Tics of Cement

Not to be copied in any form or distributed or resold
Property of:
Softideas Pvt. Ltd., 5- Sinbai Niwas, Gokhale
Model Colony, Pune-411016
Chapter 5 Raw meal
Chapter 6 Pre heating
Chapter 7 Clinkerisation
Chapter 8 Clinker cooling
Chapter 9 Cement grinding
Chapter 10 Cement storage
Chapter 11 Cement despatch
Chapter 12 Cement quality check
Chapter 13 Raw materials
Chapter 14 Cement properties
Book II - Process Calculations of Support Systems
MathCement2000
Introduction
File Name :TOC_friedrich_v8
Topic: Table of Contents
To go to cover page please click here
About using Mathcad Electronic Books
Read me
Property of:
Softideas Pvt. Ltd., 5- Sinbai Niwas, Gokhale Nagar Road,
About MathCement2000
Preface to the first edition
Book I - Process Calculations of Plant Sections
Chapter
1
Quarry
Chapter 2 Crushing
Chapter 3 Pre blending
Chapter 4 Raw grinding
Useful Tables - Earth Sciences
Chapter 3 Useful Tables - Areas and Perimeters
Chapter 4 Useful Tables - Volumes and Surfaces
Book IV - Popups
Chapter 1 Cement Chemistry
Chapter 2 Cement Glossary
Chapter 3 Cement Kiln Types
Chapter 4 Cement Properties
Chapter 5 Cement Quality Tests
Chapter 6 Pressure
Chapter 7 Psychrometry
Chapter 8 General Topics
Chapter 1 Site Conditions
Chapter 2 Dedusting Systems
Chapter 3 Laboratory Investigations
Chapter 4 Fuels and Fuel Systems
Chapter 5 Conveying Systems
Chapter 6 Fans and Blowers
Chapter 7 Raw-mix Design
Chapter 8 Plant Water
Chapter 9 Insulation
Book III - Useful Tables "Copyright 1999 by MathSoft, Inc. Reprinted by
permission of MathSoft, Inc."
Chapter 1 Useful Tables - Basic Sciences
Chapter 2
Book V - Charts and Tables
Chapter 1 Steam Tables
Chapter 2 Humidity Chart
Chapter 3 Separation Degree
Chapter 4 Coal Reactivity
Chapter 5 Conversion Tables
Chapter 6 Fineness
Property of:
MathCement 2000
Introduction
File Name : Intro_2_v8
Topic: About Using Mathcad Electronic Books
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We welcome your valuable comments which will help us to continuously improve this book
in future.
The book is open to accept limited number of advertisement for future editions. Please
contact us for details.
We apologise to any one whose name has not been mentioned by oversight.
We also gratefully acknowledge encouragement and advices given to us by many
people from the Cement Industry and particularly Mr. P.B.Kulakarni, Mr. M.M.Hirpara of
Gujarat Ambuja Cements Ltd., Mr. Sunil S. Potdar of Gammametrics India,
Mr.I.C.Ahuja of ACC
We gratefully acknowledge encouragement and support provided to us by senior
officials in ACC, notably by Dr. A.K.Chatterjee, Mr. T.N.Tiwari, Mr.R.Vasudevan, Mr. R.
Sachan, Mr. Umesh Pratap and many others.
We acknowledge references to various books,literature,journals for source materials and
some of them are:
Cement Engineers Handbook by Otto Labahn and B.Kolhaas
Cement Data Book by W.H.Duda
Industrielle Waermetechnik by J.Stepanek
Process Technology of Cement Manufacturing by VDZ
Mathcad ,Electronic Handbook, Electronic Book are registered trademarks of Mathsoft
Inc., Cambridge, USA.
MathCement 2000 is trademark of Softideas Pvt. Ltd.
This book has an Identification code : MC2000-sample-1 and should not be copied and
distributed .
MathCement 2000 is an intellectual property, conceptualised, developed and produced
by collective efforts of members of Softideas Pvt. Ltd, Pune, India.
All other highlight colours are for special attention
Input variables have yellow highlighted background Important Colour Codes :
I D: MC2000-sample-1
Topic: Read me
Introduction
MathCement 2000
MathCement 2000
Introduction
Topic: About MathCement 2000
What is MathCement 2000 ?
Hello! welcome to the world of Mathematics of Cement -that's
what MathCement 2000 all about.It is the first time that such a
book, using live math, is presented to the Cement industry.The
first edition is being taken out in the year 2000.
This book is a mathematical walk through -Mathematics of
Cement.
The purpose:
To present a ready reconner to the cement engineers for
their day to day calculations.
To remove the drudgery of repeatitive calculations.
Freedom from dependency on a computer programmer.
To provide ready to ready to use sets of calculations for
various aspects fo plant design and operations.Just
change the input data to suit your specific problems and
you have the step by step detailed calculations in seconds.
It's self documentingand therefore easy for scrutiny by third
party for checking and certification.
MathCement 2000
Introduction
Topic: Preface to the First Edition
I D: MC2000-sample-1
Preface to the First Edition
MathCement 2000 is an intellectual property, conceptualised, developed and produced
by collective efforts of members of Softideas Pvt. Ltd., Pune, India. With the advances in
Technology, electronic documentation is becoming more and more popular in many
industry segments. We in Softideas realised the need for an Electronic Handbook for
cement engineers in the plants. Mathcad from Mathsoft Inc. provides an ideal platform for
such a development specially with its feature of Live Maths.
With Live Maths feature , calculations can be presented using normal mathematical
notations and programme is generated by Mathcad automatically in the background.
We, at Softideas also realised that the engineers are normally busy with day to day
production related problems in the plants, and it is not practical to expect them to
research and develop such a book. What was needed was that somebody developed it
for them in the final usable form. That's what we have done.
We know that there are plenty of scope for improvement and we expect users feed back
to enable us come up with more comprehensive and improved design of this book.
Bahar Tepan
Director, Softideas Pvt. Ltd.,
Saumitra Pal
Director, Softideas Pvt. Ltd.,
Pune : 1st. August, 2001
Book-I Chapter 1
Quarry Section
File Name : 1_1_quarry
Topic: Expanded Table Of Contents
1_1_quarry_1 Quarry Deposit Estimation
1_1_quarry_2 Quarry - Excavator
1_1_quarry_3 Quarry Dumper Calculations
% C
L2
15 : C
L2
Limestone component (Gr. 2)
% C
L1
70 : C
L1
Limestone component (Gr. 1)
(Insert appropriate values to suit your plant condition so that total of all
components is 100%)
Raw material components
Step :-2
To find deposits required for individual components
Tonnes D
q
4.752 10
7

D
q
L T
rd
Q
d
K
1
:
D
q
Total deposits of Raw material
Calculation
days T
rd
330 :
Book-I Chapter 1
Quarry Section
File Name : 1_1_quarry_1
Topic: Quarry Deposit Estimation
Estimation of raw material deposits in terms of no. of years of plant operation.
For a Cement Plant, life cycle is an important cosideration for plant design. It is
customary to expect the plant to be operative for 30 years or more with maximum design
capacity utilisation for clinker production. Estimation of raw material deposits required,
can be done in 2 steps as elaborated below.
Step :-1
To find total deposits required for raw material having different components
Q
d
Plant Capacity in terms of Clinker production Q
d
3000 : Tonnes/day
K
1
Factor for converting Clinker to Raw meal K
1
1.6 :
L Plant life time expected L 30 : Years
T
rd
Plant running days in a year
Tonnes D
qL5
2.376 10
6

D
qL5
D
q
C
L5
100
:
D
qL5
Quarry deposit for Other Component
Other Component (example only - please note you have to use only as many
components as applicable for your plant totalling 100% )
Tonnes D
qL4
2.376 10
6

D
qL4
D
q
C
L4
100
:
D
qL4
Quarry deposit for Clay
Tonnes D
qL3
2.376 10
6

D
qL3
D
q
C
L3
100
:
D
qL3
Quarry deposit for Laterite
Tonnes D
qL2
7.128 10
6

D
qL2
D
q
C
L2
100
:
D
qL2
Quarry deposit for Limestone Gr.2
Tonnes D
qL1
3.326 10
7

D
qL1
D
q
C
L1
100
:
D
qL1
Quarry deposit for Limestone Gr.1
Calculation :
% C
L5
5 : C
L5
Other Component
% C
L4
5 : C
L4
Clay Component
% C
L3
5 : C
L3
Laterite Component
m3 V
d
125
V
d
H
v
N
d
:
Vd
Maximum capacity of Dumpers
m3 H
v
250
H
v
Q
cr
H
t
BD
LS
60
:
H
v
Hopper capacity -( volumetric)
Calculation
N
d
2 : N
d
Number of Dumpers
minutes H
t
15 : H
t
Hopper to hold material equivalent
to crusher feed in terms of
minutes
Tonnes/m3 BD
LS
1.2 : BD
LS
Bulk density of Stone (limestone)
Tonnes/Hr Q
cr
1200 : Q
cr
Crusher capacity
To find Dumper volumetric capacity
Step :-4 Check availability of Standard capacity Dumper close to the
calculated value
Step :-3 Determine maximum Dumper capacity. Feed hopper to
receive minimum 2 Dumper loads
Step :-2 Determine feed hopper capacity (volumetric)
Step :-1 Determine crusher capacity
Following steps can be followed to estimate the no. of dumpers required and their capacity.
Estimation of Number of Dumpers and Capacity.
Topic: Quarry Dumper Calculations
File Name : 1_1_quarry_3
Quarry Section
Book-I Chapter 1
Book-I Chapter 2
Crushing Section
File Name : 1_2_crushing
1_2_crushing_1 Crusher and Auxiliaries Calculations
K
1
1.6 :
C
L
Total Limestone component as percentage
of Raw mix =
C
L
85 : %
T
crw
Number of days Crusher runs in a week T
crw
6 : Days /Week
T
hd
Number of hours the crusher system has to run per
day

T
hd
12 : Hours/ Day
H
t
Hopper to hold material equivalent to crusher
feed in terms of minutes
H
t
15 : minutes
Calculations
Q
cr
Crusher capacity
RM
w
Raw material required per week

RM
w
Q
dk
K
1
7 :
RM
w
5.04 10
4
Tonnes/Week
Book-I Chapter 2
Crushing Section
File Name : 1_2_crushing_1
Topic: Crusher and Auxiliaries Calculations
Calculation of Crusher Capacity for Raw material (Limestone)
To calculate the capacity of crusher following steps can be followed .
Step :- 1 Determine Kiln capacity
Step :-2 Determine weekly requirement of crushed Limestone material
Step :-3 Determine number of days Crusher has to run per week
Step :-4 Determine number of hours the crusher system has to run per day
Q
dk
Kiln Capacity of Clinker Q
dk
4500 : Tonnes /
Day
BD
LS

BD
LS
1.2 : Tonnes./m3
K
1
Factor for converting Clinker to Raw meal
T
T
Hr
Q
crf
714
Q
crf
K
2
Q
cr
:
K
2
1.2 : Over capacity factor K
2
Q
cr
595 : Crusher Capacity =Q
cr
T/Hr
Feeder capacity Q
crf
T/Hr.
Capacity of Crusher feeding devices e.g Apron Feeder, Vibrating Screen etc
should have 20 to 30% over capacity.
Feeder for Crusher
m3 H
v
123.958
H
v
Q
cr
H
t
BD
LS
60
:
H
v
Crusher Hopper capacity -( volumetric)
Tonnes / Hrs Q
cr
595
Q
cr
LS
w
T
crw
T
hd
:
Q
cr
Crusher Capacity required

Tonnes/Week LS
w
4.284 10
4

LS
w
C
L
RM
w
100
:
LS
w
Limestone required per week
Feeder capacity Q
crf
T/Hr. Q
crf
714
T
Hr
Transportation from crusher
Crusher should be followed by a Plate conveyor or Impact conveyor of short
length.
This may be followed by Weigh Belt Scale to check crusher output.This is
followed by Belt Conveyor transporting crushed material to the Mix Bed or Raw
Mill Hopper as the case may be.
The capacity of these Transport devices should be having 50% over capacity
(over crusher capacity) This is in view of flushing from Crusher when a big stone is
crushed resulting in rush of material.
Capacity of Transporting equipment after crusher upto Mix Bed including Stacker
is given by Q
tcro
T/Hr
Q
tcro
1.5 Q
cr
:
Q
tcro
892.5
T
Hr
Book-I Chapter 3
Preblending Section
File Name : 1_3_preblending
1_3_preblending_1 Preblending and Stockpile Equipment Calculations
C
L
85 := %
Q
cr
Crusher capacity Q
cr
565 := Tonnes/ Hr
RM
d
Number of days of Raw Material stock required RM
d
7 :=
Calculation
Q
sp
Stock pile capacity in Tonnes.
RM
w
Raw material required per week
RM
w
Q
dk
K
1
7 :=
RM
w
5.04 10
4
= Tonnes/Week
LS
w
Limestone required per week
LS
w
C
L
RM
w
100
:=
LS
w
4.284 10
4
= Tonnes/Week
Book-I Chapter 3
Preblending Section
File Name :
1_3_preblending_1
Topic: Preblending and Stockpile Equipment - Calculations
Calculation of Stockpile Capacity for Raw material (Limestone)
To calculate the capacity of stockpile following steps can be followed.
Step :- 1 Determine Kiln capacity
Step :- 2 Determine weekly requirement of crushed Limestone material
Q
dk
Kiln Capacity of Clinker Q
dk
4500 := Tonnes /
Day
BD
LS

BD
LS
1.2 := Tonnes./m3
K
1
Factor for converting Clinker to Raw meal K
1
1.6 :=
C
L
Total Limestone component as percentage
of Raw mix

Q
sp
Stock pile capacity in

Tonnes -Live Capacity
Q
sp
Q
dk
K
1
RM
d
:=
Q
sp
5.04 10
4
= Tonnes
Q
stacker
Stacker Capacity

Q
stacker
1.5 Q
cr
:=
Q
stacker
847.5 = Tonnes/Hr
Stacker / Stacker Belt Capacity = Q
stacker
847.5 = Tonnes/Hr
Calculation of Ball Mill Percentage Filling as per
Measurement
1_4_rawgrinding_7 Calculation of Grinding Ball Size
1_4_rawgrinding_8 Specific Heat of Raw Material as a Function of
Temperature
1_4_rawgrinding_9 Estimation of grindability based on the operating
parameters of Mill
1_4_rawgrinding_10 Calculation of Mill Output at Different Fineness of Product
1_4_rawgrinding_11 Calculation of Efficiency of Dynamic Air Separator
1_4_rawgrinding_12 Average Piece Weight ofGrinding Media
1_4_rawgrinding_13 Ball Mill Critical Speed and Ball Charge Calculations
1_4_rawgrinding_14 Verical Roller Mill -- Calculation of Power
Book-I Chapter 4
Raw Grinding Section
File Name : 1_4_rawgrinding
1_4_rawgrinding_1 Bond Work Index of the various material based on
bond test mill result dry basis
1_4_rawgrinding_2 Calculation of power at Ball Mill shaft for Raw material ,
based on the Bond's work index
1_4_rawgrinding_3 Raw Mill and Auxiliary Equipment Capacity Calculations
1_4_rawgrinding_4 Raw Material Drying - Estimation ofTotal Moisture to be
Evaporated from Feed
1_4_rawgrinding_5 Raw Mill Heat Balance - Evaluation of Hot Gas
Requirement for Drying
1_4_rawgrinding_6
1_4_rawgrinding_15n Radiation Loss in Raw Mill Heat Balance
Property of:
kwh/sh.t ( dry basis ) W
s
11.261
kwh/sh.t ( dry basis ) W
s
44.5
S
c
0.23
P
r
0.82
10
P
f
10
F
f
:
W
s
Bond index , kwh/sh.t dry basis
Calculation
P
r
1.36 : P
r
Finished product per mill revolution , gm / rev
S
c
90 : S
c
Screen size , ( Normally 90 size ) ,
F
f
2500 : F
f
Feed size to test mill ( 80 % passing - Range 0-4 mm ) ,
P
f
60 : P
f
Product fineness test result ( 80 % Passing - Range > 90 ) ,
The Bond index of various material based on the Dry basis -
Bond test mill result is calculated as given below.
Topic: Bond Work Index of the various material based on bond test mill result
dry basis
File Name : 1_4_rawgrinding_1
Book-I Chapter 4
M
f
8 : %
M
p
Total product moisture)surface) M
p
2 : %
F
s
Specific heat of raw material F
s
0.21 : kcal/kg.deg.c
F
a
False air percentage F
a
10 : %
P Absorbed mill power P 3000 : kw
Eg Amount of dedusting gases Eg 150000 : m
3
/hr
Eg
t
Dedusting gases temperature Eg
t
105 : deg.c
Eg
s
Specific heat of dedusting gases Eg
s
0.31 : kcal/Nm
3
.deg.c
R
a
Surface area for Radiation Losses R
a
185 : m2
R
f
Radiation Loss R
f
50 : kcal/m
2
.deg.c
difference
Book-I Chapter 4
Topic: Raw Mill Heat Balance - Evaluation of Hot Gas Requirement for Drying
Hot gases required for drying of material in raw grinding in ball mill
The hot gases required for the drying of the feed moisture in the raw material while
grinding in close circuit ball mill is calculated as below.
Gh
t
Hot gases temperature ,

