RAW MIX DESIGN BESTWAY

By: Rashid Jamal

MANAGER (QC)
 RAW MIX DESIGN BESTWAY

Definition
The raw material preparation stage of cement manufacture results
in the production of araw mixthat is in a suitable state for
feeding to thekilnin which it is converted by heat intoclinker.

The raw mix consists of a mixture of materials that will react

together to form the calcium silicates that confer on the clinker
its strength-giving properties. The mineral particles in the raw
mix usually consist principally of calcium carbonate from the
limestone component of the mix, and alumino-silicates from the
clay, shale or bauxite components, together with a certain
amount of iron.
 RAW MIX DESIGN BESTWAY

Basic Requirements
There are several factors influencing the quality, quantity
and the production cost of cement, and therefore,
depending upon the manufacturing process and the
equipment used or on the actual situations of use,
specific control points are located.

Data are collected at various control points at desired

frequencies, analyzed and corrective steps are taken to
maintain consistency in, and the desired level of quality
of the product.
 RAW MIX DESIGN BESTWAY

Basic Requirements
Feedback data is systematically compiled for different
benches and mining blocks to determine the general
variation between the prospecting data and the actual
quality of limestone mined. This facilitates selective
extraction from specific areas of the quarry and blending
at the quarry to obtain a consistent grade of limestone.
This would ease the extent of controls on quality at the
later stages of operation.

The chemical composition of Portland-cement clinker is

made up of several oxide components of which some are
desirable and others are tolerated because they are
unavoidable, though unwanted.
 RAW MIX DESIGN BESTWAY

Basic Requirements
In the case of desirable oxides, the relative proportions
are optimized in such a way that a trouble-free and
smooth operation of the plant is ensured, production
efficiency and fuel economy are maximized, the quality of
the product satisfies all the requirements and at the
same time the cost of production is minimized.
 RAW MIX DESIGN BESTWAY

Cement Manufacturing Process

Limestone and Clay Quarrying, Crushing

Laterite and Bauxite Crushing

Preparation of piles and pre-homogenization

Raw Meal drying and Grinding

Clinkerization

Finish Grinding

Storage of Cement

Plant dusting System.

RAW MIX DESIGN BESTWAY

Criteria
Based on practical experience gained over several
decades and also on research investigations, the relative
proportions of major constituent oxides which will
facilitate production and also ensure a reasonable degree
of performance have been defined in modulii values;

An increasing Silica Modulus (SM) impairs the

burnability by reducing the liquid phase content, causes
slow setting, hardening and also dusting in the kiln.

The Alumina Modulus (AM) determines the composition

of the liquid phase in clinker. The lower the ratio, the
harder is the burning. A higher ratio gives rise to
lumping of clinker, high heat of hydration and fast
setting.
RAW MIX DESIGN BESTWAY

Criteri
a
The preferred values of LSF are in the range of 85 to 95
With LSF below the lower limit one can expect a
predominance of di-calcium silicate (belite) with a lower
temperature of burning,

An LSF exceeding the upper limit is expected to require a

high burning zone temperature and may result in a free-
lime content of more than 0.5 per cent. In other words,
within prescribed limits, the higher the LSF, the better
the strength of cement, but the more difficult it becomes
to burn the raw mix. Conversely, the lower the LSF, the
lower is the early strength of cement, but the easier it is
to burn the raw mix.
 RAW MIX DESIGN BESTWAY

