Aa ‘Course Name: Mechanical Maintenance of Kiln Systems Page 1 Module 14: Preheater and Precalciner Preheater and Precalciner wos westiamso © FL Smidth & Co. WSAS Course Name: Mechanical Maintenance of Kiln Systems Page 2 Le Module 14: Preheater and Precalciner ‘TABLE OF CONTENTS PREHEATER AND PRECALCINER 14.1. THE PREHEATER CYCLONE.................5 . 14.1.1 PURPOSE OF THE PREHEATER CYCLONE .. . 14.1.2 FUNCTION AND COMPONENTS OF THE PREHEATER CYCLONE 14.1.3 PRACTICAL ASPECTS . 14.1.4 DESIGN ASPECTS . Bdaan 14.2 MAINTENANCE ASPECTS FOR THE PREHEATER CYCLONE . 14.2.1 CYCLONES WITHOUT LINING 14.2.2 CYCLONES WITH LINING AND PRECALCINER . 14.23 DIMDING GATES . . 14.2.4 SLIDE GATE .... 14.2.5 CHANGE OVER GATE 142.6 MATERIAL CHUTES AND RISER DUCTS SVSXBBw 14.3. PRECALCINER . 14.3.1 PROCESS DESCRIPTION - 88 NpSUPSTIONO © FLL. Smidth & Co. ASAis Course Name: Mechanical Maintenance of Kiln Systems Page 3 . Le . Module 14: Preheater and Precalciner PREHEATER AND PRECALCINER 141. THE PREHEATER CYCLONE A preheater cyclone is a stationary entity and apart from the material flap-gates (or other valves) involves no moving of mechanical parts. As compared to other parts of the cement plant, there are therefore only limited points to be considered in terms of mechanical maintenance. However the proper function of the preheater cyclone is of vital importance in the process. Through a better understanding of the principles of operation, energy consumption can be reduced and unnecessary downtime avoided. A preheater cycione should not be thought of as. an individual machine neither in terms of dimensioning or in terms of maintenance. It should be thought of as a stage in a string. These strings have from 1 to 6 stages, but 4 or 5 stages are the most common today. Figure 14.1_5 stage preheater with bypass mixing chamber 8 STROM: © FL Smidth & Co. ASFis ‘Course Name: Mechanical Maintenance of Kiln Systems Page 4 . Module 14; Preheater and Precalciner 14.1.1 PURPOSE OF THE PREHEATER CYCLONE As the name suggests, the purpose of the preheater cyclone is to preheat the raw meal prior to it entering the Kiln. The preheater cyclone originates from the efforts which have been made in design to minimize the moving/rotating parts and improve heat consumption. Ina cyclone preheater, gases and material flow in opposite directions. Hot gases from the kiln flow from the bottom to the top, while cold material is fed into the top and flows down into the kiln. (see Figure 14.2) When the material meets the gases a heat exchange takes place; the material is heated from approx. 50°C at the top to 800- 900°C at the bottom before entering the kiln, whereas the kiln gases are cooled from approx. 1100°C at the bottom to 300-350°C at the top. 14.1.2 FUNCTION AND COMPONENTS OF THE PREHEATER CYCLONE ‘A conventional cyclone consists of a cylindrical upper part and a conical lower part (see Figure 14.2). The gases enter the cyclone via the riser pipe from the previous cyclone, or in the case of the lower-most stage, from the kiln or calciner depending on the system type. Feed material of suitable size, ie. in the range of e 0-2 mm, is introduced to the riser duct between cyclone no, 2 and cyclone no. 1 (top cyclone), where it is carried in suspension with the gases into cyclone no. 1. An almost instantaneous heat transfer between material and gases takes place, thus ensuring a high thermal efficiency. In cyclone no. 1 the suspended particles are disengaged from the gases and directed to the second preheater stage, i.e. the riser duct between cyclone no. 3 and cyclone no. 2. In this manner the preheating process is successively repeated in each preheating stage. Wp PSTN © FL Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 5 fa Module 14: Preheater and Precalciner SP: Suspension Preheater. Gas <4) Conventional single string cyclone preheater kiln without calciner. Data for 2800 tpd plant Figure 14.2 Cyclone wp VPSTIONOT © FLL Smidth & Co. A/SAg Course Name: Mechanical Maintenance of Kiln Systems Page 6 LE Module 14: Preheater and Precalciner In each case the material leaves the cyclone through the bottom cone. It flows via a material pipe through a flap-gate to the riser duct of the previous stage. Here it enters the stream of gases via a spreader box. The gases (and a small proportion of the material) leave the cyclone via a central pipe at the top of the cyclone into a riser duct leading to the next stage. in short, the cyclone preheater acts as a stepwise counter-current heat exchanger with co-current flow within the single stages. In the last preheater stage the material temperature will reach calcination temperature and normally an appreciable part of