Gh
t
280 : deg.c
Gh
s
Specific heat of hot gases Gh
s
0.34 : kcal/deg.c-Nm
3
R
t
Base temperature R
t
20 : deg.c
Amb Ambient air temperature Amb 35 : deg.c
Amb
s
Specific heat of ambient air Amb
s
0.30 : kcal/Nm
3
.deg.c
Alt Altitude ( From mean sea level ) Alt 950 : m
Fq Fresh feed quantity Fq 100 : tph
M
f
Total fresh feed moisture(surface)
Note :The latent heat of evaporation of water is 540 kcal/kg of water.
Kcal/hr Ho
w
3.978 10
6

Kcal/hr Ho
w
W 540 Eg
t
+ Amb ( ) :
kg/hr W 6522
kg/hr W
Fq 1000 M
f
M
p
( )
100 M
f
:
Moisture to be evaporated
Step :-4 Heat loss to evaporate moisture
Kcal/hr Ho
r
7.862 10
5

Kcal/hr Ho
r
R
a
R
f
Eg
t
R
t
( ) :
Step :-3 Heat loss due to radiation
Kcal/hr Ho
g
2.855 10
6

Kcal/hr Ho
g
Eg Eg
s
Eg
t
R
t
( )
273
Eg
t
273 +
,
:
Step :-2 Heat to dedusting gases
Note :The raw material temp. is normally less by 5 deg.c. than the exit gas temperature.
Kcal/hr Ho
p
1.68 10
6

Kcal/hr Ho
p
Fq 1000 F
s
Eg
t
R
t
5 ( ) :
Step :-1 Heat to raw material
Heat output :
Gh Required hot gas quantity ( Nm
3
/hr )
RG Circulating air ( Nm
3
/hr )
Calculations
Note :If the heat input is less than the heat output then only we require hot gases.
Kcal/hr Hi 2.83 10
6

Kcal/hr Hi Hi
f
Hi
p
+ Hi
a
+ :
Total heat input
Kcal/hr Hi
a
6.75 10
4

Kcal/hr Hi
a
Eg F
a
Amb
s
Amb R
t
( )
100
:
Step :-3 Heat from false air
Kcal/hr Hi
p
2.448 10
6

Kcal/hr Hi
p
P 816 :
Step :-2 Heat from grinding power
Kcal/hr Hi
f
3.15 10
5

Kcal/hr Hi
f
Fq 1000 F
s
Amb R
t
( ) :
Step :-1 Heat from fresh feed
Heat inputs :
Kcal/hr Ho 9.682 10
6

Kcal/hr Ho Ho
p
Ho
g
+ Ho
r
+ Ho
w
+ Ho
a
+ :
Total heat loss
Kcal/hr Ho
a
3.825 10
5

Kcal/hr Ho
a
Eg F
a
Amb
s
Eg
t
R
t
( )
100
:
Step :-5 Heat loss to false air
Nm
3
/hr Gh 77501
Amount of hot gases required for Drying :
Nm
3
/hr RG 7745
Nm
3
/hr RG if Mg Gh Mg Gh , 0 , ( ) :
Amount of recirculation gases :
Note "O.K."
Note if Mg Gh "O.K." , "Change the hot gases temp. or the dedusting gases quantity" , ( ) :
Nm
3
/hr Gh 77501
Nm
3
/hr Mg 85246
Nm
3
/hr Mg Eg
273
Eg
t
273 +
1
1
]
1.24 W
F
a
100
Eg
1
1
]
:
Note :If the dedusting gases quantity is less than the hot gases required then either
increase the hot gases temperature or increase the dedusting gases amount and run the
heat balance again.
Nm
3
/hr Gh 77501
Nm
3
/hr Gh if Hi Ho < Gh , 0 , ( ) :
Nm
3
/hr Gh 7.75 10
4

Nm
3
/hr Gh root Ho Hi Gh Gh
s
Gh
t
R
t
( ) +
1
]
1
]
Gh ,
1
]
:
Nm
3
/hr Gh 0 :
Let us solve for hot gases requirement.
radians 6.283
radians 2acos
H r
r
,
:
Percentage filling :
m r 2
m r
Di
2
:
r Radius inside lining
F Percentage filling of grinding media
Calculations

h
H
r
Di
H - Em pty height inside li ners in m
a
C.G o f Charge

h
H
r
Di
H - Em pty height inside li ners in m
a
C.G o f Charge
m H 0 : H Empty measured height
m Di 4 : Di Mill inside diameter
To calculate the percentage of grinding media filling in the ball mill
based on the empty measured height is as below.
Topic: Calculation of Ball Mill Percentage Filling as per Measurement
File Name : 1_4_rawgrinding_6r1
Book-I Chapter 4
F
1
2
r
2
r H r ( ) sin

2
1
1
]
100
r
2
:
F 100 %
Notes :
The filling ratio for close circuit ball mill is in the range of 26-32 %
The filling ratio for open circuit ball mill is in the range of 26-32 %
For single chamber ball mill the filling ratio is in the range of 24-28 %
C
f
2.2
C
f
100
E
f
,
P
b
F
b
:
Circulation factor :
% E
f
57.1
% E
f
P
b
F
b
F
b
C
b
P
b
C
b
,
100 :
Separator efficiency :
C
f
Circulation Factor
E
f
Separator Efficiency in %
Calculations :
% C
b
55 : C
b
Separator coarse passing
% P
b
88 : P
b
Separator product passing
%
percent material
below cut size
F
b
70 : F
b
Separator feed passing
microns S 90 : S Partical cut off size
Calculation method of separator circulation factor and the separator efficiency based on
the percentage passing of feed, product and coarse at a perticular partical cut off size are
as given below.
Topic: Calculation of Efficiency of Dynamic Air Separator
Book-I Chapter 4
GII
i
Grinding media loading , ton
BI
i
Ball size , mm
S
I
Specific surface , m2/ton
GII
j
23.9
27.1
32.3
20.8
0
: BII
j
60
50
40
30
25
:
W
I
Average peice weight , gm/peice
j 0 4 .. :
Chamber - II
GI
i
Grinding media loading , ton
BI
i
Ball size , mm
S
I
Specific surface , m2/ton
GI
i
32.5
29.0
26.5
23.9
16.4
0
0
0
: BI
i
100
90
80
70
60
50
40
30
: W
I
Average peice weight , gm/peice
i 0 7 .. :
Chamber - I
The average peice weight of the grinding media is calculated as given
below.
Topic: Average Piece Weight ofGrinding Media
Book-I Chapter 4
Calculations
Peice weight of each ball : Surface area of each ball :
m
2
WI
i
2
BI
1000
,
3
12
1
1
1
1
]
7.8 1000 : kg/peice SI
i
2
BI
1000
,
2
1
1
1
1
]
:
kg/peice m
2
WI
i
4.084
2.977
2.091
1.401
0.882
0.511
0.261
0.11
,
SI
i
7.854 10
3
6.362 10
3
5.027 10
3
3.848 10
3
2.827 10
3
1.963 10
3
1.257 10
3
7.069 10
4
Book-I Chapter 5
Raw Meal Section
File Name : 1_5_rawmeal
1_5_rawmeal_1 Calculation of Blending &Storage Silos and Auxiliary
EquipmentCapacity for Raw-meal Preparation
1_5_rawmeal_2 Calculation of Kiln Feed Raw-meal Systems
1_5_rawmeal_3n Calculation of Kiln Feed Raw-meal Quantity
Property of:
Book-I Chapter 6
Preheating Section
File Name : 1_6_preheating
No files here currently
1_7_clinkerisation_8n Kiln Capacity check
1_7_clinkerisation_9n Degree of Decarbonation of Raw Meal -Definition
1_7_clinkerisation_10n Degree of Decarbonation of Raw Meal Calculation on
Operating Data
1_7_clinkerisation_11n Reaction Enthalpy -Decarbonation and Clinkerisation
1_7_clinkerisation_12n Theoretical Heat of Clinker Formation - Calculation
1_7_clinkerisation_13n Calculation of Kiln Weight under Operating Conditions
1_7_clinkerisation_14n Calculation of Kiln Torque under Operating Conditions
1_7_clinkerisation_15n Calculation for Kiln Hydraulic Thruster
1_7_clinkerisation_16n Kiln Hydraulic Thruster - A Note
1_7_clinkerisation_17n Kiln Drive Specification
Book-I Chapter 7
Clinkerisation Section
File Name :
1_7_clinkerisation
1_7_clinkerisation_1 Calculation of Kiln and Auxiliary Equipment Capacities
1_7_clinkerisation_2 Leakages Through Kiln Air Seal
1_7_clinkerisation_3 Calculation of Specific Heats of Clinker as a Function of
Clinker Temperature
1_7_clinkerisation_4 Kiln Retention Time and Related Parameters
1_7_clinkerisation_5 Kiln Sinter Zone Cooling Fans
1_7_clinkerisation_6 Kiln Nose Ring Cooling Fans
1_7_clinkerisation_7n Kiln Tyre / Shell Ovality
1_7_clinkerisation_18n Calculation of expansion of Kiln in hot condition
Calculation of Temerature Profile of Kiln Shell in hot
condition
1_7_clinkerisation_19n
1_7_clinkerisation_20n Calcination Function
Property of:
m Y 4.395 : Y Measured min. diameter
m X 4.405 : X Measured max. diameter
m D 4.4 : D Diameter of Tyre
Percentage ovality calculation
Oval shape is in Red
having Major Dia.=X
and Minor Dia. = Y
Perfect Circle is in
Black of Dia.= D
D
Y
X
Ovality of Kiln shell beyond acceptable limit can effect life of Refractory lining in the
Kiln.Kiln shell gets rigidity only after a tyre has been mounted. However, in case of loose
tyre there exists a gap between the shell and the tyre at the top of the shell.The ovality of
the shell , therefore cannot be guaranteed.But it is important to machine the tyres
accurately with maximum ovality inside not to exceed 0.2%
Calculation for ovality of Kiln Tyres / Shells
Topic: Kiln Tyre / Shell Ovality
File Name : 1_7_clinkerisation_7n
Book-I Chapter 7
O
P
Percentage Ovality of Tyre ( % )
O
P
X Y
D
100 : %
%
O
P
0.227
Tyre ovality should be practically zero when machined and maximum 0.2% on load
(after erection)
During operation at a specific temperature the shell expand and fit exactly into the
Tyre and in such a state the shell ovality is then max 0.2% i.e same as that of tyre on
load.
If the ovalityof shell, specially under the tyre section is in the range of 0.4 to0.5%,
then the refractory life is adversely affected.
In the manufacturing workshop the Kiln shell ovality should be measured after fixing
the spider rings. Otherwise the shell becomes oval under its own weight.
If the ovality of fabricated shells show an ovality of more than 0.2% even with the
spiders mounted, it will be difficult to align the shells during erection prior to welding
of the shells at site.This is an important considerationwhy ovality of Kiln shells also
should be kept atminimum possible value.
Book-I Chapter 7
Topic: Kiln Capacity check
Calculation of capacity and loads for a given size of Kiln
Q
K
Kiln Capacity evaluation ( T/Day )
Burner
D meters -Inside shell Dia.
d m et e rs - Insi de r e f re c to ry Di a.
D Inside ( shell ) diameter of the kiln D 4.8 : m
W Refractory thickness W 200 : mm
k.cal /m
2
.hr K
TL
3.946 10
6

k.cal /m
2
.hr K
TL
K
d
2
4
:
d 4.4
m d D 2
W
1000
:
d Kiln diameter on refractory ( m )
k.cal. / hr. K 60 10
6
: K Heat input to Kiln
Kiln thermal load is calculated based on total heat input to kiln on open cross sectional
area.This should normally not exceed. 4.5 million k.cal. /m
2
/hr.but can go upto 6.0
million k.cal. /m
2
/hr.
K
TL
Kiln Thermal Load ( k.cal /m
2
.hr.)
R
LD
14.583
R
LD
L
D
:
R
LD
Kiln L / D ratio
Calculations :
% 3 : Kiln slope ( Range 3.0-4.0 )
deg. 35 : Angle of repose ( Clinker 35 deg. )
rpm N 3.5 : N Kiln speed
m L 70 : L Overall length of the kiln
t / day /m
3
Q
SP
4.607
t / day /m
3
Q
SP
Q
TH
V
i
:
Q
SP
Specific output of kiln ( t / day /m
3
)
Q
TH
4.903 10
3

t / day
t / day Q
TH
F
1
D
3.283
L
0.33
:
F
1
7 : Output factor =F
1
is a function of the type of kiln
For normal preheater kiln F
1
= 3.0
For precalciner kiln F
1
is 7 to 7.5
Q
TH
Theoretical output of Kiln ( t/ day of clinker )
V
i
1.064 10
3

m
3

m
3
V
i

d
2
4
L :
V
i
Kiln volume on refractory (internal volume)( m
3
)
Book-I Chapter 7
Topic: Calculation for Kiln Hydraulic Thruster
For calculation of operating thrust of Kiln it is necessary to first determine the total
operating weight of the kiln . Please refer to file no. 1_7_clinkerisation_13
For a more detailed note on Hydraulic Thruster please refer to file 1_7_clinkerisation_16
KILN
F
TH
W
K
TYRE
THRUST ROLLER
C.L o f KILN
KILN SECTION
W
K
Total operating weight of Kiln W
K
868 : MT
o
Let the slope of Kiln be 2 :
It should be noted that the Thrust Roller on the upper side of the Tyre is to act only as
stopper to prevent the kiln from riding out of the roller during its upward movement.
90.0
63.0
45.0
31.5
17.5 MT
Std. hyd. unit
Thrust rollers are fitted with standard hydraulic thrusting devices of standard ratings.
A typical range is shown below
Normally Thrust Rollers are provided on Pier No. 1 only.However , it is possible to
provide two sets of Thrust Rollers in 1st. and 2nd. piers. Insuch a case the load is
shared equally by each roller.
MT F
TH
30.293
MT F
TH
W
K
cos
90
180

,
:
F
TH
The thrust applied by kiln on its downhill movement due to the slope ( MT )
radian
1
0.035
180
0.035
1
180
:
To convert slope from degree to radian =
1
S
1
represents length upto end of first first section of kiln and S
2
upto end of second
section of kiln and so on
S represents length of cummulative sections of kiln
A
L
T
n
: L
i
L
T
n
: i 1 n .. : n 10 : L
T
70 :
The shell temperatures for the sections are either measured or taken from experience
The kiln is theoretically divided into n equal section - normally 10 sections and is
denoted by A
Where L is kiln length L
T
L = At designed ambient temp.
Let total length of kiln at cold condition be L
T
m
L1
L2
L3
L
KILN
Support - 1 Support - 2
Support -3
S0 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10
Calculation of expansion of Kiln in hot condition
Topic: Calculation of expansion of Kiln in hot condition
Book-I Chapter 7
S
0
0 :
S
i
L
i
S
i 1
+ :
L
0
0
1
2
3
4
5
6
7
8
9
10
0
7
7
7
7
7
7
7
7
7
7
S
0
0
1
2
3
4
5
6
7
8
9
10
0
7
14
21
28
35
42
49
56
63
70
T
205
210
230
250
280
310
310
310
290
270
250
,
:
t
a
0 : ambient temp
co eff. of linear expan = 0.01215 per deg. C
E
i
0.01215 T
i 1
t
a
( ) :
DX represents expansion of kilnsections
E
0
0
1
2
3
4
5
6
7
8
9
10
0
2.491
2.551
2.794
3.037
3.402
3.766
3.766
3.766
3.523
3.28
DX
i
L
i
E
i
: E
1
2.491
L
1
13 : L
2
38 : L
3
58 :
0 10 20 30 40 50 60 70
200
250
300
350
Kiln Shell Temp. Profile
Shell length from feed end - m
S
h
e
l
l

t
e
m
p
e
r
a
t
u
r
e

-
D
e
g
.

