Overview of the pyroprocessing components

Training PODFA

New Kiln 7 Dry Line Project - JSC Podilsky Cement / Ukraine

November 2010

Polys ius
Pyroprocessing components

Pyroprocessing components
Training PODFA
November 2010
2 Polysius
Pyroprocessing components

Pyroprocessing components
Training PODFA
November 2010
3 Polysius
Pyroprocessing components

Pyroprocessing components
Training PODFA
November 2010
4 Polysius
Pyroprocessing components - Content

Overview
Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line

Pyroprocessing components
Training PODFA
November 2010
5 Polysius
Overview
Process functions •Water evaporation
of plant sections •Dehydration of clay
•Preheating of raw meal
•Cooling of exhaust gases
•Conveyance of gas and meal
•Partial decarbonization of raw meal
•Heating of raw meal
•Combustion
•Decarbonization
•Combustion
•Conveyance of gas and meal

•Clinker cooling
•Conveyance of meal and gas •Preheating
•Residual decarbonization Combustion air
•Granulation of meal/clinker •Conveyance of
•Clinker mineral formation clinker and air
•Combustion

Pyroprocessing components
Training PODFA
November 2010
6 Polysius
Overview
Basic 80 °C 340 °C; To raw mill
and / or EP
temperatures
and flows

Pre heater
Calciner
900 °C
Tertiary Air Duct
Fuel
55 – 60 %
1700 °C Fuel 280 °C; to
860 °C Rotary kiln EP
40 – 45
%
350 °C
1400
°C
Clinker cooler 80 - 100 °C

Ambient air temp.

Pyroprocessing components
Training PODFA
November 2010
7 Polysius
Pyroprocessing components and operation - Content

Overview

Preheater/ /calciner
Preheater calciner

Rotary kiln

Cooler

Operation of the kiln line

Pyroprocessing components
Training PODFA
November 2010
8 Polysius
Preheater / calciner - Topics

Gas and material flow

Preheater system

Cyclon functioning

Double rotary airlock feeder

Pneumatic flat slide gate

Hot meal pendulum flap

Calciner types

Pyroprocessing components
Training PODFA
November 2010
9 Polysius
Preheater / calciner
Gas and material flow
Meal

Gas

Gas
Meal
Pyroprocessing components
Training PODFA
November 2010
10 Polysius
Preheater / calciner
Preheater System - DOPOL® 90

Calciner cyclone System cyclone Dedusting cyclone

Pyroprocessing components
Training PODFA
November 2010
11 Polysius
Preheater / calciner
Cyclone functioning
Gas duct
Dip pipe

Raw meal

Meal chute

Dispersions box
Gas duct
Raw meal
Pyroprocessing components
Training PODFA
November 2010
12 Polysius
Preheater / calciner
Cyclone functioning

Pyroprocessing components
Training PODFA
November 2010
13 Polysius
Preheater / calciner
Cyclone functioning

Pyroprocessing components
Training PODFA
November 2010
14 Polysius
Preheater / calciner
Cyclone functioning

= 85 micra
= 71 micra
= 57 micra

Pyroprocessing components
Training PODFA
November 2010
15 Polysius
Preheater / calciner
Double rotary
airlock feeder

Pyroprocessing components
Training PODFA
November 2010
16 Polysius
Preheater / calciner
Pneumatic flat
slide gate

Pneumatic
cylinder

Valve

Air supply
system

Pyroprocessing components
Training PODFA
November 2010
17 Polysius
Preheater / calciner
Hot meal pendulum flap

Pyroprocessing components
Training PODFA
November 2010
18 Polysius
Preheater / calciner
Calciner types

Pyroprocessing components
Training PODFA
November 2010
19 Polysius
Preheater / calciner
PREPOL MSC

Pyroprocessing components
Training PODFA
November 2010
20 Polysius
Preheater / calciner
Cyclone preheater DOPOL 90 & PREPOL MSC calcinator

