Chapter II - c

Process Effects
Objectives and Principles
Industrial Examples
 Learning Objectives

By the end of this presentation you should be able to :

 To know the individual effects of the kiln feed

parameters on clinkering temperature

 To start being informed on K1450

 To use the burning factor

Process Engineering Program – Raw Mix Optimization November 2004 2

 Content

1. Objectives
2. Individual effects
3. Burning Factor
4. Conclusion

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 Burnability Optimisation

 To get low clinkering temperature in the burning zone

 LSF target

 Raw mill fineness (90 µm)

 SiR and AR will be set

 Burnability influences heat consumption and quality

 Pure minerals are harder to burn

 Common criteria: %quartz > 45 , %calcite > 125 

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 Clinker temperature and Combinability index

Impact
Impactsur
surla
laT°
T°de
de cuisson
cuisson
1800
1800

1700
1700
T° d e c u is s o n e n °C
T° d e c u is s o n e n °C

1600
1600

1500
1500

1400
1400

1300
1300

1200
1200
0 20 40 60 80 100 120
0 20 40 60 80 100 120
K1450
K1450

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 Clinker temperature and Fuel Consumption

Impact
Impactsur
surConso
ConsoCalo
Calo
6
6
C o n s o m m a tio n c a lo rifiq u e e n %
C o n s o m m a tio n c a lo rifiq u e e n %

4
4

2
2
Cru à 12 % de re fus
Cru à 12 % de re fus
0
0
Cru à 6 % de re fus
Cru à 6 % de re fus
-2
-2
Cru à 4 % de re fus
Cru à 4 % de re fus
-4
-4

-6
-6

-8
-8
20 30 40 50 60 70 80 90 100
20 30 40 50 60 70 80 90 100
K1450
K1450

Process Engineering Program – Raw Mix Optimization November 2004 6

 Clinker Temperature

• LSF • Fineness 90µm

Process Engineering Program – Raw Mix Optimization November 2004 7

 Fineness Effect (90 µm)

Le Teil R100µ Kck1450

Cru normal 95 17,2 54
Cru normal 96 10 68
HTS 94 13 60
HTS 94 rebroyé 10 82
Le Havre
Cru HSR 13 37
Cru HSR rebroyé 8 54

 Be
Be careful
careful to
to aa very
very fine
fine material
material ::
 Poor efficiency of the cyclones of the tower
Poor efficiency of the cyclones of the tower
 Increase of the fuel consumption
Increase of the fuel consumption
 Best compromise between 8 and 10% @ 100 µm
Best compromise between 8 and 10% @ 100 µm

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 Clinker Temperature

Clinkering Temperature °C
• Silica • Alumina Ratio
Clinkering Temperature °C

Ratio

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 Liquid Phase

160

140 Ajout de Fé2O3

120

100

K1450
80 Ajout de Al2O3

60

40

20

0
5 10 15 20
Phase liquide

Process Engineering Program – Raw Mix Optimization November 2004 10

 Burning Factor

BF = LSF + 10 SR - 3 (MgO + Na2Oeq)

 Major-oxide ratios affect the rate of clinkering and fuel required to
make clinker
 MgO, alkalis or fluxes (e.g. mineralizers CaF2) can reduce melting
temperature.
 It does not account for:
 Mineralogy

 Physical effects, e.g. grain size 120 = hard to burn,

 Blending better < 115

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 Conclusion

 After Quality constraint, kiln operation has to be

part of the optimization. Fuel consumption is
important to minimize.
 Clinkering temperature and K1450 (combinability
index) are correlated.

Process Engineering Program – Raw Mix Optimization November 2004 12