Professional Documents
Culture Documents
Basic Facts About Clinker
Basic Facts About Clinker
Thermal profile............................................................................................................................... 5
2.1
Port la Nouvelle....................................................................................................................... 5
2.2
Le Teil...................................................................................................................................... 6
Alkali saturation............................................................................................................................ 20
9.1
Reminder............................................................................................................................... 20
9.1.1
Alkali sulfates.................................................................................................................. 20
9.1.2
Alkalies in solid solution................................................................................................. 20
9.2
Ranteil................................................................................................................................... 21
9.3
Ste....................................................................................................................................... 21
10.2.4
Cantagalo....................................................................................................................... 25
Example:
When the amount of 100m rejects is reduced from 20 to 10%, the global raw mix +
cement energy consumption is lowered by about 4 kWh per tonne of cement at a fineness
of 350 m2/kg.
Raw mix fineness is generally characterized by the weight of rejects in one or several sieves (a 100m
sieve is often used).
The following examples illustrate these three points:
1.1
Observed: in 1991, the purchase of a precrusher allowed the Contes plant to improve raw mix fineness.
The burning temperature (pyrometer reading or kiln outlet temp.), whose measurement integrates all
changes occurring in the burning zone, shows a poor relationship with rejects, whereas fuel consumption
shows a good relationship, as demonstrated in Figure 1, taken from four typical periods.
58.5
Oil
(l/t Raw mix)
58
57.5
57
56.5
56
12
16
20
_______________________________________ ________________________________
1
8.00
% freeCaO
Rawmix
15%>100 mIndustrialasis
6.00
5%>100 mlabgrindingofresidue
5%>100 mcompletegrinding
4.00
2.00
temperature C
0.00
1400
1450
1500
1550
1600
Figure 2: Free lime after burning for different raw mix finenesses (Martres lab test)
8.00
% free CaO
6.00
Raw mix
16% > 100m industrial as is
4.00
2.00
temperature C
0.00
1350
1400
1450
1500
1550
1600
1.2
In 1990, the Lexos plant had the chance to grind its raw mix to different finenesses (13% to 21% rejects at
100m) over a long enough period of time so that the plants monthly averages could be considered as
meaningful.
Figure 4 shows the increase in the raw mills power consumption with the increased fineness.
25
kWh/t
y =- 0.42 x +29.7
y = -0.4267x + 29.759
24
r2 =0.91
23
22
21
20
12
14
16
18
20
22
kWh/t
y = 1.38 x + 37.8
70
r2 =0,58
65
60
14
16
18
20
22
1 H. Geesen : Influence of raw meal fineness on cement grinding energy (Lexos plant)
_______________________________________ ________________________________
3
1.3
When raw meal fineness was changed at Contes2 (Figure 6), a small increase in strength at constant
Blaine fineness was observed. This allowed the plant to slightly lower the Blaine (and increase mill
production) while maintaining strength.
Raw
Month
CPA HPR
t/h
mill
1d
MPa
2d
28d
MPa
MPa
February
20.0
2.0
3850
49.0
22.5
35.7
70.0
March
13.0
0.8
3850
52.5
24.0
37.0
71.0
0.8
3680
55.5
22.6
37.0
70.0
_______________________________________ ________________________________
4
2-Thermal profile
2 Thermal profile
A short profile promotes grindability and strength development.
Note:
The optimum is achieved when the kiln torque is at the minimum value compatible with
stable kiln operation.
By thermal profile, we mean the rate of heating and cooling of the product in the kiln and cooler. The
burning zone length can also be assimilated to this concept.
The thermal profile is affected by a number of factors:
the raw mix burnability and the kilns heat consumption
the type of fuel and its preparation
the burner and its settings
cooler operation (via secondary air temperature)
kiln operation, especially the draught and fuel settings, but also
rotational speed
Generally speaking, it is somewhat difficult to compare a thermal profile from one kiln to the next. On the
other hand, for a given system, several sensors provide readings as to the burning zone length: amps or
torque of the drive motors, clinker temperature measured at the kiln outlet (or the NO in the kiln exit
gases), temperatures in the preheater cyclones, pressure drop through the Lepol grate, shell scanners,
etc.
For each kiln, the most representative indicator should to be determined and analyzed.
