Preheat Process12

Page
L\DATA\Dept150\Polysius Presentations
and Training\Polysius Training\Pyrop
rocessing\Preheater\preheat_process.p
pt
140 TEI, 140 CD
Preheater and Calciner

Process Training
Krupp Polysius Corp.
Page
2
The
modern kiln plant
and
Training\Polysius
Training\Pyrop
pt
140 TEI, 140 CD
Preheater
Calciner
Clinker cooler
CM
Raw mill
Rotary kiln
Page
3
pt
140 TEI, 140 CD
Preheater
Page
4
DOPOL 90
pt
140 TEI, 140 CD
Page
5
Gas and
material flow
and Training\Polysius
Training\Pyrop
in a preheater
pt
140 TEI, 140 CD
Page
6
L\DATA\Dept150\Polysius
DOPOL
90 B-type cyclonePresentations
1
pt
140 TEI, 140 CD
2
3
4
5
1
2
3
4
5
Cyclone
Intermediate piece
Dip pipe
Gas duct
Meal chute
Page
Cyclone
typesand Training\Polysius Training\Pyrop
7
pt
140 TEI, 140 CD
Dedusting cyclone
System cyclone
Calciner cyclone
DOPOL 90
Page
8
The
modern kiln plant
and
Training\Polysius
Training\Pyrop
pt
140 TEI, 140 CD
Preheater
Calciner
Clinker cooler
CM
Raw mill
Rotary kiln
Page
9
DOPOL
90 - preheater
design
and
Training\Polysius
Training\Pyrop
pt
140 TEI, 140 CD
Page
10
Number of cyclone
Exhaust gas
- temperature
Technical data
4
5
6
pt
140 TEI,
C 140 CD
370
315
280
- volume
Nm/kg clinker
1,372
1,353
1,345
6,5
mbar
33
38
45
Fuel consumption
kcal/kg clinker
740
718
705
Cooler efficiency
74,6
73,1
72,1
Clinker temperature
100
100
100
Nm/kg clinker
1,7
1,7
1,7
Nm/kg clinker
0,84
0,87
0,88
295
305
312
- for exhaust gas fan
kWh/t clinker
5,6
5,7
6,1
- for total kiln plant
kWh/t clinker
15,1
15,2
15,7
- exhaust gas only (with coal mill)
7,6
5,6
4,3
- exhaust gas only
8,5
6,5
5,3
- exhaust gas with exhaust air
11
9,5
8,7
- dust relative to clinker

- pressure loss
Cooling air
Cooler vent air
- volume
- temperature
Electrical power consumption
Permitted RM moisture
600
Exhaust gas temp. [ C ]
500
Dryingand
capacities
- preheater
systems
Training\Polysius
Training\Pyrop
AS 6 AS 5 AS 4
AS 3
pt
140
TEI, 140 CD AS 2
24
<-- PH exhaust temp.
20
400
16
300
PH + cooler exhaust-->
200
12
8
PH exhaust only -->
100
0
900
700
750
800
850
Fuel consumption [ kcal/kg cli ]
Drying capacity [ % - H2O ]
Page
11
Page
12
pt
140 TEI, 140 CD
Calciner
Page
13
PREPOL AS
Calciner types Training\Pyrop
pt
140 TEI, 140 CD
PREPOL AS-CC
PREPOL MSC
PREPOL MSC-CC
Page
14
PREPOL AT
Training\Pyrop
pt
140 TEI, 140 CD
Page
15
PREPOL AS Training\Pyrop
pt
140
TEI,loop
140 CD
Calciner
Fuel injection
TA-duct
Page
16
PREPOL AS-CC
Training\Pyrop
Calciner loop
pt
140 TEI, 140 CD
Combustion
chamber
TA-duct
Page
17
Combustion - Chamber (CC)
Burner
Meal inlet pt
140 TEI, 140 CD Central inlet for tertiary air
Meal inlet
Tangential inlet for

tertiary air inlet
CC-Chamber outlet
(Connection to
the calciner)
Tangential inlet for

tertiary air inlet
Tertiary duct
Page
18
PREPOL MSC Training\Pyrop
pt
140 TEI, 140 CD
Deflection chamber
Top air duct
Meal staging
PC - burner
Kiln inlet burner
Tertiary air duct
Page
19
Training\Pyrop
PREPOL
MSC-CC
pt
140 TEI, 140 CD
Deflection chamber
Top air duct
Tertiary air duct
PC - burner
Kiln inlet burner
Page
20
Tertiary air ductTraining\Pyrop
pt
140 TEI, 140 CD
Page
21
Presentations
MSC L\DATA\Dept150\Polysius
Calciner with Tire Feed Chute
pt
140 TEI, 140 CD
Page
22
Tertiary air from cooler
pt
140 TEI, 140 CD
w > 26 m/s
w < 8 m/s
w < 8 m/s
w < 6 m/s
Page
23
Tertiary
air from kiln hood
Training\Pyrop
pt
140 TEI, 140 CD
w > 26 m/s
w < 5 m/s
w < 5 m/s
Page
24
and
Training\Polysius
Training\Pyrop
Tertiary
air connection
measures
kiln hood
cooler
pt
140 TEI, 140 CD
secondary air temperature
lower
higher
thermal stress on outlet segments
+ lower
- higher
burn out in the calciner
+ better
- worse
precalcination rate
- lower
+ higher
bypass losses
- higher
+ lower
load of sintering zone
- higher
+ lower
- higher
+ lower
- bigger
+ smaller
length of burner
- longer
+ shorter
NOx - formation
(+ lower)
(- higher)
Investment cost
- higher
+ lower
thermal stress on tertiary air

