RAW MATERIALS CALCULATIONS

For 5000 t/day Clinker the Calculation of Raw Materials will be as follow:
Total Annual Clinker production

Ton/Day
5000

Ton/Year
5000 x 330 (day) = 1,650,000

Total Annual Raw Meal

Ton/Day

Ton/Year

based (on clinker factor = 0.60)

(5000 / 0.6) = 8335

1,650,000 / 0.6 = 2,750,000

Total Annual Raw Materials

Ton/Day
8335 x 0.92 x 1.1 = 8435

Ton/Year
2,750,000 x 1.1 x 0.92 = 2,783,000

Ton/Day
8435 x 0.7584 = 6397

Ton/Year
6397 x 330 = 2,111,010

Ton/Day
8435 x 0.2047 = 1730

Ton/Year
1730 x 330 = 570,900

based on convex factor = 0.92

Total Annual Limestone

Based on Raw Mix calculation (75.84%)

Total Annual Clay

Based on Raw Mix calculation (20.47 %)

Conclusion
The limestone required for (50 years operation) = 2,111,010 x 50 = 105,550,500 tons
Each quarry equal 5000 m2
According to the calculations, for limestone for 50 years in case we will use depth 50 m:
Each quarry = 5000 x 50 x 1.4 = 350,000 tons
The Limestone quarries required = 105,550,500 / 350,000 = 302 quarries/50 years
The Limestone quarries required = 2,111,010 / 350,000 = 6.0 quarries/ year
The Clay required for (5 years) = 570,900 x 5 = 2,854,500 tons/5years

Ahmed Mahmoud