Preheat Process

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Preheater and Calciner Process Training

Krupp Polysius Corp.

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The modern kiln plant Preheater

Calciner Clinker cooler C M

Raw mill Rotary kiln

Krupp Polysius Corp.

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Preheater

Krupp Polysius Corp.

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DOPOL 90

Krupp Polysius Corp.

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Gas and material flow in a preheater

Krupp Polysius Corp.

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DOPOL 90 B-type cyclone 1 2 3

4 5

Krupp Polysius Corp.

1 2 3 4 5

Cyclone Intermediate piece Dip pipe Gas duct Meal chute

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Cyclone types

Dedusting cyclone System cyclone Calciner cyclone

DOPOL® 90

Krupp Polysius Corp.

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The modern kiln plant Preheater

Calciner Clinker cooler C M

Raw mill Rotary kiln

Krupp Polysius Corp.

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DOPOL 90 - preheater design

Krupp Polysius Corp.

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Technical data Number of cyclone

4

5

6

°C

370

315

280

Nm³/kg clinker

1,372

1,353

1,345

%

8

6,5

5

mbar

33

38

45

Fuel consumption

kcal/kg clinker

740

718

705

Cooler efficiency

%

74,6

73,1

72,1

Clinker temperature

°C

100

100

100

Nm³/kg clinker

1,7

1,7

1,7

Nm³/kg clinker

0,84

0,87

0,88

°C

295

305

312

- for exhaust gas fan

kWh/t clinker

5,6

5,7

6,1

- for total kiln plant

kWh/t clinker

15,1

15,2

15,7

- exhaust gas only (with coal mill)

%

7,6

5,6

4,3

- exhaust gas only

%

8,5

6,5

5,3

- exhaust gas with exhaust air

%

11

9,5

8,7

Exhaust gas - temperature - volume - dust relative to clinker - pressure loss

Cooling air Cooler vent air - volume - temperature Electrical power consumption

Permitted RM moisture

Krupp Polysius Corp.

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Drying capacities - preheater systems

Exhaust gas temp. [ °C ]

500

AS 6 AS 5

AS 4

AS 3

AS 2



200

12 8

PH exhaust only -->

100

4

0 700

750

800

850

Fuel consumption [ kcal/kg cli ]

Krupp Polysius Corp.

0 900

Drying capacity [ % - H2O ]

600

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Calciner

Krupp Polysius Corp.

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Calciner types

PREPOL AS

PREPOL AS-CC

Krupp Polysius Corp.

PREPOL MSC

PREPOL MSC-CC

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PREPOL AT

Krupp Polysius Corp.

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PREPOL AS

Calciner loop

Fuel injection TA-duct

Krupp Polysius Corp.

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PREPOL AS-CC Calciner loop

Combustion chamber

Krupp Polysius Corp.

TA-duct

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Combustion - Chamber (CC) Burner

Meal inlet

Central inlet for tertiary air

Meal inlet Tangential inlet for tertiary air inlet

CC-Chamber outlet (Connection to the calciner)

Krupp Polysius Corp.

Tangential inlet for tertiary air inlet

Tertiary duct

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PREPOL MSC

Deflection chamber

Top air duct

Meal staging PC - burner

Kiln inlet burner

Krupp Polysius Corp.

Tertiary air duct

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PREPOL MSC-CC Deflection chamber

Top air duct

Tertiary air duct

PC - burner Kiln inlet burner

Krupp Polysius Corp.

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Tertiary air duct

Krupp Polysius Corp.

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MSC Calciner with Tire Feed Chute

Krupp Polysius Corp.

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Tertiary air from cooler

w > 26 m/s

w < 8 m/s

w < 8 m/s

Krupp Polysius Corp.

w < 6 m/s

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Tertiary air from kiln hood

w > 2 6 m / s

w < 5 m / s

Krupp Polysius Corp.

w < 5 m / s

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Tertiary air connection kiln hood secondary air temperature

cooler

measures

lower

higher

thermal stress on outlet segments

+ lower

- higher

better cooling and form of segments

burn out in the calciner

+ better

- worse

CC - Calciner

precalcination rate

- lower

+ higher

bypass losses

- higher

+ lower

load of sintering zone

- higher

+ lower

- higher

+ lower

- bigger

+ smaller

length of burner

- longer

+ shorter

NOx - formation

(+ lower)

(- higher)

Investment cost

- higher

+ lower

thermal stress on tertiary air flap and refractory size of kiln hood

Krupp Polysius Corp.

adapted dimensionnig and quality of refractory

optimized burner adjustment

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“Low-dust” kiln inlet

Krupp Polysius Corp.

