Course 2 Raw Material Preparation

2.2 Raw Materials, Blending Bed

Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 781
Fax: +49 211 45 78296
info@vdz-online.de
www.vdz-online.de

info@elearning-vdz.de
www.elearning-vdz.de

Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Overview Basic Cement Materials and Homogenization........................... 1

3 Design and Mode of Operation of a Blending Bed ........................................ 3

3.1 Stacking of Blending Beds ................................................................................. 4
3.2 Reclamation of Blending Beds ........................................................................... 8

4 Health and Safety Practices ............................................................................. 9

5 Operation and Quality ..................................................................................... 10

6 Maintenance and Inspection............................................................................ 10

7 Environmental Protection ................................................................................ 12

8 Questions on Course LB 2.2 Blending Beds ................................................ 12

Solutions............................................................................................................................... 14 i
Glossary ............................................................................................................................... 17

Index..................................................................................................................................... 18

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1 Introduction
The raw materials for cement clinker occur naturally in various deposits and formations Deposits
. In most cases the deposits are not chemically uniform nor do they contain the required
materials in the optimum composition. It is therefore important to produce a uniform
mixture from the various raw materials, i.e. to homogenize them.

Figure 1.0-1: Circular Blending Bed with Stacker Belt Conveyor and Reclamation Unit, Works Photo
MVT .

In this course you will learn more about the composition of raw materials used for clinker
production and about raw material storage and homogenization. In particular you will
learn about different types of blending beds and the respective methods for stacking and
Course Summary
reclaming.

2 Overview Basic Cement Materials and Homogenization

Basic Materials
Two main types of rocks provide the starting materials for cement production: Types of Raw Material
a) calcareous raw materials containing CaO as the main oxide
 Limestone (consisting almost entirely of calcium carbonate, CaCO3) from different
geological formations, often containing admixtures of clay and iron compounds.
 Chalk has a loose fine-grained structure and therefore is particularly suitable as a raw
material for wet processing. No blasting is required for its extraction and requirements
for crushing are neglegible.
 Marl is a natural mixture of limestone and clay. the latter contributing small amounts
of silica, clay and iron oxide. It is the most commonly used raw material.
b) argillaceous raw materials containing aluminium and silicon oxides (Al2O3 and SiO2)
 Clay, marly clay, clay slate, oil shale, slag, ash.

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 2 Overview Basic Cement Materials and Homogenization

The components containing limestone and clay form the largest proportion of the raw
material mixture for cement production. These two main raw materials are classified by
their CaCO3 content (Fig. 2.0-1).

2 100 90 75 40 10 0
96 2

Figure 2.0-1: Diagram of the Calcium Carbonate Content in Limestone, Clay and Marl .

Cement Raw Material CaCO3 Content (M-%)

high-grade limestone 96 -100 M-%

marly limestone 90 96 M-%

calcareous marl 75 90 M-%

marl 40 75 M-%

clayey marl 10 40 M-%

marly clay 2 10 M-%

clay 0 2 M-%

Table 2.0-1: Cement Raw Materials with their CaCO3 Content.

The CaCO3 content in the raw mixtures should be between approximately 75 and 79 M-
%. A marl having this composition is therefore very desirable for cement production but
is found only rarely in nature.
Other Constituents, The ratio of lime (CaO) to the other essential constituents SiO2, Al2O3 and Fe2O3, is
Ratios very important for the quality of the cement clinker. For this reason ratios have been
established and limits for these ratios have been set. If these ratios are adhered to, a
good kiln product is acheived with very few operational problems, such as large amounts
of undesired coating in the sintering zone of the rotary kiln. These ratios are the lime
saturation factor (LSF), silica ratio (SR) and alumina ratio (AR). For laboratory control
of production the following limits for the ratios have proved to be suitable for adjusting
the raw meal composition in accordance with the analysis of the components, the earlier
LSF I having been replaced by the more realistic LSF II:

