Course 2 – Raw Material Preparation

2.4 Raw Meal Homogenization Systems

Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 78–1
Fax: +49 211 45 78–296
info@vdz-online.de
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info@elearning-vdz.de
www.elearning-vdz.de

Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Design and Operating Principle ...................................................................... 1
2.1 Aeration Mixing Process .................................................................................... 1
2.2 Tangential Mixing Silo ....................................................................................... 4
2.3 CF Silo from FLSmidth A/S............................................................................... 4
2.4 Multi-Cell Silo .................................................................................................... 4
3 Health and Safety Practices ............................................................................. 5

4 Operation and Quality ..................................................................................... 7

5 Environmental Protection ................................................................................ 7

6 Questions on Course LB 2.4 – Raw Meal Homogenization .......................... 8

Solutions............................................................................................................................... 9
Glossary ............................................................................................................................... 11 i
Index..................................................................................................................................... 12

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1 Introduction

In most industrialized countries cement clinker is now predominantly produced by the dry
process. This process requires very uniform ( homogeneous ) raw meal. Advances in the
field of aerodynamics and pneumatics have made it possible to produce dry raw meal that
has a homogeneity similar to that of the raw slurry in the wet process.
In order to produce a homogeneous raw material mixture, the material is first mixed in
blending beds . In the grinding plant the material then undergoes a second homogeniza-
tion of the chemical composition. However, in most cases this is not sufficient to satisfy
the strict requirements of the burning process, so it is then necessary to mix the largest
possible quanitities of raw meal with each another.
Processes have therefore now been developed that permit extensive, cost-effective, ho-
mogenization (uniform mixing) of the raw meal, and produce appropriate silo plants with
equipment for mixing and storing the raw meal.
In this course you will learn about the key methods of raw meal homogenization. In 1
particular, you will be made familiar with pneumatic homogenization in raw meal silos.

Course Summary

2 Design and Operating Principle

As already mentioned, the cement raw materials are normally homogenized in a number Homogenization
of successive process steps, which should even out the natural variations in individual
rock layers and deposits as much as possible. Homogenization also serves to offset any
segregation effects by which larger pieces of material come to lie at the base with smaller
particles on top.
1 Blending Bed: The crushed material is first piled up and spread out in blending beds
so that it is mixed as thoroughly as possible.In this way e.g. a truckload of material is
distributed in a layer over the entire surface of the blending bed.
2 Reclamation and Raw Mill: The raw material is then reclaimed from the blending
bed across the layers, ground in the raw mill and stored in the raw meal silos.
3 Storage in the Raw Meal Silo: The material is further homogenized in the silo by
carefully controlled deposition of the raw meal i.e.by filling from constantly changing
positions in the top of the silo.
4 Aeration Mixing Process and Discharge: Variations in the chemical composition
of the raw meal are further reduced by subsequent mixing using compressed air and
carefully controlled extraction.
Methods for storing raw meal, homogenization using aeration and different strategies for
extracting the meal from the silo will now be discussed.

Course Summary

2.1 Aeration Mixing Process

The aeration mixing process (»pneumatic homogenization«) is the most popular homog- Pneumatic
enization process. The aim of the process is to generate a fluidized bed in the silo that can Homogenization

then be used to achieve the highest possible level of uniformity of the raw meal. To this
end, the raw meal is loosened by introducing compressed air through the aeration base.
Aeration of different sections of the base in turn causes the raw meal in the silo to cir-
culate and swirl, thus achieving effective, thorough mixing. In this process, one or more

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 2 Design and Operating Principle

segments function as mixing segments (high air volume, fluidized bed), whereas the other
segments are only lightly aerated (loosening, slight fluidization).
The fluidized bed generates vertical circulation of material and a high degree of mixing.
The segments are supplied in turn with mixing air in a fixed cycle to achieve homogeneous
mixing of the material in the silo (Fig. 2.1-1). If the mixing air is fed to the silo in pulses,
the raw meal is fluidized even more efficiently. This is more expensive and complex, but
results in a higher level of homogeneity.
The segments are supplied with air separately from a mixing air compressor and an aer-
ation compressor. The volume of mixing air that is introduced into the mixing segments
accounts for approximately 85 % of the total air flow. Depending on the number of seg-
ments, a distinction may be made between the Fuller process (also called the quadrant
system), the Polysius homogenizing system (nine segments) and the octant system (eight
segments).

