Session 3.3 Precalcination

CemNet Training - Course TCM01
Module 3 - Session 3
Cement Manufacturing
Technology
3. Pyroprocessing raw mix to cement clinker.
3.3. Precalcination.
Cement Technology Training
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination
At the end of session 3.2 we saw that the increasing thermal loads
inflicted on the burning zone, as cement kiln capacities rose,
effectively capped long and preheater capacities at ~3000 tonnes per
day.
Today, new cement kiln
projects of 10,000 tonne
per day capacity are
commonplace, as cement
companies seek the
economies of scale which
high capacity kilns can
deliver.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination
day.
These high capacities could
never be achieved with all
the thermal energy
requirements and fuel
supplied through the main
burner of the kiln.
2005
3. Pyroprocessing
This document is for the sole use of students enrolled on course TCM01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd 2005
http://training.CemNet.com
Cement Technology
3.3 Precalcination
day.
Kiln linings with sufficient
refractoriness to withstand
the burning zone thermal
loads involved are not
available.
The solution to this
problem was delivered by
precalcination technology.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination
In session 3.1 the chemical reactions and thermodynamics of the

conversion of raw materials to cement clinker were described.
The evaporation of any residual water, dehydration of clay
minerals, CaCO 3 calcination and clinker flux formation are all
endothermic and consume large amounts of energy.
Calcination of the CaCO 3 is
the most energy consuming
and endothermic of these
reactions.
3000
2000
1000
C3S
formation
Clinker flux
formation
Deydration of
clay minerals
Calcination of
limestone
Evaporation
of Water
0
-1000
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination
In session 3.1 the chemical reactions and thermodynamics of the

conversion of raw materials to cement clinker were described.
The evaporation of any residual water, dehydration of clay
minerals, CaCO 3 calcination and clinker flux formation are all
endothermic and consume large amounts of energy.
3000
2000
1000
C3S
formation
Clinker flux
formation
Calcination of
limestone
Deydration of
clay minerals
Evaporation
of Water
0
-1000
2005
The solution to the burning zone

thermal load problem was to direct
the thermal energy input to the
point in the kiln where this reaction
is taking place, rather than inputing
all the thermal energy through the
main burner.
3. Pyroprocessing
Cement Technology
3.3 Precalcination
A precalcination furnace was added at the base of the preheater.

In the in-line configuration shown, the precalcining
furnace is installed in the gas riser from the back of the
rotary kiln.
.to the lowest stage of the preheater.
Fuel
60% of the total kiln fuel requirements are fired in this

precalciner, relieving the burning zone of the
associated thermal load.
.and directing the
Fuelfuel input to the calcination of CaCO , where the
3
energy is absorbed by the calcination reaction.
FL Smidth In-line (ILC) precalciner
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

As the fuel is being directed to the energy consuming,
endothermic, calcination reaction of the CaCO 3 the
temperature in the precalciner furnace remains constant
between 860~900C.
The endothermic calcination reaction absorbs the
thermal energy input in the fuel and prevents the
temperature in the precalciner from rising.
Fuel
Fuel
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

Preheated combustion air is separately ducted to the
precalciner from the cooler via the tertiary air duct.
Never-the-less the vitiated combustion product gases
from the rotary kiln, with their high CO 2, H 2O and N 2
content are also passing through the precalciner.
Fuel
These dilute the oxygen in the tertiary combustion air

and suppress the combustion of the fuel in the
precalciner.
Meaning the precalciner must be
Fuel
Tertiary combustion air
over-dimensioned to ensure
adequate burn-out of the fuel.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

These combustion problems in the in-line precalciner
configuration were overcome by the development of
separate-line precalciner technology.
The vitiated exhaust gases from the rotary kiln are
directed through their own, dedicated preheater tower.
Fuel
The tertiary combustion air for the precalciner is

separately ducted to the precalciner with the calciner
combustion products directed to their own dedicated
Fuelpreheater tower.
Tertiary combustion air
FL Smidth Separate-line
In-line (ILC) precalciner
(SLC) precalciner
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

