PREPOL® - Preheater - Design

Training PODFA

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

November 2010

Polys ius
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Clinker Production

Raw material- Clinker- Cement-

preparation production production

5
9
4
1
6
2 3 6 7 8 10 11

1. Crushing 7. Burning
2. Storage, Mixing 8. Cooling
3. Dosing 9. Storage
4. Grinding 10. Grinding
5. Homogenising 11. Storage, Packing and Loading
6. Preheating, Calcining
Design Reheater- PREPOL®
Training PODFA
November 2010
2 Polysius

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PREPOL® - Preheater
Content

Preheater system

Low dust kiln inlet

Calciner – PREPOL®-MSC

Cyclone stages

Meal chutes

Tertiary air duct

Shock blower system

Removal of deposits

Design Reheater- PREPOL®

Training PODFA
November 2010
3 Polysius

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Preheater System – DOPOL® 90

Main function - Cyclone preheater:

+ heat transfer (gas/solid)
- parallel flow (each cyclone stage)
- counter flow (all stages)
+ separation (gas/solid)

 Polysius Preheater System - DOPOL® 90

Design Reheater- PREPOL®

Training PODFA
November 2010
4 Polysius

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Preheater System – DOPOL® 90

Cyclone The DOPOL 90® preheater is a counter

flow heat-exchanging system.
Gas duct

Meal chute Material flow

Calciner Gas flow

Tertiary air
duct
For PODFA we build a preheater with
2-string and 4-stages for a capacity of
7500 t/d.
Kiln inlet

Design Reheater- PREPOL®

Training PODFA
November 2010
5 Polysius

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Preheater System
Temperature profile

360 – 650°C

570 – 960°C

750 – 1130 °C

880 – 1260 °C

Calciner Tertiary air

>950°C duct
720°C

Kiln inlet
1150°C
Design Reheater- PREPOL®
Training PODFA
November 2010
6 Polysius

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Preheater System
Modular Calciner System
PREPOL AS PREPOL AS - CC PREPOL MSC PREPOL MSC - CC

→ Combustion
Important design criteria: → Retention time
→ Material transport
Design Reheater- PREPOL®
Training PODFA
November 2010
7 Polysius

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Preheater System – PREPOL MSC
Combustion conditions for NO reduction by fuel, air and meal staging
Meal
> 1,05
H2 O NO
N2 CO2
NHi
H2 O
CO2 0,9 < < 1,05
N2
NO
CHi
0,4 - 0,6 Q CO
CHi Air 0,9 < < 1,05
NO
CO2
H2 O
≤ 0,1 Q N2
CO NO
Fuel
NHi
Stage 4
Q = total fuel
= excess air figure
Stage 3

0,4 - 0,6 Q

Stage 2
Stage 1

Design Reheater- PREPOL®

Training PODFA
November 2010
8 Polysius

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Low dust kiln inlet housing

Design Reheater- PREPOL®

Training PODFA
November 2010
9 Polysius

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Low dust kiln inlet housing

The kiln inlet housing is the connection piece between the

almolst horizontal kiln and the vertical calciner. Polysius
therefore developed a special internal design for the
refractory lining of the inlet housing. This ensures an
optimum meal flow in the direction of the rotary kiln, while 1
minimising the dust formation and thus minimising the
amount of dust returned to the preheater.

The optimum meal flow is achieved as follows:

Starting from meal chute I (1) and then over the entire length 3
of the inclined inlet floor, down to the edge of the inlet trough
(2) there is a straight, continuous, unobstructed pathway (3)
into the kiln. This channel cerates a concentrated and low-
turbulence flow of meal.
2

Design Reheater- PREPOL®

Training PODFA
November 2010
10 Polysius

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Low dust kiln inlet housing

Segmented inlet trough
(3)

Air distribution box

(2)

Cooling air pipe

(1)

Design Reheater- PREPOL®

Training PODFA
November 2010
11 Polysius

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Low dust kiln inlet housing

Advantages

- Minimal dust circulations

- Increased durability of the inlet trough due to continious air cooling

- Simple exchange of the segments about the rear of the inlet housing

- Cost-effective spare parts stocking, thanks to the use of identical segments

Design Reheater- PREPOL®

Training PODFA
November 2010
12 Polysius

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Calciner – PREPOL® - MSC

Design Reheater- PREPOL®

Training PODFA
November 2010
13 Polysius

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Calciner – PREPOL® - MSC

Before entering the kiln, the raw meal has to be

calcined to make the process effective. Calcining
is a chemical process that changes the material
by releasing CO2. upper meal
Therefore Polysius has different calciner systems. feed
Which system has to be choosen is a question of
available fuel. In this case we have the MSC-
system, which means Multi-Stage-Combustion.
This calcining system with its after burn function lower meal feed
with top air and the split of meal, is capable to
reduce the NOx-emissions.
The volume of the calciner depends on the
behaviour of the fuel, to ensure optimal retention
time for combustion.
Material flow