the reaction takes place at this stage. From the last cyclone, preheated and precalcined material is directed to the kiln/calciner. ‘The action that takes place inside the cyclone is as the name suggests a cyclonic one. In other words, the riserpipe from the previous stage enters the cyclone tangentially, and the material is flung out to the sides. The centrifugal force separates the particles Until the gravitational force becomes greater and the particles slide down the bottom cone. If one were to follow the path of a particle through a cyclone, it would describe a helical path unti it reaches the bottom of the cone. The central pipe or dip pipe (see Figure 14.3) which extends into the cyclone from the top, serves as a physical hindrance for the particles to leave via the top. pS WPSTROMEO © F.L Smidth & Co. AISFS Course Name: Mechanical Maintenance of Kiln Systems Page 7 . . Module 14: Preheater and Precalciner Figure 143 Dip pipe wp UPSTART © FL Smidth & Co. AISFis ‘Course Name: Mechanical Maintenance of Kiln Systems Page 8 7 Module 14: Preheater and Precalciner Splash Plate # Figure 14.4 Dispersing box “Therefore the preheater cyclone in this manner serves both as a heat exchanger and a separator. The separating efficiency is measured in terms of the proportion of material that leaves the cyclone via the bottom cone versus the material that leaves Via the central pipe. ‘The spreader/dispersing box (see Figure 14.4) incorporates an adjustable splash plate which the acoelerated material hits as it flows down the material pipe and is thus dispersed into the gas stream. ‘The material flap-gate (see Figure 5) serves to prevent gases entering the cyclone from the bottom thus posing a hindrance for the material leaving the cyclone. The gate is designed to always tend towards the closed position. It opens as itis activated by the falling material (see also "practical aspects"). Gas ducts, cyclones and material pipes are lined with refractory brick and are pre-cast. It is important to have a smooth and dense lining, a good insulation and a stable construction (see also "practical aspects"). ‘ops WPSTIONIO ‘© FLL. Smidth & Co. A/SA G Course Name: Mechanical Maintenance of Kiln Systems Page 9 . L: . Module 14: Preheater and Precalciner Figure 145 Flap Valve 14.1.3 PRACTICAL ASPECTS For the preheater cyclone to function properly some initial conditions must be ensured: + ensure that the correct type of lining (brick/castable) is used. Mistakes can have dire consequences. * ensure that the lining is completely smooth. If necessary any protrusions should be ground off, as any unevenness will reduce the efficiency and may cause material build-ups which can block the cyclone. In any given system the temperature and pressure profiles are bom into the system, so to speak. In other words, they are set and cannot be changed without design modifications. Such modifications (refer to "1.1.4 Design Aspects”), can be carried out on operational systems to increase efficiency. New systems normally have these built in wp UPSTIONO © FL Smidth & Co. ASAS Course Narre: Mechanical Maintenance of Kiln Systems Page 10 LE Module 14: Preheater and Precalciner ‘The main problem which can occur in a cyclone is that it blocks, which in effect means that the kiln system has to be shut down. Reasons for blockage in cyclones can be: + incorrect operation + chemical + design mistake + uneven lining + material flap valve not functioning correctly + physical In terms of maintenance the last three points can be considered. The consequences of uneven lining has been mentioned above. ‘The correct function of the material flap valve must be ensured. Full and free movement must be possible. A stuck or tight operating valve will delay the material passing and in turn the cyclone will block. In the case of flap valves a loose fit must be ensured. This can be done by cutting 10-15 mm off the sides and bottom of the flap to ensure that it does not scrape the castable sides. Even though the flap may function well in a cold state, itis difficult to simulate the operating temperatures of up to 900°C. ‘The bushings of the hinge mechanism may be drilled up a further 2 mm to ensure free movement. The counter weight should be adjusted so that the valve opens with the slightest pressure e.g. pressure exerted by ones little finger. Physical blockage can be caused by foreign objects restricting the passage of material. itis therefore important that the cyclone preheater be thoroughly inspected after a cold shutdown. The most common cases of foreign objects occur when scaffolding has been erected inside the preheater during the shutdown! wps.uPsTIONKO: © FL Smidth & Co. A/Sq Course Name: Mechanical Maintenance of Kiln Systems Page 11 Fi fa Module 14: Preheater and Precalciner In some existing systems the bottom part of the cyclone cone has been exchanged with a steeper sided one i.e. from 60° to 80° inclination. This has been done in intermediate stage cyclones with good results in terms of facilitating free passage for the material out of the cyclone. (The lower cyclones are normally equipped with such a cone and new systems today have this as standard). 