(1.3)_pyro Process Theory & Kiln System Design

Cement Process Training Sociedad Boliviana de Cemento Bolivia

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Pyroprocessing Theory

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Portland Cement Clinker

Main Clinker Minerals

   C    S    A    F

=  CaO =  SiO2 =  Al2O3 =  Fe2O3

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Portland Cement Clinker

Main Clinker Minerals C3S = 3 CaO , SiO2

( Alite )

C2S = 2 CaO , SiO2

( Belite)

C3A = 3 CaO , Al2O3

(Aluminate)

C4AF = 4 CaO , Al2O3 , Fe2O3 (Ferrite) The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

Portland Cement Clinker

Typical Raw Materials Limestone Clay Silica (quartz) Iron ore

( CaCO3 ) ( Al2O3, 2 SiO2 , 2 H2O ) ( SiO2 ) ( Fe2O3 )

(Fuel) The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

Portland Cement Clinker

Main chemical constituents Ranges CaO SiO2 Al2O3 Fe2O3

Practical 58 - 68 % 18 - 26 % 3 - 8 % 0.5 - 6 %

Typical 63 - 67 % 20 - 24 % 4 - 7 % 2 - 4 %

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Portland Cement Clinker

Minor chemical constituents Ranges MgO K2O Na2O SO3

Practical 0.1 - 6 % 0.1 - 1.5 % 0.1 - 1.5 % 0.1 - 2 %

Typical 1 - 4 % 0.1 - 1.0 % 0.1 - 0.8 % 0.1 - 1.5 %

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Portland Cement Clinker

Clinker minerals Ranges Practical Typical C3S30 - 70 % 45 - 65 % C2S 10 - 50 % 15 - 30 % C3A 0 - 15 % 4 - 10 % C4AF 0 - 20 % 8 - 12 %

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Portland Cement Clinker

Minor constituents K2SO4 Na2SO4 CaSO4

( Potassium sulfate ) ( Sodium sulfate ) ( Calcium sulfate )

Free CaO Free MgO

( Free lime ) ( Free magnesia )

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Portland Cement Clinker

Potential Mineralogical Composition Calculation according to Bogue C3S = 4.07 x C - 7.60 x S - 6.72 x A - 1.43 x F C2S = - 3.07 x C + 8.60 x S + 5.07 x A + 1.08 x F C3A = 2.65 x A - 1.69 x F C4AF = 3.04 x F The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

Portland Cement, Raw Meal, and Clinker

Chemical Modules LSF = CaO / CaOmax x 100 % CaOmax = 2.80 x SiO2 + 1.18 x Al2O3 + 0.65 x Fe2O3 Typical range for LSF: 88 - 98 % The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

Portland Cement, Raw Meal, and Clinker

Chemical Modules MS (or SR ) = SiO2 / ( Al2O3 + Fe2O3 ) Typical range: 2.2 - 2.8

MA (or AR ) = Al2O3 / Fe2O3 Typical range: 1.2 - 2.5

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Portland Cement, Raw Meal, and Clinker

Effects of Changing Chemical Modules LSF: Cement Quality:  1 LSF ≈  2.5 % C3S Burnability: Higher LSF  raw mix harder to burn

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Portland Cement, Raw Meal, and Clinker

Effects of Changing Chemical Modules MS: Nodulisation: Clinker size   Cooling efficiency Clinker porosity   Grindability Burnability: Higher MS  rawmix harder to burn The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

Portland Cement, Raw Meal, and Clinker

Effects of Changing Chemical Modules MA: Burnability: Lower MA



melt formation at lower temperature

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FLS Burnability Formula Free CaO1400°C = 0.33 (LSF - 95) + 2.0 (Ms - 2.3) Chemistry + 0.93 *%Q +45µm + 0.56 * %C+125µm Mineralogy (fineness)

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Characteristic Processes within the Pyroprocessing System as Function of Process Temperature

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Kiln Volumetric Loading Calculation Volumetric Loading =

Clinker Production (tpd) Kiln effective volume (m3)

Clinker Production

= 1000 tpd

Kiln diameter

= 4.15 m

Kiln Length

= 64 m

Refractory thickness = 200 mm Volumetric Loading =

1000 tpd 3.14 x (4.15-0.2) x 64 / 4 2

= 1.41 tpd/m3

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Kiln Thermal Loading Calculation Thermal Loading =

Sp.fuel(kcal/kg) x Cl.Prod.(tpd) x Firing in kiln(%) Kiln effective area (m2) x 24

