Presentation

on

Pre-heater &

Pre-calciner Systems

FLSmidth 2008 all rights reserved.

Agenda

Evolution of Pre-heater Technology

Pre-heater Configurations

Process and Operation

Heating Up/ Start / Stop

Instrumentation and Interlocks

Safety

Discussions

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-1950

1950
to
1960

1970

1990

2000 -

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Rotary kiln for the entire process
Very long kiln low capcity

Rotary kiln capacity development

Wet/long dry Kilns
1898: 1.8x18m
35 tpd
t d
1967: 7.6x232 m
3500 tpd

Preheater kilns
1970: 6.0x96 m
4000 tpd Precalciner kilns
1984: 5.0x80 m
5500 tpd
1990: 6.0x96 m
10,000 tpd
2006 :6.6x96
12,000 tpd

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 History/Background
Over the years the clinker manufacturing process (from cold
raw meal to clinker) has changed.
More and more of the pprocess takes p
place outside the kiln.
In a rotary kiln the heat is transferred In a preheater/calciner the fine
from the gas flowing in the free cross raw meal is suspended in the gas
section to the bulk raw meal in the and heat is exchanged rapidly
bottom. An inefficient heat transfer! between the gas to the fine
particles.

Gas
Kiln

Raw meal

History/background
Volumetric Load of Kiln as Function of Type of Kiln System
Kiln System Volumetric Load
tpd/m3
Long dry/wet <1
SP 1.8 - 2.3
Calciner types 3.6 - 5. 3 (6.0)

Thanks to the preheater and the precalciner we can get much

more production for the same kiln volume; reduce heat loss etc.
etc

The rotary kiln is still second to none when it comes to formation

and handling of clinker which are sticky and partly melted.

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 Kiln sizes and preheater configurations

TPD Production 3 base Rotax 2 kiln

12000 kiln L/D~13

Three string 6.00 95

Two string
10000
One string 5.75 91
6.00 72
5.50 87
8000 5.75 69
5.25 82

Kiln dimensio
5.50 66
6000 5.00 78
5.25 62
4.75 74 5.00 60

ons
4.55
4 55 71 4.75 56
4000 4.35 67
4.55 54
4.15 64
3.95 60 4.35 51
4.15 49
3.75 57 3.95 46
2000 3.60 54 3.75 44
3.60 42
3.30 49 3.45 40

0
SP ILC-E ILC SLC SLC-I SLC-D

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Standard kiln types

FLS 2-base kiln Rotax 2
13 x D inside lining
6.8 x D 3.6 x D
23xD
2.3
D

FLS 3-base kiln

17 x D inside lining
6.4 x D 2xD
1.3 x D 5.3 x D
D

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 Suspension Preheater

ILC - In-Line Calciner

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 Different Preheater Types

Typical Preheater Tower

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 Heat transfer

Material
M t i l Heat
Separation Transfer

The counter current flow between the raw meal and the kiln gases
provides for the heat transmission as shown in the figures above and in
detail in the figure bellow

Cyclone

The gas enters the cyclone (Figure 1)

tangentially at the top of the cylindrical
section and spirals downwards into the
conical section. Dust particles which have
more inertia than the gas molecules, are
pulled out of the gas towards the wall.
The dust is collected at the bottom, while
the gas leaves the cyclone by the central
outlet at the

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 Design components.
The cyclone preheater consists of the following parts:
1 Tangential duct + 1st stage central pipe
2 Cyclones
3 Riser duct
4 Where necessary, a calciner
5 Smoke chamber
6 Down pipe with various equipment .
7 Where necessary, a bypass duct
8 Platforms + various cleaning equipment
9 Instrumentation
10 Central Pipes

PREHEATER Major Parts

Cyclones
Riser ducts
Calciner
Feed chutes
Kiln riser transition piece

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Low NOx calciner
Raw meal duct

Mixing zone Splitter gate

Vmin(ILC) = 6m/s
Restriction area
Retention time
(ILC) = 3.3s

Splitter gate

Tertiary air duct inlet

Reduction zone

Fuel
Kiln riser

Simulation of mixing
of TAD and Kiln
gases in ILC-
Calciner

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 Fuels for Calciner firing

Coal
Oil
Natural Gas

Alternate Fuels for Calciner firing

Petroleum coke
Solid waste
Tire chips

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Process in pyro system

TEMPERATURE TYPE OF
RANGE IN C CHARACTERISTICS PROCESSES PROCESS
- 100 Drying, evaporation of free water Endothermic
100 - 400 Elimination of absorbed water Endothermic
400 - 750 Decomposition of clay minerals Endothermic
Kaolinite metakaolinite
600 - 900 Decomposition of metakaolinite to free Endothermic
reactive oxides
600 - 1000 Decomposition of carbonates to free Endothermic
reactive oxides
800 - 1300 Combination of reactive oxides to form Exothermic
intermediate or final clinker minerals
1300 - 1380 Formulation of clinker melt from aluminates Endothermic
and ferrites
1250 - 1500 Formation of Alite (C3S) the principal Endothermic
clinker mineral