14.1.4 DESIGN ASPECTS During the seventies, the development efforts within cement pyroprocessing systems concentrated on reducing the specific fuel consumption by increasing the number of preheating stages in the raw meal preheater, as well as reducing the rotary kiln dimensions by the introduction of kiin systems with stationary precalciners, At the same time, the pressure drop across the Kiln system was allowed to increase, and many kilns with 4-stage or 5-stage preheaters designed in this period are operating with a total pressure drop across the system of 700-1000 mm WG with most of the pressure drop occurring in the preheater. Due to the increasing safety and pollution control requirements imposed on power Plants, electricity prices have been climbing steadily whereas fuel prices have been stable or even decreasing. Furthermore some governments are encouraging savings in electricity consumption by imposing taxes on the price of electricity. This means that ‘along with specific fuel consumption, the specific power consumption of Pyroprocessing systems has been in focus in recent years. In a kiln system with a pressure drop of 700-1000 mm WG, the specific energy consumption of the exhaust gas amounts to 10-15 kWh/mt clinker, and it was obvious. to try to reduce this figure by introducing preheaters with a lower pressure drop. Considerable efforts have been made in this area since the mid eighties and most manufacturers today supply low pressure drop cyclones. (see Figure 14.6) 95 VPSTIRUNOT © FL. Smidth & Co. A/SAS Course Name: Mechanical Maintenance of Kiln Systems Page 12 L: 7 Module 14: Preheater and Precalciner Old design Figure 146 Low pressure drop cyclones ‘The criteria aimed for in modem cyclones are: + low pressure drop + high separating efficiency + small physical dimensions ‘The reduction in pressure drop is partly achieved by larger inlet and outlet areas for a given cyclone size and partly by providing more space for the gas flow in the top part of the cyclone. The length of the central pipe is also a factor taken into consideration. (see Figure 14.6) ‘The most common are the traditional reversed flow cyclones with vertical axes of which most manufacturers today supply an LP (Low Pressure drop) version. ‘Wp PSTN © FL. Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 13 ta Module 14: Preheater and Precalciner convenvena! cyclone wt hor zonal syetone heveal'ate” ——_yeone Figure 14.7 Low pressure drop cyclones ‘As mentioned in the introduction, a preheater cyclone should be thought of as a stage ina string. This is especially the case when considering the design since the geometry is optimized for the preheater operating as a whole. This means that each string should have an upper stage design (sometimes double cyclone), an intermediate stage and a lower stage design regardless of the cyclone type (see ?). 1. Stage 2. Stage oO Figure 148 Cyclones ps vPSTIONNO © FLL Smidth & Co. WSModule 14: AR Mechanical Maintenance of Kiln Systems Page 14 Preheater and Precalciner In the lower stages the height of the cylindrical part of the cyclones is kept low, since To great importance is attached to high degrees of separation in these stages. This decreases the pressure drop and simultaneously reduces the head room. Only cyclone stage no. 1 is sized for a high degree of separation. ‘An area that has been concentrated on recently, is the efficiency of the lowermost cyclone, The efficiency of this cyclone is lower than at the other stages. Some typical values are listed below. (Efficiency = Separation capacity): Stage 4: Stage 2: Stage 3: ‘Stage 4: Stage 5: 93% 88% 85% 82% 78% ‘The lowermost cyclone has often been provided without a central pipe. The reason for this is the high operating temperature (approx. 