Advantages of Precalcination :

Large capacities achievable

Possibility to extend the capacity of
existing plants
Small dimensions of kiln tube

Low specific thermal load in kiln tube

Possible application of low grade fuels
in the precalciner
Advantages of Precalcination :
Problems caused by circulating elements
can be better solved

Increased refractory life time in the

burning zone
Low Nox emission
More stable kiln operation

High kiln availability

Disadvantages of Precalcination :

Higher exhaust gas temp. & heat

consumption ( very minor increase )
Higher pressure loss over the preheater

Increased complexity of the kiln

system
The Circulating load, efficiency and
Tromp-value can be calculated as follow:

Temp. difference between gas &

precalcining stage should be as low as
possible

Combustion of fuel in precalciner

should be complete even at low
excess air ( 2 % O2 )
Calcining of Raw Meal :

CaCO 3 ⎯⎯→
⎯ CaO + CO 2
heat
EXO

Heat absorbed

Heat produced
ENDO
0 200 400 600 800 1000
TemperatureoC
EXO EXO
Clinkerization Clinker
Cooling

ENDO ENDO
1200 1400 oC
S - Curve
100

% Calcining 80

60

40

20

600 700 800 900 1000

Temperature0C
The combustion in the precalciner takes
place under quite different conditions
compared to the main firing
The temp. of the combustion environment is
in the order of 850 to 900 oC

Some P.C. systems use pure air for

combustion “off-line & separate line
systems”, while other use an air-gas
mixture In line systems”
The combustion in the precalciner takes
place under quite different conditions
compared to the main firing
In all P.C. systems preheated raw raw meal
is suspended in the combustion air of air gas
mixture respectively in order to absorb the
heat released, thereby maintaining the
temp. at a comparatively low level.
Parameters influence on the combustion
performance
Optimal distribution of the fuel
Retention time for combustion has to be
sufficient
The flow pattern of the air or air-gas
mixture has to be favourable to the
combustion
The raw meal distribution in the
combustion has to be optimal
Performance of P.C. systems can primarily be
judged on two characteristic value

Temp. difference between gas &

precalcining stage should be as low as
possible

The completeness of the Combustion

influence the overall heat consumption
of the system
Specific Heat Consumption

True & apparent calcination

True & apparent calcination degree
Calcination degree is the main
parameter used for controlling the
precalciner operation in P.C. system
True calcination degree
Degree to which the calcination is
accomplished

Apparent calcination degree

Factors which can limit the maximum
possible degree of waste fuel usage

Clinker properties must not be affected

The input of circulating elements must

not be excessive
The combustion characteristics of the
fuel must not be poor to the degree of
having low ignition in the calciner

Must be no emission of toxic products

Basic arrangement of precalcining systems

Special
Arrangement of
AS-GROUP

Precalciner
Kiln String
String
Advantages of the two string :

Easy control of gas flow in both strings

without throat part or damper in hot gas
ducts.

Start up operation like for normal SP kiln

 Comparison of AS & AT system
Item
• Portion of fuel to the precalciner
• Largest kiln in operation
• Kiln ∅ for given
capacity ( 4 st SP = 100%)
• Suitable type of cooler
Suitability for extension of existing SP kiln
• Burning conditions in rotary kiln
Thermal load in burning zone ( 4 st SP =
100%)
Behaviour regarding circulating elements
Heat loss at 10 % bypass ( 4 st SP = 100%)
Exhaust gas temperature ( 4 st-preheater )
(280°C)
• Heat consumption
• Pressure loss over
preheater
AS AT
up to 65 % max. 35 %
10000 t/d , ∅ 6.2 x 105 m 4700 t/d ,∅ 5.2 x 80 m
approx. 75 - 80 % approx. 85 - 90 %
only grate or rotary coolers all types
poor tertiary air duct very good for low P.C. rates
normal flame temperature lower flame temperature and stable operation due to
( normal excess air ) high excess air (20 - 30 %)
approx. 60 - 70 % at 60 % P. C. fuel approx. 85 - 95 % at 30 % P.C. fuel
like 4 st SP kiln due to the high O2 - content of the kiln atmosphere ,
reduced volatility of sulphur and therefore decrease
of encrustation in transition zone and riser pipe
approx. 40 % ( bypass will be smaller than in 4 approx. 90 % ( bypass will have same size as in 4 st
st SP kiln ) SP kiln )
higher than 4 st SP (295°C) higher than 4 st SP (285°C)
slightly higher than 4 st SP slightly higher than 4 st SP
higher than 4 st SP slightly higher than 4 st SP
In line , off line & separate line calciners :
In line calciner
The gases supplied to the calciner will mix
with the hot gases from the kiln inlet
Off line calciner
The gases supplied to the calciner are
provided via tertiary air duct
Separate line calciners
It is an offf line calciner with additional
string taking the hot gases from kiln inlet
Comparison of calciner Arrangement
Advantages Low NOx version Suitable for modification. Two independent combustions
(reducing kiln NOx ). Easy combustion control

