(Automatic) Modeling of raw materials and clinker composition.

Raw mix modeling

Oxides (in dry material) Calculated
Table of
raw mater. components CaCO3
CaO SiO2 Al2O3 Fe2O3
calculated
Software version №2

Lime stone 54.18 1.09 0.39 0.20 96.76

Components

Clay 20.44 36.98 9.67 5.32 36.50

Iron ore 6.27 18.30 8.60 56.90 11.20
Siliceous sand 0.00 100.00 0.00 0.00 0.00

Raw Mix = 42.66 13.65 3.36 2.10 76.18

CaO SiO2 Al2O3 Fe2O3 MgO

Clinker chem. = 42.66 13.65 3.36 2.10 0.9

composition
Clinker

Param.
C3S = 44.41
Clinker 50.03 = C3S+C2S
mineral C2S = 5.61 LSF =
composition (Bogue C3A = 5.35 CaO fee = 0.0 SM =
eq.)
C4AF= 6.38 AM =

MANUAL COMPOSITION

sum = 100.0% C S A F CaCO3

Lime stone 65.8% 54.18 1.09 0.39 0.20 96.76
Clay 32.2% 20.44 36.98 9.67 5.32 36.50
Iron ore 0.6% 6.27 18.30 8.60 56.90 11.20
Siliceous sand 1.4% 0.00 100.00 0.00 0.00 0.00
Raw Meal= 42.28 14.12 3.42 2.18 75.51
MgO =
 Clinker by manual composition
SM AM LSF C3S = 34.64
49.00
2.52 1.57 93.97 C2S = 14.36
C3A = 5.37
C4AF= 6.63
CaO free = 1.0

19. Sept 201 CaO SiO2 Al2O3 Fe2O3

Lime stone 52.50 0.00 0.07 0.00

Clay 22.60 40.20 9.40 3.50

Iron ore 6.27 18.30 8.60 56.90

 composition.

modeling Comp. content

(mass%)
Loss of
ignition by Water
MgCO3 Cl -
SO3 rest content % Dry mass
calcul.

0.65 0.00 0.02 0.90 42.91 2.00 66.8%

4.38 0.08 0.05 7.02 18.34 5.00 31.6%
0.90 0.04 0.12 3.94 5.40 1.00 0.5%
0.00 0.00 0.00 0.00 0.00 0.00 1.1%
Sum = 100.0%

1.82 0.03 0.03 2.84 34.47 2.92 105.0 Clinker Burnability LS

Kiln Coating AR & SR 100.0

Cl-
(max) SO3
0.027 0.0 95.0
Obtained:
90.0
Clinker
98.0 85.0
2.5
80.0
1.6 1.7 1.9 2.1 2.3 2.5 2.7 2.9

MgCO3 Cl- SO3 SUM %

Kiln Coating AR & SM
0.65 0.00 0.02 99.10 3
4.38 0.08 0.05 92.98
Re-
quir
0.90 0.04 0.12 96.06 2.5 ed:
0.00 0.00 0.00 100.00

1.84 0.03 0.03 97.13

2
AR

0.9

1.5

1
 2

AR
al composition 1.5

= C3S+C2S
1

0.5
1.5 2 2.5 3 3.5
SR

CaCO3
calculated MgCO3 Cl- SO3 % Dry mass
93.75 5.40 0.05 0.6 0.65671327
40.36 4.00 0.02 0 0.32624498
11.20 0.90 0.04 0.12 0.01704175
0
 Kiln Coating AR & SR
2.5

2.3
Comp. content Required quality parameters:
(mass%) Obtained: 2.1

Param. Required: 1.9

% Wet mass 4 Comp.
1.7

AR
66.1% LSF = 98 98.0
1.5
32.3% SM = 2.5 2.5
1.3
0.5% AM = 1.6 1.6
1.1
1.1%
0.9
100.0%
0.7
Clinker Burnability LSF & SR
0.5
1.5 2 SR
2.5

