Dear Mr Rajiv,

                   From what you wrote its difficult to understand about your main Burner setup.You wrote you have opened only the axial air (11500) where as you kept the swirl air (0) which definitely will give a bad flame which may be one of the causes you are facing..If you can give further details about the type of burner will be helpful for others to study your case.In our case which is a 7200 t/d plant we have a polysius burner where we keep open 100 % axial air damper, 80 % swirl air, we adjust the pipe such that we get axial, swirl pr of about 120 to 150 mbar pressure that results in a strong favourable flame.

Mohan.M

Biju:

What is the  formulae used for Liquid calculation at 1450 deg C? is it

1.13 C3A+1.35C4AF+MgO+ Na2O +K2O 

or

 1.13 C3A+1.35C4AF+MgO+Na2O +K2O + SO3

Some places SO3 is shown while in some it is not. Which is the correct one

I agree with Michael.  In molar balance with K2O and Na2O, SO3 forms alkali sulphates which contribute to the liquid phase . However SO3 in excess of the molar balance with the alkalis will then form a solid solution (up to about 2% w/w) with the silicates, particularly C2S, and is therefore not available to contribute to the liquid phase.

So, any liquid phase formula which does not take these aspects into account will be an approximation. Then again, that's all you need most of the time anyway.

Of the two formulas given above, I would say the second one is the closer approximation, as long as the molar SO3/Alkali ratio is <= 1.

 

Regards,

Ted.

 

Dear Mr Rajiv,

Based on the replies that you have sent so far and analyzing the same, it is recommended that immediately Fe2O3 in raw mix is brought down from the present level of 2.5 to around 2.0 +- 0.1 and compensate with clay gradually at raw meal VRM stage keeping CaO value at 41.2. Kiln must have stable operation ( no stoppages,).Do not do too many changes at a time.

Monitor

• shift wise Clinker Targets CaO (64.0 + - 0.5), Free CaO (below 2 %) and Fe2O3 (3.3 + -0.1);
  
• daily full analysis of clinker to know the moduli values and clinker compounds ;
  
• also sieve analysis of clinker to understand reduction in dustiness.

Kiln Operators should be taken in to confidence and note down

• their observations besides your own.
• Take the help of a competent process engineers who knows kiln,cooler operation.
• Fuel feed to precalciner may be required to increase depending upon the temperature profile and accordingly kiln fuel adjustment.
• Cooler operation is adjusted so that adequate secondary and tertiary air temperatures are maintained.
• Maintain adequate negative kiln hood draft value as per the process.
  

Also,

• record the physical properties of daily clinker for its strength ( 1D/3D/7D/28D) and compare for the improvement.

This should help you to some extent.However, there appears to be further scope to optimize raw mix composition

Pl.try out the above recommendations for 5 days(stable operation) collect all the data as mentioned above and see whether the problem of dusty clinker minimizes or not, what other benefits in clinker quality and kiln operation you get; and give me the feedback.

Pl.confirm.
 
Best Wishes

Bhaskar Agate
09096832830 (M)

1.13*c3a+1.35*c4af+mgo+na2o+k2o+so3

There for.

What is 1.13 and 1.35