In the name of Allah, the Beneficent, the Merciful

THE BYPASS
A solution for
Process

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Lets talk about bypass

What happens in the system ?

What are the minor elements ?
What do the minor elements do ?
Why do we need a bypass system ?
What is the bypass system ?
What are the calculations ?

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What happens in the system ?

Grinding

Heating up
Raw Meal

Raw Materials

Volatilization

Clinkerization
Clinker

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Hot Meal

What are the minor elements ?

They are chemical components of the raw materials with a
low concentration towards the other components.

Although some have no impact on the chemical process, others might lead to major
troubles.

In the cement industry, Cl, SO3, Na2O and K2O are,

among others, particularly monitored

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What are some elements doing ?

Problem with volatile elements
Low volatilization
temperature

Condensation on
cooler particles

Extraction from
material

Increase of
local
concentration

Flowing with
gases
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PROBLEMS

What are some elements doing ?

Volatilization temperature
+
Condensation temperature

2 Cases

Internal
Cycle

External
Cycle

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Internal and External Cycles

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Internal and External Cycles

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Definition of the Volatility

Volatility of a component

QVolatilized
Volatility
QTotal
Component

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Definition of the Volatilization

Volatilization of a component X in the kiln
Recirculation part
Hot meal

Clinker

X Ck

Volatilization X 100 1
X Hm
Note: Calculation done LOI free
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Volatility or Volatilization ?
Volatility
is a physical property of a component
is depending on the temperature
Is depending on the crystallographic structure
Volatilization
is depending on the considered area
is depending on the operation

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Different behaviors
Chloride
Alkalis
Sulfur

start evaporate around 650C

start evaporate around 900C
start evaporate around 1000C

Conclusion :
The various content of element is different according to the
analyzed area (kiln feed, meal cyclone 2, hot meal,
clinker,).
Nevertheless, most of the highest concentrations are
located at the kiln inlet, depending on the salt formation.

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Formation order

The salt formation

K 2O 2Cl 2 KCl
Na 2O 2Cl 2 NaCl
CaO 2Cl CaCl 2

Chlorines

K 2O SO3 K 2 SO 4
Na 2O SO3 Na 2 SO 4
CaO SO3 CaSO 4

Sulfates

K 2O CO 2 K 2CO3
Na 2O CO 2 Na 2CO3
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Carbonates

Calculation of the salt concentration

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Calculation of the salt concentration

K 2O 2Cl 2 KCl

Reaction 1

71

94
Quantity of KCl formed :

Cl used during the reaction :

Cl remaining after the reaction :

KCl

Cl KCl

149

149
100
a
94
100 e

71
100
a
94
100 e

71 100

Cl R1 c a
94 100 e

With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI

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Calculation of the salt concentration

Reaction 2

Na 2O 2Cl 2 NaCl
62

Quantity of Na2O that can be used with Cl :

NaCl formed during the reaction :

Na2O remaining after the reaction :

71
Na 2O

117

62
Cl R1
71

117
NaCl
Cl R1
71
100 62
Na 2OR 2
b Cl R1
100 e 71

With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI

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Calculation of the salt concentration

Reaction 3

Na 2O SO3 Na 2 SO 4
62

Quantity of Na2SO4 formed with Na2O : Na 2SO 4

SO3 used during the reaction :

SO3 remaining after the reaction :

80

142

142
Na 2OR 2
62

80
SO3 Na 20 R 2
62
100
80
SO3R 3
d
Na 2OR 2
100 e 62

With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI

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Why do we need such calculations ?

Better understanding of the cycles with the analysis

Better understanding of the build ups
Criteria of decision for a bypass system

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What is the bypass system ?

Raw Material composition
in minor elements

Volatility of some
elements
Process

Cycles creations
Bypass system
Salt formation
Troubles
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What is the bypass system ?

Clean gas emission

Separation
Electro filter

Cooling
Quenching chamber
Conditioning tower

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Dust collection

How much bypass ratio ?

The bypass
Decreases the concentration of minors in the
kiln inlet by taking a part of the kiln gas
Taking part of the heat
Taking part of the production
What has to be the bypassed gas quantity ?

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Two different ways

1 - Assuming that
Bypass % Cl % input (free of LOI) x 100
2- Complete calculation of the salts, taking into
account the volatility, the type of system (kiln,
preheater). Using the whole chemical theory.