As the precalciner fuel is fired in pure tertiary air with
23% oxygen by mass the problems of poor combustion
are eliminated with separate-line precalciner
technology.
FL Smidth Separate-line
In-line (ILC) precalciner
(SLC) precalciner
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

The necessity for twin preheater towers was
overcome by offsetting the precalciner furnace
from the gas riser, therefore meaning that the
vitiated kiln exit gases do not pass through the
precalcalciner.
FL Smidth Separate-line-downdraft (SLC-D) precalciner
The tertiary combustion air for the precalciner is Fuel

separately ducted to the precalciner.
Fuel
Precalciner fuel is fired in pure, preheated tertiary

air containing 23% oxygen by weight.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

The necessity for twin preheater towers was
overcome by offsetting the precalciner furnace
from the gas riser, therefore meaning that the
vitiated kiln exit gases do not pass through the
precalcalciner.
FL Smidth Separate-line-downdraft (SLC-D) precalciner
The combustion products from the precalciner are

then drawn down into the gas riser from the kiln.
Firing in pure tertiary air and the long residence
time of these precalciners makes them particularly
suited to low volatile fuels (petroleum coke)., or alternative fuels.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination
Precalcination technology has resulted in a step change in the

production capacity of cement kilns.
Long wet cement kilns typically have a length to diameter ratio
of 50:1..
..and might be supported on 5 or more tyre and
roller stations.
L = 50xD
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

Long wet cement kilns typically had a length to diameter ratio of
50:1..
roller stations.
They can extend to well over
200m in length and have
production capacities of 1
million tonnes per year.
Although less than 200m in
length and production
capacities of ~_ million tonnes
per year is more normal.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

Long wet cement kilns typically had a length to diameter ratio of
50:1..
roller stations.
Specific production capacity
is typically 0.55 tpd/m 3 of
the internal volume of the
rotary kiln.
Exceptionally this specific
output might be as high as 0.8
tpd/m 3.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

The feed to a long wet cement kiln is a slurry of the raw materials
with >30% water content.
Evaporating this water from
the slurry is the first process
in the rotary kiln.
This evaporation consumes
~1000 kJ of thermal energy per
kg of clinker increasing the
overall thermal energy
consumption to 5000 kJ/kg, or
significantly higher.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

Heat exchange between the kiln gases and the feed at the back of
the rotary kiln is inefficient, and therefore festoons of chains are
hung from the inside of the kiln shell to pick up the feed material
and promote this heat exchange.
These chains typically extend to 70%
of the internal diameter of the kiln
.. and 30% of the length of the
kiln.
2005
0.7D
3. Pyroprocessing
Cement Technology
3.3 Precalcination

Heat exchange between the kiln gases and the feed at the back of
the rotary kiln is inefficient, and therefore festoons of chains are
hung from the inside of the kiln shell to pick up the feed material
and promote this heat exchange.
Efficient, well maintained chain
systems combined with chemical
dewatering agents are required to
reduce the thermal energy
consumption to 5000 kJ/kg clinker
and boost the kiln output to 0.8
tpd/m 3
2005
Cement Technology
0.7D
3. Pyroprocessing
3.3 Precalcination

Long dry cement kilns typically have a length to diameter ratio of
35:1.. ..and again might be supported on 5 or more
tyre and roller stations.
L = 35xD
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

They can extend to 160m in
length and have production
capacities of _ million tonnes
per year.
Although 300,000 tonnes per
year is a large long dry kiln.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

These kilns are particularly
suited to desert climates where
there was no water available to
slurry the raw materials.
Thermal energy efficiency is
better than long wet kilns as the
water in the slurry does not
have to be evaporated.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

Festoons of chains are again
used to promote heat exchange
between the feed and kiln gases
at the back of the kiln.
However, as the feed is a dry
powder these kilns are prone to
high dust losses.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

Festoons of chains are again
used to promote heat exchange
between the feed and kiln gases
at the back of the kiln.
These dust losses adversely
impact on the thermal
efficiency and productivity of
the kilns.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

