Contents
Quality KPIs
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Raw Meal Fineness
Target: To be defined on an individual basis
Purpose: To indicate if the quality parameters for the raw meal production have been achieved consistently
Criteria: Samples are taken according to the sampling plan. The result is calculated for the entire population of samples over the reporting period.
Reporting: Each month for the current production year and the result for the preceding production year
Impact: High standard deviation or average not in target will make burning conditions of the raw mix unstable
Causes of under-performance:
Lack of control
Variable raw materials feed or air flow
Inconsistent raw materials supply
Raw materials are difficult to grind
Separator efficiency
Bad sampling
Kiln Feed Chemistry
Measured for:Blending Silo kiln feed (Lime Saturation Factor, Silica and Alumina Modulus)
Target: To be defined on an individual basis
Purpose: A measure of the control and homogeneity of the production of kiln feed.
Criteria: Samples are taken according to the sampling plan.
The result is calculated for the entire population of samples over the reporting period.
Reporting: Each month for the current production year and the result for the preceding production year
Impact: A high variation in kiln feed chemistry or average not in target causes unsteady kiln operation and high variations in product quality
Causes of under-performance:
Lack of homogenization in the blending silo.
Lack of ratio control in raw meal production
Clinker Chemistry
Measured for:Clinker (C3S and Free Lime)
Target:To be defined on an individual basis
Purpose:Measurement of control of kiln operation and clinker quality
Criteria:
Samples are taken according to the sampling plan.
The result is calculated for the entire population of samples over the reporting period.
C3S is calculated according to the Bogue Formula (see Definitions)
Reporting: Each month for the current production year and the result for the preceding production year
Impact: High variation in clinker chemistry will result in poor product quality
Causes of under-performance:
Unsteady kiln operation
High variation in kiln feed quality
Inconsistent fuel or feed rate to kiln
Uncontrolled addition of filter dust
Wrong kiln parameters
Cement Quality
Measured for: Cement (Fineness in Blaine, Strength at 28 days)
Target:To be defined on an individual basis
Purpose:To measure the variation in finished product quality
Criteria: Samples will be daily composite samples from all hourly process control samples in accordance with sampling plan. Samples must be well homogenized.
The result is calculated for the entire population of samples over the reporting period.
Reporting: Each month for the current production year and the result for the preceding production year
Impact: High variation will result in variable concrete strength and requires higher cement content in concrete.
Causes of under-performance:
Inadequate targets for clinker chemistry
Lack of control of raw meal and clinker production
Lack of control of the cement circuit
Sampling error
Separator efficiency