1 2 3 4
2

5 6 7 8

Figure 2.1-1: Diagram of a Mixing Silo with Eight Aeration Segments (1-8) .

Design The dimensions of a homogenizing silo are determined on the basis of a filling volume
of 10 to 12 hours output from the grinding mill to ensure that the chemical variations
are theoretically evened out. The height of material in the silo should not exceed 1.5
times the silo diameter to ensure thorough mixing. The air required is approximately
10 to 13 m3 air/t raw meal and the energy consumption is 0.65 to 0.84 kWh/t raw meal.
The air pressure of the mixing air is about 2 to 2.2 kg/cm2, and that of the fluidizing
air is about 1.75 kg/cm2.

Internal fittings in the silo, such as a pressure-relief cone, can further improve the mixing
effect. Because of the inner cone, the horizontal material layers produced when the silo is
filled cannot move downwards uniformly (Fig. 2.1-2). This brings about primary mixing

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 2.1 Aeration Mixing Process

of the raw meal in the silo. It is also possible to achieve improved homogenization by
providing a downstream mixing chamber. The designs vary with the different suppliers.
At this point in the online course you will watch a video instead of this image.

Figure 2.1-2: Movement of Material at the Pressure-Relief Cone .

The basic elements of pneumatic dry mixing systems are air distribution boxes (Fig. 2.1-
3) that are located on the silo base. The main component is an air-permeable, porous
cover that may be made of ceramic plates or woven textile. Air is forced from below into
the raw meal through the porous plate, which produces fine currents of air that bring the
raw meal into a quasi-fluid (»fluidized«) state.

Between 50 and 80 % of the silo base is aerated depending on the type of homegeniza-
tion process and the design of the mixing silo.

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 2 Design and Operating Principle

pressure of material
porous
plate

air inlet
air pressure

aeration box

Figure 2.1-3: Schematic View of an Air Distribution Box .

4 2.2 Tangential Mixing Silo

Tangential mixing silos were developed specially for the storage of fine-grained bulk
materials. The main components of a tangential mixing silo (Fig. 2.2-1) are the inner
cone (1), the aeration surface with extraction points (2) and the central mixing chamber
(3). The silo outlets are postioned under the inner cone and extend into the centre.
Depending on the fill level of the mixing compartment, parts of the silo base are aerated,
causing the raw meal located in that part to be »fluidized«. In this state it is possible to
draw the meal off and transport it to the mixing chamber.
The bulk material is transformed into a fluidized bed in the mixing container, which en-
sures the homogeneity of the raw meal. The raw meal is drawn off continuously through
an outlet at the mixing container.

2.3 CF Silo from FLSmidth A/S

The base of the CF-silo (CF = controlled flow) is divided into seven identical hexagons
irrespective of the size of the silo. In the centre of each hexagon there is a discharge open-
ing below a steel cone. This cone protects the discharge opening from excessive pressure
and improves the flow behaviour of the raw meal. The area surrounding each discharge
opening is divided into six segments that can be aerated independently, producing 6 x 7 =
42 individually controllable surfaces on the silo base (Fig. 2.3-1).
The homogenizing effect is achieved in this design by maintaining different extraction
speeds at the individual outlets. Fig. 2.3-2 shows a schematic view of this mixing effect.
A further positive factor is the fact that the seven main segments can be activated sep-
arately. Selective withdrawal from e.g. three or five different segments also results in
blending of the layers in the silo.

