"Holderbank" Cement Seminar 2000

Materials Technology I - Mix Design

Chapter 13

Mix Design
1. MIX DESIGN .•....••.••..........•.•.......•........•...•....•...........•.•••..•••.•...•.......•.......•.•......•....•••. 265
2. Program for Optimal Raw Mix Design ....••.•...........•.••.•.••••.•.......•........•.......•........•.. 283

© Holderbank Management & Consulting, 2000 Page263

 *U :t•l ~ •l:t ;~:f.,~ I tU
"Holderbank" Cement Seminar 2000
Materials Technology 1- Mix Design

Page 264 © Holderbank Management & Consulting, 2000

 "Holderbank" Cement Seminar 2000
Materials Technology 1- Mix Design

MIX DESIGN

1. GENERAL ..................................................................................................................... 266

2. DEFINITION OF CRITERIA FOR MIX CALCULATION ................................................. 267
3. PRINCIPLES AND METHODS OF MIX PROPORTIONING .......................................... 269
3.1 X-Pattern ................................................................................................................ 269
3.2 Manual Calculation ................................................................................................. 270
3.3 Graphical Methods ................................................................................................. 270
3.4 Programmable Calculator ....................................................................................... 270
3.5 Computer Optimisation ........................................................................................... 270
4. PRINCIPLES OF RAW MIX ASSESSMENT ................................................................. 275
4.1 Mix Type ................................................................................................................. 276
4.2 Comparison of Raw Mix with Standard Specifications ............................................ 276
4.3 Assessment of the Mineralogical Composition of Cement Raw Mixes .................... 278
4.4 Assessment of Raw Mixes with regard to Cement Production and Choice of Process279
4.5 Evaluation of Laboratory Test Results .................................................................... 280

© Holderbank Management & Consulting, 2000 Page265

 "Holderbank" Cement Seminar 2000 *0: C•l I! •l:t ;~ :1., ~I~-
Materials Technology 1- Mix Design

1. GENERAL
A raw mix design comprises not only raw mix proportioning but also considerations of such
factors as standard specifications of the cement types to be produced, the market situation
and the available process installations.

Raw material situation Standard specifications for

cement types to be produced
Process installations
Market situation -J

[selection of criteria]

I Mix proportioning J

The selection of criteria is dictated by the standard specifications.

Designing raw mixes does not only involve the proportioning (calculation) but includes an
evaluation of the obtained results. The latter involves optimisation with respect to costs and
materials.

Selection of criteria --
n
Proportioning (calculation)

1J
Evaluation, optimisation

Page266
© Holderbank Management & Consulting, 2000
 "Holderbank" Cement Seminar 2000
•o :t·l ~ ·l:t J=t·,~ 1ta
Materials Technology 1- Mix Design

2. DEFINITION OF CRITERIA FOR MIX CALCULATION

Any type of cement has to conform to the individual cement standards of a particular
country. Standards (standard specifications) normally include chemical specifications for
clinker and cement. Together with the physical and strength requirements, they guarantee a
suitable quality potential for the respective cement type.
With regard to the raw material aspects only the chemical requirements are significant:

Product
specification -- Clinker/
cement
Raw mix :
Raw material
composition : components
quality
chemical

In other words: the product specifications dictate the clinker/cement quality which in turn
dictates the chemical composition of the raw mix and finally the selection of the raw material
components.
The above sequence can also be reversed: an existing raw material configuration with little
freedom as to the proportioning of the raw mix, may permit the manufacture of only one
particular type of clinker.

Table 41 Influence of chemical requirements on raw materials

Chemical Influence on raw material

requirements
min. S03 Rejection of S03-bearing components
(e.g.) gypsum-containing shale)
min. MgO Rejection of MgO-bearing components
(e.g. dolomitic limestone)
min. Alkali Selection of raw material with low alkali-content
min. CsA Selection of components with very low alumina
content and I or high iron content

Table 41 shows the influence of chemical requirements on the choice of raw materials.

© Holderbank Management & Consulting, 2000 Page 267

 "Holderbank" Cement Seminar 2000
Materials Technology I- Mix Design

The following chemical criteria are normally used as a basis for raw mix proportioning (Table
42; on clinker basis):

Table 42 Chemical criteria for raw mix proportioning

criteria nnormal" range formulas, remarks

Umit
(for clinker)

MgO max. 5% (6%) for all cements

3 - 4,5% depending on cement type

cao -
LIME STANDARD or 0,9 - 1. or
Lil~ SATURATION 90 - 100%
FACTOR

"Improved" 100 (CaO + 0,75 MqO) **

~e standard ** 90 - 100%
2,80 Si0 2+ 1,18 Al 2 0 3+ 0,65 Fe 2 o 3
Si0 2
Index of activity 2,5 - 3,5 Al 2 o3

Hydraulic ratio 2,0 - 2,4 CaO

SILICA RATIO 1,8 - 3,4

ALUMJ:NA RATIO 1,5 - 2,5

(0,7 - 3,5)

Total alkali < 0,6% Na o + 0,66

2
K
2 o for low alkali
clinker

so - 60% except for ASTM type IV

max. 3% BS for sulfate-resisting cement

max. 5% ASTM

* for cement ** 100 (Cao + 1,5) for Mq0<:2%

The proportioning of raw mixes for ordinary Portland cement is mostly based on the
following specific criteria:
+ MgO
• Lime standard or lime or saturation factor (or C3S)
• Silica ratio
• Alumina ratio

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 "Holderbank" Cement Seminar 2000
Materials Technology I- Mix Design

As Table 42 indicates, ratios are the preferred chemical criteria for proportioning since they
offer the advantage of expressing the main and most important chemical parameters such
as Si02 , Al 20a, Fe20 3 and CaO in one single figure.
Other important criteria such as type and composition of fuels should not be overlooked.
Coal ash as a combustion product of coal, for instance, has to be analysed quantitatively
and qualitatively and should be treated as an individual raw material component. Fuel oil has
to be considered as a potential carrier of sulphur, etc.
Additional criteria which could have bearing on the mix proportioning refer to performance
characteristics, e.g.:
• minimum dust emission
• burnability and coating properties
+ extreme components which affect machine performance
or to economic factors, e.g.:
+ maximum overall economy
.. ···
• easy and simple operations
• minimum number of components
However, performance characteristics in particular can normally be controlled regarding the
"normal" chemical requirements for cement raw mixes. The economic factors, on the other
hand, are of the same significance as the chemical requirements.

