RAW MIX

It is Finely ground blend of calcareous and argillaceous and additive/corrective materials in
predetermined proportions.
Raw mix is subjected to semi fusion state resulting in series of physio chemical reaction yielding
clinker, a synthetic mix of calcium silicate, calcium aluminate and calcium alumina ferrite phase in
hardened state.

◦ PRINCIPLE OF RAW MIX DESIGN:

-It should be of
1)Acceptable cost and controllable.
2)Maximum permissible contents of magnesia, chloride, alkali and sulphate.
 Affects Of Raw Mix
Chemical Composition
Clinker Quality
Fuel Consumption
Refractory Lining
Undesirable Coating Formation
Clinker Production
Economy Of Plant
 PARAMETERS TAKING INTO CONSIDERATION
Raw Materials: Availability, Chemical and Mineral Composition.
Fuels: Proximate, GCV, Sulphur, Moisture.
Manufacturing Process: Wet Or Dry
Effect Of Unit Operations: Grinding, Blending, Fineness.
Minor Constituents: Source, Effects, Need Additives.
Economics Of Design: Ensuring total company productivity material conservation, waste reduction.
 MODULI VALUES AND THEIR EFFECTS
Moduli values responsible for producing clinker on firing.
Governed by four major oxides.
Cao, Sio2, Al2O3, Fe2O3.

Silica Modulus- SiO2/Al2O3+Fe2O3

Alumina Modulus-Al2O3/Fe2O3
Lime Saturation Factor-
100*CaO/2.85*SiO2+1.18Al2)3+0.65*Fe2O3
 MODULUS
 A High Silica Modulus:
 Results harder burning and high fuel consumption.
 Causes difficulty in coating formation and hence radiation losses from shell high.
 Deteriorates the kiln lining.
 Results in slow setting and hardening cement.
 A High Alumina Modulus:
 Impacts harder burning and entails higher fuel consumption.
 Increase proportion of C3A and reduces C4AF.
 Reduces liquid phase and kiln output.
 Quick setting and strength at early stages.
 Increases viscosity of liquid phase at constant temperature.
 If Alumina modulus is low and raw mis without free silica, clinker sticking and balling is high.
 LIME SATURATION FACTOR
 A High Lime Saturation Factor:
 It makes difficult to burn raw mix.
 It needs more fuel to drive of Co2 gas.
 Tends to produce unsound cement.
 Increases C3S content and reduce C2S content

Lime Saturation Factor- 100*CaO/2.85*SiO2+1.18Al2)3+0.65*Fe2O3.

 REQUIRED PHASE% IN
CLINKER
C3S – 45%
C2S – 34%
C3A – 4.5%
C4AF – 12%
FCaO – 2%
MgO – 1%
 MOLECULAR WEIGHTS OF OXIDES
CaO = 40+16= 56
SiO2 = 28+(16*2)=60
Al2O3 = (2*27)+ (3*16) = 102
Fe2O3 = (2*56)+(3*16) = 160
MgO = (24+16) = 40
 MOLECULAR WEIGHTS OF
PHASES
C3S= (3*CaO)+SiO2 = (3*56)+60=228
C2S=(2*CaO)+SiO2= (2*56)+60=172
C3A=(2*CaO)+Al2O3=(2*56)+102=270
C4AF=(2*CaO)=Al2O3+Fe2O3=(2*56)+102+160=486
 REQUIRED OXIDE PERCENTAGE

CaO= (C3S% *3*CaO / C3S) + (C2S% * 2 * CaO) / C2S) + (C3A% * 3 * CaO /

C3A) +(C4AF% * 4 * CaO / C4AF)
SiO2 = (C3S * SiO2 / C3S) + (C2S% * SiO2) / C2S)
Al2O3 = (C3A% * Al2O3 / C3A) + (C4A*Al2O3/C4AF)
Fe2O3 = (C4AF%*Fe2O3/C4AF)