Cement = Clinker + Gypsum

When we want to use clinker only in the form of fine powder,the clinker powder
gets hardness with in few minutes(less than 5 minutes).we cannot get any working time.
The Gypsum is used acts as retarder.It delays the hardening process.Hence in all types of cement
Gypsum is an essential one.
In simple clinker ground with gypsum is called Cement.

Gypsum
Gypsum is CaSO4.2H2O
There are three types of Gypsum
Mineral gypsum
Marine Gypsum
By product Gypsum (Chemical Gypsum)

Clinker Raw meal+Coal ash

Raw meal
Raw meal is a ground fine powder, mixture of Limestone and other additives.
Limestone
Limestone is a natural material from mother earth.
Additives
Additives are the materials which have a particular consitituent in higher percentage.
Example
Iron ore Rich in iron content (Fe2O3) > 40 %
Bauxite Rich in Alumina content (Al2O3) > 50 %
Sand Rich in Silica content (SiO2) > 90 %
High grade limestone Rich in Calcium content (CaO) > 46 %
Low grade limestone Low in Calcium content (CaO) < 42 %
Clay Rich in Silica content (SiO2) > 60 %
Shale Low in Calcium content (CaO) < 42 %

Coalash
Coal ash is residual content after complete burning of coal.
This coal ash can not be separate from the system.It mix with raw meal during burning process
and become a part of clinker.
The influence of coal ash on quality we can seen in Raw Mix calculation slide.
wder,the clinker powder
get any working time.
ss.Hence in all types of cement

gher percentage.

meal during burning process

Manufacture Limestone

As limestone is one of the basic raw material the manufacturer shall have a own mine.
Lime stone excuvated from earth using the following steps:
Estimation on Quality and quantity
Drilling
Blasting
Transporting
Crushing
Stacking
The limestone after blasting depends upon the characteristics the fragmentation
takes place.The size varies from .2m to 2.0 m.
Depending upon the size and and hardness of the limestone the Crusher selection shall be made.
There are many types of Crushers:
Jaw crusher
Roller crusher
Impact crusher
The blasted limestone shall be tranported to crusher for crushing.The crushed limestone shall be
stored uniformaly to minimise the quality variation.In most of the cement industries the stacker
has been installed for this purpose.This shall stack the crushed limestone in layerwise through a
length of 50 to 120 m long.This will reduce the variation in the quality.
These crushed limestone are having size of 3 mm to 100 mm size.
Depending upon the crusher output size,material characteristics,financial condition ,
power requiremnet and maintenance cost the selection of Rawmill shall be carried out.
At present there are mainly two types of Rawmill. One is Ball mill and the other one is Vertical
Roller Mill.In this mill Rawmeal is produced.
Rawmeal
Raw meal is manufactured by mixing and grinding Limestone and other required additives.
The selection of additivies is mainly based on the quality of the limestone available.
In raw meal mainly 85 - 99 % is only limestone balance other additives.

Based on the quality of Limestone one shall select the other additives.
Additives selection shall be carried out on the basis of quality,quantity availablity
consistence in the quality,their process and finaly cost.

Limestone along with other additives are transported to rawmill.In rawmill these materials are
made fine powder by crushing action by rollers incase of Vertical roller mill or by impact and friction action
in case of Ball mill. The main purpose is the reduction in the size of the material .The output size of the material
is not more than 25 % on 90 micron normally.This size again depends upon the burnability of the
raw material.
The main feature in Rawmill is to produce consistantly uniform rawmeal.The uniform rawmeal is the quality
variation shall be minimum.Once we have a ulmost uniform material the kiln operation is normal and the quality
is of premium one.The Raw meal control shall be done by the Laboratory Personals.
Raw mix calculation and rawmeal control shall be seen seperately.

After grinding the rawmeal is stored in silo.The modern rawmeal silos are designed in such a
way to reduce the quality variation further . There are different openings at the silo bottom with different
extraction rate. The different openings will deliver the material at different quantity with time limits.
This facility leads to extract the material in all the opening in a particular time period.ie In a given
point of time all the opening will deliver material once and the cycle continues.

