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IN THE KILN
Spurrite and
Sulfo-spurrite ring
In calcining zone
Reduction in kiln
Diameter due to
Ring formation
Hard Burning
Due to the presence of
Calcite and Quartzite
Fuel characteristics
Volatile
recycling
Selection of
refractories
SINTER RING
In general, chemical composition of the sinter ring material is that of
the clinker with no appreciable concentration of volatile elements.
From a mineralogical viewpoint, the normal clinker minerals like alite,
belite and free CaO are observed. The bonding mechanism
responsible for sinter ring formation is the freezing of the clinker.
The rings, depending on their origin, may be dense or porous, and
may develop slowly or just in a few hours. The first symptoms of
ring formation are:
A higher negative pressure before the exhaust fan.
Incomplete fuel combustion as indicated by "CO" analyzer.
Intermittent charge retention.
Abnormal temperature gradients in the kiln shell.
Higher amperages in the kiln motor.
The reasons for ring formation, well agreed between many plant
operators, may be classified in three groups:
Process.
Operation.
Maintenance.
The next group deals with operation troubles that can lead to
ring formation. These are:
Discontinuous feed.
Material segregation.
Flame pattern and position.
Improper combustion.
Successive kiln upsets.
Calcium Langebeinite
K2Ca2(SO4)3
>1250
______
Closed pores
Open pores
Silica infiltrated surface or vitrified surface on brick can avoid infiltration of low melting ,low
Viscous components .This avoids destruction of refracories but spurrite rings cannot
be avoided fully. Properly balanced chemistry , well tuned flame with hot and oxdised
conditions and properly operated kiln and Calciner can only elimiinate ring formation or
reduce the aggravation.
Uniform coating
Preferably 5 or 6 %
Of the diameter
Spurrite Rings:
Carbonate or spurrite rings are formed through
CO2desorption into
the freshly formed free lime, or even through belite
recarbonation. These rings are hard, layered, and exhibit the
same chemistry as regular clinker. X-ray diffraction however,
clearly indicates the presence of spurrite, a mineral with
composition C2S.CaCO3.
Spurrite is a form of carbonated belite. When the carbonate in
the spurrite is replaced with sulfur the new mineral is called
sulfated spurrite. Spurrite rings form whenever the partial
pressure of CO2 above the bed of material is high enough to
invert the calcining
reaction. In coarsely ground, silica-rich raw mixes, the free lime
does not have sufficient time in the calcining zone to react with
silica, therefore increasing the chances for spurrite deposits.
Alkali rings:
The third type of ring occurs whenever the sulfur-to-alkali
molal ratio is( encrustration index)
less than 0.83, usually in kilns with heavy chlorine loads. In such
cases, low-melting potassium salts provide the binder for clinker
dust travelling up the kiln. Through a "freeze-and-thaw"
mechanism, these rings can assume massive proportions. Alkali
rings are far less common than other types because sulfur and
carbonates usually are in excess relative to potassium. In lime
recovery kilns, for example, where alkali is always in excess of
sulfur, severe ringing and balling sometimes occur.
around
1200 deg c
This is the result of bad flame which I witnessed In my own plant in my short
tenure. 72 hours stoppage , loss of 11000 tons of clinker or 11 million Indian
rupees as net cash loss. More over it is an unsafe activity
Favorable temperature
profile
1500
degc
1200
1000
Long flame ,high back end temperature ,high volatile recycle
Favorable area for spurrite ring
formation
Unfavorable Temperature
profile, flat
1500
1200
Less sulfur volatile absorption and formation of more
thermally unstable stable sulfites of alkali and calcium
1000
The burner can be more inclined ,shape the flame closer to the ring which reduces the
Thickness. The jack and knuckle ball arrangement in the telescopic piece allow this
up and down motion Which only Nova flam has.
Fives Pillards novaflam got the ability to slice the ring and
avoid 3 days Stoppage.
The burner can be more inclined ,shaped the flame closer to the ring which reduces the
Thickness. The jack and knuckle ball arrangement in the telescopic piece allow this
up and down motion Which only Nova flam has..Caution extra care must be taken
When High alumina bricks are used which is inferior in its thermal properties than
magnesite Bricks.
Pillard s Novaflam got the ability to slice the ring and avoid 3 days
Stoppages.
Shark teeth
Shark teeth forms when ash in coal is high and high dust circulation from cooler to kiln.
This makes the clinker more sticky and many occasions lead to snow man formation on
Static cooler and rhino horn on burner. Chemistry ,if it is not controlled can lead to dusty
Clinker and shark teeth at the kiln tip.By pushing the burner in and adjusting flame gives
great relief to this problem.Cooler air distribution also reduces this problem.
Shark teeth lead segregation in the clinker discharge and leads to red river in the cooler .
By simple to and fro movement of swirler tip and by alteration of primary air
Pressure at burner inlet , can change length and shape of the flame.
Novaflam is user friendly ,simple and very versatile burner.
Do you need a old time master burner who does jugglery now and then to tune the flame
by adjusting two or three valves for axial,radial and stabilising air like a
magician on the Stage. Nova flam says NO.
Novaflam has simple operation unlike
DdD
complicated operation with other burners. More user friendly than any other burner.