4900 kJ/kg clinker is the typical
fuel consumption, which
exceptionally can be reduced to
below 4000 kJ/kg with highly
efficient chain systems.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

Specific productivity of 0.7
tpd/m 3 of the internal volume of
the kiln is typical.
Exceptionally this can be raised
to 0.9 tpd/m 3 of the internal
volume of the kiln.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

The first major innovation away from long kilns was the Lepol
process developed by Otto Lelep and delivered by Polysius.
These incorporate a drying
and calcining chamber
before the rotary kiln.
The dry kiln feed powder is
mixed with ~9% water in a
nodulising pan, and the
resulting nodules are fed to
a travelling grate within the
chamber.
2005
3. Pyroprocessing
Cement Technology
3.3 Precalcination

A travelling grate transports
the nodules of kiln feed
through the Lepol chamber.
Drying
Calcining
The chamber is divided into

drying and calcining
chambers.
Hot gases from the kiln are drawn successively through the bed
of material on the grate passing through the chambers.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

A significant proportion of
the thermal work is taken
out of the rotary section of
the kiln and transferred to
the drying and calcining
chambers of the Lepol
grate.
Intimate contact between hot kiln gases and the feed on the
grate results in efficient preheating and calcination.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

A significant proportion of
the thermal work is taken
out of the rotary section of
the kiln and transferred to
the drying and calcining
chambers of the Lepol
grate.
Thermal energy consumption can be as low as 3200 kJ/kg
clinker, although 3750 is more normal.
2005
3. Pyroprocessing
10
Cement Technology
3.3 Precalcination

Lepol cement kilns typically have a length to diameter ratio of
25:1.. ..and are supported on 3 or 4 tyre and roller
stations.
L = 25xD
Annual capacity in excess of 500,000 tonnes of clinker per year

are achieved by the largest Lepol kilns.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

stations.
L = 25xD
Specific output is normally around 2.0 tpd/m 3, and exceptionally

might be 2.5 tpd/m 3 or higher.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

stations.
L = 25xD
Taking the preheating and part of the calcination out of the rotary
kiln and into the Lepol chamber therefore more than doubled the
specific output of cement kilns compared with long kilns.
2005
3. Pyroprocessing
11
Cement Technology
3.3 Precalcination

The main problem faced
with these kilns are high
wear rate and maintenance
costs associated with the
Lepol grate.
These operate with green
nodules at ambient
temperature at the inlet.
3. Pyroprocessing
2005
Cement Technology
3.3 Precalcination

In the 1950s suspension preheater technology was developed, and
this was widely installed from the 1960s.
All modern cement kilns
incorporate suspension
preheaters.
3. Pyroprocessing
2005
Cement Technology
3.3 Precalcination

Hot exhaust gases from the rotary kiln are
drawn up through the successive stages of the
preheater tower.
Heat exchange between the feed descending
the towers takes place in the gas risers
between the successive collection cyclones of
the preheater.
FL Smidth Suspension Preheater (SP)
2005
3. Pyroprocessing
12
Cement Technology
3.3 Precalcination

preheater tower.
Feed is alternately lifted into the cyclones,
while being preheated, and collected in the
cyclones and passed down to the next stage of
the preheater.
All the preheating and 25~30% of the
calcination is again taken out of the rotary
section of the kiln.
3. Pyroprocessing
2005
Cement Technology
3.3 Precalcination

preheater tower.
Feed is alternately lifted into the cyclones,
while being preheated, and collected in the
cyclones and passed down to the next stage of
the preheater.
Suspension preheaters have virtually no
moving parts and therefore eliminated the
wear problems of the Lepol grate.
3. Pyroprocessing
2005
Cement Technology
3.3 Precalcination

Thermal energy efficiency can be boosted by
the addition of more preheater stages.
Preheater exit gas temperature will reduce by
~30C for each additional preheater stage,
from ~360C for a 4-stage preheater, to
~330C for a 5-stage preheater, to ~300C for
a six stage preheater.
However, civil costs and pressure drop across
the preheater tower rise with each additional
preheater stage.
2005
3. Pyroprocessing
13
Cement Technology
3.3 Precalcination