Clinker Production

= 1000 tpd

Kiln diameter

= 4.15 m

Sp.Fuel consumption = 814 kcal/kg clinker Firing in kiln Thermal Loading =

= 85% 1000 tpd x 814 x 85 x 4 3.14 x (4.15-0.2) x 24 2

= 2.61 Gcal/hr/m2

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Kiln Burning zone filling degree Calculation B.Z Filling Degree =

3.2 x Clinker Production (tpd) Kiln effective dia3 x incl. X kiln speed

Clinker Production

= 1000 tpd

Kiln diameter

= 4.15 m

Kiln inclination

=4%

Kiln Speed

= 1.9 rpm

B.Z filling degree =

3.2 x 1000 tpd (4.15-0.2) x 4 x 1.9 3

= 8.0 %

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Kiln Burning zone residence time Calculation B.Z residence time =

325 Kiln incl. X kiln speed

Clinker Production

= 1000 tpd

Kiln diameter

= 4.15 m

Kiln inclination

=4%

Kiln Speed

= 1.9 rpm

B.Z residence time =

325 4.0 x 1.9

= 42.8 %

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Volumetric and Thermal Load of Kiln as Function of Type of Kiln System

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SP - Suspension Preheater Kiln

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SP Preheater 



Features – Normal capacity range 600 - 3000 tpd clinker – Ratio of firing in riser duct: 0-15% – Maximum possible range for by-pass of kiln gases: 030% Advantages – Grate or Planetary cooler can be employed. – Lower specific power consumption (with planetary cooler) – Simple operation - suited for manual control – Lowest investment costs for small capacities – A higher chloride content in the kiln feed can be accepted. As compared to pre-calcining systems with tertiary air duct (without by-pass)

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ILC-E - In-Line Calciner using Excess Air

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ILC-E Calciner 



Features – Normal capacity range is 800-3500 tpd clinker – Firing ratio in calciner: 10 - 25% Advantages – Grate or Planetary cooler can be employed – Lowest investment costs for medium capacities – Low specific power consumption (with planetary cooler) – Easy operation due to the high excess air level in the kiln – Low tendency to coating formation in the kiln inlet and the riser duct – Longer useful lifetime of kiln lining due to stable coating formation in the kiln – More chloride and sulphur in the kiln feed can be accepted than for pre-calcining systems with tertiary air duct. The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

ILC Calciner

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ILC Calciner

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ILC-I Calciner

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ILC - In-Line Calciner

Raw meal

Air Fuel The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

ILC Calciner For Burning of Petcoke 180° bend for improved  mixing Restriction for improved  mixing Oxidizing  zone Tertiary  air

70­85% of material Part of  raw meal to top of calciner

High temp.  bottom part

Reducing zone Fuel 15­30% of material

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ILC Calciner 

Features – Normal capacity range 1500 - 5000 tpd with single string preheate • up to 10,000 tpd clinker with double string preheater



– Firing ratio to calciner: 55% - 60% – Maximum possible variation in the kiln gas bypass: – 0% - 100% Advantages – High material and gas retention time in calciner due to its large volume and moderate swirl – Well suited for low grade fuel – Low refractory costs due to the low thermal load and stable kiln coating – Possibility of reducing the kiln NOx in the calciner – Well suited for burning of coarse waste fuel • (tyre chips) in the calciner

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SLC - Separate Line Calciner

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SLC with Three Preheater Towers

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SLC Calciner 

Features – Normal capacity range 3000 - 7000 tpd clinker with one kiln string and one calciner string and 7500 12,000 tpd clinker with one kiln string and two calciner strings – Firing ratio in calciner: 55% - 60% – Maximum variation in the by-pass of kiln gases: 0% 100%

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SLC Calciner (Continued) 

Advantages – High material and gas retention time in the calciner which dimensions are moderate, since kiln gases do not pass through it – Very well suited for all types of pulverized coal, even low volatile coal or petcoke, as the combustion in the calciner takes place in hot atmospheric air, and (as an option) the combustion temperature can be controlled independently of the temperature of the calcined material fed to the kiln – Low refractory costs due to low thermal kiln load and stable kiln coating – Independent and accurate draught control for kiln and calciner string by adjusting the speed of the individual fans – No damper in the tertiary air duct – Production of up to 40% of the total capacity using the kiln string only The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

SLC-I: Separate Line Calciner with In-line Calciner

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SLC-I Calciner 

Features – Normal capacity range: 5500 - 10,000 tpd clinker – Firing in SLC calciner: 40% - 50% – Firing in ILC calciner: 10% - 15% – By-pass range of kiln gases: 0% - 30%

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SLC-I Calciner (Continued) 