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 CaO
LSF = 2.80SiO2 +1.18Al2 O3 +0.65Fe2 O3 100 92. . . 97 Lime Saturation
Factor II
SiO2 (LSF II)
SR = Al2 O3 +Fe2 O3 2.0. . . 2.6 Silica Ratio
(SR)
Al2 O3
AR = Fe2 O3 1.6. . . 2.0 Alumina Ratio
(AR)
The reaction during the burning process is affected by the amount of liquid phase at the
particular sintering temperature as well as by the ratios resulting from the adjustment made
to the raw mix.
Evaluation of the chemical analyses shows which ratios in the planned raw mix need to
be corrected by way of additives. These additives must be provided reliably and cost-
effectively in the required amounts. The following materials can be used corrective raw
materials:
 siliceous raw materials containing the oxide SiO2: sand, sandstone, silica
 aluminiferous raw materials containing the oxide Al2O3: bauxite , kaolin
3
 iron-containing raw materials containing the oxide Fe2O3: iron ore, pyrites ash

Blending (Homogenization) of Cement Raw Materials

In order to achieve good, continuously uniform kiln operation with regard to heat con-
sumption, clinker quality, and coating conditions, the composition of the raw meal may
only vary within a narrow range. CaCO3 content or LSF may only vary by about 0.5 to
1,0 %. There are many ways of keeping variations over time within an acceptable range:
 selective extraction from the quarry to provide the desired mix composition
 preliminary homogenization of the crushed raw material in a blending bed
 controlling the mixture before the mill
 secondary homogenization of the raw meal in mixing silos
Due to the large amounts of raw materials commonly produced today, it is no longer cost-
effective control variations in the CaCO3 content in the raw material by selective extraction
in the quarry. A suitable alternative is the blending bed technique which has been used
effectively for years in the iron & steel and in the mining industry. Another advantage is
that the blending bed stockpiles, generally consisting of crushed limestone or marl, provide
a material buffer for supplying the raw meal grinding plants.

3 Design and Mode of Operation of a Blending

Bed
The crushed material from the quarry is stored in stockpiles according to a precise plan.
Blending is achieved by mixing while the crushed stone is reclaimed by special equipment.
A blending bed generally consists of a circular stockpile or two longitudinal stockpiles Blending Bed
(arranged one behind the other or in parallel), one of which is reclaimed while the other is
being stacked. The stock of crushed stone in one stockpile should be sufficient for at least
one weeks kiln production.

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 3 Design and Mode of Operation of a Blending Bed

Example
The required stock of crushed stone is calculated from the kiln output and the clinker
factor which represents the mass of raw material required for the production of 1 t of
clinker. It is usually taken as 1.6. With a kiln output of 3,000 t/d the stock of crushed
stone per stockpile in the blending bed should be at least 3,000 t/d 1.6 7 d = 35,000
t.
Blending Effect The blending effect is approximately 5/1 to 10/1 (e.g. a decrease in the variation of the
CaCO3 content from approximately 10 % to 1.5 %) depending on the initial variation
and the sophistication of the system for stacking and reclaiming the blending bed. Homog-
enization of the raw material components in a blending bed is the most commonly used
method in the cement industry for blending crushed stone. The individual components are
then fed separately to the raw mill via feed bins and weigh belt feeders in accordance with
the planned chemical composition of the raw meal. Chemical analysis of the raw meal
leaving the raw mill provides information about any corrections that may be needed.
In the case of longitudinal stockpiles the blending beds are normally stacked along a lon-
4 gitudinal axis. If there is not enough space for longitudinal stockpiles then the material is
stacked in ring-shaped or circular stockpiles. However, the investment costs for circular
stockpiles are about 30 40 % higher than for longitudinal stockpiles of the same capacity.

3.1 Stacking of Blending Beds

Stacking Raw material stockpiles can be built up with various methods. In practice two main meth-
ods of stacking are used:
1 by a conveyor belt with discharge carriage (Fig. 3.1-1) or
2 by a travelling boom stacker that moves along the blending bed (illustrations Fig.
3.1-2 and Fig. 3.1-5).
The thickness of the material layers is controlled by the speed of the stacking equip-
ment.

