1683
-402
HEAT OF REACTION excl. HEAT OF COMBUSTION (A + B): -1711
-409 ( kcal / kg clinker )
Heat of combustion (C):
( kJ / kg clinker )
( kJ / kg clinker )
( kcal / kg clinker )
Heat of reaction
Heat of decomposition
Heat of decomposition (A):
Heat of formation (B):
Encl.: 6.1
Case No: 20100035 2010-05-14 Page 2 of 2
Encl.: 7.1 Page 1
PLANT : Grasim Cement, Raipur Case. No.:
MATERIAL : Rawmix Date :
PROJECT : VRM No. :
MILL FEED, COMPOSITION
M1 : 96.29%
M2 : 1.00%
M3 : 1.61%
M4: 1.10%
SIEVE ANALYSIS - MOISTURE DETERMINATION :
Sample Id. : M1 M2 M3 M4 M5 M6 M7 M8 MIX
AS RECEIVED
Moisture : (%)
Sieve Residues :
: (%)
: (%)
40 mm : (%)
25 mm : (%)
16 mm : (%)
8 mm : (%)
4 mm : (%)
2 mm : (%)
1 mm : (%)
500 m : (%)
250 m : (%)
200 m : (%)
90 m : (%)
45 m : (%)
32 m : (%)
AFTER PRECRUSHING, -25mm
Moisture :
+4 mm : (%)
+4mm, max : (%)
-4 mm : (%)
-4 mm, max : (%)
Sieve Residues :
16 mm : (%)
8 mm : (%)
4 mm : (%)
2 mm : (%)
1 mm : (%)
500 m : (%)
250 m : (%)
200 m : (%)
90 m : (%)
45 m : (%)
32 m : (%)
AFTER PRECRUSHING, -16 mm Mill Feed
Sieve Residues :
8 mm : (%) 8.42
4 mm : (%) 49.94
2 mm : (%) 73.52
1 mm : (%) 85.42
500 m : (%) 91.91
250 m : (%) 95.16
200 m : (%) 95.54
90 m : (%) 96.97
45 m : (%)
32 m : (%)
Wet sieving :
90 m : (%)
45 m : (%)
Spec. Surf. (m/kg)
20100035
2010-04-14
ATOXIN10-11
Limestone
Clay
Shale
Iron ore
LABORATORY REPORT
F.L.Smidth Research Center - Chennai, India
VERTICAL MILL
Mill feed composition and Sieve analysis
Encl.: 7.1 Page 2
PLANT : Grasim Cement, Raipur Case. No. :
MATERIAL : Rawmix Date :
PROJECT : VRM No. :
MILL FEED, COMPOSITION
M1 : 96.29%
M2 : 1.00%
M3 : 1.61%
M4: 1.10%
TEST PARAMETERS
Mill : Moisture :
Revolutions : (rpm) 100 Mill feed : (%) 2.44
Grind. pres. : (bar) 90 Product : (%) 0.17
Grind. force : (kN) 26
(kN/m) 596
Gas :
Quantity : (m/h) 996
Temp out : (C) 91
TEST RESULTS
Period 1 2 3 4 5 6 7
Separator : Static () 39 30 25 22
Dyn. press. (mmWg) 238 238 239 238
Grinding bed:
Average for rollers: (mm)
Power consumption :
Mean : (kW) 4.46 4.56 4.65 4.77
Total (spec.) : (kWh/t) 10.39 9.27 8.78 8.66
Production :
Total : (kg) 26.7 21.9 34.1 35.5
Rate : (t/h) 0.429 0.492 0.530 0.550
Sieve residue :
90 m : (%) 7.2 14.2 21.0 26.0
200 m : (%) 0.9 1.3 3.3 5.0
Grinding constants :
90 m : (kWh/t) 9.21 11.12 13.20 15.15
200 m : (kWh/t) 5.10 4.94 6.02 6.77
- Factor : 0.116 0.118 0.121 0.124
ABRASION TEST
Wear parts : Abrasion :
Table : Cromin 15 Table : (g) 0.3
Rollers : Cromin 15 Roller 1 : (g) 0.1
Roller 2 : (g) 0.1
Test time (h) 1.37 Roller 3 : (g) 0.2
Average (net) (kW) 4.61 Total : (g) 0.7
Ground mat. (t) 0.662
Fineness, average : Table : (g/t) 0.5
90 m (%) 18.1 Rollers : (g/t) 0.6
TOTAL ABRASION 1.1 (g/t)
0.5 (g/h)
0.1 (g/kWh)
20100035
2010-04-14
ATOXIN10-11
Limestone
Clay
Shale
Iron ore
LABORATORY REPORT.
F.L.Smidth Research Center - Chennai, India
VERTICAL MILL
Encl.: 7.1 Page 3
PLANT : Grasim Cement, Raipur Case.No. :
MATERIAL : Rawmix VRM No.: Date :
PROJECT :
20100035
2010-04-14 ATOXIN10-11
y = 0.0059Ln(x) + 0.1036
R
2
= 0.9261
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
0.100
0.110
0.120
0.130
0.140
0.150
0.0 5.0 10.0 15.0 20.0 25.0
Sieve residue 90 mm, Alpine (%)

-
F
a
c
t
o
r
Rawmix Log. (Rawmix)
LABORATORY REPORT
F.L.Smidth Research Center - Chennai, India
VERTICAL MILL
m-factor vs. Sieve residue on 90mm
Encl.: 7.1 Page 4
PLANT : Grasim Cement, Raipur Case.No. :
MATERIAL : Rawmix VRM No.: Date :
PROJECT :
20100035
2010-04-14 ATOXIN10-11
y = 10.922e
-0.0097x
R
2
= 0.9167
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
12.00
0.0 5.0 10.0 15.0 20.0 25.0
Sieve residue 90 mm, Alpine (%)
S
p
e
c
i
f
i
c

p
o
w
e
r

c
o
n
s
u
m
p
t
i
o
n

(
k
W
h
/
t
)
Rawmix Expon. (Rawmix)
LABORATORY REPORT
F.L.Smidth Research Center - Chennai, India
VERTICAL MILL
Specific power consumption rate vs. Sieve residue on 90mm
Encl.: 7.1 Page 5
PLANT : Grasim Cement, Raipur Case.No. :
MATERIAL : Rawmix VRM No.: Date :
PROJECT :
20100035
2010-04-14 ATOXIN10-11
y = 0.3975e
0.0132x
R
2
= 0.9609
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
0.0 5.0 10.0 15.0 20.0 25.0
Sieve residue 90 mm, Alpine (%)
P
r
o
d
u
c
t
i
o
n

(
t
/
h
)
Rawmix Expon. (Rawmix)
LABORATORY REPORT
F.L.Smidth Research Center - Chennai, India
VERTICAL MILL
Production rate vs. Sieve residue on 90mm
Grasim Cement, Raipur
India

Case No: 20100035 2010-05-14 Page 1 of 1


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