Advantages – High material and gas retention time in the SLC calciner

• Calciner dimensions are moderate since kiln gas does not pass through it

– Very well suited for all fuel types, even very low volatile fuels, as the combustion takes place in hot atmospheric air and (as a option) the temperature in the calciner can be controlled independently of the temperature of the calcined material to the kiln – Low refractory costs due to low thermal load and stable kiln coating – Independent draught control for kiln and calciner string, for example by adjusting the speeds of the individual preheater string fans – Production up to 50% using the kiln string only, operating as an ILC-E kiln – Well suited for high capacity systems, where the triple-string SLC system is not wanted and the flexibility of the SLC system is desired

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SLC-D - Separate Line Calciner - Downdraft

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SLC-D - Separate Line Calciner - Downdraft

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SLC-D-NOx Calciner 

Separate high temperature combustion chamber for burning low-volatile and waste derived fuels



Tertiary air with meal enters tangentially as in LP-cyclone to promote hot-core zone



Raw meal is elevated to top of calciner by tertiary air to minimize preheater height

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SLC-D-NOx Calciner 

Features – Normal capacity range 1500 - 5000 tpd clinker for one preheater string and 4500 - 10,000 tpd clinker for two preheater strings – Firing ratio to calciner: 55% - 60% – Maximum variation in the by-pass of kiln gases: 0% - 30% – Designed to operate under high temperatures for NOx reduction

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SLC-D-NOx Calciner 

(continued)

Advantages

– High material and gas retention time in calciners which dimensions are moderate, since kiln gases do not pass through the calciner – Specifically designed for all normal fuel types including even pulverized low-volatile coal which or without high ash content, as the combustion takes place in hot atmospheric air – The combustion temperature in the calciner can be controlled independently of the temperature of the calcined material fed to the kiln – Low refractory costs due to the low thermal kiln load and stable kiln coating – Smallest possible tower dimensions, as the calciner can be installed separate from the main cyclone tower – The two-string version of the system allows production down to 40% of the rated capacity – The ability to operate the calciner under high temperature to reduce NOx without impacting fuel consumption, CO emissions, or top stage temperature

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Semi-dry System With Slurry Feed Directly to Dryer

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Design of LP Cyclone Types

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E x a m p le s o f F.L .S m id t h o p e r a t io n p la n t s w it h lo w h e a t c o n s u m p t io n H e a t b a la n c e (k c a l/ k g C lin k e r ) P la n t lo c a t io n H e a t in e x h a u s t g a s a n d d u s t H e a t in f r e e w a t e r e v a p o r a t io n H e a t in b y p a s s g a s R a d ia t io n lo s s f r o m p r e h e a t e r R a d ia t io n lo s s f r o m k iln To t a l c o o le r lo s s H e a t o f r e a c t io n F re e h e a t f r o m a ir, f u e l a n d f e e d N e t s p e c ifi c h e a t c o n s u m p t io n

P la n t A M e x ic o 134

P la n t B In d o n e s ia 184

P la n t C U SA 135

P la n t D T h a ila n d 182

0 37 28 132 374 -3 0

0 22 31 125 384 -2 9

39 48 44 113 320 -3 1

0 35 25 124 360

677

719

673

697

(6 5 1 w / o b y p a s s ) P la n t A - 6 - s t a g e IL C p r e h e a t e r w / 2 - s u p p o r t k iln a n d c o n v e n t io n a l c o o le r (3 0 0 0 M T P D ) P la n t B - 4 - s t a g e S L C - I p re h e a t e r w / c o n v e n t io n a l c o o le r (7 8 0 0 M T P D ) P la n t C - 6 - s t a g e IL C p r e h e a t e r w / S F C r o s s - B a r c o o le r a n d 1 5 % o p e r a t in g b y p a s s (3 7 0 0 M T P D ) P la n t D - 5 - s t a g e S L C p r e h e a t e r w / c o n v e n t io n a l c o o le r (1 0 . 0 0 0 M T P D )

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Rotary Kiln with Two Supports

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Rotary Kiln with Three Supports

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FLS Standard Kiln Dimensions FLS 2-base kiln 13 x D inside lining 6.8 x D

2.3 x D

3.6 x D

øD

FLS 3-base kiln 17 x D inside lining 1.3 x D

6.4 x D

5.3 x D øD

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2xD

Kiln Types

Speed nominal Rpm

Speed max Rpm

Inclination

SP

2.0

2.5

3.5

ILC-E

2.25

3.0

3.5

ILC/SLC-D/ SLC-I/ ROTAX-2

3.6

5.0

4.0

3.6

5.0

3.5

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%

Conventional Live Ring

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Conventional Kiln Support

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Kiln Drive with Girth Gear and Pinion