Chemical Reaction of the Rawmeal is as follows

Temperature Process Chemical transformation

< 200 deg C Escape of Free Water

200 - 400 Escape of Absorbed Water

Decomposition of Clay. Example : With formation of Al4(OH)8SiO10 -

400 - 750
metakaolinite >2(Al2O3.2SiO2) + 4 H2O

Decomposition of metakaolonite and other Al2O3.2SiO2 -> Al2O3 +

600 - 900
compounds, with formation of a reactive oxide mixture 2 SiO2

CaCO3 - > CaO + CO2

Decomposition of Limestone, with formation of CS and 3 CaO +2SiO2 + Al2O3 ->
600 - 900
CA 2(CaO.SiO2) + CaO .Al2O3
 CS + C -> C2S
2C + S - > C2S. CA
800 - 1300 Uptake of Lime by CS and CA formation of C4AF
+ 2C - > C3A. CA +3C
+F -> C4AF

1250 - 1450 Further uptake of CaO by C2S C2S + C - > C3S

 other required additives.

awmill these materials are

mpact and friction action
he output size of the material
rnability of the

m rawmeal is the quality

ion is normal and the quality

los are designed in such a

bottom with different
with time limits.
d.ie In a given

cal transformation

SiO10 -
O3.2SiO2) + 4 H2O

SiO2 -> Al2O3 +

2 SiO2

> CaO + CO2

+2SiO2 + Al2O3 ->
O2) + CaO .Al2O3
> C2S
> C2S. CA
C3A. CA +3C
+F -> C4AF

S + C - > C3S
To burn the coal we require air .The required air being supplied by the fans.The clinker
from kiln falls to a COOLER with a temperature of around 1350 degree.This hot clinker
shall be cooled immediately.Hence a series of fans are provided in the Cooler with
different pressure and volumes.The air from the fans passes through the cooler
cools the clinker and provides air for combustion of coal and fineally driven out through
preheater by smoke gas fan.The main advantage of the modern plants is the less fuel
consumption by cycling the hot air available in the system.From the cooler inlet a duct
is connected to the calciner vessel to use the hot air from the cooler.The temperature
of the gas normally 750 - 850 degree.This hot air is passing through the calciner vessel.
A portion of cooler air is taken to coal mill for drying purpose.
Clinker
Clinker is a semi finished product.It can be manufactured in different process.
Wet process
Semi Dry process
Dry process with Preheater

Kiln In all the three types kiln is required.Kiln is a rotating equipment installed with 3 - 5 % slope.
The length of kiln may 65 meter to 100 meter in the modern kilns.
The diameter of the kiln may 2.5 meter to 5.0 meter.
The production capacity depends upon the size of the kiln.
In kiln the rawmeal is burnt using Oil or Coal or Natural Gas
The temperature required to produce clinker is approximately 1400 - 1450 degree centigrade.
To withstand the temperature the kiln shell be protected with refractory linings.
The selection of refractory is depends upon the coating formation of the raw materials,
and type of burner used.
The temperature is obtained by burning fuels as stated earlier.
The selection of fuels are purely depends upon the availablity and cost.
In most of the Indian cement industries are using Coal as a fuel.
To burn coal we need temperature and air.The initial temperaute is obtaind by burning
oil and air is provided by running fans.Once the sufficient temperature obtained by the
system then coal shall be fed for burning.The quantity of coal fed is depends upon the
the quantity of rawmeal fed and the temperature condition in the system and the
quality of the coal.The crucial operation of kiln shall be seen seperately.
d with 3 - 5 % slope.

0 degree centigrade.

raw materials,

nd by burning
btained by the
ends upon the
Preheater

Preheater is a system in which a series of cyclones are mounted in such a way

the raw meal fed is follow certain path.In the preheater the material path is from top to
bottom and the hot air path is from bottom to top.
The number of cyclones are based on the clinker production targeted.
In the proheater the rawmeal is fed from top cyclone and reaches the bottom and the hot air passed
from bottom to top.In this process the rawmeal having a temperature about 70 -80 at the top
gains a temperature upto 870 degree at the bottom.In preheater one cyclone is called Calciner
vessel.The hot air duct from cooler is connected to this vessel.In this 60 -65 %of total
requirement of coal being fired.All the rawmeal fed is passes this cyclone and attains the required
temperature. During this process the rawmeal decomposes and 90 - 95 % carbondioxide are
removed from the rawmeal.(Rawmeal is having normaly having 75 - 80 % calcium carbonate.)
In this process the rawmeal is well prepared for clinkeraisation.
Chemical Quality of Clinker :
Chemical parameter Normal value
Loss on ignition 0.2 - 0.8
Insoluble Residue < 0.2
Magnisium oxide 1 - 3
Caicium oxide 63 - 65

