Академический Документы
Профессиональный Документы
Культура Документы
auoz Buzdzp asp UTP [a] snp 4971TF VW? Up \ Pretenycy PRS OF soqurey oyours zouai 4 ues aye kseuryad Wira Azezor Suyoop jens uvy aed oem 1 Bupsop Azanjs NTIM SS¥I0Ud ‘LIM| ___a-orsee__ [ow anual — i Sen corse ava] sav PoE EE CaP NID SSBO0Nd LIM £7 + UoROsedo x 2,07 ‘B9/,WN O'¢ : pojoysm eo Zz gz : B4/,WN o'r Pepuposip 40/puo a LT vee "t0 xz Up 0y pewimes 9,049 ‘6%/ QUIN Ht Y + a> Asopuozes soqui at — 64/64 gio + ysnp T tt 2,00FE ‘119 6% 4 2,002 a 2,081 ‘Oyun eos © “OQ. SE : (T), Y ; 64/0 ooss T Mm be 9,00 : joow + ould 9,006 : 806 L a ro, OH } i ' ' 2,0% 07H use We 84/ry 0002 - 00S + UoRdwnsuos jo9y ‘oeds 24/1 OL - oF + (Guu epIsuy) poo, za Ww 6/64 sz'o—so‘o Sasso) ysng Peli/y gto — ¥'0 + (Gum episul) poo) uy Ayoodbo 04 “Je4 %S1-O1 74Bjem ujpYD jO,0,, ee -oc : so70uwDjg/18u97 My - St: doje uny we oosz - oF : 1)6uey uyw/us QZ — OF ? Peeds joRUEJeyUINDWI9 UY} wose - 9% : Je, 2WU0Ig OfH xe - ez | ‘Kune: pes) uy P/+ oo9¢ — oor : AyodogANNEX 6 (Cross-section of the Calcinator ~ slurry dryer oes awe senionmeinloa! uch 8 Sis mt thru 8 Schematic of the F. L. Smidth-CaleinatorANNEX 7 two tdentte: fer geztngs a } sasee || _ iy ash hot 1,0} I x H st | caletner | lexan fh HT, i Uh! masing sore HEH yg | oa ! i Wt rah i soe yh wt 7 ¢ = Rit. fi = Baia NOK) 7% ow Drier Crusher €T¢50«275 Aatborg Portiend 4/3 Rerdai pient. 4000 mtpa Table Comparison of specific power consumption of wet- process kilns and semi-wet process kiln with drying department Specific power consumption |wWet process |Semi-wet process in kWh/mt (kWh/st) clinker without slurry filtration Kiln drive 7.0 (6.4) 2.5 (2.3) Cooler and clinker crusher | 0.5 (0.4) 7.0 (6.3) ID-fan © 3.0 (2.7) 15.0 (13.6) Crusher and mixing screw 3.5 (3.2) Dedusting and sundry equip. | 3.5 (3.2) 3.0 (2.7) Total, kiln and drying dept.|14.0 (12.8) | 31.0 (28.2) Mae BeesANNEX 8 Teprayewr mer = WU o}our = WW uey aye uy Axepuose aye pyoo i ee d cs or oosmseaurrSI yepine soy uyTD “HOLDERBANK” 3enp r03TTF axouing wey aye Areunfad apt deeper Buysop jong wey sua ayeem, (redarj wejshs) NTIM SSHDOUd AUG-IWGSwl0d31, AdAL SSIOOUd ANG — INAS Sy 10'0 + aenp on ro BY By/ewn zz b 20 BH/uiIN 54/64 zo'o . tox ¢ ae 8y/64 0 soqu g — {| Lt 2, oor | 4 SAAN; 2,098 '34/ uN 6'0 a + ap Kiopuoses 2,00%1 ‘te 61 1 -@_,| SE By/r4 ore] 9,08e }. By/cUN ott | 67 ,wN os’ > jyw mos oy tox s 54/64 6 9, OOF Ch a aeeneen ud Buin 0 + woposede jouuou Pew/r Zh -8 2 Poo] 93019 Ppw/} OSL - og +: (6uju spisuj) poo; Za Pow} 7S - Shot eps) POO] UI 2 54/p4 oo9e — OOZE +: UoRdwNsucD Dey ‘oeds gat = tbo Joyouunig/4j6ue7 x st - ¢ : edoys uy IEE CG EenI=e oc 1)5u07 Cn a Pods up woer -e : 49,0wW01g OFH % FL — LL ‘s9Inpou jouw: peo) UID p/* 000z - coc : Ayoodog=e Tor oma seen] os _ siva| rave] ND SS300Nd ANG ONO ANNEX 10 et 9,02 ‘Bx/,wN o'f + woRosedo poyoye 2,08 ‘9 By, <—————*” {44 Lt | + equi b7/, WN ot to xz soqui oF pepioosp 40/puo up} 0) pounyes 64/64 oc‘: y8nP 9,082 ‘B4/,WN IL + yo uopuooes t. ,00r1 io BY 1 2,022 ‘B¥/,uN