The Alite Group Heating

Temp F 212 212 572 752 1652 932 1112 1652 >1472 >2282 2642

Providing effective training for Operator Certification. Heating

Temp C 100 100 300 400 900 500 600-900 >800 >1250 1450

Reactions inside the kiln

Evaporation of H2O Loss of physically adsorbed water Removal of structural H2O (H2O and OH groups) from clay minerals Structural changes in silicate minerals Dissociation of carbonates (calcination) Formation of belite, intermediate products, aluminate and ferrite Formation of liquid phase (aluminate and ferrite melt) Completion of reaction and growth of alite and belite Crystallization of liquid phase into mainly aluminate and ferrite

Cooling
2372 2264

Cooling
1300-1240

BOGUES POTENTIAL COMPOSITION

(AR > 0.64) C3 S C2 S or C2S C3 A C4AF = = = = = 4.071 2.867 (8.61 2.650 3.040 C ((7.6 S) + (6.718 A) + (1.43 F) + (2.852 S)) S (0.754 C3S) S + 5.07 A + 1.08 F) 3.07 C A (1.692 F) (Limited to < 8.0% in ASTM Type II ) F

Typical % for Type I / GU

( 48 65 ) ( 10 30 ) ( 5 15 ) ( 5 12 ) 2600F 2700F 2610F 2662F 28 30 1425C - 1782C 1432C 1461C

REQUIRED BURNING TEMPERATURE (RBTF) RBT = 2340 + 8.12C3S (6.73C3A + 22.75C4AF + 32) COATING TENDENCY (AW)
(AR> 0.64)

Typical (RBT)Range Type I-II Type IL Typical (AW) Range

AW = C3A + C4AF + 0.2 C2S > 30 too much coating, rings, snowman, Soft Burning Mix < 28 less coating, stable coating
Pg 1 mike.singleton@alitegroup.com

Prepared for IEE by: The Alite Group

The Alite Group

Providing effective training for Operator Certification.

AR

Kiln Coating Behavior

very thin coating dusty clinker (little of viscous melt phase)

thick coating clinker ball or sinter ring formation - 1.9 (plenty of viscous melt phase)

- 1.6
thin coating

NORMAL COATING
thin coating (little of fluid melt phase)

- 1.3 refractory attack

(plenty of fluid melt phase)

2.2
Recommended Targets for Product Uniformity Kiln Feed (or Clinker) LSF SM AR Typical values for the key Moduli 96 2.55 1.6

2.5

2.8

SM

Acceptable Recommended Standard Deviation in Standard Deviation in Short term Long Term Hourly Samples Daily values 24 Hour period over one month <1.2 <1.0 <0.04 <0.03 <0.04 <0.03 Out of the Mill <4.0 <3.0
Acceptable Standard Deviation = 0.04 Typical (AR)Range = 1.4 1.8 Type I-II = 1.65 Type IL = 1.95 Acceptable Standard Deviation = 0.04 Typical (SR) Range = 2 3 Type I-II = 2.55 Type IL = 2.50

Raw Meal LSF

No pre-blending With pre-blending

ALUMINA TO IRON RATIO (AR) >2.5 viscous clinker melt, high early strength, high heat of Al O hydration AR = 2 3 < 1.3 less viscous (wetter) brick infiltration, coating Fe2O3
washing, low early strength

SILICA RATIO Modulus (SR) (SM) >3 hard-to-burn clinker, scarce / thin coating, high thermal SiO2 SR = loading, dusty clinker, high early strength Al2O3 + Fe2O3 < 2 excess & unstable coating, brick fluxing, clinker
balling, snowman and ring formation

LIME SATURATION FACTOR-(LSF)-Clinker Basis

If the MgO is below 2%

LSF = 100(CaO + 0.75MgO) (2.85SiO2 ) + (1.18 Al 2 0 3 ) + (0.65 Fe2 O3 )

If the MgO is above 2%

LSF = 100(CaO + 1.5MgO) (2.85SiO2 ) + (1.18 Al 2 0 3 ) + (0.65 Fe 2 O3 )
Acceptable Standard Deviation = 1.2 Typical (LSF) Range 94 98, Type I-II = 95.9 Type IL = 92.6

> 98 hard-to-burn, high free lime & C3S higher early strength, higher fuel consumption. < 90 easy to burn, excess coating, excess liquid phase, possible brick infiltration, reduced cement strength, low free lime.

Prepared for IEE by: The Alite Group

Pg 2

mike.singleton@alitegroup.com