FreeCaO 1 - 1.5

Lime Saturation Factor(LSF) .87 - 0.95

Alumina modules (ALM) .8 - 1.8
Silica modules (SLM) 2.2 - 2.6

Physical Parameter
To determine the physical characteristics the clinker shall be ground with 4- 5 % of Gypsum
in the ball mill to a desired fineness value (normaly 2700 -3000 cm2/gm).The ground cement shall be
taken for physical analysis.

The following tests shall be conducted

Fineness 2700 - 3000

Normal consistency 26 - 30 %

Setting time
Initial 60 - 200
Final 75 - 250

Soundness
Le chatilier Expansion 1 -2 mm
Auto clave Expansion 0.1 to 0.4 %

Compressive Strength

3 days 300 -400 kg/cm2

7 days 400- 500
28 days 500 -650
 Indication
How old the clinker it is ?
Any adultration took place
It indicates the posibility of expansion
It decides the main quality of clinker along with Sio2,
Al2O3 and Fe2O3
Indicates the burning condition

Indicates the clinker quality

These modules mainly helps the burning process.

characteristics the clinker shall be ground with 4- 5 % of Gypsum

alue (normaly 2700 -3000 cm2/gm).The ground cement shall be

Grindability of the clinker

Water requirement

Indicates the time available to work on the mix during

construction before the cement gets harden

Expansion due to Free CaO

Expansion due to Free CaO and also due to magnisium
oxide

Strength achived by the cement at various ages

CLINKER
Clinker is formed by burning of limestone and other additive material at the
temperature of 1400 - 1450 degree centigrade.
This clinker shall posses some basic quality.For any cement the the cement quality
depends up on the quality of the clinker.
The clinker mainly has four phases.These are as follows:

C3S Tri Calcium Silicate

C2S Di Calcium Silicate
C3A Tri Calcium Aluminate
C4AF Tetra Calcium Alumino Ferriate

In the clinker manufacturing process first all the iron are reacted with alumina and cao
forming C4AF.The remaining Alumina reacts with CaO forming C3A.
The SiO2 reacts with CaO forming C2S.The remaing CaO reacts with C2S forming C3S.

The main charactristic of clinker is development of strength,when it reacts with Water.

The reaction means hydration taking place and the cement mass becomes hard.
The main contribution of initial strength is mainly due to C3S and the later strength is due
to C2S. C3A and C4AF are not having any singificant role in the strength development.

If C3A is high more 9 % the heat of hydration is high.C3A reacts with water very fast.Hence
the high C3A content cement needs a little more gypsum.

There are the following quality requirement to asses the quality of clinker:
ry fast.Hence
Heat consumption kcals/kg cl
Coal cal.value kcals/kg coal(nett)
Coal ash content %
Coal consn.Kg coal /kg cl(hc cons/cal.val)
Ash absobtion %(coal consn * ash)
Clinker(raw meal ignited)

LST HG LST IRONORE LST HG LST

Loss 35.00 37.50 2.00
SiO2 13.50 10.00 8.00 20.77 16.00
Al2O3 3.35 2.80 1.00 5.15 4.48
Fe2O3 1.60 1.20 85.00 2.46 1.92
CaO 43.10 46.00 1.00 66.31 73.60
MgO 1.25 1.00 0.50 1.92 1.60
K2O 0.85 0.60 0.20 1.31 0.96
Na2O 0.16 0.20 0.05 0.25 0.32
SO3 0.05 0.05 0.10 0.08 0.08

