Impact of Fuel Ash on Clinker Quality

Tom Lowes
 Impact of Fuel Ash on Clinker Quality

 In the embedded spreadsheet the Bogue calculations for LSF, C3S etc
allowing for SO3 but not include IR are used to predict the change on the
clinker chemistry when changing a coal ash for 20 to 45% for a typical
calciner process
 This shows a drop in LSF of 8% and C3S of 23%, with a drop is one day
strength of 4 Mpa and 2 Mpa at 28 days.
 The spreadsheet is written in such a way that it can be readily modified to
incorporate more than one fuel and hence is ideal to assess the impact of
AFR. However note that these are Bogue and not actual C3S etc, the AFR
ash lumps do not combine easily and can make C3S much lower than
Bogue
 The prediction for a typical clinker and coal ash is on the next slide,
changes are permitted to the red cells, without knowledge of the
password
 Bogue compound Composition Change with Coal Ash
Current Clinker Coal Ash Analysis New Climker
BS w SO 3 % BS w SO3
SiO2 21.73 LSF 93.2 SiO2 50.00 Coal Ash Current % 20 SiO2 22.89 LSF 85.2 Change in LSF -8.0
Al2O3 4.87 LCF 91.8 AI2O3 19.16 Coal CV current kcals/kg 6500 Al2O3 5.46 LCF 83.9 Change in C3S -21.3
Fe2O3 3.83 S/R 2.50 Fe2O3 7.47 Coal Ash New % 45 Fe2O3 3.98 S/R 2.42 Change in C3A 1.3
CaO 65.02 A/F 1.27 CaO 15.00 Coal CV New kcals/kg 4875 CaO 62.97 A/F 1.37 Change Ash/Clk 4.1
MgO 2.00 C3S 55.0 MgO 2.79 Plant kcals/kg 800 MgO 2.03 C3S 33.7 Drop 1 day Mpa -4.0
SO3 0.79 C2S 20.8 SO3 1.40 % Coal Current/Clk 12.3 SO3 0.81 C2S 40.2 Drop 28 day Mpa -2.2
K2O 0.72 C3A 6.4 K2O 2.79 % New Coal/Clk 16.4 K2O 0.81 C3A 7.7
Na2O 0.04 C4AF 11.7 Na2O 0.77 t extra ash/100 t clk 4.1 Na2O 0.07 C4AF 12.1
F. CaO 1.00 C4AF+C2F 0.0 Cl 0.62 F. CaO 0.98 C4AF+C2F 0.0
eqNa2O 0.51 Total 100.00 eqNa2O 0.60
Total 100.00 Total 100.00