900°C). wes wPSTIANEOH © F.L Smidth & Co. ASA G Course Name: Mechanical Maintenance of Kiln Systems Page 15 . lL: . Module 14: Preheater and Precalciner Figure 14.9 Central tube for lowermost cyclone stage This high temperature makes it difficult to incorporate @ central pipe that will last. In many cases the efficiency can be raised by fiting the cyclone with a central pipe. The central pipe forces the gas further down inside the cycione before leaving as well as inhibiting any tendency for the gas to travel straight from the inlet to the outlet. With the advance in materials technology replaceable central pipes made of heat and wear resistant steel are now on the market. This central pipe (see Figure 1.9) has an expected lifetime of more than two years, but regular replacement during planned shutdowns, for example for re-bricking the kiln buming zone, should be foreseen. wo STINT © FL Smidth & Co. A/SFi Course Name: Mechanical Maintenance of Kiln Systems Page 16 . Module 14: Preheater and Precalciner Another way to improve the efficiency of the lowermost cyclone is the implementation of @ special design (triangular cut) of the inlet to the cyclone (See Item C in Figure 14.8). By forcing the gas away from the cyclone center and further out towards the wall, a larger fraction of the material will leave the cyclone through the bottom cone. Both measures can be effective in raising the cyclone efficiency, while the penalty in each case will be an increase in the pressure drop over the cyclone. ‘An improvement in the operational parameters of the preheater tower is sometimes possible with a modification of the fourth-stage cyclone. This is because an increased efficiency of the cyclone leads to a reduction in the amount of dust that is lifted up to the stages above and improves the temperature profile of the tower. The resulting reduction in the exit gas temperature will reduce the heat loss out of the preheater, reducing the specific heat consumption and thus also the amount of Kiln exhaust gas. While the pressure drop will increase over the fourth-stage with any of these modifications, this is partly balanced out by the reduction in pressure loss over the other cyclone stages that occur as less kiln gas is pulled through the cyclones. The example in Figure 14.10 serves to illustrate this relationship. Figure 14.10 oolumn B depicts the changes that can take place in a preheater tower when the fourth-stage cyclone inlet is fitted with a triangular cut and the efficiency moderately increased. The temperature in the third stage as well as out the preheater is reduced, which will give an improvement in the heat consumption. The pressure drop over the cyclone expressed in the pressure drop coefficient is seen to increase and the pressure drop over the preheater also increases slightly. pS. UPSTANEO © FL Smidth & Co. NSfi 5 Course Name: Mechanical Maintenance of Kiln Systems Page 17 tla Module 14: Preheater and Precalciner In column C a situation is portrayed in which the cycione efficiency is improved with the fitting of central pipe. Here a larger improvement in the fourth-stage efficiency is achieved which gives a bigger reduction in the specific heat consumption. The increase in pressure drop over the cyclone is similar to the previous example but this time it is more than outweighed by the reduction in the pressure drop over the other stages, and the net result is a reduction in the total pressure drop over the preheater tower and a saving in the ID fan power. In column D it is seen that the installation of both the triangular cut inlet and the central tube in the cyclone is not optimal as it increases the pressure drop over the cyclone unduly without yielding further improvements in the efficiency. ‘The two possible bottom stage solutions with central pipe and triangular cut are compared with a cyclone without any efficiency increasing precautions in Figure 14.10 95 wPSTROMOT © FL Smidth & Co. A/S= Module 14: AS Course Name: Mechanical Maintenance of Kiln Systems Page 18 LE Preheater and Precalciner 1B) LP cyclone with trangular cut ©) LP cydone with central tube D) LP oycione wth both tiangutar cut and central tube ‘Comparison between lowermast cycione performance in a 4-stage ILC preheater for A) LP cyclone design without efficiency increasing precautions A 8 c D Cyclone efficiency (%6) 7 at 87 7 Cyclone pressure drop cosficient (%) 400 120 120 125 Heat of re-carbonization (kcalkg clinker) a 2 6 6 Gas temperature ater third stage cyclone 784 752 736 738 co) Volume of ext gas after first stage 100 84 62 62 ‘eycione (%6) Mass of exit gas after fist stage cyclone 100 95 88 68 % Gas temperature ater fist stage cyclone 362 355 us Ba co, Heat consurrtion 100 95 88 88 of kiln) Preheater pressure drop (4) 100 1006 72 985 1D fan power consumption without cooling 100 85 30 a7 tower (%) 1D fan power consumetion wth coding 40 20 43 96.1 tower (%) Figure 14.10 Comparison of cyclone performances. wes uPstrantor © FLL. Smicth & Co. ASCourse Name: AR Mechanical Maintenance of Kiln Systems Page 19 Preheater and Precalciner 14.1.5 (CASE STUDY: EFFICIENCY SIMULATION PLANT: Tabasco Macuspana CONDITIONS Production 2,600 td Fuel Natural gas Calorific value (Hl) 7,207 kcalim? Heat consumption 810 kcalikg cl Fuel price 0.077 Ussim? Power price 0.048 USSKWh EFFECTS Before After Heat consumption 810 kcalkg cl 800 kcallkg c! ‘Smoke gas temp. oul. 362°C 345°C Cyclone efficiency 1% 87% Heat of recarbonization 27.8 kcallkgcl 13.9 kcallkg cl Pressure loss coeff. 