C
T
i
S
i
DX
10
22.963 Expansion of sec. 10 DX
5
23.814 Expansion of sec. 5
DX
9
4
DX
8
3
DX
7
2
DX
6
1
Expansion of each section is given by DX
i
in mm
The shell is equally divided into n equal sections (n is fixed at n =10 )
DX
0
0
1
2
3
4
5
6
7
8
9
10
0
17.435
17.86
19.561
21.262
23.814
26.365
26.365
26.365
24.665
22.963
L1
L2
L3
L
KILN
Support - 1 Support - 2
Support -3
S0 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10
0 10 20 30 40 50 60 70
15
20
25
30
Kiln Shell Expansion at each section
Shell lengths from feed end -m
E
x
p
a
n
s
i
o
n

-

m
m
DX
i
S
i
DXL
2
110.14
DXL
2
if SS
2
( )
5 > DXL
23
, if SS
1
4 = DXL
21
, DXL
22
, ( ) ,
1
]
:
DXL
23
DX
1
DX
2
+ DX
3
+ DX
4
+ DX
5
+ DX
6
+ E
SS
2
ML
2
+ :
DXL
22
DX
1
DX
2
+ DX
3
+ DX
4
+ DX
5
+ E
SS
2
ML
2
+ :
DXL
21
DX
1
DX
2
+ DX
3
+ DX
4
+ E
SS
2
ML
2
+ :
ML
2
3 ML
2
mod L
2
A , ( ) :
SS
2
5 SS
2
trunc
L
2
A
,
:
L
2
Full Shell sections upto
DXL
1
32.38
DXL
1
if SS
1
( )
2 > DXL
13
, if SS
1
1 = DXL
11
, DXL
12
, ( ) ,
1
]
:
DXL
13
DX
1
DX
2
+ DX
3
+ E
SS
1
ML
1
+ :
DXL
12
DX
1
DX
2
+ E
SS
1
ML
1
+ :
DXL
11
DX
1
E
SS
1
ML
1
+ :
E
SS
1
ML
1
14.944
ML
1
6 ML
1
mod L
1
A , ( ) :
E
SS
1
2.491
SS
1
1 SS
1
trunc
L
1
A
,
:
A 7
L
1
DXL 226.658 DXL
2
110.14
DXL
3
211.228 DXL
1
32.38
mm DXL 226.658
DXL DX
:
DXL
3
211.228
DXL
3
if SS
3
( )
9 > DXL
33
, if SS
3
7 = DXL
31
, DXL
32
, ( ) ,
1
]
:
DXL
33
DX
1
DX
2
+ DX
3
+ DX
4
+ DX
5
+ DX
6
+ DX
7
+ DX
8
+ DX
9
+ DX
10
+ E
SS
3
ML
3
+ :
DXL
32
DX
1
DX
2
+ DX
3
+ DX
4
+ DX
5
+ DX
6
+ DX
7
+ DX
8
+ DX
9
+ E
SS
3
ML
3
+ :
DXL
31
DX
1
DX
2
+ DX
3
+ DX
4
+ DX
5
+ DX
6
+ DX
7
+ DX
8
+ E
SS
3
ML
3
+ :
DXL
2
110.14
ML
3
2 ML
3
mod L
3
A , ( ) :
SS
3
8 SS
3
trunc
L
3
A
,
:
L
3
Property of:
Calculation of Grate Cooler Offset from Kiln axis 1_8_clinkercooling_5n
Calculation of Grate Cooler Recuperation Efficiency -
T.A.Duct Tapping from Kiln Hood
1_8_clinkercooling_4
Calculation of Grate Cooler Recuperation Efficiency -
T.A.Duct Tapping from Cooler
Calculation of GrateCooler Drive Power 1_8_clinkercooling_2
Calculation of Clinker Transport Equipment Capacity and
Clinker Stockpile
File Name :
1_8_clinkercooling
Clinker Cooling Section
Book-I Chapter 8
mm
N Max. grate speed ( Shaft speed , rpm ) N 22 : strokes/min
Calculations
F Cooler grate total drive force (Kilo Newton)
F G
a
D
f
: KN
KN
F 345
T Torque at ecenctric shaft (KN.m )
T F
S
l
2 1000
: KN.m
T 20.7 KN.m
This torque has to be transmitted by Chain wheel
N Maximum RPM of driven sprocket ( strokes per minute )
Shaft power :
Book-I Chapter 8
Clinker Cooling Section
File Name :
Topic: Calculation of Grate Cooler Drive Power
Grate cooler motor power calculation :
The grate motor power is calculated as below. See Sketch alongside
P
m
Grate motor power P
m
kw
G
a
Grate area G
a
30 : m2
D
f
Specific cooler grate drive force D
f
11.5 : KN/m
2
S
l
Stroke length S
l
120 :
P
s
2 N T
60
: KW
P
s
47.689 KW
Grate motor power :
P
m
1.4 P
s
: KW
P
m
67 KW
Similarly calculate for all grates individually
F
Ecc entr i c
o
Ecc ent r i c Dr i ve
Gear b o x o utput
s1/2
F
Ecc entr i c
o
Ecc ent r i c Dr i ve
Gear b o x o utput
s1/2
Property of:
Expected Power Draw of Cement Mill as a Function of
Speed
1_9_cementgrinding_12n
Cement Mill Grinding Performance as a Function of
Surface Generated
1_9_cementgrinding_11n
Mill Radiation Loss 1_9_cementgrinding_10n
Cement Mill Cooling Air 1_9_cementgrinding_9n
Cement Mill Output at Different Finenesses 1_9_cementgrinding_8n
Sizing of Close Circuit Cement Mill 1_9_cementgrinding_7n
Calculation of Water Spray in the Mill for Cooling 1_9_cementgrinding_6
Estimation of grindability of Clinker based on the operating
parameters
1_9_cementgrinding_5
Calculation of Cement Mill Output as a function of
Grinding Media Load
Cement Mill Heat Balance and Calculation of Hot Gas for
Drying
Calculation of Cement Grindability based on Ziesel Value 1_9_cementgrinding_2
Calculation of Cement Mill and Auxiliary Equipment 1_9_cementgrinding_1
File Name :
1_9_cementgrinding
Cement Grinding Section
Book-I Chapter 9
N 12 : rpm
F Percentage filling F 28 : %
G Grindability , Kwh/ton at 3000 blaine G 30 :
K
f
K factor K
f
9.55 :
Calculations
The blaine correction factor :
B
f
e
P
f
3000
( )
1000
1
1
]
0.49
:
B
f
1.103
The grindability at the required product fineness :
G
f
G B
f
: Kwh/t .
Kwh/t
G
f
33.089
Book-I Chapter 9
File Name : 1_9_cementgrinding_4
Topic: Calculation of Cement Mill Output as a function of Grinding Media Load
Production of the ball mill - Clinker grinding based on Grinding media loading
The theoretical production based on the grindability of the clinker is as given
below.
P
r
Production P
r
tph
P
f
Product fineness P
f
3200 : blaine
Di Ball mill inside diameter Di 4 : m
L Ball mill effective length ( I + II Chamber ) L 14 : m
N Ball mill speed
The grinding media :
G
m
Di
2
L 4.5 F
4 100
: ton
G
m
221.671 ton
The available mill shaft power :
P
G
m
K
f
Di ( )
1.36
: kw
P 3113 kw
The production based on the grindability :
P
r
P
G
f
: tph
P
r
94 tph
tph Cap
new
132
Cap
new
round
Cap
k
0 ,
,
:
k 0.907
k 10
B
2
B
1
1000
0.213
:
Correction factor = k
Cap
new
To find what would be new capacity of mill ( tph )
Calculations :
cm
2
/gm B
2
2800 : B
2
Desired fineness of cement acc. to Blaine
cm
2
/gm B
1
3000 : B1 Present fineness of cement acc. to Blaine
tph Cap 120 : Cap Present Mill output
For an operating mill capacity at a certain fineness is known . Following calculation
method predicts expected outputs at other desired finenesses.
Calculation of Mill output at other finenesses
Topic: Cement Mill Output at Different Finenesses
File Name : 1_9_cementgrinding_8n
Book-I Chapter 9
Book-I Chapter 10
Cement Storage Section
File Name :
1_10_cementstorage
1_10_cementstorage_1 Calculation of Cement Transport and Silo and Auxiliary
Equipment
Property of:
Q
silo
T
d
Q
cm
T
h
( )
VBD
c
:
Q
silo
Silo capacity
Calculation
Tonnes/m
3
VBD
c
1.2 : VBD
c
Bulk density of cement for volume
Hrs T
h
16 : T
h
Mill running hours per day
days T
d
8 : T
d
Capacity in terms of number of days stock
To find capacity of Cement silo
Step :- 2
Tonnes / Hr. Q
tr2
144
Book-I Chapter 10
Cement Storage Section
File Name : 1_10_cementstorage_1
Topic: Calculation of Cement Transport and Silo and Auxiliary Equipment
Many times cement production can be enhanced by grinding coarser than originally
contemplated or by adding Pozzolanic material. Hence it is of great importance to
foresee such possibilities at design stage and design the capacities for maximum
anticipated capacity of the Mill
Step :- 1
To find the capacity of conveyor from Vibrating screen located at discharge of Cement
mill
Transportation of cement from the mill after Vibrating Screen etc.should be designed
for 20 % over capacity w.r.t. mill capacity.
Q
cm
Max Capacity of Cement Mill Q
cm
120 : Tonnes/ hr
F
od
Over design factor F
od
1.2 :
Calculation
Q
tr2
Conveyor capacity
Q
tr2
F
od
Q
cm
:
Q
silo
12800 m
3
Step :- 3
To find capacity of Silo Discharge Apparatus
Q
p
Demand of Packing m/c per hour Q
p
100 : Tonnes/Hr
Over design factor (100 %) F
od
2 :
Calculation
Q
d
Silo Discharge Apparatus Tonnes/Hr
Q
d
F
od
Q
p
:
Q
d
200 T/Hr
Note - There should be always a standby discharge apparatus
Book-I Chapter 11
Cement Despatch Section
File Name :
1_11_cmtdespatch
Currently no files here
Property of:
Kiln Dust Loss in Terms of Kiln Feed Raw Meal-and
Apparant Degree of Calcination
1_12_quality_11n
To Calculate Quantity of CaO Required to Attain Specific
Value of Total Carbonate Content in Kiln Feed Raw Meal-
1_12_quality_10n
1_12_quality_9n
Total Carbonate Content in Kiln Feed Raw Meal-
Calculation
1_12_quality_8n
Percentage Liquid and Burnability Index Cement Clinker -
Calculation
Complex Compounds of Cement Clinker - Calculation by
Bogue's Formulae
1_12_quality_7n
Burnability Factor of Kiln Feed Raw Meal - Calculation 1_12_quality_6n
Hydraulic Ratio of Kiln Feed Raw Meal - Calculation 1_12_quality_5n
Lime Saturation Factor Calculation 1_12_quality_4n
Alumina Ratio and Requirement of Components 1_12_quality_3n
Silica Ratio and Requirement of Components 1_12_quality_2n
Loss on Ignition of Kiln Feed Raw Meal 1_12_quality_1n
Topic: Expanded Table Of Quality Checks
File Name : 1_12_quality_n
Quality Checks
Book-I Chapter 12
LSF
PW
CaO
2.8 PW
SiO2
1.65 PW
Al2O3
+ 0.35 PW
Fe2O3
+
:
To find Lime Saturation Factor ( LSF ) When > 0.64
Condition 1 :-
Check if the figure AR
RM
is > 0.64
AR
RM
1.849
AR
RM
PW
Al2O3
PW
Fe2O3
:
AR
RM
Alumina Ratio of Raw Meal
Calculation
% PW
SiO2
22.3 : PW
SiO2
Percentage of SiO2 in Kiln feed raw meal

% PW
CaO
66.01 : PW
CaO
Percentage of CaO in Kiln feed raw meal
% PW
Al2O3
5.4 : PW
Al2O3
Percentage of Al2O3 in Kiln feed raw meal

% PW
Fe2O3
2.92 : PW
Fe2O3
Percentage of Fe2O3 in Kiln feed raw meal
Analysis on Loss Free Basis
Calculation of Lime Saturation Factor of Kiln feed raw meal ( LSF )
Topic: Lime Saturation Factor - Calculation
File Name : 1_12_quality_4n
Quality Checks
Book-I Chapter 12
Condition 2 :-
To find Lime Saturation Factor = LSF When < 0.64
LSF
PW
CaO
2.8 PW
SiO2
1.1 PW
Al2O3
+ 0.7 PW
Fe2O3
+
:
By using if statement we can evaluate LSF
LSF if AR
RM
0.64 >
PW
CaO
2.8 PW
SiO2
1.65 PW
Al2O3
+
0.35 PW
Fe2O3
+
...
,
PW
CaO
2.8 PW
SiO2
1.1 PW
Al2O3
+
...
,
0.7 PW
Fe2O3
+
...
,
1
1
1
1
1
]
:
LSF 0.912
PW
MgO
Percentage of MgO in Kiln feed raw meal PW
MgO
1.365 : %
PW
Alkalies
Percentage of Alkalies in Kiln feed raw meal

PW
Alkalies
0.413 : %
PW
SO3
Percentage of SO3 in Kiln feed raw meal PW
SO3
0.338 : %
LOI Loss On Ignition LOI 35 : %
Calculation
TC Total Carbonate (Calculated from Analysis on Raw Basis)
TC 1.784 PW
CaO
2.09 PW
MgO
+ :
TC 79.399 %
Note if the analysis is given in Loss Free Basis then multiply by conversion factor
=F
LFtoR
F
LFtoR
100 LOI
100
:
Book-I Chapter 12
Quality Checks
File Name : 1_12_quality_9n
Topic: Total Carbonate Content in Kiln Feed Raw Meal- Calculation
Calculation of Total Carbonate Content in Kiln Feed Raw Meal
Analysis of Kiln Feed Raw Meal on Raw Basis
PW
Fe2O3
Percentage of Fe2O3 in Kiln feed raw meal PW
Fe2O3
1.898 : %
PW
Al2O3
Percentage of Al2O3 in Kiln feed raw meal

PW
Al2O3
3.51 : %
PW
CaO
Percentage of CaO in Kiln feed raw meal PW
CaO
42.907 : %
PW
SiO2

PW
SiO2
14.495 : %
Conditional Calculation
Let us define Analysis Basis as = BASIS
If analysis is on Raw Basis then
If analysis is on Loss Free Basis then
Define BASIS
BASIS 1 :
TC if BASIS 0 > 1.784 PW
CaO
2.09 PW
MgO
+ ( ) , F
LFtoR
1.784 PW
CaO
2.09 PW
MgO
+
...
,
,
1
1
]
:
TC 79.399
Book-I Chapter 13
Raw Materials
File Name :
1_13_rawmaterials_n
Topic: Expanded Table Of Raw Materials
1_13_rawmaterials_1n Raw Materials for Cement Production
Property of:
The final clinker is the product after combustion, during which process, the raw
materials lose gaseous components . Thus the resultant balance material analysis is
reported without possibility of any further loss. This report is termed as loss free
basis.By predicting the anticipated losses , it is possible to report the analysis of raw
material s in Loss Free Basis.
Raw materials as analysed in Laboratory are reported as Raw Basis
Tetracalcium alumino ferrite is represented by C
4
AF
Tricalcium aluminate is represented by C
3
A
Dicalcium silicate is represented by C
2
S
Tricalciun silicate is represented by C
3
S
Complex compounds of Cement are represented by :
Rest components represented by R
Fe
2
O
3
represented by F
Al
2
O
3
represented by A
SiO
2
represented by S
CaO represented by C
The principle oxides that constitute cement clinker are:
Alumina : principal source of Al
2
O
3
Laterite : principal source of Fe
2
O
3
Sand stone : principal source of SiO
2
Clay : principal source of SiO
2

Lime stone : principal source of CaCO
3
and hence CaO
Principle Raw Materials :
Variable Definitions for Raw materials section
Topic: Raw Materials for Cement Production
File Name : 1_13_rawmaterials_1n
Raw Materials
Book-I Chapter 13
F
2
F
3
F
ASH
And So On
LOI [ ] LOI
1
LOI
2
LOI
3
LOI
ASH
When the total of all components including LOI is 100% then the analysis is reported in
Raw Basis
When the total of all components excluding LOI is 100% then the analysis is reported in
Loss Free Basis.
To convert from one basis to another following steps can be followed
Step :- 1 To convert to Loss Free Basis from Raw Basis
O
I
O
R
100 LOI
100 :
O
R
%
Or
Let
F
RtoLF
100
100 LOI
:
LOI
Then
O
1
F
RtoLF
O
R
: F
RtoLF
O
I
represents percentage oxide value in Loss Free Basis
O
R
represents percentage oxide value in Raw Basis
Since the Raw meal is a mix of two or more raw materials, the analysis is indexed to
indicate the belongingness of particular values as follows.
raw material -1 raw material -2 raw material -3 Ash
CaO [ ] C
1
C
2
C
3
C
ASH
SiO
2
[ ] S
1
S
2
S
3
S
ASH
Al
2
O
3
[ ] A
1
A
2
A
3
A
ASH
Fe
2
O
3
[ ] F
1
%
C Percentage of CaO in Kiln feed raw meal C 66.01 : %
S Percentage of SiO2 in Kiln feed raw meal

