06-08-28

Cement Plant Cement Plant PyroPyro--TechnologyTechnology

Palle GrydgaardMSc, Chem. Eng.Head of Process, PD1-P1F.L.Smidth A/SVigerslev All 77 DK-2500 Valby Copenhagen DenmarkTel +45 36 18 10 00 Direct line +45 36 18 20 63Fax +45 36 17 10 91palle.grydgaard@flsmidth.com

06-08-28

Trends in cement process:Trends in cement process: dry process larger production units

> 5.000 t/d up to 12.000 t/d lower energy consumption

06-08-28

Wet Kilns1898: 1.8x18m

35 tpd1967: 7.6x232 m

3500 tpd

Preheater kilns1970: 6.0x96 m

4000 tpdPrecalciner kilns1984: 5.0x80 m

5500 tpd1990: 6.0x96 m

10,000 tpd2006: 6.6x93 m

>12.000 tpd

History of kiln capacity developmentHistory of kiln capacity development

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RotaxRotax--2 kiln for 5500 tpd2 kiln for 5500 tpd

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SLC SLC --Separate Separate

Line Line CalcinerCalciner

10000 10000 t/dt/d

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Kiln heat consumption (1 kcal/kg = 4.18 kJ/kg) Process kcal/kg

Wet process with chains +/- cross ~1400-1600

Long dry process with chains +/- cross ~1100

1-stage cyclone preheater ~1000

2-stage cyclone preheater ~900

4-stage cyclone preheater ~800

4-stage preheater+precalciner+SFcooler ~735-750

5-stage preheater+precalciner+SFcooler ~710-730

6-stage preheater+precalciner+SFcooler

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Main Raw Material: Limestone

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TYPICALValues

Clinker Raw Mix Limestone Clay Iron ore

Mix %dry 83.92 13.31 2.77

SiO2 %Al2O3 %Fe2O3 %CaO %MgO %K2O %Na2O %LOI %

21.064.874.70

64.391.940.570.34

13.773.193.07

42.111.270.370.22

34.61

5.191.411.34

49.481.110.160.07

39.73

64.0613.96

5.952.181.421.721.039.51

32.205.22

41.9110.69

5.410.331.03

Total 98.83 98.83 98.69 100.00 97.37

LSF %MSMA

95.002.201.04

95.002.2

1.04

289.921.891.05

1.093.222.36

8.650.680.12

C3S %C2S %C3A %C4AF %

62.813.24.9514.3

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Calcination Reactions

CaCO3 = CaO + CO2

Al2O3, 2 SiO2, 2 H2O = Al2O3, 2 SiO2 + 2 H2O

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Chemical changes during burning

Liquid phase

Free CaOCaCO3

Quartz

Clays

C S2

C S3

C A3

C AF4

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ILC ILC -- InIn--Line CalcinerLine Calciner

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SLCSLC--D Separate D Separate CalcinerCalciner -- DownflowDownflow

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Modern Dry Process Kilns Plant Name

Kiln size

DxL, m

L/Di Load t/d/m3

Prod. t/d

Heat Cons.

Kcal/kg

Remarks

Ozarow 5.75x92 17 4.3 8500 ~750 4 stage preheater + ILC + 3 supports + grate cooler

Siam City 6.0x96 17 4.3 10000 ~720 5 stage preheater + SLC + 3 supports + grate cooler

Zuari 4.55x68 16 5.7 5200 ~730 4/6 stage preheater + SLC + 3 supports + grate cooler

Sean Quinn 4.55x54 13 5.2 3800 ~735 5 stage preheater + ILC + 2 supports + grate cooler

Saloniki

4.55x58 14 4.5 3500 ~720 5 stage preheater + ILC + 2 supports + SF cooler

Ramos 4.55x56 13.5 4.2 3150 ~700 6 stage preheater + ILC + 2 supports + SF cooler

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Heat Consumption

kcal/kg (kJ/kg)

SURFACE HEAT LOSS FROM KILN 30 (125)

SURFACE HEAT LOSS FROM PREHEATER 35 (146)

COOLER LOSS 115 (481)

EXIT GAS HEAT LOSS 145 (606)

HEAT OF REACTION 400 (1673)

FREE INPUT WITH RAW MEAL + FUEL - 25 (- 105)

NET HEAT CONSUMPTION 700 (2927)

