The document discusses the raw materials and chemical processes involved in manufacturing Portland cement. It describes the key oxides (calcium, silica, alumina, iron) needed in the raw mix and how the Bogue equations are used to calculate the compounds (C3S, C2S, C3A, C4AF) formed during burning. An example raw mix design is provided along with the calculations to determine the compounds using the Bogue equations on the loss-free chemical analysis. The moduli calculations for lime saturation, silica ratio, and alumina ratio are also outlined. Finally, it briefly describes the wet and dry production processes and shows images of Portland cement clinker.

1. CON 123
Cementitious Materials
Session 3
Typical Raw Mix Design

2. Primary Oxides of Raw Materials Necessary
for Portland Clinker Production
Materials used in the manufacture of
Portland cement must contain appropriate
proportions of:
 Calcium Oxide: CaO
 Silica Dioxide: SiO2
 Alumina Oxide: Al2O3
 Iron Oxide: Fe2O3

3. Raw Mix Chemistry
Bogue Potential Compounds
Tricalcium silicate C3S
Dicalcium silicate C2S
Tricalcium aluminates C3A
Tetracalcium Aluminoferrite C4AF

4. Bogue Equations
(C3S) = (4.071*%CaO) - (7.600*%SiO2) - (6.718*%Al2O3)
- (1.430*%Fe2O3)
(C2S) = (2.867*%SiO2) - 0.7455*%C3S)
(C3A) = (2.650*%Al2O3) - (1.692*%Fe2O3)
(C4AF) = (3.043*%Fe2O3)

5. Moduli for Burning
 Lime Saturation (LSF)
 Ca/(2.85Si + 1.18Al +0.65Fe)
 Silica Ratio (S/R)
 Si/(Al +Fe)
 Alumina Ratio (A/F)
 Al/Fe

6. Calcareous Materials
Comparative Chemical Analysis
High Low Mid
Analyte
Grade Grade Grade
CaO 54.60 32.15 50.96
SiO2 0.95 28.50 4.54
Al2O3 0.92 7.80 0.45
Fe2O3 0.38 2.95 0.19
Loss on Ignition 42.03 26.65 41.97

7. Argillaceous Materials
Comparative Chemical Analysis
Analyte Plant Clay Fly Ash Iron Ore
CaO 5.70 0.80 0.76
SiO2 68.00 52.67 11.00
Al2O3 12.60 23.40 1.50
Fe2O3 2.95 5.92 84.20
Loss on Ignition 7.20 12.59 0.67

8. Other Argillaceous Materials
Comparative Chemical Analysis
Plant Silica BF
Analyte
Sand Fume Slag
CaO 0.33 42.09
SiO2 99.20 95.74 39.45
Al2O3 0.51 9.67
Fe2O3 0.50 0.14 0.67
Loss on Ignition 0.20 2.32 1.00

9. Example Raw Mix Design
Material Chemical Analysis
High Plant Iron
Analyte
Grade Clay Ore
CaO 54.60 5.70 0.74
SiO2 0.95 68.00 11.00
Al2O3 0.92 12.60 1.50
Fe2O3 0.38 2.95 84.20
Loss on Ignition 42.03 7.20 0.67

10. Example Raw Mix Design
Chemical Analysis
High Grade Iron Ore
Analyte Plant Clay 20.24%
78.26% 1.50%
CaO 54.60*.7826=42.73 5.70*.2024=1.15 0.74*.015=0.01
SiO2 0.95*.7826=0.74 68.00 *.2024=13.76 11.00*.015=0.17
Al2O3 0.92*.7826=0.72 12.60 *.2024=2.55 1.50 *.015=0.02
Fe2O3 0.38*.7826=0.30 2.95 *.2024=0.60 84.20*.015=1.26
Loss on Ignition 42.30*.7826=32.90 7.20 *.2024=1.46 0.67 *.015=0.01
‘ Rounded to the
‘’ Add Sum of Rows
.00

11. Example Raw Mix Design
Chemical Analysis
Calculated Loss Ignited Loss
Analyte Raw Feed
Free Free
CaO 43.89 43.89/(1-.3437) 66.87
SiO2 14.67 14.67/(1-.3437) 22.35
Al2O3 3.29 3.29/(1-.3437) 5.01
Fe2O3 2.16 2.16/(1-.3437) 3.29
Loss on Ignition 34.37

12. Bogue Equations
Using Loss Free Analysis - C3S Calculation
 (C3S) = (4.071*66.87CaO) - (7.600*22.35SiO2) -
(6.718*5.01Al2O3) - (1.430*3.29Fe2O3) =
 Use numbers from Loss Free Analysis

13. Bogue Equations
Using Loss Free Analysis - C2S Calculation
 (C2S) = (2.867*22.35SiO2) - 0.7455*64.01C3S)=
 Use numbers from Loss Free Analysis

14. Bogue Equations
Using Loss Free Analysis - C3A Calculation
 (C3A) = (2.650*5.01Al2O3) -
(1.692*3.29Fe2O3)=
 Use numbers from Loss Free Analysis

15. Bogue Equations
Using Loss Free Analysis - C4AF Calculation
 (C4AF) = (3.043*3.29Fe2O3)=
 Use numbers from Loss Free Analysis

16. Moduli for Burning Calculation
 Lime Saturation (LSF)
 66.87(CaO)/(2.85*22.35(Si) + 1.18*5.01(Al)
+0.65*3.29(Fe) =
 Silica Ratio (S/R)
 22.35(Si)/5.01(Al) +3.29(Fe)=
 Alumina Ratio (A/F)
 5.01(Al)/3.29(Fe) =
 Use numbers from Loss Free Analysis

17. Pyro-Processing Systems
 Wet Process
 Dry Process
 Dry Pre-heater
 Dry Precalciner

18. Rotary kiln (furnace) for manufacturing Portland cement clinker.
Inset view inside the kiln.
18

19. Process of Clinker Production

20. Process of Clinker Production

21. Process of Clinker Production

22. Portland Clinker Compounds
Polished thin-section(left) examination of Portland clinker shows alite (C3S) as light,
angular crystals. The darker, rounded crystals are belite (C2S). Magnification 400X.
(right) Scanning electron microscope (SEM) micrograph of alite (C3S) crystals in
Portland clinker. Magnification 3000X.

23. Clinker
Portland cement clinker is formed by burning calcium and siliceous raw materials in a
kiln. This particular clinker is about 20 mm (3¼4 in.) in diameter.