2.4 Multi-Cell Silo

In contrast to the previous processes described, in a multi-cell silo (Fig. 2.4-1) there is no
actual mixing zone. This design consists of a number of silo cells and is used mainly for
raw meals that tend to segregate.

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 1

Figure 2.2-1: Tangential Mixing Silo (Source: Polysius AG) .

The underlying mixing principle is simple: the individual silos are filled one after the
other, but are emptied concurrently. The raw meal is then fed directly to the preheater.
This prevents any segregation during intermediate storage.

3 Health and Safety Practices

The following measures must be taken:
 All silo doors and silo entrances must be kept properly closed and secured by padlocks.
 The interior of the silo may only be entered when the silo is empty.
 Only suitable, reliable people who are familiar with this work may take a vehicle into
the silo. The employer must give written permission for this (vehicle operating permit).
 Welding regulations must be observed.
 The welding power source must never be placed in small, enclosed spaces on electri-
cally conductive segments.

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 3 Health and Safety Practices

Figure 2.3-1: Schematic View of a CF Silo (Source: FLSmith) .

Figure 2.3-2: Layer Movement in a CF Silo .

 Among other regulations, the Association’s BGV C 12 regulation »Silos« and Sec-
tion 8 »Hazardous Work« of the Association’s BGV A 1 regulation »Basic Prevention
Principles« must be observed.

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 7

Figure 2.4-1: Multi-Cell Silo (Source: Polysius AG) .

4 Operation and Quality

Uniform raw meal quality is a basic requirement for trouble-free kiln operation. Varia-
tions in the chemical composition or particle size distribution may cause problems in the
preheater area.
Good raw meal homogenization is crucial for constant clinker quality. A high free lime
content e.g. may be caused by insufficient homogenization. This generally only occurs
for limited periods but should be avoided nevertheless.

5 Environmental Protection
Good primary homogenization and uniform metering of all raw materials and fuels must
be ensured so that fluctuations in kiln operation can be largely avoided. Uniform raw meal
also allows the specific energy consumption of the kiln to be kept substantiallly constant.
Large variations in the quality of the raw meal (e.g lime staturation factor) lead to higher
fuel consumption.
The raw material used for the clinker burning process mainly consists of limestone and
clay or marl, a natural mixture of the two. ’Corrective materials’, such as sand or iron
oxide-bearing compounds, are also used. In recent years secondary raw materials that

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 6 Questions on Course LB 2.4 – Raw Meal Homogenization

replace natural raw materials have also been used increasingly. These materials generally
also contain sulfur combined in different forms and amounts.
The sulfur contained in these materials is predominantly combined inorganically as sulfate
(SO42-) or as sulfide (S2-).
Sulfur combined as sulfide may lead to increased SO2 emissions from the preheater as
a result of its high volatility. If the raw material deposit locally contains high sulfide
concentrations it is possible to even out the level of SO2 emissions by selective extraction
and appropriate mixing and homogenization of the raw materials. This is particularly the
case if the quarry does not contain homogeneous raw materials and a number of fractions
are extracted from the quarry and homogenized using a blending bed.
The extraction is generally planned on the basis of the CaCO3 content and, if appropriate,
on the basis of the content of other main constituents. However, knowledge of the distribu-
tion of the pyrites or marcasite content of the quarry is also necessary when dealing with
the sulfide content of the raw material mixture.

8
6 Questions on Course LB 2.4 – Raw Meal Homogenization
You can test your knowledge by answering the following questions.

