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C =CaO
S =SiO2
A =Al2O3
F =Fe2O3
Limestone ( CaCO3 )
Clay ( Al2O3, 2 SiO2 , 2 H2O )
Silica (quartz) ( SiO2 )
Iron ore ( Fe2O3 )
(Fuel)
Ranges
Practical Typical
CaO 58 - 68 % 63 - 67 %
SiO2 18 - 26 % 20 - 24 %
Al2O3 3 - 8 % 4 - 7 %
Fe2O3 0.5 - 6 % 2 - 4 %
Ranges
Practical Typical
MgO 0.1 - 6 % 1 - 4 %
K2O 0.1 - 1.5 % 0.1 - 1.0 %
Na2O 0.1 - 1.5 % 0.1 - 0.8 %
SO3 0.1 - 2 % 0.1 - 1.5 %
Clinker minerals
Ranges
Practical Typical
C3S30 - 70 % 45 - 65 %
C2S 10 - 50 % 15 - 30 %
C3A 0 - 15 % 4 - 10 %
C4AF 0 - 20 % 8 - 12 %
C4AF = 3.04 x F
The information contained or referenced in this presentation is confidential and proprietaryto
FLSmidth and is protected by copyright or trade secret laws.
Portland Cement, Raw Meal, and Clinker
Chemical Modules
CaOmax =
2.80 x SiO2 + 1.18 x Al2O3 + 0.65 x Fe2O3
Chemical Modules
Effects of Changing
Chemical Modules
LSF:
Cement Quality:
1 LSF 2.5 % C3S
Burnability:
Higher LSF raw mix harder to burn
Effects of Changing
Chemical Modules
MS:
Nodulisation:
Clinker size Cooling efficiency
Clinker porosity Grindability
Burnability:
Higher MS rawmix harder to burn
Effects of Changing
Chemical Modules
MA:
Burnability:
Lower MA melt formation at lower
temperature
Free CaO1400C =
325
B.Z residence time =
Kiln incl. X kiln speed
Raw
meal
Air
Fuel
Features
Normal capacity range 3000 - 7000 tpd clinker with
one kiln string and one calciner string and 7500 -
12,000 tpd clinker with one kiln string and two
calciner strings
Firing ratio in calciner: 55% - 60%
Maximum variation in the by-pass of kiln gases: 0% -
100%
Advantages
High material and gas retention time in the calciner which
dimensions are moderate, since kiln gases do not pass
through it
Very well suited for all types of pulverized coal, even low
volatile coal or petcoke, as the combustion in the calciner
takes place in hot atmospheric air, and (as an option) the
combustion temperature can be controlled independently
of the temperature of the calcined material fed to the kiln
Low refractory costs due to low thermal kiln load and
stable kiln coating
Independent and accurate draught control for kiln and
calciner string by adjusting the speed of the individual fans
No damper in the tertiary air duct
Production of up to 40% of the total capacity using the kiln
string only
Features
Normal capacity range: 5500 - 10,000 tpd clinker
Firing in SLC calciner: 40% - 50%
Firing in ILC calciner: 10% - 15%
By-pass range of kiln gases: 0% - 30%
Features
Normal capacity range 1500 - 5000 tpd clinker for
one preheater string and 4500 - 10,000 tpd
clinker for two preheater strings
Firing ratio to calciner: 55% - 60%
Maximum variation in the by-pass of kiln gases:
0% - 30%
Designed to operate under high temperatures for
NOx reduction
P la n t A - 6 - s t a g e IL C p r e h e a t e r w / 2 - s u p p o r t k iln a n d c o n v e n t io n a l c o o le r (3 0 0 0 M T P D )
P la n t B - 4 - s t a g e S L C - I p re h e a t e r w / c o n v e n t io n a l c o o le r (7 8 0 0 M T P D )
P la n t C - 6 - s t a g e IL C p r e h e a t e r w / S F C r o s s - B a r c o o le r a n d 1 5 % o p e r a t in g b y p a s s (3 7 0 0 M T P D )
P la n t D - 5 - s t a g e S L C p r e h e a t e r w / c o n v e n t io n a l c o o le r (1 0 . 0 0 0 M T P D )
D
FLS 3-base kiln
17 x D inside lining
6.4 x D 2xD
1.3 x D 5.3 x D
ILC Residence time For coal, gas, and oil the target is a
minimum of 3.3 seconds in the cylindrical section. When
firing petcoke or other difficult fuel the minimum target
is 5.0 seconds. Note that the loop duct for the ILC
normally adds another 2-3 seconds of residence time.
Reduce Ms More liquid Big clinker Should always be considered if dust is a problem
Better balls when Significant effect on burnability, but small effect on
granulometry - too low Ms strength
less dust Slightly lower Ms > 2,5: consider a decrease
Improved cooler C3S in clinker Ms < 2,3: try to increase
efficiency A decrease in Ms will often result in a decrease in
quarts and silicates along with having a positive
effect on the burnability.
C
Reduce Ma Liquid starts at Slightly lower Easy to do if iron ore is available
H lower temperature C3S Minor effect on burnability
E Better Longer time in kiln for good nodulisation
M granulometry
I
S
T The information contained or referenced in this presentation is confidential and proprietaryto
FLSmidth and is protected by copyright or trade secret laws.
R
Effects on Burnability Improvement
M Reduce Easier for calcite Calcite is a Often the first and easiest choice, if the
I coarse particles to react soft material mill has extra capacity
N calcite and will be Relatively small effect on burnability
E particles affected by Over-burning is often a problem because
R finer grinding big free CaO particles from large Calcite
A Finer grinding particles are impossible to burn away. If
L will require the operator does not know this, the only
O more energy option seems to be to burn harder
G in the mill possibly resulting in dusty clinker
Y Possible mill No effect on cement quality
capacity Finer grinding will have minor effect on
problems coarse silicates and quarts
(lower Will normally improve clinker grind ability
production)
Propos
Resulting Potential Comments
ed
advantage problems Good ideas
Change
W Burn The production Short brick If the free CaO can be kept at a
H Harder may be life due to reasonable value, the cement
A OR changed with high strength will be OK
T add acceptable free temperature Harder burning will increase
E CaF2 CaO More NOx crystal sizes and result in clinker
L OR emission harder to grind resulting in more
S Read More energy needed in the cement mill.
E about energy is The use of petcoke as fuel may be
minerali needed ruled out due to increased sulphur
sed evaporation
clinker