Technical Information

Sheets
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 138
1 . Gy p s u m A n a l y s i s
2 . Gy p s u m A d d i t i o n L e v e l
3 . L S F a n d B o g u e C o mp o s i t i o n
4 . Wa t e r - S o l u b l e A l k a l i s
5 . C e me n t S S A , R e s i d u e a n d R o s i n - R a mml e r P S D S l o p e
6 . C e me n t F i n e n e s s
7 . Vo l u me L o a d i n g
8 . Mi l l C r i t i c a l S p e e d
9 . Mi l l P o we r C a l c u l a t i o n
1 0 . P o wd e r Vo i d F i l l i n g
1 1 . Mi l l A i r f l o w
1 2 . Mi l l E x h a u s t De w P o i n t
1 3 . C i r c u l a t i n g L o a d
1 4 . C e me n t Gr i n d a b i l i t y
1 5 . S e p a r a t o r P e r f o r ma n c e
1 6 . A i r S e t Te n d e n c y
contents
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 139
GYPSUM ANALYSIS
1. Analyses required are: SO
3
, losses at 50C, 250C
and 950C
2. Calculate the gypsum content (CaSO
4
.2H
2
O) from the loss
between 50C and 250C. This is assumed to represent the
water of crystallisation. At 50C it is assumed to be free
moisture. The water of crystallisation is:
2H
2
O/CaSO
4
.2H
2
Oi.e. 36/172.14 = 20.9%
3. Calculate the SO
3
accounted for by this level of gypsum,
i.e. multiply by
SO
3
/CaSO
4
.2H
2
O i.e. 80.06/172.14 = 46.5%
4. Allocate the remaining SO
3
(Total SO
3
gypsum SO
3
) to
anhydrite.
5. Calculate the amount of anhydrite present as SO
3
, i.e.
SO
3
/CaSO
4
i.e. 80.06/136.14 = 58.8%
6. The loss between 250C and 950C can be allocated
to calcite
EXAMPLE:
(i) Analysis: SO
3
= 43.9%
loss at 50C = 0.55%
loss at 250C = 13.77%
loss at 950C = 16.12%
(ii) Gypsum = (13.77 0.55)/20.91 = 63.2%
Therefore the SO
3
of this = 63.2 * 0.465 = 29.4%
(iii) SO
3
of anhydrite = 43.9 29.4 = 14.5
Therefore the anhydrite = 14.5/0.588 = 24.7%
(iv) Loss between 250C and 950C = 16.12 13.77 = 2.35
Therefore the calcite (possibly) = 2.35/0.44 = 5.3%
SUMMARY:
Gypsum = 63.2%
Anhydrite = 24.7%
Calcite = 5.3%
TECHNICAL INFORMATION TIS MS001
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 140
GYPSUM ADDITION LEVEL
1. Analysis required are: Clinker SO
3
Gypsum SO
3
(i.e. SO
3
of gypsum additive) Cement SO
3
2. % Gypsum = (Cement SO
3
Clinker SO
3
)/(Gypsum SO
3
Clinker SO
3
) * 100
3. EXAMPLE:
Clinker SO
3
= 0.88%
Gypsum SO
3
= 43.9%
Cement SO
3
= 3.20%
Therefore % gypsum = (3.20 0.88)/(43.9 0.88) *100 = 5.39%
4. For the presence of non-clinker components it is necessary to calculate a new target for the
SO
3
or a new effective Clinker SO, i.e.
(i) 5% limestone (of 0% SO
3
) in the cement.
New target (for the clinker/gypsum)
Cement SO
3
=
(limestone SO
3
* limestone %) + (new target SO
3
* (1-limestone %))
i.e. 3.20 = 0 * 0.05 + SO
3
target * (1 - 0.05)
Therefore New SO
3
target = 3.20/0.95 = 3.37%
Therefore in the clinker/gypsum have 5.78% gypsum and 94.22% clinker
Therefore in the cement have
Clinker = 89.5%
Gypsum = 5.5%
Limestone = 5.0%
(ii) For 5% limestone on a clinker basis, calculate a new clinker/limestone SO
3
, i.e.
