Preheat Process

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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD
140 TEI, 140
Preheater and Calciner Process Training
Krupp Polysius Corp.
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The modern kiln plant

Preheater
Calciner
Clinker cooler
C M
Raw mill Rotary kiln
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Preheater
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DOPOL 90
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Gas and material flow in a preheater
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DOPOL 90 B-type cyclone

1 2 3 1 2 3 4 5 Cyclone Intermediate piece Dip pipe Gas duct Meal chute
4
5
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Cyclone types
Dedusting cyclone System cyclone Calciner cyclone
DOPOL 90
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The modern kiln plant

Preheater
Calciner
Clinker cooler
C M
Raw mill Rotary kiln
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DOPOL 90 - preheater design
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Technical data
Number of cyclone
Exhaust gas - temperature - volume - dust relative to clinker - pressure loss Fuel consumption Cooler efficiency Clinker temperature Cooling air Cooler vent air - volume - temperature Electrical power consumption - for exhaust gas fan - for total kiln plant Permitted RM moisture - exhaust gas only (with coal mill) - exhaust gas only - exhaust gas with exhaust air % % % 7,6 8,5 11 5,6 6,5 9,5 4,3 5,3 8,7 kWh/t clinker kWh/t clinker 5,6 15,1 5,7 15,2 6,1 15,7 Nm/kg clinker C 0,84 295 0,87 305 0,88 312 C Nm/kg clinker % mbar kcal/kg clinker % C Nm/kg clinker 370 1,372 8 33 740 74,6 100 1,7 315 1,353 6,5 38 718 73,1 100 1,7 280 1,345 5 45 705 72,1 100 1,7
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Drying capacities - preheater systems

600 500 400 300 200
PH exhaust only --> AS 6 AS 5 AS 4 AS 3 AS 2
24 20 16 12 8 4 0 900 Drying capacity [ % - H2O ]
<-- PH exhaust temp.
Exhaust gas temp. [ C ]
PH + cooler exhaust-->
100 0 700 750 800 850
Fuel consumption [ kcal/kg cli ]
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Calciner
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Calciner types
PREPOL AS
PREPOL AS-CC
PREPOL MSC
PREPOL MSC-CC
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PREPOL AT
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PREPOL AS
Calciner loop
Fuel injection TA-duct
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PREPOL AS-CC
Calciner loop
Combustion chamber
TA-duct
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Combustion - Chamber (CC)

Burner
Meal inlet
Central inlet for tertiary air
Meal inlet
Tangential inlet for tertiary air inlet Tangential inlet for tertiary air inlet
CC-Chamber outlet (Connection to the calciner)
Tertiary duct
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PREPOL MSC
Deflection chamber
Top air duct
Meal staging PC - burner
Tertiary air duct
Kiln inlet burner
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PREPOL MSC-CC
Deflection chamber
Top air duct
Tertiary air duct
PC - burner
Kiln inlet burner
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Tertiary air duct
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MSC Calciner with Tire Feed Chute
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Tertiary air from cooler
w > 26 m/s
w < 8 m/s
w < 8 m/s
w < 6 m/s
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Tertiary air from kiln hood
w > 2 6 m / s
w < 5 m / s
w < 5 m / s
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Tertiary air connection

kiln hood secondary air temperature
thermal stress on outlet segments burn out in the calciner precalcination rate bypass losses load of sintering zone thermal stress on tertiary air flap and refractory size of kiln hood length of burner NOx - formation Investment cost cooler measures
lower
+ lower + better - lower - higher - higher - higher - bigger - longer (+ lower) - higher
higher
- higher - worse + higher + lower + lower + lower + smaller + shorter (- higher) + lower optimized burner adjustment adapted dimensionnig and quality of refractory better cooling and form of segments CC - Calciner
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Low-dust kiln inlet
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Calciner volume loading

T h e r m a l c a l c i n e r l o a d i n g i n k c a l / m / h F u e l t y p e N a t u r a l g a s F u e l o i l P R E P O L A S P R E P O L A T < 1 0 0 0 0 0 < 1 2 0 0 0 0
< 1 5 0 0 0 0 < 1 8 0 0 0 0
h i g h r e a k t i v e C o a l
< 1 3 0 0 0 0
< 8 7 0 0 0
l o w r e a k t i v e C o a l e . g . P e t C o k e
< 9 0 0 0 0
< 6 0 0 0 0
< 8 0 0 0 0
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Fuel design and distribution
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Coal - activity
O2-concentration [%]
Time [s]
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NOx - generation in clinker burning process
Calciner:
Fuel - NOx - exess air - nitrogen content - reactivity
Sintering zone:
Thermal NOx - temperature - exess air - retention time
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Combustion conditions for NO reduction by fuel, air and meal staging

