Rotary Kiln Systems Explained

Kiln Systems
Dick Bekker CTL/TT
The Rotary Kiln
Holcim Group Support
Introduction to Cement Concrete & Aggregates
August 2006
In the Kiln System..

..the following processes occur:
1. Drying
2. Preheating
3. Calcination
4. Sintering
5. Cooling
3
August 2006
Materials into the kiln Raw Feed

The Primary Feed materials to the Kiln system are:
Limestone
Silica
Aluminum
Iron
These supply
CaO
SiO2
Al2O3
Fe2O3
(C)
(S)
(A)
(F)
These raw materials must be present in the correct
proportions in the raw meal or kiln feed.

4
August 2006
Major Clinker Compounds

The kiln system produces the clinker
compounds from raw-meal and coal ash
C3S
3CaOSiO2
alite
C2S
2CaO SiO2
belite
C3A
3CaO Al2O3
aluminate
C4AF
4CaO Al2O3 Fe2O3
ferrite
5
August 2006
Significance of the Clinker Minerals..

C3S
C2S
Contributes to early strength (1 - 28d+)

Contributes to late strength (28 d - ...)
Increases heat of hydration
Contributes to very early strength (1 - 2 d)
C3A
Increases heat of hydration

Reduces resistance to sulphate attack
C4AF Little effect

6
August 2006
Clinker Production Processess
We can identify four distinctly different production

processes
1. Wet Process
2. Dry Process
3. Semi-dry Process
4. Semi-wet Process
The wet process was the predominant process in

the past.
Today all new installations are dry process based

7
August 2006
Wet Production Process
August 2006
Wet Kiln System
August 2006
Semi-Wet Production Process
10
August 2006
Semi-Wet Kiln System - with grate preheater LEPOL
11
August 2006
Semi-Dry Kiln System - with grate pre-heater LEPOL
12
August 2006
Dry Production Process
13
August 2006
Dry Process Kiln System Pre-Heater
14
August 2006
Dry Process Kiln System -
Pre-Heater and Pre-Calciner
15
August 2006
Dry Process Kiln - Pre-Heater and Pre-Calciner

Five processes occur in a kiln
Drying
Preheating
Calcining
Sintering
Cooling
Preheater Pre-calciner Kiln
60%
Fuel Split
40%
16
August 2006
Components of a Kiln System
17
August 2006
18
August 2006
Chains
19
August 2006
Co-Current Heat Exchange
20
August 2006
Double Pendulum Flap
21
August 2006
5-Stage Cyclone Preheater
22
August 2006
23
August 2006
Counter-Current Heat Exchange
24
August 2006
Pre Calciner - General Features

Gases To
Second Stage
Raw Meal IN
Fuel
Raw Meal To
Kiln
Gases from Kiln
25
August 2006
26
August 2006
Kiln at Devils Slide
27
August 2006
Kiln Tire and Shell
28
August 2006
Kiln Shell Support & Drive - Dry Process
29
August 2006
The Kiln Hood
30
August 2006
The Kiln Hood

Connects the kiln to the cooler
Access door for maintenance and associated
equipment
Orifice for the burner
Cooled sight holes for observation, pyrometer, etc
31
August 2006
32
August 2006
The Burner Pipe
33
August 2006
The Ideal Flame
hot !
short !
stable
!
Complete
combustion:
- CO = 0
- SO2, NOx
"long" flame
"short" flame
Homogeneous:
- no temperature peaks
- no local CO on the clinker bed
34
August 2006
Coal and Gas Burner
35
August 2006
Burners
36
August 2006
Burner Adjustment
Adjustment of tip cross
section
axial- and radial air channel
connection
central air transport
air
Coal
Oil
PA
Kiln
central air
damper /
flap
axial- and radial

air damper / flap
Typical burner set-up (Rotaflam):

60% axial air, 30% radial air, central air 50mbar ( 10%)
37
August 2006
Coal and Oil burner before Operation
38
August 2006
Coal and Oil burner after Operation
39
August 2006
Alternative Fuels
Recycling wastes as fuel not only saves energy but also
safely destroys them
40
August 2006
Wet v/s Dry - A Question of Cost
Chains
41
August 2006
Wet v/s Dry - A Question of Cost

