Cemeng Dragon Calciner:

An Alternative Option
D.S. Venkatesh,
Freelance Tech. Consultant, Bangalore
Here is a novel and innovative approach, when existing preheater/precalciner is a bottle-neck for
enhancing Clinker output of existing dry process cement plants and also contain GHG emissions, by way of
capturing CO2 by further processing techniques.
1.0 Introduction:
More often, every dry process cement plant finds that the rotary kiln will have substantial untilised production
potential and the clinker cooler can be easily upgraded, the preheater/precalciner set up along with exhaust fan
remains a bottleneck in enhancing clinker production for upgrading existing clinkerisation plant. The so-called
mini cement plants in India or elsewhere based on conventional Suspension Preheater and Rotary kiln have been
upgraded by recourse to In-line Precalcinator technology for enhanced productivity, though there may be a few
installations still operating without. Higher capacity plants have installed Precalciners in the hot air stream from the
Clinker Cooler, with a separate suspension Cyclone preheater stream in spite of high system pressure drop. Fluidised
Advanced Clinkering Kiln technology by M/s Kawasaki. Japan replaces rotary kiln and clinker grate cooler but
conventional suspension cyclone preheaters and precalcinator are retained. Oxy-fuel combustion is being advocated
for reducing the CO2 emission levels. Can there be a choice in place of Cyclone preheater/precalciners for
preheating and pre-calcining the raw meal? Perhaps, Cemeng Dragon Calciner Technology can be a better choice to
function equally well with either rotary kiln or Fluid bed Advanced Kiln system and Oxy-fuel combustion systems.
2.0 What is inside a Cemeng Dragon Calciner?
Cemeng Dragon Calciner is an apparatus for heating and optimum calcination of powdered raw materials
developed employing time tested simultaneous indirect and direct heating principles. The Calciner comprises of a
battery of serpentine pipes of heat resisting metal alloys housed within the chimney of a hot gas generator utilizing
heat in the exhaust gases, enabling the heating of pipes exteriorly for indirect heat exchange. Simultaneously, direct
heating of raw materials in the pipe is achieved by addition of suitable solid fuel while preparing the raw materials.
Compressed air/Oxygen carries the meal through the pipes. Alternately, superheated steam is injected into the pipes.
Steam acts as a catalyst for calcination process.
2.0 Construction Details of Cemeng Dragon Calciner:
The pipe can be of any shape formed as a serpentine, flat or helical spirals arranged in spaced superposed relation.
The pipe is continuous and is preferably formed or bent so that the pairs of coils are connected at their inner ends
and pairs of the same are connected at their outer ends. This is the preferred construction. The turns in the coiled
pipe are staggered or out of alignment providing torturous passages for the ascending heated gases and establish
maximum contact with it.. The length of the pipe is not limited but can be as necessary to preheat and precalcine the
material contained within. Connected with the upper end of the preheating pipe is a compressed air supply pipe
equipped with a cut off valve. The schematic arrangement of the Dragon Calciner is shown in figure below:

Cemeng Dragon Calciner

Pipe flat Spirals

Calciner with Rotary

Kiln

Pipe with fins

Dragon Pipes Arrangement

Heat resistant Coating

3.0 How Cemeng Dragon Calciner functions:

Dry powdered raw material is fed along with compressed air/Oxygen into the intake end of pipe such that it is sealed
against back pressure, and the outlet end of the pipe is open for discharge. The powdered solid material has voids
between its minute particles, which voids are filled with air/Oxygen. While at atmospheric temperature, it would be
impossible to properly force the powdered raw meal through the preheating pipe without injecting air/Oxygen into
the same, as it would pack within the pipe, but when heated to a sufficiently high temperature, it flows freely and is
converted into a form having the characteristics of a liquid and readily passes through the preheating pipe without
injecting air into the same. Satisfactory results can be obtained by heating to a temperature of from 500deg F to
2500deg F in case of cement raw materials. The expansion of the heated air/Oxygen within the material confined
within the pipe as also the liberated Carbon di oxide from partial or complete calcination in the pipe propels the
material through the pipe, not impairing the fluid properties of the heated materials.
Pet coke breeze or fines would be appropriate for simultaneous and combined grinding along with raw materials, as
it has high ignition point. The amount of solid fuel forming constituent of powdered raw materials mix or black meal
would be to suit preheating of the material and the required degree of calcination .The compressed air/Oxygen
injected would be as required for combustion of the fuel in the black meal. along with about five percent of excess
air. Superheated steam at high temperature and pressure, when used, could be injected after the preheating stage to
provide the heat required for calcinations. Residence time of materials in the calciner is predominantly dependent on
amount of Compressed air/Steam injection, viz velocity of flow. At the discharge end of the Pipe, the calcined
material ejects out along with the stream of hot exhaust gases, comprising air/steam and carbon di oxide due to
burning of fuel as also that released from raw material from de-carbonization, if so required, facilitating separation
of material and gas stream through a separator.

4.0 Advantages of Cemeng Dragon Calciner:

Cemeng Dragon Calciners offer the advantage of flameless combustion of fuel and no additional burner and
accessories are required. As the black meal flows through the Pipe calciner, the fuel in meal gets burnt to heat the
raw meal progressively to calcining temperature and then calcine the material. Besides, the material conveying
air/Oxygen Itself would be the combustion air for the fuel, thus no additional blowers are required. Further, after the
discharge of calcined material, the hot exhaust gases are deflected to ascend through the calciner to utilize the
available heat to the maximum extent, and providing additional heat for the calcination process. It would be
necessary to install only a start up burner for the hot gas generator forming part of the Dragon Calciner apparatus.
Thus these can be stand-alone units.
Cemeng Dragon Calciner has versatility and its geometry is highly flexible in view of different possible shape
configurations. The required residence time for the meal in the calciner can be altered by changing the quantum of
conveying air or selecting suitable pipe cross-section to maintain requisite flow velocity within wide limits. The
large surface area of pipes would be beneficial for exterior heat exchange from exhaust gases. The pressure drop in
Calciner will be as low as 250 mm wg. The foot print for Cemeng Dragon Calciner would be considerably less when
Compared with suspension cyclone preheater/precalciners.
Cemeng Dragon Calciner can function equally well with either a rotary kiln or fluidized bed kiln where the calcined
material discharged from calciner is subject to clinkerisation. The rotary kiln can now be effectively used up to its
furnace capacity limits and the kiln exit gases directed through the Dragon Calciner. Besides, clinker cooler hot air
can be gainfully utilized for production of superheated steam by installing a suitable boiler at Clinker cooler. The
superheated steam generated can be transported to the Cemeng Calciner, thus, eliminating the larger tertiary air
ducting set up.
Carbon di oxide is considered to be the major source of GHG responsible for global warming; man-made CO2
contributes approximately 63.5% to all greenhouse gases. The cement industry is responsible for approximately 5%
of global anthropogenic carbon di oxide emissions emitting nearly 900 kg of CO2 for every 1000 kg of cement
produced. Cemeng Dragon Calciner offers a way, when superheated steam is used, to capture CO2 by further
processing techniques and reduce CHG emissions.

For Re-engineering, please contact:

D. S. Venkatesh,
Freelance Tech. Consultant,
# 105, Seventh Cross, Bilekahalli Dollar Layout,
BTM 2nd Stage, Bangalore 560076
Phone: 91 080 26688098 Mob : 09342816950
E-mail: dsvenkatesh40@yahoo.com
Referece : References for materials in this article will be provided on request