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ASIA-PACIFIC PARTNERSHIP

Cement Formulae Hand Book

©

2009,

Confederation of Indian Industry

While every care has been taken in compiling this Formula Handbook, neither CII- Godrej GBC nor Asia-Pacific Partnership (APP) accepts any claim for compensation, if any entry is wrong, abbreviated, omitted or inserted incorrectly either as to the wording space or position in the handbook. The handbook is a store of information so that it will be useful to the plant personnel involved in energy conservation and can be used by them readily. All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without the prior written permission from CII- Sohrabji Godrej Green Business Centre, Hyderabad. Published by Confederation of Indian Industry CII - Sohrabji Godrej Green Business Centre Survey # 64, Kothaguda Post, R R District, Hyderabad - 500 084, India.

FORE WORD

Indian cement industry is the second largest producer in the world with installed capacity of 206.9 Million TPA as on 31.12.2008 and is expected to grow at the rate of 10% in the coming years. Though the Indian cement plants are front runners interms of capacity utilisation and energy consumption levels, the potential for further energy reduction still exists. Adapting latest technologies, fine tuning, continuously tracking the performance, keeping up date on the latest developments and sharing of best practices are key areas that can bring down energy consumption levels. Up keeping the knowledge on basics, latest norms and reference data are essential for the emerging engineers for understanding the hidden opportunities, estimating and achieving the energy conservation potential through fine tuning, technology replacement etc. This pocket hand book has been compiled from useful information available at various sources, intended as a store of information so that it will be useful to the plant personnel involved in energy conservation activities and can be used by them as a ready reckoner even at the site.

(G. Jayaraman) Kolkata

Acknowledgement

CII express our sincere gratitude to the following experts for their assistance, value added input and immense cooperation extended in completing the “Cement Formulae Hand Book”. Mr C K Jain, Vasavadatta Cements Mr G C Pandey –Lafarge Malaysia Mr J Thirumeni, India Cements Mr L Rajasekar, Grasim Industries Mr Murthy Rao, Madras Cements Ltd Mr Manoj Jindal, ACC Mr M C Gupta, Century Cements Mr P Ramasamy, Star Cement Mr R Bhargav, Shree cements Mr S Natarajan, Grasim Industries

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FORMULAE

CONTENTS

Chapter No.

Title

Page. No.

I

Quality Control Formulae

9

II

Formulae used in Combustion calculations

14

III

Kiln Performance & Efficiency

16

IV

Useful formulae in Kiln Design & Operation

18

V

Grinding Mill Investigation

20

VI

Electrical Engineering

23

VII

Fan Engineering

24

VIII

Fluid Flow

26

IX

Heat Transfer

29

X

Physical Chemistry

31

XI

Transport Equipment

32

XII

Finance

35

XIII

Safety Formulae

37

XIV

Miscellaneous Formulae

38

2

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NORMS

CONTENTS

Chapter No.

Title

Page. No.

I

Electrical Energy Consumption Target

45

II

Thermal Energy Consumption Target

45

III

Operating Hours

46

IV

Days of Storage

46

V

Comparison between different dry process technologies

47

VI

Kiln & Pre-Heater

48

VII

Kiln Gas Velocities

48

VIII

Comparison between different types of Coolers

49

IX

Primary Air Momentum

49

X

Cyclones

50

XI

Bag Filters

50

XII

Moisture level of various Limestone

50

4

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REFERENCE DATA

CONTENTS

Chapter No.

Title

Page. No

1.

Atmospheric Pressure and Density Vs Altitude (00c)

53

2.

Specific gravities & grindabilities

54

3.

Bulk densities of materials for silo storage

55

4.

Molecular weight of chemicals (g/g mol)

56

5.

Thermal conductivities of various substances

57

6.

Angle of repose

57

7.

Typical data for solid fuels (% as recd/mineral-matter-free)

58

8.

Typical data for liquid fuels

59

9.

Physical data of exhaust gas with various levels of (dry) excess air

59

10.

Typical specifications used by vendors for burners with indirect firing systems

60

11.

Gross calorific values of fuels

60

6

12.

Proximate & ultimate analysis of indian coal

61

13.

Ball mill-ball weight & surface area

62

14.

Ball mill charge volume

63

15.

Useful data for grinding mill study

64

16.

Ball mill charging

65

17.

BIS specification of additives

67

18.

BIS specifications for various cements

68

19.

GHG emission factor for various grids

71

20.

Transformer loss

72

21.

Bricks per ring

73

22.

Emissivity value of surfaces

78

23.

Conversion factor

78

24.

Heat Balance Calculation

81

Conclusion

Page No. 81

7

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FORMULAE

8

9

Chapter – I Quality Control Formulae 1.

Loss on ignition (LOI) (CO2 from Calcination) Ignition loss

=

0.44 CaCo3 + 0.524 Mg Co3 + …. + combined H2O + Organic matter

LOI refers to the release of volatile matter such as CO2, water vapor and other combustibles 2.

Silica Modulus/Ratio (SM) SM

=

SiO2 Al2O3 + Fe2O3

Typical Range

:

1.8 – 2.7

Higher the silica modulus harder to burn and exhibits poor coating properties. Lower the silica modulus there may be more melt phase and coating can become thick and leads to ring formation and low early strength (37days) in the cement 3.

Alumina Modulus/Alumina iron ratio (AM) = Al2O3

AM

Fe203 Typical Range

:

1.0 – 1.5

Clinker with higher the Alumina modulus results in cement with high early strength 4.

Lime saturation factor (LSF) a.

If alumina modulus > 0.64 LSF

= CaO 2.8 SiO2 + 1.65 Al2O3 + 0.35 Fe2O3

10 b.

If alumina modulus < 0.64 LSF

= CaO 2.8 SiO2 + 1.1 Al2O3 + 0.7 Fe2O3

Typical Range

:

92-105 %

When the LSF approaches unity, the clinker is hard to burn and often shows the excessive free lime contents. 5.

6.

% Liquid % Liquid

=

1.13 C3A + 1.35 C4AF + MgO+ Alkalies

C 3A

:

% of Tricalcium Aluminate

C4AF

:

% of Tetra-calcium Alumino ferrite

Bogue’s Formula for Cement Constituents a.

If alumina modulus >

0.64

C3S

4.071 CaO – (7.602 SiO2 + 6.718

=

Al2O3 + 1.43 Fe2O3 + 2.852 SO3)

b.

C2S

=

2.867 SiO2 – 0.7544 C3S

C3A

=

2.65 Al2O3 – 1.692 Fe2O3

C4AF

=

3.043 Fe2O3

If alumina modulus
4000, it is turbulent flow N Re

3.

:

D*v*ρ µ

D

:

diameter of the pipe (m)

V

:

velocity of fluid (m/s)

ñ

:

density of fluid (kg/m3)

µ

:

viscosity of fluid (kg/ms)

Flow Measurement Using Pitot Tube Pitot tubes are used to measure air flow in pipes, ducts, and stacks, and liquid flow in pipes, weirs, and open channels a. Conditions for measuring point: 

Straight stretch of min 5D before & 2D after the pt. is necessary (D= inside diameter of the duct)

27 

As straight stretch as possible



No bends, flanges or dampers

b. Isokinetic point b1. For circular ducts :

Dia

0