Total 98.86 99.35 97.85 98.25 98.96

THEORITICAL CLINKER REQUIRED

LST HG LST IRON ASH

SiO2 20.77 16.00 8.16 60.00
Al2O3 5.15 4.48 1.02 25.00
Fe2O3 2.46 1.92 86.73 7.00
CaO 66.31 73.60 1.02 5.00
MgO 1.92 1.60 0.51 1.00
K2O 1.31 0.96 0.20 0.60
Na2O 0.25 0.32 0.05 0.20
SO3 0.08 0.08 0.10 2.00
LSF 100.72 143.37 1.27 2.47
SIM 2.73 2.50 0.09 1.88
ALM 2.09 2.33 0.01 3.57
C3S 73.84 145.08 -188.79 -613.73
C2S 3.84 -63.57 165.83 635.02
C3A 9.50 8.63 -143.88 54.42
C4AF 7.48 5.84 263.67 21.28

DELTA Ca 66.31 73.60 1.02 5.00

DELTA Si 20.77 16.00 8.16 60.00

Dry % 0.826 0.097 0.014 0.063

0.070 0.882 0.103 0.015
1.537 1.357 0.165 0.015
Wet % 1.000 0.883 0.108 0.010
IRON 0.010 0.015 4.36 2.5
0.015 0.023 6.78 2.1

300
COAL CV HC COAL CONS MOIS
4800 680 0.142 0.13 0.163
690 0.144 0.165
700 0.146 0.168
710 0.148 0.170
720 0.150 0.172
730 0.152 0.175
740 0.154 0.177
750 0.156 0.180

4860

10500 29
3500 24.5
3500 40

17500 530250 30.3

600
3800
40
0.158 13 0.800 0.181
0.063
0.937

IRONORE COAL ASH

8.16 60.00 1.75

1.02 25.00
86.73 7.00
1.02 5.00
0.51 1.00
0.20 0.60
0.05 0.20
0.10 2.00

97.81 100.80

CLINKER ANALYSIS
SiO2 22.61 0.937 0.937 0.937
Al2O3 6.29
Fe2O3 3.85 140.928 0.32
CaO 62.25 44.932 3.79
MgO 1.81
K2O 1.21
Na2O 0.25
SO3 0.20
LSF 85.00
SIM 2.23 Min Max
ALM 1.63 85 93
C3S 33.72 2 2.6
C2S 39.39
C3A 10.16
C4AF 11.70
% LIQUID 30.79

0.937
SiO2 13.07
Al2O3 3.26 0.2
Fe2O3 2.36
CaO 43.00
LSF 102.44
SIM 2.32
ALM 1.38

COAL RATE COST/CL COAL RATE COST/CL

1450 236.1 1380 224.7
239.6 228.0
243.1 231.3
246.5 234.6
250.0 237.9
253.5 241.2
256.9 244.5
260.4 247.8 1
1 Total Carbonates

CaCO3 + 2 Hcl - > CaO + H2O + CO2

100 grams of Calcium Carbonate requires 72.9 gms of Hcl

36.45 gms in 1000 in 1 litre = 1N

18.225 gms in 1000 in 1 litre = 0.5 N

1 cc of 0.05N Hcl contains 0.018225 gms of HCl

72.9 gms Hcl = 100 gms of CaCO3

0.018225 gms of Hcl = 0.025 gms of CaCO3

Weight of Sample 0.5 gm

Percentage of Total Carbonate = 5 %

1cc of 0.5N Hydrochloric Acid represents 5 % Calcium Carbonate

If the weight of Sample = 0.5 grams.

MgCO3
MgCO3 + 2 Hcl ->MgCl2 +CO2 +H2O
24.41+12+48
84.41 MgCl2 + 2 NaOH - > Mg(OH)2 + 2Nacl

MgCl2 One Molecule of MgCl2 requires 2 molecules of NaOH.

24.41+35.45*2 95.314 grams of MgCl2 reacts with 80 grams of NaOH.