Figure 3.1-1: Stockpile Stacking via a Conveyor Belt and Throw-Off Carriages, Schematic View .

Circular Blending Beds

Circular stockpiles are normally built up continuously using the Chevcon method (simi-
lar to the Chevron method described below). In this way, it is possible to stack and reclaim
the material continuously with no gaps in the blending bed. This results in gradual transi-
tion zones with maximum fill of the blending bed.
At this point in the online course you will see an animation of the stacking and reclamation
of a circular blending bed.

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 3.1 Stacking of Blending Beds

Figure 3.1-2: Blending Bed Stacking via a Boom Stacker, Schematic View .

A pivoting stacker (conveyor belt) from which the stockpile is built up is positioned in
the centre of the circular stockpile (Fig. 3.1-3). The stacker passes horizontally over an
angle of 90 to 120 for a specific time interval and discharges material continuously as
it moves. The discharge height is adapted to suit the material in the blending bed.The
discharge height of the stacker therefore varies in order to avoid excessive drops and any
possible segregation effects. After a certain number of passes the material reaches the
required bed height. The stacker then is offset by 2 -3 and begins again to pass through 5
an angle of 90 to 120 and to discharge material onto the existing stockpile.

belt stacker material supply

scraper chain loosening rake

material discharge

Figure 3.1-3: Stationary Slewing Belt Conveyor and Slewing Scraper Conveyor for Stacking and Re-
claiming a Circular Stockpile, Schematic View .

Longitudinal Stockpiles
The raw material layers in a blending bed may be built up with different methods. The
best-known methods are:
 Coneshell stacking
 Chevron stacking
 Windrow (small-line) stacking

Coneshell Method (Coneshell Stacking)

Individual cones of material are deposited behind one another until the maximum possible
height is reached. This method allows the greatest amount of material to be stacked but
the material is homogenized to a lesser extent, (Fig. 3.1-6).

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 3 Design and Mode of Operation of a Blending Bed

Figure 3.1-4: Storage of raw material in the blending bed (Source: Polysius).

Figure 3.1-5: Belt Stacker at a Blending Bed Stockpile, Works Photo MVT .

Chevron Method (Large-Line Stacking)

In modern plants the material is stacked in superimposed layers by a belt stacker above the
centre of the stockpile. In this case the individual layers of material are arranged on top
of one another resembling a roof (Fig. 3.1-7). This widespread method allows continuous
stacking and reclamation of material if two longitudinal blending beds are used.
At this point in the online course you will see an animation.

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 3.1 Stacking of Blending Beds

Figure 3.1-6: Stockpile Stacking Using the Coneshell Method (Coneshell Stacking), Schematic View .

Figure 3.1-7: Stockpile Cross-Section Using the Chevron Method (Chevron Stacking), Schematic View
.

Windrow Method (Small-Line Stacking)

The material is stacked in a large number of small lines and layers. With the Windrow
Method it is possible to achieve very good homogenization and also to mix materials with
very different particle sizes. However, the cost involved in this type of stockpiling is
significantly higher as the belt stacker also has to travel transversely across the blending
bed. (Fig. 3.1-8).

Figure 3.1-8: Stockpile Stacking Using the Windrow Method (Small-Line Stacking), Schematic View .

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 3 Design and Mode of Operation of a Blending Bed

3.2 Reclamation of Blending Beds

Satisfactory blending of the raw material can generally only be achieved if the stockpile
is reclaimed in slices at the end face. The composition of each slice should correspond
End Face approximately to the average composition of the blending bed.