ZL -O_,| Se ° 20d 1 6/4 g009 9} dn 1 6%/r4 Ose — ooBE 49 64/64 s'o 0} dn Ayndoo 04 ‘j1 xz1-8 www oz — Ob uy - St y/r4 ooze 9,0S¢ 9,005 : jew = o8S09 2.0001 + ynoyym — | Seesos9/euoYD YIM — Pw uopduinsuos yoey ‘2eds Pw sesso] 38nd 1YBJOm sossos0/sujDYD wi poods jopuaseywunos}9 UY w edojs uly P/y 806 = / sujpyo ou - 08 s'0 - so se - of o4t - oF 9 - st o00z - coz (Guu epjsuj) poo; Za (Bujuy) epysuj) poo) uy soyouunjq/4y6u07 \yBueq 49yowo1g AyondogANNEX 11 quading -0D \ jpouw Moy VT spp quading AajuNCD NM aBnis yous “_ jpeaw mpyANNEX 12 DISCHARGE ELECTROSTATIC aw INDUCED STACK. PRECPITATOR DRAUGHT FAN DEDUSTING ‘CYCLONE: HOT WATER FEED busi Oise PRE-HEATER, CYCLONE 4 FILTER SLURRY PResses PRE-HEATER {il FILTRATE SLORY TEED (CRUSHER / DAYER TANK 2FuTee CAKE SLOS Te terete. Pets mm we er F328 mm we Pe i6Smmws Tee ce ve soleey were remere : Pom wo 0 45% (Tbe: co s0% 0 = 27.6% f. s736¢ Treat 20 cara bib mews, oo tam wo ed Corot errs = este cop 306% FEED: 45.1 1/n HO; 19.3 % PRODUCTION: 709 1/6 CONSUMPTION, 993 k cal/ka One-stage cyclone preheater: flowsheet_and operating data 700 t/d FLS kiln, Rugby Portland Cement, Southam works eTar NUM YALWSH3Yd 1S—Z ANNEX 13 110 B/p4 ida x ez 2,02 sd EOS Uh or 66 448 + woposedo + poloyeuy Oe [T_T b 84/4 ooBe ooze - cose : Bh - tb + - & a4 us mos 99 B/_ WNL + soqui fi > Lb < % xz 4p Ksopuoses squ g — ort te By 4 36 byt 1'0. :y6np 2 S9/gN S"t . tox ¢ sq s7— LI 9, 005 uoRduinsuos yoy -seds, poods uy edojs ui pew/y Pou/r 7A) Ps 9,05 59/64 co't ost —- 08 episuj) poo; 2a zh = 90 9pisuyy) PDO} UII se - 9% : Joyouinjg/Wi6u27 o6L -— O£ yybue7 Oueaeocie: s9yeunig ost - oof : * Ayoodoguey aye suey st Aaepuosas aye pjoo = Z tl EI 2g 4[009 fuezaue ld vo aqe6 yaLM ‘ Fy 2 ‘U[py deqeayaad worsusdsns abe3s-p Fepoos -FaRTITS Fy ka qt qenp 209155 y ees uTTy aaqzp ayex8 [Ww é yopmno royuy]> re ( 3enp 209715 aoqureyo eagzp apy Li uopysues; ff et 203115 ‘Suzsop tony xoyendpoad uey sv8 oystm 94530979 0103 Suguopaypucs wopio0fur torem, sateys Brejoos Axejoueyd yepno zaxuyT auopoKo y yREm urejshs zoqeoyord Tur anes 07g = yourng wey aye Areurad Buysop jong syeur merANNEX 15, TaeaiaaT arp Arnos 4 . 1 Y VAN! ~f D068 - 018 AL 98010 hozoq peour mex (| ~—_| #]2,00zt - ort #88 wrx 9, 0tL - 089 mr oBefe moqeq feour mes 2, ove - 08 At 88 Buyavor #08 ance 2, oF = 025 mr eBeye Siyazay yeous mer t 2, 024 - 069 Ti 98840 Guyavay.'se5 3110 y f 2, oFe - 01s 2, 088 - o¢s atne Daraeot eof 32 of 1 1 odefe moreq frau aes yf souo[2ho oma 1 aes 2409 - oF reour aes + ad CTE TTTANNEX 16 DOPOL ‘90 (Polysius) 5-STAGE PREHEATERNUM MSaLVBHSed 1S—> ANNEX 17 £'% + Uoosedo 9,0¢ ‘64/ WN O'S poyoyeuy 9,08 ‘Ho By 4 a 7 4 4 4 ad — a x ond g O} oz [ [ i + aoqu 5y/guN z't f----b----L__L_] | tou @ 9,028 ‘64/,4N sB’O + ajo ksopuoses: woqu gg 9,00r1 By O, OSOb Oy/By 0 3 y8NP Lt S/N LF't 2,0r% BY/, UN -O_.. f= 7 tou sit Sy/ey ogee soqui 2. 