0.05 * limestone SO
3
+ 0.95 * clinker SO
3
= 0.836%
Then re-calculate as in 1. to find %gypsum = 5.49%.
Therefore clinker = 100 5.49 * 0.95 = 89.8%
Therefore in the cement have
Clinker = 89.8%
Gypsum = 5.49%
Limestone = 4.72%
TECHNICAL INFORMATION TIS MS002
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 141
LSF AND BOGUE COMPOSITION
LSF =
(CaO 0.7 * SO
3
) / (2.80 * SiO
2
+ 1.18 * Al
2
O
3
+ 0.65 * Fe
2
O
3
)
Silica Ratio =
SiO
2
/ (Al
2
O
3
+ Fe
2
O
3
)
Alumina Ratio =
Al
2
O
3
/ Fe
2
O
3
BOGUE Composition:
C
3
S = 4.07 CaO 7.6 SiO
2
6.73 Al
2
O
3
1.43 Fe
2
O
3
- 2.85 SO
3
C2S = 2.87 SiO
2
0.754 C
3
S
C
3
A = 2.65 Al
2
O
3
1.69 Fe
2
O
3
C
4
AF = 3.04 Fe
2
O
3
Note: For Bogue calculations (not potential) use total CaO free lime
TECHNICAL INFORMATION TIS MS003
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 142
WATER SOLUBLE ALKALIS
TECHNICAL INFORMATION TIS MS004
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 143
CEMENT SSA, RESIDUE AND ROSIN-RAMMLER PSD SLOPE
Note:
Above represent the Rosin-Rammler slope (n) of the psd.
Based on neat OPC only, i.e. no non-clinker components present.
Based on determination of psd by x-ray sedimentation.
Can provide a useful rapid guide to compare the sharpness of psds, e.g.
350m
2
/kg and 10% residue: Slope = 1.09
380m
2
/kg and 9% residue: Slope = 1.06
Hence in the 2nd cement the reduction in residue is not compatible to the higher SSA. For the
same psd slope the residue would need to be 8%.
TECHNICAL INFORMATION TIS MS005
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 144
CEMENT FINENESS
TECHNICAL INFORMATION TIS MS006
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 145
VOLUME LOADING
TECHNICAL INFORMATION TIS MS007
Area of Segment = r
2
Area of Triangle =
1
/
2
* r cos * 2 r sin
= r
2
cos sin
Area below level = r
2
- r
2
cos sin
= r
2
( - cos sin )
Area of circle = ! r
2
Volume occupied = r
2
( - cos sin ) / ! r
2
= ( - cos sin ) / !
r cos = h - r
= cos
-1
{(h - r)/r}
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 146
BALL MILL PARAMETERS
MILL CRITICAL SPEED
Critical Speed when mv
2
/r = mg
v
2
/r = g or v
2
= rg
v
2
= D/2g or v = (D/2 * g)
0.5
Also = (2 ! N)/60
N = (60 ) / (2 !)
Also v = r
= v/r
N
c
= (60 v)/(2 ! r)
N
c
= (60 v) / ( ! D)
N
c
= {60 (D/2 * g)
0.5
} / ( ! D)
N
c
= 42.3 / D
0.5
Where
m = mass
g = gravity
D = mill diameter
v = tangential velocity
= angular velocity
N = mill speed (rpm)
N
c
= mill critical speed (rpm)
TECHNICAL INFORMATION TIS MS008
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 147
MILL POWER CALCULATION
1. The mill power (gross) can be measured from the kWh meter.
(i) Note the meter factor, usually in kWh/revolution
(ii) Time 10 revolutions of the disk
(iii) Calculate the revolutions per hour
(iv) Calculate the mill power
Revs/hour * kWh/rev
EXAMPLE:
Meter factor = 3.210 kWh/rev
Time for 10 revolutions = 28.46 secs
Therefore have = 1264.9 revolutions/hour
Mill Power = 1264.9 * 3.210 = 4060kW
Note: meter factor is also sometimes in revs/kWh or revs/MWh.