Limeston
e
Description SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl

Drilling 3.64 0.57 0.32 52.50 1.00 0.12 0.01 0.04 0.00

Drilling 2.53 0.37 0.28 53.91 0.80 0.08 0.02 0.08 0.003

Drilling 2.18 0.23 0.22 53.75 0.91 0.05 0.01 0.03 0.005

Drilling 5.12 0.22 0.23 53.01 1.29 0.05 0.01 0.85 0.003
 RAW MIX DESIGN BESTWAY

Clay

Description SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl

1 50.47 11.75 4.80 11.14 2.57 1.99 1.21 0.03 0.000

2 50.73 12.24 4.83 11.13 2.66 2.02 1.09 0.02 0.00

3 50.06 12.17 4.90 11.54 2.62 2.22 1.02 0.11 0.01

Avg 50.60 12.00 4.82 11.14 2.62 2.01 1.15 0.02 0.00
 RAW MIX DESIGN BESTWAY

Laterite & Bauxite

Description SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl

Laterite 30.31 11.11 32.09 3.21 1.62 1.74 0.11 0.65 0.005

Bauxite 38.88 30.32 15.06 0.97 0.38 0.48 0.06 0.64 0.00
 RAW MIX DESIGN BESTWAY

Raw Materials Used For Clinker Manufacturing

LIMESTONE
LIMESTO NE
75 to 80 % per ton of Raw Meal

CLAY
CLAY 12 to 25 % per ton of Raw Meal

LATERITE
LATERITE
2.8 to 3.8 % per ton of Raw Meal

BAUXITE
BAUXITE 0.50 to 0.90 % per ton of Raw Meal

SAND STONE
SAND STONE
3.0 to 8.0 % per ton of Raw Meal for
SRC
CLINKER
CLINKER
RAW MIX DESIGN BESTWAY

Minor Elements %age for Smooth

Plant Operation

Na +
Na =<
+ KK = %
1.00 %
< 1.00

< 1.00
= <
SS = %
1.00 %
IN KILN FEED

=<
Cl =
Cl %
0.015 %
< 0.015
 RAW MIX DESIGN BESTWAY

Cement Chemistry
Constituents PS 232:2008 (R) Normal Range Source/Raw
Limits Material
Lime (CaO) No Limit 62~65 % Limestone
Silica (SiO2) No Limit 20~22 % Clay/slate
Iron (Fe2O3) No Limit 3~4 % Laterite
Alumina (Al2O3) No Limit 4~5 % Bauxite
Sulphur (SO3) 3.00 % Max 2.4~2.8 % Gypsum
Magnesia (MgO) 6.00 % Max 2~3 % Limestone/Clay
Potassium (K2O) No Limit 0.5~1.0 % Limestone/Clay
Sodium (Na2O) No Limit 0.1~0.4 % Limestone/Clay
Chloride (Cl)% 0.1 % Max 0.001~0.05 % Limestone/Clay
 RAW MIX DESIGN BESTWAY

General

Cement Plant Design Constraint

Feasibility

Cost/Ton of Raw Meal Manufacturable Types

of Cement
 RAW MIX DESIGN BESTWAY

Raw Mix Design 1

Cost/To Moist.
Materials % age T/hrs SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl LSF SM AM
n %
Lst 135 0.00 76.90 0.00 3.44 0.50 0.34 51.96 0.92 0.10 0.01 0.08 0.00 497.86 4.06 1.48
Sand Stone 1000 6.00 0.00 0.00 85.00 2.78 2.00 1.20 0.31 0.70 0.28 0.35 0.00 0.49 17.78 1.39
Laterite 1482 0.00 3.40 0.00 31.36 11.04 32.37 2.72 1.70 2.14 0.11 1.08 0.01 2.23 0.72 0.34
Bauxite 790.11 0.00 0.80 0.00 38.88 30.32 15.06 0.97 0.38 0.48 0.06 0.64 0.00 0.63 0.86 2.01
Clay 113.03 0.00 18.90 0.00 51.35 12.00 4.82 11.14 2.62 2.01 1.15 0.02 0.00 6.91 3.05 2.49
Cost/Ton of Raw
182 100.00 0.00
Meal
SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl
Raw Meal
13.72 3.27 2.39 42.16 1.26 0.53 0.23 0.11 0.00 96.15 2.42 1.37
Clinker (With
21.27 5.07 3.71 65.35 1.96 0.83 0.36 0.17 0.0059 96.15 2.42 1.37
out coal ash)
Coal Ash 47.23 21.25 5.1 4.3 2.895 0.38 0.06 3.74 0.0025 2.68 1.79 4.17
Coal Ash% 2.32 1.10 0.49 0.12 0.10 0.07 0.01 0.00 0.09 0.00
Clinker % 97.68 20.78 4.96 3.62 63.83 1.91 0.81 0.35 0.15 0.01
Clinker With
100.00 21.87 5.45 3.74 63.93 1.98 0.82 0.35 0.24 0.01 91.18 2.38 1.46
coal Ash
L.
C3S C2S C3A C4AF ASR Alkali.Eq
Parameters Phase
Clinker
Composition 64.41 12.40 7.17 11.28 26.88 0.17 0.90
With Out coal
ash
Clinker
Composition 51.31 24.01 8.11 11.37 28.15 0.24 0.89
With coal ash