3. PRINCIPLES AND METHODS OF MIX PROPORTIONING

Proportioning (calculation) of potential cement raw mixes can be accomplished by various
methods:

3.1 X-Pattern
The x-pattern represents a linear estim-ation of two raw material components by selecting
the anticipated titration value (total carbonate content) of the potential raw mix as basis.

1. Component X parts A
Titration A

Titration of
raw mix

2. Component
Titration B Y parts B

or as a numerical example.
)

© Holderbank Management & Consulting, 2000 Page 269

 "Holderbank" Cement Seminar 2000
•a: t•l ll·l=t ·~=1·' ~ 1ta
Materials Technology I - Mix Design

1. Component
Limestone 68,3 (76 - 7,7)
94,5% CaC0 3

caco 3 content
of potential
raw mix shall
be 76%

2. Component
Claystone 18,5 {94,5 - 76}
7,7% CaC0 3

The potential raw mix with a titration value of 76% would thus consist of:
limestone 68.3 3.69
--=--
claystone 18.5 1
or
limestone 78,6 %
. claystone 21,3%
The resulting analysis of the raw mix has to be checked with regard to the requirements of
' the standard specifications.

3.2 Manual Calculation

There are a number of mathematical methods for two and three-component systems.
Formulas are not complicated but comprise a large number of steps. The method of manual
calculation as such is outdated.

3.3 Graphical Methods

These methods require preparatory work (manual calculations) for the determination of the
relevant figures which are the basis for the construction of the diagrams and graphs.
Graphical methods represent a rather archaic stage of mix proportioning.

3.4 Programmable Calculator

Programmable calculators normally produce one solution (out of possibly several).
Obviously, this method is the best way to obtain a quick solution.

3.5 Computer Optimisation

It provides the optimum of a series of possible solutions considering the price factors as
variables. If the available raw materials cannot meet the specified requirements for the raw

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 "Holderbank" Cement Seminar 2000
•o :c-1 ~ ·J::t:~='·'~ 1:a
Materials Technology 1- Mix Design

mix, an approximate and an exact_solution considering the missing constituents are

produced (Tables 43- 47).
Note: Mix calculations are normally based on dry raw materials. In practice, the natural
moisture contents of the raw material components have to be considered too. This may
entail alterations of the original mix proportions.

Table 43

·······················
u s•o·•F.
·········································. ···············
:............. ...........•..........................................................
H~42Zl2 ~~
~

A II a L 'f' !1: F. tl

···········-····················--·-·······--~----·--·---==:::::~::::::: .. i ......... i .........i ......... i .........i ..........i ...... ~---i

I . I • _ I I >n I ruo~ I can I HGn 1 no 1 HA2U I •e~T I CIOFAF.I I 503 I ••~1• I
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CILLIOE :niLI
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:::o•a.•~eK2~
AL203
l i;i:i:~ • 5 :~:~
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c:-.llh
110 ~~; 37
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~~~
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15 17&0
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5102 · • I ALKALI ,u•t I
UU$f&"IDIRD : so•~.:5~ .oi.o~• 9~.353 I ClftFREI I :
TO!IERDE•11'1DIJL
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1
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US 1 55.5)1 •TOT~~-·--•••----~:;i;;-· UUSUMUARD 92,35U II
C'.S I' ~lft2 21,1'i··''
~!:r•2ClA zn!:;:: :~~~~ :::~~: ~
r.an 6'S,,571 1
KOH,OFIEIITE l wGn ,1121 1
lf41!:n ,lA•l I
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...................... -- .. ------ ·-·---- .. -............ .I

I

~------------ -- ------------------.----·------·--· ·-------- -·- ·---·---------·---·--- ----t

© Holderbank Management & Consulting, 2000 Page 271

 "Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design

Table 44

-------------~·------------------------------.--------~--------------------
29.6.77 OPTl"%ERUNG

A N A L V S E N

NR GVER S%02 AL203 FE20' CAD "GO K20 NA20 TIO CRO ~NO S03 P20 CL F REST PREIS

l .:!00
2
190
19:!~ 41~0
~s
1:!07
...
.,0 !-:!~0
~9S ~~.n
42
·23~
4
99 109
4 3
:i2
0
0
s
e
e
9
4
11
1
9
0
0
·•:s . 10+00
0 • 10+00
3 elt 6330 1~:~ •oo ~40 !•2 219 2'SO 44 0 6 9 8 11 0 68 .22+00
... :!?3 107 297 7297 2" ~3 40 31 ~:; 0 2 141 0 0 0 6~ • !:i9+00

ANF 0 R DE AUN0 E N RE S UL T AT E

I'IAX. "IN. RRE$1.11.. TAT 11 I SCHUNOSVERHAEL. TNl S t·:L INKERANALVSE

l'lt::-0 l 00. fJI)O • fJt:•CI 1. 14:0 LJI'IESTCINE . 7~3'5 c::::s !'i9. :;ooo
NA21)+, t.:iSK20 1 !tl). 000 . (t(tO 1. 14:::t SHt.L.E LOI.I • 1:::!62 c~s 11. s~:-1
At,.~t)3 1 (If). ('t)r) . (1(11) ~•. :07~ H1OH
~:HAL.E • 114'S C~A 9. e-67~
F£~03 l 00. 0•)0 . f.l•)rJ 3.022 PYRITE ClND , (U)!S9 C~AF 9. ~~~~
$1 (10: I t)O. OC•t) . 1';11)(1 21. €!~:1) • (10•)0 1'1~0 1. 14~3
Y.ALt:STI\~JtiARD1 000. 0!:~0 -. r.•~·•) 94. 179 • 0000 At..t·:ALI 1. ~1.>10
TC•I'IF.F'<C•EI'IOC•UL 1. $.a'5 l. 7':'•~ 1. $4~ . 0000 HY[•R 1'1CIDUL 2. 1::11
~JLli~ATI'IODUL. :!. :;·;•:; :!. !i4:i :. :'·45 • 00(10 TONERt•EI"'CIOUL. 1. E:4~·o
c~::. 60. ~·:,o ~.9. ~(•t:. ~·~'. ~·•)0 • (10(10 SILIY.ATI'IODUL" 2.~450
C:!$ 100. 000-100. 0(r0 17.St:.:i • (1000 ~ALI~STANDARD 94. 17? 1
C~A 100. 0"0 . 000 9. us • 0000 !:to: 21. &7~:;
C4AF'+2C3A
Y.C•I'IPON. 1
200. 00~-100. OCtO 2S. :·21
1. 000 • 000 . 7:i2
•••••••••••••••••••
T 0 T AL 1. 0000
AL~(I'3
FE203
:i.S7~3
3. O~lS
c:r.o 65. 74~3
l'l(;t) 1. 145'3
OPTl1'11,tl'l PREIS • 11S74+00 • 6~SS
NA20 . 72~S
TJC•~ • 2242
C'R:!03 • orJQO
I'IN203 • 1224
S0'3 . 1441
PlOS . oa~o•
CL . o:;o~
F' • OCICJO
REST . 6592