The stockpiled material is therefore normally reclaimed in slices from the end face and is
removed by loosening with loosening rakes and transported away with scraper chains
(Fig. 3.2-1), or is removed using a reclaiming scraper or a reclaiming cable that moves
like a windscreen wiper. This results in a blend of the material over the entire reclamation
face.
Reclamation The reclaiming scraper consists of a boom and a circulating chain with scrapers. The
scraper boom is made so that it can be lowered and pivoted. Depending on its design the
reclaiming scraper can reclaim the blending bed from the end face or else along the longi-
tudinal axis alongside the stockpile. The material that has been loosened and reclaimed is
transported away by conveyor belts.
8

Figure 3.2-1: Reclaiming Scraper for End-Face Reclamation of a Blending Bed .

The heaped material may, e.g., be removed with a triangular loosening rake. As the rake
moves back and forth over the end face the heaped material trickles over the reclamation
cross-section to the foot of the stockpile where it is picked up by the chain scraper and
removed (Fig. 3.2-2).

Blending bed reclamation from the longitudinal side of the stockpile (Fig. 3.2-3) wil
result in lower blending efficiency.
Longitudinal Face
The chain scraper is equipped with wear-resistant blades that, in the case of longitudinal
blending beds, move the loose material towards the reclaiming belt running parallel to the
bed and, in the case of circular blending beds, move the loose material to the discharge
point via the central column.

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 9

Figure 3.2-2: Loosening Rake and Chain Scraper at the End Face .

Figure 3.2-3: Reclaiming Scraper for Blending Bed Reclamation along the Longitudinal Face of the
Stockpile .

4 Health and Safety Practices

It is obligatory for operational and maintenance staff to wear personal protective equip-
ment. The following precautionary measures must also be taken before and during any
work at the blending bed:
 Production supervisors and managers must be informed of any work that is about to
take place.
 Machinery and systems must be isolated and secured against reconnection during
maintenance and repair work.
 Rail clamps on undercarriages must be closed before any work begins.
 The power supply to all electrical components must be switched off.
 Before disconnecting any hydraulic and lubricant lines checks should be carried out to
ensure they have been depressurized.
 Entering the working areas of reclaiming scrapers and stackers during operation is
prohibited.
 Protective screens must be replaced once work has been completed, particularly at the
central column discharge point or on the bridge scraper reclaimer where there is an
increased risk of falling.

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 6 Maintenance and Inspection

 The safety regulations regarding continuous conveyors must be observed.

5 Operation and Quality

Production Adverse effects on the production operation must be avoided. These may occur if:
 the bulk material is moist as this clogs chutes and transfer points,
 the bulk material is too coarse as the coarse material then will collect at the foot of the
stockpile, this segregation leading to unstable operation caused by vibrations during
subsequent grinding and drying, particularly in vertical roller mills.
With a favourable layout, the size of a longitudinal stockpile may be subsequently adapted
for larger production output. In contrast to this the size of a circular stockpile cannot be
changed at a later stage.
Clinker Quality The quality of the clinker can only be ensured if the quality of the raw material is constant.
 A longitudinal stockpile is recommended if the chemical and physical properties of
10 the raw materials vary significantly.
 In the case of limestone a blending bed can reduce variations in the CaCO3 content
from 10 % to < 1.5 % (Fig. 5.0-1).
 Excessive variations in raw meal quality require constant adjustments of kiln param-
eters like thermal input and kiln speed in the clinker burning process and may lead to
increased coating in the rotary kiln and consequently to uneconomic plant operation.
Circular Stockpile
97
96
95
LSF

94
93
92
91
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
hours
Longitudinal Stockpile
97
96
95
LSF

94
93
92
91
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
hours
output value
input value
output value at the end of the stockpile

Figure 5.0-1: Change in Input and Output Values of the LSF of Raw Materials with Time during Blend-
ing Bed Operation.

6 Maintenance and Inspection

Regular Inspection  Checking of the belt systems
 blade-type belt cleaner
 tension take-up
 drive pulley, tensioning pulley, snub pulley
 roller station

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  rubber belt
 Inspection of the lifting elements in accordance with manufacturers specifications
 Checking of the chain scraper for
 chain tension
 chain wear
 cleanliness of the guides
 wear and functioning of the supporting rollers
 wear of the blades, inc. attachment
 Checking of the central chute for wear
 Checking of the undercarriages for
 alignment
 functioning of the rail clearers
 Checking of the inclined reclaimers for
 wear and tension of the drive chain
 lubrication of the rails
 condition of the rake teeth
11
 angle of repose

Figure 6.0-1: Longitudinal Blending Bed with Corresponding Plants .