Two recent examples can be given :
2.1
Port la Nouvelle
kWh / t
75
70
65
60
55
50
45
1050
1100
1150
1200
1250
1300
1350
1400
1450
_______________________________________ ________________________________
5
2-Thermal profile
75
B B 1 0 (k W h /t)
70
65
60
55
50
Nm
45
600
700
800
900
1000
1100
1200
1300
1400
1500
2.2
Le Teil
500
Kiln amps
kWh / t
80
Grindability
improvement
450
400
350
300
75
70
65
60
250
55
200
50
30/05/1995 04:00
30/05/1995 12:00
30/05/1995 20:00
31/05/1995 04:00
31/05/1995 12:00
_______________________________________ ________________________________
6
3-Burning atmosphere
3.1
Saint Constant
The following results have been observed at the Saint Constant plant, where unground fluid coke with up
to 2% rejects at 5mm is burned:
Fuel
Fuel oil 100%
Coke 23.8%
Coke 47.7%
Coke 47.7%
v SO3
(%)
47.1
59.6
83
67
Clinker
SO3 (%)
1.39
1.6
1.2
1.96
Clinker
K2O (%)
0.94
1.04
0.98
1.15
Emissions
SO2 ppmV
2
7
1278
200
Emissions
SO3 ppmV
25
19
43
58
3.2
Brookfield
At Brookfield (long dry kiln), where raw mix SO3 is 1.5%, the kiln went through many cycles that were
recognizable by:
the cyclical variation of kiln torque
the cyclical variation of clinker production, with surges every eight hours
variation in the clinker SO3 and K2O content : SO3 between 1% and 4%
Cyclical operations, with a period of about two hours, were observed on other long kilns such as Bath and
Exshaw (kiln 4), where the raw mixes are rich in volatile elements.
One solution used to reduce the sulfur cycle is to divert part of the electrostatic precipitator dust (the
finest and highest in sulfur content) away from the kiln circuit.
At Brookfield, some tests were carried out on the kiln exit oxygen values. An increase in the draught
augmented the dust pick-up, which lead to a redesign of the chain section. A setting of 3.2% oxygen was
decided upon instead of 1.9%. Of course, this had a negative impact on heat consumption, but a positive
effect on the quantity of by-passed dust.
Kiln exit oxygen (%)
volatilization SO3 (%)
Dust eliminated (t/d)
1.9
78
90
3.2
4
32
40
_______________________________________ ________________________________
7
3-Burning atmosphere
3.3
Le Teil
The figure below shows the impact of oxygen levels on the volatilization of sulfates (clinker SO3 in the C4
material).
% SO
C4 C4
%3 SO3
%
2 Preheater
%O
O2
sortie tourexit
%%
SOSO3
clinker
3 Clinker
5,5
4,5
4
3,5
3
% OO2
sortie tourexit
2 preheater
4,5
2,5
2
% SO
3 C4
SO3
C4
% SO
3 Clinker
SO3
KK
1,5
1
3,5
0,5
3
17/sep
09:00
0
17/sep
13:00
17/sep
17:00
17/sep
21:00
18/sep
01:00
18/sep
05:00
18/sep
09:00
18/sep
13:00
18/sep
17:00
18/sep
21:00
Figure 12: Influence of the oxygen level at preheater exit on sulfate volatilization.
Figure 12 shows the switch from 60% to 100% coke on September 17 at 9 a.m. (beginning of chart).
In cyclone 4, one can see the increase in SO3 attaining 4% at 1400h. The clinker SO3 remains low. The
sulfur introduced as a result of the additional coke does not leave the system: there is a risk of plugging.
At 1400h the preheater exit O 2 was raised from 4.4% to 4.9%; the C 4 material SO 3 content goes down
from 4% to 2.5%, the clinker SO3 content increases from 0.7% to 1.3%. The oxygen increase allows an
acceptable sulfur balance to be reached with 100% coke thereby avoiding plugging in the cyclones, ring
formation, etc.
_______________________________________ ________________________________
8
4-Free lime
4.1
When free CaO increases from 0.5 to 1.5%, initial set decreases by about 40 to
50 minutes. This impact may vary greatly from clinker to clinker4 (-10 to 100
minutes).
