Grinding

Systems & Cement Composition Optimisation

Cement additives added value

Laurent GUILLOT – Cemtech Asia 2016 – Manila Philippines | Date: 20-21 June 2016

Cement additives added value

• Process & Cement additives interactions

§ Process specificities (grinding/separation)
§ Ball mills / closed circuits
§ Grinding optimization from raw mix to clinker

• Strength enhancers and cementitious

§ Cementitious materials reactivity
§ Pozzolan cements
§ Composite cements

• Conclusion & Stakes for future

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 Cement additives added value

• Process & Cement additives interactions

§ Process specificities (grinding/separation)
§ Ball mills / closed circuits
§ Grinding optimization from raw mix to clinker

• Strength enhancers and cementitious

§ Cementitious materials reactivity
§ Pozzolan cements
§ Composite cements

• Conclusion & Stakes for future

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Cement additives added value

u Main cement grinding technologies

HORIZONTAL BALL MILL

How to optimize with cement additives ?

HOROMILL ®

ROLLER PRESS
VERTICAL MILL

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 Cement additives added value

Ø Different types of separators (from 1st to 4th generation)

Different
performances

How to optimize with cement additives ?

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Cement additives added value

• Increase mill productivity

• Mill specific power consumption reduction
• Better separation
• Coating phenomena limitation
• Improvement of PSD / Cement Quality
• Improvement of powder flowability

þ Grinding aids to be designed accordingly

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 Additives for cement manufacturing optimization

Closed Circuit
Elevator
Separator
Fines - Cement

Filter
Rejects

Grinding aid
Mill

1. Clinker 2. Gypsum 3. Mineral addition

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Cement additives added value

Ø Grinding aid has an impact (balance):

Grinding efficiency Materials flows

à In the mill
à In the mill
à In the separator
Materials: Powder:
CHRYSO® ADM 3
Chemical composition Size distribution
CHRYSO® ADM 831
Mineral composition Particle shapes
CHRYSO® AMC 12
Microstructure Surface charges
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 Cement additives added value

u Example of ball mill – Closed circuit

Grinding efficiency Materials flows

In the mill In the mill

Breakage performance Flow of materials (rate of discharge)

þ Grinding aids to be designed accordingly n9

Cement additives added value

CHRYSO® ADM 3
CHRYSO® AMC 12 CHRYSO® ADM 831

Raw Meal Cement

workshop workshop

CHRYSO CHRYSO

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 Cement additives added value

u Raw meal grinding optimization

CHRYSO® AMC 12 (recommended dosage = 400 ppm)

- Typical mill output gains: from +7% to +20%
- To be used if raw meal workshop is the bottle neck of plant process

Example: Ball mill, closed circuit, raw mix 2% moisture content

u CHRYSO® AMC 12
§ Possibility to stop one mill and focus production on only performing lines
§ Optimisation of running hours during peak-off periods
§ Flexibility for maintenance periods
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Cement additives added value

• Cement grinding optimization (ball mill)

- CHRYSO® ADM 3
Grey cements
- CHRYSO® ADM 831

- Recommended dosage = 300 ppm ; to be optimized at plant level

- Typical mill output gains: from +10% to +20%

Example: Ball mill, closed circuit (3 rd generation separator)

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 Cement additives added value

u Cement grinding optimization (vertical roller mill)

Mill output increase

High mill output

CHRYSO® VRM 159

Regular
grinding aids
Low mill vibration

Mill vibration reduction

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Cement additives added value

u Industrial results:
§ Type of mill: Vertical Roller Mill

þ Mill output increase at constant water addition and vibrations

þ Water reduction at constant mill output and vibrations

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 Cement additives added value

þ Process Grinding aids to be designed accordingly

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Cement additives added value

• Process & Cement additives interactions

§ Process specificities (grinding/separation)
§ Ball mills / closed circuits
§ Grinding optimization from raw mix to clinker

• Strength enhancers and cementitious

§ Cementitious materials reactivity
§ Pozzolan cements
§ Composite cements

• Conclusion & Stakes for future

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 Cement additives added value

The higher the CaO content,

the better the reactivity

SiO 2 / Al2 O 3 ~ constant

ó Performance driver = CaO content

Sources:
Vanessa KOCABA-Marie Curie Course 5 - Sustainability-Düsseldorf- 8th December
2008, adapted from Adam D. NEUWALD, What are SCMs and how can you use
them to your advantage?, MC Magazine, September-October 2004.