Question 6.0 A:
1. What is the main process used to homogenize raw meal?
2. Name and describe an important basic element of pneumatic dry mixing.
3. Explain the operating principle of an air distribution box.
4. What percentage of the total surface area of the base of a mixing silo is fitted with
air distribution boxes of this type?
5. Name some homogenization processes and explain them briefly.
6. Name and describe the safety measures to be taken when working in silos.
7. What is the function of a raw meal homogenizing system?
Solutions see p. 9

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Solutions
Solution for 6.0 A:
1. Pneumatic dry homogenization with air distribution boxes
2. Air distribution boxes with an air-permeable, porous cover that may be made of
ceramic plates or woven textile fabric.
3. Air distribution boxes are located in the silo base. Air is forced from below into the
raw meal through the porous plate which produces air currents that bring the raw
meal into a fluidized state.
4. Depending on the type of homogenization process and the design of the mixing silo
50 to 80 % of the silo base are fitted with air distribution boxes.
5. a) Aeration mixing process: the silo base is divided into a number of segments that
are aerated separately. One or more segments operate as mixing segments (high air
flow), while the others are only lightly aerated (fluidized). This achieves vertical
circulation of material with a good mixing effect. The segments are supplied in turn
with mixing air. 9
Fuller process: quadrants
Krupp-Polysius: 9 segments
Octant process: 8 segments
b) A tangential mixing silo has an inner cone, an annular aerating surface with a
number of extraction points and a central mixing chamber. The silo outlets are lo-
cated under the inner cone and reach toward the centre.
c) CF-Silo from FLS: the silo base is divided into 7 independent hexagons. In the
centre of each hexagon there is an outlet opening under a steel cone. The area
surrounding each outlet opening is divided into 6 segments that can be aerated in-
dependently. The mixing effect is produced by the different extraction rates from
the individual outlets.
d) Multi-cell silo:
A number of adjacent silo cells are filled one after another but are emptied concur-
rently. The raw meal is fed directly to the preheater which prevents any possible
segregation during intermediate storage.

6. a) The interior of the silo may only be entered when the silo is empty.
b) Only suitable and reliable operators who are familiar with this type of work may
take a vehicle into the silo. The employer must give written permission for this.
c) Welding regulations must be observed
d) The welding power source must never be placed in small, enclosed spaces on
electrically conductive segments
e) Association regulations must be observed
7. To produce uniform raw meal quality as a basic requirement for continuous trouble-
free kiln operation with low fuel consumption resulting in consistently high clinker
quality
Questions see p. 8

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Glossary
aeration blending
Process in which a homogenization of powders is achieved by controlled introdution of compressed air
aeration box
Air distribution box through which compressed air is introduced into the floor of a silo for the homogenization
of a raw meal
blending bed
A blending bed is produced by placing layers of raw material successively on two or more stockpiles in a recti-
linear or circular pattern. Blending beds are used for preliminary homogenization of the crushed raw stone. This
is generally required due to the large variations in the chemical compositions of the deposits.
fluidizing air
Air with a pressure of ca. 1,75 kg/m2 for maintaining the flowability of a raw meal
free lime
CaO; free lime; the fraction of CaO that has not combined with SiO2, Al2O3 or Fe2O3 in the burning process
homogeneous
ideally mixed – opposite of heterogeneous
homogenize 11
to make uniform
mixing air
Air with a pressure of 2,0-2,2 kg/m2 for controlled homogenization of raw meal in a silo
Multi-cell silo
Complex made up of several silos which are filled consecutively and emptied simultaneously without by means
of compressed air
particle size distribution
The frequency distribution of different particle sizes. A combination of different degrees of fineness is known as
a wide particle size distribution or a wide particle range.
pressure relief cone
Cone-shaped structure in the base of a silo below which withdrawal aggregates may be installed
raw meal (raw meal)
The raw materials for Portland clinker, blended and ground to a particle size of less than 0.2 mm.
segregation
Separation of a mixture into different fractions

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 Index

A
aeration blending 1
aeration box 3

B
blending bed 1

F
fluidizing air 2
free lime 7

H
homogeneous 1
homogenize 1

12
M
mixing air 2
Multi-cell silo 4

P
particle size distribution 7
pressure relief cone 4

R
raw meal 1

S
segregation 5

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