Saint-Constant
A burning intensity study undertaken with St. Constants long dry kiln, allowed the plant to compare the
relationship between clinker free lime and initial setting time, as shown in the table below:
180
160
140
120
100
0.2
0.4
0.6
0.8
1.2
1.4
1.6
4.2
Bath
At Bath, another long dry process, numerous tests were carried out to reduce initial and final setting times
in response to a customer request. These tests were all aimed at increasing the free lime content to
0.9%: fineness, mix composition, kiln speed/feed ratio, etc. None of these tests gave the desired results.
The solution applied today consists of adding limestone at the kiln outlet, in the nose ring area. This
addition could technically be done at the cooler inlet, however this would not be in accordance with ASTM
standard which apply to part of the plants sales.
The results are as follows:
4 Lime quality (specifically its burning temperature, its hydration level, etc.) and clinker quality have an influence on the results obtained.
_______________________________________ ________________________________
9
4-Free lime
Concrete
set.
time
10C
Sample
SSB
(m2/
kg)
free
lime
(%)
Setting
time
23C
(plant)
Setting
time
23C
(CTS)
Concrete
setting
time
(h:min)
Concrete
setting
time
24C /
2%CaCl2
Concrete
setting
time
10C /
2%CaCl2
Concrete
set.
time
24C
Reference
Test 1
Test 2
360
357
371
0.35
0.7
0.9
165
125
120
180
110
115
5:45
4:55
4:40
3:30
4:45
5:10
8:30
3:10
4:25
4:30
7:15
4.3
Val dAzergues
Following a clients request (BDI), in order to improve the reactivity of Val dAzergues CEM I 52.5 R,
particularly in heat-cured (HC) concrete, the level of free lime was increased by adding lime from different
sources. The increase in short-term HC concrete strength is partially related to the initial setting time. The
gain in short-term HC concrete strength (2h30) slightly penalizes the long-term (5h30).
Two types of lime sources were tested industrially:
The co-grinding of 5% ash containing 30% free lime and clinker results in a better performing cement with
a setting time that decreases by 60 minutes.
Cooler limestone
Some trials with limestone injection (6/10 mm) were done in the cooler throat (at a temperature of 1250 to
1350 C). By introducing 2.5% limestone, 0.95% added free lime was obtained and, for the most part,
incorporated in the clinker. The gain in initial setting time was 40 to 60 minutes.
Normal
+5%
Ash
Free lime
1,10
2,10
2,90
2,50
Blaine
cm2 /g
4320
4480
4600
4420
Setting time
initial
175
110
110
135
(min)
final
245
180
170
255
Strength EN
1d
24,7
25,3
24,5
24,0
(MPa)
28d
69,1
67,2
66,9
67,2
0,5
3,8
6,0
3,8
5h30
24,1
29,4
25,3
26,7
80C (MPa)
4.4
Limestone
Woodstock
At Woodstock, a comparable test was carried out at the kiln outlet, where the effect was minimal. This
could be related to the level of lime saturation, which is lower in this plant. This conclusion was also
reached in the Delta-free lime study carried out by LCR: the decrease in setting time through an increase
in free lime is most effective when the degree of lime saturation in the raw mix is high.
