The Cement Institute™ Quality Control Formulas 1. Loss on ignition (LOI) (CO2 from Calcination) Ignition loss = 0.44 CaCo, +0524 Mg Co, +... + combined H,O + Organic matter LOI refers to the release of volatile matter such as CO,, water vapor and other combustibles 2. Silica Modulus/Ratio (SM) SM = Sid, ‘Alz03 + Fe,03 Typical Range: «18-27 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 (3-7days) in the cement 3. Alumina Modulus/Alumina iron ratio (AM) AM. A\O3 Fez0s Typical Range 2 1.0-15 Clinker with higher Alumina modulus results in cement with high early strength 4. Lime saturation factor (LSF) The ratio of the effective lime content to the maximum possible lime content in the clinker. a. If Alumina modulus > 0.64 LSF = CaO 2.8 SiO, + 1.65 Al,Os + 0.35 FeO, 1|Page #200 copyright | THE CEMENT WSTTUTEThe Cement Institute™ If Alumina modulus < 0.64 LSF = cao 2.8 SiO, + 1.1 Al,0, + 0.7 Fe,0, Typical Range =: 92-105 When the LSF approaches unity, the clinker is hard to burn and often results in excessive free lime. 5. % Liquid % Liquid = 113 CyA + 1.35 C,AF + MgO+ Alkalies CA 2 % of TriCalcium Aluminate CAF 2 % of Tetra-Calcium Alumino Ferrite 6. Bogue’s formula for cement constituents a. IfAlumina modulus > 0.64 Cs = 4.071 CaO - (7.602 SiO, + 6.718 Al,O, + 1.43 Fe,0, + 2.852 SO) Gs. = 2.867 SiO, - 0.7544 C,S CA = 2.65 Al,Qs — 1.692 Fe,0, CAF = 3,043 Fe,03 b. If Alumina modulus < 0.64 CS = 4.071 CaO ~ (7.602 SiO, + 4.479 ‘Al,O, + 2.859 Fe,0; + 2.852 SOs) CS = 2.867 SiO, 0.7544 C,S CoA = 0 (CaAF+C,F) = 2.1 AlOs + 1.702 FezO5 Typical value Cas = 45-55% C28 = 20-30% 2|PageThe Cement Institute™ 7. Degree of calcination c(%) = (f,-d)x100 fi (or) = (1 = LOMgampie) X (100 - LOloea) (100 = LOleanpie) X (COleee) c : Apparent percent calcination of the sample fi Ignition loss of the original feed d, : Ignition loss of the sample 8. Sulphur to Alkali Ratio SO, = (S080) Alkali (K,0/94) + (0.5Na,0/62) Typical value ats SO; a (S0,/80) Alkali (K,0/94) + (Na,0/62) - (C71) Typical value “08 Higher sulphur to alkali ratio leads to pre-heater buildups affecting the kiln operation 9. Free Lime % free Limey4oo = 0.31 (LSF - 100) + 2.18 (SM - 1.8) +0.73Q+0.33C+034A LSF : Lime saturation factor SM © Silica modulus/ratio Q : 445 wi residue after acid wash (20% HCl) identified by microscopy as quartz c : +125 uresidue which is soluble in acid (ie coarse LS) A : +45 p residue after acid wash identified by microscopy as non-quartz acid insoluble Note: Q, C &A expressed as % of total raw mix sample 3|Page[rei] The Cement institute™ 10.Excess sulphur (gm SO,/ 100 kg clinker) Excess sulphur = (1000 x SO,) - (850 x K,0) — (650 x Na,O) Limit 250 — 600 gm/100 kg clinker Above these limits, sulphur gives rise to coating problems in Pre-heater tower. 11. Blending ratio Blending ratio is the ratio of estimated standard deviations of feed and product. standard deviation of CaO in feed standard deviation of CaO in product Blending ratio = V@/2) N : Number of layers For calculating standard deviation Consider the feed values X, XY X23. Xn Mean for the feed values: X+ x1 +x2 4x3...%) = Xa Standard deviation for the feed : St LOK PO x,t. AK POL 12. Raw meal to clinker factor Raw meal to clinker factor= 100 ~ ash absorbtion 100 - LO! % of ash in fuel x specific fuel consumption Specific fuel consumption = kg coal kg clinker = Specific heat consumption NCV of coal Ash absorbtion Note: LOI assumed to be negligible in clinker. 4|PageThe Cement Institute™ 13. Kiln feed to clinker factor Kiln feed to clinker factor = Kiln feed_(kg Clinker output (kg) Note: Considering error in kiln feeding system as negligible. (or) Kiln feed to olinker factor = Raw Meal to Clinker Factor x (100) Top Stage Cyclone Efficiency 14. Clinker to cement factor Clinker to cement factor = Clinker + Gy + Flvash/slag + additives (ka) Clinker consumed (kg) 15. Insoluble residue The material remaining after cement is treated with hydro chloric acid of specific concentration and for designed time. (or) Insoluble residue can be used to measure amount of adulteration or contamination of cement with sand. Cement is soluble in dilute HCI where as ‘sand is insoluble. The amount of insoluble material determines the level of adulteration. In PPC (Fly-ash) cement, insoluble residue is used to estimate the percentage of fly-ash present in the cement. 5|Page