COMBUSTION AND

TEN GOLDEN RULES

Murat SOYLU
October 2012
RULE 1

• Obtaining finer material on 90 and 200 µ residues

decreases the burning heat and cement grinding
specific energy.
• This also makes the strength higher.
• Decrease the residue amount from 20% to 10% on
100 µ mesh, gain 4 kWh/t energy.
By Producing Finer Meal

• Saving for:
– Burning fuel energy,
– Cement grinding energy

Is obtained…
Finer Meal = kW

25
kWh/t y = - 0.4267 x + 29.759
y = -0.4267x + 29.759
24 R = 0.9145
2

23

22

21

(%) > 100 µm of raw mix

20
12 14 16 18 20 22
Finer Meal = Energy Saving

%Free lime
8.00

15%>100 Microns- Industrial as it is

6.00
5%>100 - lab grinding of residue
5%>100 - complete grinding
4.00

2.00

0.00
Temperature °C
1400 1450 1500 1550 1600
Finer Meal = Saving on Grinding Energy
Rule 2

• Short burning zone effects the grindability and

strength development positively.
Hot and Short Burning Zone

• Makes the clinker easily grindable.

Short Burning Zone = Better Grindability

75

70

65
BB10 (kWh/t)

60

55

50

45 Nm
600 700 800 900 1000 1100 1200 1300 1400 1500

Kiln Motor
Short Burning Zone = Better Grindability (Grindability
and Burning Zone Length)

500 80

450 75
Kiln motor current, A

Increasing grindability
400 70

kWh / t
350 65

300 60

250 Decreasing kiln motor current 55

200 50
30/05/1995 04:00 30/05/1995 12:00 30/05/1995 20:00 31/05/1995 04:00 31/05/1995 12:00
Rule 3

• Stable conditions requires oxidizing environment.

• Reducing environment increases the volatile cycle.
• This causes the fluctuations of alkali sulphate and
circulating elements.
• Thus, bad clinker is produced.
Let the Kiln Breathe

• With the reduction of volatile matter;

– Stable kiln operation,
– Stable clinker quality

Are achieved.
Rule 4

• Increase of clinker free lime content decreases the

initial and final setting time.
• Limestone addition accelerates the initial and final
setting time.
– Key Values;
• Increase of free lime from 0.5% to 1.5%, initial and final setting time
decreases for 40-50 minutes.
Addition of small amount of free lime

• Makes the clinker

NERVOUS
Decrease of Free Lime and Setting Time

Initial Setting
( min. )

180
160

140
120
100 %
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Free Lime in Clinker
Rule 5

• Increasing the C3S proportion of clinker develops the

1,2,3 and 7 day strength. After 28 days, strength
development may be less because of C2S effect.

– Key Values;
• +10% C3S +2 to 5 MPa early strength
development.
In short and middle term,

MPa Gaining
C3S increase 10% + 5 to 6 MPa.

-10% C2S
STRENGTH (C3S)

60.0
R-28d
55.0
50.0
45.0 R-7d
40.0
N/mm 2

35.0
R-2d
30.0
25.0
R-1d
20.0
15.0
45.0 50.0 55.0 60.0

C3 S
Rule 6

Hard to Grind…

C2 S
+ 10 % C2S + 4 kWh/t
Grindability

% Case 1 Case 2 D
LSF Clinker 94,50 98,60 + 4,10

C3 S 56 64 +8

C2 S 22 15 -7

C3 A 10,20 9,60 =

C4 A F 8,20 8,00 =
Free. CaO 1,27 1,30 =

kWh/t BB10 46,70 44,40 - 2,30

SSB BB10 ( cm2/g ) 3680 3710 =
kWh/t Industrial 53,10 51,60 - 1,50
28 d. Industrial 32,0 35,5 + 3,5
Rule 7

• Whatever the formation is, alkalis do not affect the 28

days strength positively.

– Key Values;
• +0.1% increase in equivalent Na2O

• -1 N/mm2 at 28 days
Effect of Alkalis

70

65
28 –days strength (MPa)

60

55

50

45
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
% Total Alkalis
Rule 8

• Regarding early strength, with the optimum sulphate

content, soluble alkalis, especially alkali sulphates
develops the early strength.

– Key Values;
– +0.1% Equivalent Na2O

– +0.5 to 1.5 N/mm2 @ 1 day strength

 ALKALI SULPHATES

1 K2O and 1 SO3 (MOLAR) 1 K2SO4 (Soluble)

These soluble alkalis are good for 1-2 days strength.

Rule 9

• Change of crystal formation of C3A from cubic to

orthorhombic,

– Bad burnability,
– Process problems,
– Sensitivity to aging
– Decrease in 28 days strength.
Alkalis more than sulphates

• Excess alkalis go into the crystal structure

Na2O, C3A NC8A3

K2O, C2S KC23S12

DECREASE IN 28 DAYS STRENGTH

Rule 10

• If the clinker SO3 amount is more the molar

saturation rate, a significant increase is observed on
clinker fineness and grindability.

– Key Values;
• +1% excess SO3 +5 kWh/t
 SO3 > Na2O , K2O

Dusty Clinker,
More kWh/t Cement Grinding

+ 1% Excess SO3 + 5 kWh / t

( @ 350 m2 / kg )
 Excess Sulphates
* Finer Clinker

100

80

60
% Passing

0,1 % S03
40 1,3 % SO3

20

0
0 5 10 15 20 25
Screen ( mm )
 Excess Sulphates
100

80

60
0,1 % SO3
% Passing

40 2,9 % SO3
20

0
0 5 10 15 20 25 30 35
Screen( mm )

100

80

* Finer Clinker
Passing

60
0,1 % SO3
40 1,2 % SO3

20
%

0
0 10 20 30 40 50 60

Screen( mm )