______________________________________
________________________________
10
5-Clinker C3S
Order of magnitude:
5.1
65.00
% C3S
60.00
55.00
50.00
45.00
10/06/92
03/06/92
26/05/92
19/05/92
13/05/92
05/05/92
29/04/92
21/04/92
07/04/92
31/03/92
24/03/92
17/03/92
12/03/92
10/03/92
3/03/92
12/02/92
9/02/92
8/02/92
7/02/92
40.00
_______________________________________
________________________________
11
5-Clinker C3S
1.80
1.60
1.40
% SO3
1.20
1.00
0.80
0.60
0.40
0.20
10/06/92
03/06/92
26/05/92
19/05/92
13/05/92
05/05/92
29/04/92
21/04/92
07/04/92
31/03/92
24/03/92
17/03/92
12/03/92
10/03/92
3/03/92
12/02/92
9/02/92
8/02/92
7/02/92
0.00
60.0
55.0
28d
y = 0.42 x + 32.24
r2 = 0.31
7d
y = 0.55 + 15.51
r2 = 0.58
50.0
45.0
N /m m
40.0
35.0
y = 0.58x + 1.42
r2 = 0.67
2d
30.0
25.0
y = 0.45x - 2.59
r2 = 0.43
1d
20.0
15.0
45.0
50.0
55.0
60.0
C3 S
Figure 17: Evolution of strengths as a function of C3S (Villaluenga plant)
1 day: gives a moderate correlation (r 2=0.43) which improves in the case of multiple regression
using the proportion of sulfate in the clinker. Result: 4.5 MPa for 10% C 3S
2 days: good correlation (r 2=0.67). Result: 5.8 MPa for 10% C3S
7 days: good correlation (r 2=0.58). Result: 5.5 MPa for 10% C3S
28 days: poor correlation (r2=0.31). Result: 4.1 MPa for 10% C3S
It must be noted, however, that the SO3 and C3S evolved in the same manner during those four months
and it is therefore difficult to distinguish their individual effects and the impact of optimum sulfate
addition. This may explain why the slopes of the linear regressions (1 day and 28 days in Figure 17) are
very similar.
______________________________________
________________________________
12
5-Clinker C3S
5.2
Villaluenga 1501
Production in normal conditions for kiln 1501 (kiln w/ AS precalciner). This corresponds to the same
period as the start up of kiln 2302 but the C3S is less variable .
Clinker characteristics: the average values are C3S =57.9, SR=2.7, A/F=1.73, SO3/alkalies molar ratio =
0.92.
The compressive strengths vs. C3S content for different ages are show in Figure 18:
60.00
y = 0.59x + 20.84
r 2 = 0.59
55.00
28d
50.00
y = 0.68x + 5.61
r 2 = 0.66
40.00
N /m m
45.00
35.00
7d
30.00
2d
y = 0.54x + 0.771
r 2 = 0.59
1d
y = 0.28x + 4.88
r 2 = 0.22
25.00
20.00
15.00
50.0
55.0
60.0
65.0
C3 S
Figure 18: Evolution of strengths as a function of C3S (Villaluenga plant, kiln 1501)
1 day: very weak correlation (r2=0.22). Result: 2.8 MPa for 10% C3S
2 days: good correlation (r 2=0.59). Result: 5.4 MPa for 10% C3S
7 days: good correlation (r 2=0.66). Result: 6.8 MPa for 10% C3S
28 days: poor correlation (r2=0.59). Result: 5.9 MPa for 10% C3S
5.3
Whitehall
For reasons that have to do with the quarry, the Whitehall plant had to perform some clinker production
tests with low C3S levels. The industrially produced clinkers were ground in the lab at constant sulfate
addition. The table on the following page shows the test results.
40
35
1 d
30
3 d
MPa
25
7 d
28 d
20
15
10
5
0
10
20
30
40
50
60
C3 S
Figure 19: Evolution of strengths as a function of C3S
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________________________________
13
6-Clinker C2S
Order of magnitude:
6.1
Ocumare
The Ocumare plant5 (FNC - Venezuela) recently modified its raw mix composition (February 1997) by
increasing the lime saturation in order to improve clinker reactivity. All other parameters including the
clinker free lime remained constant. The table below summarizes the situation over a consecutive twomonth period, before and after changing the mix.
%
January 1997
LSF Clinker
February 1997
Feb. - Jan.
94,50
98,60
+ 4,10
C3 S
56
64
+8
C2 S
22
15
-7
C3 A
10,20
9,60
C4 A F
8,20
8,00
Free CaO
1,27
1,30
46,70
44,40
- 2,30
3680
3710
kWh/t Industrial
53,10
51,60
- 1,50
28 d. Industrial
(ASTM standards)
32,0
35,5
+ 3,5
kWh/t BB10
SSB BB10 (
cm2/g
6.2
Karsdorf
Until 1994, only one clinker with high lime saturation (KST = 98) was used for the entire cement product
range. At that time, the new European standards lowered the upper limit of 28-day strength of CEM I
32.5 to 52.5 MPa from its previous 55 MPa. Meeting this demand was not easy. The solution, which
consisted of reducing cement fineness, caused problems with bleeding, which was unacceptable for the
users.
