Results and Discussions The chemical composition of normal raw mix for high strength Portland cement is shown

in Table-1. Calculated amount of coal ash was added to the normal raw mix and pulverized thoroughly. The chemical analysis of this raw mix containing coal ash is shown in Table-2. Table-1 Chemical analyses of normal raw mix for high strength Portland cement.
Contents SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O SO3 Wt (%) 14 !" 3 #3 2 2# 42 $$ " %# " 1# " 4! " 1"

Table-2 !nalysis of normal and designed raw mix containing coal residue.
No&'al &a( 'i) (it* coal &esidue Designed &a( 'i) (it* coal &esidue SiO2 1+ #! 14 !3 Al2O3 $ ## 3 #$ Fe2O3 2 #% 2 2# CaO 3# %! 42 $$ MgO 1 "" 1 "" Na2O " 21 " 2" K2O " !" " $" SO3 " 1! " 1!

The heat of clin"erization for one "g of clin"er from 1.## "g of raw mix is given in Table-$% which is the sum of different endothermic and exothermic processes% which absorb or evolves different amount of energies respectively. &vaporation of free water at 1'' (C re)uires #$* cal+g. The heat absorbed in the dehydration of "aolin at 2' (C is 1,*cal+g. -n the case of montmorillonite the corresponding value is #*.# cal+g. and for illite .$ cal+g. The product of dehydration shows an exothermic reaction at about /''-/#' (C arising from the crystallization of the amorphous material and amounting in the case of "aolin to 02 1 1' cal+g dehydrated "aolin. The heat absorbed in dissociation of calcium carbonate is .22 cal+g at 2' (C and $/$ cal+ g at */' (C. 2or magnesium carbonate the values found by different investigations vary from 2*.3$2. cal+g at 2' (C. The reaction of the dehydrated clay products with lime is associated with a considerable evolution of heat% which varies with the cement composition and raw materials% but only about #'-0' cal+g when slag and limestone are used. ! heat evolution of 1'' cal+g% is sufficient theoretically to raise the temperature of the reacting masses by over $'' (C. 2or different raw mixes and for slightly different data% different authors have calculated values from .'' to .$' "cal+"g clin"ers 41$5. The net heat of melting arises from the failure of all the glass to crystallize on cooling and is obviously a variable factor. The observed heat of clin"erization in the cement plant is *.'-*#' "cal +"g% which is almost double of the calculated heat of the clin"erization. The excess amount of heat is wasted from the "iln in different forms. The main loss is in the form of thermal radiations from the "iln shell and multicyclones. The shell temperature out side is about .'' (C% which is the clear evidence of loss of heat from the "iln. 6econdly the temperature of the

out coming clin"er from the cooler is about 2''-$'' (C% which loses its heat to the open environment. The third loss of heat from the cement "iln is in the form of exit gases% from the chimney after multicyclones. 6o the heat re)uired in practice of course become considerably greater than this theoretical value on account of the heat lost. 7ith a wet process "iln thermal efficiencies are not much above $' percent% but with special heat recuperators values approaching #' percent are obtained in the semi dry and dry processes and rather more with shaft "ilns. Calculation of the Coal Quantity for Clinkerization !s clear from Table-. that the calorific value of the coal under investigation is ##'' "cal+"g. 8ne "g of clin"er as clear from the Table-$ needs about .2' "cal+"g. This means that ##'' "cal is produced from the burning of 1'''g coal9 therefore .2' "cal of heat% which is needed for one "ilogram of clin"er% is obtained by burning 0,.$,g of coal. 2rom the above discussion% it is clear that 0,.$, g of coal should be pulverized with raw meal to produce one "ilogram of the clin"er% which is e)uivalent to 1.## "g of the raw mix. This can also be calculated that for one "ilogram of raw meal% ./.20g of coal is re)uired. :ut the observed heat re)uired in cement "iln is *#' "cal+"g% which is almost double to that .2' "cal+"g. 6o the use of coal becomes up to 1'' g per one "ilogram of raw mix. NOOR,-.,AM/N AND K0-RS0/D A./ 1 C*e' Soc 2a3 4 5ol 334 No 24 2"11 14% Table-$ ;eat of clin"erization for one "ilogram of clin"er formation.
0eat a6so&6ed 3cal73g 0eating &a( 'ate&ial 8&o' 2" 9C to 4$" 9C 1+" De*:d&ation o8 cla: at 4$"9C 4" 0eating 'ate&ials 8&o' 4$"9C to %"" 9C 1%$ Dissociation o8 calciu' ca&6onate at %"" 9C 4+$ 0eating t*e deca&6onated 'ate&ial 8&o' %"" 9C to 14"" 9C 12$ Net *eat o8 'elting 2$ ;otal 1"3" 0eat <=ol=ed 3cal73g <)ot*e&'ic c&:stalli>ation o8 de*:d&ation cla: 1" <)ot*e&'ic *eat o8 8o&'ation o8 ce'ent co'?ound 1"" Cooling clin3e& 8&o' 14"" 9C to 2" 9C 3!" Cooling Ca&6on dio)ide (CO2) 8&o' %"" 9C to 2" 9C 12" Cooling stea' 8&o' 4$" 9C to 2" 9C including condensation to (ate& 2" ;otal !1" Net t*eo&etical *eat &e@ui&ed to 8o&' 13g o8 clin3e& 1"3" , !1" A 42" 3cal