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Cement additives added value

u Types of cement reactivity according to additions:

Slag cements
Compressive strengths

Fly Ash / Pozzolana cements

Portland cements

Limestone cements

Use of
adequate
cement
additives to
optimize
Temps cement
Short-term: Long-term: reactivity
Clinker >> additions Positive impact of additions

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 Cement additives added value

Area of
interest to
balance
strength loss
due to
pozzolana
influence

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Cement additives added value

u Activators: a balance between cementitious and performances

Mechanical
Strength Late Strength
Enhancer
Early & Late Strength
Enhancer
Reference
Early Strength
Enhancer
Choice of product to be adapted according to
reference profile and targets to reach :
à Increase of strengths at same clinker content
à Same strengths with lower clinker content
à To balance impact of alternative fuels

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 Cement additives added value

u Example of pozzolana cement

§ Ball mill, 2 nd generation separator

Reference CHRYSO® AMA40E

(0 g/t) (500 g/t)
% Pozzolana 28 32
Blaine (cm²/g) 3550 3450
Mill output (tph) 95 106
2 days (MPa) 19,5 20,2
7 days (MPa) 31,4 31,5
28 days (MPa) 45,2 46,7

u CHRYSO® AMA40E
§ Focus on cement early strength activation: +4% Pozzolana increase
§ Cement quality & Strengths maintained
§ +12% Mill output increase
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Cement additives added value

u Example of composite cement

§ Ball mill, 3 rd generation separator
Reference CHRYSO® AMA50EL
(0 g/t) (700 g/t)
% Pozzolana 17 19
% Limestone 10 14
Blaine (cm²/g) 4550 4650
Mill output (tph) 72 83
2 days (MPa) 15,2 15,1
7 days (MPa) 25,6 26,2
28 days (MPa) 34,3 34,5

u CHRYSO® AMA50EL
§ Focus on cement early and late strength activation:
• +2% Pozzolana increase
• +4% Limestone increase
§ Strengths maintained
§ +15% Mill output increase
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 Cement additives added value

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Cement additives added value

• Process & Cement additives interactions

§ Process specificities (grinding/separation)
§ Ball mills / closed circuits
§ Grinding optimization from raw mix to clinker

• Strength enhancers and cementitious

§ Cementitious materials reactivity
§ Pozzolan cements
§ Composite cements

• Conclusion & Stakes for future

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 Cement additives added value

ð CHRYSO cement additives: a full range of dedicated solutions

Cr VI Air Entraining Technical

Grinding aids Activators
Reducing agent Agents products

• CHRYSO® ADM 3 • CHRYSO® AMA 30L (Late strength activation)

• CHRYSO® ADM 831 • CHRYSO® AMA 40E (Early strength activation)
• CHRYSO® AMA 50EL (Early & Late strength activation)
• CHRYSO® AMC 12

• CHRYSO® VRM159
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Cement additives added value

u Conclusion
Mechanical
St r engt h Lat e St rengt h
Enhancer
Early & Lat e St rengt h
Enhancer
Reference
Early St rengt h
Enhancer

1d 2d 7d 28d Time

þ Grinding aids / Activators to be designed accordingly

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 Cement additives added value

CHRYSO solutions:
- Early strengths
- Late strengths à A current range of products adapted
- Early & Late strengths for each type of targets

Solutions for all cement types: à Large R&D projects in CHRYSO Labs
- Slag (worldwide) to develop new solutions
for the future cement challenges
- Fly ashes
- Pozzolana
- Limestone

Solutions for different type of mills:

- Ball Mills
- Vertical Roller Mills
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Cement additives added value

u Examples of evolutions for coming years

ð Standard evolution
• India (BIS): Higher cementitious content
• Europe (EN) : low-clinker ternary cements Ä New cement
• North America (ASTM, CSA) : limestone cements compositions

ð Process optimization
• Separate grinding Ä New process
conditions
• Blenders

þ New Grinding aids / Activators to be proposed

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 Cement additives added value

Thank you
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