5 Presentation given by L. Corda, J.A. Sbardella from Gerencia Desarollo y Procesos, Cementos La Vega, TYTP Combustion Meeting on April 15-16,
1997 at Yozgat.
______________________________________
________________________________
14
6-Clinker C2S
It was therefore decided to produce a second clinker less saturated in CaO (KST = 90), which gives less
28 day strength because of lower C3S content.
The results obtained6 are as follows:
KST = 90/92
45
25
45
% C 3S
% C 2S
KWh/t BB10 @ 3500 SSB
KST = 96/98
55
15
41
Difference
-10
+10
+4
The increase in the percentage of Belite causes the mill power consumption to increase by:
+ 4 kWh/t for + 10% C2S
It must be stated that this solution is not satisfactory firstly because of increased energy cost and
secondly because the strong reactivity of the Belite at Karsdorf doesnt allow for a significant reduction of
28-day strength in the cement considering the clinkers high lime saturation. Figure 21 below shows the
results of laboratory-ground cement made from two industrial clinkers with two different sulfate addition
rates (2/3 gypsum 1/3 SH). Another method is being studied, which consists of modifying the sulfate
addition of KST 98 clinker. The trouble here lies with the risk of rheological disturbances.
KST = 90
60
KST = 98
60
56
54
54
50
41
40
30
20
50
43
40
SO3 =2.3
24.5
17.3
SO3 =2.9
23.5
50
44
40
30
30
26.5
18.2
17.8
11
10
9.8
20
14.5
10 8.8 9
0
0
10
J ours
20
30
10
J ours
20
30
6 Presentation given by G. Cochet and G. Staupendahl at the CTI/CTEC Technical Days in Madrid, October 1996. Study of clinker grindability at
Karsdorf by G. Cochet, CTI, September 1995.
______________________________________
________________________________
15
Order of magnitude:
It is usually very difficult to change the alkali content in a given plant without greatly altering other
parameters, because the content in the individual raw materials tend to be relatively constant.
7.1
The measurements performed on 29 industrial cements 8 (from Lafarge Ciments and Lafarge Corp. as well
as French competitors) confirm the above relationship.
When the TOTAL alkalies increase from 0.2% to 1.8%, one notices that the mechanical strength at 28
days9 decreases from 66 MPa to approximately 45 MPa.
The regression equation indicates a loss of 1.3 MPa for an increase of 0.1% in total alkalies, with a
correlation coefficient of 0.88.
The results are shown in the diagram below:
70
2 8 -d a y S tre n g th (M P a )
65
60
55
50
45
0
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
% Total Alkalies
Fig
ure 22: Influence of total alkalies on 28-day strength
7.2
Laboratory testing10 was carried out on a single clinker to measure the effects of alkaline sulfate addition
in the water:
7 The clinker alkalies may occur in different forms depending upon the degree of alkali saturation by sulfates. The total alkalies Na 2O+K20 are present
in either or both of the following forms:
Soluble alkalies
The alkalies combined with sulfate are Na 2SO4, K2SO4, K2SO4(CaSO4)2. These compounds can make their appearance during industrial production
when the fuel is changed from a natural gas to a sulfur-bearing fuel like bunker oil or petroleum coke or when gypsum is added to the raw mix. In this
case, there will be more soluble alkalies at the expense of alkalies in solid solution.
Alkalies in solid solution
The alkalies that are not combined with sulfates will enter the aluminate and silicate crystal lattices, modifying their reactivity. This can be a problem for
the C3A (loss of workability) as mentioned in the ninth basic fact.
8 R. Guyot, R. Ranc, B. Cariou: Sulfates Synthesis Report , June 1983.
9 at a constant Blaine and with sulfate addition optimized for 28-day strength.
10 M. Debos, G. Chaudouard
______________________________________
________________________________
16
Rc MPa
R 28j
70
R 28j + K2O
60
R 7j + K2O
50
R 7j
40
R 2j + K2O
30
R 2j
20
R 1j + K2O
10
R 1j
0
25
30
35
40
45
50
55
60
65
______________________________________
________________________________
17
Order of magnitude:
The soluble alkalies [Na2SO4, K2SO4, K2SO4(CaSO4)2] in the clinker are, as mentioned above, mainly in
the form of K2SO4 although they are calculated on the basis of Na 2SO4 equivalent.
