”

A QUICK “CEMENT REFERENCE GUIDE©

C = CaO = LIME Molecular Weight =56.1 K = K2O POTASSIUM 3CaO•SiO2 = C3S = Alite IL = Type I “Light Color”
S = SiO2 = SILICA Molecular Weight = 60.3 N = Na2O SODIUM 2CaO•SiO2 = C2S = Belite Coal = CnHn Methane =CH4
A = Al2O3 = ALUMINA Mol. Weight =102.2 M = MgO MAGNESIUM 3CaO•Al2O3 = C3A = Aluminate Limestone = CaCO3 Mol.Weight =100
F = Fe2O3 = IRONN Molecular Weight =159.6 S= Sulfur = SO3= 4CaO•Al2O3•Fe2O3 = C4AF = Ferrite 1yd3 of Concrete = ±3880 lbs.
FeO = IRONR Molecular Weight = 71.8 Gypsum = CaSO4 •2H2O It takes ±1.65t of KF to make 1t of Clk. and contains, ±564 lbs. of cement
ALKALI EQUIVALENT (AE) Alkalis can react with some silicate aggregates. Not all aggregates are reactive. To minimize risk “Low Alkali Cement” can be specified.
AE = Na2O + (0.659 K2O) To be considered “Low Alkali Cement” under ASTM C150, the (AE) must be < 0.60%
Concentration PPM to % 1,000,000ppm = 100% 10,000ppm + 1.0% 1,000ppm = 0.1% 1ppm = 0.0001%
1 million BTU/ Ton = 1163.152 kJ / kg Typical: Wet kiln = 5500kJ/kg, PC kiln = 3200 kJ/kg of clinker Typical Temps. °F °C
[1 k Joule = 0.9485 BTU] [1 BTU = 1.054 k Joules] To burn a pound of coal requires 10.478 pounds of air Room Temp 72 22
PSI x 0.0703 = kg / cm2 ( 1 PSI = 0.703 kg/cm2) Typical ignition loss for Kiln Feed is 35.5% Boiling Water 212 100
PSI x 6.895 = kPa ( 1 PSI = 6.895 kPa ) Typical Ratio for Kiln Feed to Clinker is 1.55 ∼ 1.85kf : 1clk Preheater Exit Temp 662 350
1 micron μ = 10-6 Meters ( a hair is about 60 microns) Typical SPG of Cement = 3.15 Kiln Exit Temp (PC) 1922 1050
325 Mesh = 44μ 200 Mesh = 74μ 48 Mesh = 297μ Air = 78% N2 & 21% O2 Air @ STP = 1.293g/lit = 0.0808 lb. / ft3 Burning Zone Temp 2750 1510
3600 Blaine = 3600 cm2/g, a surface area of 24” x 24” 1” water gauge = 2.490 millibars 1mb = .0295 inches of water The Sun (Photosphere) 10652 5900
Standard Conditions Metric System = 0°C & 760 mm Hg Standard Conditions English System = 60°F & 30 in. Hg Chemical Bonds Fail 12632 7000
Convert Fahrenheit to Celsius °F = 9/5 °C + 32 Convert Celsius to Fahrenheit °C = 5/9 ( °F – 32) Rankine = °F + 459.6 Kelvin = °C+273
To change 1 lb. of water @ 32°F to steam = 1150.2 BTUs To change 1 kg. of water @ 0°C to steam = 639.1 kcal. Ice to Water: 1 lb. = 144 BTU, 1 kg = 80kCal
To calculate Circle Sphere Cylinder Cone Torus Frustum
Grinding Ball Ball Mill Pile of Material Kiln Chain Flat-Top Pile
the total Surface Area of a: πr2 π D2 π D (0.5D + h) π r (r2 + h2)1/2 Dπ2d π s (R + r)
3 2 2
the Volume of a: 0.5236 D 0.7854 D h 1.0472 r h 0.25 (π2 d2 D) 1.0472 h ( r2 + R r + R2)

