Kiln Systems

Cement Manufacturing Course 2008

by Urs Gasser (CTS)

Learning Objectives Kiln Systems

Understand the process of clinker burning Know how to distinguish the basic process types Know the typical operating parameters of the main

process types
Know main equipment type for clinker burning and

understand its principle

Holcim Group Support

Kiln Systems
Process Types

Types of kiln systems

with typical operating parameters:

Wet process Semi wet process Semi dry process Dry process Critical Process Parameters

The optimum kiln system

Holcim Group Support

Process Steps Clinker Burning

INPUT: Raw Meal
Drying

Preheating
Calcining Sintering Cooling

OUTPUT: Clinker

Holcim Group Support

Process Requirements and Technical Solutions

Heat exchangers in a kiln system
CaCOfree CaCO3 C3S C2S Spurrite Quarz Clays CA C12A7 C2F C4AF 1000 1200 1400 1400 C2AS C3A Liquid phase C4AF 1200C C3A

Quantity

200

400

600

800

Drying

Heating

Calcining

Sintering

Cooling

CC-99064.dsf / Kma 22.2.99

Process Technology

Holcim Group Support

Heat Exchangers in a Kiln System

HOT GAS FROM COMBUSTION HOT GAS FROM COMBUSTION AIR

KILN FEED MATERIAL

DRYER

PREHEATER

CALCINER

KILN

COOLER

ROTARY VERTICAL

ROTARY VERTICAL HORIZONTAL

ROTARY VERTICAL

ROTARY

ROTARY HORIZONTAL VERTICAL

Holcim Group Support

Process Types
Wet Process

Slurry, H2O

25..40%

Semi Wet Process

Cake Nodules, 17..21%H2O

Semi Dry Process

Meal-Nodules, 10..12%H2O
Dry Process

Meal,

< 1% H2O

Holcim Group Support

Typical Process Parameters

Process: Feed moisture [%H2O] Heat consumption [kJ/kg] Installation: Max production [t/d] Kiln dimensions [m] Volume load [t/d m3] BZ load

Exit gas temp [C]

ID fan press

[mbar]

[t/d m2]

Holcim Group Support

Dry Process Kiln (with 4-stage SP)

Dry process kiln ( with 4-stage SP)
1.65kg/kg 50 C 360 C -50 mbar 3,5 %O2 1,41 Nm3/kg dust: 0.1kg/kg

550C 1.45 Nm3/kg, 240C 720C

830C

3250kJ/kg
1050 C - 3 mbar 2 %O2 1,2 Nm3/kg

20mbar

50mbar

clinker : 1kg cli, 1400C secondary air: 0.9 Nm3/kg, 860C installed: 3.0Nm3/kg, 20C 1kg cli, operation: 2.3 80C Capacity Diameter Length Length/Diameter Kiln load (inside lining) BZ load (inside lining) : : : : : : 500 3.5 50 14 1.5 100 - 3200 5.5 - 90 - 16 2.2 - 180 t/d m m

j = 30%

Kiln speed : Kiln slope : Spec.heat consumption :

1.5- 2.0 3 4 3150 - 3500

rpm % kJ/kg cli

t/m3d t/m2d

CC-99073.dsf / Kma 17.2.99

11

Holcim Group Support

Dry Process Kiln (with 5-stage SP and PC)

Dry process kiln (with 5-stage SP and PC)
1,65 kg/kg 50C 310 C -50 mbar 3 % 1.30 Nm3/kg Staub: 0.1 kg/kg

500C 1.45Nm3/kg, 240C 650C

1800 kJ/kg (60%)

770C

870C 2%O2 0.5Nm3/kg, 1100C 1200 kJ/kg (40%) 20mbar 50mbar clinker : 1kg cli, 1400C secondary air: 0.35 Nm3/kg, 1100C 1100 C -3 mbar 2 % O2 0,43 Nm3/kg

j = 90%
Kiln speed Kiln slope Spec.heat consumption : : : 2.5 4.5 rpm % 3.5 4 kJ/kg cli 2900 - 3500

1kg cli, 110C

Installed: 2.0Nm3/kg, 20C operation: 1,8

Capacity Diameter Length Length/Diameter Kiln load (inside lining) BZ load (inside lining)

: : : : : :

1500 3.5 40 10 3 185

- 10'000 t/d 6.2 m - 105 m - 16 5.5 t/m3d - 350 t/m2d

CC-99079.dsf / Kma 17.2.99

13

Holcim Group Support

Kiln Systems Critical Process Parameters

Key for top performance is regular checking of the

critical process parameters:

Overall: Feedrate & variation Heat consumption O2 / CO at kiln inlet O2 at system exit Kiln motor current Temperatures: Burning zone Kiln shell profile Gas at system exit Clinker exit PC cyclone exit Tertiary air Chain zone Laboratory: Chem. feed variation Free lime in clinker Sulfur in clinker Fuel as fired Hot meal LOI Hot meal SO3, Cl, Alk

14

Holcim Group Support

Large Capacities, BZ Load and Process Type 0 1000 2000 3000 0 1000 4000 2000 5000 3000 6000 4000 7000 5000 8000 6000 7000
7
7 t e
et
SP

8000

Thermal load [MW/m2]

Thermal load [MW/m2]

w
SP

6 5 4 3 0

6 5

-A PC

-A PC

AS PC-

AS PC-

4 3

1000 2000 0

3000 1000 4000 2000 5000 3000 6000 4000 7000 5000 8000 6000 9000 700010000 8000 Kiln capacity t/d Kiln capacity t/d
15

CC-99080.dsf / Kma 24.2.99 CC-99080.dsf / Kma 24.2.99

Holcim Group Support

Process Technology

Process Technology

Large Capacities, Kiln Size and Process Type 0 1000 2000 3000 4000 5000 6000 7000 8000
7

Thermal load [MW/m2]

Kiln diameter [m]

et
SP

6 5 4 3 0

6 5

et

SP

AT PC-

AT -A-S PC PC

AS PC-

4 3

1000 2000 0

3000 2000 4000 1000

5000 3000 6000 4000

7000 5000

8000 6000

7000 8000 9000 10000

Kiln capacity t/d Kiln Capacity [t/d]

7
et w Holcim Group Support
16

/m2]

CC-99080.dsf / Kma 24.2.99

Process Technology

The Optimum Kiln System

High availability and rate No failures Low heat

consumption
Low power consumption
Stable operation Suitable for variety of

fuels Controlled sufficient quality

17

Holcim Group Support

The Optimum Kiln System 2008

1) 5 stage preheater with low pressure drop cyclones

3) Oversized kiln for AFR

2) Low NOx with staged TA swirl chamber

4) High momentum multi channel burner 5) High efficiency cooler 6) Roller crusher 8) Splined tyre fixation 7) Pneumatic seals on both ends
18

Holcim Group Support

The Optimum Kiln System 2002

Expected Performance
High avi. And rate
Heat consumption Power consumption

>
< ~

0.9

3000 kJ/kg cli 15 kWh/t cli

19

Holcim Group Support