2. The mill net power can be estimated from the diameter, mill speed and the height above the
charge (HAC) for each chamber.
Net Power (kW) = 0.2846 * D * A * W * N
Where D = effective chamber diameter (m)
A = 1.073 V/100 (where V = the chamber volume loading%)
W = the weight of grinding media in the chamber (tonnes)
N = the mill speed (rpm)
Calculate for each chamber individually
EXAMPLE:
D = 4.45m
V = 30.4%
W = 100.8 tonnes
N = 14.6rpm
Net power = 0.2846 * 4.45 * (1.073 30.4/100) *100.8 * 14.6 = 1433kW
3. The gross power/net ratio should be between 1.05 and 1.10.
TECHNICAL INFORMATION TIS MS009
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 148
POWDER VOID FILLING
1. The powder (or material) void filling can be estimated during a mill internal inspection. The
following data is required for each chamber:
Effective diameter
Height above charge (HAC)
Height above powder (HAP)
Note: A realistic estimate can only be made for a crash stop situation.
2. Determine the volume loading from the diameter and HAC (see also TIS MS007).
3. Determine the volume % to the powder level using the diameter and HAP as above for the
volume loading (use HAP in place of HAC).
4. When the powder level is below the media:
Void Filling = powder vol% / media vol%
5. When the powder level is above the media:
Void Filling = (powder vol% - 0.55*media vol%) / (0.45*media vol%)
Note: 0.45 represents an average media voidage
EXAMPLE 1
D = 4.45
HAC = 2.92
HAP = 3.17
Volume loading (media) = 30.4%
Volume loading to powder = 23.8%
Therefore the void filling = 23.8/30.4 = 78%
EXAMPLE 2
D = 4.50
HAC = 3.05
HAP = 2.98
Volume loading (media) = 27.9%
Volume loading to powder = 29.7%
Therefore the void filling = (29.7 0.55*27.9) / (0.45* 27.9) = 114%
TECHNICAL INFORMATION TIS MS010
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 149
MILL AIRFLOW
1. Mill design airflow rules:
2-3 volume changes per minute (volume of mill above media charge)
0.4kg air per kg cement
1 m/sec air velocity in mill (using mill diameter)
EXAMPLE 1
Mill of 1000kW, effective diameter = 2.42m, volume =
60m
3
, volume above media = 42m
3
, 22t/hr
2-3 volume changes: mill airflow = 5,000 7,500m
3
/hr
0.4kg air per kg cement: mill airflow = 11,400m
3
/hr
1 m/sec air velocity in mill: mill airflow = 16,500m
3
/hr
EXAMPLE 2
Mill of 4400kW, effective diameter = 4.45m, volume =
210m
3
, volume above media = 147m
3
, 115t/hr
2-3 volume changes: mill airflow = 17,700 26,500m
3
/hr
0.4kg air per kg cement: mill airflow = 59,000m
3
/hr
1 m/sec air velocity in mill: mill airflow = 56,000m
3
/hr
BEWARE of in-leaks, i.e. a significant proportion of air passes the filter exhaust but not
necessarily through the mill.
2. Temperature Balance.
Filter Exhaust, F = Mill Air, M + In-leaks, L
Therefore M = 55,000 * (347-288)/(391-288) = 31,500 m
3
/hr
TECHNICAL INFORMATION TIS MS011
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 150
MILL EXHAUST DEW POINT DEW-POINT TEMPERATURE ESTIMATION
EXAMPLE:
Water Input: T/hr Moisture % Water T/hr
Clinker 118.5 0 0
Gypsum 3.4 5 0.17
Other (e.g. limestone) 3.9 4 0.16
Water Injection 1.22 100 1.22
Air(1) 25 1 0.25
Gypsum Dehydration 0.61
Total 2.41
(1) Airflow assumed to be 0.2kg/kg cement, i.e. 25,000kg/hr.