95.31
40 grams of NaOH in 1 litre = 1 N
10 grams of NaOh in 1 Litre = 0.25 N

1cc of 0.25N NaOH contains 0.01 gram

80 grams of NaOH reacts with 95.314 grams of MgCl2

0.01 gram of NaOH 0.01191425 grams of MgCl2

One Molecule of MgCl2 can form one Molecule of MgCO3

95.31 gram of MgCl2 forms 84.41 grams of MgCO3

.01191425 grams of MgCl2 - > 0.0105516928

Weight of Sample 0.5

Percentage of Magnesium Carbonate = 2.11

 In Total carbonates we are considering all carbonates as
Calcium Carbonates ( 100 )

Correction for the above 100 / 84.4 1.184834

(Molecular wt of CaCO3 / Mol. Wt of MgCO3)

% MgCO3 = 2.11 * 1.18

1 cc of 0.25N NaOH represents 2.49 % of MgCO3

Percentage of Calcium Carbonate = Total Carbonates - MgCO3

CaO
Na2C2O4 + H2SO4 - > Na2SO4 + H2C2O4

2KMnO4 + H2SO4 + 5Na2C2O4 ---> 2K2SO4 + 2MnSO4+8H2O+ 10 CO2 +

5Na2SO4

Equivalent weight of Na2C2O4 (Sodium Oxalate) is 134 / 2 = 67

67 gms in 1 litre 1 N
0.4 gms in I litre = 5.9701492537

This we are titrating with KMnO4 for getting Normality of KMnO4

V1N1 = V2N2

5.97 = Vol of KMnO4 * N2

N2 = 5.97 / x (Vol of KMnO4)

2KMnO4 + 8H2SO4 + 5CaC2O4 ---> K2SO4 + 2MnSO4+8H2O+ 10 CO2 +

5Ca2SO4
` Calcium Oxalate

5 Calcium Oxalate reacts with 2 KMnO4

Ca 40
C 12 316.06 gms of KMnO4 reacts with 640 gms of Calcium Oxalate
O 16
K 39.1 316.06 gms of KMnO4 reacts with 200 (5*40) gms of Calcium
Mn 54.94
Equivalent weight of KMnO4 = 31.6

1 cc of 1N KMno4 represents 31.6/1000 *200 gms of Ca

1 cc of 5.97 / x (Vol of KMnO4) = (5.97/x) * ((31.6/1000) *200)

ms of CaCO3
ms of CaCO3
ates - MgCO3
There are some other formulas used in cement manufacturing

Silica Modulus The ratio between Silica to Alunina + Iron

SIM SiO2/(Al2O3+Fe2O3)

Alumina Modulus The ratio between Alunina to Iron

ALM Al2O3/Fe2O3

Hydralic Modulus The ratio between CaO to Silica + Alunina + Iron

HM CaO/(SiO2+Al2O3+Fe2O3)

These are the four main clinker phases. The formulas were derived by the scientist Bhoge
These formulas called Bhoge clinker phase formulas.
C3S (4.07*(CaO - FCaO)) = (7.602*SiO2 + 6.718 * Al2O3 + 1.43 * Fe2O3)
C2S 2.867 * SiO2 - 0.7544 * C3S
C3A 2.65 * Al2O3 - 1.69 * Fe2O3
C4AF 3.043 * Fe2O3

IF A / F > = 1.4
LIQUID CONTENT @ 6.1 * Fe2O3 + MgO + Alkalies
1338 deg C
Else
LIQUID CONTENT @ 8.2 * Al2O3 - 5.22 Fe2O3 + MgO + Alkalies
1338 deg C

LIQUID CONTENT @ 2.95*Al2O3+2.2*Fe2O3+MgO+Alkalies

1400 deg C

LIQUID CONTENT @ 3*Al2O3+2.25*Fe2O3+MgO+Alkalies

1450 deg C

Molar Ratio Sulphur to Alkalies

SO3 / ( 0.85 * K2O + 1.3 Na2O ) ( All the values are of Clinker)

Active Sulphur to Alkali Ratio

SO3 / ( 0.85 * K2O + 0.65 Na2O ) ( All the values are of Clinker)

Sulphur Excess ( Grams per 100 kg of Clinker)

SO3 - ( 0.85 * K2O + 0.65 Na2O ) * 1000

K2O in Sulphate Phase(KS)