Page 272
© Holderbank Management & Consulting, 2000
 "Holderbank" Cement Seminar 2000 •a :[.] ~ ·l=t;J='·'~ 1:u
Materials Technology I - Mix Design

Table 45

. . .. ····· ...... . . OPTI4&LISIUUMI

·····················································································
. . .

.....................................................................................
•• . 0.. • . . . . . . . •. •. .. • . .

I
...............
I . I
&HiLtSI"

·········································································•·········································•••·················
1 . I I I I I I I I
I KO~POIIEIIfEM I CVE~ I 5102 I AL70~ I ruo~ I C&O I MQO I 120 I IIUO I lUI I CUriEl I SOS I "II~ I
I••••·•••••••••·········•·········
I LIMESto•E. I ~7,U I 1,11
.••..... ~.; •••••••••••••••••••••••••.. ,............. ,•••••••••••••••.••••••••••• •••••••••••••••••••
.At I ,41 U,tl ,43 ,It I ,U ,u I I I U,Ul -1
I SMALE LON I li,H I cs,to j~.iD I t,iit sS,IO 1,•1 l,ll I loll ,71 I I I U,•IE •1
I SHALE NICM I 1,41 I U,Ao 1·3,31 I 4,1. ~.41 ,n 2,21 I 2,51 lo47 I t I n,llf U
I •TII1E CIMDI. I,U I 11,11 J,to I 7l,U 2,51 ,st .,cs I ,n loU I I I \S,AU U
I SILICA SINO! ~.50 I 19 1 ~1 ~.h I 2,il i,IO ;21 ,U I oil ,42 I I I \S,Uf •l
I I I I I I I
I I I I I I I
I I I I I I I
I I I I I I I
I
I
I
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I
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:.............!......... !......... .........!......................................!................... ~ .........!.........!.........•
•••u••••• .. •iu i••••••••
: JMretOEirJ:NDFN : -£SULfJIE :
I•............................................................•..........••............•.
I ,..............................................
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-~~~ ~ !~.!.1 ~~!:.~~~~!~..1!.~!!~~!
s.2'1
!.....!..........~!:~=~~~~~!:~!!~!~!!....!..........~~!:!~~:!:!~~~!......... !
LIHESIDN£ en ·u,,nt
1JCJZ 1
I N12D•t,nUU IUoCII I ,AU S~JLE LON olllZ CU !1 1 1101 1
I lU~l IUoUI I I 4,1&6 SMILE HIGH I CU ,,IU2 1
I n:a3 :11.11& I I . ~.nt PUITI CIND 1 1121 cur U,UIJ 1

•751:
I SIDI I I tloUI SILICl liND 0 tlt5 ~GO loUII 1

I uLws""'"' im.esi I ·'·"'" ,.,.,7 :~:m1 1

I :r~~=~t::m tm 1 ~:m ::m ""I"Df"'''IL a.m.
1
I
I C:IS
: g:
61.500 J
UO,tili
I
•i~::~:~ ::::::
s.•H
•••••••••••••••••••••••••
TOTAL lollll
SILIUIHIDVL
IILKST&Nii&"D
SIDl
2,U•t
t6,•:SU
UoU\1
I CHF•7CJ& 2llolll U,4J3 JLUJ o, UU
II •oH,D!IEtrfE 1.011 run
cao '·''"
''·'l•l
I t~GO 1,, 2Ut
1 •:zo ,,,.,
I II&JO ,St'IO
I ""0•, "DDuL :l,l••e
l Gl•s o
I ••~n l,UUI£ ll

© Holderbank Management & Consulting, 2000

Page273
 "Holderbank" Cement Seminar 2000
Materials Technology I- Mix Design

Table 46

.•••••••••••••••• ;..~ ••• ;..;.e;. .......................................................... .

.
........... ..
'057
;. .. ..
i5n5D,ICA
~.;. ~ ;.-.;,.;.;. .......... ..........••.......•..........................
MIXES I~IG&N ~a,
;.
7-

&NILYSEH

I I I I I I
····~··········
········································································-~·····························································
I I I I I I I I
I Maft,DIIEHTEN I OVER I S I 02 I &~2a~ I • rUa3 I C&a I NGO I KZD I N&20 I ~EST I CAOF~E I I SO~ I ,.EI ~ I
l···················································································••t•••··············
I LIMESTD,E I &Z,tD l,to ,n ,«0 52,90 I ,c~ I ,oc ,U I ,n .........
0
···················1
0 U,U~ •1 l
I SH&L£ ~~w I 19,31 4l,AO iz,io a,io UoiD I 1,41 I 1,00 ioU I ,70 0 I U,UF. '1 I
I SN•LE MICN I 1,40 63,~0 1~,30 . 4,tio 3,CO I ;93 I 2,20 2,50 I 1,•7 0 I 11,10! U I
I 'TRITE CINDI 2,96 14,90 2,00 7~.AO 2,50 I ,5t I ,41 ,U I 1,12 0 I 15,6U •1 1
I SILICA SANDI J,50 U,3a 2,50 2.11 1,11 I ,21 I oiZ oDI I ,•z I I IS,UE U I
I I I I I I I
I I I I I I I
I I I I I I I
I I I I I I I
l I I I I I I
l I I I I I 1 I I
1····································-················
I
I
.
I I I
..................................
I
,..............................................,I
I I I I I

