Particle Size Distribution

PSD
 To exploit the full potential of the different cement constituents
it is crucial to optimize their particle size distribution PSD

Clinker Gypsum MIC

Effect on: Effect on: Effect on:
- Setting - Setting - Late strength
- Early strength - (Early strength) - Durability

Ideal PSD: Ideal PSD: Ideal PSD:

- Small size - Extremely fine, but - Coarser than clinker
- Narrow PSD no to control - Broad PSD

% % %

μm μm
Finess test methods
Method Determination of Comments

• Sensitive toward changes in cement composition

Specific surface area
Blaine (SSA) • Influenced mainly by very fine fraction (< 10 µm > 80 % of
SSA)

• Sieve residues in many cases too small to give

reproducible/reliable result (ideal 10- 15 % residue)
Sieve residue Single point of PSD Agglomeration of particles (in particular for fine cements) or
•
material losses can falsify result

• Result influenced by calculation method (e.g. Mie)

• Sometimes difficult measurement of very fine/coarse fraction
Laser (depending on instrument/detectors)
granulometry Full PSD
• Drift of instrument needs to be monitored and set points to
be adjusted

BET SSA and nano scale • Only useful for very fine materials (e.g. silica fume)
pores
 Particle Size Distribution

PSD impacts:
 Water demand

 Workability

 Setting time

 Strength development

4
 PSD in Compound Grinding
• Compound grinding of
separator tailings
[t/h]
[°C]
materials with different
[%R] grindabilities  is affecting
GA
the product PSD
[g/t]
[°C]
[mbar]
Blaine: Some of the
[m3/h] components achieve the
°C
necessary fineness faster
[m3/h]
[t/h] inside the mill (could be
[%]
[kW
[%R,cm2/g]
[°C]
pozzolana, limestone, fly
]
ash) 
[%R] [cm2/g]
acc. Blaine  Waste of energy
Cumulated Low flexibility in terms
residues of influencing the PSD

mill length [m] [m]

longitudinal sieving graph

 PSD in Separate Grinding and Compound Grinding
Optimal Mix Adaptation Compound Mix Adaptation

% %
Clinker
Clinker

Limestone
Limestone

μm μm
Clinker high fineness, better strength Clinker PSD coarser and wider,
development may define residues
Limestone complementary PSD, Limestone too fine, defines Blaine
definesthe residue
Limestone is softer than the clinker and tend to concentrate in the finer
fractions of the cement
The slope of the cement particle size distribution

Narrow PSD Wide PSD

Large void volume Small void volume

High water demand Low water demand
Ideal clinker PSD to achieve maximum reactivity
ideal
%

not
ideal

3 μm 30 μm μm
Ideal clinker PSD to achieve maximum reactivity
High fraction < 30 um
High fineness
(Narrow PSD)
 In compound grinding the cement components
are distributed according to their grindabilities

Soft Limestone Hard Limestone

% Clinker
%
Clinker

Limestone
Limestone

μm μm
limestone cement the residue based fineness control
• The residue in blended cements is
Soft Limestone generally clinker
• For blended cements:
– Always control fineness on basis of
residue!
% – In particular when using soft
Clinker limestone

• Blaine
– Mainly influenced by very fine
Limestone particles (1 to 5 µm)
– Increase of gypsum or limestone
proportion can increase Blaine
significantly

μm
Product PSD and Separator Operation
%D
Good separation (raw meal & Good
coal): separator
% R 200 m
0.02 < < 0.05
% R 90 m
Bad separator

Improvable separation (raw meal &

coal):
Separation Process
% R 200 m
0.05 >
% R 90 m

m
Comparison for compound grinding
Drying Control of achievable
potential PSD fineness
Roller press circuit 0 0 ++
Roller press circuit with hot gas + 0 ++
Horomill 0- ? ?
Horomill with hot gas + ? ?
Ball Mill + 0- ++
0
Ball Mill with hot gas ++ - ++
Vertical mill 0 ++ ++
+
Vertical mill with hot gas +++ ++ ++
+

++ Very good
Conclusion
In BM circuits the possibilities of influencing the PSD are limited and very
much depending on the separator type

The particle size distribution plays an important role for the cement
performance

The available test methods show different aspects of the fineness and should be used
complementary.

Blaine is neither a suitable control parameter for blended cements nor for pre-
hydrated materials.

But monitoring the Blaine can give useful additional information

Improvement Of PSD
1 Optimization of tube mill performance
• Adjustment of ball charge
• Improvement steel to clinker ratio
• Adjustment of material level in the first chamber
• Adjustment of the circulation load
•Improvement Separator efficiency (RRS) 2-
control fineness on basis of residue
3- Reduce mill ventilation (verify impact on cement temperature). 4-
Control Cards for Process Control