Modulus calculation HM
of raw mix 2.23

Target values acc. to

practice. Not official min 1.7

1.9 2.1 2.3 2.5 2.7 2.9 3.1 3.3

M 105.00
Clinker Burnability LSF & SM

Re-
quir
ed: 100.00
LSF

95.00

90.00

85.00
 LSF
95.00

90.00

85.00

3 3.5 80.00
1.70 1.90 2.10 2.30 SM
2.50 2.70 2.90 3.10 3.30
Kiln Coating AR & SR

SR
2.5 3 3.5

SM AM LSF C
2.50 1.60 98.00 42.66

2.4 1.4 95 76-78

 Calculation Sheet for n-componential mix design

Raw mix modeling Data sheet

Table of Oxides (in dry material) Loss of Water
raw components C S A F ignition content
1 Lime stone 54.18 1.09 0.39 0.20 42.91 2.00
Components

1 Laporac 20.44 36.98 9.67 5.32 18.34 5.00

1 Quartz Sa 6.27 18.30 8.60 56.90 5.40 1.00
1 Clay 0.00 100.00 0.00 0.00 0.00 0.00

1. Required quality parameters:

Obtained:
Property: Required:
1 comp. 2 comp. 3 comp. 4 comp.
LSF = 98 1484.6 98.0 98.0 98.0
SR = 2.5 1.9 33.4 2.5 2.5
AL = 1.6 2.0 2.0 1.8 1.6

2. Calculation models:
1 comp. C S A F Los of Ignition Dry Comp. %

Lime stone 54.18 1.09 0.39 0.20 42.91 100.0%

MIX = 54.18 1.09 0.39 0.20 42.91 Sum = 100%
Two components calculation model:
2 comp. C S A F Los of Ignition Dry Comp. %

Lime stone 54.18 1.09 0.39 0.20 42.91 84.4%

Clay 0.00 100.00 0.00 0.00 0.00 15.6%
MIX = 45.75 16.49 0.33 0.17 36.23 Sum = 100%

3 comp. C S A F Los of Ignition Dry Comp. %

Lime stone 54.18 1.09 0.39 0.20 42.91 65.9%

Laporac 20.44 36.98 9.67 5.32 18.34 33.7%
Clay 0.00 100.00 0.00 0.00 0.00 0.4%
MIX = 42.59 13.59 3.52 1.92 34.45 Sum = 100%

4 comp. C S A F Los of Ignition Dry Comp. %

Lime stone 54.18 1.09 0.39 0.20 42.91 66.8%

Laporac 20.44 36.98 9.67 5.32 18.34 31.6%
Quartz San 6.27 18.30 8.60 56.90 5.40 0.5%
Clay 0.00 100.00 0.00 0.00 0.00 1.1%
MIX = 20.32 6.50 1.60 1.00 16.42 Sum = 100%
 Raw mix (%) % relative
Auxiliary C mix = 20.32 31.8%
part of S mix = 6.50 15.0%
calculation
4-comp. A mix = 1.60 0.2%
F mix = 1.00 0.5%
 Comp. content
(mass%)
% Dry mass % Wet mass
66.8% 66.1%
31.6% 32.3%
0.5% 0.5%
1.1% 1.1%
Sum = 100.0% 100.0%
 Basic data elements for Chart Kiln Coating Behavior