Pyroprocessing components
Training PODFA
November 2010
21 Polysius
Pyroprocessing components and operation - Content

Overview

Preheater / calciner

Rotarykiln
Rotary kiln

Cooler

Operation of the kiln line

Pyroprocessing components
Training PODFA
November 2010
22 Polysius
Rotary kiln - topics

Kiln types and tertiary air duct

Kiln shell

Reactions and mineral formations

Technological kiln design

Low dust kiln inlet

Examples

Pyroprocessing components
Training PODFA
November 2010
23 Polysius
Rotary kiln
Kiln types and tertiary air duct

Gas
Meal
Fuel

Pyroprocessing components
Training PODFA
November 2010
24 Polysius
Rotary kiln
Kiln types and tertiary air duct - Rotary kiln development
5 - support kiln

3 - support kiln

2 - support kiln

Pyroprocessing components
Training PODFA
November 2010
25 Polysius
Rotary kiln
Kiln types and tertiary air duct - Rotary kiln development
3-support kiln vs. 2-support kiln

Statically undefined Statically defined

• possibility of • constant support loading

- extreme overload
- plastic deformation • elastic deformation only

• requirement for • no sensitivity to misalignment

- extra safety margin
- regular adjustment
Pyroprocessing components
Training PODFA
November 2010
26 Polysius
Rotary kiln
Kiln types and tertiary air duct - Tertiary air duct

Pyroprocessing components
Training PODFA
November 2010
27 Polysius
Rotary kiln
Kiln types and tertiary air duct - Function of the kiln shell

Conveys material

Guides gas from cooler to kiln

Creates a constant moving material bed

Allows heat exchange between gas and material

Holds the brick lining

Pyroprocessing components
Training PODFA
November 2010
28 Polysius
Rotary kiln
Kiln types and tertiary air duct - Reactions and mineral formations

Preheater Kiln

Calciner
Raw meal

Clinker
Clay minerals

Temperature [°C]
Pyroprocessing components
Training PODFA
November 2010
29 Polysius
Rotary kiln
Kiln types and tertiary air duct - Technological kiln design - rotary kiln zones

Calcination

Transition

Sintering

Cooling
Preheater
Calciner
2 6 6 1
Calciner kiln
Preheater

7 3 4 1
Preheater kiln
0 Kiln length in D 15
Pyroprocessing components
Training PODFA
November 2010
30 Polysius
Rotary kiln
Kiln types and tertiary air duct - Technological kiln design
Test procedure
representative raw material sample
test in gradient furnace
analysis of test results

Characteristic data of raw material

• Fuel properties Computer

• Product quality simulation Results
• Concept of kiln kiln dimensions
line
of kiln speed
burning process

Pyroprocessing components
Training PODFA
November 2010
31 Polysius
Rotary kiln
Kiln types and tertiary air duct - Rotary kiln dimensioning

Kiln length (m)

L/D = ~ 12 - 17
Kiln diameter (m)

Clinker production (t/d)

Spec. volumetric load = ~ 4,0 - 4,5
Kiln volume (m³)

Energy flow (kJ/h)

Sintering zone load = ~ 12 - 25*106
Kiln cross section (m²)

Pyroprocessing components
Training PODFA
November 2010
32 Polysius
Rotary kiln
Kiln types and tertiary air duct - Rotary kiln design
Process - technological dimensions

Kiln with calciner

Kiln with preheater

10 12 14 15 17
L / D ratio

Number of stations and L / D ratio

2 - Stations

3 - Stations
3 - Stations

10 12 14 17
L / D ratio
PODFA L / D = 82 m / 5,4 m = 15,2
Pyroprocessing components
Training PODFA
November 2010
33 Polysius
Rotary kiln
Kiln types and tertiary air duct - Gas velocity in rotary kiln