 Material selection Measures toCounteract

 wear-resistant materials Wear

 Structural measures
 chain scraper design
 bucket attachment
 Protection against abrasion
 Use of lubricant
 increasing sliding properties

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 8 Questions on Course LB 2.2 Blending Beds

 protection against corrosion

7 Environmental Protection
The main emissions during raw material storage and homogenization are dust and noise.
Countermeasures  Dust
 cover the store
 dust extraction and filter plants at critical transfer points
 Noise
 cover the store
 enclose the drives
The capital investment costs for covering the store are approximately 20 % greater with
longitudinal stores than with circular stores and are therefore of the same order of magni-
tude as the total cost of the mechanical equipment.
Energy Consumption  The uniformity of the CaCO3 content of raw meal increases with reduced variation in
12
the CaCO3 content of the raw material and this results in reduced fuel consumption
of the kiln.
 The electrical power demand of the blending bed is low when compared with the
total energy consumption of a cement works.

8 Questions on Course LB 2.2 Blending Beds

You can test your knowledge by answering the following questions.

Question 8.0 A:
1. Into which two main types can the starting materials for cement production be
grouped?
2. Classify the main raw materials on the basis of their respective CaCO3-contents
3. Name the main corrective raw materials and their respective oxides
4. From which oxide contents are the lime saturation factor (LSF I), silica ratio (SR)
and alumina ratio (AR) calculated?
5. Why is the blending bed technique used? Give the two main reasons
6. What are the two main methods of stacking that are use to differentiate between
blending beds?
7. Explain the two methods of stacking
8. What are the two fundamental types of blending beds?
9. Describe the two designs.
10. Name the methods used for reclaiming blending beds
11. What safety equipment is essential for operational and maintenance staff?
12. Name specific precautions that must be taken before and during any work in a
blending bed
13. Why is entry to the working areas of reclaiming scrapers and stackers prohibited
during operation?
14. Which accident prevention regulations in particular must be observed?
15. Name the factors that affect the production operation and their consequences
16. Which blending bed store is recommended if the properties of the raw materials
vary considerably?

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17. What reduction in the variation of the CaCO3-content of the raw materials can be
achieved with a blending bed?
18. Explain the effect that a reduction in this variation has on the production process?
19. How great is the electrical power demand of a blending bed compared to the total
energy consumption of a cement works?
20. What aspects of the plant engineering should be taken into consideration when
selecting materials for machinery and what are the reasons for this?
21. Which units of the blending bed must be inspected and serviced?
22. What must be checked in particular on the undercarriages of blending bed machin-
ery?
23. What checks must be carried out on an inclined reclaimer in a blending bed?
24. What are the main emissions from blending beds?
Solutions see p. 14

13

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 8 Questions on Course LB 2.2 Blending Beds