II. •.•rcoDE.~IIN,DF,.~ I RESULT•TE I

••••••••••••••••••••••••• I ••••••••••••••••• I
1·······-~---···-~---··················---~---·-························•!'••••························································1
I I I • I I I I
I I OaERf CAESlE I UNT, OR~N7E I RESULT&T I . MISCiiiiNGSYUHULTNIS I KLINK!R•lNA~YSE I
I I•••••••••••••• •••••••••• ,;. ••••••••••••••••••••••••••• ,. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Mr.o I uo.ooo I i,•U I LIMESTONE 1 7Ul I CJS · St,!OU
N&20•~oUIK2D I ua,ono I ,821 I SMALE LOW 1 26U I CZS l7,tnc
&L20~ I IOO.Ofti I 5,ft7C I SMILE MIDW 0 ,1 CH lO,U,
ruol I lftO,OOO 1 lo'll I PYRITE CIND 1 0020 I CHr 9,7nU
SIDZ I I Zi ,,~ I SILICA SAND Dl52 I MGD 1,•177
,no:
1

ULOSTIIID&AD ~ UDO,OH •e,ii5D ~ tC,65C ~ ~~~:~~~

TONER~E••OOIII. I 1,12~ S,77, I s,U5 I YDMEAOF.NaOIIL
SI~IKl!•NODU~ I 2oC~5 :i,l15 I 2ol75 I SILIUTNOOU~
I I I ULCST&NaA~D
ClS I •o.!lai .. s~.!o~ J !5o,soo ·•••r•••••••••••••·••••••• r
czs I •JGO,OOO I 17,945 TDU~ loDOOO I

.....
"02 Z1,St.1t
Cll r uo.ooo 1 sa.s.2o 1 &L20l ',17.J6
I ZU,DIO I 30,Ql6 I
cu.r•2CU
I
I loOOi
I
0 I
I
I
rnol
C&D ,,,,. ,..
~.zt 4

I
I
I
I
I
I
I
I
I
·=·
120
N120
MTCIA, MOGUL
~.
,••zs
,)1U
2,s•:u
I I I
I I I Gl•s 0
I I I

Page 274 © Holderbank Management & Consulting, 2000

 "Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design

Table 47

--------------------------------------------------------------------------
2066 0~0~0-044 "tXES JL!GAN NR ~~

ANALYSEN
NR GVER 5!02 AL203 FE203 CAD "GO K20 NA20 TlO CRO ftNO 503 P20 CL F REST PREIS

1 42~0 190 ~9 39':5290 42 4 4 3 0 e 8 4 1 0 4:5 • 10+00

2 1925 4150 1207 ~98 1576 239 99 109 :52 0 8 9 11 9 0 0 • 10+00
3 839 63eo 1329 400 340 92 219 250 44 0 6 9 8 l1 0 68 • 22•00
4 293 1477 287 7297 247 53 40 31 5:5 0 2 141 0 0 0 6:5 • :58+00

AN F 0 R D E R U N 0 E N R E S U L T A T E

PIA X. PI lN. RRESIJl..TAT PIISCHUNG5YERHAELTN15 I<L.INKERANALYSE

MGO 100.000 .000 1.362 LIMESTONE • 72~0 C3S 5~5000
NA20+.6~9K20 100.000 ."000 1.010 SHALE LOW . 2116 C2S 16.6421
AL20~ 100. 000 . 000 5. 933 SHA\..E HIGH . 05~-s C3A 10.2874
FE203 100. 000 . 000 3. 216 PYRITE CIND . 003~ C4AF 9.77~4
5102 100.000 .000 21.453 . 0000 PIQO 1.3622
KALY.STANDA~DlOOO. 0~0 ~ 0~0 94.860. • 0000 ALY.ALl 1.2040
TCINERt•E110DIJL 1. 94:5 1. 79~ 1. 845 . 0000 HVDR.MODUL 2. 143e
SILIKATMODUL 2.39~ 2.34~ 2.345 . 0000 TONERDEMODUL 1.8450
C3S 60.~00 ~9.~00 ~~~00 . 0000 SILIKATI10DUL 2. 34'0
C2S 100.00o-100.000 16.642 . 0000 Y.AL~STANDARD 94.8~00
C3A 10~000 .000 10.287 . 0000 Sl02 21. 4~29
C4AF+2C~A
K011PON. 1
200.000-100.000 30.350
1. 000 . 000 • 729
•••••••••••••••••••
T 0 TAL 1.0000
AL203
FE203
5.9327
3.2156
CAO 6~. ~038
PIGO 1.3~22
OPTIJ'M1 PREIS Y-20 • 567:!
NA20 . 63~-e
Tl02 .2507
CR203 . OO•;.o
MN203 . 1259
503 • 1410
P20S . 0927
CL . 0538
F • 0000
REST . 57699

--------------------------------------------------------------------

4. PRINCIPLES OF RAW MIX ASSESSMENT

Basically, eval~at~on and assess~ent of raw material components {4.4) and raw mixes refer
to the. same pnnc~~les. The only ?Jffe.rence exists in the immediate comparison of the
?~e~mcal compos1t1on of a raw m1x With the standard specifications of the products for which
1t 1s mtended.

© Holderbank Management & Consulting, 2000

Page275
 "Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design

4.1 MixTvoe
The possible combinations of different rocks used in raw mixes can be classified as mix
types. Important varieties are:
+ Argillaceous limestone (marl) having the composition of a natural cement. An optimum
homogenisation is realised in the rack texture itself. The reactions can easily take place
even with a coarsely grained raw mix.
+ The same rock in a metamorphic condition contains well crystallised silicates instead of
clay minerals. Under otherwise similar conditions, the reactivity is lower than in the first
case and there is a high probability that dust formation will occur in the preparation and
burning process.
+ Contrary to the above cases is the combination of pure limestone with pure clay. To get
a close contact between lime and silicate, both components have to be ground finely and
homogenised intensively. Depending on the type of clay minerals, the mixes can be
more or less reactive,
+ A further mix type is the combination of relatively pure limestone, argillaceous limestone
and sandstone. Quartz introduced by the sandstone will decrease the grindability and
the burnability to some extent. Problems may occur when less reactive minerals are
present in the other two components.
Rock combinations actually used can easily be related to this series of mix types. The
situation becomes more complicated when additions like pyrite ash, iron ore or bauxite are
used.