098 sould " 2,088 ~ 0,00L ud Ww 6¥/ry OOS — OSI: YoRdwnsuoS yosy ~seds f—) x se -€ edoje uy wd gt - St peods uy 9,085 Pz4/} O8L — OO ( @pisuj) poo; Za Puy ve = St episul) PbO} UI pS = Ht so, 0w01G/4)6ue) 9,08 wo 06 - (OS uy6u07, 54/64 so" woiss - St 49, 0WUD{G P/y ooze — 00S AyodogANNEX 18 i ; 4 i bj & : ; A ii | asl a. ae tT Ww c ( syatem dEANNEX 19 x ar ~o 2 fa #0 - OU shaft stages A { VJ Raw mix feedANNEX 20 bad CTT UT G/L 000€ N1D1 YANID1W9Iud ®L_ 3 = Jon oma] ayn] ova sive] _rwvac] PeIECECR CLP «SV, AdAL NIM YANIOWOIYd 18—> cz 9,0% oz ‘tv/qun OF: Pe or 9,08 11 64 5 PEEL ANNEX 21 jpsedo yu tp a4 OL [ —-—-bL... [A 92,0501 “By ,wn st'o¢ — | + 4p ksopucooe 9,0%% "BH/,4N S¥'L -o.| (eo) Bx/ra sed We 64/rx oose “ wd g'g - Pyw/y ose — Ppwi/y sig = wosoh - wizg = P/t 0006 — 8y/,uiN, to % soqu: 06 = sv'o e- osot Ly 9,00¢t ‘Ho OX L 9,082 uojdunsuos yoay “oeds edoys uy paods uy epysul) pool Za episu) PDO] UID 49} 0w}G/4}6ue7 yy6ue7 J0,ew0|G Ayoodog 410 Asoy.10y "B/N S'o (409) 64/4 oser ‘ Od ys mos 0} yon By un 20 x soqut jean) 208s Zoxz 9,028 9,082 9,028 9,08 64/64 sortANNEX 22 MOST IMPORTANT KILN AND PROCESS TYPES (Rotary are ay) cyclone stages 44200 (150) 300 (900) 3850 (050) 3480 (820) yay 233 Breet | BS eee 30 .[ «0 ‘comparatively external slurry, preneater preheater and precaleination 3480 (820) Beeld ‘3800 (900) Aes 2450 (820) Belt 5400 (2300) was $400 (2300) 20.2425 Pa ELC eeANNEX 23 Basic Process Selection Decision Chart ‘easy washmilling possibl; foisture content ry raw meal wet preparation Preparation acceptable 4/5-stage SP - conventional 4/5-stage SP- 3-chamber kiln, precale. 4/5-stage SP— feiln, precale. grate preheater sep.tert.air duct. kiln sep.tert.airduct kiln Lepol bypass: system eed ECT asANNEX 24 — L/D = 30 (long wet kiin) L/D = 15 (dry preheater kiln) L/D = 11 (short dry PC kiln) DZ = Drying Zone PZ = Preheating Zone CZ = Calcining Zone SZ = Safety Zone TZ = Transition Zone BZ = Burning (Sintering) Zone KZ = Kiln Internal Cooling Zone ae Process Technology Division Date 05.05.92 CC-GA-C ROTARY KILN ZONES Nome 6iANNEX 25 ”'Y ro Mechanical kiln inlet seal (KHD) KILN INLET SEALS Pneumatic kiln inlet seal_(FLS)ANNEX 26 / Srspane "Bice Kiln outlet seal (KHD) KILN OUTLET SEALS "Fish scale" outlet_seal “HOLDERBANK”ANNEX 27 laa 24y SAOUUINY O20 ed eee cee eq Woy Jo Ino poretnsyeD worrdunavo> —_(y upu/as 9g 30 Arfoofe0 [eRUese;uMDI]9 Vordn — (¢ ema ov 0 sopiduumavoo tenuve wesut sounyea teoq Jo ane wondaumeves N94 (erWez;UNDI]> w bor - 26 a 06 sb - se ot oo evi 22 a un 784} (84/74 002412) STTaRABTOS TNE ay 60 oo or or 00 soo [ae yeu! ave Aaepuoa9g so 0 v0 zo #10 v0 V0 | 12 84/,00n faved ore $0 ve #e-0% se-sz sree se-e | 4 204 IDE o2- 01 oz-0 e2- et ste ot stot (e ov-0% @iserst | ow wepeier IDL 0001 - 005 092 o0zt - 006 oor - o0¢ 00s 0009 - o00s 009 - o00¥ 09- 0% $-2@ Oz- St 02 - Or 09- Of S9- OF $9 - OF Un/s qwewos lang w- 39 she st sae os 82 0s - $2 a - of oF - oF De Wied aoa ou wz 095 ost 1 or oe 09 2 ye ze 021 021 - 06 ose - 002 (02 = 08 055 - osF oar = ont Ose - oz 20 ero weet er oT Feri ve ers on wen z-s0 o> | o> | stem ee cae es teow aes Aap aeveoyoad sensor “3 wojeuodene ( o0c9 - oases | tv osse - ostt ooge- ase | (y 0005 - oor | (r corr - osée osee-oste | (t osee-oste | 1 Bra ofr 08 oor ont ort ort 06 oor - a0 woe-oor | pert peo ooejane 20-S'0 ez on 60 9O-s'0 b0- 90 oro? Ves Peet . auieedg: 21070 renee seg soynoqosd 2v0poho wna ede wary Aap a0 Aap Buoy oBeie-y aANNEX 28 Immersion Tube Low Pressure Drop Design ‘Splash Box Sufficient Meal Duct Diameter Meal Flap Splash Box CYCLONE STAGEPREHEATER MEASUREMENTS ANNEX 29 Dole 2710 Hel 3390 ki/ks id [ETE aeANNEX 30 NO VTIVLSNI SSVdAG GYVGNVLS uaaNWHO ‘ONIHONAND SNNGNVH SVDAPPENDIX 1: HISTORICAL DEVELOPMENT The word cement is more than 2'000 years old, but impure limes have been used much longer as a building material, It is historically established, that the Ph cenicians used a pozzolanic lime about 700 B.C. and also the Romans produced some sort of cement or hard burned lime. From the middle ages, it is known, that in Holland a type of hydraulic cement was formed out of lime and tuff in dome shaped kilns. Our cement, as we know it today, is now more than 200 years old, "invented" by the Englishman John Smeaton in i756. It was burned in bottle kilns. The better known inventor of portiand cement was Joseph Aspdin, who patented his burnin process in 1824. He also used dome kilns of approx. 36 ft height and 17 ft dia- meter with a production of 90 bbl (= 15 t) per charge, each of which took several days to produce. Fuel consumption was 50% of clinker weight in coal which corresponds to 15'500 ki/kg cli (= 3'700 kcal/kg cli). In 1880 an important step forward was made with the development of the con- tinuously working shaft kiln, which had a much better heat economy. An example of such a kiln was the "Dietzsche Etagenofen" which is shown in Annex ... 1. From 1877 experiments have been conducted with rotary kilns and in 1897 the first successfully working unit of this type was developed in America by Hurry and Seaman. These first rotary kilns were wet process kilns with a daily capacity of 50 to 100 tons. Their heat consumption was again very high (about 30% of clinker in coal = 9'500 kd/kg cli) and they had an incredible dust emission (usually more than one third of the whole production). In order to decrease heat consumption, chain systems were installed in wet kilns to improve heat transfer during drying. Behind long dry kilns, waste heat steam boilers were arranged for the same purpose. It took almost another 30 years, before a further substantial amount of heat en- ergy could be saved by reducing the water content of the feed and by a better heat exchange in the preheating and. calcining zone. In 1930 an officer of the army of the tsar, Dr. Lellep, took an important step in this direction. He de- veloped the travelling grate preheater, which is fed with moist nodules. This invention was taken over by Polysius and got the name LEPOL kiln. Some years la- ter, there was a Czech patent of a cyclone raw meal preheater and in 1953 the first suspension raw meal preheater system was installed by Kloeckner-Humboldt~ Deutz AG in Germany. This