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Hydraulic Thrust Roller

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CHOOSING A NEW PREHEATER Preheater cyclones are chosen by maintaining a minimum exit gas velocity Minimum exit velocities by stage:

stage stage stage stage stage stage

1 2 3 4 5 6

4 stage 9.0 m/s 11.0 m/s 11.0 m/s 13.5 m/s

5 stage 9.0 m/s 11.0 m/s 11.0 m/s 11.0 m/s 13.5 m/s

6 stage 9.0 m/s 11.0 m/s 11.0 m/s 11.0 m/s 11.0 m/s 13.5 m/s

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CHOOSING A NEW CALCINER Calciner sizes are chosen based on fuel fired, velocity, and residence time ILC calciners are used for most projects; however, an SLC-D may be used for firing waste fuels ILC Velocity – target of 8 m/s inside refractory, can go as high as 12 m/s. Older calciners had lower velocities. ILC Residence time – For coal, gas, and oil the target is a minimum of 3.3 seconds in the cylindrical section. When firing petcoke or other difficult fuel the minimum target is 5.0 seconds. Note that the loop duct for the ILC normally adds another 2-3 seconds of residence time.

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CHOOSING A KILN Kiln sizes are normally chosen based on material loading on a mtpd/m3 basis inside refractory. Choosing on this basis for a modern system means that other criteria such as burning zone loading will normally be met. For new kilns we normally stay under 4.8 mtpd/m3. However, based on kiln burnability this value may be slightly increased or decreased. In addition many customers today will specify kiln sizing based on maintaining a given kiln exit gas velocity or kiln hood velocity. The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

Effects on Burnability Improvement Proposed Change Reduce LSF

Resulting advantage  

Slightly more liquid phase Less dust

Comments Good ideas

Potential problems •

Less C3S – lower potential strength

 

  

Reduce Ms

• •

•

More liquid Better granulometry less dust Improved cooler efficiency





Big clinker balls when too low Ms Slightly lower C3S in clinker

    

Often easy to do, by adding less Limestone If LSF larger than app. 100, it may be impossible to burn to low free CaO. It is better to decrease LSF to achieve low CaO in clinker, as it is a waste to have excess calcite through the kiln being calcined heated and cooled. Microscopy of clinker can reveal if it is possible to burn the clinker to a lower free CaO. the primary reason for having too high LSF is incorrect Chemical Analyses of the raw mix. Unsatisfactory homogenisation of the raw materials will give fluctuations in LSF and affect the burnability in unforeseeable ways making it very difficult for the operator to operate the kiln. Should always be considered if dust is a problem Significant effect on burnability, but small effect on strength Ms > 2,5: consider a decrease Ms < 2,3: try to increase A decrease in Ms will often result in a decrease in quarts and silicates along with having a positive effect on the burnability.

C  • • Reduce Ma Liquid starts at Slightly lower Easy to do if iron ore is available H  lower temperature C3S Minor effect on burnability E  • Better Longer time in kiln for good nodulisation M granulometry I S The information contained or referenced in this presentation is confidential and proprietaryto T FLSmidth and is protected by copyright or trade secret laws. R

Effects on Burnability Improvement M I N E R A L O G Y

Reduce coarse calcite particles

•Easier for calcite

•Calcite is a

Often the first and easiest choice, if the

particles to react

soft material and will be affected by finer grinding •Finer grinding will require more energy in the mill •Possible mill capacity problems (lower production)

mill has extra capacity Relatively small effect on burnability Over-burning is often a problem because big free CaO particles from large Calcite particles are impossible to burn away. If the operator does not know this, the only option seems to be to burn harder – possibly resulting in dusty clinker No effect on cement quality •Finer grinding will have minor effect on coarse silicates and quarts •Will normally improve clinker grind ability

Reduce coarse quarts particles

•easier to avoid

May require

big C2S clusters •Will normally improve clinker grind ability

separate grinding of sand component i.e. more energy and investment

•Good effect on burnability •Other components should be examined.

Different sands may have identical chemistry but different sizes of quartz

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Effects on Burnability Improvement Propos ed Change W H A T E L S E

Burn Harder OR add CaF2 OR Read about minerali sed clinker

Resulting advantage

Potential problems

Comments Good ideas

•The production

Short brick

•If the free CaO can be kept at a

may be changed with acceptable free CaO

life due to high temperature More NOx emission More energy is needed

reasonable value, the cement strength will be OK •Harder burning will increase crystal sizes and result in clinker harder to grind resulting in more energy needed in the cement mill. •The use of petcoke as fuel may be ruled out due to increased sulphur evaporation

The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.

The information contained or referenced in this presentation is confidential and proprietaryto FLSmidth and is protected by copyright or trade secret laws.