BOGUE’S POTENTIAL COMPOSITION Typical % for Type I / GU

(AR > 0.64) C3 S = 4.071 C – ((7.6 S) + (6.718 A) + (1.43 F) + (2.852 S)) ( 45 ∼ 65 )
C2 S = 2.867 S – (0.754 C3S) ( 10 ∼ 30 )
or C2S = (8.61 S + 5.07 A + 1.08 F) – 3.07 C
C3 A = 2.650 A – (1.692 F) ( 5 ∼ 15 )
C4AF = 3.040 F ( 5 ∼ 12 )

Cement Types, Their Typical Composition & Use

Typical Bogue Clinker
ASTM ASTM Chemical Composition % Compounds Comments
C150 C1157 SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI Insol C3S C2S C3A C4AF BSA
Res. CM2/gr

Type I GU 20.9 5.2 2.3 64.4 2.8 2.9 1.0 0.2 55 19 10 7 3700 General use C109 = Typical 7 day Strength 4,900 psi @ 3600BSA
Type II MS 21.7 4.7 3.6 63.6 2.9 2.4 0.8 0.4 51 24 6 11 3700 Moderate Sulfate Resistant C3A must be < 8.0%
Type III HE 21.3 5.1 2.3 64.9 3.0 3.1 0.8 0.2 56 19 10 7 5400 High Early Strength C109 = Typical 1 day Strength 1800 psi
Type IV LH 24.3 4.3 4.1 62.3 1.8 1.9 0.9 0.2 28 49 4 12 3800 Low Heat of Hydration (Or use Type I with GGBFS or Fly-ash)
Type V HS 25.0 3.4 2.8 64.4 1.9 1.6 0.9 0.2 38 43 4 9 3800 High Sulfate Resistance (Or use Type I with GGBFS)
WHITE WH 24.5 5.9 0.6 65.0 1.1 1.8 0.9 0.2 33 46 14 2 4900 Used for decorative work. The key is to minimize the iron content <0.5%
SLAG 37.1 8.32 .86 38.5 11.3 2.9 +.8 5200 GGBFS Must be used in concert with Portland cement

ASTM C150 Cement Types

Type I Normal Use
Type I. Portland cement is a general-purpose cement suitable for all uses where the special properties of other types are not required.
It is used in concrete including pavements, floors, reinforced concrete buildings, bridges, tanks, reservoirs, pipe, masonry units, and
pre-cast concrete products.
Type II. Moderate Sulfate Resistance
Type II Portland cement is used where precaution against moderate sulfate attack is important. It is used in normal structures or
elements exposed to soil or ground waters. Where sulfate concentrations are higher than normal but not unusually severe.
Type II cement has moderate sulfate resistant properties because it contains no more than 8% tricalcium aluminate (C3A). Sulfates in
moist soil or water may enter the concrete and react with the hydrated C3A, resulting in expansion, scaling, and cracking of concrete.
Some sulfate compounds, such as magnesium sulfate, directly attack calcium silicate hydrates.
Type I-II This is not a designated ASTM cement type. Type I-II is simply a Type II cement, that can develops sufficient early strength to
be competitive in the Type I market.
Type III. High Early Strength
Type III Portland cement provides strength at an early period, usually a week or less. It is generally chemically and physically similar to
Type I cement, except that its particles have been ground finer. It is used when forms need to be removed as soon as possible or when
the structure must be put into service quickly. In cold weather its use permits a reduction in the length of the curing period.
Type IV. Low Heat of Hydration
Type IV Portland cement is used where the rate and amount of heat generated from hydration must be minimized. It develops strength
at a slower rate than other cement types. Type IV is intended for use in massive concrete structures, such as large gravity dams, where
the temperature rise resulting from heat generated during hardening must be minimized. Type IV cement is not readily available.
Type V. High Sulfate Resistance
Type V Portland cement is used in concrete exposed to severe sulfate action principally where soils or ground waters have a high
sulfate content. It gains strength more slowly than Type I cement. The high sulfate resistance of Type V cement is attributed to a low
tricalcium aluminate content, not more than 5% and a low ferrite content. Use of a low water-to cement ratio and low permeability are
critical to the performance of any concrete exposed to sulfates.

