Cement production – Calculation of raw mix composition 1

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13.8 = 68.5 x 100/ 496.1

21.4 = 13.8 x 100 / (100-35.6)

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Limestone = 3.324 x 100 /(3.324 + 1) = 76.87%
Marl = 1 x 100 /(3.324 +1) = 23.13%

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76.87 x 8.70 /100 = 6.69 14.33 x 100 /(100 – 34.67) = 21.94

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1. Using alligation alternate method to get a raw mix with CaCO3 content of 80%.
With limestone 82% CaCO3 and clay 25% CaCO3.
2. Using alligation alternate method to get a raw mix with CaCO3 content of 72%.
With limestone 90% CaCO3 and clay 12% CaCO3.
3. Suppose that the following raw materials are available:

a) For 72% CaCO3 in raw meal using alligation alternate method to get limestone to clay
proportion.
b) Raw mix composition %.
c) Clinker composition %.

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4. Suppose that the following raw materials are available:

a) For 76% CaCO3 in raw meal using alligation alternate method to get limestone to clay
proportion.
b) Raw mix composition %.
c) Clinker composition %.
5. Two raw materials are given with the following chemical composition:

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 a) Assuming a hydraulic module HM = 2.1, calculate the composition of raw mix %.
b) Composition of clinker %.

6. Two raw materials are given with the following chemical composition:

a) Assuming a hydraulic module HM = 2.4, calculate the composition of raw mix %.

b) Composition of clinker %.

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Limestone = 53.03 x 100 / (53.03 + 13.69 + 1) = 78.26
Clay = 13.69 x 100 / (53.03 + 13.69 + 1) = 20.24
Pyrite cinders = 1 x 100 / (53.03 + 13.69 + 1) = 1.5

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1. Two raw materials are given with the following chemical composition:

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a) Assuming a lime saturation factor KSK = 0.95, calculate the composition of raw mix %.
b) Composition of clinker %.

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2. Two raw materials are given with the following chemical composition:

a) Assuming a lime saturation factor KSK = 0.98, calculate the composition of raw mix %.
b) Composition of clinker %.

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3. Three raw materials are given with the following chemical composition:

a) Assuming a lime saturation factor KSK = 0.91 and silica ratio SM = 2.45.Calculate the
composition of raw mix %.
b) Composition of clinker %.

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4. Three raw materials are given with the following chemical composition:

a) Assuming a lime saturation factor KSK = 0.97 and Alumina ratio TM = 1.95 .Calculate the
composition of raw mix %.
b) Composition of clinker %.

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21.5 – 1.07 = 20.43 4.53 x 100 /97.73 = 4.63

Composition contributed from 32

coal ash
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1. Calculate clinker chemical composition consisting of two components, limestone and clay,
considering the influence of the coal ash on the composition of the clinker; the lime
saturation factor KSk = 0.95. The coal consumption rate is 20% referred to the clinker
weight, the ash content of the coal is 11 %; and the ash absorbed by the clinker is 100%.
2. Calculate raw mixed ignited; the silica ratio and alumina ratio?

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From the “Proportion” column of Table 2.11 we get column 3, 4 of table 2.9

From the “Required” row of table 2.11 41

From column 1 & 2 of table 2.9 we get table 2.10 below :

C3S of Limestone = 4.071 x 95.33 – 7.6 x 2.18 – 6.718 x 0.88 – 1.43 x 0.67 = 364.65
C3S of Clay = 4.071 x 5.55 – 7.6 x 65.75 – 6.718 x 17.05 – 1.43 x 6.95 = -601.58
1 – 0.3141 = 0.6859 363 x 0.6859 = 248.97 -267.23 x 0.6859 = - 183.31

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50% C3S required
25% C2S required

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1. Calculate the raw mix proportion of limestone and clay and potential
composition mineral of clinker with the C3S required of 62% with the following
raw material chemical composition:
1. Limestone: SiO2 : 2.5 ; Al2O3 : 0.9 ; Fe2O3 : 0.60 ; CaO : 95. 57 and MgO : 0.43
2. Clay: SiO2 : 66 ; Al2O3 : 16.76 ; Fe2O3 : 7.37 ; CaO : 5.12 and MgO : 2.01 and other 2.74
2. Calculate the raw mix proportion of limestone, clay and sand and potential
composition mineral of clinker with the C3S required of 52% and C2S 24% with
the following raw material chemical composition:
1. Limestone: SiO2 : 3.71 ; Al2O3 : 2.98 ; Fe2O3 : 3.12 ; CaO : 90.19
2. Clay: SiO2 : 57.02 ; Al2O3 : 30.21 ; Fe2O3 : 10.87 ; CaO : 1.9
3. Sand: SiO2 : 96.09 ; Al2O3 : 2.39 ; Fe2O3 : 1.5 ; CaO : 0.02

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1. Can you figure out what is the effect between potential compound composition
calculation with C3S = 50% & C2S = 25 % and C3S = 25 % & C2S = 50% according
to the calculation method of the above example (Bogue calculation method)?
2. Can you figure out what is the difference between potential compound
composition calculation with 4 only main oxides (SiO2, Al2O3, CaO, Fe2O3) and in
case including the auxiliary components?

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Q&A
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