4.2 Comparison of Raw Mix with Standard Specifications

Any raw mix composition has to be compared with the locally applied standard specifications
in order to evaluate potential conformity. As an example, Table 48 compares two analyses
of typical Portland cements with the ASTM-specifications for the five main types of Portland
cement, whereb these es are desi nated as follows:
Type I Ordinary Portland cement
Type II Moderate sulphate resistance or
moderate heat of hydration
Type Ill High early strength
Type IV Low heat of hydration
T eV

Page276 © Holderbank Management & Consulting, 2000

 "Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design

Table 48 Raw mix composition and specification.

clinker chemical requirements according to
composition ASTM specifications for type:
I II I II Ill IV v
Loss on 0.43 0.69 <3.0 <3.0 <3.0 <2.5 <3.0
ignition
Si02 20.8 22.8 >21.0
AI203 6.0 3.8 <6.0
Fe203 2.5 4.4 <6.0
GaO 66.7 65.2
MgO 1.4 2.2 <6.0 <6.0 <6.0 <6.0 <6.0
So3 • 0.52 0.16 <3.0 <3.5 <3.0 <3.5 <4.0 <2.3 <2.3
~0 0.80 0.39
NA20 0.20 0.30
Mn203 0.50 0.05
P20s 0.16 0.07
Ti02 0.27 0.26
Cl O.D1 0.01
Total 99.84 100.33
Silica 2.4 2.9
ratio
Alumina 2.4 0.9
ratio
Lime 99.6 93.4
saturation
c3s 59.9 65.1 <35
c2s 14.4 16.2 >40
c~ 11.7 2.8 <8 <15 <7 <5
C~F 7.6 12.7 <20 ••

* depending on C3A content ** C,AF + 2 CaA

It is obvious in Table 48 that mix I conforms to the specifications for type I (ordinary Portland
cement) and type Ill (high early strength), but not for the other types.
Mix II conforms to all cement types except type IV (low heat of hydration).
If a composition of a potential raw mix does not meet the specifications for a particular type
of cement, the following measures have to be weighed:
• Modification of proportioning criteria (lime saturation factor, silica ratio, CaA- or Al2 0 3
content, etc.)
• Selection of necessary corrective materials (silica sand, etc.)
• Replacement of components (replacement of an alumina rich claystone by a silica-rich
material for production of ASTM type IV and V cements, etc.)
• Replacement of the selected fuel type or fuel quality (coal with little ash instead of coal
with a high ash content, if the coal ash composition becomes a critically influencing
parameter, etc.)

© Holderbank Management & Consulting, 2000 Page2n

 •a: [•] I! •l =I;~ :1-1 ~I tM
"Holderbank" Cement Seminar 2000
Materials Technology 1- Mix Design

Influence of minor ("deleterious") elements

The main influencing effect of the so-called deleterious constituents or elements on
preparation and production is discussed in chapter 4.4.2. The following deals only with limits
and effects of these constituents in the cement raw mix. Under normal circumstances, the
following ranges and limits are to be expected:

Table 49 Deleterious constituents in cement raw mixes

deleterious "normal" range limits remarks

constituents % %
(clinker basis) (clinker basis)
Alkalis:
K20 0,5-0,8 0,6 for low-alkali
Na20 0,2-0,4 as Na20 clinker
MgO 1-3 5-6 according to local
specifications
so3 0,2-1,0 1 - 1,5 higher S03 in
clinker reduces
quantity of
gypsum to be
added
P20s 0,0 .. -0,3 0,5-0,8
Cl 0,01 -0,03 depending on and
(0,01 - 0,1) determining the
process
F 0,01-0,1 air pollution
Cr203 0,01 -0,04 dermatitis
Fe203 3-5 0,3 for white cement
production

These limits should not be regarded as isolated figures but rather as part of a multi-
component system (including contributions from the fuel). Particular attention should be
given to the systems of:
K20 ----- Na20 ----- so3
K20 ----- Na20 ----- Cl
whereby an effort should be made to achieve equalised alkali sulphur balance in order to
prevent problems in the kiln system.
Only a few deleterious constituents are limited by specifications, e.g. the MgO and the total
alkali-content (for low-alkali clinker). The others are not specified (limited) but practical
experience with processing and quality requirements of the product (clinker/cement) dictate
their quantitative limits.

4.3 Assessment of the Mineralogical Composition of Cement Raw Mixes.

A routinely performed assessment of a raw mix includes as a very important part the
examination of the mineralogical composition (Table 50).

.)

Page278 © Holderbank Management & Consulting, 2000

 Wld :C•l ~ •l=l ;~ :l-1 ~I :a
"Holderbank" Cement Seminar 2000
Materials Technology I- Mix Design

Table 50 Mineralogical assessment of raw mix

Minerals Effects on technology

Aragonite (CaC03) dry grinding -7 coating in the mill and high
power consumption
Quartz (Si02) grinding -7 abrasion, wear and high
power consumption
burning -7 ill!pairs burnability
Feldspar burning -7 impairs burnability,
low reactivity
Clay minerals:
Montmorillonite preparation -7 water absorption,
Illite stickiness
Kaolinite burning -7 improved burnability
Chlorite dust production -7 reduced dust prod.
Mica coating properties -7 facilitates coating
Palygorskite
Minerals of good reactivity low, require more energy for
crystallinity transformation
Minerals of low reactivity high, less energy necessary for
crystallinity transformation

4.4 Assessment of Raw Mixes with regard to Cement Production and Choice of
Process
As discussed previously, the properties of the raw materials, i.e. raw mixes, largely influence
the choice of process in general, and the various stages of production. Tables 51 and 52
indicate the most significant relations and functions.

© Holderbank Management & Consulting, 2000 Page 279

 "Holderbank" Cement Seminar 2000
Materials Technology 1- Mix Design

Table 51 Significance of raw mix properties in cement production. (Compare also

Table 51 p. 5/3 referring to raw material properties).