Prepared for IEE

e-mail: mike.singleton@alitegroup.com 1 11/19/07
Typical Kiln System Process Data
3
mTpd/m Fuel Residence Kiln Exit Gas
3
Kiln Volume inside Kcal/kg cli Time System ΔP Nm /kg
refractory
System Rpm L/D kWh/t Minutes Exit Temps mm H2O clinker
Long Wet 1 0.45~0.8 30~35 1300~1650 17~25 180~240 150~180°C 150~180 3.4
Long Dry 1 .05~ 0.8 30~35 1100~1300 20~35 180~240 380~400 150~200 1.8
Preheater 2.0 1.5~2.2 14~16 750~900 25 30~40 350 500~700 1.5
Precalciner 3.6 3.5~5.0 10~14 720~850 25 20~30 300~360 500~700 1.4

Critical Temperatures
It stands to reason, with the quantities of thermal energy used in the manufacture of cement that some of this energy has the potential to
damage the equipment used in the process. A prime example of this damage is the damage to kiln shells when there is a loss of coating
or a failure of refractory.
Approximate Approximate Comments
Temp ºF Temp ºC At 20ºC The Tensile Strength of steal is 345 N/m2
TYPICAL SURFACE TEMPS. 390 200 Kiln Hood & Feed End Shell
470 243 BZ Shell Heavy Coating
540 280 BZ Shell Normal Coating
640 340 BZ Shell Light Coating (Apply cooling fans if available)
710 375 Apply cooling fans
KILN SHELL COLORS NOTE: At 380ºC Tensile Strength of steal is 131 N/m2
Dull Red Visible at night 750 400 Very thin coating some brick spalling. If hot spot is under a tyre - stop
kiln then call Supervisor
At 450ºC The Tensile Strength of steal is 57 N/m2
Red Visible at twilight 885 475 No coating brick damaged. Stop kiln then call Supervisor
Limit for elastic deformation of steal is 480ºC
Red Visible in daylight 975 525 Major brick damage-Stop kiln and call Supervisor
Red Visible in sunlight 1075 580 No brick left. Stop kiln fire, call Supervisor Prepare resume
Bright Red/Yellow 1290 700 Shell damage. Stop fire. Stop Kiln. GO HOME & HIDE
BURNING ZONE COLORS Material Temperatures
Lowest Visible Red 890-1200ºF 475-650ºC Need more heat - increase fuel Keep F. E. O2 < 10%
Dark red to cherry red 1200-1380 650-750 Need more heat - increase fuel Keep F. E. O2 < 10%
Cherry Red to bright red 1380-1520 750-825 Need more heat - increase fuel Lower F. E. O2 < 7%
Bright red to orange 1520-1750 825-950 To cold to feed - increase fuel Keep F. E. O2 < 7%
Orange to yellow 1750-2100 950-1150 FET> 1050ºC Start feeding - increase fuel Keep FE O2 < 5%
Yellow 2100-2280 1150-1250 BZT Cold Slow down & add fuel
Yellow to light straw 2280-2570 1250-1410 BZT weak Watch for push
Bright straw to white 2570-2750 1410-1510 BZT Strong Steady State
White to brilliant 2750-2890 1510+1590 BZT Very Hot Reduce Fuel, continue to feed, control FEO2 <5%
Watch for liquid.

Particle Size Clinker

Screen Aperture Inches Microns
Size (mm) μ C3S
(Mesh / in)
0.00001 0.1 Nano-meter = diameter of 1 Hydrogen Atom
C2S
0.5 Smoke
0.001 1 1000 angstroms C3A
3 Smallest effective Cement Particle
30 Largest effective Cement Particle C4AF
325 44 95% of cement should be < than 40μ
300μ x 300μ
230 .063 0.0025 63 Human Hair (2.5 thousands = .0025 of an inch)
150 0.10 0.004 100 Sheet of paper
120 125 Most kiln feed should be < than 125μ
100 0.150 149
32 .5 0.0197 500 0.5mm lead for drafting pencil
10 2.00 2,000
1/4 in 0.25 6,350
9 0.354 9000 9mm
3/8 in 9,510
1/2 in 0.50 12,700
1 in 25,000 Medium grinding ball
2 in 59,800 Large grinding ball

Blaine v/s Particle Size μ

65
55
45
35
25
15
5
2500 3500 4500 5500
Blaine cm2/gr
Prepared for IEE
e-mail: mike.singleton@alitegroup.com 2 11/19/07