Cement Formulae - Green Business Centre

1 About CIIA bout CII-Godrej GBCThe Confederation of Indian Industry (CII) works to create and sustain an environment conducive to the growth of industry in India, partnering industry and government alike through advisory and consultative is a non-government, not-for-profit, industry led and industry managed organisation, playing a proactive role in India's development process. Founded over 115 years ago, it is India's premier Business association, with a direct membership of over 7800 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 396 national and regional sectoral catalyses change by working closely with government on policy issues, enhancing efficiency, competitiveness and expanding Business opportunities for industry through a range of specialised services and global linkages.

2 It also provides a platform for sectoral consensus building and networking. Major emphasis is laid on projecting a positive image of Business , assisting industry to identify and execute corporate citizenship programmes. Partnerships with over 120 NGOs across the country carry forward our initiatives in integrated and inclusive development, which include health, education, livelihood, diversity management, skill development and water, to name a this vision, CII's theme for 2009-10 is 'India@75: Economy, Infrastructure and Governance.' Within the overarching agenda to facilitate India's transformation into an economically vital, technologically innovative, socially and ethically vibrant global leader by year 2022, CII's focus this year is on revival of the Economy, fast tracking Infrastructure and improved 64 offices in India, 9 overseas in Australia, Austria, China, France, Germany, Japan, Singapore, UK, and USA, and institutional partnerships with 221 counterpart organisations in 90 countries, CII serves as a reference point for Indian industry and the international Business Sohrabji Godrej Green Business Centre (CII Godrej GBC)

3 , a division of Confederation of Indian Industry (CII) is India's premier developmental institution, offering advisory services to the industry on environmental aspects and works in the areas of Green Buildings, Energy Efficiency, Water Management, Renewable Energy, Green Business Incubation and Climate Change activities. The Centre sensitises key stakeholders to embrace Green practices and facilitates market transformation, paving way for India to become one of the global leaders in Green businesses by 2015. The Centre is housed in a Green building which received the prestigious LEED (Leadership in Energy and Environmental Design) Platinum rating in 2003.

4 This was the first Platinum rated Green building outside of and the third in the world. The Centre was inaugurated by Shri A P J Abdul Kalam, the then President of India, on July 14, 2004. CII-Sohrabji Godrej Green Business Centre is a unique and successful model of public-private partnership between the Government of Andhra Pradesh, Pirojsha Godrej Foundation and the Confederation of Indian Industry (CII), with the technical support of No 64, Kothaguda Post, Hyderabad - 500 084 Tel: +91 40 23112971-73 Fax: +91 40 23112837 Email: / / FormulaeHandbookVersion 2010 2010, Confederation of Indian IndustryWhile every care has been taken in compiling this Cement Formula Handbook(version ), CII- Godrej GBC does not accept any claim for compensation, ifany entry is wrong, abbreviated, omitted or inserted incorrectly either as to thewording space or position in the handbook.

5 The handbook is a store of informationso that it will be useful to the plant personnel involved in energy conservationand can be used by them rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted, in any form or by any means electronic,mechanical, photocopying, recording or otherwise, without the prior writtenpermission from CII- Sohrabji Godrej Green Business Centre , by Confederation of Indian IndustryCII - Sohrabji Godrej Green Business CentreSurvey # 64, Kothaguda Post,R R District, Hyderabad - 500 084, Indian Cement industry today stands at260 MTPA capacity, with greater growth prospectsand promising future ahead.

6 Cement industry hasbeen an excellent example of a fast growing sectorshowing consistent and steady reduction in itsenergy consumption. This has largely beenpossible by steady and continuous improvementacross all equipments in Cement take these initiatives forward, one of the basic essentials is availabilityof right information at easy disposal. CII-Sohrabji Godrej GreenBusiness Centre , as part of its World Class Energy Efficiency initiative,has been releasing several publications, case study booklets etc. on aregular basis to make the latest information available to all stakeholdersin the Cement industry. One such initiative was the release of CementFormula Handbook in Cement Formula Handbook was extensively circulated amongthe industry.

7 The response for the handbook has been very encouragingand received positive feedback from various stakeholders. One of thestrong feedback to CII-Sohrabji Godrej Green Business Centre was tosustain this activity and release updated version of Formulae Handbookon a regular Cement Formulae Handbook (Version ) is an outcome of theexcellent response & feedback to the earlier handbook (2009). I wouldsincerely request all the readers to not only make full use of thehandbook across your organizations but also to pass any comments /suggestions / feedback on Cement Formulae Handbook (Version )you may have to CII-Sohrabji Godrej Green Business feedback will encourage us at CII-Sohrabji Godrej Green BusinessCentre to take such initiatives in future.

8 (G. Jayaraman)Chairman, Green Cementech 2010, CII- Godrej GBC &Executive President, Birla Corporation Control Formulae9 IIFormulae used in Combustion14 CalculationsIIIF lame Momentum Calculation16 IVKiln Performance & Efficiency17 VHeat Transfer19 VIEconomic Insulation Thickness21 VIIP hysical Chemistry25 VIIIU seful Formulae in Kiln Design &26 OperationIXGrinding Mill Investigation28 XTromp Curve Calculation and31 SignificanceXIElectrical Engineering34 XIIFan Engineering352 Chapter Flow37 XIVE conomic Pipe Thickness41 XVPipe Loss Calculation43 XVIT ypical Characteristics of PneumaticTransport Systems46 XVIIT ransport Equipment49 XVIIIBest practices in Compressed Air18 System50 XIXF inance56 XXSafety Formulas58 XXID

9 Etails on Waste Heat Recovery (WHR)59 XXIIM iscellaneous Formulae653 NORMSCONTENTSC hapter Level of Various Limestone73 IIElectrical Energy Consumption Target73 IIIT hermal Energy Consumption Target74 IVOperating Hours74 VDays of Storage75 VIComparison Between Different75 Dry Process TechnologiesVIIKiln & Pre-Heater76 VIIIKiln Gas Velocities76 IXComparison Between Different77 Types of CoolersXPrimary Air Momentum77 XIElectro static Precipitator78 XIIH armonic Levels at Different Section79 XIIIT ypical data for Different Lighting-80 Efficacy, Life etc45 REFERENCE DATACONTENTSC hapter Pressure and85 Density Vs Altitude (00c) Gravity & Density of Materials for Weight of Chemicals88(g/g mol) Conductivities of of Data for Solid Fuels90(% as recd/mineral-matter-free) Data for Liquid Data of Exhaust Gas with95 Various Levels of (dry) Excess Specifications used by96 Vendors for Burners with IndirectFiring Calorific Value of Mill-Ball Weight & Surface Mill Charge Data for Grinding Mill Mill Specification of Specifications for Physical Properties ofDifferent Insulating Standards - for Stack,Ambient Air and per value of Balance Calculation122 ConclusionPage No.

10 1227 FORMULAE89 Chapter - I Quality Control Formulae1. Loss on ignition (LOI) (CO2 from Calcination)Ignition loss= CaCo3 + Mg Co3 + .. +combined H2O + Organic matterLOI refers to the release of volatile matter such as CO2, water vapor andother combustibles2. Silica Modulus/Ratio (SM)SM= SiO2Al2O3 + Fe2O3 Typical the silica modulus harder to burn and exhibits poor coating the silica modulus there may be more melt phase and coating canbecome thick and leads to ring formation and low early strength (3-7days)in the cement3. Alumina Modulus/Alumina iron ratio (AM)AM= Al2O3Fe203 Typical with higher Alumina modulus results in Cement with high earlystrength4.