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Calciner volume loading T h e r m a l c a l c i n e r l o a d i n g i n k c a l / m ³ / h F u e l t y p e

P R E P O L A S

P R E P O L A T

N a t u r a l g a s

< 1 5 0 0 0 0

< 1 0 0 0 0 0

F u e l o i l

< 1 8 0 0 0 0

< 1 2 0 0 0 0

h i g h r e a k t i v e C o a l

< 1 3 0 0 0 0

< 8 7 0 0 0

l o w r e a k t i v e C o a l

< 9 0 0 0 0

< 6 0 0 0 0

e . g . P e t C o k e

Krupp Polysius Corp.

< 8 0 0 0 0

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Fuel design and distribution

Krupp Polysius Corp.

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O2-concentration [%]

Coal - activity

Time [s]

Krupp Polysius Corp.

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NOx - generation in clinker burning process

Calciner: Fuel - NOx - exess air - nitrogen content - reactivity

Sintering zone: Thermal NOx - temperature - exess air - retention time

Krupp Polysius Corp.

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Combustion conditions for NO reduction by fuel, air and meal staging Meal

> 1,05

H2 O NO N2 CO2

0,4 - 0,6 Q

NHi H2 O CO2 N2 NO CH i CO NO

> 0,1 Q Fuel

CHi

Air

CO2 H2 O N2 CO

0,9 <

< 1,05

0,9 <

< 1,05

NO NH i

Stage 4

Q = total fuel = excess air figure

Stage 3 0,4 - 0,6 Q Stage 2 Stage 1

Krupp Polysius Corp.

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NOx at kiln inlet [gNO2/kgcli]

NOx and O2 at kiln inlet

O2 at kiln inlet [%]

Krupp Polysius Corp.

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NOx - generation in calciner [NO2/kgcli]

NOx - generation and volatiles

Volatile matter in fuel [%]

Krupp Polysius Corp.

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NOx [NO2/kgcli]

NOx and Nitrogen in fuel

Nitrogen in fuel [%]

Krupp Polysius Corp.

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NO2 [mg/Nm3] @ %O2

Nox and calciner temperature

Calciner temperature [ºC]

Krupp Polysius Corp.

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NOx - emission [gNO2/kgcli]

Operating results MSC plants

Krupp Polysius Corp.

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Operating results MSC plants 2 .5

A S -MS ope Cra - ope t ion ra 2 8 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

1 .5 5 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

NOx-Emison[gNO2/kgCli]

1

3 5 %

3 2 % 5 3 %

0 .5

0

Krupp Polysius Corp.

3 0 %

2 8 %

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NOx - emission [gNO2/kgcli]

Operating results MSC plants

Krupp Polysius Corp.

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Operating results MSC plants 2.5

KI - A MS S -C op er op at er io at nion AS - oper ation 2

8 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

1.5

5 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

NOx-Emison[gNO2/kgKl]

1

3 5 %

3 2 %

0.5

0 P l a n t

F u e l

5 3 %

2 8 %

3 0 %

A 8 0 % P e t C o k e 2 0 % C o a l

V o l a t i l e s i n f u e l

1 5 %

Krupp Polysius Corp.

B L i g n i t e

4 5 %

C C o a l B l e e c h i n g E a r t h P a p e r w a s t e F l y A s h 2 7 , 3 %

D C o a l T y r e s P l a s t i c

E O i l P a p e r w a s t e P l a s t i c C a r b o n M a r l

~ 2 5 %

> 4 0 %

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NOx - emission [gNO2/kgcli]

Operating results MSC plants

Krupp Polysius Corp.

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Operating results MSC plants 2.5

KI - A MS S -C op -er op at er io at nion AS - oper ation 2

8 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

1.5

5 0 0 m g N O 2 / N m ³ ( 1 0 % O 2 )

NOx-Emison[gNO2/kgKl]

1

3 5 %

3 2 %

0.5

0 P l a n t

F u e l

5 3 %

2 8 %

3 0 %

A 8 0 % P e t C o k e 2 0 % C o a l

V o l a t i l e s i n f u e l

1 5 %

Krupp Polysius Corp.

B L i g n i t e

4 5 %

C C o a l B l e e c h i n g E a r t h P a p e r w a s t e F l y A s h 2 7 , 3 %

D C o a l T y r e s P l a s t i c

E O i l P a p e r w a s t e P l a s t i c C a r b o n M a r l

~ 2 5 %

> 4 0 %

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NOx - prognosis NOx - emission

Krupp Polysius Corp.

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CO - prognosis

Krupp Polysius Corp.

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