14

12
Gas velocity [m/s]

10

6 4,0 tpd/m³ 4,5 tpd/m³ 5,0 tpd/m³

2 3 4 5 6 7 8
Kiln diameter [ m ]
Pyroprocessing components
Training PODFA
November 2010
34 Polysius
Rotary kiln
Kiln types and tertiary air duct - Low dust kiln inlet

Controlled inflow of hot meal

Minimized dust intake into calciner

Reduction of internal re-circulation

Meal

Gas
Pyroprocessing components
Training PODFA
November 2010
35 Polysius
Rotary kiln
Kiln types and tertiary air duct - Examples

DO NOT COPY THESE EXAMPLES

Kiln shell and tyre Kiln inlet sealing

Pyroprocessing components
Training PODFA
November 2010
36 Polysius
Rotary kiln
Kiln types and tertiary air duct - Examples

DO NOT COPY THESE EXAMPLES

Riser duct at calciner throttle

Riser duct at calciner throttle

Pyroprocessing components
Training PODFA
November 2010
37 Polysius
Pyroprocessing components and operation - Content

Overview

Preheater / calciner

Rotary kiln

Cooler
Cooler

Operation of the kiln line

Pyroprocessing components
Training PODFA
November 2010
38 Polysius
Cooler - topics

POLYTRACK clinker cooler

Aeration and air distributors

Cooler parameters

Pyroprocessing components
Training PODFA
November 2010
39 Polysius
Cooler

Meal

Gas

Pyroprocessing components
Training PODFA
November 2010
40 Polysius
Cooler - POLYTRACK

Air blast unit

Socket for Upper housing
Bull-nose
cooling

Static Movable grate

grate

Inspection ports Grate equipment

Drive and Lower housing
Grate sub-structure
unit thermo couples
Pyroprocessing components
Training PODFA
November 2010
41 Polysius
Cooler - POLYTRACK
Clinker Tetiäry air Waste air
(1400 °C) (900 °C) (280 °C)
Secondary
air (950 °C)

Static grate

Cooling air Clinker

(25 °C) (80 °C)
Pyroprocessing components
Training PODFA
November 2010
42 Polysius
Cooler - POLYTRACK

POLYTRACK 10 tracks
2 grates
6 modules

Pyroprocessing components
Training PODFA
November 2010
43 Polysius
Cooler - POLYTRACK M
Mode of working

Example of a POLYTRACK® with

5 transport tracks
M Material flow direction V 1.
V Forward stroke
1. 1st return stroke
2. 2nd return stroke
3. 3rd return stroke

2. 3.
Pyroprocessing components
Training PODFA
November 2010
45 Polysius
Cooler - POLYTRACK
Aeration arrangement

Pyroprocessing components
Training PODFA
November 2010
46 Polysius
Cooler - POLYTRACK
Air distributors in chambers 1 -3

Pyroprocessing components
Training PODFA
November 2010
47 Polysius
Cooler - POLYTRACK
Air distributors in chambers 1 -3

To replace a pendulum
counterweight, first remove
one of the spring cotters
and then pull out the pin.
Then the pendulum
counterweight can be
removed.

Install analogously in
reverse order.

Pyroprocessing components
Training PODFA
November 2010
48 Polysius
Cooler - POLYTRACK
Clinker temperature as a function of crushed clinker

350

Clinker temperature [°C]

300
250
200
150
100
50
0 10 20 30 40
Amount of crushed clinker [%]
Crushed clinker at 400°C

Crushed clinker at 600 °C

Pyroprocessing components
Training PODFA
November 2010
49 Polysius
Cooler - POLYTRACK
Cooler efficiency
82

80

78
Cooler efficiency [%]

76

74

72
Referring to 20 °C ambient air and
70
1400 °C clinker temperature
68
0,75 0,8 0,85 0,9 0,95
Secondary- and tertiary air [Nm³/Kg Cl.]

Pyroprocessing components
Training PODFA
November 2010
50 Polysius
Pyroprocessing components
Training PODFA
November 2010
51 Polysius