Raw mix design

By Evgueni Porokhovoi. 2019

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Introduction

The raw mix design is made according to the raw material

characteristics and the compliment of the quality needs, that allow
us to obtain a better product in the best operation conditions and
with the lowest cost possible, keeping in mind clearly that the raw
materials can’t be changed, but just controlled.

The potential or real composition of the raw mix determines the

number of the mixture’s component and the relative quality
needed, where it’s important to consider the limitations that the
raw mix could have, by specification of the product and process.

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Examples of raw materials

NN Material SiO2 Al2O3 Fe2O3 CaO MgO LOI SO3 K2O Na2O TiO2 P2O5 Cl Total
1 Limestone 2.79 0.43 0.50 52.25 0.71 42.01 0.22 0.08 0.09 0.01 99
2 Limestone 1.58 0.36 0.17 54.19 0.23 42.69 0.22 0.20 0.30 100
3 Limestone 9.44 2.36 0.77 45.15 2.41 38.40 0.00 0.00 0.00 99
4 Limestone 12.00 2.50 1.10 42.50 4.50 36.00 0.05 0.42 0.15 99
5 Limestone 1.35 0.42 0.30 53.36 0.38 42.64 0.13 0.00 0.20 99
6 Limestone 8.50 2.30 1.00 47.80 0.60 38.80 0.10 0.40 0.10 100

7 marl 19.60 3.55 1.24 40.62 1.00 33.21 0.60 0.48 0.10 100
8 marl 16.97 3.65 1.31 42.01 0.97 34.06 0.12 0.69 0.24 100
9 marl 16.49 3.61 1.39 41.13 1.10 33.70 0.70 0.50 0.10 99
10 marl 23.71 5.17 1.92 37.24 1.44 29.48 0.20 0.51 0.25 100
11 marl 15.69 2.54 2.13 43.74 0.44 34.82 0.10 0.20 0.05 0.07 100

12 Clay 57.99 8.74 4.23 11.56 2.45 11.28 0.27 2.57 0.44 100
13 Clay 61.86 13.77 3.66 6.12 2.94 7.77 0.25 1.80 1.40 100
14 Clay 53.41 11.82 4.41 10.66 1.85 10.90 2.07 2.20 1.52 0.10 99
15 Clay 48.50 13.90 6.45 12.23 2.27 12.64 0.26 3.26 0.18 100
16 Clay 51.86 5.54 2.83 17.41 2.82 16.76 0.40 1.05 0.46 0.17 99

17 Sand 78.65 9.65 1.46 2.04 1.03 1.34 0.62 1.21 0.65 97
18 Sand 95.40 1.04 0.43 1.19 0.19 1.18 0.03 0.51 0.10 0.09 0.02 0.02 100
19 Sand 86.80 1.27 1.03 3.84 1.00 1.38 0.40 1.00 0.50 97
20 Sand 94.31 2.68 0.50 0.05 0.09 0.73 0.01 1.00 0.11 0.09 100

21 Iron 8.61 2.04 76.17 3.20 0.69 3.63 4.89 0.24 0.72 0.00 100
22 Iron 15.00 3.59 67.40 4.46 1.07 0.80 2.54 0.75 0.80 96
23 Iron 20.00 6.50 60.00 4.50 1.50 1.70 0.88 0.80 0.16 96
24 Iron 10.00 3.41 70.00 5.58 9.00 0.50 1.15 0.20 0.10 100
25 Iron 3.92 2.31 81.41 2.92 1.83 0.63 1.96 0.76 0.25 0.02 0.02 96

26 Alumina 7.00 52.00 21.00 3.00 0.10 13.00 0.50 0.50 0.30 97
27 Alumina 24.50 40.60 15.00 1.00 0.87 13.80 0.30 0.49 0.19 97
28 Alumina 20.96 42.42 17.53 1.56 0.63 13.95 0.00 0.05 0.02 97

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Loss on Ignition

• During the burning process, approximately between 34 and 37%

of the raw meal escapes with the gases; that’s what is called “Loss
on Ignition” (LOI) of raw material.
• It consists, principally, in the disappearing of CO2 during the
carbonate minerals transformation (commonly called
decarbonation).
• Loss on ignition is defined in laboratory by the lost of weight of
the laboratory sample at the 1000° temperature.
• Other CO2, the Loss on Ignition content the organic components
of raw material.

