Rotary Kiln Process Training: Krupp Polysius Corp

Page 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.
ppt
140 TEI, 140 CD
Rotary Kiln
Process Training
Krupp Polysius Corp.

Page 2 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD
The modern kiln plant
Preheater
Calciner
Clinker cooler
C
M
Raw mill
Rotary kiln

140 TEI, 140 CD
Process - technological kiln design
T
e
st
pro
c
ed
ur
e
r
epr
ese
nta
t
ii
ver
awmat
er
ia
ls
am
pl
e
t
es
ti
n gr
ad
ie
ntf
ur
na
ce
a
nal
ysi
sof
te
str
esu
l
ts
C
h
ar
ac
te
r
is
t
ic
da
t
aof
raw
ma
t
er
ia
l
• Fuel properties C
ompu
te
r
• Product quality R
e
su
l
t
s
• Concept of kiln
s
i
mul
at
io
n k
i
l
n d
i
men
s
io
ns
line o
f k
i
l
n s
p
eed
b
u
rn
i
ngpr
oce
s
s

140 TEI, 140 CD
Rotary kiln design
Required kiln parameter:
• Length and diameter

• Kiln inclination
• Degree of filling
• A-Mass
• Kiln inlet gas velocity
• Kiln speed
• Kiln shell cooling
Kiln static calculation

• Kiln drive power

140 TEI, 140 CD
Rotary kiln zones
Calcinaton
Transiton
Sintering
Coling
Prehater CalcinerPrehater
2 6 6 1
C
a
l
ci
ner
Ki
ln
7 3 4 1
P
r
eh
ea
t
er
Ki
ln
0 K
i
l
n L
e
ng
t
hi
n D 1
5
140 TEI, 140 CD
Kiln flame - temperature profile

140 TEI, 140 CD
Kiln temperature profils
2400
GasM(l
a o
teG
n ri
a
ga s
)Ml (s
(l
ao h
ten
ori
g
rta
))l (s h o rt )
2200
2000
1800
1600
1400
Temperatue[°C]
1200
1000
800
0 102030405060
K iln L en g

140 TEI, 140 CD
Kiln dimensions
• raw material characteristic

moduli: LSF, SM, AM
grinding fineness
quartz grain distribution
homogeneity
• impurities: alkali, SO3, Cl
• clinker quality (low alkali)
• type and quality of fuel

fuel preparation
alternative fuels
fuel flexibility

140 TEI, 140 CD
Kiln inlet temperature & kiln length
T emp erat u re ki
1 ,3 5 0
1 ,3 0 0
1 ,2 5 0
1 ,2 0 0
1 ,1 5 0
1 ,1 0 0
1 ,0 5 0
9 10 1112
1314
151617
L en g t h / d

140 TEI, 140 CD
Kiln dimensioning
Le
n
gt
h/
di
ame
t
er N
u
mb
er
ofki
l
n
K
i
l
n S
y
st
em V
o
lu
me
lo
ad
i
ng
rat
i
o su
p
por
ts
t
pd/
m³ -
L
o
ngK
i
l
n
-
wet 0
,
5..
.
0,7 3
0.
.
.40 5
-6
-
dry 0
,
5..
.0,
9 3
0.
.
.40 5
-6
L
e
po
l 1
,
7..
.2,
2 (
10)
13.
.
.17 (
2)3-
4
G
e
po
l 1
,
5..
2,0 1
5.
.
.17 3
-4
Cy
cl
one
pr
ehe
a
te
r
(
DOPOL
)
1
-
st
age 0
,
7..
.1,
0 2
5.
.
.35 5
-6
2
-
st
age 0
,
8..
.1,
2 2
0.
.
.30 4
-5
3
-
st
age 1
,
5..
.2,
0 1
5.
.
.17 3
-4
4
-
st
age 2
,
0..
.2,
5 (
14)
15.
.
.17 (
2)3-
4
5
-
st
age 2
,
0..
.2,
5 (
14)
15.
.
.17 (
2)3-
4
C
al
cin
erK
il
n (
PREP
OL)
-
Prepo
lA
T (2
..
.6
-s
t
age
) 2
,
5..
.3,
5 (
12,
5)1
4.
.
.17 (
2)3-
4
-
Pre
po
lA
S(
2.
..
6-
st
age
) 4
,
0..
.5,
0 (
11)
12.
.
.15
(
17) 2
-3(
4)