Aspects of Raw mix properties

production
Quarrying see Table 40
Crushing
Transport
Storage
Grinding
Slurry preparation clay mineral content, fineness
Drying clay mineral content, porosity
Homogenising chemical and mineralogical variability
Nodulising clay mineral content
Dewatering clay mineral, slurry characteristics(filtration)
Burnability mineralogical composition, fineness,
degree of weathering, intergrowth
and size of rock fragments
Dust formation mineralogical composition
crystallinity
Coating formation chemical composition

It becomes obvious that the clay mineral content is of paramount importance form many
aspects of production.

Table 52 Summari-ses the most important raw mix properties influencing the
choice of process.

Raw mix Related features WET DRY

properties PROCESS PROCESS
moisture clay mineral content, high low
content porosity
plasticity, clay mineral content high low
stickiness
homogeneity chemical, physical and poor high
mineralogical variability
chemical chemical composition high low
characteristics regarding alkalis,. sulphur,
chloride, etc._ (contentsl

Table 52 only summarises raw mix aspects. However, other factors, e.g.
• seasonal fluctuations of moisture content
• transport, haulage etc.
are, of course, also determining factors in the choice of process.

4.5 Evaluation of Laboratory Test Results

The steps which are regarded as the final part of a mix design, are preparation, examination
and evaluation of test results produced in a laboratory.

Page280 © Holderbank Management & Consulting, 2000

 •a: t•l ~ ·l:t .~ =1·1 ~ 1:a
"Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design.

4.5.1 Preparation
The proper preparation of laboratory raw mixes for testing is the prerequisite for reliable test
results and subsequent evaluation.
It is as important as sampling and it should, therefore, be emphasised that both these
processes have to be carried out under observation of strictly defined rules and controls.

4.5.2 Significance of Laboratory Investigations

The characteristics and behaviour of a cement raw material or mix during the various stages
of production can never be predicted on the basis of the test results and findings of
laboratory investigations alone. Laboratory testing has the disadvantage that many
influencing and technologically important parameters such as kiln atmosphere, industrial
preparation, etc., can be neither simulated nor reproduced on a laboratory scale. Laboratory
produced test results, however, permit the recognition and interpretation of tendencies,
whereby a broad variety of individual findings assures a more reliable final evaluation. It is
thus recommendable to conduct a series of tests, the results of which can be used to
support and control each individual finding. For instance, when the filtration properties of a
cement slurry have to be assessed, mineralogical/chemical investigations grain size
distribution tests, rheological tests on slurry and specific filtration tests should be conducted
rather than a specific filtration test only. The same idea is applicable for all the other
assessments of technological properties such as _burnability characteristics, grindability
properties, etc.
In order to guarantee that the laboratory results correspond as closely as possible to the
findings of industrial practice, the design of the laboratory testing methods and other
aspects such as limits, reproducibility, etc. should periodically be checked and compared.

4.5.3 Summary of Laboratory Tests

The following tests are available and normally applied in the cement industry (Table 53).

Table 53 Laboratory tests

Material aspects Test designation Limits, reproducibility,

Stickiness soil tests
Burnability burnability test
Grindability grindability test
Volatility of circulating volatility test
elements
Coating behaviour coating test
brick selection
Filterability filtration test, testing of
slurry rheology
Nodulisability granulation test,
thermo-shock test
strength test
practice relevance
tendencies only, but
good practice relevance
quantitative estimate of
kWh/t requirements
quantitative estimate of
primary volatility in
various atmospheres
tendencies only,
acceptable practice
relevance
quantitative estimate of
key-factors quantitative
assessment of rheology
tendencies only, practice
relevance acceptable

© Holderbank Management & Consulting, 2000 Page281

 "Holderbank" Cement Seminar 2000
Materials Technology 1- Mix Design

Normally these technological tests are supported by:

+ chemical analysis (highly accurate)
+ mineralogical analysis (semi-quantitative)
+ grain-size analysis (accurate)

Page282 © Holderbank Management & Consulting, 2000

 W'd: t•l I! •l :t ;J=1·' ~I tU
"Holderbank" Cement Seminar 2000
Materials Technology 1- Mix Design

Program for Optimal Raw Mix Design

1. MIXOPT•.•••.••••••••.•••••••••..•••••.•••••••••••••••••••••.••.•.•.••••.•..•••...•.•••••••.••••••••.•••••••••••••.•••••.••.•.•. 284
1.1 OPTIMAL RAW MIX DESIGN ON PERSONAL COMPUTER. ................................ 284
2. PROGRAM FOR OPTIMAL RAW MIX DESIGN ........................................................... 284
2.1 FACILITIES ............................................................................................................ 284

© Holderbank Management & Consulting, 2000 Page283

 "Holderbank" Cement Seminar 2000
•a: t•l 111·1 ~ ;~=1·'~ 1tee
Materials Technology I- Mix Design

1. MIXOPT

1.1 OPTIMAL RAW MIX DESIGN ON PERSONAL COMPUTER

MIXOPT is a comprehensive program for the optimal design of raw mixes and determination
of product characteristics. It is tailored to the specific needs of the cement industry and
offers a wide range of applications in the field of raw meal preparation and product design:
• Up to 9 components may be included to determine a raw mix of desired characteristics.
• Fixed values or ranges may be set for chemical (e.g. Na2 0-equivalent) and
mineralogical (e.g. C~) constraints of product characteristics.
• The component quantities can also be restricted. This might be necessary in case of
limited availability or for fuel ash.
• Lowest cost product is determined within given product constraints if costs of
components are entered
• Alternatively to cost optimisation, optimisation or minimisation of a particular chemical
component is possible.
• Blending of materials or determination of raw meal, clinker and cement characteristics
can be accomplished apart from raw mix optimisations.
• Program includes data base and print facilities.
Typical MIXOPT applications are illustrated on the following pages.
The knowledge required to operate the programs can quickly be acquired. Dialogue, window
menu selection, and user's help facilities make it very user-friendly. Previous computer
knowledge is not required.
The program or further information is provided by:
"Holderbank" Management and Consulting Ltd.,
Technical Centre Materials Division,
5113 Holderbank,
Switzerland
or
"Holderbank" Consulting Ltd.
2310 Lakeshore Road W.
Mississauga,
Ontario
Canada LSJ 1K2