Cost/Ton of Raw Meal Raw Mix Clinker

LSF SM AM LSF SM AM
Rs. 181.78 91.18 2.38 1.46
96.15 2.42 1.37
 RAW MIX DESIGN BESTWAY

Raw Mix Design 2 (Back Shale)

Cost/To
Materials Moist.% % age T/hrs SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl LSF SM AM
n
Lst 135 0.00 79.20 0.00 4.63 1.01 0.52 50.74 1.02 0.19 0.01 0.13 0.00 350.39 3.03 1.93
Sand Stone 1000 6.00 0.00 0.00 85.00 2.78 2.00 1.20 0.31 0.70 0.28 0.35 0.00 0.49 17.78 1.39
Laterite 1482 0.00 3.20 0.00 31.36 11.04 32.37 2.72 1.70 2.14 0.11 1.08 0.01 2.23 0.72 0.34
Bauxite 790.11 0.00 0.00 0.00 38.88 30.32 15.06 0.97 0.38 0.48 0.06 0.64 0.00 0.63 0.86 2.01
Clay 113.03 0.00 17.60 0.00 51.35 12.00 4.82 11.14 2.62 2.01 1.15 0.02 0.00 6.91 3.05 2.49
Cost/Ton of Raw 174 100.00 0.00
Meal
SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl
Raw Meal
13.71 3.26 2.30 42.24 1.32 0.57 0.22 0.14 0.00 96.61 2.47 1.42
Clinker (With out 21.24 5.06 3.56 65.47 2.05 0.88 0.34 0.22 0.0059 96.61 2.47 1.42
coal ash)
Coal Ash 47.23 21.25 5.1 4.3 2.895 0.38 0.06 3.74 0.0025 2.68 1.79 4.17
Coal Ash% 2.32 1.10 0.49 0.12 0.10 0.07 0.01 0.00 0.09 0.00
Clinker % 97.68 20.75 4.94 3.48 63.95 2.00 0.86 0.33 0.19 0.01
Clinker With coal 100.00 21.85 5.43 3.60 64.05 2.07 0.87 0.33 0.28 0.01 91.61 2.42 1.51
Ash
C3S C2S C3A C4AF L. Phase ASR Alkali.Eq
Parameters
Clinker
Composition 65.32 11.63 7.37 10.82 26.66 0.21 0.92
With Out coal
ash
Clinker
Composition 52.22 23.24 8.31 10.93 27.93 0.27 0.90
With coal ash

Cost/Ton of Raw Meal Raw Mix Clinker

LSF SM AM LSF SM AM
Rs. 174.13 96.61 2.47 1.42 91.61 2.42 1.51
 RAW MIX DESIGN BESTWAY

Raw Mix Design (SRC)