type of kiln now became dominant because of its heat economy and nowadays other systems are only chosen in special cases. In former years, the main reason for the selection of the wet process was, that effective homogenization of ground raw material was not possible except in the form of a slurry. In developing special techniques for dry material homogenization such as mix beds, mixing chamber silos etc., this factor could be eliminated. Utilising a rather old idea, since about 1966 especially Japanese cement machine manufacturers have designed several successfully working precalcining kiln systems. Calcination is already done in a stationary calciner system, where se- condary firing is installed. By this means, it is possible to design kiln systems with a comparatively small rotary part diameter but a very large capa- city up to more than 10'000 t/d. Kiln systems built after 1990 include 6-stage preheaters with up to 4000 t/d per string, pure air calciners, designed for a variety of fuels and emission con- trol. Using modern low primary air burners, low pressure drop cyclone designs and high recuperation efficiency coolers allow further reduction of heat and po- wer consumption.Roman lime kilo, crea 50 AD. Vindonissamuseum Swiczerland. English borde Lila, circa 1760 Dietzsch' multi stage shaft kilnAPPENDIX 2: TEST QUESTIONS a 10. ll. 12. 13. What are the four basic process types for burning clinker? Which factors define a kiln system? What is the effect of slurry water content reduction from 37% to 34% on heat consumption in case of a wet kiln? Why is the total heat consumption of a plant with a 4-stage preheater kiln system not affected by the raw material moisture as long as the moisture is below 12%? Which kiln systems are suitable to produce low alkali cement? Comment on reasons and consequences thereof! Which zones occur in a kiln tube of a long wet kiln? Give characteristi- cal material temperatures! What are typical figures for a wet kiln? Length/diameter ratio Slurry water content Exhaust gas temperature Heat consumption (ki/kg cli)? How can the slurry water content be reduced in case of a wet process? What are the main reasons for the high heat consumption of a long dry kiln compared to a preheater kiln? Comment on the following items of a LEPOL kiln: Requirements for raw material Heat consumption Utilization of exhaust gas for drying! How does a cyclone stage of a raw meal preheater work? What type of heat exchange occurs within the stage? Why have shaft preheater stages in practice not fulfilled what was theo- retically expected? What is the typical heat consumption of a 4-stage preheater kiln system with 2000 t/d capacity?14. 15. 16. ing problems in a cyclone preheater cau- What must be installed if clo: ‘eutphur, alkalis or chlorine) disturb nor- sed by circulating compounds mal operation? What is the maximum allowable thermal Toad per cross sectional area in MN/m? of a 4~stage preheater kiln? What kind of kiln system must be installed for 7000 t/d? Why?