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The kiln bypass removes volatile elements like chlorine and sulfur from clinker production to control coating and clogging. A bypass extracts hot kiln gases with high volatile concentrations before they condense. Quenching cools the gases, causing volatiles to condense on collected bypass dust. Insufficient bypass rates or low volatile withdrawal can cause clogging or kiln shutdowns, while proper hot meal analysis and bypass adjustment prevents issues.
The kiln bypass removes volatile elements like chlorine and sulfur from clinker production to control coating and clogging. A bypass extracts hot kiln gases with high volatile concentrations before they condense. Quenching cools the gases, causing volatiles to condense on collected bypass dust. Insufficient bypass rates or low volatile withdrawal can cause clogging or kiln shutdowns, while proper hot meal analysis and bypass adjustment prevents issues.
The kiln bypass removes volatile elements like chlorine and sulfur from clinker production to control coating and clogging. A bypass extracts hot kiln gases with high volatile concentrations before they condense. Quenching cools the gases, causing volatiles to condense on collected bypass dust. Insufficient bypass rates or low volatile withdrawal can cause clogging or kiln shutdowns, while proper hot meal analysis and bypass adjustment prevents issues.
Category : Equipment Module: Kiln Bypass Unit: Bypass Principle 01 o 0! "ersion: 1#0 $%&0'&0( Bypass Principle Purpose: A )ypass creates a *al*e or circulating elements in t+e kiln and remo*es elements suc+ as Cl, sulur and alkalis until t+e coating-clogging situation in t+e pre+eater-kiln )ecomes controlla)le .it+ t+e +elp o cleaning# A )ypass is used or t+e remo*al o alkalis in case lo.&alkali cement is )eing produced Function/ Description: /+e kiln gases containing t+e *olatili0ed elements 1see unit circulation p+enomena2 are e3tracted at t+eir point o +ig+est concentration, i#e# t+e kiln inlet# /+is pre*ents t+em rom condensing in t+e pre+eater to.er and creating cyclone )lockages t+ere# 4t can roug+ly )e stated t+at or eac+ 100g-t cli o c+lorine o total input, 15 o )ypass rate is necessary# 6ue to t+e )ypass t+e +eat consumption o t+e kiln system is roug+ly increased )y 10 k7-kg cli or precalciner kilns and $0 k7-kg cli or pre+eater kilns per percent o )ypass rate# /+e eiciency o )ypass installations is most eicient or Cl and muc+ less or 8 and alkalis# /+ereore Cl )ypass rates are muc+ smaller t+an ot+er )ypass rates# Ater t+e )ypass t+e +ot kiln gases are quenc+ed in a mi3ing c+am)er .it+ t+e +elp o quenc+ing air alone or .it+ quenc+ing air and .ater in9ection# /+is quenc+ing +as t.o main reasons: 6ue to t+e cooling do.n o t+e gases t+e gaseous *olatile elements solidiy and condense on t+e kiln dust and is e3tracted as )ypass dust# /+is dust can )e separated rom t+e gas stream and remo*ed rom t+e kiln system# /+e +ot kiln gases 1ca# 11:0;C2 are cooled do.n to 1:0&(:0;C 1according to t+e ilter type used2 in order not to damage t+e ilter 1e#g# )ag ilters2 and-or in order to impro*e t+e eiciency o t+e ilter 1e#g# Electrostatic precipitators2 /+e quenc+ed gases are introduced into a ilter .+ere t+e )ypass dust is separated rom t+e gas# /+e gas is lead to t+e main or a separate )ypass stack or is reintroduced into t+e kiln system 1cooler, pre+eater, ra. mill, etc#2#/+e potential or t+e e3traction o *olatiles .it+ a )ypass is gi*en )y: *olatile e3traction potential < dust quantity = *olatile&concentration /+e collected )ypass dust is used or instance in cement as a iller or t+e *olatile elements can )e .as+ed out and remo*ed, t+e rest o t+e dust )eing reused as ra. material# Impact if not correctly functionin Clogging in t+e pre+eater to.er or ring ormation in t+e kiln E*entually kiln s+ut do.n Cement quality pro)lems in case o lo.&alkali cement production !auses of malfunctions 4nadequate )ypass rate 1too lo.2 /oo lo. alkali *olatili0ation and .it+dra.al 1lack o c+lorine added2 Erroneous +ot meal analysis o *olatile elements Pre"enti"e actions Correct +ot meal analysis o *olatile elements at least once per s+it Ad9ustment o t+e )ypass rate according to t+e +ot meal analysis See site specific unit for a##itional information$ respecti"e correcti"e actions an# applica%le safety instructions& 'M( #enotes maintenance issue
AD)*+,&#sf / -ma ./&+&*. 0uenc1 air fan 0uenc1 c1am%er clin2er intro#uction into t1e cement %a filter coolin to3er %ypass %a filter %ypass fan