Assumed to be 70% relative humidity and 20oc, humidity = 0.01
Humidity of Mill exhaust air = 2.41/25 = 0.096
From diagram the dew-point temperature = 53C
TECHNICAL INFORMATION TIS MS012
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 151
CIRCULATING LOAD
EXAMPLE 1, Sieve residues:
a = 47%, f = 4%, r = 65%
Therefore A/F = (4 - 65)/(47 65) = 339%
EXAMPLE 2, Blaine SSA balance:
A = 150, F = 50, R = 100 and f = 350, r = 200, a = ?
a = (Ff + Rr)/A = (50*350 + 100*200)/150 = 250
TECHNICAL INFORMATION TIS MS013
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 152
CEMENT GRINDABILITY
AVERAGE GRINDABILITY CURVE. EXAMPLE:
Mill condition A: 66.4 t/hr at 370m
2
/kg
Mill condition B: 69.7 t/hr at 355m
2
/kg
Comparison of mill performance, i.e. is the reduction in Blaine SSA compatible with the
higher mill output?
Assume constant mill power, say 2200kW
Condition A: kWh/t = 2200/66.4 = 33.13
From graph, the kWh/t at 370 = 45.0
Condition B: kWh/t = 2200/69.7 = 31.56
From graph, the kWh/t at 355 = 41.7
Therefore using the grindability curve a reduction in SSA from 370 to 355 would be
expected to provide a 45.0/41.7 increase in mill output.
Hence expect t/hr to increase from 66.4 to 71.7. Therefore the increase was less
than expected.
TECHNICAL INFORMATION TIS MS014
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 153
SEPARATOR PERFORMANCE
1. Determine the psds for the separator feed, fines and rejects streams (a, f, r) and present as
cumulative finer.
2. Sum each psd. Determine A, F, R.
i.e. A = F + R, A = 100, F = A(a - r)/(f - r)
3. Using the calculated A, F, R, re-calculate the feed psd,
i.e. a = (Ff + Rr)/A at each size interval.
4. Use the measured r and calculated a to derive the Tromp Efficiency at each size interval,
i.e. Rr/Aa * 100%. Plot against the mid interval size.
5. Equiprobable size (effective cut-size) is interpolated at Tromp Efficiency = 50%.
6. Imperfection, I, = (D
75
D
50
) / (2 x D
50
)
7. The By-Pass, S, is the minimum Grade Efficiency.
Coarse Grade Efficiency Tromp Curve
Sum a = 668.1
Sum f = 814.4
Sum r = 517.2
A = 100
F = 50.8
R = 49.2
Circulating Load (A/F) = 197%
Equiprobable Size = 35 microns
Imperfection = 0.32
By-Pass = 19%
TECHNICAL INFORMATION TIS MS015
contents chapter 12
C E M E N T T E C H N O L O G Y N O T E S 2 0 0 5 154
AIR SETTING TENDENCY
1. The air setting tendency of cement is strongly influenced by the presence of free lime
and K
2
O
2. Higher levels of K
2
O with gypsum and moisture can form SYNGENITE, which can lead to
the formation of lumps in silos
3. Higher levels of free lime tend to act as a desiccant and thus can mitigate the problems of
air setting
4. Air set propensity can be assessed by exposing a sample of cement to storage in closed bags
at 27C, 95% RH at 4psi in a humidity cabinet for 3 days. The % retained at 600 microns is
then determined. This then represents the AIR SET TENDENCY.
TECHNICAL INFORMATION TIS MS016
contents chapter 12