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Raw material consumption

• Raw Mix / Clinker factor FRM = 100 / (100 % - LOI %)

Consequently, and putting a practical case, for a plant with a FRM

= 1.6 (due to the Loss on Ignition), with a 1,000,000 tons/year
of clinker production capacity, 1,600,000 tons/year of raw meal
is needed :

• Tons of Raw Mix (annual) = FRM x Tons of Clinker (annual)

• Tons RM (annual) = 1.6 x 1,000,000 ton/year
• Tons RM (annual) = 1,600,000 ton/year

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Raw mix composition

The most used raw materials for clinker fabrications are :

• Limestone : ~ 65-85 % in the raw mix
• Clay or marl : ~10-25 % in the raw mix
• Sand : ~1-5 % in raw mix
• Iron corrector : ~0-3 % in raw mix
• Alumina corrector ~0-5 % in raw mix

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Raw mix composition

The main raw mix target indicators are :

• Lime Saturation Factor (LSF) : CaO / (2,8 x SiO2 +
1,2 x Al2O3 + 0,65 Fe2O3) x 100. Between 95 and
100 in raw mix.
• Silica Ratio (SR) = SiO2 / (Al2O3 + Fe2O3). Between
1 and 2 in raw mix.
• Alumina Ratio (AR) = Al2O3 / Fe2O3. Between 1 and
2 in raw mix.

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Example of raw mix calculation
Prop.% SiO2 Al2O3 Fe2O3 CaO MgO LOI SO3 K2O Na2O P2O5 TiO2 Cl- Total Cost
PREHOMO
Mix of massve marble with siliceous marble 100.0 9.57 0.75 0.57 48.43 1.13 39.25 0.16 0.10 0.04 0.00 0.00 0.000 100 $3.00
0 $0.00
0 $0.00
0 $0.00
Total 100.00 9.57 0.75 0.57 48.43 1.13 39.25 0.16 0.10 0.04 0.00 0.00 0.000 100 $3.00
BINS
Total Marble 88.7 9.57 0.75 0.57 48.43 1.13 39.25 0.16 0.10 0.04 0.00 0.00 0.00 100 $3.00
Clay 3.0 77.50 12.20 4.29 1.92 0.99 2.59 0.14 0.30 0.25 0.00 0.00 0.000 100 $2.00
Shale 4.2 71.53 17.99 5.86 0.19 0.55 0.75 0.04 2.30 0.74 0.00 0.00 0.000 100 $4.00
Iron Corrector (Peru) 1.5 3.75 0.66 90.46 0.79 0.55 1.22 0.28 0.08 0.60 0.00 0.00 0.000 98 $10.00
Alumina corrector (Bauxite Spain) 2.6 9.00 55.70 11.50 1.30 0.30 14.50 1.25 0.10 0.10 94 $10.00
Add 5 0.0 0 $0.00
RAW MIX 100.0 14.11 3.24 2.54 43.07 1.07 35.32 0.18 0.20 0.09 2.44 1.28 0.00 100 $3.30

FUEL ASH 0.00 65.00 24.00 5.00 2.00 0.70 0.80 0.20 0.50 0.90 0.40 98 $0.00

CLINKER 21.81 5.02 3.92 66.59 1.66 0.29 0.31 0.13 2.44 1.28 0.00 100 $5.10

CLINKER C3S C2S C3A C4AF SR A/F ALK K.H. DBC LSF Alk/SO3 %LIQ RM/CK F CaO
MINERAL. 61.11 16.43 6.66 11.93 2.44 1.28 0.33 0.93 4.25 95.8 1.51 26.0 1.55 1.0

CONSTRAINTS PAR L.L. ACT. U. L.

LSF 90.00 95.75 100.00
MS 2.40 2.44 2.45
A/F 1.20 1.28 1.35
C3S 61.00 61.11 62.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
Title of the run:
Maceo Raw Mix. Material from Cerro Mauro. With clay and shale

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Different possible scenarios

Raw Mix 1 Raw Mix 2 Raw Mix 3

% Mix of massive marble with siliceous marble 88.50 88.90 88.70
% Clay 6.90 0.00 3.00
% Shale 0.00 7.50 4.20
% Iron corrector (Peru) 1.70 1.50 1.50
% Alumina corrector (Bauxite Spain) 3.00 2.20 2.60

LSF 95.71 95.90 95.75

MS 2.43 2.43 2.44
A/F 1.21 1.27 1.28
Na2OEq 0.22 0.43 0.33

C3S 61.38 61.44 61.11

C2S 16.28 16.04 16.43
C3A 6.14 6.60 6.66
C4AF 12.41 12.00 11.93

Relative cost (indicator) in USD/t of Raw Mix 3.26 3.33 3.30

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Dozing of raw material

Limestone Iron ore

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 Sampling and Analysis

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Sampling in the quarry

Sampling tube

Correct sampling
of drill chips cone

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Sampling in the quarry

Automatic sampler FLS

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Sampling in the quarry

Automatic sampler on the drill rig.

Prachovice plant (Czech Republic)

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Sampling in the plant

Automatic sampling after raw mill. Automatic sampling after homo

Bayano plant (Panama) silo. Bayano plant (Panama)

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Sampling in the plant

Pneumatic post of samples from the plant to laboratory

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 Samples preparation (coarse material)

The first step is laboratory crushing. Different types of laboratory crushers

exists. The presented one from the new Cemex laboratory is jaw crusher.
After this step the crushed material is put to the splitting tool and the fully
representative sample is prepared.