Asum = K2O + 1.52 Na2O
X = SO3 / Asum

IF X =< 0.5 then K2O in Sulphate Phase = 11 * X

IF X > 0.5 & <= 0.95 then K2O in Sulphate Phase =

41.9532+279.7257 * X - 185.7181 * X ^2 + 22.77998 * X ^ 3

IF X > 0.95 then K2O in Sulphate Phase = 80

Z = 2 * K2O / ( 1.52 * Na2O )

Sodium in Sulphare Phase (NSU) (K2O in Sulphate Phase(KS) * Asum / 100 ) / ( 1.52 * ( Z + 1))

Potassium in Sulphare Phase Z * 1.52 * NSU

Sodium in Clinker Na2O in Clinker - NSU

Potassium in Clinker (KCL)

IF KSU > KCL then KSU = KCL

Else
Potassium in Clinker (KCL) K2O in Clinker - KSU

Sulphur in Sulphate Phase(SS) ((NSU / 0.61994 ) + (KSU / 0.942 )) *.80066

Sulphur in Clinker Phase SO3 in Clinker - SS

SOLUBLE ALKALI CONTENT

Total alkali K - dash = K2O + 1.52 * Na2O

Sulphate Module MSO3 = SO3/0.85* K - dash

SOLUBLE ALKALI =

MSO3 less than or equal to 0.5 then KS dash = 1.18 * SO3

MSO3 > 0.5 and < 1.0 then KS dash = 0.7 * SO3 + 0.2 * K- dash

MSO3 > 1 then KS dash = 1.18 * SO3

Recovery Factor

Counter * ( 1 - Moisture in KF ) * (1- LOI of KF) * (1- Dust Loss) * 1.041

Ash Absorbtion =

Heat Consumption 700

Coal CV Net 5000
Coal Ash 28
Coal Cons 0.14
Ash Absorbtion 0.0392
For 1 Mt of Clinker
Raw meal 0.9608
ash 0.0392

For .9608 Rawmeal 1.000 Mt of Clinker

For 1 Rawmeal 1.041

Percentage Calcination

100([1- ((Calciner loss (100-KF loss)) / (KF loss(100 - Calciner loss)))]

KF loss 35
Calciner loss 3.6 Let x be the LOI of KF
100
Let 100 -x be the loss free KF material
A 234
Let y be the LOI of Last stage cyclone
B 3374
Let 100 -y be the loss freeLast stage material
C 0.07

D 0.93 [(x / (100 - x )) - (y / (100 - y ))] / (x / (100 - x ))

E 93.06 (x / (100 - x )) / (x / (100 - x )) - (y / (100 - y )) / (x / (100 - x ))

1 - (y / (100 - y )) / (x / (100 - x ))

1 - ( y * (100 - x )) / (x *(100 - y))

[1 - ( y * (100 - x )) / (x *(100 - y))] *100

Normality of Acid From Percentage and Specific Gravity

 % of HCl = 35
Sp.Gravity 1.18

1000 ml = 1180 gms

HCl = 35 % = 413 gms

36.45 gms in 1000 cc = 1 N

413 gms in 1000 cc = 11.33

% of H2SO4 = 95
Sp.Gravity 1.84

1000 ml = 1840 gms

H2SO4 = 95 % = 1748 gms

49.02 gms in 1000 cc = 1 N

1748 gms in 1000 cc = 35.66
rived by the scientist Bhoge

.43 * Fe2O3)

Example
Na2O 0.22
K2O 1.17
SO3 1.53
1.19

1.35
 392.5

1.50
1.02

80

7.00

100 ) / ( 1.52 * ( Z + 1)) 0.10

1.05

0.12

0.12

1.02

0.51
t stage material

] / (x / (100 - x ))

) - (y / (100 - y )) / (x / (100 - x ))
 DERIVATION OF BHOGE FORMULAS

Molecular weights

CaO SiO2 Al2O3 Fe2O3 Total

C3S 168 60 228
C2S 112 60 172
C3A 168 102 270
C4AF 224 102 159.7 485.7

% Components

C3S C2S C3A C4AF

w x y z
a CaO 0.7368 0.6512 0.6222 0.4612
b SiO2 0.2632 0.3488
c Al2O3 0.3778 0.2100
d Fe2O3 0.3288

