Precalciners
Learning Objectives Precalciners
Understand the principle of precalcination.
Know the basic precalciner types
Know the main features of the various precalciner types
Know the advantages of precalcination
Understand the principle of low NOx precalciners
Know possibilities and limits of lump fuel in precalciners
Precalciners: Content
Content
Principle and theoretical aspects
Precalciner design
ILC precalciners
Pre-combustion chambers
Low NOx precalciners
Solid AFR in PC: priority and new solutions
Optimization possibilities
Main Benefits of Precalciner Technology
Energy Balance of Process Steps for Clinker Burning
Endothermic Processes:
Dehydration of clays
Decarbonisation of calcite
Heat of melting
Heating of raw materials
(0 to 1450 C)
Total endothermic
Exothermic Processes:
Recrystallistion of dehydrated clay
Heat of formation of clinker minerals
Crystallisation of melt
Cooling of clinker
Cooling of CO2 (ex calcite)
Cooling and condensation of H2O
Total exothermic
Net Theor. Heat of Clinker Formation:
Endothermic - exothermic
kJ/kg cli
165
1990
105
2050
kcal/kgcli
40
475
25
490
4310
kJ/kg cli
40
420
105
1400
500
85
2550
kJ/kg cli
1760
1030
kcal/kgcli
10
100
25
335
120
20
610
kcal/kgcli
420
AT (Air Through) and AS (Air Separate)
Definitions:
PA = Primary Air
SA = Secondary Air
TA = Tertiary Air
TA
TA
PA
SA
PA
SA
Precalciner Preheater Arrangements
1 or 2 strings
In-Line
Off-Line
2 strings only
Pre-Combustion
Chamber
Hybrid
Separate Line
Comparison of Calciner Arrangements
Requirements I
Process:
High calcination degree
Good control of calcination degree
No material drop-out (meal, ashes etc)
No build-ups on walls
Simple and rapid start-up procedure
Forgiving operating behaviour
Flexibility regarding fuel ratio BZ / PC
Safe regarding equipment overheating
Minimum primary air requirement
Minimum pressure drop
Requirements II
Combustion:
High burnout degree of fuels
Best mixing of air (O2) with fuel
Instant ignition of all fuels
Direct return of fuel residues to kiln
Optimum combustion monitoring / control
Fuels:
Suitable for all fuel types (high flexibility)
Insensitive to changes of mix of fuels
Suitable for low reactivity and toxic fuels
Requirements III
Emissions:
Reduction of pollutants from BZ
No (low) generation of pollutants in PC firing
Possibility for SNCR
Tertiary Air System:
No dust deposits and dust cycles
No hot dust handling
Reliable O2-control for BZ and PC firing
Design:
Easy integration in preheater
Stepwise upgrading possible
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Precalciner Control
Via Fuel Rate
Normally 45% to 60% of total fuel
According to Calcination Degree
of bottom cyclone hot meal (via LOI);
Normally 85% to 95% apparent calcination degree
According to Gas Temperature at exit of bottom
cyclone;
Normally 840C to 890C
True and Apparent Calcination Degree
True calcination degree:
Degree to which the calcination is completed, i.e. extent
to which the CO2 is dissociated from the CaCO3.
Extremes: Raw meal
0%
(LOI=35%)
Clinker
100% (LOI= 0%)
Apparent calcination degree:
The calcination degree determined from a hot meal
sample taken from the meal duct of the bottom cyclone
O2 Control for PC/BZ: Tertiary Air Damper
pID fan
pC5 exit
Var. Dp1
Dp2
~pamb
/
O2 Control for PC/BZ: Kiln Riser Orifice
pID fan
pC5 exit
~pamb
Dp1
Var. Dp2
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Precalciner Elements
Long tubes gooseneck type
Large volume vessel type
Tertiary air frontal impact
Tertiary air tangential inlet
Orifice
Bends, curves and vessels
Multiple burners
Hot spot with and without control
Precombustion chamber
Dimensioning Criteria for Precalciners
1. Gas Retention Time (for combustion in pure air)
decisive for complete combustion
Fuel Reactivity
low
medium
high
Gas Retention Time
> 3.5
sec
> 2.5
sec
> 2.0
sec
2. Meal Retention Time
decisive for complete calcination
Actual meal retention times are 6 to 12 seconds,
at the above gas retention times.
Calcination takes much less than that which
means that meal retention time is not a
decisive design criteria.
Fuel Reactivity Examples:
Low:
Petrol coke
Medium:
Bituminous coal, natural gas
High:
Lignite, fuel oil
Inline Calciners:
Due to less favourable conditions for combustion
(presence of kiln gas, imperfect mixing of
tertiary air with kiln gas), the following rule of
thumb can be used for sizing this PC type:
Recommended gas retention time + 0.5 to 1 sec
Standard Precalciners
In-Line and Off-Line AT
FLS, KHD, KSL, Polysius
In-Line Calciners I
Polysius PREPOL
gooseneck type
In-Line Calciners II
FLS ILC
controlled hot spot
Pre-Combustion Chambers
RSP (Technip), FCB, Polysius, FLS
Calciners with Precombustion Chambers I
Onoda / CLE RSP (~1985)
Calciners with Precombustion Chambers II
FLS SLC-D
Downdraft (~2000)
Low NOx Precalciners
FLS, KHD, Polysius a.o.
Low NOx Precalciners
Polysius PREPOL
MSC
(Multi Stage Combustion)
KHD PYROCLON
Low NOx-Topair
Precalciners for Lump Fuels
(Tires etc): Future Development
FLS, Polysius, KHD,
Blue Circle, Ash Grove
PC for Solid AFR: FLS Hot Disc
FLS
Hot Disc
PC for Solid AFR: BC-Lafarge AFR Ram
Ash Grove
Controlled Ram for AFR modules
(Patent 2001)
Pre-Calciner: Typical Problems
1) CO at outlet
of PC or cyclone
5) Material
build-ups
6) Refractory
damage
2) Locally too
high temp.
7) Tertiary air
damper failure
3) Unburnt fuel
particles in
hot meal
8) Tertiary air duct
blockage
(elbow type only)
4) Too high / low
calcination
degree
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Main Benefits of Precalciner Technology
1. More stable kiln operation due to better kiln control via two separate
fuel feed/control points
2. More stable kiln operation due to controlled meal conditions at kiln inlet
3. Reduced thermal load of burning zone
4. Lower refractory consumption as a result of 1. to 3.
5. More than double capacities possible with given kiln (10'000 t/d: 6 x 95m)
6. Possibility of increasing capacity of existing kilns
7. Reduced volatilisation of circulating elements
8. Reduction of cycles (S, Cl, Na2O, K2O) with lower bypass rate / losses
9. Makes short kilns possible with 2 stations, L/D < 12
10. Possibilities of NOx reduction
11. Lump fuel (AFR) utilization (in-line only)
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