S 22.3 : %
MGO Percentage of MgO in Kiln feed raw meal MGO 2.1 : %
AL

Percentage of Alkalies in Kiln feed raw meal AL 0.635 : %
REST Percentage of Rest oxides in Kiln feed raw meal REST 3.2 : %
LOI Percentage of Loss On Ignition in Kiln feed raw meal LOI 35 : %
F
LFtoR
100 LOI
100
:
LOI represents percentage lOSS ON IGNITION in Raw Basis
F
RtoLF
is common factor for conversion fron Raw To Loss Free basis
Step :- 2 To convert from Loss Free Basis to Raw Basis
O
R
100 LOI ( ) O
I
100
:
LOI
%
Or
Let
F
LFtoR
100 LOI
100
:
LOI
Then
O
R
F
LFtoR
O
I
: F
LFtoR
O
I
represents percentage oxide value in Loss Free Basis
O
R
represents percentage oxide value in Raw Basis
LOI represents percentage lOSS ON IGNITION in Raw Basis
F
LFtoR
is common factor for conversion fron Raw To Loss Free basis
Analysis on Loss Free Basis
F Percentage of Fe2O3 in Kiln feed raw meal

F 2.92 : %
A Percentage of Al2O3 in Kiln feed raw meal A 5.4 :
REST
R
Percentage of Rest oxides in Kiln feed raw meal REST
R
F
LFtoR
REST : %
F
R
F
LFtoR
F : F
R
1.898
A
R
3.51
A
R
F
LFtoR
A :
C
R
F
LFtoR
C : C
R
42.907
S
R
F
LFtoR
S : S
R
14.495
MGO
R
F
LFtoR
MGO : MGO
R
1.365
AL
R
F
LFtoR
AL : AL
R
0.413
REST
R
F
LFtoR
REST : REST
R
2.08
LOI Percentage of Loss On Ignition in Kiln feed raw meal LOI 35 : %
F
LFtoR
0.65
Analysis on Raw Basis
F
R

Percentage of Fe2O3 in Kiln feed raw meal F
R
F
LFtoR
F : %
A
R
Percentage of Al2O3 in Kiln feed raw meal A
R
F
LFtoR
A : %
C
R
Percentage of CaO in Kiln feed raw meal C
R
F
LFtoR
C : %
S
R

S
R
F
LFtoR
S : %
MGO
R
Percentage of MgO in Kiln feed raw meal MGO
R
F
LFtoR
MGO : %
AL
R
Percentage of Alkalies in Kiln feed raw meal AL
R
F
LFtoR
AL : %
Book-I Chapter 14
Cement
File Name : 1_14_cement_n
Topic: Expanded Table Of Cement
1_14_cement_1n Evaluation of combined water in cement
Property of:
Corresponds to co-efficients when cement is hydrated
for 13 year
a
13
data
2
:
a
6.5
data
1
:
for 6.5 year
for 1 year
a
1
data
0
:
data
0 1 2
0
1
0.23 0.23 0.23
0.17 0.18 0.2
:
Co- efficients are given by the following table ( acc. to Kantro and Copeland)
r a
1
C
3
S [ ] a
2
C
2
S [ ] + a
3
C
3
A [ ] + a
4
C
4
A F [ ] + =
let us call this ratio = r so that
W
C
C
a
1
C
3
S [ ] a
2
C
2
S [ ] + a
3
C
3
A [ ] + a
4
C
4
A F [ ] + =
then W
C
/ C ratio is given by the following formula
Let the quantity of cement be C gms
Let combined water in set and hardened cement be W
C
gm
Water that is held in the pores of the solid paste is free water or capillary water.
The water that is held at the surface of the cement by surface tensionof gel
particles is called adsorbed water or gel water.
After hydration of cement water that is chemically combined with the compounds
and form part of the solid is called combined water.There also exists adsorbed
water and free water .
Topic: Evaluation of Combined Water in Cement
File Name :
1_14_cement_1n
Cement
Book-I Chapter 14
W
C
2.479 gm
W
C
r C :
C 10gm : Let quantity of cement be
This would mean that after 13 years, the cement has combined water of 24.789 %
of its weight .
a
3
0.109 r 24.789 %
a
2
0.522
a
0.23
0.196
0.522
0.109
a
1
0.196
r 0.248
a
0
0.23
r a
0
C
3
S [ ]
100
a
1
C
2
S [ ]
100
+ a
2
C
3
A [ ]
100
+ a
3
C
4
A F [ ]
100
+ :
a if t 1 = a
1
, if t 13 = a
13
, a
6.5
, ( ) , ( ) :
C
4
A F [ ] 9 :
i 0 3 .. :
C
3
A [ ] 13 :
C
2
S [ ] 27 :
C
3
S [ ] 51 : and let cement constituents be in %
t 13 : let the time period of hydration be = t years
Valid for t equal to 1,
6.5 and 13 only
a
13
0.23
0.196
0.522
0.109
,
a
6.5
0.234
0.178
0.504
0.158
,
a
1
0.228
0.168
0.429
0.132
Book-II Chapter 1
Plant Site Condition
File Name :
2_1_sitecondition
2_1_sitecondition_1 The Barometric pressure at site based on the altitude
and temperautre.
Property of:
B
p
635
mm of Hg
mm of Hg B
p
P
273
273 Amb +
,
:
Barametric pressure at ambient temperature
P 716
mm of Hg
mm of Hg P
760
E
f
:
Site pressure at zero deg.c. temperature
E
f
1.061
E
f
1
1 0.0065
Alt
288

,
5.255
:
Elevation factor
Calculations:
deg.c Amb 35 : Amb Ambient temperature
m Alt 500 : Alt Altitude ( Above mean sea level )
mm of Hg B
p
B
p
Barometric pressure
The Baraometric pressure based on the altitude of the site and the ambient temperature is
calculated as given below.
Topic: The Barometric pressure at site based on the altitude and temperautre.
File Name :
2_1_sitecondition_1
Plant Site Condition
Book-II Chapter 1
Property of:
Chimney Design 2_2_dedusting_13n
Electrostatic Precipitator- To calculate Migration Velocity 2_2_dedusting_12n
Electrostatic Precipitator- Performance Evaluation 2_2_dedusting_11n
Electrostatic Precipitator- Specific Collection Area 2_2_dedusting_10n
Electrostatic Precipitator- Deutsch Efficiency Formula 2_2_dedusting_9n
Sizing of Gas Conditioning Tower 2_2_dedusting_8n
GCT and ESP -Calculation of Gas Volume 2_2_dedusting_7
Glass Bag House -Calculation of Gas Volume as Function
of temperature.
Book-II Chapter 2
Dedusting Systems
File Name : 2_2_dedusting
2_2_dedusting_1 Estimation of Vent Air Volume
2_2_dedusting_2_1r K- Factors
2_2_dedusting_3 Calculation of Pressure Losses in Ductings
2_2_dedusting_4 Design Parameters for Design of Duct Systems
2_2_dedusting_5 Duct Balancing
2_2_dedusting_6
Book-II Chapter 2
Dedusting Systems
File Name :
2_2_dedusting_1
Topic: Estimation of Vent Air Volume
ESTIMATION OF VENT AIR VOLUMES
Estimation of vent air volume is the first step in engineering a dust collection system. The
air volume to be vented form any machinery hood or transfer point depends on many
factors such as the physical nature of the material handled, air currents and surges
created by the movement of machinery parts and materials, the type of enclosure
provided. Therefore, certain accepted standards which give rule-of-thumb methods have
to be followed. The following recommended procedures extracted from:
Industrial Ventilation-
Published by American Conference of Government
Industrial Hygienists, U.S.A.
could be used as guideline in estimation of air volumes.
It may be noted here, for guidance, that when the venting volume is expressed in cubic
meters, this refers to actual operating conditions at site under consideration. however, if
the volume is expressed in NM
3
, then this volume is to be corrected for actual operating
temperature and altitude above mean sea level.
1. CLOSED TOP BINS:
Volume = K x volume of entering material.
The value of K ranges form 1 (for large bins, low feed rates, coarse feed) to
50 (small bins, high feed rate, fine material).
The minimum rate is 3600 M
3
/Hr per M
2
of bin opening.
2. BUCKET ELEVATORS:
1800 M
3
/Hr/Sq. Metre of elevator casing section. For elevators over 10 M height,
connect exhaust from both top and bottom.
3. BELT CONVEYORS:
3600 M
3
/Hr per sq. metre of openings in enclosure, but minimum
1950 M
3
/Hr/metre belt width for belt speeds under 1 M/sec.
2800 M
3
/Hr/metre belt width for belt speeds over 1M/sec.
Additional volume for greater than 1 metre fall and dusty material:
1200 M
3
/Hr for belt width 300 mm to 1000 mm
1700 M
3
/Hr for belt width above 1000 mm
4. FLAT DECK SCREEN:
3600 M
3
/Hr/M
2
through hood openings, but minimum.
900 M
3
/Hr/M
2
screen area.
5. CYLINDRICAL SCREEN:
1800 M
3
/Hr/M
2
circular cross section of screen, but minimum.
7200 M
3
/Hr/M
2
of enclosure opening.
6. AIRVEYOR & PNEUMATIC SCREW PUMP SYSTEMS:
Multiply free air volume of the system as follows:
For conveying distances upto 150 M --- 1.5 times
For conveying distances over 150 M --- 1.75 times
7. PNEUMATIC GRAVITY CONVEYOR & BLENDING SYSTEMS:
1.0 times free air volume of the system.
8. SCREW CONVEYORS:
If dust tight, ventilate feed point only. Use 1100 M
3
/Hr per metre of nominal conveyor
diameter corrected for height of fall of feed.
9. CRUSHERS:
At feed end: Minimum of 2700 M
3
/Hr/M
2
of feed hood opening.
At discharge: Measure air current surges and allow 50% excess.
10. ROTARY CRUSHER:
These act as fans. Restrict ingress of air at feed point. Measure air quantity at
discharge and add 50%. (Crusher manufacturer's recommendations to be called for).
11. GRINDING MILLS:
Use the larger of the following:
A. 0.5 M/sec to 0.6 M/sec through the cross section area of the mill.
B. 1 M/sec through each aperture.
C. 8.5 M
3
/Hr/HP of Raw Mill motor rating.
D. 13 M
3
/Hr/HP of Cement Mill motor rating.
(N.B. These figures are for operating temperatures of the Mills).
12. MECHANICAL AIR SEPERATORS:
Where cooling or drying is carried out in Separator, use outlet volumes from detailed
calculations. Maximum air volumes at 88
o
C are indicated below for Air Separators:
Separator Size *Volume at Sea Level
4.267 M dia. 31,300 M
3
/Hr
4.877 M dia. 44,000 M
3
/Hr
5.486 M dia. 59,500 M
3
/Hr
6.096 M dia. 74,000 M
3
/Hr
6.706 M dia. 83,300 M
3
/Hr
7.315 M dia. 92,700 M
3
/Hr
* For any other temperature or altitude, correct volume by applying density
correction factor.
13. GRATE OPENINGS:
A. (Floor or bench dumping - not enclosed)
2700 to 3600 M
3
/Hr/M
2
of grate area.
B. (Enclosed three sides and top)
2700 M
3
/Hr/M
2
of net face area.
14. 60 T/Hr CEMENT PACKER :
i) Packer Guard --- 100 M
3
/Min.
ii) Top of Packer --- 15 M
3
/Min.
iii) Control Screen --- 20 M
3
/Min.
Book-II Chapter 2
Dedusting Systems
File Name : 2_2_dedusting_5
Topic: Duct Balancing
BALANCING OF DUCT SYSTEM RESISTANCE
1. In a ducting network having branch entries or exits, it is essential to balance system
resistance at every joint (i.e., where a branching takes place), in order to obtain desired
flow rate in each branch.
2. In the typical network shown below, balancing
is to be done as follows:
10
1
2
11
12
3
4
5
6
7
8
9
Dedust ing Networ k
13
10
1
2
11
12
3
4
5
6
7
8
9
Dedust ing Networ k
13
4. Find resistance Wg in 11_13&12_13 say R
1
& R
2
respectively (mm of Wg)
3. Select Main & Branch - 11_13 Main, 12_13 Branch entry
2. Select velocities in ducts 11,13&12,13 (m/sec)
1. Find volume flow rate - m
3
at temp. Deg. C, at point 11 & 12 (m
3
/sec,
0
C)
3. Actual Balancing: Typical at junction 13
Fan SP = R
6
+ Outlet VP at '6'
Total system resistance = R
6
=R
8
=R
9
7:8 & 7:9 7
(R
7
+ R
7,9
)/ R
9
(R
7
+ R
7,8
)/ R
8 =
(R
5
+ R
5,7
)/ R
7
(R
5
+ R
5,6
)/ R
6 =
5:6 & 5:7
5
R
3
+ R
3,4
+ R
4,5
= R
5
R
3
10:3 & (R
2
+2:3) 3
R
2
1:2 & (R
13
+13:2) 2
R
13
11:13 & 12:13 13
Resistance Balance Resistance between Junction Reference
5. Find which is higher resistance - say R
1
> R
2
6. Find percentage of balance = ((R
1
- R
2
)/ R
1
) x 100 %
7. Item 6 should be < 20%
8. If item 6 > 20% redo, line with less resistance 12,13. Increase velocity, to find R
12 , 13

> R
2
say, now R
12_13
= R
3
9. Recheck % balance, i.e., find which resistance is greater between R
3
& R
1
say R
3
> R
1
Therefore, % balance = ((R
3
- R
1
)/R
3
) x 100% < 20% O.K.
10. Now between R
3
& R
1
which are within 20% of balance, R
3
> R
1
11. Now governing resistance is R
3
= R
13
which is resistance in line 12_13
12. Re-evaluate volume flow in line 11_13 for this governing pressure
Vol 11_13 = Q
final
= Q
estimated
x square root (R
3
/R
1
)
where R
3
and R
1
are in mm of Wg.
Q
estimated
= Original estimated volume flow (m
3
/sec)
Q
final
= actual volume flow or corrected (m
3
/sec)
13. Now we know volume flow at 13_2 which is Q
11_13
+ Q
12_13
=Q
13_2
If there is appreciable temp difference between two air current, find volume of mix and
temp.
14. Select velocity in 13_2, which should be velocity in 11_13 & 12_13
15. Find resistance in 13_2 (mm of Wg)
16. Add R
13
to item 15 to get resistance in point 2 = R
13
+ R
13_2
17. Find VP in line 13_2 (velocity will depend upon standard pipe)
VP = V
2
x Pair/2g mm of Wg (for metric)
18. Find equivalent VP in terms of velocity in line 11_13&12_13, say, line 1&2
respectively
therefore, equivalent VP = VP
1_2
=(Q
1
+ Q
2
)
2
x P
air
/ (A
1
+ A
2
)
2
x