0.3288 c4af = d
c4af = d/.3288
c4af = 1/.3288 d
c4af = 3.0414 d
C4AF = 3.0414 Fe2O3

c= 0.3778 y +0.2100 z
.3778y+3.0414*.2100 d
.3778y + 0.6387 d
.3788 y = c - .6387d
y = c/.3778 - .6387/.3778 d
y= 2.646903 c - 1.690577 d
y= 2.65 Al2O3 - 1.69 Fe2O3
C3A = 2.65 Al2O3 - 1.690577 Fe2O3

b= .2632w+.3488x
.3488x +.2632w = b
.3488x = b- .2632w
x= b/.3488 - .2632w/.3488
x= 2.866972 b - 0.754587 w
C2S= 2.867SiO2 - 0.7546 C3S

a CaO 0.7368 0.6512 0.6222 0.4612

a= .73368w+.6512x+.6222y+.4612z
a= .7368w+.6512(2.867SiO2-0.7546w)+.6222(2.65*Al2O3-1.69*Fe2O3)+.4612*3.0414Fe2O3
a= .7368w+1.867SiO2-.4914w+1.6488Al2O3-1.0515Fe2O3+1.4027Fe2O3
a= .2454w+1.867SiO2+1.6488Al2O3+.3512Fe2O3
.2454w+1.867SiO2+1.6488Al2O3+.3512Fe2O3 = a= CaO
.2454w = CaO - 1.867SiO2-1.6488Al2O3-.3512Fe2O3
 w= CaO/.2454 -((1.867/.2454)SiO2+(1.6488/.2454)Al2O3+(.3512/.2454)Fe2O3)

C3S= 4.075 CaO -(7.608SiO2+6.718Al2O3+1.43Fe2O3)

IF C3S = 100 means C2S ,C3A,C4AF all are nil.

ie Al2O3 and Fe2O3,SO3 are nil 0.205867

CaO/2.8 Sio2 = 1.02

CaO = 2.856 * SiO2

1 4.07 CaO - 7.6 SiO2 = 100

2.867 * SiO2 -0.75 C3S = 0
2.867 SiO2 - (.75 *100) = 0
2 2.867 SiO2 =75
4.07 * 2.856 *SiO2 - 7.6 SiO2 = 100

26.15975

2 SiO2 = 75/2.867 = 26.16

1 4.07 * CaO - 7.6 * 26.16 = 100

198.816
4.07 * CaO = 100 + 198.82

CaO = 298.82/ 4.07

73.42015
CaO = 73.42

If C2S is 100

4.07 * CaO - 7.6 SiO2 = 0

2.86 * SiO2 - 0.75*0 = 100 34.96503
SiO2 = 100/2.86 = 34.96

4.07 *CaO - 7.6*34.96 = 0 265.696

4.07 * CaO = 265.70
65.28256
CaO = 265.7/4.07 = 65.28
 54 55.85

Fe2O3)+.4612*3.0414Fe2O3
+(.3512/.2454)Fe2O3)
 45 Micron
Coarse (Rg) 78

Fines(Rf) 18

Outlet(Rm) 50

New feed(Ro) 100

Circulating Factor C = (Coarse - Fines) / (coarse - Outlet)

2.142857

Efficiency = (LogRo/Rf - C*log(((Ro+(c-1)Rg))/((Rf+(c-1)Rg))))/(LogRo/Rf - C*log(((Ro+(c-1)*100))/((Rf+(c-1)*100

Part 1 Part2

Part 1 0.215813
Part 2 0.295841

Efficiency = Part1/Part2 *100

Efficiency = 72.94897
Ro+(c-1)*100))/((Rf+(c-1)*100))))
Part2
LSF Formula derivation

LSF is the combining capacity of lime with Silica,Alunina and

Iron.The formula for the calculation of LSF is

LSF = CaO/(2.8*SiO2 +1.18*Al2O3 + 0.65 *Fe2O3)

In C3S Weight
CaO 168
SiO2 60
60 SiO2 168 CaO
1 SiO2 2.8 CaO

In C4AF 224 CaO

Out of 4 CaO molecules in C4AF 2.15 CaO molecules reacts with Alumina
Balance reacts with Fe2O3
102 Al2O3 224*2.15/4/102 CaO
120.9375
1 Al2O3 1.18 CaO