2. PROGRAM FOR OPTIMAL RAW MIX DESIGN

2.1 FACILITIES
+ BLENDING OF COMPONENTS
+ DETERMINATION OF PRODUCT CHARACTERISTICS
• Raw Max
• Clinker
• Cement

Page 284 © Holderbank Management & Consulting, 2000

 •a :c., .. ·) =t ;J :1-1 ~ 1:u
"Holderbank" Cement Seminar 2000
Materials Technology I- Mix Design

+ RAW MIX DESIGN WITH UP TO 9 COMPONENTS

• Fixed Value or Range for Product Constraints of:
• Limitation of Component Concentrations
• Input Specification such as:
• Reference to Moist or Dry Components
+ COST OPTIMISATION OF PRODUCT
+ DATA BASE FACILITIES FOR:
• Components
• Product Constraints (e.g. for different clinker types)
• Calculated Product
+ PRINT FACILITIES
• Single Mix Design
• Compilation of Mixes
+ GENERAL USER FACILITIES
• Insertion and Copying Mode
• Title Specification
• File Clearing
• Help

. )

© Holderbank Management & Consulting, 2000 Page 285

 "Holderbank" Cement Seminar 2000
•y: [•1 I! •l:t ;~ :1-1 ~I !UP
Materials Technology I - Mix Design

Fig.1 Blending of Components.

s • 1
•c t New 0 p • ,. .. t i o n

? --> H • 1 p

c ~ --> ·T I t I e
--->
-->
0 -->
C om p o
p I"' 0 d u
0 p t i m
n e n t s
c t
I z a t I o n
1o1 -->
t1 ->
Wo r k s
H I X - t
h •
a b 1
••
t print - out
F --> F i 1 • s
E --> E X I t
any other key ---> T i t 1 • ..
1ow•r case keys all0111ed : t •T etc

~Y,O M P ONENTS
Material 1 imest I imest 1 imest I imest 1 imest 1 imest 1 imest TOTAL.
Mat.- No gtl gt2 gt3 9t4 gt~ gto gt7
i/a./c ·No i 01 i 02 i 03 I 04 I 05 I 06 I 07 i 10
Humidity o.oo o.oo o.oo o.oo o.oo o.oo o.oo o.oo
L..O.I. 36.61 35.10 36 • .:51 3.:5.80 36.45 36.61 36.61 36.40
Si02 11 .51 13.50 11 .51 11 .51 11.CO 12.00 12.60 11. 9:i
Al2!l3 2.~a 2.51 2.61 2.~1 2 • .:55 2.66 2.~1 2.57
Ft203 1.44 1.44 1.3S 1.44 1.53 1.49 1.44 1. 45
CaO 3~ . .;o 38.40 39.00 40.00 39.40 38.76 39.40 39.19
M90 4.53 4.85 4.~3 4.53 4.53 4.53 4.20 4.53
sos 0.65 0 • .:55 0.65 0.65 0.65 O • .:SS 0.~~
)> 0.64
t~20 1.44 1.44 1 .44 1.44 1.44 1.44 1.43 1.44
N-.20 0 .JS 0.1S o.te o.Je 0 .1S 0.03 o .1'a 0.16
Ti02 0.17 0.17 o. !7 0.17 0.17 0.17 0.17 0.17
Mn203 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14
~20~ 0.43 0.43 0.43 0.43 0.43 0.43 0.43 0.43
0.02 0.02
.....
Cl-
Rest
0.02
o.o1
0.97
0.02
0.01
1.1-:"
0.02
0.01
1.33
0.02
0.01
0 .J ~
0.02
0.01
1 .41
0.01
1.07
c.o!
0.32
0.02
0.OJ
0.'12
Total 100.01 100.01 100.01 100.01 100.01 100.01 100.C1 100.01
Co~t .wet 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
Fr.t.ime
Jnsolub.
?roper~. 1.00 1.00 1.00 1.00 1.00 1.00 1.00 7.00

Page 286 © Holderbank Management & Consulting, 2000

 "Holderbank" Cement Seminar 2000
Materials Technology I- Mix Design

Fig. 2 Product Characteristics.

s • 1 • c t N •"'
Operat I o n
? -> H • 1 p
T --> T I t 1 •
®
¢-->Com p o n • n t 5
---> P r 0 d u c t
-> 0 p t I ml z & t o n
w -> w 0 r k 5 h • • t print - out
H -> H I X - t & b 1 •
F -> F I 1
E --> E X I
•t •
any other key - - > p r 0 d u c t
lower c:ase keys a11ow•d : t • T • tc: ..

® R 0 D u c T
.
Constraints .
Modu I i /Sofilu• .c h • m• c o m p 0 s i t i o n
Clinker
!Minimum M&ximum'Raw~ix Clink•r' Raw-Mix
Lim• Saturat.: 05102 L.O.I. ').05
SIll c:a Ratio: ~~S!3 SI02 21.77
Alumina Ratio: ~ .~9 A1203 ~.0~
C3S 55.~0 Fe203 ~-:i:7
C2S zo.5~ CaO 6~.~1
C3A Sli3 t1g0 1.00
C4AF SsJ~ S03 2.90
C4AF + 2C3A 2:i.?!i! K20 g.:;;9
SI02 Na20 0.14
A1203 Proportions TI02 0.02
HgD t1n203 !!IC~
Na2D-•q. I P20:S !!10~
No.1 tipol k 1(1(1 • (10
......
. Cl-

R•st
0.01
0.01
0."':6
Total JOO.OO
LPh-1338 IS.O~
LPh-1400 ~~.45
Alk/503 01~!1
Na20-eq. 0.53

Pr-oduc:t ,Total~: 100.00 Co~t 0.00

© Holderbank Management & Consulting, 2000 Page 287

 "Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design

Fig. 3 Mix Optimisation.

5 • 1 • c t New Dp t r a t I o n
?-> H • 1 p
T--> T I t 1 •
® ~--> c om p o n • n t 5
---> p r 0 d u c t
-> 0 p t I 1111 z a t I o n
w --> w 0 r k s h t e t print - out
H -> H I X - t ~ b 1 •
F -> F I 1
E --> E X I
•t s

~ny oth•r kt)" --> p r 0 d u c t

lower case ktYii allowed : t •T etc: ..

u c T
. Constraints® . Modul i/Sogue
R 0 D
I
I c h e m. c om p 0 s i t i 0 n
IMinimum M&ximumiR~~ixClinker' Ra101~ix Clinker
Lime Saturat.:
S II I c:a Ratto: .::
I
O§zO;:
~.e~
L.O.I.
5102
I
I

:
'J.OS
21.7?