Solutions
Solution for 8.0 A:
1. calcareous raw materials containing CaO as the main oxide, and
argillaceous raw materials containing mainly the oxides of alumina and silicon
2. 96-100 % CaCO3: high-grade limestone
90-96 % CaCO3: marly limestone
75-90 % CaCO3: calcareous marl
40-75 % CaCO3: marl
10-40 % CaCO3: clayey marl
2-10 % CaCO3: marly clay
2 % CaCO3: clay
3. Siliceous raw materials containing SiO2: sand, sandstone, quartz
Aluminiferous raw materials containing Al2O3 bauxite, kaolin
Iron-containing raw materials containing Fe2O3: iron ore, calcined pyrites
14 4. LSF I = CaO, SiO2, Al2O3, Fe2O3
SR = SiO2, Al2O3, Fe2O3
AR = Al2O3, Fe2O3
5. Blending of cement raw materials before the grinding and burning processes,
material buffer for supplying raw meal grinding plants
6. a) Chevron method (roof stacking)
b) Coneshell method (cone-shell stacking)
7. a) The individual material layers are deposited on top of one another like roofs
b) Individual cone shells of material are deposited behind one another up to the
maximum possible height
8. a) Longitudinal blending beds
b) Circular blending bed
9. Longitudinal blending bed: stacking longitudinally, reclamation from the end face
Circular blending bed: stacking and reclamation equipment move simultaneously
around a central column
10. a) loosening rakes and removal by scraper chains,
b) reclaiming scraper and transport by scraper chains
c) reclaiming scraper along the longitudinal side of the stockpile and removal with
conveyor belts
11. Protective screens.
The occupational safety regulations regarding continuous conveyors must be ob-
served!
12. a) Production supervisors and managers must be informed.
b) Machinery must be isolated and secured against reconnection
c) Rail clamps on undercarriages must be closed
d) The power supply to electrical components must be switched off
e) Hydraulic and lubricant lines must be depressurized before disconnection
13. For reasons of occupational safety
14. The occupational safety regulations regarding continuous conveyors (VBG-10)
15. a) the loose material is too moist: chutes and transfer points may become clogged
b) the loose material is too coarse: it may collect at the foot of the stockpile and
segregation of the mill feed may lead to unstable operation of vertical roller mills
16. Two longitudinal stockpiles arranged side-by-side, stacking by the Chevron method
(roof stacking) and reclamation from the end face
17. Reduction in variation of the CaCO3-content from about +/- 10 % to +/- 1.5 %

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18. Fewer adjustments of kiln parameters such as
a) thermal input and
b) kiln speed, resulting in
c) reduced coating in the rotary kiln and
d) more economic plant operation
19. very low, approximately 2 %
20. Choose wear-resistant materials. Maintenance costs
Lower operating costs
21. a) belt systems, i.e. blade-type belt cleaner, tension take-ups, drive pulley and ten-
sioning pulley, roller station, rubber belt,
b) chain scraper, i.e. chain tension and chain wear
cleanliness and wear of the guides and rollers
c) inclined reclaimers
d) undercarriages
22. a) alignment
b) functioning of the rail clearers
15
23. a) wear and tension of the drive chain
b) lubrication of the rails
c) condition of the rake teeth
d) angle of repose
24. a) dust
b) noise
Questions see p. 12

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Glossary
alumina ratio
Ratio of aluminium oxide to iron oxide
bauxite
important aluminium ore
blending bed
A blending bed is produced by placing layers of raw material successively on two or more stockpiles in a recti-
linear or circular pattern. Blending beds are used for preliminary homogenization of the crushed raw stone. This
is generally required due to the large variations in the chemical compositions of the deposits.
calcined pyrites
Iron oxide (Fe2O3), obtained during the production of sulfuric acid from pyrites (an iron-sulfur mineral).
chalk
Soft, loosely compressed sedimentary rock formed from calcium carbonate
clinker factor
Mass ratio of raw meal to cement clinker produced.
deposits
Natural accumulation of minerals, the extraction of which is profitable. 17
formation
Clearly recognizable rock unit
homogenize
to make uniform
lime saturation factor
Specifies the ratio of lime to quartz, iron oxide and aluminium oxide.
limestone
Rock consisting almost entirely of calcium carbonate (CaCO3)
marl
Sedimentary rock that is composed approximately half of clay and half of limestone.
mass %, M.-%
Abbreviation for percent by mass; measure of the proportion by mass of a component in a mixture
segregation
Separation of a mixture into different fractions
silica ratio
Ratio of quartz to iron and aluminium oxides.

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 Index

A
alumina ratio 2

B
bauxite 3
blending bed 3

C
calcined pyrites 3
chalk 1
clinker factor 4

D
deposits 1

18
F
formation 1

H
homogenize 1

L
lime saturation factor 2
limestone 1

M
marl 2
mass %, M.-% 2

S
segregation 10
silica ratio 2

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