2

g mm of Wg (for metric system)
For metric system: Pair = Kg/m
3
Q
1
= m
3
/sec in Branch 1
Q
2
= m
3
/sec in Branch 2
A
1
= m
2
- area or Branch 1
A
2
= m
2
- area or Branch 2
g = 9.81 m/s
2
- Accelaration due to gravity
19. Find difference between VP in line 13_2 and equivalent VP
i.e., (VP
13_2
- VP
1_2
) < 2.5 mm of Wg
20. If fig in 19 above is > 2.5 mm of Wg then add this to resistance of line 13_2, to get
resistance at point 2
therefore, Pressure at point 2 = R
13
+ R
13_2
+ (VP
13_2
- VP
1_2
) mm of Wg
This resistance is added to indicate requirement of extra pressure for accelaration to
higher velocity, required in the line, after a branch has been connected.
21. Proceed for balancing at joint 2 as described for joint 13 and so on, till complete
network is balanced.
Abbreviations used:
R
1_2
- means resistance between point 1 & 2
R
2
- means resistance / static pressure at point 2
VP - Velocity Pressure
5) The gas velocity in the ESP = v m/sec. is constant
4) Under the influence of Electric field, the charged dust particles move towards the
collecting electrodes at uniform velocity = W cms. / sec.
3) Influence of Electric Wind is negligible.
2) Dust collected on the plates are not reentrained into the gas stream.
1) Dust particles are uniformly distributed over the entire cross sectional area of ESP
We shall assume the following:
0.998
1
R
C
R
O
:
Then the efficiency of dust collection
gms. / m
3
R
C
0.1 : R
C
Dust concentration at ESP outlet
gms. / m
3
R
O
60 : R
O
Dust concentration at ESP inlet
Efficiency of an ESP is defined by its capacity to remove dust from the carrying gases. If
the gas volume flow rate is constant, the dust concentration at the inlet and at the out let
can be denoted by the following variables.
An appreciation of Deutsch Formula
This example is for understanding of Deutsch Formula and not for evaluation of ESP
efficiency
Topic: Electrostatic Precipitator- Deutsch Efficiency Formula
File Name : 2_2_dedusting_9
Dedusting Systems
Book-II Chapter 2
m
2
d
f
0.02
m
2
d
f
2 b dx :
d
f
Now the elemental collecting area ( m2 )
gms. g 0.09
b . 2d . dx is equal to the volume of the inter electrode space of length dx -
considered in m
3
g R
X
b 2 d dx :
m dx 0.01 : dx Let us consider an inter electrodes space
of length at a distance = x from inlet.
m b 1 : b Let us denote the electric field height
m d 0.15 : d Let the distance between collecting and
discharge electrode be
gms. /m
3
R
X
30 : R
X
Let dust conc. at distance x from inlet be
gms. g g The amount of dust particle at this space
R
C
R
O

d
x
dx
b
L
W
V
Collecting Electrode
Discharge Electrode
R
O
R
C
g
1
g
(
(
d 6.397
Now let us put the limits of dust loading and time and integrating we get the following
k 0.035
k
dg
g
:
gms. dg 3.12 10
3

dg dg :
Since dust is removed from gas , we will assign negative (-) sign to the value of dg
dg 3.12 10
3

gms.
dg R
X
V :
R
X
30
Since the dust content in this space is R
X
gms.dust settled =dg
m
3
V 1.04 10
4

m
3
V 2 b dx
W
100
dt :
cm/sec W 13 : W Migration velocity
dt .04 :
quantity of dust = d
g
gms. settle on this elemental
area at a time dt sec.after a time tx ( the time to
travel fron inlet to distance = x )
This means , all the dust particles with migration velocity of = W/100 m/sec., within a
distance of W x dt/100 from the two surfaces of collecting area will settle down on the
plates. Since the particles are assumed to be uniformly distributed, the gas volume which
contain all these dust particles = V m
3

Let us now assume that a quantity of dust = d
g
gms. settle on this elemental area at a
time dt after a time tx ( the time to travel fron inlet to distance = x )
mg / m
3
R
C
1000 R
C
:
R
C
0.000136
gms. / m
3
R
C
R
O
e
W
100
t
d
:
R
C
Dust conc. at outlet (gms. / m
3)
t 15
sec
sec t
L
v
:
m/sec v 0.8 : v Gas velocity
m L 12 : L Total length of ESP
Since the gas travels through the total active length of the ESP = L m in total time = t
sec. at a velocity = v m/sec. we have:
R
X
R
O
e
W
tx
100 d
:
Or
ln
R
X
R
O
,
W
100 d
tx 0 ( ) : ln
R
X
R
O
,
W
100 d
tx 0 ( ) :
Or
K
1
0
tx
t
W
100 d
(
(
d :
tx 5 : time tx ( the time to travel fron inlet to distance = x )
K
1
R
O
R
C
g
1
g
(
(
d :
efficiency of collection
v velocity of gas in ( m/sec )
d Distance between Collecting and Discharge Electrodes in ( m )
L Total active length of ESP in ( m )
W Migration velocity in ( cm. / sec )
Where
0.9999977397
exp
1
100
W
L
v d ( )
1
1
]
2.26 10
6

e
W
100
L
v d
1 e
W
100
L
v d
:
Since t= L/v we can write the expression as
1 e
W
100
t
d
:
Or
1
R
O
e
W
100
t
d
R
O
:
Or
0.998
1
R
C
R
O
:
Or
mg / m
3
R
C
0.136
Now please refer to evaluation of Sp. Collecting Area = f m2/m3/sec
f W
L
v d
:
So the Deutsche formula can be written as
1 e
W
100
L
v d
:
Or
1 e
W f
100
:
Corrollaries
In the process of deriving the basic formula for ESP collection efficiency we can make the
following important observations.
1 e
W
100
L
v d
:
1) For same efficiency and all other conditions of operations remaining same W/d is a
constant = K
1
Or W= K
1
*d
i.e. W increases in direct linear proportion to d - the distance between collecting and
discharge electrodes.This would , however, mean higher voltage and rating of
Transformer / Rectifier sets
2 ) W / v is a costant i.e W increases in direct proportion of v - velocity of gases.But the
velocity cannot be increased very much as it has negative influence of re- entraining the
dust particles.
Property of:
Volatility 2_3_laboratory_11
Separation of ESP and Filter Dust 2_3_laboratory_10
Burnability Investigation 2_3_laboratory_9
Raw Mix Investgation 2_3_laboratory_8
Fuel Investgation 2_3_laboratory_7
Mineralogical Investigations 2_3_laboratory_6
Chemical Tests 2_3_laboratory_5
Tests Conducted at Physical Laboratory 2_3_laboratory_4
Purposes of Tests 2_3_laboratory_3
Coal Samples -A Point of View 2_3_laboratory_2
Quantity of Raw Material Samples for Lab. Investigation 2_3_laboratory_1
File Name : 2_3_laboratory
Laboratory Investigations
Book-II Chapter 3
Book-II Chapter 3
File Name : 2_3_laboratory_5
Topic: Chemical Tests
Tests Conducted at Chemical Labs:
For ease of understanding a sample Lab report has been referred to:
Summary report/observation:
1) It may be observed that Sulphate Resistant cement is defined as ASTM - Type V
where C
3
A 5% and (C
4
AF + 2C
3
A) 20%.
2) Alkali equillibrium factor Q is < 1 (Q=0.71). Hence no alkali by pass is required.
If Chlorine content is > 0.04% then Alkali by pass is necessary (Cl - Free of Loss basis).
Alkali & Sulphates combine to form alkali sulphates.
when Q = 1 all alkalies combine with sulphates. (Equillibrium)
Q > 1 There is excess of SO
3
.
Q < 1 There is Alkali excess.
71 94 62
80
2 2
3
Cl
O K O Na
SO
Q
+ +
where SO
3
, Na
2
O etc are % of these present in Clinker (including ash effect) on loss free
basis. 80, 62 etc. represent Molecular weight of SO
3
, Na
2
O etc.
3) Influence of fuel ash is significant and reduces Lime standard by 10 points, eg. from
105 in Raw meal to 95 in clinker.
4) Burnability is normally poor with high Quartz content in Raw meal. But due to the fact
that most of the quartz is in size fraction < 90, the influence of same on Burnability is
minimum.
5) Raw mix and ESP dust (size fraction 0 - 32) show similar chemical composition.
Individual Tests:
All raw materials are assessed interms of colour, structure, hardness in mole's scale,
moisture content on receipt and moisture absorption when kept under water.
Under water storage of material reveals its properties with respect to flowability specially
for clay etc. Crushing strength is determined for crusher selection.
Bulk density of material is determined after crushing the material in laboratory crusher.
This value is used to determine storage value, eg. for stockpile value, Raw material
hopper value etc. The grain size analysis is done after crushing in the Laboratory
crusher to predict grain size distribution after crushing operation in industrial scale and
this information is used in crusher selection & design.
Chemical composition of Raw materials is determined by Atomic Absorption test. This
can also be done by X'ray analysis. Individual components are determined as under:
%SiO
2
- By Atomic absorption test (AAS)
%Al
2
O
3
%TiO
2
- Calorimetric - By Photometer
%Fe
2
O
3
%Mn
2
O
3
%CaO - Complexometric - Titration
%MgO - By Atomic absorption test (AAS)
%SO
3
- (Total Sulphur) LECO
%P
2
O
5
- Calorimetric - By Photometer
%Na
2
O - By Flame Photometer
%K
2
O
%Cl - By Titration
Book-II Chapter 3
File Name : 2_3_laboratory_8
Topic: Raw Mix Investgation
Rawmix Design:
One of the most important purpose of various tests is to determine a suitable Raw mix
capable of producing cement of desirable quality. We have already analysed
composition of various raw materials and correctives as well as fuel ash. Following
parameters are fixed:
1) Consider coal ash absorption in clinker as 100%.
2) Set value for lime standard at 95%. This is the most important set value for
determining Raw mix composition so that Lime saturation factor in clinker is 95%.
Normal range 92 - 97% in clinker.
3) Second set point is for Silica ratio (2.4 to 2.8 in clinker).
4)Third set point is for Alumina ratio (1.8 to 2.2 in clinker).
For solving the equations, following rule may apply.
For 2 component mix - 1 set point i.e., Lime saturation factor
3 component mix - 2 set point i.e., Lime saturation factor and Silica ratio
4 component mix - 3 set point i.e., Lime saturation factor, Silica ratio, Alumina
ratio
Normal liquid phase - 22 - 28%
If liquid phase is less, then cement is harder to burn, and produces SRC(Sulphate
resistant cement). Various formulae for different ratios are indicated. If TiO
2
and Mn
2
O
3

are separately determined, then TiO
2
should be included in Al
2
O
3
and Mn
2
O
3
should be
included in Fe
2
O
3
for calculating the ratios.
Property of:
Reactivity of Coal as a Function of Fineness 2_4_fuel_6n
Calculation of Flame Temperature 2_4_fuel_5n
Calculation of Products of combustion 2_4_fuel_4n
Calculation of Combustion air 2_4_fuel_3n
Calculation of Coal Analysis and Heat Values of Coal 2_4_fuel_2
Calculation of Capacities in Coal Preparation Section 2_4_fuel_1
File Name : 2_4_fuel
Fuels and Fuel Systems
Book-II Chapter 4
Book-II Chapter 4
File Name : 2_4_fuels_2
Topic: Calculation of Coal Analysis and Heat Values Coal
Fuel Analysis and Calculation of Heat Values of Coal
This document covers fuel analysis and heat values calculation for solid fuel and liquid
fuel namely, coal and fuel oil respectively.
If a fuel as received in the plant is analysed without any change in its state then it will be
termed as "Analysis (as received basis)".
Normally ultimate analysis of fuel on as received basis will be available from the
laboratory.
Solid fuel i.e., Coal, in many a case, is dried to a large extent before being fired into the
furnace. Dryers used are capable of drying the surface moisture of coal and the inherent
moisture remains in coal. This is because the temperature of coal is not allowed to
exceed 80-100
0
C (to avoid coking and preignition in the pipeline) and at this
temperature, with sufficient heat available only surface moisture can be dried where as to
dry inherent moisture, the coal should be heated to 108
0
C. This is not done due to
associated 'Process problems'.
In any material's drying operation, inherent moisture cannot be dried at temperature <
100
0
C. Inherent moisture is a function of property of material's degree of being
hydroscopic.
It must be understood that ultimate analysis of coal (as received), indicates the total
moisture content in coal i.e., surface + inherent moisture and so is the case with coal
analysis (as fired). Analysis (dried basis) reports zero percent moisture in coal since all
the moisture is first driven out under controlled heat before analysis is undertaken.
COAL:
1. Of the various rank and types of coal, we shall confine ourselves to Bituminous coal as
available in India.
2. Coal has basically two parts - i) Organic and ii) Inorganic.
Mtot1 A1 + V1 + C1 + 1
C1 0.52 C1 52.0% : Fixed Carbon
V1 0.16 V1 16.0% : Volatiles
A1 0.22 A1 22.0% : Ash
Mtot1 0.1 Mtot1 Msur1 Minh1 + :
Total moisture,
H
2
O=H
2
O(S)+H
2
O(I)
Minh1 0.03 Minh1 3.0% : Inherent moisture, H
2
O(I)
Msur1 0.07 Msur1 7.0% : Surface moisture, H
2
O(S)
Basis of report - As received
Proximate Analysis - Typical Report
4. Coal analysis must report total moisture, inherent moisture and surface moisture in
coal (as received).
3. Coal, as received in plant, is termed coal(as received). All coal contains moisture.
Moisture as reported on coal(as received), is total moisture consisting of surface
moisture(due to washing or rain) and inherent moisture(due to property of coal itself to
absorb moisture in humid air). Surface moisture can be dried if left in the air and the coal,
so dried is termed as coal(air dried). If air dried coal is heated under controlled condition
at 108+2
0
C, inherent moisture is dried up. Coal so dried is termed as coal(dried or oven
dried). It may be mentioned here, that in industrial drying of coal in dryers, coal is dried in
air, with coal temperature not exceeding 65-80
0
C. Through this process of drying only
surface moisture can be dried.
Inherent moisture in coal can vary from 1 to 14% depending on the nature of coal itself.
Coal absorbs water from air and attains saturation level depending upon the humidity
and temperature of surrounding air. Hence, even if coal was dried at 108
0
C to remove
inherent moisture it would once again absorb the equivalent quantity of moisture on
storage in hoppers. Hence in industrial application this is wasteful and not practiced.
Organic part consists primarily of moisture(inherent and free), hydrocarbons, fixed
carbon and the inorganic part consists of minerals like Kaolinite, Pyrite, Rutite. Main
elements in organic part are H
2
, N
2
, S, O
2
and to some extent Cl etc.
The various types of coal are Peat, Lignite, Brown, Semi Bituminous, Bituminous,
Anthracite, Graphite
On Proximate analysis, H
2
O, Ash, volatile matter and fixed carbon are reported. Ash is
non-combus- tible and is generated by minerals minus moisture in clay and CO
2
from
carbonate. Organic part gives volatiles, H
2
O, and fixed carbon.
Analysis of Coal (Dried)
Surface moisture, H
2
O(S) Msur3 0 :
Inherent moisture, H
2
O(I) Minh3 0 :
Total moisture,
H
2
O=H
2
O(S)+H
2
O(I)
Mtot3 Msur3 Minh3 + : Mtot3 0
Ash A3 A1
1
1 Msur1 Minh1 + ( )
: A3 0.244
Volatiles V3 V1
1
1 Msur1 Minh1 + ( )
: V3 0.178
Fixed Carbon C3 C1
1
1 Msur1 Minh1 + ( )
: C3 0.578
Mtot3 A3 + V3 + C3 + 1
5. Ultimate analysis of coal is necessary on 'As Received' basis to determine calorific value,
combustion air, products of combustion etc.
Ultimate Analysis --> Typical Report Basis -- As Received
Generally higher the volatiles, higher is the inherent moisture.
Hence, Analysis of Air Dried Coal is as follows:
Surface moisture, H
2
O(S) Msur2 0 :
2
O(I) Minh2 Minh1
1
1 Msur1
: Minh2 0.032
Total moisture,
H
2
O=H
2
O(S)+H
2
O(I)
Mtot2 Msur2 Minh2 + : Mtot2 0.032
Ash A2 A1
1
1 Msur1
: A2 0.237
Volatiles V2 V1
1
1 Msur1
: V2 0.172
Fixed Carbon C2 C1
1
1 Msur1
: C2 0.559
Mtot2 A2 + V2 + C2 + 1
s1 0.01
Chlorine, Cl ch1 0% : ch1 0
mtot1 a1 + c1 + h1 + n1 + o1 + s1 + ch1 + 1
Drying performance in dryer is drying of surface moisture from say 7% to 1%, with
reference to original coal. This would mean - if analysed after drying, the surface
moisture will be more than 1%. This can be seen as below
Ultimate Analysis -- Air Dried
Surface moisture, H
2
O(S) (after drying) msur 1.0% : msur 0.01
Surface Moisture lost after drying msloss msur1 msur : msloss 0.06
Surface Moisture, H
2
O(S) msur2 msur
1
1 msloss
: msur2 0.011
Thus it can be seen that in air
dried(in dryer)/ as fired coal has
surface moisture > 1%.
2
O(I) minh2 minh1
1
1 msloss
: minh2 0.032
Total moisture,
H
2
O=H
2
O(S)+H
2
O(I)
mtot2 msur2 minh2 + : mtot2 0.043
Ash a2 a1
1
1 msloss
: a2 0.234
Surface moisture, H
2
O(S) msur1 7.0% : msur1 0.07
2
O(I) minh1 3.0% : minh1 0.03
Total moisture,
H
2
O=H
2
O(S)+H
2
O(I)
mtot1 msur1 minh1 + : mtot1 0.1
Ash a1 22.0% : a1 0.22
Carbon, C c1 52.0% : c1 0.52
Hydrogen, H
2
h1 4.0% : h1 0.04
Nitrogen, N
2
n1 3.0% : n1 0.03
Oxygen, O
2
o1 8.0% : o1 0.08
Sulphur, S s1 1.0% :
minh 0% : minh 0
Inherent Moisture loss after fully drying is miloss minh1 minh : miloss 0.03
Surface Moisture, H
2
O(S) msur3 msur
1
1 msloss miloss + ( )
: msur3 0.011
Inherent Moisture, H
2
O(I) minh3 minh
1
: minh3 0
Total Moisture mtot3 msur3 minh3 + : mtot3 0.011
Ash a3 a1
1
: a3 0.242
Carbon c3 c1
1
: c3 0.571
Carbon c2 c1
1
1 msloss
: c2 0.553
Hydrogen h2 h1
1
1 msloss
: h2 0.043
Nitrogen n2 n1
1
1 msloss
: n2 0.032
Oxygen o2 o1
1
1 msloss
: o2 0.085
Sulphur s2 s1
1
1 msloss
: s2 0.011
Chlorine ch2 ch1
1
1 msloss
: ch2 0
mtot2 a2 + c2 + h2 + n2 + o2 + s2 + ch2 + 1
Ultimate Analysis --- Fully Dried
Inherent Moisture, H
2
O(I) (after fully drying)
gcv3 gcv1 1 mtot3 ( ) :
Gross Calorific Value (as fired) = Gross on wet (as fired)
Kcal/kg gcv2 5.035 10
3

