Raw Mix

N
O

Raw Mix
I
S
I
V
I
D

Raw mix quality has a major impact on the operation and

profitability of the cement plant as well as on the quality of
T

finished products.
N
E

The key parameters determining raw mix quality are:

M

- uniformity,
E

- grindability and burnability,

C

- optimized composition.
E

These key parameters must be the object of continuous efforts for improvement, from the
H

engineering stage of new plant projects through the entire economic life of the plant.
T
F
O
S
E
N

A) ENGINEERING
I

It is the responsibility of the engineering group to find the best way of producing the
R

raw mix.
T

Raw mix quality is a determining factor in project feasibility.

C

Each project, as a precondition of feasibility, must provide the means to produce a good raw
O

mix as defined below:

D

Uniformity - Ensure the chemical and mineralogical uniformity of the raw mix.
-

- Define measuring criteria and optimum target levels for uniformity.

- Define the technical requirements of the installations.
1
0
0
2

Grindability - Define the degree of burnability which is economically feasible, (raw mix composition,
and grinding energy and rejects).
E

Burnability - Evaluate the range of available fuels which are compatible with the raw mix.
N

- Match the raw mix to operational constraints, process limitations (volatilization, etc.),
U

and desired product attributes.

J

Optimization - Define the process flow and equipment needed to optimize the raw mix.
- Identify the limits for raw mix quality imposed by external constraints (product
characteristics, grinding equipment, environmental constraints, available fuels, the use
of waste, etc.).
Raw Mi
N
O
I

B) MANUFACTURING
S

Mastering of raw mix chemical, physical and geologycal characteristics guar-

I

antees the kiln performances and the clinker quality.

V
I

Uniformity Heterogeneity of the raw mix leads to higher operating costs through:
D

- overburned clinker with its inferior reactivity and grindability, not to mention higher
heat consumption,
T

- shortened brick life and increased risk of damage to the kiln and clinker cooler,
N

- fluctuating volatilization, which results in variable clinker quality, non-optimized

E

product quality and a limitation in sulfur content of fuels.

M
E

All plants shall achieve the Lafarge Performance Index (IPL C3S) £ 14. If this index is above
30, an emergency action plan has to be implemented.
C

Each plant must regularly review the effectiveness of its raw mix preparation and set and
E

commit itself to attaining uniformity standards.

H
T

Grindability The effects of poor burnability, which may also be a consequence of unmastered
F

and grinding, are similar to those of raw mix heterogeneity.

O

Burnability
• Each plant must regularly redefine the optimum level of burnability that is compatible
S

with its own situation by considering all the direct and indirect cost factors.
E

• The plant must also guard against long-term drift or deterioration in burnability. In all
N

cases, burnability must stay above a Lafarge K factor of 50, except for justified cases.
I
R
T

Optimization Raw mix optimization targets these goals:

C

- good product quality in terms of uniformity and reactivity,

O

- lower cement production costs, which is a balance between different parame-

D

ters:
- electrical consumption
-

- heat consumption
- percent of waste as raw material
1

- maintenance costs
0

- well-maintained physical conditions and production capacity of the plant,

0

- development of raw material reserves to maximum by taking into account the

2

evolution of environmental and marketing conditions.

E
N
U
J