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114
Hill Microscopy
24/3/04
3:58 pm
Clinker Microscopy F
CLINKER MICROSCOPY
Clinker formation
The basic process of portland cement
manufacture is the combination of silica
with calcium to produce hydraulic
compounds.
The transformation of the raw materials
into clinker involves both chemical and
physical processes as the material passes
through the kiln system. Burnability of the
raw material is one important aspect of
the chemical processes it defines how
easily the raw materials are transformed
into the desired clinker phases throughout
the clinkering reactions. Physical processes
of clinker production include the formation
of clinker nodules.
Raw materials
The raw materials used are designed and
proportioned to provide the appropriate
amounts of the various clinker phases. The
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114
Hill Microscopy
24/3/04
3:58 pm
Clinker Microscopy F
CLINKER MICROSCOPY
Burnability
Burnability is the ease with which the raw
materials are transformed into the desired
clinker phases, and is commonly measured
by the amount of free (unreacted) lime
remaining in the clinker (low free lime
indicates an easy-to-burn mix). The
burnability of a raw mix is determined by
its chemical composition, mineralogy of
the raw materials, and its fineness. A
number of equations relating the free lime
after laboratory burns under various
conditions to the composition of the raw
mix and and the fineness of certain
Figure 2: from raw feed to final product, the clinker production process is outlined by the following sequence of events.
Diagrams are simplified for illustrative purposes.
Nodulisation process
Clinkering reactions
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114
Hill Microscopy
24/3/04
3:58 pm
Clinker Microscopy F
CLINKER MICROSCOPY
Figure 2 continued : raw feed to final product the clinker production process
Cross-section of view of kiln
Nodulisation process
Clinkering reactions
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114
Hill Microscopy
24/3/04
3:58 pm
Clinker Microscopy F
CLINKER MICROSCOPY
Figure 3
Figure 4
Smaller well-dispersed
free CaO.
Free CaO
crystals
Photomicrograph
demonstrates reaction
between belite and free
CaO to form alite.
Belite crystals
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114
Hill Microscopy
24/3/04
3:58 pm
Clinker Microscopy F
CLINKER MICROSCOPY
Figure 6
Troubleshoot problems
When there is a problem with clinker
production or cement performance, the
clinker microstructure can provide a clue
as to the cause. Again, routine physical
and chemical tests can provide some
insight, but often microscopy can help to
provide a complete solution.
Monitor process changes
If a change in any aspect of clinker
production is anticipated (such as new raw
materials, burner pipe position), analysis
of the microstructure is important before,
during, and after the change. The
operator can pinpoint the effects of the
change, whether positive or negative, and
predict changes in cement performance.
___________________________________I
Acknowledgments
This paper was previously presented at:
"22nd International Conference on
Cement Microscopy" 2000, Montreal,
Canada
Vagn Johansen and Greg Miller are
gratefully thanked for their valuable
contributions and suggestions in the
preparation of this manuscript.
Photomicrograph
demonstrates belite
cluster as result of large
quartz grain.
Conclusion
Role of microscopy at cement plant
As we have seen, there is a relationship
between clinker microstructure, the kiln
feed, and burning conditions. In addition,
since each clinker phase reacts differently
with water, the clinker microstructure can
reveal information about cement
performance. Therefore, clinker
microscopy is a valuable tool at the
114 ICR APRIL 2004
References
[1] Fundal E (1979) The Burnability of
Cement Raw Mixes, World Cement
Technology, FLS Review (22)
[2] Miller, FM (1981) Microscopy as an
Aid in Evaluation of Mix Burnability and
Clinker Formation, Proceedings of the
Third International Conference on
Cement Microscopy, pp181-192.
[3] Theisen K (1992) The Influence of
Raw Mix Burnability on the Resulting
Cement Clinker, Proceedings of the 14th
International Conference on Cement
Microscopy, pp74-88.
[4] Wolter, A (1985) Influence of the Kiln
System on the Clinker Properties in
Zement-Kalk-Gips, (10) pp612-614.
[5] Campbell DH (1999) Microscopical
Examination and Interpretation of
Portland Cement and Clinker, Portland
Cement Association, Skokie, IL, pp11-15.
[6] Lea, FM and Hewlett, PC (Eds) (1998)
Leas Chemistry of Cement and Concrete,
4th Edition. London Arnold Publishers.
[7] Ono Y (1995) Onos Method,
Fundamental Microscopy of Portland
Cement Clinker.
[8] Taylor HFW (1990) Cement
Chemistry, New York, Academic Press.