Gross Calorific Value (as received) = Gross on wet (as received)
Kcal/kg gcv1 5.595 10
3

gcv1 8105.5 c2 34077.8 h2
o2
8
,
+ 2183.3 s2 +
1
1
]
:
Gross Calorific Value (dry basis) = Gross on dry (dry basis)
6. Calorific Value:
In practice we require another derived form of analysis i.e., Coal(as fired) i.e., the state at
which coal is fired in the furnace, after it has been dried (surface moisture) in a dryer.
For efficient furnace operation, it is necessary to dry the coal as far as possible. But
keeping in view what has been stated above, only surface moisture is dried. Thus higher
the inherent moisture, lower will be the net calorific value of coal in as fired condition.
Even surface moisture is not dried fully since very fine coal, if fully dried off surface
moisture, tend to seggregate and create operational problems.
Thus it can be seen that coal as fired may have about 1% surface moisture and all the
inherent moisture. This will depend on the drying performance of the drying unit.
mtot3 a3 + c3 + h3 + n3 + o3 + s3 + ch3 + 1
ch3 0 ch3 ch1
1
: Chlorine
s3 0.011 s3 s1
1
: Sulphur
o3 0.088 o3 o1
1
: Oxygen
n3 0.033 n3 n1
1
: Nitrogen
h3 0.044 h3 h1
1
: Hydrogen
gcv3 5.533 10
3
Kcal/kg
Net Calorific Value or Net on wet (as fired)
ncv1 gcv1 1 mtot3 ( ) 586 mtot3 9 h3 + ( ) :
ncv1 5.295 10
3
Kcal/kg
Net Calorific Value or Net on dry (dry basis)
ncv2 gcv1 586 9 h2 :
ncv2 5.37 10
3
Kcal/kg
Net Calorific Value or Net on wet (as received)
ncv3 gcv2 586 mtot1 9 h1 + ( ) [ ] :
ncv3 4.766 10
3
Kcal/kg
C
pN2
T ( ) 25.79 8.09 10
3
T + 1.46 10
6
T
2

0.88 10
5
T
2
+ :
The formulas to the left, from
Noggle,
Physical Chemistry (3rd Ed)
are valid up to 3000 K.
C
PH2O
(T) Sp. heat of H
2
O at temp. T
C
PCO2
(T) Sp. heat of CO
2
at temp. T
C
PN2
(T) Sp. heat of N
2
at temp. T
Temp. of gases in flame =T
Specific heats of gases as function of temp. T
The products of the combustion include H
2
0 and CO
2
;as the combustion is in air, the
nitrogen of the air will remain, unconsumed, with the products and, thus, its heat capacity
need to be considered.
In an adiabatic flame, the heat of combustion, is used to heat the products of the
combustion.
Also as the heat released immediately heats up the products of combustion in its vicinity,
the process is assumed as adiabatic.
An attempt to calculate the temperature of a flame can be error prone as it is possible
that there can be dissociation of products of combustion.( CO
2
dissociates to CO +O
2
)

an endothermic reaction.
Cold primary air as also raw meal in case of insufflation (feeding raw meal along with
coal firing through the Burner)cool down the flame.Raw meal also brings down the net
calorific value of fuel and raw meal mixture.
Ash absorbs heat from the flame itself. When the ash content of coal is greater than 20%
there can be significant cooling of the flame.
A high flame temperature is necessary in the Kiln to attain very quick transfer of heat
from the flame to the refractory in the Sinter Zone by radiation.Since radiation is a
function of 4th power of temperature, it is imperative that higher the temperature of the
flame better is the heat transfer at the sintering zone of kiln where highest temperature is
is required to convert C
2
S to C
3
S.
Topic: Calculation of Flame Temperature
File Name : 2_4_fuels_5n
Book-II Chapter 4
o2
O1
100
: o2 0.022
Moisture =H
2
O % H2O1 5 : h2o2
H2O1
100
: h2o2 0.05
Ash =ash % ash 40 : ash2
ash
100
: ash2 0.4
Total moisture (surface)= mtot3 mtot3 0.04 :
Calorific Value:
Gross Calorific Value (dry basis) = Gross on dry (dry basis)
gcv1 8105.5 c2 34077.8 h2
o2
8
,
+ 2183.3 s2 +
1
1
]
:
gcv1 4.689 10
3
Kcal/kg
Gross Calorific Value (as fired) = Gross on wet (as fired)
gcv3 4.501 10
3
Kcal/kg
C
pCO2
T ( ) 41.58 15.6 10
3
T + 2.95 10
6
T
2

7.97 10
5
T
2
:
C
pH2O
T ( ) 26.06 17.7 10
3
T + 2.63 10
6
T
2

2.20 10
5
T
2
+ :
Ultimate Analysis of coal (BY WEIGHT):
Carbon = C % C1 46.99 : c2
C1
100
: c2 0.47
Hydrogen =H
2 %
H1 2.82 : h2
H1
100
: h2 0.028
Nitrogen = N
2 %
N1 1.03 : n2
N1
100
: n2 0.01
Sulphur =S % S1 0.5 : s2
S1
100
: s2 5 10
3

Oxygen =O
2
% O1 2.16 :
Sp. heatof air =Sair k.cal. /kg.
o
C k.cal. /kg.
o
C
Temp. of air - primary and secondary
mix. t
air
o
C
t
air
600 :
o
C
Sp. heat of coal S
coal
k.cal. /kg.
o
C S
coal
0.25 :
k.cal. /kg.
o
C
Temp. of Coal t
coal

o
C t
coal
25 :
o
C
S
flg
0.26 :
Sp. heat of flue gas S
flg
k.cal. /kg.
o
C k.cal. /kg.
o
C
Flame temperature = T
o
C
o
C
T
gcv3 A
TH1
S
air
t
air
+ F S
coal
t
coal
+
V
f
S
flg
ash2 S
ash
+
:
T 2690
o
C
Calculation of flame temp. T
o
C
Calorific value of coal as fired =gcv3 gcv3 4.501 10
3
k.cal / kg. coal
Air for combustion A
TH1
kg. / kg. coal A
TH1
6.992 : kg. / kg. of coal
Quantity of coal F kg. F 1.0 : kg.of coal
Flue gas quantity (products of combustion) V
f
V
f
7.577 : kg. / kg. of coal
Ash content per kg. fuel =ash2 ash2 0.4 kg. / kg. of coal
Sp. heat of ash S
ash
k.cal. /kg.
o
C S
ash
0.2 :
k.cal. /kg.
o
C
S
air
0.24 :
Property of:
Troughed Belt Conveyor-Calculation of Capacity 2_5_conveying_6n
Belt Drives -Length of Drive Belt 2_5_conveying_5n
Belt Conveyor -Length of Conveyor Belt in a Roll 2_5_conveying_4
Screw Conveyor 2_5_conveying_3
Deep Bucket or Deep Pan type Conveyors -Power and
Filling
2_5_conveying_2
Vertical Bucket Elevator -Power and Filling 2_5_conveying_1
File Name : 2_5_conveying
Conveying Systems
Book-II Chapter 5
n
30
D
:
D
For heavy and abrasive material
n
45
D
:
D
For heavy and non abrasive material
For light and non abrasive material
n
60
D
:
D
Screw speed is selected as followes
C
1
0.9
0.8
0.7
0.65
,
:
0
5
10
15
20
,
:
C factor = C Gradient = degree
As a thumb rule pitch should be atleasr 12 times the average piece size of material.and 4
time the maximum size of material
Standard dia. of screw range from 0,15 to 0.6 m but can go up in special cases to 1000mm
or more.
Pitch of the screw is normally equal to the diameter or upto 0.8 times the screw diameter.
The capacity of a screw conveyor depends upon average cross sectional areaof the flow
of material in the trough and the material speed,These depend on trough diameter,the
screw lead and speed.
Capacity Calculation as a Function of Geometry and speed of Screw Conveyor
Topic: Screw Conveyor
File Name : 2_5_conveying_3nr1
Conveying Systems
Book-II Chapter 5
C 1 :
Filling factor ( varies between 0.75 to 0.85 ) 0.8 :
Calculations :
F Average cross sectional area of the material flow ( m
2
)
F
D
2
4 1000 1000
C : m2
F 0.057 m2
v Speed of movement of the material along the axis ( m/s )
v S
p
n
1000 60
: m / s
v 0.1 m / s
Q Capacity of the conveyor ( t/h )
Q F v B
d
3600 : t / h
Q 25.447 t / h
Q Throughput ( tph ) Q tph
B
d
Bulk density , ton/m
3
B
d
1.25 : ton/m
3
n Screw speed , rpm n 20 : rpm
S
p
Screw Pitch , mm S
p
300 : mm
D Diameter of Trough D 300 : mm
L Length of Screw L 5 : m
C Factor for variation of material cross section
For horizontal flow C=1 : At 20
0
gradient C= 0.65)
Ref . Materials Handling Equipment by M.P.Alexandrov
kW N
gs
1.408
N
gs
Q
H
367
C
1
Q L
367
+ :
m H 0.3 : H Lift of the screw
N
gs
Power at shaft If the screw has to move material in a gradient (

kW)
kW
N
HS
1.387
N
HS
C
1
Q L
367
:
C
1
4 :
Cement , Gypsum, clay, Ash,
Lime
Lump Coal
C
1
1.2
1.6
2.5
4
,
:
Pulverised Coal
Friction factor C
1
Flour , Cereal, Saw dust
Power requirement calculation:
N
HS
Power at shaft for horizontal conv.
Book-II Chapter 6
Fans and Blowers
File Name : 2_6_fans
2_6_fans_1 Calculation of Fan Motor Power
2_6_fans_2 Calculation of Fan Volume Rating
2_6_fans_3n Design of Large Fans -Requirement of Motor Data
2_6_fans_4n Calculation of Expansion of Fan shaft -During Hot Condition
Property of:
G
d
0.630 : kg/m
3

G
d.l
Dust load in the gases G
d.l
50 : gm/m
3

Calculations :
Fan consumed power without dust load :
F
sp
F
v
F
p
10 ( ) 100
102 F
e
3600
: kw
10 is the factor to convert m bar to
mm of wg.
F
sp
285 kw
Fan consumed power considering the dust load :
F
sp.d
F
sp
G
d
G
d.l
1000
+
,
G
d
: kw
F
sp.d
307 kw
Book-II Chapter 6
Fans and Blowers
File Name : 2_6_fans_1
Topic: Calculation of Fan Motor Power
The motor power of fan based the design parameters.
The calculation of the motor power of fan based on the design parameters is as given
below .
F
v
Fan volume F
v
220000 : m3/hr
F
p
Fan static pressue F
p
38 : mbar
F
e
Fan efficiency F
e
80 : %
G
d
Density of the gases
Fan motor power
F
l
Factor for losses in
belt/coupling
F
l
1.12 :
M
mp
F
sp.d
F
l
: kw
M
mp
344 kw
Property of:
Calculation of Potential Clinker Composition 2_7_rawmix_8
Raw-mix Calculation with to meet Potential Clinker
Compounds
2_7_rawmix_7
Raw-mix Design - Calculation with Four Components 2_7_rawmix_6
Raw-mix Design - Calculation of Coal Ash Absorption 2_7_rawmix_5
Raw-mix Design based on Lime Saturation Factor and
Silica Ratio
2_7_rawmix_4
Raw-mix Design based on Lime Saturation Factor 2_7_rawmix_3
Raw-mix Design based on Hydraulic Module 2_7_rawmix_2
Raw-mix Design for Two Components 2_7_rawmix_1
File Name : 2_7_rawmix
Raw-mix Design
Book-II Chapter 7
Therefore, to get a raw mix with a CaCO
3
content of 76%, 45 parts of limestone
should be mixed with 13 parts of clay. Thus the proportion of the components in
the raw mix, i.e., limestone:clay =45:13 =3.462 : 1,
P 3.462
l 13 Parts of Clay
P
c
l
:
c 45 Parts of Limestone
P Proportion of Limestone to Clay
c 45
c R C : Parts of CaCO
3
deficient in clay
l 13
l L R : Parts of CaCO
3
excess in Lime stone
C 31 : % of CaCO
3
content in Clay
L 89 : % of CaCO
3
content in Limestone
R 76 : % of CaCO
3
content desired in Raw Mix
In this method, the proportion of limestone with certain percentage of CaCO
3
, and
proportion of clay with with certain percentage of CaCO
3
are determined, to get a raw
mix with a certain desired CaCO
3
content
Example:
In this simple method we determine the proportion of two raw material components only.
CaCO
3
is fixed as set point.
Calculation for two components
Raw mix design is a process of determining the quantitative proportions of the components
of Raw mix ensuring that the clinker produced from such mix attain desired chemical and
mineralogical composition.
Topic: Raw-mix Design for Two Components
File Name : 2_7_rawmix_1
Raw-mix Design
Book-II Chapter 7
F
2
7.37 :
CaO C
1
52.60 : C
2
1.40 :
MgO M
1
1.11 : M
2
0.98 :
SO
3
So
1
0.85 : So
2
0.85 :
LOI LOI
1
43.16 : LOI
2
7.47 :
Total
1
S
1
A
1
+ F
1
+ C
1
+ M
1
+ So
1
+ LOI
1
+ : Total
1
100
Total
2
S
2
A
2
+ F
2
+ C
2
+ M
2
+ So
2
+ LOI
2
+ : Total
2
100
Inserting into Kind's formula the calculation symbols used previously, we get
KS
xC C
x
xA A
x
xF F
x
xS S
x
k

+
+

+
+
+
+
+
_
,
+
+
_
,
1 2 1 2 1 2
1 2
1
165
1
0 35
1
2 8
1
. .
.
Book-II Chapter 7
Raw-mix Design
Topic: Raw-mix Design based on Lime Saturation Factor
Calculation based on the Lime saturation factor
Calculation of raw mix composition based on the lime saturation factor using Kind's
saturation factor.
Given 2 raw materials, Kind's lime saturation module is:
92 . 0
8 . 2
) 35 . 0 65 . 1 (
2
3 2 3 2
SiO
O Fe O Al CaO
KS
k
Limestone Clay
SiO
2
S
1
1.42 : S
2
62.95 :
Al
2
O
3
A
1
0.48 : A
2
18.98 :
Fe
2
O
3
F
1
0.38 :
F
1c
0.305 F
2c
p
c
F
2
: F
2c
1.458
C
1c
p
l
C
1
: C
1c
42.192 C
2c
p
c
C
2
: C
2c
0.277
M
1c
p
l
M
1
: M
1c
0.89 M
2c
p
c
M
2
: M
2c
0.194
So
1c
p
l
So
1
: So
1c
0.682 So
2c
p
c
So
2
: So
2c
0.168
LOI
1c
p
l
LOI
1
: LOI
1c
34.62 LOI
2c
p
c
LOI
2
: LOI
2c
1.478
Total
1c
S
1c
A
1c
+ F
1c
+ C
1c
+ M
1c
+ So
1c
+ LOI
1c
+ : Total
1c
80.213
Total
2c
S
2c
A
2c
+ F
2c
+ C
2c
+ M
2c
+ So
2c
+ LOI
2c
+ : Total
2c
19.787
and solving for x:
( )
( )
( )
( )
x
KS S A F C
C KS S A F
C KS S A F
C KS S A F
k
k
k
k
+ +
+ +