TYPICAL HEAT BALANCE:6-STAGE MODERN KILN SYSTEM

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Maximum utilization of kiln exhaust gases - 100 % to raw mill 5 stage ILC 6 stage ILC

Kiln heat consumption 725 kcal/kg cl 700 kcal/kg cl

Exhaust gas temperature 312 0C 280 0C

Exhaust gas quantity 2.18 kg/kg cl 2.16 kg/kg cl

Drying capacity in a vertical roller mill running 20 hours/day (ambient temperature of 15 0C)

8.6 % H2O 7.3 % H2O

Drying capacity in a vertical roller mill running 20 hours/day(ambient temperature of 0 0C)

7.4 % H2O 6.2 % H2O

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High-temperature ILC low-NOxCalciner

Reduction zone (1100C)

Air from cooler(3 air)

Kiln gas

High-temperature oxidation zone (1100C)

Calcination zone (900C)

CO eliminating duct Stage 2

cyclone

Stage 3 cyclone

Stage 4 cyclone (880C)

Calciner fuel input

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Two stringTwo stringILC LowILC Low--NOx NOx precalcinerprecalciner

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Upgrading of Upgrading of 3500 tpd 3500 tpd preheater kiln topreheater kiln totwotwo--string ILC string ILC Low NOxLow NOxprecalciner precalciner system system designed for designed for 8500 tpd8500 tpd

FLS SLC - D Calciner

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SLCSLC--DD

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5500 tpd SLC-D precalciner system designed for 100% petcoke firing

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FLS Standard Rotary Kiln DimensionsFLS Standard Rotary Kiln DimensionsFLS 2-base kiln

FLS 3-base kiln

13 x D inside lining2.3 x D 6.8 x D

3.6 x D

17 x D inside lining

1.3 x D 5.3 x D6.4 x D 2 x D

D

D

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Inlet & Outlet Lamella SealsInlet & Outlet Lamella Seals

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Duoflex kiln burnerDuoflex kiln burnerPrimary air inlet

Burner trolley

Burner pipe with refractory

Valve for radial air Valve for axial air

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waste oil

wood chips or plastic

chips

fuel oil

pulverised coal

plastic chips or oil contaminated refuse

>>>

DUOFLEX BURNER FOR ALTERNATIVE FUELSDUOFLEX BURNER FOR ALTERNATIVE FUELS

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Waste Fuel: An opportunityWaste Fuel: An opportunity

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THE (SMIDTH-FULLER)SF CROSS-BAR COOLER

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Stationary and Moveable Cross-Bars

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Stationary and Moveable Cross-Bars

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Air flow through Air flow through holes in tongueholes in tongue

Air flow through Air flow through idle holeidle hole

Air flow throughAir flow throughgapsgaps

AIR DISTRIBUTION PLATE WITH MFRAIR DISTRIBUTION PLATE WITH MFR

PQA

AQVP

221

21

22 && =

==

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Mechanical Flow Regulators Mechanical Flow Regulators

HIGHER

VALVE dP

LOW BED RESISTANCE

HIGH BED RESISTANCE

LOWER

VALVE dP

C O N S T A N T A I R F L O W

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5 stage ILC kiln

Fuel Type Bituminous Coal

Heavy Fuel Oil

Natural Gas

Net Heat Valuekcal/kg fuel

6430 9780 11300

Kiln Heat Cons.kcal/kg clinker

727 720 731

CO2 from Raw Mat. kg/kg clinkerCO2 from Fuel kg/kg clinker

0.5400.281

0.5400.230

0.5400.174

Total CO2 kg/kg clinker 0.821 0.770 0.714

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TYRES

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HOTDISC HOTDISC DESIGN DESIGN

CONCEPTCONCEPT

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HOTDISC

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Hotdisc connected to calciner

History of kiln capacity developmentRotax-2 kiln for 5500 tpdMain Raw Material: LimestoneTYPICAL HEAT BALANCE:6-STAGE MODERN KILN SYSTEMFLS SLC - D CalcinerFLS Standard Rotary Kiln DimensionsInlet & Outlet Lamella SealsTHE (SMIDTH-FULLER)SF CROSS-BAR COOLERStationary and Moveable Cross-Bars5 stage ILC kilnTYRESHOTDISC DESIGN CONCEPT