Endothermic = Energy consuming process

Exothermic = Energy releasing process

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 Energy consumption (typical)
kcal/kg
Heat of Reaction Clinker

Evaporation of combined water 20

Decomposition of clay minerals 35

Decomposition of carbonates 475

Heat of formation of clinker minerals -115

Total heat of reaction 415

However with losses modern pyrosystems consume approx.

700-750 kcal/kg clinker

Kiln heat consumption

Process kcal/kg
W t process with
Wet ith chains
h i +/-
+/ cross ~1400-1600
1400 1600

Long dry process with chains +/- cross ~1100

1-stage cyclone preheater ~1000

2-stage cyclone preheater ~900

4-stage cyclone preheater ~800

4-stage preheater+precalciner+Cross bar cooler ~735-760

5-stage preheater+precalciner+ Cross bar cooler ~715-740

6-stage preheater+precalciner+ Cross bar cooler ~700

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 TYPICAL HEAT BALANCE:
5-STAGE MODERN KILN SYSTEM
Heat Consumption
kcal/kg
SURFACE HEAT LOSS FROM KILN 28
SURFACE HEAT LOSS FROM PREHEATER 40
COOLER LOSS 107
EXIT GAS HEAT LOSS 163
HEAT OF REACTION 415
FREE WATER 5
FREE INPUT WITH RAW MEAL + FUEL - 30
COMBUSTIBLES IN RAW MEAL -8
NET HEAT CONSUMPTION 720

By adding a number co-current heat exchanging cyclone stages

on top of each other then counter-current heat exchanging can be

The
h number
b off stages d
determines
i
the degree of heat
exchanging in With increasing number of
Preheater

the preheater stages, the heat consumption

will decrease and the
temperature of the exit gas
from the top stage lowered.
The drying potential of the
exit gas also drops.
Cyclone P

2 3 4 5 6 stages
>850 790 750 725 710
Lower heat consumption
550 450 360 315 275
Lower exit gas temperature

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 Number of stages choosen from raw material moisture

Raw 0-3% 0-5% 0-8% 0-12% 0-16% 0-22%

material
Humidity
Preheater 5 or 6 5 4 or 5 3 or 4 2 or 3 1 or 2
stages

Cyclone Preheater

Cyclone sizing is based on pressure drop considerations. The pressure

drop which is proportional to the square of the gas velocity is normally
500 1000 Pa.
A too large preheater with low velocity will make the preheater unstable
as the raw meal may drop through instead of be lifted up to the
cyclone.
A too small preheater will give a high pressure drop and thereby a high
fan power consumption

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 Preheater cyclones

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Typical Preheater Cyclone Efficiency

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Calciner Gas Vel & RT

Safety

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 Protective clothing

When working with hot dust a complete fireproof suit must be worn.

Hot dust

Hot dust can unexpectedly blow out through any opening in the
system. Keep doors and ports closed! Hot dust can ignite
flammable materials in the area.

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 Dust hazard

Be careful around kiln seals. Hot dust can blow out during
process upsets. Kiln dust also contains lime, which can burn
skin and eyes.

Dust hazard

Know where your shower and eyewash stations are!

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 Fall Protection

Always wear your safety harness when working above ground.

Air blasters

Discharge Lock Out the Test That the

Shut off
the Tank Air Valve Tank is Empty
the Air

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 Lockout/Tagout

Follow your plants safety lockout procedures. Lock out all

equipment affecting the area in which you are working.

Carbon Dioxide (CO2)

Carbon dioxide (CO2) is a normal product of the

biological process, but too much CO2 can kill.

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 Steam Explosions

Use of water around a kiln can be deadly. Water coming into

contact with hot kiln feed or clinker can vaporize in an instant,
causing a steam explosion. Especially, be careful around wet
process kilns.

Preheater Flush

Never work anywhere on a kiln system while a preheater vessel is

plugged. If the plug breaks free it will rush like water through the
system, burning everything in its path.

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 Preheater Flush

These men were working inside a kiln when a preheater

flush occurred. Two fatalities resulted.

Preheater Flush

These men were working outside a clinker cooler when a

preheater flush occurred, spewing hot material through an open
man-door. Two fatalities resulted.

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Coating in an ILC preheater

Coating collapse

Do not work under loose kiln coating.

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 g{t~

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