Download - Cement Plant Pyro-Technology.pdf
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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 [email protected]
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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
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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
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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