We will discuss the design and operation of
suspension preheaters further in a later session
of the course.
3. Pyroprocessing
2005
Cement Technology
3.3 Precalcination

Thermal energy consumption of 3500 kJ/kg
clinker is typical, although this can be reduced
to 3000 kJ/kg clinker in exceptional cases.
Specific output of 2.10 tpd/m 3 is typical,
although in excess of 2.70 tpd/m 3 can be
achieved in exceptional cases.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

With the addition of precalcining furnaces at the base of the
preheater and before the rotary kiln all the thermal work of
precalcination has been taken out of the rotary section of the kiln.
Typical kiln productivity
has risen to over 4.10
tpd/m 3.
The length of these kilns
has reduced to 70m, or less.
2005
3. Pyroprocessing
14
Cement Technology
3.3 Precalcination

The space required and
footprint of modern
precalciner kilns is only _
that of long wet kilns..
while, output has been
more than tripled to over
10,000 tonnes per day with
the largest precalciner kilns.
2005
Cement Technology
3. Pyroprocessing
3.3 Precalcination

Some Indian cement
companies have been able
to boost the output of their
kilns to over 7.00 tpd/m 3.
We will explore the ways
they have done that in
succeeding sessions of the
course.
2005
3. Pyroprocessing
Cement Manufacturing
Technology
3. Pyroprocessing raw mix to cement clinker.
3.3. Precalcination.
2005
3. Pyroprocessing
15

Session 3.3 Precalcination

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CemNet Training - Course TCM01

Cement Technology Training

Cement Technology Training

CemNet Training - Course TCM01

In session 3.1 the chemical reactions and thermodynamics of the

Cement Technology Training

In session 3.1 the chemical reactions and thermodynamics of the

Cement Technology Training

The solution to the burning zone

CemNet Training - Course TCM01

A precalcination furnace was added at the base of the preheater.

60% of the total kiln fuel requirements are fired in this

Cement Technology Training

A precalcination furnace was added at the base of the preheater.

FL Smidth In-line (ILC) precalciner

Cement Technology Training

A precalcination furnace was added at the base of the preheater.

These dilute the oxygen in the tertiary combustion air

Cement Technology Training

CemNet Training - Course TCM01

A precalcination furnace was added at the base of the preheater.

The tertiary combustion air for the precalciner is

Cement Technology Training

A precalcination furnace was added at the base of the preheater.

Cement Technology Training

A precalcination furnace was added at the base of the preheater.

The tertiary combustion air for the precalciner is Fuel

Precalciner fuel is fired in pure, preheated tertiary

CemNet Training - Course TCM01

A precalcination furnace was added at the base of the preheater.

The combustion products from the precalciner are

Precalcination technology has resulted in a step change in the

Cement Technology Training

Precalcination technology has resulted in a step change in the

CemNet Training - Course TCM01

Precalcination technology has resulted in a step change in the

Precalcination technology has resulted in a step change in the

Precalcination technology has resulted in a step change in the

Cement Technology Training

CemNet Training - Course TCM01

Precalcination technology has resulted in a step change in the

Precalcination technology has resulted in a step change in the

Cement Technology Training

Precalcination technology has resulted in a step change in the

Cement Technology Training

CemNet Training - Course TCM01

Precalcination technology has resulted in a step change in the

Precalcination technology has resulted in a step change in the

Precalcination technology has resulted in a step change in the

CemNet Training - Course TCM01

Precalcination technology has resulted in a step change in the

Cement Technology Training

Precalcination technology has resulted in a step change in the

Cement Technology Training

Precalcination technology has resulted in a step change in the

CemNet Training - Course TCM01

Precalcination technology has resulted in a step change in the

The chamber is divided into

Precalcination technology has resulted in a step change in the

Precalcination technology has resulted in a step change in the

CemNet Training - Course TCM01

Precalcination technology has resulted in a step change in the

Annual capacity in excess of 500,000 tonnes of clinker per year

Precalcination technology has resulted in a step change in the