kiln process

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  • 8/13/2019 Kiln Process

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 1

    Rotary K i ln

    Process Train ing

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 2

    CM

    The modern kiln plant

    Raw mill

    Clinker cooler

    Calciner

    Rotary kiln

    Preheater

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 3

    Test procedurerepresentatiiverawmaterial sample

    test ingradient furnaceanalysisof test results

    Characteristicdataof rawmaterial

    Computer

    simulationof

    burningprocess

    Resultskilndimensio

    kilnspeed

    Process - technological kiln design

    Fuel properties

    Product qualityConcept of kiln

    line

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 4

    Rotary kiln design

    Required kiln parameter:

    Length and diameter

    Kiln inclination

    Degree of filling

    A-Mass

    Kiln inlet gas velocity Kiln speed

    Kiln shell cooling

    Kiln static calculation

    Kiln drive power

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 5

    Calciner

    Calcination

    Transition

    Sintering

    CalcinerKiln

    PreheaterKiln

    KilnLengthin D0

    2 6 6

    7 3 4

    Cooling

    Rotary kiln zones

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 6

    Kiln flame - temperature profile

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 7

    0 10203040506

    Kiln Le

    800

    1000

    1200

    1400

    1600

    1800

    2000

    2200

    2400Ga s (lo n g )M a te ri a l (l o n g )Ga s (s h o rt)M a te ri a l (s h

    Kiln temperature profils

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 8

    Kiln dimensions

    raw material characteristic

    moduli: LSF, SM, AMgrinding fineness

    quartz grain distribution

    homogeneity

    impurities: alkali, SO3, Cl

    clinker quality (low alkali)

    type and quality of fuel

    fuel preparation

    alternative fuels

    fuel flexibility

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 9

    9 10111213141516

    Length /

    1,050

    1,100

    1,150

    1,200

    1,250

    1,300

    1,350

    Temperature

    Kiln inlet temperature & kiln length

    L \DATA\D t150\P l i P t ti d T i i \P l i T i i \P i \Kil \kil tP 10

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

    Page 10

    KilnSystem VolumeloadingLength/diameter

    ratioNumber of kilnsupports

    tpd/m -LongKiln

    - wet 0,5...0,7 30... 40 5- 6

    - dry 0,5... 0,9 30... 40 5- 6

    Lepol 1,7... 2,2 (10) 13... 17 (2) 3- 4

    Gepol 1,5.. 2,0 15... 17 3- 4

    Cyclonepreheater(DOPOL)

    1-stage 0,7... 1,0 25... 35 5- 6

    2-stage 0,8... 1,2 20... 30 4- 5

    3-stage 1,5... 2,0 15... 17 3- 4

    4-stage2,0... 2,5 (14) 15... 17 (2) 3- 4

    5-stage 2,0... 2,5 (14) 15... 17 (2) 3- 4

    Calciner Kiln(PREPOL)

    - Prepol AT(2...6-stage)2,5... 3,5 (12,5) 14... 17 (2) 3- 4

    - Prepol AS(2...6-stage)4,0... 5,0 (11) 12... 15(17) 2- 3(4)

    Kiln dimensioning

    L:\DATA\Dept150\PolysiusPresentation and Training\PolysiusTraining\Pyroprocessing\Kiln\kiln process pptPage 11

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

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    Capacity t/d 22

    Nom. Kilndiameter m 4,

    Diameter @inlet m ,

    A- Ma mm 26FF m m ,

    Length m 4,

    L/D-inner - 12,

    L/D-outer - 12,

    Volumeloading tpd/m 4,

    KilnFuel kcal/kgCli 3

    Thermal loading kcal/mh 3,06E+0

    Kilnvolume m 4

    Freecrosssection m 10,1

    Outer Surface m 6

    Radiation kcal/kgKl 2,

    KilnFilling

    Kilninclination [%] 3,Kilnspeed [1/min] 3,

    Processtype AS

    Degreeof filling Process [%] 6,

    Degreeof filling mechanical [%] 8,

    Difference(>1,5%) [%] 2,3

    Degree of filling

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    140 TEI, 140 CD

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    Process- technological dimensions

    Kilnwithpreheater

    Kilnwithcalciner

    10 12 1415 17

    L/Dratio

    3- Stations

    Numberof stationsandL/ Dratio

    2- Stations

    10 12 14 17

    L/Dratio

    3- Stations

    Rotary kiln design

    L:\DATA\Dept150\PolysiusPresentation and Training\PolysiusTraining\Pyroprocessing\Kiln\kiln process pptPage 13

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    Krupp Polysius Corp.

    L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt

    140 TEI, 140 CD

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    Thermal kiln loading

    Kiln diameter [m]

    Thermalload

    ing[kcal/m2/h]

    Millions

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    140 TEI, 140 CD

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    Gas velocity in rotary kiln

    2 3 4 5 6 7

    K iln dia

    6

    8

    10

    12

    14

    L/D = 1L/D =L/