..
Alumin~ Ratio: ! .~9 A1203 I =~Q~
C3S I
55.50 Ft203 ~.~?
C2S I
~o.~s CaD 6!;121
C3A I 8:~3 HgO t.oo
C4AF
C4AF + 2C3A .
I
I

I
S.l;ii:
2~~7~
SC3
IC20
2.90
g.:;9
5102 I
I Na20 0.14
A1203
. Proportions TI02
I
I 0:92
MgO I
Hn203 Q.C~
NaZD-tq.
No.1 tipoi k
I
. 100.00
I
P20~

......
Cl-
gig~
o.ot
0:01
Rest o.:o
Total JOO.OO
LPh-1338 1 s. (10
LPh-1400 ~~-45
A1k/SC3 o.~~
Na20-eq. !;!.53

P,.oduet ,Tot~!~= 100.00 Co<Et o.oo

Page288 © Holderbank Management & Consulting, 2000

 "Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design

Fig. 4 Compilation of Results.

I • I • c t .... 0 •• P a I I o •

@ ..............
't-tlle I •
T-JTitl•
e-tc•••••••••
<!>=''"'•tl•c
, ) ........... 1
t
...... _,
M-tMia•latl•
P-J ., I o o
l - 1 I • l·t

.,. ....... It•• --· T

,_,. . . . . . .,.. • • • - •
I I I
' t • T •• etc
o

!"!... _
t t

....... . ..'..... ....

••'-••••• ~~ ~:·· ~· ~!'"
COPIPDNINT.
f" ,~~·· ............ .....__
.........
C<

..
~~··.. •••
Ne liD Ill IWII.OI ·-··
IIMIDI ... •• JIMIIS ~
Mllt114
.....
··-··· ..... • •• ....'·"
~. n.ea rs.a:~

··-- ..................,. ...........•. .............'·".... ........... ..

l'a.IC ... I fl I 02 I II I ... I OS I .- '
z.zo z...
0 II t I • a I ••• .._ldllr 0.10 I.H
,1.11 O..DI 0.00 Ill lea

-
1 ...

... • ......
~.a.l. aS.lll 11·21 15·7·
11112 A.H Sl C»

--·10 .
AI- 14." J ••• CH

-- ....... ........... ....

T I t I
•• ..,
Coli . ~
o.a
~·-
I oliO
e.aa 11112
ttt•h
+ a.H
Dolt
+ ..,
AIZDI

... "··-· ....... . , •o.n -··

Tlllel hal • • laT............... ••• r•·
... 21
I.ID

.... ,......,..
TIIZ 1.17

.,_,
I > . ....,.•
..,, "'• .... I-.e_,,
,_ I.H •••• ••••
••••, •••• l.r
• · • C.ll1a I

.....
JIO.Z TUrr• I
~ -... I •••••
•••o
11.10
~.ID

........... ,._. Cl•

....
..-...
e.aa I 2.1D

nta .... •• •• ••c•••••• .,.....

All .. I flits ......... 111 W
,a;;;·· loZO
I
.............
Ho.s•••• I
,.....•••• 01 .. SUI
-·-·~~~
.......
........
C..l.-t
IN.ID IH ...
IID.n 1~ ....7 P'IPIU I
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© Holderbank Management & Consulting, 2000 Page 289

 "Holderbank" Cement Seminar 2000
Materials Technology I - Mix Design

Fig. 5 Storage of Data, Constraints and Results.

S e 1 e c t N e w 0 p e r a t c n
? --> H e 1 p
T --> T 1 t· 1 e
C --> C c m p o n e n t s
P ---> P r o d u c t
0 -->.0 p tim I : a t i o n
W --> W or k s h e e t print - out
J1 I x - t a b 1 e
F------ ~ -->.Exit
-->
--> F I 1 e s

any cth•r key -----> P r o d u c t

lower cas• k•ys allowed : t • T •• etc

®I
the
1 ~ ~

fol I owing 77 files are avallablea 43 comp., S prod., 26 mix

lOPART.Ctf'l PARJDS.CHM
~S1l2.CI-t1 AL.T014.MIX
1 5AREN • CH"' SB113.Cii'1
PAR106.CH'1 AL.T02.M1X
54S3D.CHt1 SB114.CHM
PAR107.CHM AL.T03.MIX
:S71&S3.CH'1 AL.203". Ct-11
AL.TO 1 • PRt> AL.T04.MIX
57164.CHt1 CAL.JS.CHM
AL.T02.PRD AL.TO:'i.MIX
571 &SS • CH'f CEMENT. Ctt1
AL.TC3.PRD AL.T06.MIX
5?1&S6.CH'1 CLINKE.CI-t1
EMPTY.PRD AL.T07.MIX
571 &S7. C!-1'1 · GT1 .• CHM
START .PRO AL.TOS.MIX
.~694.CJol'1 GT2.CI+'I
TIPOP.PRD AJ,.T09.MlX
576PS.Ct-11 GT3.Cif1
TJPDPAR.PRD Ca1ENT~MIX
57696.Ct-1'1 GT4.CHM
TYPE1 .PRD CLINKE.MIX
5769B.CHI'1 ~~.CHH 01 .MIX CPJ.MlX
5B1D2.CI-I'I GT6.CI+t 77S.HIX GTM1.MIX
:SS104.CHM t11 .CI+'I n7.:1IX Ml01.MIX
:SB106.CI-I'I MEZCLA.CHM BOO.MIX PP1.MIX
58107.CHt1 PAR100.Ctf'1 AL.T01 .MIX START.MIX
5BJOB.CHM PAR101.CH'1 At.TOt 0 .MIX TORREJ.MIX
5B109.CHM PAR102.CI+'I AL.TOll .:1IX
58110 .CHM PARlOS.CI+S AL.T012.MIX
~B111.CHM PARJ04.Cif1 AL.TD13.:1IX
move the cursor to a file. mark/unmark for deletion with '•'
to end operations on this screen press Esc

Page 290 © Holderbank Management & Consulting, 2000