Cost/To Moist.
Materials % age T/hrs SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl LSF SM AM
n %
Lst 135 0.00 79.00 0.00 3.44 0.50 0.34 51.96 0.92 0.10 0.01 0.08 0.00 497.86 4.06 1.48
Sand Stone 1000 6.00 6.50 0.00 85.00 2.78 2.00 1.20 0.31 0.70 0.28 0.35 0.00 0.49 17.78 1.39
Laterite 1482 0.00 7.00 0.00 30.42 11.74 35.47 0.63 1.43 1.96 0.09 0.53 0.01 0.52 0.64 0.33
Bauxite 790.11 0.00 0.00 0.00 38.88 30.32 15.06 0.97 0.38 0.48 0.06 0.64 0.00 0.63 0.86 2.01
Clay 113.03 0.00 7.50 0.00 51.35 12.00 4.82 11.14 2.62 2.01 1.15 0.02 0.00 6.91 3.05 2.49
Cost/Ton of Raw 219 100.00 0.00
Meal
SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl
Raw Meal
13.89 2.29 3.24 42.31 1.04 0.41 0.12 0.13 0.00 96.84 2.51 0.71
Clinker (With out 21.53 3.55 5.01 65.58 1.61 0.64 0.18 0.20 0.0060 96.84 2.51 0.71
coal ash)
Coal Ash 47.23 21.25 5.1 4.3 2.895 0.38 0.06 3.74 0.0025 2.68 1.79 4.17
Coal Ash% 2.32 1.10 0.49 0.12 0.10 0.07 0.01 0.00 0.09 0.00
Clinker % 97.68 21.03 3.47 4.90 64.06 1.58 0.62 0.18 0.17 0.01
Clinker With coal 100.00 22.12 3.96 5.02 64.16 1.64 0.63 0.18 0.26 0.01 91.81 2.46 0.79
Ash
C3S C2S C3A C4AF L. Phase ASR Alkali.Eq
Parameters
Clinker
Composition 71.73 7.61 0.92 15.24 24.56 0.27 0.60
With Out coal
ash
Clinker
Composition 58.47 19.32 2.01 15.25 25.88 0.36 0.60
With coal ash

Raw Mix Clinker

Cost/Ton of Raw Meal
LSF SM AM LSF SM AM
Rs. 218.76 96.84 2.51 0.71 91.81 2.46 0.79
 RAW MIX DESIGN BESTWAY

Raw Mix Design (HES)

Cost/To Moist.
Materials % age T/hrs SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl LSF SM AM
n %
Lst 135 0.00 80.20 0.00 4.63 1.01 0.52 50.74 1.02 0.19 0.01 0.13 0.00 350.39 3.03 1.93
Sand Stone 1000 6.00 0.00 0.00 85.00 2.78 2.00 1.20 0.31 0.70 0.28 0.35 0.00 0.49 17.78 1.39
Laterite 1482 0.00 2.60 0.00 31.36 11.04 32.37 2.72 1.70 2.14 0.11 1.08 0.01 2.23 0.72 0.34
Bauxite 790.11 0.00 1.20 0.00 38.88 30.32 15.06 0.97 0.38 0.48 0.06 0.64 0.00 0.63 0.86 2.01
Clay 113.03 0.00 16.00 0.00 51.35 12.00 4.82 11.14 2.62 2.01 1.15 0.02 0.00 6.91 3.05 2.49
Cost/Ton of Raw 174 100.00 0.00
Meal
SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl
Raw Meal
13.21 3.38 2.21 42.56 1.28 0.53 0.20 0.14 0.00 100.36 2.36 1.53
Clinker (With out 20.47 5.24 3.43 65.97 1.99 0.83 0.31 0.22 0.0059 100.36 2.36 1.53
coal ash)
Coal Ash 47.23 21.25 5.1 4.3 2.895 0.38 0.06 3.74 0.0025 2.68 1.79 4.17
Coal Ash% 2.32 1.10 0.49 0.12 0.10 0.07 0.01 0.00 0.09 0.00
Clinker % 97.68 20.00 5.11 3.35 64.44 1.94 0.81 0.30 0.19 0.01
Clinker With coal 100.00 21.09 5.61 3.47 64.54 2.01 0.82 0.30 0.28 0.01 95.00 2.33 1.62
Ash
C3S C2S C3A C4AF L. Phase ASR Alkali.Eq
Parameters
Clinker
Composition 72.20 4.23 8.07 10.42 26.76 0.23 0.85
With Out coal
ash
Clinker
Composition 58.94 16.02 8.99 10.54 28.03 0.29 0.84
With coal ash

Raw Mix Clinker

Cost/Ton of Raw Meal
LSF SM AM LSF SM AM
Rs. 174.26 100.36 2.36 1.53 95.00 2.33 1.62
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