140 TEI, 140 CD
Degree of filling
C
apacit
y t/
d 2
200
N
om .Ki
ln d
iam et
er m 4,
00
D
i
am eter@ i
nlet m 4
,0
A
- Maß mm 2
600
F
F m m 0
,2
L
e
n gt
h m 48
,0
L
/D-i
nner - 1
2,
63
L
/
D -
outer - 1
2,
00
V
ol
um e l
oadi
ng tp
d/
m ³ 4,
50
K
i
lnFu el k
ca
l
/kgCl
i 340
T
her
m alloa
ding k
ca
l/
m ²
h 3
,
06E
+
006
K
i
lnvolum e m³ 489
F
r
ee crosssecti
on m² 1
0,
18
O
uterSurfa
ce m² 603
R
adi
ation k
ca
l/
kgKl 29
,6
Kil
n Fi
ll
ing
K
i
lnincl
inat
i
on [
% ] 3,
50
K
i
lnspee d [
1/mi
n] 3,
00
P
r
o c
es styp
e A
S
D
egree off
il
ling Proc
es
s [
%] 6,
03
D
egree off
il
ling m ec
ha
ni
cal [
%] 8,
41
D
i
fference(> 1,
5 %) [
%] 2
,
378
140 TEI, 140 CD
Rotary kiln design
P
r
oc
es
s-
te
ch
n
ol
ogi
cal
dim
en
s
i
ons
K
i
l
n w
i
t
h c
a
lc
i
ner
K
i
l
n w
i
t
h p
r
eh
ea
t
er
1
0 1
2 1
415 1
7
L/
Dra
t
i
o
N
u
mb
er
ofs
t
at
i
ons
an
dL
/Dr
at
i
o
2
-S
ta
t
i
ons
3
-S
t3
-
a
t
i
oS
nt
a
st
i
ons
1
0 1
2 14 1
7
L
/
Dra
t
i
o

140 TEI, 140 CD
Thermal loading [kcal/m2/h] Thermal kiln loading

Millions
Kiln diameter [m]

140 TEI, 140 CD
Gas velocity in rotary kiln
14
12
10
L
/
D
=
1
4
,
0
Gasvelocity[m/s]
8 @
1
2
0
0
°
C
6 4,0 4,
tp5d5,
t/m
p
0d³t
2 3 4 5 6 7 8
K iln diame

140 TEI, 140 CD
Gas velocity in rotary kiln
14
12
10
@
1
2
0
0
°
C
:
Gasvelocity[m/s]
8 4
,
5
t
p
d
/
m
³
6 L/DL=
/D12,
L=
/D5
14
2 3 4 5 6 7 8
K iln diame

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Page 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.

Krupp Polysius Corp.

The modern kiln plant

Krupp Polysius Corp.

Process - technological kiln design

Krupp Polysius Corp.

Rotary kiln design

Required kiln parameter:

• Length and diameter

Kiln static calculation

Krupp Polysius Corp.

Rotary kiln zones

Kiln flame - temperature profile

Krupp Polysius Corp.

Kiln temperature profils

Krupp Polysius Corp.

• raw material characteristic

• impurities: alkali, SO3, Cl

• clinker quality (low alkali)

• type and quality of fuel

Krupp Polysius Corp.

Kiln inlet temperature & kiln length

Krupp Polysius Corp.

Krupp Polysius Corp.

Rotary kiln design

Krupp Polysius Corp.

Thermal loading [kcal/m2/h] Thermal kiln loading

Kiln diameter [m]

Krupp Polysius Corp.

Gas velocity in rotary kiln

Krupp Polysius Corp.

Gas velocity in rotary kiln

Krupp Polysius Corp.

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