Impact of Coal Residue on the Raw Mix Parameters 7hen coal is burnt with the raw mix% it produces heat which is utilized to convert the raw mix in to clin"er. The residue+ash% lift after burning of the coal disturb the composition of raw mix and clin"er obtained from it. !s clear from the Table-.% coal contains 1/.$2< ash% which contains maximum amount of silica =#'.0/<>. 7ith the addition of 1'' g of coal with one "ilogram of raw mix% all the parameters of the raw mix are changed. The chemical analysis of the resulting raw mix containing coal ash is represented in Table-2% which shows that silica contents is increased from 1..,'< to 10.*,< and lime contents from .2.##< to $*./,< =Table-2>. The rest of elements are also disturbed. The net result of the coal used as a fuel is that% the composition of raw mix does not remains in the limits which may give

clin"er having all parameters not in accordance to the standard specifications. -n order to bring% all the parameters of the resulting "iln feed and clin"er to the normal range% new raw mix designing was performed% in which the re)uired amount of coal ash has been incorporated in such a way that the composition of the final raw mix containing coal ash% remains within the specification. Table-. Physico-Chemical Parameters of studied Coal =<>.
Moistu&e 5olatile Matte& As* Sul8u& Fi)ed Ca&6on 0:d&ogen Calo&i8ic 5alue 3cal73g 1! 1# 41 !4 1% 32 $ 1! 1! 1! 1 #" $$""

The chemical analysis of the newly designed raw mix for coal as a fuel is given in Table-#. 2rom the table it is clear that the newly designed raw mix in which coal residue has been used% contains almost the same composition as that of normal raw mix represented in Table-1. ?uring the raw mix designing lime content has been increased and silica content decreased. The reason for this is that coal residue contains high silica and low lime content. Table-# Chemical !nalysis of normal Clin"er.
Contents SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O SO3 Wt (%) 22 !3 $ %4 3 $3 !$ %$ 1 $2 " 2# " +1 " 1!

Impact of Coal Residue on the Clinker and Clinker Moduli The chemical composition of normal clin"er with out coal ash% prepared from normal raw mix in the furnace is shown in Table-#. 7hen sufficient amount of coal residue was added with normal mix and was clin"erized% percentages of all the elements changed as clear from the Table-,. Table-, Chemical !nalysis of @ormal and newly designed Clin"er containing coal residue.
No&'al clin3e& containing coal &esidue Designed clin3e& containing coal &esidue SiO2 2+ !# 22 !+ Al2O3 % 12 $ %+ Fe2O3 4 4# 3 $4 CaO !" 3# !$ %$ MgO 1 $$ 1 $$ Na2O " 32 " 32 K2O " %4 " %4 SO3 " 24 22 !+ MA 2 "3 1 !% MS 2 "4 2 3# .SF " !! " %" C3S ,32 %" $" 32 C2S 1"4 1+ 2+ "3 C3A 1! $# % #4 C4AF 13 !4 1" ++

!ccording to :ritish standards specification% A! ranges from 1.$ to 2.#% if it exceeds the upper limit% the viscous slag and high early strength is exhibited. 6imilarly if it is less than 1.$% then fluid slag% low early strength and low heat of hydration occur. The recommended and acceptable range of A6 is 2-$. -f A6 goes below this range% burning become very easy but excessive li)uid phase and low

strength cement is obtained. !t the upper limit of A6% the high strength cement is obtained but the burning become very difficult% if it crosses the upper limit% then no clin"erization ta"e place at all. The normal and acceptable range of B62 is './'-'./*. -t does not create any problem in cement manufacturing process NOOR,-.,AM/N AND K0-RS0/D A./ 1 C*e' Soc 2a3 4 5ol 334 No 24 2"11 1$" B62 C A6 C and its strength% even if reaches as low as '.*% however% it should not be less than '.*. 2rom the results of the present study it is clear that the clin"er moduli B62 is out of range. Aoduli are the relationship among different oxides present in cement raw mix or clin"er. These moduli are used to control the percentage of oxide of elements in raw mix during raw mix designing. ?ifferent cements have different ranges of moduli which have to be controlled during clin"erization. Therefore clin"er moduli are very much important in )uality control during cement manufacturing. The moduli of raw mix and clin"er are almost the same. The moduli are classified as follow% Alumina Modulus (MA) !lumina modulus is the relationship between the oxide of aluminum and iron and is given as A! C
2$ 2$

