Contents
Assessment of Cement Raw Materials
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Why assess raw materials?
- Judge suitability for cement manufacturing
- Allow selection of suitable equipment and processes
- Criteria
-Chemical composition to conform with cement requirement
-Handling and comminution properties
-Burning behaviour
- Determined by
-Chemical composition
-Mineralogical composition
-Petrographical properties
Assessment of Raw Materials Based on Chemical Characteristics
Raw Materials for the Cement Industry
Main Components
-Calcareous
-Argillaceous
-Cement Stone
Corrective Materials
-C, S, A, F rich Materials
Additive Materials
-Gypsum
-Fly-Ash
-Pozzolan
-Slag
-Mineralizer
Chemical Composition
SiO2 MgO Tl
Al2O3 SO3 Cd
Fe2O3 K2O Hg
CaO Na2O etc.
TiO2
Cr2O3
P2O5
Cl
F
Element Typical for Average earth cement (%) crust (%)
Ca 46 4
Si 10 28
Al 3 8
Fe 3 5
Classification of Calcareous Components
95 – 100 High-grade Limestone Limestone
Marble
Chalk
Coral Limestone
85 – 95 Limestone Lime Sand
Shell Deposit
75 – 85 Marly Limestone Marly Limestone
Classification of Argillaceous Components
65-75 25-35 Calcareous Marl Calcareous Marl
35-65 35-65 Marl Marl
25-35 65-75 Clayey Marl Clayey Marl
15-25 75-85 Marly Clay Clay
Loess
5-15 85-95 Clay Claystone
Mudstone
0-5 95-100 High Grade Clay Siltstone
Shale
Corrective Materials
deficiency of material concentration
“Iron” (Fe2O3) Iron Ore 60% Fe2O3
Pyrites Ash 60-90% Fe2O3
“Alumina” (Al2O3) Bauxite 50% Al2O3
Laterite 25% Al2O3
Kaolinite 40% Al2O3
“Silica” (SiO2) Quartz sand 80% SiO2
Quartzite 80% SiO2
“Lime” (CaO) Limestone 90% CaCO3
Marble
Effects of Minor Elements
Raw Meal (%) Cem. (%)
MgO 0.50 – 4.00 5 – 6 Expansion
Standards
SO3 0.04 – 1.06 2.3 – 4 Volatilisation
Standards Setting behaviour
Emission
K2O 0.01 – 1.40 0.6 Volatilisation
Na2O 0.03 – 0.60 Low Alk. Alkali Aggregate Reaction
Raw Meal (%) Cem. (%)
P2O5 0.03 – 0.50 appr. 1.0 Reduces early strength
Cl 0.01 – 0.2 0.05 – 0.1 Volatilisation
in several Corrosion
Standards
F 0.00 – 0.24 Flux
Increased setting time
Raw Meal (%)
TiO2 0.10 – 0.47 Flux
Retards init. setting
Increases strength
Cr2O3 0.01 – 0.05 “Chromium Eczema”
Colour
Mn2O3 0.03 – 0.83 Colour
Effects of Environmentally Relevant Compounds
Raw Meal
Pyritic Sulfur 0 – 0.8 % Emissions
(10-20% – SO2)
Organic Carbon 0.05 – 0.7 % Emissions
(1-10 % – Volatile
Org. Carbon)
Ammonium 20-500 ppm Emissions
– Ammoniac
– Aerosol (NH4Cl, NH4NO3, …)
– NOx
Assessment of Raw Materials Based on Mineralogical Characteristics :
Mineral
-Minerals are the physically and chemically homogeneous, naturally occurring solid components of the earth.
There are about 4000 mineral species known.
Minerals are crystalline.
Crystal
-Crystals are homogeneous solids, in which the atoms are arranged in a regularly repeating pattern.
Rock
-Rocks are aggregates of minerals.
Mineralogical Composition of Raw Mixes:
4 Clay Minerals e.g. Al4[Si4O10](OH)8 Amphiboles e.g. Ca2Mg5Si8O22(OH)2 Pyroxenes e.g. Ca2[Si2O6] Olivine (Mg,Fe)2[SiO4]](https://sp-ao.shortpixel.ai/client/to_auto,q_lossless,ret_img,w_729,h_386/https://www.cementequipment.org/wp-content/uploads/2016/09/Mineralogical-Composition-of-Raw-Mixes.jpg)
Aragonite CaCO3
Dolomite CaMg(CO3)2
Magnesite MgCO3
Siderite FeCO3
Silicates Quartz SiO2
Feldspars e.g. (K,Na)AlSi3O8
Micas e.g. K2Al4[Si6Al2O20](OH,F)4
Clay Minerals e.g. Al4[Si4O10](OH)8
Amphiboles e.g. Ca2Mg5Si8O22(OH)2
Pyroxenes e.g. Ca2[Si2O6]
Olivine (Mg,Fe)2[SiO4]
Mineralogical Composition of Raw Mixes
Magnetite Fe3O4
Hydroxides Gibbsite Al(OH)3
Goethite FeO(OH)
Sulfides Pyrite FeS2
Sulfates Gypsum CaSO4 x 2 H2O
Anhydrite CaSO4
Properties of Clay Minerals
Sheet Structure: Presence of interlayered exchangeable ions and water
Exploitation Methods
Preparation, Handling Stickiness, Coating
Slurry Properties Water Content, Rheology
Raw Meal Properties Moisture Content, Nodulisability
Burning Behaviour Burnability
Mineral Content, Grain Size
Reactivity of Minerals, Coating,
Dust Formation,Volatility of Alkalis
Special Products Expansion Properties
Hardness of abundant minerals (Mohs)
Quartz 7
Feldspar 6 “hard”
Pyroxene 6 minerals
Amphibole 6
Calcite 3
Dolomite 3.5
Mica 3 “soft”
Chlorite 2 – 3 minerals
Clay minerals 2
Assessment of Raw Materials Based on Petrographic Characteristics:
Rock Characteristics
- Mineral Assemblage: Types of minerals present
- Texture and Structure
-Spacial distribution of minerals
-Form of minerals
-Size distribution of minerals and pores
-Orientation of minerals and pores
- Consolidation
Physical Rock Properties
- Density and Porosity
- Water Absorption, Moisture
- Compressive Strength
- Elasticity
- Cleavability
- Hardness
- Crushability
- Abrasivity
- Grindability
- Reactivity under increasing temperature
Raw Materials Assessment – Summary
- Chemical Composition
-Main classes of raw materials?
-Main elements?
-Most critical minor elements
- Chemical Composition
-Main classes of raw materials?
-Main elements?
-Most critical minor elements
- Rock Properties
-Technical properties related to mineralogical composition, grain size, porosity, and solidification of a rock?
if you have any questions
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