Gas flow
Burner

Design Reheater- PREPOL®

Training PODFA
November 2010
14 Polysius

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Cyclone stages
Type C

Type B

Type A

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Training PODFA
November 2010
15 Polysius

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Cyclone stages Type C

Cyclone design
Type B

Type A

Dedusting cyclone

System cyclone Stage 4

Calciner cyclone Stage 2, 3

Stage 1
Design Reheater- PREPOL®
Training PODFA
November 2010
16 Polysius

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Cyclone stages gas

Function of cyclone stage
Gas duct
Dip pipe

Gas duct

raw meal

Meal chute

Splash box

raw meal gas

Design Reheater- PREPOL®

Training PODFA
November 2010
17 Polysius

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Cyclone stages
Cyclone roof for compensation

The cyclone roof is designed in such a way, that it functions as a

compensator. Therefore the roofs of the cyclones are mounted under
pretension. That means, they are – under cold condition – drawn
upwards by half the dimension of the expected heat expansion. In
warm condition then, the pretensioned cyclone roofs will vault by half
the dimension of the expected head expension down-wards across
the zero line.

Design Reheater- PREPOL®

Training PODFA
November 2010
18 Polysius

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Cyclone stages
Dip pipes

The dip pipe is movable suspended at his upper end. The function of the dip pipe, is to increase the separation
efficiency and thus to reduce the dust circulations. The material of the dip pipe has to resist the temperature in the
cyclone and must have a good resitants against chemical attack.

Design Reheater- PREPOL®

Training PODFA
November 2010
19 Polysius

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Cyclone stages
Mounting dip pipe

Design Reheater- PREPOL®

Training PODFA
November 2010
20 Polysius

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Cyclone stages
Advantages

• Compact construction with at the same time good degree of separation

• The element design of the dip pipe allows a partial renovation of the dip pipe
from below.

• The elements are portable so that no hoists are required in the cyclone.

Design Reheater- PREPOL®

Training PODFA
November 2010
21 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Cyclone stages
Maintenance

Design Reheater- PREPOL®

Training PODFA
November 2010
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Cyclone stages
Maintenance

Design Reheater- PREPOL®

Training PODFA
November 2010
23 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Cyclone stages
Maintenance

Design Reheater- PREPOL®

Training PODFA
November 2010
24 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Cyclone stages
Maintenance

Design Reheater- PREPOL®

Training PODFA
November 2010
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Meal chutes

The meal chutes are conveying pipes

between cyclones and lower feeding points.
They lead the raw material, seperated in
pendulum flap the cyclone, to the next stage below. A
meal chute consists of several bolted pipe
sections, expansion joints, supports etc.
Each com-ponent is equiped with refractory
by a thickness of 85mm.

dispersion box distributor flap

expansion joint

support

Design Reheater- PREPOL®

Training PODFA
November 2010
26 Polysius

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Hot meal pendulum flap

lever with
sliding weight

inspection port

bolted cover
housing with
refractory lining

flap blade

Design Reheater- PREPOL®

Training PODFA
November 2010
27 Polysius

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Hot meal pendulum flap

Hot meal pendulum flaps are discharge devices for a varying mass flow of material with simulteneous
shutting-off the counterflowing hot gas.

The clear cross-section which remains when the flap blade is closed corresponds approximately to the
filling level at nominal capacity of the plant.

With increased mass flow of material the flap blade opens. Then the flap blade closes again by means
of the external sliding weights up to the internal stop.

The sliding weights of the levers and there position themself should be so adjusted that the flap could
open very easily to avoid blockages.

Design Reheater- PREPOL®

Training PODFA
November 2010
28 Polysius

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Hot meal pendulum flap

Pendulum flap with protection cover

Design Reheater- PREPOL®

Training PODFA
November 2010
29 Polysius

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Expansion joints

1 corrugated steel expansion joint 1 fabric expansion joint

2 ceramic fibre wool 2 ceramic fibre wool
3 refractory lining 3 refractory lining
4 guide pipe, stainless steel 4 guide pipe, stainless steel
5 earthing bridge
Design Reheater- PREPOL®
Training PODFA
November 2010
30 Polysius

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Dispersion box

incorrect correct

Cleaning device required and needs to operate on a regular basis

Design Reheater- PREPOL®

Training PODFA
November 2010
31 Polysius

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Tertiary air duct

1 Tertiary air duct (main duct – ø1530)
2 Top air duct (branch duct – ø830)
3 Suction chamber (3500x2600)
4 Fixed point
5 Pendulum support
2 6 Sliding gate
7 A-R-seal (axial-radial-seal)
8 Vibration damper
Direction of thermal expansion
7 6
1
7 3

4
5
8 5

Design Reheater- PREPOL®

Training PODFA
November 2010
32 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Tertiary air duct
TA – duct at kilnhood
Connection to cooling air
Seal to be installed

Tertiary air duct

Kiln hood

Ring pipe for seal air

Outlets for seal air

Design Reheater- PREPOL®

Training PODFA
November 2010
33 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Tertiary air duct
TA – duct at kilnhood

Cooling air
Tertiary air duct
Ring pipe

Kiln hood
Dip tube into TA

Design Reheater- PREPOL®

Training PODFA
November 2010
34 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Tertiary air duct
TA – duct throttle valve

1 Housing
2 Valve blade
3 Shaft
4 Bearing
5 Linkage
6 Operating lever
7 Actuator

It reduces the flow rate of the tertiary air flow to

the set value to achieve an optimum combustion
in the kiln and in the pre-calciner.