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POLYSIUS process of decision for BP%

SO3, Cl,
Na2O, K2O

X% BP

X% BP

Yes

Bypass
Calculation
X%

<4%

Cl < 1%
hot meal

% Salts in hot meal

> 6%
< 60%

> 4%
< 6%

% CaSO4

> 60%
X% BP

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Example of decision
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Calculation of the bypass ratio

From the measurements done on site

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Definition of the Bypass Ratio

BypassRatio

VBypass
VKi ln

V Bypass = Volume of gas going to the bypass

V Kiln = Volume of gas going out of the kiln

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Definition of the calculation parameters

WD
to
VBP
to
VAF
to

WD
t1

VA
to

VBP
t1
VAF
t1
%O2(BP)

Va
ta

%O2(k), Vk

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Calculation of V Kiln
The volume coming out of the kiln is composed by :
1. The volume of the gas combustion
2. The volume of the decarbonation
3. The volume of excess air

VKi ln VComb VCO 2 VEx

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- V Comb
- V CO2
- V Ex

Calculation of V Comb
The main combustion equations are :
C + O2

CO2

S + O2

SO2

H2 + O2

H2O

CXHY + (x+Y/4) O2

x CO2 + Y/2 H2O

CXHY with Y = 2x + 2

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Calculation of V Comb
VComb CO 2

VComb H 2O

CO CO 2 x.CxHy Wg

100

H 2 H 2 S H 2O .CxHy Wg
2

100

VComb SO 2

VComb N 2

V Air min

H 2S Wg
100

0.79 VAir min N 2 Wg

100
100

2,381 CO 2,381 H 2 7,143 H 2S 4,762 O 2 4,762 x .CxHy Wg

4

100

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Calculation of V Comb
CO, CO2, H2, H2S, H2O, O2, N2, CxHy
% from natural gas composition analysis

VComb VCombCO 2 VComb H 20 VComb SO 2 VComb N 2

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Calculation of V CO2
CaO

MgO

CO3Ca CO2 + CaO

100
44
56

CO3Mg CO2 + MgO

84,3
44
40,3

44
CO2 CaO
56

44
CO2
MgO
40,3

0,748 CaO 1.092MgO 100 -

VCO2
) WCK
(
1,977 100
100

being the carbonation degree

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Calculation of V Ex
V Comb+ V CO2

V Kiln

V Ex
O2 Air

%O 2 ( k )
VEX
x (VCO2 VCOMB )
21 - %O 2 ( k )

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O2 Kiln
inlet

Calculation of V Kiln
The volume coming out of the kiln is composed by :
1. The volume of the gas combustion
2. The volume of the decarbonation
3. The volume of excess air

VKi ln VComb VCO 2 VEx

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- V Comb
- V CO2
- V Ex

Calculation of V BP
INPUTS

WD
to

OUTPUTS

VBP
to
VAF
to

WD
t1

VA
to

VBP
t1
VAF
t1
%O2(BP)

Va
ta

%O2(k), Vk

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Calculation of V BP
INPUT
VBP x CPGAS x (t1 20)
+ Va x CPAIR x (ta 20)
+ WD x CPdust x (t1 20)
+ VFA x CPair x (ta 20)
OUTPUT
VBP x CPGAS x (t0-20)
+ Va x CPAIR x (t0-20)
+ WD x CPdust x (t0 20)
+ VFA x CPair x (t0 20)

With False Air being calculated with O2 content in the bypass

VFA K VBP
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%O2 ( BP) %O2 ( Ki )

K
21 %O2 ( BP)

Calculation of VBP
As far as
Inputs = Outputs
VBP
CPAIR (t 0 - 20) - CPAIR (t a - 20)
Va
CPGAS (t 1 - 20) - CPGAS (t 0 - 20) - K CPAIR (t 0 - 20) - CPAIR (t a - 20)

WD

CPdust (t 1 - 20) - CPdust (t 0 - 20)

CPGAS (t 1 - 20) - CPGAS (t 0 - 20) - K CPAIR (t 0 - 20) - CPAIR (t a - 20)

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Calculation of the bypass ratio

Finally, knowing V Kiln and V BP

BypassRatio

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VBypass
VKi ln

Conclusion
Minor elements are to be considered for
operation decisions
Chemistry is able to help for any investigation
concerning the process troubles
The volatilization and cycles of the elements can
be handled through process operation
A good knowledge of the element circulation is
necessary for a good trouble shooting

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Questions and/or comments ?

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