In the name of Allah, the Most

Merciful, the Most Kind

) 1
2
 RAW MIX

“ RAW MIX OR KILN FEED IS A FINELY GROUND

BLEND OF LIME STONE, ADDITIVE OR
CORRECTIVE MATERIALS MIXED IN
PERDETERMINED PROPORTIONS ”

3
 RAW MIX DESIGN

OBJECTIVE :-
1) Measure the quantitative proportions of raw
material.
2) In order to obtain desired clinker quality .
3) Determine chemical composition and burn
ability of raw meal.

4
 Introduction
• The lime stone is main raw material for
manufacturing of the clinker ,
• Laterite, Clay etc are also used as a corrective
material to maintain desired quality of clinker.

5
In order to obtain a product of desired quality
the various steps involved in the process need
careful control and in this direction input of Raw
mix Design formation is extremely important.
Mineral composition :-
Mineralogical composition of the raw material like
L/stone, Laterite etc are very important for raw
mix designing point of view. Important
characteristics are –
• Physical amenability to crushing , Grinding &
homogenization .
• Individual dissociation or Breakdown character.
Therefore knowledge of mineralogical
composition of all raw material is very essential to
understand their behavior during the
manufacturing process. The following are the
oxides occur in raw mix.
 OXIDE MINERAL

1) CaO Lime Stone and Gypsum .

2) SiO2 Quartz, Clay , Shale
3) Al2O3 Clay , etc.
4) Fe2O3 Heamatite , Laterite , Magnetite
etc.
5) S Gypsum.

8
 Raw mix design

Few chemical parameter known as moduli

values responsible for producing clinker on
firing. Moduli values are governed by five major
oxides like CaO, SiO2, Al2O3, Fe2O3, MgO.

The compositional requirement of a raw mix

and the chemical phase composition of the clinker
aimed at are summarized as follows.
9
1 ) Silica modules :-
Effect :- A High SM
1) Results in harder burning and high fuel consumption
2) Causes difficulty in coating formation and hence the
radiation from shell is high.
4) Deteriorates the kiln linings
5) Increase unsoundness ( High CaO )
6) Results in slow setting & Harding cement
Range ( Ratio )
2.0 – 3.0
Empirical formula
SiO2

Al2O3 + Fe2O3
2 ) Alumina modules :-
Effect :- A High AM
1) Imparts harder burning and entails higher fuel cons.
2) Increase the proportion of C3A and reduce C4AF
3) Reduce the liquid phase and kiln output
4) Tends to render quick setting and strength at early strength
1) If A/F is low and raw mix is without free SiO2, Clinker
sticking and balling is high .

Range ( Ratio )
0.60 – 1.3
Empirical formula
Al2O3
11
Fe2O3
3 ) Lime saturation factor :-
Effect :- A High LSF
1) Make it difficult to burn raw mix
2) Tends to produce unsound cement
3) Increase C3S contents
4) Reduce C2S contents
5) Slow setting with high early strength .

Range ( Ratio )
95.0 – 105.0
Empirical formula
CaO x 100

2.8 SiO2+ 1.2 Al2O3+ 0.65 Fe2O3 12

4 ) Free SiO2 :-
Effect :- A High Free SiO2

1) Increase power & Fuel consumption

2) Difficult in coating formation
3) Deteriorates refractory lining

Range :- As low as possible

Normally in Kiln feed free silica not more than

3 % is desirable.
13
5 ) Magnesia :-
Effect :- A High MgO

1) Crystals when MgO more than 2 %

2) Reduces viscosity and surface tension of clinker liquid
3) Tend to ball easily in the burning zone.

Range ( % )
0.0 – 6.00

Empirical formula
MgO

14
6 ) Alkali :-
Effect :- A High Alkali
1) Improve burnability
2) Increase liquid %
3) Easy coating formation
4) External & Internal alkali cycle formation

Range ( % )
0.20 – 0.30

Empirical formula

Na2O + K2O
15
7 ) Sulphur :-
Effect :- A High Sulphur
1) More than 2.5 – 4.0 % cause sulphate expansion.
2) Chocking of the preheater & formation
of kiln coating

Range ( % )
0.50 – 1.00
Empirical formula
S

16
8 ) Chlorides :-
Effect :- A High Chloride
1 ) Forms more volatile Cl and cause
operational problem due to its complete
vaporization in the burning zone.
2 ) Increase ring formation .

Range ( % )
0.00 – 0.015

Empirical formula

Cl
17
 9 ) Clinker Liquid :-
1) Formation of dense clinker
Effect :- A High Liquid 2) Easy burning
content 3) Hard to grind

Effect :- A Low Liquid 1) Porous clinker

content 2) Hard burning

Range ( % )
25.0 – 29.0
Empirical formula at 1450 OC
3 Al2O3+ 2.25 Fe2O3+ MgO +Alkali
OR
1.13 C3A + 1.35 C4AF + MgO + Alkali 18
 Method of calculation – Raw mix design

There are many method of calculation from the most simple

to more complicated ones. The basis of calculation is on the

Chemical composition of raw material.

19
 Raw mix design – Two component

1) Aligation Alternate Method :-

This is the simplest method for solving blending problem. The

Method allows the determination of the proportion of two
raw material components with lime content as per set point.
For example :-
What mixing proportion is required for Imp coal with 17.0 %
Ash & Ind coal with 35.0 % ash , to get a fine coal ash 20.0 %
Ash content.

20
 Ash %

Imp coal 17.0 ( 35 - 20 ) 15.0 part Imp coal

20.0

Ind coal 35.0 ( 20 - 17 ) 3.0 part Ind coal

21
 Converting the parts proportion to weigh percentage

15.0 x 100
% Imported coal =
( 15.0 + 3.0 )

= 83.33 %

3.0 x 100
% Indigenous coal =
( 15.0 + 3.0 )

= 16.67 %
22