159.7 Fe2O3 224*1.85/4/159.7 CaO

1 Fe2O3 0.65 CaO

736.1357

13.6
 651
128216.67
 Titration and Substances used Chemical Formula
Acid-Alkali Titration
Sodium carbonate (Washing Soda) Na 2CO 3
Sodium bicarbonate (Baking soda) NaHCO 3
Potassium carbonate (Pearl ash) K 2CO 3
Potassium bicarbonate KHCO 3
Sodium hydroxide (Caustic soda) NaOH
Barium hydroxide Ba(OH) 2.8H 2O
Oxalic acid (hydrated) H 2C 2O 4.2H 2O
Hydrochloric acid HCl
Sulphuric acid H 2SO 4
Redox Titration
Potassium permanganate KMnO 4
Potassium dichromate K 2Cr 2O 7
Ferrous sulphate (hydrated) {Green vitriol} FeSO 4. 7H 2O
Ferrous sulphate (anhydrous) FeSO 4
Ferrous ammonium sulphate (Mohr's salt) FeSO 4. (NH 4) 2SO 4
6H 2O
Oxalic acid (hydrated) H 2C 2O 4.2H 2O
Iron (ferrous) Fe
Iodine Titration
Iodine I 2
Hypo (Sodium thiosulphate) Hydrated Na 2S 2O 3.5H 2O
Anhydrous Sodium thiosulphate Na 2S 2O 3
Arsenious oxide As 2O 3
Copper sulphate (hydrated) {Blue vitriol} CuSO 4.5H 2O
Argentometric Titration
Silver nitrate (caustic lunar) AgNO 3

Equivalent Weights Table for the Major Cations and AnionsCationsAnionsElemen

ElementEquivalent WeightElementEquivalent WeightCalcium (Ca)20.04Chloride

 Equivalent Weight

M.W./2 = 53.06
M.W./1 = 84.00
M.W./2 = 69.00
M.W./1 = 100.00
M.W./1 = 40.00
M.W./2 = 157.75
M.W./2 = 63.04
M.W./1 = 35.46
M.W./2 = 49.04

M.W./5 = 31.606
M.W./6 = 49.03
M.W./1 = 278.00
M.W./1 = 152.00
M.W./1 = 392.14

M.W./2 = 63.04
At. W./1 = 55.84

M.W./2 = 126.92
M.W./1 = 248.19
M.W./1 = 158.09
M.W./4 = 49.45
M.W./1 = 249.68

169

ionsCationsAnionsElementEquivalent WeightElementEquivalent WeightCalcium (Ca)20.04Chloride (Cl)35.4

alcium (Ca)20.04Chloride (Cl)35.453Magnesium (Mg)12.1525Carbonate (CO3)30.004Sodium (Na)22.9898B

 )20.04Chloride (Cl)35.453Magnesium (Mg)12.1525Carbonate (CO3)30.004Sodium (Na)22.9898Bicarbonate

04Sodium (Na)22.9898Bicarbonate (HCO3)61.016Potassium (K)39.098Sulfate (SO4)48.03Lithium (Li)6.94N

22.9898Bicarbonate (HCO3)61.016Potassium (K)39.098Sulfate (SO4)48.03Lithium (Li)6.94Nitrate (NO3)62

3Lithium (Li)6.94Nitrate (NO3)62.004Iron (Fe)27.97Bromide (Br)79.904Manganese (Mn)27.469Nitrogen (N

6.94Nitrate (NO3)62.004Iron (Fe)27.97Bromide (Br)79.904Manganese (Mn)27.469Nitrogen (N)14.007Stront

n)27.469Nitrogen (N)14.007Strontium (Sr)43.81Ammonium (NH4)18.039Barium (Ba)68.665Phosphate (PO4

gen (N)14.007Strontium (Sr)43.81Ammonium (NH4)18.039Barium (Ba)68.665Phosphate (PO4)31.66

8.665Phosphate (PO4)31.66
e (PO4)31.66