Excess air used for combustion. Good combustion. Good combustion

Suitable for lump fuel. Suitable for modifications. Suitable for modifications.
Weak points Mixing of air with gas Higher peak temperature ( NOx ! Higher peak temperature ( NOx ! )
)
Larger volume required P.C. dropout can fill TAD P.C. dropout can fill TAD
Incomplete combustion Asymmetry regarding circulating elements
Requires 2 strings
Height requirement (depending on ( not feasible for < 3000 t /d )
type / design )

Strings of different sizes

( problem > 7000 t/d )
Design features
of precalciner
Sketch of
AS & AT
System
 AS System
with two
separate string
Advantages of precalcination

Large AT & very large AS capacities

with still acceptable kiln dimensions &
thermal load in the burning zone
Low temp. combustion requirement
requirements in the precalciner allows
the use of low grade “junk” fuels

High bypass rates are possible without

too high heat losses.
Advantages of precalcination

Reduction of brick consumption in the

burning zone

Lower Nox emission due to combustion of part

of the fuel at lower temp. in the precaliner

The partition of the fuel requirement between

rotary kiln & precalciner enables a better
control of kiln operation
Increased refractory life & more stable kiln
operation can increase kiln availability
Disadvantages of precalcination

Increased exhaust gas temp. & heat

consumption

Increased pressure drop over the preheater due

to the precalciner & possible kiln gas & tertiary
air throttling

The precalciner itself, the additional fuel

preparation, dosing, transport & firing system
, an eventual tertiary air duct increase the
complexity of the system and therefore also
the risk of shutdown
Calciners
from FCB
 Pyrotop
Calciner

Meal
Fuel
Low NCx fuel
Flow pattern
in Pyrotop
Calciner
Calciner from
FLS- Fuller
Pyroclone Calciner KHD
Repol Calciner
“Polysius”
Prerov Calciner
Arrangement of the counter current raw mix
preheater of the Prerov Eng. work
P.C. Systems worldwide
PC System Units Total Capacity Total Capacity
t/d %
FLS 38 99’000 11.4
Prepol 50 146’000 16.8
Pyroclon 55 123’000 14.2
EVS-PC 5 8’500 1.0
SF/NSF 59 188’000 21.6
RSP 43 127’000 14.?
KSV/NKSV 11 40’000 4.6
MFC/N-MFC 24 71’500 8.2
GG 2 7’000 0.8
DD 9 32’000 3.7
CSF 3 9’000 1.0
SCS 5 18’000 2.1
Total 304 869’000 100.0
P.C. Systems worldwide
PC System Units Total Capacity Total Capacity
t/d %
FLS 38 99’000 11.4
Prepol 50 146’000 16.8
Pyroclon 55 123’000 14.2
EVS-PC 5 8’500 1.0
SF/NSF 59 188’000 21.6
RSP 43 127’000 14.?
KSV/NKSV 11 40’000 4.6
MFC/N-MFC 24 71’500 8.2
GG 2 7’000 0.8
DD 9 32’000 3.7
CSF 3 9’000 1.0
SCS 5 18’000 2.1
Total 304 869’000 100.0
Flash furnace, stage IV, & feed hood of the
“SF” Precalcining system
Features of
MFC PC
System
Features
of RSP
PC
System
Features
of KSV
NKSV
PC
System
Features
of KSV
NKSV
PC
System
DD - PC
System
Fratures
of
GG PC
System
CSF PC
System
 SCS
PC
System
 Voest
Alpine
PASEC
System
PASEC Precalciner Process can achieve
lower heat consumption

Choice of a PC system

Future development
 In Closed
Grinding Circuit

Grinding Process

Influenced By Separation