HS E LSMIDTH icceansrionat cement pronuction SEMINAR ‘The coarse calcite is determined in the sieving residue + 125 ym as seen below: Specialists in microscopy may not be available in most cement plants. In that case, it is possible to use the total acid insoluble residue + 45jum and the total residue on 125pim as good guidelines for variations in the bumability. A formula to assist in this task will be given later in this lecture. 2.2. Effects of Chemical Composition on Burnability In addition to the coarse grains, both the lime saturation factor as well as the amount of liquid phase in the raw mix at the burning temperature influence the bumability. Knowing the effect on bumability caused by the coarse grains, the effect attributable to chemical composition can be determined. Statistical treatment of the data from a large number of raw meals of differing types has shown that the chemical parameters of significance are the lime saturation factor LSF, and the silica modulus Mg (which is inversely related to the content of liquid phase).FS ELSMIDTH wreanarionat cement PRODUCTION SEMINAR The following formule may be used for estimating the free CaO after buming for a period of 30” minutes at 1400" C in the laboratory: ¢ Coinwacic CaO sor = 0.33 (LSF -95) + 1.8 (Mg-2) + 0.93 SIO) sesm + 0.56 C8CO5 41255 tne y t pate ' This shows that Ms and the coarse quartz content are the most important factors for the ‘bumability ie. the resulting free lime. $20 Eetimates 7] 400° tor 20min 161 C20 seq0" 10.33 (LSF-95)+ 1.8(Mg-2)+ iQ. 444°093*+C2CO5.1264°0.58 HH CHEMisTAY T2325 67 So OH RUE WT wD mone The figure above shows the correlation between free lime calculated according to this equation and the corresponding measured free lime after laboratory burnability tests. Each total free lime consists of three contributions. It is clear that the various raw mixes are very different from each other, with respect to which of the factors (coarse quartz, coarse calcite, or chemistry) contributes to the main part of the potential free lime. If the free lime content after buming at 1400°C for 30 minutes is known, the free lime content for other burning temperatures may also be calculated. 10FE ELSMIDTH reanarionat cement propuction SEMINAR 4% C20 Estimated CHEMISTRY Use of this model makes it possible to optimize the bumability of a raw mix consisting of given raw materials, not only in laboratory experiments but also under plant conditions. Assuming that the contributions from the calcite, the quartz, and the chemical composition in a certain plant raw mix is known, the free lime will be as shown in the figure above. Grinding to a 12% residue on the 90 jum sieve instead of to 17%, improves the bumability from 7.8 to 6.5% free lime after 30 minutes at 1400°C due to a reduction in the amount of calcite ‘grains coarser than 125 pm. ‘The bumability may also be improved by changing the chemistry. Changing the lime saturation factor from 98 to 94 improves the bumability from 6.5% to 5.2% free lime (1400 °C, 30 min. in the lab.), as shown above. However less alite will be found in the clinker. We are still dealing with laboratory free CaO results, after buming for 30 minutes at 1400 °C. Decreasing M, = increasing the liquid phase, will also improve the bumnability. At the plant from which this example is taken, the clinker was bumed to an average free lime of 2.7%. After the feed fineness was increased, this free lime level could be achieved at a lower burning temperature, or its equivalent - a shorter buming time. With no changes in kiln operation, a lower clinker free lime was achieved. nHFS ELSMIDTH sreanationat cement PRODUCTION SEMINAR In this case, a 10% reduction in buming time wes realized. This corresponds, for practical purposes, to 2 10% increase of the kiln output. Such a case is illustrated in the graphs below, where the sieving residue is shown corresponding to the kiln output. % Residue on 90 Hm sieve 20 18 16 14 | 12 10 | Lopete peter Production, tons /dey t 1500 + 1400 1300 1200 74g Bi 25 25 27 29 B12 4 6 B 10 12 14 16 18 20 22 24 26 August ‘September 12FS FLSMIDTH irennariona: cement proouction seminar 3. ALTERNATIVE BURNABILITY DETERMINATION Quantitative microscopy is a time consuming technique not mastered by most cement laboratories. It is therefore encouraging that an adequate description of changes/variations in burnability in a given plant may also be obtained by using the raw mix acid insoluble residue > 45 um and the total residue > 125 jum, instead of the microscopically determined parameters. The burnebility expression obtained with LSF, M,, acid insoluble residue Agsun > 45um, and total residue Ty25ym > 125 pum as parameters is slightly different: Gees See Ca0i00'c = 0.35 (LSF- 96) + 1.58 (Ms - 1.6) + 0.55 Asim + 0.12 Tis i Ce i ' 4, CLINKER FORMATION The size distribution of the cement clinker is very important with respect to effective plant operation Dusty, fine grained clinker seriously endangers satisfactory maintenance free operation of grate coolers and generally strongly reduces the lining brick life in the buming zone of the kiln. Dust, retumed from the clinker cooler often leads to the formation of a porous, unstable and pumice-like coating on the brick lining, instead of the desired dense, stable coating. Furthermore, the handling of very dusty clinker is problematic and the grindability is often inferior to that of a coarser, dust free clinker. Experience has shown that energy consumption in the cement mills may increase up to 40%, ‘when the clinker granulometry changes from the desired clinker nodules to the dusty or pumice like type. 13