Homogenisation Piles - 2011 - Ah
Homogenisation Piles - 2011 - Ah
Homogenisation Piles - 2011 - Ah
Cement Manufacturing
Operations
Homogenisation of
Unground Raw
Materials
Homogenising Raw
Materials
• A consistent theme so far has been the need for Consistency.
• This need starts before the raw material has even left the
quarry face.
Consistency from the Quarry
Face
• Before extracting a single tonne of material, the quarry
manager has a model of the deposit and what material he will
find where.
• This was on the assumption that all the raw material could be
used.
6
Site for the Expansion
Boreholes across the site – CaO%
Boreholes across the site – Silica
Ratio
Fig. 4 Variation of CaO content of chalk through the boreholes.
Ground level is at the left of the plot. The top of the Gault Clay is at the right.
55
50
45
% CaO
40
30
39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
m above top of Gault Clay
Combinability Studies
• The decision on which mix to use will depend on the burnability,
the market and the cost.
lsf 1.02 1.02 1.02 0.98 0.98 0.98 0.98 0.98 0.97
Pfa 3 - 4%
Combinability Studies
Combinability of kiln feeds
sample 4 sample 5
1700
Firing temperature
1600
1500
1400
1300
0 2 4 6 8 10 12 14
Free lime %
Working sequence and layout
• Chalk haulage and access to the quarry
Excavators load trucks which travel along the working
face, split into 5m benches Conveyor
To the raw
material
store by
Access to the floor for conveyor
placement of restoration
materials (also geological
study/drainage works)
Block model
• This is a computer model of the quarry divided into blocks in each
of which the chemistry and other properties are known.
• The block model determines the day to day operation of the quarry
for its lifetime.
30
Standard deviation of the Lime Saturation Factor
25
20
15
10
0
SD from quarry sd from raw mill sd into kiln sd clinker
• Post-milling Homogenisation
• Batch blenders
• Cascade blenders
• Low energy blenders
The Blending Stockpile
The Blending Stockpile
The Blending Stockpile
• Longitudinal
• Circular
• Radial
• Portal
The Longitudinal Stockpile
The Circular Stockpile
The Radial Stockpile
Portal Reclaimer
The Blending Stockpile
General Guidelines:
Length 90 to 180 metres (longitudinal)
Height 7 to 12 metres