+ +
+ +
28 165 035
28 165 035
28 165 035
28 165 035
2 2 2 2
1 1 1 1
2 2 2 2
1 1 1 1
. . .
. . .
. . .
. . .
With this formula we calculate how many parts of limestone in the raw mix are
apportioned to one part of clay. Accordingly we get:
we know that KS
k
0.92 :
x
2.8 KS
k
S
2
1.65 A
2
+ 0.35 F
2
+ ( ) C
2
C
1
2.8 KS
k
S
1
1.65 A
1
+ 0.35 F
1
+ ( )
: x 4.054
Thus 4.054 parts of limestone are apportioned to one part of clay:
p
l
x
x 1 +
: p
l
0.802 p
c
1
x 1 +
: p
c
0.198
Limestone x 0.8020 Clay x 0.1980
S
1c
p
l
S
1
: S
1c
1.139 S
2c
p
c
S
2
: S
2c
12.456
A
1c
p
l
A
1
: A
1c
0.385 A
2c
p
c
A
2
: A
2c
3.756
F
1c
p
l
F
1
:
Clinker
S f S
m
: S 21.274
A f A
m
: A 6.48
F f F
m
: F 2.759
C f C
m
: C 66.46
M f M
m
: M 1.697
So f So
m
: So 1.33
LOI 0 :
Total S A + F + C + M + So + LOI + : Total 100
The resulting Kind's lime saturation factor is
KS
k
C 1.65 A 0.35 F + ( )
2.8 S
: KS
k
0.92
100% Raw mix
S
m
S
1c
S
2c
+ : S
m
13.595
A
m
A
1c
A
2c
+ : A
m
4.141
F
m
F
1c
F
2c
+ : F
m
1.763
C
m
C
1c
C
2c
+ : C
m
42.469
M
m
M
1c
M
2c
+ : M
m
1.084
So
m
So
1c
So
2c
+ : So
m
0.85
LOI
m
LOI
1c
LOI
2c
+ : LOI
m
36.098
Total
m
S
m
A
m
+ F
m
+ C
m
+ M
m
+ So
m
+ LOI
m
+ : Total
m
100
Now calculating the clinker composition as of raw mix free of loss due to ignition
f
100
100 LOI
m
: f 1.565
F
3
4.5 :
CaO C
1
66.0 : C
2
63.0 : C
3
66.0 :
Rest
Balance
R
1
4.0 : R
2
4.3 : R
3
4.0 :
Total
1
S
1
A
1
+ F
1
+ C
1
+ R
1
+ : Total
1
100
Total
2
S
2
A
2
+ F
2
+ C
2
+ R
2
+ : Total
2
100
Total
3
S
3
A
3
+ F
3
+ C
3
+ R
3
+ : Total
3
100
p
1
4.071 C
1
7.600 S
1
6.718 A
1
1.430 F
1
: p
2
4.071 C
2
7.600 S
2
6.718 A
2
1.430 F
2
:
q
1
8.602 S
1
5.068 A
1
+ 1.078 F
1
+ 3.071 C
1
: q
2
8.602 S
2
5.068 A
2
+ 1.078 F
2
+ 3.071 C
2
:
r
1
2.650 A
1
1.692 F
1
: r
2
2.650 A
2
1.692 F
2
:
s
1
3.043 F
1
: s
2
3.043 F
2
:
Book-II Chapter 7
Raw-mix Design
Topic: Calculation of Potential Clinker Composition
Oxide contents and potential composition
The calculation to find the required amount of potential clinker compounds showed that
small quantity fluctuations in the proportioning of the raw components, with their
resultant small differences in the oxide contents, cause large fluctuations in the potential
phase composition of the clinker and consequently, as in this case, the reduction of
C
3
S-content by 50%, and an increase in C
2
S-content of 100%. This is also shown below
in the compilation of three different clinkers with small differences in the oxide contents,
and the resulting large fluctuations in the calculated phase composition.
Clinker analysis and potential compound composition
Constituent Clinker I % Clinker II % Clinker III %
SiO
2
S
1
20.0 : S
2
21.8 : S
3
20.0 :
Al
2
O
3
A
1
7.0 : A
2
7.6 : A
3
5.5 :
Fe
2
O
3
F
1
3.0 : F
2
3.3 :
Oxide Clinker
SiO
2
S 22.5 :
Al
2
O
3
A 5.0 :
Fe
2
O
3
F 2.5 :
TiO
2
T 0.5 :
Mn
2
O
3
Mn 0.3 :
CaO C 63.0 :
MgO Mg 1.8 :
K
2
O K 0.4 :
Na
2
O Na 0.4 :
SO
3
So 2.6 :
Insoluble Ins 0.5 :
LOI LOI 0.5 :
p
3
4.071 C
3
7.600 S
3
6.718 A
3
1.430 F
3
:
q
3
8.602 S
3
5.068 A
3
+ 1.078 F
3
+ 3.071 C
3
:
r
3
2.650 A
3
1.692 F
3
:
s
3
3.043 F
3
:
Compound Clinker I % Clinker II % Clinker III %
C
3
S p
1
65.37 p
2
35.017 p
3
73.302
C
2
S q
1
8.064 q
2
36.125 q
3
2.079
C
3
A r
1
13.474 r
2
14.556 r
3
6.961
C
4
AF s
1
9.129 s
2
10.042 s
3
13.694
The chemical compositions of three different clinkers have been listed above. The oxide
contents do not vary widely; but the calculated potential compositions show considerable
differences. Therefore, when calculating the composition of the raw mix, it should be
taken into consideration that a variation of 1% in the CaO-content causes a variation in
the tricalcium silicate content by about 10-14% and, vice-versa, a fluctuation in the
C
3
S-content by 1%, causes a corresponding increase or decrease in the CaO-content by
1/14 = 0.07%, or a change in the CaCO
3
-content of the raw mix by 0.07 1.78 = 0.12%.
If the CaO-content is kept constant and the values for the other oxides change, there is a
corresponding change in contents of the resulting clinker minerals.
Also one and the same clinker can show different calculated potential compound
compositions, when on the one hand, one calculates with only the four main oxides, and
on the other hand when including also the auxiliary components which participate in the
formation of minerals. For a nume- rical presentation of this fact, the following clinker
analysis may be used for calculation.
CaO free
Mn
2
O
3
4 CaO Al
2
O
3
Mn
2
O
3
(C
4
AMn)

Na
2
O 8 CaO Na
2
O
3
3Al
2
O
3
(C
8
NA
3
)
TiO
2
CaO TiO
2
SO
3
CaSO
4
K K
2
SO
4
; the rest of SO
3
to CaSO
4
The auxiliary components contribute to the following formation of minerals:
i.e., 1.719 : 1
p
q
1.719 The ratio of C
3
S : C
2
S is
Total 93.042 Total p q + r + s + :
s 7.607 C
4
AF
r 9.02 C
3
A
q 28.107 C
2
S
p 48.308 C
3
S
The calculated potential composition is:
s 3.043 F :
r 2.650 A 1.692 F :
q 8.602 S 5.068 A + 1.078 F + 3.071 C :
p 4.071 C 7.600 S 6.718 A 1.430 F :
Total 100 Total S A + F + T + Mn + C + Mg + K + Na + So + Ins + LOI + :
A comparison of the two results shows wide differences in the potential composition of
the same clinker. Also the ratio C
3
S : C
2
S has changed and is roughly 1 : 1, according to
the second method of calculation. Differences in potential composition are the result of
differences in the mineral formations used for the calculation.
99.50 Total
36.29 C
2
S
37.89 C
3
S
3.28 C
3
A
0.92 C
4
AMn
7.61 C
4
AF
1.80 MgO
5.27 C
8
NA
3
0.86 CaO TiO
2
3.84 CaSO
4
0.74 K
2
SO
4
1.0 CaO - free
%
Considering the mineral formation as quoted above, the potential clinker composition is:
Book-II Chapter 8
Plant Water
File Name : 2_8_water
2_8_plantwater_1n Quality of Plant Cooling Water
Property of:
Book-II Chapter 9
Insulation
File Name : 2_9_Insulation
2_9_insulation_1 General Specifications for Insulation in Cement Plant
Property of:
3_1_UT_8 Properties of Metals - Co-efficient of Linear Expansion per
Degree C
3_1_UT_9 Properties of Metals - Electrical Resistivity
3_1_UT_10 Properties of Metals - Poission's Ratio
3_1_UT_11 Properties of Metals - Modulus of Elasticity
3_1_UT_12 Properties of Metals - Melting Point in Degrees Kelvin at
Atmospheric Pressure
3_1_UT_13 Properties of Common Solids - Density
3_1_UT_14 Properties of Common Solids - Specific Gravity
3_1_UT_15 Properties of Common Solids - Specific Heat
3_1_UT_16 Properties of Common Solids - Thermal Conductivity
Book-III Useful Tables-1
Basic Sciences
File Name : 3_1_UT_v8
3_1_UT_1 Basic Sciences Fundamental Physical Constants
3_1_UT_2 Basic Sciences Temperature Scales
3_1_UT_3 Basic Sciences Periodic Table of Elements
3_1_UT_4
3_1_UT_5 Calculus Reference Formulae Table of Integral Formulas
3_1_UT_6 Properties of Metals - Thermal Conductivity at Atmospheric
Pressure ,250C
3_1_UT_7 Properties of Metals - Specific Gravity
3_1_UT_17 Properties of Gases - Specific Gravity
3_1_UT_18 Properties of Gases - Specific Heat at 1.0 Atm Pressure, 20C, Except as
Noted
3_1_UT_19 Properties of Gases - Molecular Weightat 1.0 Atm Pressure, 20C,
Except as Noted
"Copyright 1999 by MathSoft, Inc. Reprinted by permission of MathSoft, Inc."
Property of:
5.0507866 10
27
joule
tesla
Nuclear magneton
9.2740154 10
24
joule
tesla
Bohr magneton
0
2.06783461 10
15
weber : Magnetic flux quantum
e 1.60217733 10
19
coul : Elementary charge
Electromagnetic Constants
h 6.6260755 10
34
joule sec : Planck's constant (h)
G 6.67259 10
11
m
3
kg sec
2
: Newtonian constant of
gravitation
0
8.854187817 10
12
farad
m
: Permittivity of vacuum
0
4 10
7
newton
amp
2
: Permeability of vacuum
c 299792458
m
sec
: Velocity of light in vacuum
Universal Constants
Topic: Fundamental Physical Constants
File Name : 3_1_UT_1_v8
Basic Sciences
m
1.8835327 10
28
kg : Muon mass
Muon
928.47701 10
26
joule
tesla
Electron magnetic moment
r
e
2.81794092 10
15
m : Classical electron radius
2.42631058 10
12
m
Electron Compton
wavelength
1.75881962 10
11
coul
kg
Electron specific
charge (electron
charge to mass ratio)
m
e
9.1093897 10
31
kg : Electron mass
Electron
3.63694807 10
4
m
2
sec
Quantum of
circulation
E
h
4.3597482 10
18
joule : Hartree energy
a
0
0.529177249 10
10
m : Bohr radius
R 10973731.534 m
1
: Rydberg constant
7.29735308 10
3
: Fine structure constant
Atomic Constants
8.314510
joule
mole K
Molar gas constant
96485.309
coul
mole
Faraday constant
AMU 1.6605402 10
27
kg :
Atomic mass
constant
N
A
6.0221367 10
23
mole
1
: Avogadro constant
Physico-Chemical Constants
1.31959110 10
15
m
Neutron Compton
wavelength
m
n
1.6749286 10
27
kg : Neutron mass
Neutron
26751.5255 10
4
rad
sec tesla
Proton gyromagnetic
ratio
1.41060761 10
26
joule
tesla
Proton magnetic moment
1.32141002 10
15
m
Proton Compton
wavelength
1836.152701
Ratio of proton mass to
electron mass
m
p
1.6726231 10
27
kg : Proton mass
Proton
Boltzmann's constant k
b
1.380658 10
23
joule
K
:
Molar volume of ideal
gas at STP
22.41410
liter
mole
Stefan-Boltzmann
constant
5.67051 10
8
watt
m
2
K
4
:
First radiation constant 3.7417749 10
16
watt m
2
Second radiation constant 0.01438769 m K