WET
Process
DRY
Process
kJ / kg
Clinker
kJ / kg
Clinker
Evaporation
of water
2050
38
20
Heat of reaction
1760
33
1760
55
Heat loss
from Process
1050
19
1120
35
540
Radiation &
Convection
TOTAL 5,400
10
300
100%
3,200
100%
42
August 2006
Energy Consumption by Process Type
PH/PC
Short Dry/PH
Long Wet
KJ/kg
7000
6500
6000
5500
5000
4500
4000
3500
3000
2500
250
500
1000
1500
2000
2500
3000
3500
4000
6000 10000
Tons/Day
Source: Holnam
44
August 2006
Dry Process Kiln - Pre-Heater and Pre-Calciner

Highest efficiencies as low as
2,900 kJ/Kg
High capacity - up to 4,000 T/d
for each pre-calciner string
Up to 12,000T/d per kiln system
Very low quantity of solid waste
System of choice for modern
plants
Preheater Precalciner Kiln
45
August 2006
Main Equipment of a Modern Kiln System
Dry process kiln (with 5-stage SP and PC

Dry process kiln (with 5-stage SP and PC)
Kiln ID
Kiln ID
Fan
Fan
Filter
Fan
Cooler
Dedusting
Meal
Dosing
Meal
Dosing
Precalciner
Fuel Dosing
Air-to-Air
5-stage
5-stage
Suspension
Suspension
Preheater
Precalciner
Fuel Dosing
Preheater
Cooler
Water
Kiln Fuel
Dosing
Low NOx
Precalciner
Low
NOx
Burner
Precalciner
Primary
Burner
Air Fan
Cyclone
Preheater
Cyclone
Preheater

Introduction to CementKiln
Concrete
& Aggregates
Drive
Burning Zone
Conditioning
Tower
46
August 2006
The Optimum Kiln System 2005

1) 5 stage preheater
with low pressure
drop cyclones
2) Large in-line
calciner with
AFR feeder
5) Oversized kiln
for AFR
6) High momentum
multi channel burner
3) Low NOx
with staged TA
swirl chamber
4) Pre-combustion
chamber, staged
meal feed
7) High efficiency
cooler
8) Roller
crusher
10) Splined
tyre fixation
9) Pneumatic seals
on both ends
47
August 2006
Starting up the Kiln System
Dry process kiln (with 5-stage SP and PC

Dry process kiln (with 5-stage SP and PC)
Kiln ID
Kiln ID
Fan
Fan
Filter
Fan
Cooler
Dedusting
Meal
Dosing
Meal
Dosing
Precalciner
Fuel Dosing
Air-to-Air
5-stage
5-stage
Suspension
Suspension
Preheater
Precalciner
Fuel Dosing
Preheater
Cooler
Water
Kiln Fuel
Dosing
Low NOx
Precalciner
Low
NOx
Burner
Precalciner
Primary
Burner
Air Fan
Cyclone
Preheater
Cyclone
Preheater

Introduction to CementKiln
Concrete
& Aggregates
Drive
Burning Zone
Conditioning
Tower
48
August 2006

Rotary Kiln Systems Explained

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Kiln Systems

Dick Bekker CTL/TT

The Rotary Kiln

Holcim Group Support

Introduction to Cement Concrete & Aggregates

In the Kiln System..

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Materials into the kiln Raw Feed

These raw materials must be present in the correct

proportions in the raw meal or kiln feed.

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Major Clinker Compounds

4CaO Al2O3 Fe2O3

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Significance of the Clinker Minerals..

Contributes to early strength (1 - 28d+)

Increases heat of hydration

C4AF Little effect

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Clinker Production Processess

We can identify four distinctly different production

The wet process was the predominant process in

Today all new installations are dry process based

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Wet Production Process

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Wet Kiln System

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Semi-Wet Production Process

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Semi-Wet Kiln System - with grate preheater LEPOL

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Semi-Dry Kiln System - with grate pre-heater LEPOL

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Dry Production Process

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Dry Process Kiln System Pre-Heater

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Dry Process Kiln System -

Pre-Heater and Pre-Calciner

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Dry Process Kiln - Pre-Heater and Pre-Calciner

Preheater Pre-calciner Kiln

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Components of a Kiln System

Holcim Group Support

Introduction to Cement Concrete & Aggregates

Components of a Kiln System