Meal H2 O NO N2 CO2 NHi H2 O CO2 N2 NO CH i CO
NO
> 1,05
0,9 <
< 1,05
0,4 - 0,6 Q
CHi
Air
0,9 <
< 1,05
> 0,1 Q Fuel Stage 4
CO2 H2 O N2 CO NH i
NO
Q = total fuel = excess air figure
Stage 3 0,4 - 0,6 Q Stage 2 Stage 1
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NOx and O2 at kiln inlet
NOx at kiln inlet [gNO2/kgcli]
O2 at kiln inlet [%]
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NOx - generation and volatiles

NOx - generation in calciner [NO2/kgcli]
Volatile matter in fuel [%]
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NOx and Nitrogen in fuel
NOx [NO2/kgcli]
Nitrogen in fuel [%]
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Nox and calciner temperature
NO2 [mg/Nm3] @ %O2
Calciner temperature [C]
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Operating results MSC plants
NOx - emission [gNO2/kgcli]
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2. 5
A S -MS ope Cra - ope ti on ra 2

8 0 0 m g N O 2 / N m ( 1 0 % O 2 )
1. 5
5 0 0 m g N O 2 / N m ( 1 0 % O 2 )
3 2 % 5 3 % 3 0 %
3 5 % 2 8 %
NOx-Emison[gNO2/kgCli]
0. 5
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2.5
KI - A MS S -C o p er o p at er io at nio n AS - o p er at io n
2
8 0 0 m g N O 2 / N m ( 1 0 % O 2 )
1.5
5 0 0 m g N O 2 / N m ( 1 0 % O 2 )
NOx-Emison[gNO2/kgKl]
3 2 % 3 0 %
3 5 % 5 3 % 2 8 %
0.5
0 P l a n t
F u e l
A 8 0 % P e t C o k e 2 0 % C o a l
B L i g n i t e
C C o a l B l e e c h i n g E a r t h P a p e r w a s t e F l y A s h 2 7 , 3 %
D C o a l T y r e s P l a s t i c
E O i l P a p e r w a s t e P l a s t i c C a r b o n M a r l > 4 0 %
V o l a t i l e s i n f u e l
1 5 %
4 5 %
~ 2 5 %
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2.5
KI - A MS S -C o p er o p at er io at nio n AS - o p er at io n
2
8 0 0 m g N O 2 / N m ( 1 0 % O 2 )
1.5
5 0 0 m g N O 2 / N m ( 1 0 % O 2 )
NOx-Emison[gNO2/kgKl]
3 2 % 3 0 %
3 5 % 5 3 % 2 8 %
0.5
0 P l a n t
F u e l
A 8 0 % P e t C o k e 2 0 % C o a l
B L i g n i t e
C C o a l B l e e c h i n g E a r t h P a p e r w a s t e F l y A s h 2 7 , 3 %
D C o a l T y r e s P l a s t i c
E O i l P a p e r w a s t e P l a s t i c C a r b o n M a r l > 4 0 %
V o l a t i l e s i n f u e l
1 5 %
4 5 %
~ 2 5 %
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NOx - prognosis
NOx - emission
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CO - prognosis

Preheat Process

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Preheat Process

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Page 1

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Preheater and Calciner Process Training

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

The modern kiln plant

Raw mill Rotary kiln

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Gas and material flow in a preheater

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

DOPOL 90 B-type cyclone

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Dedusting cyclone System cyclone Calciner cyclone

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

The modern kiln plant

Raw mill Rotary kiln

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

DOPOL 90 - preheater design

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Drying capacities - preheater systems

24 20 16 12 8 4 0 900 Drying capacity [ % - H2O ]

<-- PH exhaust temp.

Exhaust gas temp. [ C ]

100 0 700 750 800 850

Fuel consumption [ kcal/kg cli ]

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140

Fuel injection TA-duct

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt CD

140 TEI, 140