2e 8 !l 8

ilica Modulus (M ) 6ilica modulus is the relationship of the oxide of silica with aluminum and iron and is given as
2$2$

6i8 Al ! + "e !
2

#ime aturation "actor (# ") Bime saturation factor is the relationship of the oxide of calcium with silicon% aluminum and iron and is given as
2.* i! 1.2Al ! '.,#"e ! Ca! ++
22$2$

Chemical composition of clin"er obtained from the designed raw mix during this study is given in Table-,. 2rom the close comparison of Table-, and 2% it is clear that the composition of clin"er obtained from the designed raw mix with coal residue is almost the same as that of normal clin"er. <)?e&i'ental Material and Methods The chemical composition of the normal raw mix for high strength Portland cement% which was used in this wor"% is given Table-1. The coal used in wor" was obtained from Dabba Taar and Dabba Ehush"% Ehyber Pa"htoon Ehwa% Pa"istan% whose analysis was carried out 41.5 in our previous wor"% as

given in Table-. and Table-0. Table-0 Chemical analysis of coal ash.

Contents SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O SO3 Wt (%) $" +% 2! !2 % "# 2 !1 1 2" " $" 2 "! " +2

Clinker "ormation The raw mix was converted into paste with small amount of water. 6mall granules in the range of #-1' mm were manually made and dried in the oven at 11' FC. These granules were ignited in the muffle furnace at 1.#' FC for one hour using nic"el crucible for complete clin"erization. !ll the raw mixes were converted into clin"er using the same procedure. The blac" color clin"er was cooled in desiccators and stored in polythene bags. The clin"er was studied for different physical and chemical parameters as per Pa"istan standard specifications. 2rom the heat of clin"erization Table-$ and calorific value of coal samples Table-.% the amount of coal used for the clin"erization of one "ilogram of the raw mix was calculated. :ased on the calculation% new raw mix was designed with incorporating the exact amount of coal ash with the raw material. The raw mix designed and normal raw mix with which coal ash was mixed% were analyzed. :oth the raw mixes were converted in to clin"ers and were again analyzed using the same techni)ue. Conclusion The results of the present study shows that coal of cherat mines can be used as a maGor fuel in cement "iln for clin"erization. The optimum amount of coal found during this study is 1'< of the raw mix. The residue lift after the burning of coal replaces some of the siliceous content of the raw material. 7ith the proper raw mix designing% the use of coal in the "iln does not disturb any of the parameters of the clin"er. Re8e&ences 1. !. :entur% A C$ % Mater in Ci&il $n'ineerin'% 14% 1 =2''2>. 2. @oor-ul-!min% E. !li and A. T. 6hah% %ournal of the Chemical ociety of Pakistan% 31% $0' =2''/>. $. ?. ?. :ui% D. ;u and P. 6troeven% Cement and Concrete Composite% 2+% $#0 =2''#>. NOOR,-.,AM/N AND K0-RS0/D A./ 1 C*e' Soc 2a3 4 5ol 334 No 24 2"11 1$1 .. H. EIIntee% J. Kevenhoven% J. :ac"man and A. ;upa% Ciments% ()tons% Pl*tres% Chaux% #'-#, =2''$>. #. E. Hrsula% K. Jon% :. Jainer and A. ;upa% L!lternative fuels + The impact of alternative fuels on the cement manufacturing processL. $xtended a+stract% accepted% after re&iew for ,-th .ordic Concrete Research ymposium% /elsin'0r% 1enmark% pp $% =2''2>. ,. E. Manesan % E. JaGagopal and E Thangavel% Cement and Concrete Composites% 2%% #1# =2''0>.

0. E. Manesan% E. JaGagopal% and E. Thangavel% Cement and Concrete Composites% 2%% #1# =2''0>. *. D. Khang% 7. ?ong% B. Duan% B. Niao% D. Kheng and D. 6heng% %ournal of /azardous Materials% 14%% #2$ =2''0>. /. 2. Moodarzi% "uel% #$% 20$ =2'',>. 1'. 2. Moodarzi% "uel% #$% .2# =2'',>. 11. E. !li% @. !min and A. T. 6hah% %ournal of the Chemical ociety of Pakistan% 31% $0# =2''/>. 12. 2. Dhon% 2. CheGne% 2. Carlos% D. &der and Carlos% "uel% ##% .2. =2''/>. 1$. E. !li% @. !min and A. T. 6hah% Chinese %ournal of 2eochemistry% 2+% 2.2 =2''*>. 1.. E. !li% @. !min and A. T. 6hah% Chinese %ournal of 2eochemistry% 2+% 2.2 =2''*>. 1#. @. !min and E. !li% %ournal of the Chemical ociety of Pakistan =submitted>. NOOR,-.,AM/N AND K0-RS0/D A./