Small laboratory jaw Splitting laboratory device for Final sample after
crusher crushed material laboratory crushing

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Samples preparation

The next step is to prepare the pulverized sample from the

crushed material. The small scale laboratory mill is used.

Laboratory mill for samples grinding Final sample in

pulverized form

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Final samples preparation

• To analyze samples two main methods are existing :

1. Pressed pallets
2. Fused bead
• In first case the pulverized material is just put under pressure but
the crystalline structure of analyzed material is not destroyed. The
XRF machine will then analyze the existing structure.
• In second case the tested material is fused, the initial structure is
disappeared and formed the new vitreous bead.
• This second method give the most precise results (no structure
influence) but it is more expensive.

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Final samples preparation

Automatic press to prepare Fusing machine to prepare the

pressed pallets samples fused bead samples

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Two types of samples to be analysed

Pressed pallet samples Fused bead samples

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XRF analysis

The analytical technique widely used in modern laboratory is XRF

technique or analysis of elements by X-ray fluorescence (absorption).
Very important process is the calibration of X-ray machine to the
specific material to be analyzed. The analysis could be semi-
quantitative or quantitative in function of analyses precision required.

Example of XRF machine ThermoScientific

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Example of sampling map of the plant
Fe clay Al clay

USA impactor crusher with

grizzly -50 mm 390 t/h Manual sampling station.
Sampling tower will be
Babarkot quarry. added
Block North HG lst or Fe clay or Al clay
Single boom stacker
by badges of 400 t
Drilling/blasting

2 x Surface miner
150 and 200 t/h

Babarkot quarry. Dubble side reclaymer (400 t/h)

Block East
Mat. from piles

Preblending stock- piles (covered)

5 x 400 t hoopers Lst from 2 x ~ 15000 t
Fe clay Al clay
pile Lst from
pile HG lst

5 x MERRIC weight feeders

Air merge homo silo

Sampling points Vertical Loeushe mill
250 (340) t/h
with dynamic separator

To the kiln

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 Cross-belt “on line” analyzers

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“On line” analysis

Definition : Analysis measured and obtained practically at the time

when the product and/or part of it (sample) is processed, without
physical collect of samples and sample preparation.
The advantage of instantaneous measurements is that user is able to
react faster to control the process and quality product targets
provided the user has the right infrastructure installed in the
production line.

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 “On line” analysis

When is justified the on-line analyzer:

• When there are mixes of different homogeneous materials: limestone +
clay + other.
• When there are mixes of similar materials differing in some composition
characteristics : limestones of different SiO2, CaO, SO3 – content.
• When there is low flexibility to make mistakes in the materials
proportioning into the stock-pile (low corrective power of raw material
bins).
• When mining plan is not perfect, it is recommended to assure the control
of the targets correcting via on-line analysis.
• When we try to improve the life of the reserves and at the same time tries
to achieve the expected quality target for the process or product.
• When there is not a sampling tower.

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Two different technologies

• There are 2 available technologies to analyze materials on a belt

conveyor :
➢ Pulsed Fast Thermal Neutron Activation (PFTNA)
➢ Prompt Gamma Neutron Activation (PGNA)
• The radiation source is Neutrons produced by a neutron generator
for PFTNA and neutrons produced by Californium 252 for PGNA
• Radiation emitted by the material on the belt is Gamma rays
• Power penetration in the material is all material on the belt

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Sodern cross-belt analyzer

Sodern analyzer works under the principle of Pulsed Fast Thermal

Neutron Activation (PFTNA) :
• Uses a neutron generator able to produce a clean neutron emission that
is constant with the time, allowing a stable analytical performance
during the complete tube life avoiding the recalibrations (like in case of
PGNA).
• The detection technique of the different gamma signals allows Sodern
to have a better static calibration. No dynamic calibration (just
adjustments)
• The neutron generator can be switched off when the analyzer is not in
use, but the radiation emitted is higher than the one of the analyzers
using the PGNA. Sodern supplies suitable shielding to protect workers
from this high radiation.
• The price of Sodern is the most attractive one : 400 kUSD vs 456 kUSD
of Scantech and 530 kUSD of ThermoFisher.

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Raw mix composition

• Scantech and ThermoFisher analyzers work under the

same analytical principle (Prompt Gamma Neutron
Activation).
• This technique has the disadvantage of use a radio isotopic
source (252-Californium), this kind of source can not be
switched off and the radiation emitted is lower than the
produced by the neutron generator.
• The intensity of the radiation emitted decrease with the time,
due to that the analyzer must be calibrated every 3 months,
the accuracy of the results depend on the good calibration of
the X-ray fluorescence equipment.
• Accuracy with the PGNA analysis is affected by variable flow
of material on the belt.

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“On line” analyzer

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Cross-belt analyzer

Scantech PGNA cross-belt ThermoFisher PGNA cross-belt

analyzer in APO plant (Philippines) analyzer in Brooksville plant (USA)

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