Circle elements
Kiln Coating BehavioV-Offset H-Offset Radius Step
1.6 2.5 0.3 Param. Required: Obtained:
Y axis X axis LSF = 98 98
AR SM k*PI() k SM = 2.5 2.5
Horizontal and 1.6 2.8 0 0 AM = 1.6 1.6
Vertical Lines
1.692705 2.785317 0.314159 0.1
Y axis X axis 1.776336 2.742705 0.628319 0.2
AR SM 1.842705 2.676336 0.942478 0.3 Arrow
1.6 2 1.885317 2.592705 1.256637 0.4 Slope= 0.0 0.0
1.6 3 1.9 2.5 1.570796 0.5 Interc.= 1.6 1.6
1.2 2.5 1.885317 2.407295 1.884956 0.6 x 2.5 2.5
2 2.5 1.842705 2.323664 2.199115 0.7 y 1.6 1.6
1.776336 2.257295 2.513274 0.8
1.692705 2.214683 2.827433 0.9
1.6 2.2 3.141593 1
1.507295 2.214683 3.455752 1.1
1.423664 2.257295 3.769911 1.2
1.357295 2.323664 4.08407 1.3
1.314683 2.407295 4.39823 1.4
1.3 2.5 4.712389 1.5
1.314683 2.592705 5.026548 1.6
1.357295 2.676336 5.340708 1.7
1.423664 2.742705 5.654867 1.8
1.507295 2.785317 5.969026 1.9
1.6 2.8 6.283185 2
1.692705 2.785317 6.597345 2.1

BOGUE CALCULATION
BOGUE CALCULATION
C3S = 4.0710CaO-7.6024SiO2-1.429
C3S = 4.0710CaO-7.6024SiO2-1.4297Fe2O3-6.7187Al2O3

C2S = 8.6024SiO2+1.0785Fe2O3+5.06
C2S = 8.6024SiO2+1.0785Fe2O3+5.0683Al2O3-3.0710CaO
C3A = 2.6504Al2O3-1.6920Fe2O3
C3A = 2.6504Al2O3-1.6920Fe2O3
C4AF = 3.0432Fe2O3
C4AF = 3.0432Fe2O3
Clinker analysis
SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 LOI IR
21.5 5.2 2.8 66.6 1 0.6 0.2 1 1.5 0.5
Free lime = 1.0% CaO

Using the above analysis, the calculation is as follows:

Worked example of a Bogue calculation:

Combined CaO = (66.6% - 1.0% free lime) = 65.6%

This is the figure we use for CaO in the calculation.

From the analysis, we have:

CaO=65.6%; SiO2=21.5%; Al2O3=5.2% and Fe2O3=2.8%

The Bogue calculation is therefore:

C3S = 4.0710CaO-7.6024SiO2-1.4297Fe2O3-6.7187Al2O3

C2S = 8.6024SiO2+1.1Fe2O3+5.0683Al2O3-3.0710CaO

C3A = 2.6504Al2O3-1.6920Fe2O3

C4AF = 3.0432Fe2O3

Therefore:

C3S = (4.0710 x 65.6)-(7.6024 x 21.5)-(1.4297 x 2.8)-(6.718 x 5.2)

C2S = (8.6024 x 21.5)+(1.0785 x 2.8)+(5.0683 x 5.2)-(3.0710 x 65.6)

C3A = (2.6504 x 5.2)-(1.6920 x 2.8)

C4AF = 3.0432 x 2.8

So:

C3S = 64.7%

C2S = 12.9%

C3A = 9.0%
C4AF = 8.5%

The essential reactions in making Portland cement are the calcinations of limestone to produce lime (calcium ox
During clinkering, the clinker contains solid phases and a liquid phase.
The liquid is vital in that it acts a flux, promoting reactions by ion transfer; without the liquid phase, combinabil
The liquid phase is composed largely of oxides of calcium, iron and aluminum, with some silicon and other mino
ALCULATION

710CaO-7.6024SiO2-1.4297Fe2O3-6.7187Al2O3

024SiO2+1.0785Fe2O3+5.0683Al2O3-3.0710CaO

504Al2O3-1.6920Fe2O3
Total
98.9
roduce lime (calcium oxide) and the combination of this lime with silica to make belite and, especially, alite.

iquid phase, combinability ("combinability", or "burnability") would be poor and it would be very difficult to make cement.
e silicon and other minor elements. As the clinker leaves the kiln and cools, crystals of aluminate and ferrite form from the
ficult to make cement.
nd ferrite form from the liquid.