flap and refractory
size of kiln hood
better cooling and

form of segments
CC - Calciner
adapted dimensionnig
and quality of refractory
optimized burner adjustment
Page
25
Low-dust kiln inlet
pt
140 TEI, 140 CD
Page
26
Fuel type
Calciner volume loading
Thermal calciner loading in kcal/m/h
pt
140 TEI,
PREPOL
AS140 CD PREPOL AT
Natural gas
< 150000
< 100000
Fuel oil
< 180000
< 120000
high reaktive Coal
< 130000
< 87000
low reaktive Coal
< 90000
< 60000
e.g. Pet Coke
< 80000
Page
27
Fuel design and distribution
pt
140 TEI, 140 CD
Coal - activity
pt
140 TEI, 140 CD
O2-concentration [%]
Page
28
Time [s]
Page
NOx - generation in clinker burning process
29
pt
140 TEI,
140 CD
Calciner:
Fuel - NOx
- exess air
- nitrogen content
- reactivity
Sintering zone:
Thermal NOx
- temperature
- exess air
- retention time
Page
conditions for NO reduction by fuel,
30Combustionand
Training\Polysius Training\Pyrop
air and meal staging
Meal
pt
140
TEI,
140 CD > 1,05
H O
2
NO
N2 CO2
0,4 - 0,6 Q
NHi
H2 O
CO2
N2
NO
CH i
CO
NO
> 0,1 Q
Fuel
CHi
Air
CO2
H2 O
N2
CO
0,9 <
< 1,05
0,9 <
< 1,05
NO
NH i
Stage 4
Q = total fuel
= excess air figure
Stage 3
0,4 - 0,6 Q
Stage 2
Stage 1
NOx and O2 at kiln inlet
Training\Pyrop
pt
140 TEI, 140 CD
NOx at kiln inlet [gNO2/kgcli]
Page
31
O2 at kiln inlet [%]
NOx - generation in calciner [NO2/kgcli]
Page
32
pt
140 TEI, 140 CD
NOx - generation and volatiles
Volatile matter in fuel [%]
NOx and Nitrogen in fuel
pt
140 TEI, 140 CD
NOx [NO2/kgcli]
Page
33
Nitrogen in fuel [%]
Nox
calciner temperature
and and
Training\Polysius
Training\Pyrop
pt
140 TEI, 140 CD
NO2 [mg/Nm3] @ %O2
Page
34
Calciner temperature [C]
Presentations
Operating
results MSC plants
pt
140 TEI, 140 CD
NOx - emission [gNO2/kgcli]
Page
35
Page
36
NOx - Emission [gNO2/kgCli]
2.5
Operating
results MSCTraining\Pyrop
plants
pt
140
TEI,
140 CD
AS - operation
MSC
- operation
2
800 mgNO2/Nm
(10 % O2)
1.5
500 mgNO2/Nm
(10 % O2)
35%
32%
53%
0.5
30%
28%
Presentations
Operating
results MSC plants
pt
140 TEI, 140 CD
Page
37
Page
38
NOx - Emission [gNO2/kgKl]
2.5
1.5
Operating
plants
KI - AS
MSC
- operation
pt- operation 140
TEI,
140 CD
AS - operation
800 mgNO2/Nm
(10 % O2)
500 mgNO2/Nm
(10 % O2)
32%
0.5
30%
Plant
Fuel
Volatiles in
fuel
53%
35%
28%
A
80% Pet Coke
20 % Coal
B
Lignite
C
Coal
Bleeching Earth
Paper waste
Fly Ash
D
Coal
Tyres
Plastic
E
Oil
Paper waste
Plastic
Carbon Marl
15 %
45%
27,3 %
~25 %
>40 %
Presentations
Operating
results MSC plants
pt
140 TEI, 140 CD
Page
39
Page
40
NOx - Emission [gNO2/kgKl]
2.5
1.5
Operating
plants
KI - AS -pt
operation 140
MSC -TEI,
operation
140 CD
AS - operation
800 mgNO2/Nm
(10 % O2)
500 mgNO2/Nm
(10 % O2)
32%
0.5
30%
Plant
Fuel
Volatiles in
fuel
53%
35%
28%
A
80% Pet Coke
20 % Coal
B
Lignite
C
Coal
Bleeching Earth
Paper waste
Fly Ash
D
Coal
Tyres
Plastic
E
Oil
Paper waste
Plastic
Carbon Marl
15 %
45%
27,3 %
~25 %
>40 %
Page
41
NOx - emission
NOx - prognosis
pt
140 TEI, 140 CD
Page
42
CO - prognosis
Training\Pyrop
pt
140 TEI, 140 CD

Preheat Process12

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Page

Preheater and Calciner

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

- for exhaust gas fan

- for total kiln plant

- exhaust gas only (with coal mill)

- exhaust gas only

- exhaust gas with exhaust air

- dust relative to clinker

Krupp Polysius Corp.

Exhaust gas temp. [ C ]

PH exhaust only -->

Fuel consumption [ kcal/kg cli ]

Krupp Polysius Corp.

Drying capacity [ % - H2O ]

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Tangential inlet for

Krupp Polysius Corp.

Tangential inlet for

Top air duct

Krupp Polysius Corp.

Tertiary air duct

Top air duct

Tertiary air duct

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

secondary air temperature

thermal stress on outlet segments

burn out in the calciner

load of sintering zone

thermal stress on tertiary air

Krupp Polysius Corp.

better cooling and

optimized burner adjustment

Krupp Polysius Corp.

high reaktive Coal

low reaktive Coal

e.g. Pet Coke

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

NOx at kiln inlet [gNO2/kgcli]

O2 at kiln inlet [%]

Krupp Polysius Corp.

NOx - generation in calciner [NO2/kgcli]

NOx - generation and volatiles