CASE STUDY: Optimization of clinker content in limestone-based cements - Ball Mill process

OBJECTIVE

This case study is based on a real field trial to produce cement with lower carbon footprint optimazing clinker factor and SCM content.

The 2 main objectives of the field trial were:

• From product side: to substitute Type 1 cement (CEM I) by Type 1L cement (CEM II/A-L) maintaining strength profile equal or better than Type 1 at all ages
• From Production side: to maintain production with a mill output around ~150 mTph

DESCRIPTION

During this field trial, we have compared CHRYSO^®ICARE technology to a conventional product in terms of mill output and we have adjusted limestone addition and fineness/blaine targets.
The Type 1 cement (reference) and the Type 1L cement were sampled for lab testing.

Details and targets :

Cement type: ASTM C595 Type 1L (CEM II/A-L)
Process type: Roller press + Ball Mill
Mill output: 150 mTph
CHRYSO tested product: CHRYSO^®ICARE RP2199-5

As late strengths are high, the next step is to perform a long-term trial to increase limestone content. There are different levers to reach this target, for example:

• Optimization of the PSD
• Adjust CHRYSO^®ICARE RP2199-5 to reach higher early strengths
• Perform a mill audit to optimize grinding process