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Techenical Presentation RA

Raw MILL Residue Control

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Ananth Iyer
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328 views27 pages

Techenical Presentation RA

Raw MILL Residue Control

Uploaded by

Ananth Iyer
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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14

th
Aug2013
Presented by : Roopesh Agrawal
Contents
What is Residue ?
How it is measured?
Residue control in raw mill operation?
What is the significance of the raw meal
residue measurement on 90 micron and
212 micron sieves, respectively.?
What are the impact/ role of raw meal
residue in Kiln Operation?
Conclusion
What is Residue ?


It is the measurement of fineness where the
retained is estimated in percentage by sieve
analysis or by mixing in chemical solution.

quantity of retained (over size or insoluble) on
selective sieve or in base of pot is calculated in
percentage w.r.t. total sample quantity is known
as %residue
Residue Measurement

In case of Raw meal It is
measured by sieving methods :


1) Dry sieving 2) Wet sieving
dry sieving - the certain amount of grounded
material passed through desired sieve size ,after
sufficient shaking % age retained calculated
wet sieving - the certain amount of grounded
material passed through desired sieve size
through water shower with sufficient shaking
% age retained calculated
wet sieving method is well established for raw
meal residue measurements




This is to analyze that the >90u fraction of
the raw meal done by XRF , dry sieving and
wet sieving then compare with the SiO2
content.
The dry sieving such as by an Alpine air jet
system does not remove all of the ultra-fine
clay particles which stick to the larger
particles by static attraction and bias the
chemical analysis.

Residue Control!

Residue control in raw mill operation
It is a main control parameter of raw mill
operation hourly the sample collected from
circuit sampler and residue measured on
90 and 212 , results variation controlled by
regulating the separator speed and mill fan
flow
Variation in Residue controlled by regulating the
separator speed and mill fan flow
Raw meal residue on 90 and 212 the values
are in range between:

R(90) = 17 19 %
R(212) = 1- 2 %

It is normal to see ratio between R90 : R212
=10:1 in VRM. For better burnability in kiln
Significance of Raw Meal
Residue Measurements on 90
& 212

Measurements of residues on 90 and 212
allows the Rosin Rambler distribution line to be
calculated. The residues of quartz at the
coarse size fraction and calcite at the fine
fraction are also used for kiln feed burnability
assessments.
The critical size for calcite is thought to be
around 90um, while the critical size for quartz
is about 32um. Significant amounts of calcite
or quartz above these levels are generally
agreed to worsen raw meal burnability test

After analyzing the chemistry, we can
conclude -
Quartz(>32u) and Calcite (>90u)
It is possible to determine the best way for
proper control / improving the burnability of
your raw mix.
Impact of Raw Meal Residue in
Kiln Operation

Raw meal fineness directly influences the
relative quantities of clinker minerals
produced

i.e. finer particles will react faster and
therefore reaction more completely in the
given time
Along with LSF and SR, the amount of
oversize calcite and quartz particles have a
strong impact on the raw meal burnability,
CaO(free) = 0.6 * Quartz(>32u) + 0.2 *
Calcite(>90u) + 0.3 * LSF + 1.6 * SR 34
where the coefficients would be slightly
different for each plant.



Conversion of C2S into C3S by reaction with
CaO occurs by diffusion of CaO through the
liquid phase
The rate of reaction is dependent on the
diffusion rate of CaO through the liquid. this
diffusion rate and the burning zone residence
time together determine the critical
distance..
That dissolved CaO has to travel through the
liquid for complete reaction. therefore
particles have to be smaller than this critical
distance to allow CaO diffusion and complete
reaction in the time available in the kiln.

Coarser particles will not react timely and
resulting in unreacted free lime in clinker
If the quartz particles are too coarse (>~40um)
, frequent large C2S clusters will be produced at
the expense of C3S... leaving a
proportionate amount of unreacted free lime.



If the calcite particles are too coarse
(>~100um), localized CaO over-saturation
produces a "wall" of C3S crystals around the
particle and the remaining CaO cannot readily
diffuse out through this barrier and react with
nearby silica... again resulting in unreacted free
lime.


Conclusion
Raw meal residue directly effects the kiln
feed burnability

Along with LSF and SR, the amount of
oversize calcite and quartz particles have a
strong impact on the raw meal burnability, and
hence the resultant clinker free lime.

Thank You

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