There are two ways to increase soluble alkalies:
Increase the sulfates insofar as the alkalies are not yet saturated. In this case, the soluble alkalies
will increase. This can be done either via the fuel (ex. : gas bunker oil or low sulfur content oil
high sulfur content oil) or via the raw mix (adding sulfates to the mix).
Increase the alkalies in the raw mix insofar as there are available sulfates. This can be done by
using a siliceous sand that is rich in alkalies, for example (sea sand).
These two examples will be further investigated.
8.1
Increasing sulfates
%Na2O
Total
0.1
SSB (m2/kg)
0.2
% K2O
Total
1.15
400
11.5
Gypsum addition
1.1
1.15
0.1
375
18.0
Ste
0.1
0.6
0.2
402
11.5
1.3
0.6
0.2
413
17.0
Ranteil
% SO3 Clinker
As is
As is
Gypsum addition
1d (MPa)
% SO3 Clinker
% K2O Total
% Na2O Total
SSB (m2/kg)
Gaz
0.20
0.40
0.06
370
12.5
Fuel oil
1.00
350
15.5
low-s oil
0.60
360
18.0
Hi-s oil
1.00
340
21.0
0.95
0.10
______________________________________
________________________________
18
1d (MPa)
For both plants, when one operated with gas and the other with low-sulfur oil, the alkalies were not totally
saturated. There would have to have been 0.40% and 0.93% of SO3 in the clinker to saturate the alkalies
at the Martres and La Malle plants, respectively.
The switch to higher sulfur content oils in both cases produced the saturation of the alkalies and,
therefore, an increase in the amount of soluble alkalies, with a positive impact on 1-day compressive
strengths.
In the lab, the increase in the portion of soluble alkalies was also tested, confirming industrial results. In
these laboratory tests, 1.85% of K 2SO4 (=1% K20) was added to clinker, equivalent to a 1.85% addition of
K2SO4 to the cement during the mixing with water.
The table below confirms once more the positive effect on early strength and the negative effect on longterm strength.
Term
As is
1 day
20.3
28.1
28.2
7 days
54.3
53.0
53.8
28 days
8.2
74.3
66.2
Figure 26: Strength of cements spiked with K2SO4 in the lab
66.3
Increasing alkalies
At the Retznei plant, in the past, we used an additional source of SiO 2 containing alkalies with high
amounts of Na2O between 2.2 and 2.5%, and K2O between 1.2 and 1.4%
Analysis of the raw mix at that time showed that the alkali content was the highest of all cement plants in
Austria, with 0.45% of Na2O eq. (in the raw mix). Today, with a source of silica that is poorer in alkalies
(Na2O = O and K2O = 0.5%), we have brought the Na2O eq. values down to around 0.3%.
The consequences of this drop in raw mix alkali content can be seen in terms of both short (lesson 8) and
long-term (lesson 7) mechanical performances in the table below.
Rmeq Na2O=0.45%
Rmeq Na2O=0.3%
Measured
Caldulated at
Measured
Calculated at
(addition 16%)
O% addition1
(addition 20%)
0% addition
1 day
17.1 0.1
21.1 0.1
13.9 0.12
18.5 0.12
28 days
46.8 0.19
57.8 0.19
47 0.23
62.7 0.23
Number of tests
143
100
Figure 27: Cement strength with varying levels of alkalies (Retznei)
Despite slight variability in the alkalies and the difference in cement composition (additive ratios of 16 and
20%), it remains possible to compare the results.
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19
9-Alkali saturation
9 Alkali saturation
The molar saturation of alkalies by SO3 in the clinker facilitates workability control.
9.1
Reminder
11 M. Debos, G; CHAUDOUARD. Portland Cement: chemistry - mineralogy - properties of phases - reactivity (June 1991).
12 R. Ranc. Influence of alkalies on the physical and mechanical properties of Portland cements . Sept. 93.
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20
9-Alkali saturation
The above observations are taken from examples of industrial and lab testing which compare the
properties of normal clinkers without sulfates and clinkers made from a sulfate-rich raw mix as the result
of the addition of gypsum.
These tests were all carried out for the purpose of improving the rheological properties of cement (by
eliminating the causes of false set).
