Precalciners

Learning Objectives Precalciners

Understand the principle of precalcination.

Know the basic precalciner types
Know the main features of the various precalciner types
Know the advantages of precalcination
Understand the principle of low NOx precalciners

Know possibilities and limits of lump fuel in precalciners

Precalciners: Content
Content
Principle and theoretical aspects
Precalciner design
ILC precalciners
Pre-combustion chambers

Low NOx precalciners

Solid AFR in PC: priority and new solutions
Optimization possibilities

Main Benefits of Precalciner Technology

Energy Balance of Process Steps for Clinker Burning

Endothermic Processes:
Dehydration of clays
Decarbonisation of calcite
Heat of melting
Heating of raw materials
(0 to 1450 C)
Total endothermic
Exothermic Processes:
Recrystallistion of dehydrated clay
Heat of formation of clinker minerals
Crystallisation of melt
Cooling of clinker
Cooling of CO2 (ex calcite)
Cooling and condensation of H2O
Total exothermic
Net Theor. Heat of Clinker Formation:
Endothermic - exothermic

kJ/kg cli
165
1990
105
2050

kcal/kgcli
40
475
25
490

4310
kJ/kg cli
40
420
105
1400
500
85
2550
kJ/kg cli
1760

1030
kcal/kgcli
10
100
25
335
120
20
610
kcal/kgcli
420

AT (Air Through) and AS (Air Separate)

Definitions:
PA = Primary Air
SA = Secondary Air
TA = Tertiary Air

TA

TA
PA

SA

PA
SA

Precalciner Preheater Arrangements

1 or 2 strings

In-Line

Off-Line

2 strings only

Pre-Combustion
Chamber

Hybrid

Separate Line

Comparison of Calciner Arrangements

Requirements I
Process:

High calcination degree

Good control of calcination degree
No material drop-out (meal, ashes etc)
No build-ups on walls
Simple and rapid start-up procedure
Forgiving operating behaviour
Flexibility regarding fuel ratio BZ / PC
Safe regarding equipment overheating
Minimum primary air requirement
Minimum pressure drop

Requirements II
Combustion:

High burnout degree of fuels

Best mixing of air (O2) with fuel
Instant ignition of all fuels
Direct return of fuel residues to kiln
Optimum combustion monitoring / control
Fuels:

Suitable for all fuel types (high flexibility)

Insensitive to changes of mix of fuels
Suitable for low reactivity and toxic fuels

Requirements III
Emissions:

Reduction of pollutants from BZ

No (low) generation of pollutants in PC firing
Possibility for SNCR
Tertiary Air System:

No dust deposits and dust cycles

No hot dust handling
Reliable O2-control for BZ and PC firing
Design:

Easy integration in preheater

Stepwise upgrading possible
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Precalciner Control
Via Fuel Rate

Normally 45% to 60% of total fuel

According to Calcination Degree

of bottom cyclone hot meal (via LOI);

Normally 85% to 95% apparent calcination degree
According to Gas Temperature at exit of bottom

cyclone;
Normally 840C to 890C

True and Apparent Calcination Degree

True calcination degree:

Degree to which the calcination is completed, i.e. extent

to which the CO2 is dissociated from the CaCO3.
Extremes: Raw meal
0%
(LOI=35%)
Clinker
100% (LOI= 0%)
Apparent calcination degree:

The calcination degree determined from a hot meal

sample taken from the meal duct of the bottom cyclone

O2 Control for PC/BZ: Tertiary Air Damper

pID fan

pC5 exit

Var. Dp1
Dp2
~pamb
/

O2 Control for PC/BZ: Kiln Riser Orifice

pID fan

pC5 exit

~pamb

Dp1
Var. Dp2
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Precalciner Elements
Long tubes gooseneck type
Large volume vessel type
Tertiary air frontal impact

Tertiary air tangential inlet

Orifice
Bends, curves and vessels
Multiple burners

Hot spot with and without control

Precombustion chamber

Dimensioning Criteria for Precalciners

1. Gas Retention Time (for combustion in pure air)

decisive for complete combustion

Fuel Reactivity
low
medium
high

Gas Retention Time

> 3.5
sec
> 2.5
sec
> 2.0
sec

2. Meal Retention Time

decisive for complete calcination

Actual meal retention times are 6 to 12 seconds,
at the above gas retention times.

Calcination takes much less than that which

means that meal retention time is not a
decisive design criteria.

Fuel Reactivity Examples:

Low:
Petrol coke
Medium:
Bituminous coal, natural gas
High:
Lignite, fuel oil
Inline Calciners:
Due to less favourable conditions for combustion
(presence of kiln gas, imperfect mixing of
tertiary air with kiln gas), the following rule of
thumb can be used for sizing this PC type:
Recommended gas retention time + 0.5 to 1 sec

Standard Precalciners
In-Line and Off-Line AT
FLS, KHD, KSL, Polysius

In-Line Calciners I

Polysius PREPOL
gooseneck type

In-Line Calciners II

FLS ILC
controlled hot spot

Pre-Combustion Chambers
RSP (Technip), FCB, Polysius, FLS

Calciners with Precombustion Chambers I

Onoda / CLE RSP (~1985)

Calciners with Precombustion Chambers II

FLS SLC-D
Downdraft (~2000)

Low NOx Precalciners

FLS, KHD, Polysius a.o.

Low NOx Precalciners

Polysius PREPOL
MSC
(Multi Stage Combustion)

KHD PYROCLON
Low NOx-Topair

Precalciners for Lump Fuels

(Tires etc): Future Development
FLS, Polysius, KHD,
Blue Circle, Ash Grove

PC for Solid AFR: FLS Hot Disc

FLS
Hot Disc

PC for Solid AFR: BC-Lafarge AFR Ram

Ash Grove
Controlled Ram for AFR modules
(Patent 2001)

Pre-Calciner: Typical Problems

1) CO at outlet
of PC or cyclone

5) Material
build-ups

6) Refractory
damage

2) Locally too
high temp.

7) Tertiary air
damper failure

3) Unburnt fuel
particles in
hot meal

8) Tertiary air duct

blockage
(elbow type only)

4) Too high / low

calcination
degree
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Main Benefits of Precalciner Technology

1. More stable kiln operation due to better kiln control via two separate
fuel feed/control points
2. More stable kiln operation due to controlled meal conditions at kiln inlet
3. Reduced thermal load of burning zone

4. Lower refractory consumption as a result of 1. to 3.

5. More than double capacities possible with given kiln (10'000 t/d: 6 x 95m)
6. Possibility of increasing capacity of existing kilns

7. Reduced volatilisation of circulating elements

8. Reduction of cycles (S, Cl, Na2O, K2O) with lower bypass rate / losses
9. Makes short kilns possible with 2 stations, L/D < 12
10. Possibilities of NOx reduction
11. Lump fuel (AFR) utilization (in-line only)
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