Design Reheater- PREPOL®

Training PODFA
November 2010
35 Polysius

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Tertiary air duct
TA – duct throttle valve
1. Housing

6. Operating lever

3. Shaft

4. Bearing

2. Valve blade
5. Linkage
7. Actuator

Design Reheater- PREPOL®

Training PODFA
November 2010
36 Polysius

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A-R (Axial-Radial) seal

1 Guide pipe, stainless steel

2 Tertiary air duct – sliding joint
3 Seal for axial movement
4 Seal for radial movement
5 Seal suspension
6 Earthing bridge

Design Reheater- PREPOL®

Training PODFA
November 2010
37 Polysius

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Shock blower system

In areas where we expect a high risk of material

deposits or coatings, an automatical cleaning
5 system with Shock-Blower is installed.

The areas are:

1. Kiln inlet housing
4 2. Orifice of calciner
3 3. Outlet kone of cyclon I
4. Bend to cyclon I
5. Head of calciner
2

1
It is only an proposal according to our
experiences, the final position can change
during operation.

control cabinet
Design Reheater- PREPOL®
Training PODFA
November 2010
38 Polysius

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Shock blower system

Design Reheater- PREPOL®

Training PODFA
November 2010
39 Polysius

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Shock blower
Units

Regulator and
filter unit Operating air (by
customer)

Valve unit

Control Control voltage (by

system customer)

Blasting
system

Design Reheater- PREPOL®

Training PODFA
November 2010
40 Polysius

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Shock blower
Cleaning nozzles
0°- exhaust angle 90°- exhaust angle

Design Reheater- PREPOL®

Training PODFA
November 2010
41 Polysius

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Shock blower
Weldings

Design Reheater- PREPOL®

Training PODFA
November 2010
42 Polysius

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Shock blower
Weldings

Design Reheater- PREPOL®

Training PODFA
November 2010
43 Polysius

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Shock blower system
Examples

Design Reheater- PREPOL®

Training PODFA
November 2010
44 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Shock blower system
Examples

Big blaster arrangement at

kiln inlet housing
Design Reheater- PREPOL®
Training PODFA
November 2010
45 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Shock blower system
Safety

• The big blaster air cannon is a pressure vessel whose

content is explosively released. The stored air escapes
with sonic speed.
• Do not transport or mount the big blaster air
cannon when they are filled.
• The compressed air system which is connected to the big
blaster air cannon should have the following protective
devices :

• Safety pressure limiting valve

• Stop valve
• Safety pressure aerating valve
• Emergency-out electrically controlled and
automatic at the feeding air line, capable of switch
off the compressed air supply to all connected air
cannons and capable of release all air cannons
without danger

Design Reheater- PREPOL®

Training PODFA
November 2010
46 Polysius

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Removal of deposits

Cleaning openings slider solenoid valve

Compressed air cleaning

valve station
Compressed air
ring pipe
Design Reheater- PREPOL®
Training PODFA
November 2010
47 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Removal of deposits
Compressed air cleaning system

Design Reheater- PREPOL®

Training PODFA
November 2010
48 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Removal of deposits
Compressed air cleaning system

17.1 Compressor plant

17.2 Pressure Vessel
17.3 Piping in
preheater tower
17.4 Connecting fittings
17.10 Compressed air
from network
17.11 Compressed air
to consuming points
17.12 Solenoid Valve
17.13 Manually valves
17.14 Emergency valves

Design Reheater- PREPOL®

Training PODFA
November 2010
49 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt
Removal of deposits
Compressed air cleaning system
Cleaning of cyclone outlets

Ring pipe for cleaning air

Cleaning system will be connected
to compressed air system and
will be operated via solenoid valves

Spreading box at end of meal

chute into gas duct

Cleaning system will be connected to

compressed air system and will be
operated via solenoid valves

Design Reheater- PREPOL® Cleaning of spreading boxes

Training PODFA
November 2010
50 Polysius

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Removal of deposits
Manual cleaning

Danger of falling out

materials!

Design Reheater- PREPOL®

Training PODFA
November 2010
51 Polysius

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Removal of deposits
Manual cleaning – poking holes

Design Reheater- PREPOL®

Training PODFA
November 2010
52 Polysius

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Design Reheater- PREPOL®
Training PODFA
November 2010
53 Polysius

S:\Team\Training\Transfer\PODFA-Presentationen-Maintenance_Training\06-02-PODFA-Design-Preheater.ppt