9.2
Ranteil
The table below presents the laboratory results 13 (burning and grinding) due to the addition of gypsum to
the raw mix at Ranteil (non-saturated alkalies).
Clinker as is
Sulf. raw mix
Sulf. raw mix
% raw mix
% gypsum SO3 kk
100
0,35
0
97,95
1,40
2,05
96,0
2,40
3,95
SSB
2
( cm / g )
3830
1d
MPa
28,6
Fluidity
(%)
88
2,50
26,0
112
10,5
2,90
26,2
125
12,5
SO3 cem.
2,0
3770
3920
W/C
6,5
9.3
C3A
Cubic ( pure )
Ste
As is
Cement (sulfated kk)
K20 tot.
Na2O tot.
SO3
SSB
(cm/g)
Rsidue17(mm)
after 2 min after 30 min
1d
MPa
0,1
0,37
0,10
2,80
3510
14
29
11,5
2,9
0,56
0,09
2,90
3500
10
19
16,0
13 Ray. Allgre. Study on the influence of the addition of gypsum to the raw mix at Ranteil (1972)
14 Ray. Allgre. CB N.20 IDSG industrial trial at the Ste plant - OS 11445 March 1971.
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21
10-Excess of sulfates
Order of magnitude:
If the clinker excess SO3 is increased beyond the molar saturation of alkalies, the following are observed:
an increase in clinker fineness
an increase in grinding energy
Each of these points will be dealt with separately.
100
% p a s s in g
80
60
0,1 % S03
40
1,3 % SO3
20
0
0
10
15
20
25
mm
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22
10-Excess of sulfates
passing
60
0,1 % SO3
40
2,9 % SO3
80
20
0
0
10
15
20
25
30
35
mm
100
% passing
80
60
0,1 % SO3
1,2 % SO3
40
20
0
0
10
20
30
40
50
60
mm
10.2.1 Mekns
At the Meknes18 plant, a gradual switch to coke was made without any major changes to equipment, raw
mix or products.
16 Ray. Allgre / CB 20 OS n 11445 Industrial test JDSG at the Ste plant March 1971
17 M. Debos Sulfates conference (L'Isle d'Abeau) : Influence of sulfates on kiln operations Nov. 1993
18 Meknes plant. Market reports 1994/95
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23
10-Excess of sulfates
coke
coal
fuel
SO3
F2
kk
K2OT
Na2OT
C/K
Mill kW
CPJ 45
F3
1994
47,37
51,01
4,62
0,45
0,75
~ 0,35
#0
1,222
38,52
1995
74,14
21,30
3,56
0,95
1,18
~ 0,35
#0
1,237
40,29
10.2.2 Ste
In the industrial study16 on sulfate addition to the raw mix at the Ste plant (1971), cement grinding trials
were carried out both in the lab and in the plant.
The results are expressed in terms of:
output for the industrial trials
mill rotations and SSB (Blaine specific surface) for the lab trials.
SO3 kk
K2OT
Na2OT
SO3 cem
Prod.
t/h
Industrial tests
kk normal
kk sulfated
0,1
2,9
0,37
0,56
0,10
0,09
2,8
2,9
Lab.tests
kk normal
kk sulfated
0,1
2,9
0,37
0,56
0,10
0,09
21
17
3150
2700
2880
2580
2000
2000
Figure 34: Cement grinding results for raw mixes with gypsum addition (Ste plant)
10.2.3 La Couronne
The use of petcoke at the La Couronne19 plant produced an increase in clinker SO3 content and a
reduction in terms of pure cement production rate from the various mills.
1991
1992
SO3 kk
0,80
1,45
K2 O
0,89
0,92
Production t / h
(B0)
CPA 55
21,6
20,3
(B3)
CPA 55
19,3
18,2
(B3)
CPA HPR
14,2
13,2
r2 =0.67
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10-Excess of sulfates
r2 =0.66
shows the increase in the number of BB10 mill rotations (image of industrial grindability) to obtain a
cement at 350 10 m2/kg.
4800
4600
rotations BB10
4400
4200
4000
y = 1008 x + 3255
3800
r 2 =0.66
3600
3400
0.2
0.4
0.6
0.8
1.2
1.4
SO3 kk
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1.6