Data from CRC Handbook of Chemistry and Physics, 73nd edition,
edited by David R. Lide, CRC Press (1992).
Find the corresponding temperatures in the Fahrenheit, Kelvin,
and Rankine scales.
C T
stm_C
100.00 : Steam point (Celsius):
C T
ice_C
0.00 : Ice point (Celsius):
Example: The ice point T
ice
is the temperature at which ice and
air-saturated water are in equilibrium at atmospheric pressure. The
steam point T
stm
is the temperature at which steam and liquid water
are in equilibrium at atmospheric pressure. These temperatures are:
T
R
9
5
T
K
,
R =
T
R
T
F
459.67 + ( )
R = Absolute temperature (Rankine):
F T
F
32
9
5
T
C
+ = Fahrenheit (F) scale:
C T
C
T
K
273.15 = Celsius (C) scale:
Formulas
T Absolute temperature (Kelvin):
Variables
While the internationally accepted SI system of units calls for Kelvin
as a temperature unit, other commonly used temperature scales
include Celsius, Fahrenheit, and Rankine.
Topic: Temperature Scales
Basic Sciences
T
stm_K
373.15 K
T
stm_K
T
stm_C
273.15 + ( )
K :
Kelvin
F T
stm_F
212
T
stm_F
32
9
5
T
stm_C
+ :
Fahrenheit
Steam Point
T
ice_R
491.67 R
T
ice_R
9
5
T
ice_K
K
,
R :
Rankine
T
ice_K
273.15 K
T
ice_K
T
ice_C
273.15 + ( )
K :
Kelvin
F T
ice_F
32
T
ice_F
32
9
5
T
ice_C
+ :
Fahrenheit
Ice Point
Rankine
T
stm_R
9
5
T
stm_K
K
,
R :
T
stm_R
671.67 R Rankine
Actinide Series
Lanthanide Series
Transition Elements (Heavy Metals)
Halogen-
s
Nonmetals Alkaline Earth Metals
Alkali Metals
Inert
Gases
Topic: Periodic Table of Elements
Basic Sciences
25 Magnesium
20 Tin 29 Lead
12 Thorium 12 Iron
6.5 Tantalum 6 Iridium
70 Sodium 14.2 Gold
19 Silver
Data from CRC Handbook of Tables for Applied Engineering
Science, 2nd edition, edited by R. Bolz and G. Tuve, CRC
Press (1973).
35 Zinc 7 Niobium
8 Vanadium 13 Nickel
13.4 Uranium 5 Molybdenum
4.5 Tungsten 22 Manganese
8.5 Titanium
12 Beryllium
9 Platinum 9 Antimony
5 Osmium 25 Aluminum
Metal Metal
Expansion
Coefficient
(-10
6
)
Expansion
Coefficient
(-10
6
)
Topic: Properties of Metals - Co-efficient of Linear Expansion per Degree C
Basic Sciences
16.6 Copper
3 Silicon 12 Cobalt
37 Selenium 6 Chromium
8 Rhodium 30 Cadmium
83 Potassium 13 Bismuth
54 Plutonium
Silica, fused transparent 0.87 Butter
2.57 Serpentine 1.8 Brick
2.25 Sandstone 1.9 Bone
0.92 Rubber, soft, pure gum 2.9 Biotite
1.1 Rubber, soft, commercial 2.70 Beryl
1.19 Rubber, hard 0.97 Beeswax
2.18 Rock salt
1.53 Starch 1.4 Celluloid
0.95 Spermaceti 0.69 Cardboard
2.7 Soapstone 0.96 Caoutchouc
3.0 Slate 0.99 Camphor
2.9 Slag 2.7 Calcspar
2.07 Silica, translucent 4.3 Calamine
2.21
1.07 Pitch 2.64 Albite
0.84 Peat blocks 2.29 Alabaster, sulfate
0.89 Paraffin 2.73 Alabaster, carbonate
0.93 Paper 2.6 Agate
Material Material
Density
(gm/cm
3
)
Density
(gm/cm
3
)
Topic: Properties of Common Solids - Density
Basic Sciences
2.7 Basalt
1.07 Resin 1.3 Asphalt
2.65 Quartz 1.8 Asbestos slate
5.0 Pyrite 2.4 Asbestos
0.19 Pulp board 2.75 Anorthite
2.8 Porphyry 3.1 Amphiboles
2.4 Porcelain 1.09 Amber
Garnet
1.22 Ebony 1.2 Gamboge
0.76 Dogwood 7.5 Galena
0.80 Cherry 3.18 Fluorite
0.53 Cedar 2.63 Flint
0.38 Butternut 2.65 Feldspar
1.06 Box 3.37 Epidote
1.00 Blue gum 4.0 Emery
0.64 Birch 1.15
0.91 Logwood 2.51 Graphite
a
0.69 Locust 2.70 Granite
1.25 Lignum vitae 1.27 Glue
0.53 Larch
3.78 Elm 0.57
Gas carbon 1.88 Hickory 0.77
Gelatin 1.27 Holly 0.76
Glass, common 2.6 Juniper 0.56
Glass, flint 4.4
Wax, sealing 1.4 Coal, bituminous
3.1 Tourmaline 1.6 Coal, anthracite
3.6 Topaz 2.2 Clay
1.02 Tar 8.12 Cinnabar
0.94 Tallow, mutton 0.36 Charcoal, pine
0.94 Tallow, beef 0.57 Charcoal, oak
2.8 Talc 2.4 Chalk
1.59 Sugar 2.9 Cement, set
Ebonite
0.80 Beech 2.84 Dolomite
0.46 Basswood 3.27 Diamond
0.36 Bamboo 4.0 Corundum
0.13 Balsa 0.54
1.8
Cocoa butter 0.90 Wood:
Coke 1.4 Alder 0.55
Copal 1.09 Apple 0.75
Cork 0.24 Ash 0.75
Cork linoleum
0.77 Teak, Indian 1.14 Meerschaum
0.50 Sycamore 2.72 Marble
0.59 Spruce 3.9 Malachite
0.95 Satinwood 5.1 Magnetite
0.43 Poplar 1.18
Data from CRC Handbook of Tables for Applied Engineering Science,
2nd edition, edited by R. Bolz and G. Tuve, CRC Press (1973).
a
Some values reported as low as 1.6.
0.50 Willow 2.2 Opal
1.00 Water gum 3.5 Ochre
0.67 Walnut 2.88 Muscovite
0.98 Teak, African 2.9 Mica
0.917 Ice
0.75 Oak 3.0 Hornblende
0.69 Maple 5.1 Hematite
0.85 Mahogany, Spanish 2.32 Gypsum
0.66 Mahogany, Honduras 1.35 Gum arabic
Linoleum
0.72 Plum 2.72 Limestone
0.49 Pine, yellow 1.35 Lime, slaked
0.43 Pine, white 0.86 Leather, dry
0.84 Pine, pitch 1.88 Ivory
0.67 Pear
30.070 Ethane (C
2
H
6
)
2.014 Deuterium (D
2
)
70.906 Chlorine (Cl
2
)
28.011 Carbon monoxide (CO)
44.01 Carbon dioxide (CO
2
)
56.108 1-Butene (butylene) C
4
H
8
58.12 n-Butane (C
4
H
10
)
54.09
Basic Sciences
Topic: Properties of Gases - Molecular Weightat 1.0 Atm Pressure, 20C, Except as Noted
Molecular
Weight
Gas
Acetylene 26.04
Air (mixture) 28.966
Ammonia (NH
3
) 17.02
Argon (Ar) 39.948
Butadiene (C
4
H
6
)
Methane (CH
4
) 16.044
Methyl chloride (CH
3
Cl) 50.488
Neon (Ne) 20.179
Nitric oxide (NO) 30.006
Nitrogen (N
2
) 28.0134
Nitrous oxide (N
2
O) 44.012
Oxygen (O
2
) 31.9988
Ozone (O
3
) 47.998
Ethyl chloride (C
2
H
5
Cl) 64.515
Ethylene (ethene) C
2
H
4
28.054
Fluorine (F
2
) 37.996
Helium (He) 4.0026
Hydrogen (H
2
) 2.016
Hydrogen chloride (HCl) 36.461
Hydrogen sulfide (H
2
S) 34.076
Krypton (Kr) 83.80
Propane (C
3
H
8
) 44.097
Propylene (C
3
H
6
) 42.08
Sulfur dioxide (SO
2
) 64.06
Xenon (Xe) 131.30
Data from CRC Handbook of Tables for Applied Engineering Science,
2nd ed., edited by R. Bolz and G. Tuve, CRC Press (1973).
Pop_cmtproperty_7_freelime Cement Properties - Minor Constituents-Free lime
Pop_cmtproperty_8_magnesia Cement Properties - Minor Constituents-Magnesia
Pop_cmtproperty_9_alkalies Cement Properties - Minor Constituents-Alkali
oxides
Pop_cmtproperty_10_titanium Cement Properties - Minor
Constituents-Titanium dioxide
Pop_cmtproperty_11_P2O5 Cement Properties - Minor
Constituents-Phosphorous pentoxide
Pop_cmtproperty_12_setting Cement Properties-Setting and Harding of Cement
Pop_cmtproperty_13_1_hydration Cement Properties -Influences of age on rate
of hydration
Pop_cmtproperty_13_2_hydration Influences of Composition of cement on rate of
hydration
Pop_cmtproperty_13_3_hydration Influences of fineness of cement on rate of
hydration
Book-IV Pop ups
Cement Properties
File Name :
4_4_pop_cmtproperties_n
Pop_cmtproperty_1_oxides Cement Properties -Oxides
Pop_cmtproperty_2_C3S Cement Properties - Major
Constituents-Tricalcium silicate
Pop_cmtproperty_3_C2S Cement Properties - Major
Constituents-Dicalcium silicate
Pop_cmtproperty_4_C3A Cement Properties - Major
Constituents-Tricalcium aluminate
Pop_cmtproperty_5_C4AF Cement Properties - Major
Constituents-Tetracalcium aluminoferrite
Pop_cmtproperty_6_gypsum Cement Properties - Minor Constituents-Gypsum
Pop_cmtproperty_13_4_hydration Influences of water / cement ratio on
hydration
Pop_cmtproperty_13_5_hydration Influences of temperature on hydration
Pop_cmtproperty_13_6_hydration Influences of admixtures on hydration
Property of:
1 - 3 SO
3
[ ]
0.1 - 0.2 P
2
O
5
[ ]
0.1 - 0.4 TiO
2
[ ]
0.5 - 1.3 Na
2
O K
2
O + [ ]
0.1 - 5.5 MgO [ ]
0.5 - 6.0 Fe
2
O
3
[ ]
3 - 8 Al
2
O
3
[ ]
17 - 25 SiO
2
[ ]
60 - 67 CaO [ ]
Composition (wt. %) Oxide
Approximate Composition of Portland Cement
Cement Properties -Oxides
File Name :
Pop_cmtproperty_1_oxides
Pop up files:
Cement Properties
Book-IV Chapter 4
Book-IV Chapter 4 Pop up files:
Cement Properties
File Name :
Pop_cmtproperty_5_C4AF
Cement Properties - Major Constituents-Tetracalcium
aluminoferrite
Tetracalcium aluminoferrite
C
4
A F [ ] ranges from 5% to 10 % in ordinary portland
cement average being about 8 %
C
4
A F [ ] is a complex compound consisting of 4
parts of CaO , 1 part of Al
2
O
3
and 1 part of
Fe
2
O
3.
C
4
AF is known to react with water
instantaneously resulting in flash set of
cement within a few minutes. and is
accompanied by release of heat of
hydration of about 420 J /gm. Its strength
attainment is quite uncertain and can be
very low like C
3
A or very high as C
3
S
CS - Compressive Strength- N/mm
2
day - Number of days
day
1
3
7
28
60
90
135
180
270
360
,
: CS
0.2
0.4
1
2
3.7
4.8
5.5
5.7
5.8
5.9
,
:
0 100 200 300 400
0
2
4
6
Compressive Strength of C4AF
Days
C
o
m
p
r
e
s
s
i
v
e

S
t
r
e
n
g
t
h

-

N
/

m
m
2
CS
day
According to Bogue
Cement Properties
File Name :
Pop_cmtproperty_10_titanium
Cement Properties - Minor Constituents-Titanium dioxide
Titanium dioxide
Ti O
2
[ ]
Though present in small quantity ranging from 0.1 to
0.4% titanium dioxide does not have any significance
influence on properties of cement.
Cement Properties
File Name :
Pop_cmtproperty_13_4_hydration
Cement Properties -Influences of Water/ -Cement ratio on
rate of hydration -
Influences of water / cement ratio on hydration
The ration of water mixed with cement is defined as W/C
ratio. As the ratio is higher, it ensures that that there is
sufficient availability of water to hydrate the cement
particles.
As the initial rate of hydration is high, the effect of varying
w/c ratio donot show any perceptable difference at the
initial period.But as the time passes and the rate of
hydration falls the differences are seen i.e at higher w/c
ratio the the average rate of hydration is higher.
Property of:
Cement Quality Tests-Heat of hydration Pop_CmtTests_5_Hydration
Cement Quality Tests-Soundness Pop_CmtTests_4_Soundness
Cement Quality Tests-Workability Pop_CmtTests_3_Workability
Cement Quality Tests-Setting Times Pop_CmtTests_2_Setting
Cement Quality Tests-Compressive Strength Pop_CmtTests_1_compressive
File Name : 4_5_pop_cmtqtests_n
Cement Quality Tests
Book-IV Pop ups
Quality tests
File Name : Pop_CmtTests_1_compressive
Cement Quality Tests-Compressive Strength
Compressive Strength
Description
It is the resistance to load under compression . A
morter or concrete is prepared as per standards
(BS4550 for UK). Water, cement, fine aggregate ,
course aggregate are mixed and standard mould s
are prepared. The moulds are kept immersed in
water.This is the most important property of
commercial cement . Higher fineness contribute to
early strength andalso higher strength of cement.
Air entrained in concrete ,if abnormal , the mix must
be rejected. Compaction of concrete in the mould is
of great importance.
Test
Compressive strengths are failure strengths of
cement moulds kept under water for curing and
development of strength. Tests are usually carried
out after 3days, 7days and 28days. The strengths
achieved are known as 3day strength, 7day
strength and 28day strength respectively. For OPC
min. strength as per BS12 are 13N/mm2 after
3days, 29N/mm2 after 28days.
Book-IV Pop ups
Pressure
File Name : 4_6_pop_pressure_n
Pop_Pressure_1_def Pressure- definitions
Property of:
Property of:
Psychrometry-Enthalpy of Moist Air Pop_Psychro_8_enthalpy
Psychrometry-Dry Air-Water Vapour and Wet Air- Pop_Psychro_7_DryWetAir
Psychrometry- Psychrometric Relations Pop_Psychro_5_relations
Psychrometry -Dew Point Temperature Pop_Psychro_4_DewPt
Psychrometry-Relative Humidity Pop_Psychro_3_RH
Psychrometry-Specific Humidity Pop_Psychro_3_1_sphumidity
Psychrometry-Wet Bulb Depression Pop_Psychro_2_wetBulbDep
Psychrometry-Dry Bulb -Wet Bulb Pop_Psychro_1_wet_dry_bulb
Psychrometry Pop_Psychro_0_psychrometry
File Name :
4_7_pop_psychrometry_n
Psychrometry
Book-IV Pop ups
Psychrometry
File Name : Pop_Psychro_1_wet_dry_bulb
Psychrometry-Dry Bulb -Wet Bulb
Dry Bulb Temperature
The temperature of air,as measured by any
ordinary thermometer is indicator of Dry Bulb
Temp. of air.
Wet Bulb Temperature
When the bulb of the thermometer is wrapped by a
wet cloth and kept continuously moist during the
measurement period, the temperature so indicated
is Wet Bulb Temp.
Psychrometry
File Name : Pop_Psychro_4_DewPt
Psychrometry -Dew Point Temperature
Dew Point Temperature
When a given volume of air, containing certain
quantity of water vapour is made to cool continuously,
it reaches a temperature when it cannot hols the
water vapour any more. The air ,for the given quantity
of water vapour attains its saturation temp.The water
vapour now starts condensing as temp. is lowered
any further.This temperature is called the Dew Point
Temperature.
How to read from Steam Table
Dew point temp. can be directly obtained from the
Steam Table. This can be read as saturation
temp.corresponding to the partial pressure of water
vapour in the air.If say the partial pressure of water
vapour is P
v
then we can read the dew point temp.as
the saturation temp.of steam corresponding to the
pressure P
v
Property of:
Equations Pop_Gen_6_equations
Degree of Freedom of a Problem - A Definition Pop_Gen_5_def. deg. freedom
Degree of Freedom Analysis Pop_Gen_4_Deg. of Freedom
Variables and Constants Pop_Gen_3_Variables
Units Pop_Gen_2_Units
Dimension Pop_Gen_1_Dimension
File Name : 4_8_pop_gentopics_n
General Topics
Book-IV Pop ups
General Topics
File Name : Pop_Gen_1_Dimension
Dimension
A dimension is an attribute of a physical object which
qualifies a measured value. Fundamentally, all
measurement of physical objects somehow relate to Mass
(M), Length (L) and Time (T). These are, therefore, known
as Basic or Fundamental Dimension.All other attributes of
an object can be expressed in terms of the fundamental
dimensions. by using physical principles.
General Topics
File Name : Pop_Gen_4_Deg.ofFreedom
Degree of Freedom Analysis
A degree-of-freedom (DF) analysis is an accounting of the
variables associated with a problem and the facts and
relations available to determine values for those variables.
To analyse a problem it necessary to check the classes of
variables,theiir relationship,and the other information that
are available.
Book-V Charts & Tables
Steam
File Name : 5_1_charts_steam_n
chartsandtables_1_steamtables Charts and Tables - Steam Tables
Property of:
mbar Y data
air
1
:
deg C X data
air
0
:
Column "3" has data on Humidity of Steam in terms of gms / Nm3 of dry air
Column "2" has data on Humidity of Steam in terms of gms / kg.. of dry air
Column "1" has data on Partial pressure of Steam
Column "0" has data on Dew Point Temp.
data
air
0 1 2 3 4
0
1
2
3
4
5
6
7
8
9
10
11
20 23.37 14.7 18.99
21 24.85 15.66 20.24
22 26.42 16.68 21.55
23 28.08 17.76 22.94
24 29.82 18.89 24.4
25 31.66 20.09 25.96
26 33.6 21.37 27.6
27 35.64 22.74 29.34
28 37.79 24.17 31.18
29 40.04 25.67 33.12
:
Table of Humidity of a Saturated Gas
Total Pressure 1013 mbar
Steam tables are very useful to determine psychrometric properties ofhumid air. From the tables
below ,we can determine dew point temperature, humidity and partial pressure and their
correlation.
Steam Tables
Charts and Tables - Steam Tables
File Name : chartsandtables_1_steamtables
Pop up files: General Topics Book-V Chapter 1
fit P
vs
( )
25.691
TD 25.691 deg. C
To find from table , humidity = w1 gms /kg. dry air Function " linterp" reads the value
of third argument P
vs
in the
column named by first argument
by linear interpolation.Then reads
off the corresponding value from
the column named by the second
argument.Column data should be
in acsending order for
interpolation to work.
fit1 P
vs
( )
linterp Y Z
1
, P
vs
, ( ) :
w1 fit1 P
vs
( ) :
fit1 P
vs
( )
20.974
w1 20.974 gms /kg. dry air
To find from table , humidity = w2 gms /Nm
3
dry air
fit2 P
vs
( )
linterp Y Z
2
, P
vs
, ( ) :
fit2 P
vs
( )
27.093 gms /Nm
3
dry air w2 fit2 P
vs
( ) :
w2 27.093 gms /Nm
3
dry air
Z
1
data
air
2
:
gms
kg dry air
density of dry air 1.29 kg/Nm
3
Z
2
data
air
3
:
gms
Nm
3
dryair
To find dew point temperature =TD deg. C for given partial pressure of water vapour P
vs
mbar
Let partial pressure of water vapour in saturated air be P
vs
kg / cm
2
P
vs
0.033 : kg / cm
2
Or
P
vs
1000 P
vs
: mbar
P
vs
33 mbar
fit P
vs
( )
linterp Y X , P
vs
, ( ) : TD fit P
vs
( ) : deg. C
13 /3/01
Refer pp 37 in bookDust load measurements
in Gas Flows-- Lurgi
Book-V Charts & Tables
Reactivity of Coal
File Name : 5_4_charts_reactivity_n
chartsandtables_4_coalreactivity Charts and Tables- Reactivity of Coal
Property of:
0 10 20 30 40
0
1
2
3
4
Lignite 40 % R on 90 mic.
Anthracite -15 5 Ron 90 mic.
Coal Reactivity Chart
Time in sec
L
o
s
s

o
f

O
x
y
g
e
n
4
0
O
LIGNITE
O
ANTHRA
40 0 T
T DATA
0
:
O
ANTHRA
DATA
2
: O
LIGNITE
DATA
1
:
DATA
0 1 2
0
1
0 0 0
2 3 1
:
Loss of
O2
% O
LOSS
Burnout time of coal sec T
Reactivity of Coal
Charts and Tables- Reactivity of Coal
File Name : chartsandtables_4_coalreactivity
Pop up files: General Topics Book-V Chapter 4

Tics of Cement

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Second radiation constant 0.01438769 m K

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