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  • Production of Clinker With 1-2% Free Lime

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    Mukti M Muzakki
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    Free lime levels in clinker are generally unwanted and indicate insufficient burning. Higher free lime can be achieved by reducing fuel, increasing kiln speed, or increasing the lime saturation factor (LSF) and modulus of substitution (MS) of the raw meal. However, this can result in smaller, dustier clinker nodules and negatively impact operation stability, cement production, and concrete strength. Specifically: 1) Dusty clinker reduces brick life in the kiln and leads to unstable coatings that increase shell temperatures. 2) Finer clinker endangers grate cooler operations and causes harder cement handling. 3) Higher free lime causes higher calcium hydroxide levels during cement hydration,

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    Free lime is one of the indicator in clinker production

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    Production of clinker with 1-2% free lime

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    Free lime levels in clinker are generally unwanted and indicate insufficient burning. Higher free lime can be achieved by reducing fuel, increasing kiln speed, or increasing the lime saturation factor (LSF) and modulus of substitution (MS) of the raw meal. However, this can result in smaller, dustier clinker nodules and negatively impact operation stability, cement production, and concrete strength. Specifically: 1) Dusty clinker reduces brick life in the kiln and leads to unstable coatings that increase shell temperatures. 2) Finer clinker endangers grate cooler operations and causes harder cement handling. 3) Higher free lime causes higher calcium hydroxide levels during cement hydration,

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    © All Rights Reserved
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    164 views11 pages

    Production of Clinker With 1-2% Free Lime

    Uploaded by

    Mukti M Muzakki
    Free lime levels in clinker are generally unwanted and indicate insufficient burning. Higher free lime can be achieved by reducing fuel, increasing kiln speed, or increasing the lime saturation factor (LSF) and modulus of substitution (MS) of the raw meal. However, this can result in smaller, dustier clinker nodules and negatively impact operation stability, cement production, and concrete strength. Specifically: 1) Dusty clinker reduces brick life in the kiln and leads to unstable coatings that increase shell temperatures. 2) Finer clinker endangers grate cooler operations and causes harder cement handling. 3) Higher free lime causes higher calcium hydroxide levels during cement hydration,

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    © All Rights Reserved
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    of 11

    Kajian Produksi Clinker dengan

    Free Lime 1-2%

    Mukti Mabrur Muzakki


    Dept. Cement Production 2
    PT. Semen Baturaja (Persero) Tbk
    Free Lime
    • Any lime has not reacted with silica, alumina or iron will be left as free
    CaO. They are generally unwanted material indicating : insufficient
    burning of the clinker (CaO), decomposition of C3S in clinker or too
    high LSF
    • Temperature, residence time and burn ability influence achieved free
    lime level

    PT Semen Baturaja (Persero) Tbk 2


    Ways to achieve higher free
    limeAction Probable Effects

    Reduce fuel - Lower heat consumption


    - Less liquid phase

    Increase kiln speed - Increase capacity


    - Shorter burning time

    Increase LSF and MS - Harder burnability


    of raw meal

    PT Semen Baturaja (Persero) Tbk 3


    • Increased LSF and MS will give
    lower liquid phase (harder
    burnability)
    • Lower liquid phase tend to give
    smaller clinker nodules size-
    dusty
    • If there is not enough liquid,
    the outer parts of the nodules
    become enriched in silicates,
    some of which form dust

    PT Semen Baturaja (Persero) Tbk 4


    Effects on clinker product
    • When two C3S crystals meet, they
    have a high probability of growing
    together to form coarse C3S
    particles; The more C3S is formed,
    the higher the probability of getting
    large particles consisting of several
    C3S crystals grown together
    • Reduced fuel : lower temperature
    same retention time, less C3S
    formed and smaller nodules size,
    dusty
    • Increased kiln speed : shorter
    burning time same temperature, less
    C3S formed and smaller nodules
    size, dusty
    PT Semen Baturaja (Persero) Tbk 5
    Effects on operation stability
    • Dusty clinker strongly reduces the brick life in the burning zone of the
    kiln. Dust returned from the clinker cooler often leads to the
    formation of a porous, unstable and pumice-like coating on the brick
    lining, instead of the desired dense and stable coating.
    • Unstable coating lead to higher kiln shell temperature
    • Finely grained clinker seriously endangers satisfactory maintenance
    free operation of grate coolers.

    PT Semen Baturaja (Persero) Tbk 6


    Effects on cement production
    • Higher free lime may cause higher Ca(OH)2 when hydrating, can
    cause destructive expansion of hardened concrete

    (Mtarfi et.al , 2017)

    PT Semen Baturaja (Persero) Tbk 7


    Effects on cement production
    • Higher free lime gives lower
    compressive strength,
    because of low C3S in
    clinker
    • Higher clinker factor
    needed to achieve the
    same compressive strength
    with lower free lime

    (Mtarfi et.al , 2017)

    PT Semen Baturaja (Persero) Tbk 8


    Effects on cement production
    • An additional amount of water is necessary for free lime hydration
    present in the samples and that makes the increase in mixing
    consistency

    (Mtarfi et.al , 2017)

    PT Semen Baturaja (Persero) Tbk 9


    Effects on cement production
    • Dusty clinker will be harder to handle, may cause vibration

    PT Semen Baturaja (Persero) Tbk 10


    Refferences
    • FLSmidht. 2009. “Kiln Process and Operation Vol.1”. FLSmidht
    Institute.
    • Mtarfi et.al. 2017. Effect of Clinker Free Lime and Cement Fineness on
    The Cement Physicochmical Properties. Morocco : University of
    Mohammed Premier
    • Taylor, HFW. 1990. Cement Chemistry. London : Academic Press.

    PT Semen Baturaja (Persero) Tbk 11

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