100 12 LESS CONSUMPTION Heat economy 969,305 m3/year Power consumption 304,200 kWhiyear LESS COSTS Fuel 74,562 USSlyear Power 14,040 US/year Total 88,602 USS/year wes uPstrameor © FLL Smidth & Co. A/SFis ‘Course Name: Mechanical Maintenance of Kiln Systems Page 20 —s Module 14: Preheater and Precalciner PAY-BACK TIME, Central Pipe price _ 38,785 _ Cost reduction ~ 98,602 °*° 88s It can be seen in the simulation the effects of installing a central pipe in the fourth (bottom) stage cyclone of a 2600 tpd plant, have been a reduction of the heat consumption by 10 kcal/kg cl and an improvement of the efficiency of the cyclone by 10%, ‘The net effect on the combined fuel and electricity consumption has been a saving of nearly 100.000 USD/year. This gives a payback period of about half a year. 95 UPSTRONOY © FLL. Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 21 ta 14.2 MAINTENANCE ASPECTS FOR THE PREHEATER CYCLONE Module 14: Preheater and Precalciner In general the cyclone pre-heater system consists of a number of cyclones and a precalciner connected together by means of material chutes and riser ducts. Dividing, change-over and sliding gates are incorporated into the system in order to control flows of materials and gases. The entire system together with its supporting construction constitutes a pre-heater tower. Because of high temperatures and heights, special precautions are to be taken when repairing and maintaining, For that reason specific security requirements and procedures are described in the following. Some examples of preventive maintenance of specific gates are also included. With regard to excessive wear and corrosion, its recommended that the causes are investigated and remedial action be carried out as a phase of preventive maintenance. Maintenance of auxiliary equipment (ie. items that faciitate access to the pre-heater tower such as lifts, fights of stairs, platforms, railings, catwalks) are not dealt with in this section. The maintenance of these items has to follow the maintenance routines of the rest of the plant. 95 UPSTIONO © FLL Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 22 Le 7 Module 14: Preheater and Precalciner 14.24 CYCLONES WITHOUT LINING Text 1 2 3 4 5 6 Cyclone 2A | 2A* At A 1 = Lubrication D = per 8 hour operation 2. = Cleaning S = Weekly 3. = Inspection & adjust ment M= Monthly 4. = Checking of condition A= Yearly 5 = Replacement (including lubricants) T = See text in instruction manual 6 = Performance test * = Also at each plant stop ‘number in front of a letter indicates frequency of procedure - i.e. 2A = Twice a year. 14.214 ‘Cleaning Extemal surfaces and surrounding areas are to be cleaned. 1424.2 Inspection When the system is inspected for incipient cakings and cloggings the following safety measures must be observed: + Hot raw meal can accumulate in cyclones, riser and feed pipes. This must be removed. ps STANT © F.L Smidth & Co. ASFi g Course Name: Mechanical Maintenance of Kiln Systems Page 23 . Le = Module 14: Preheater and Precalciner . Inspection and/or cleaning of cyclones, riser and feed pipes is not without risk. This can, however, be minimized, if the following simple rules are followed: 7 Before starting work check that the electrical power to the air blaster control box is turned off, and that all blasters are without air. + There should be a minor vacuum in the system during all inspection and leaning work. The vacuum will reduce the risk that hot air and dust is blown e@ ‘out over the cleaning-personnel. + Personnel that shall inspect a cyclone, riser or feed pipe must be equipped with a face mask, helmet, long heat insulated fire-proof gloves and either clogs or another form of protective footwear. If there is risk of dust falls or other objects faling onto the personnel, they must be equipped with a safety belt with a lifeline attached, The other end of the line must be held by an assistant standing in a protected position. Before opening a cleaning door or hatch, check via the peep hole that a heap of dust is not piled against the door. Hot material pouring out can be dangerous. ‘When opening a door or hatch NEVER stand in front of or below the door as hot dust or raw meal can pour out. It is advisable to stand on a scaffolding/staging lifted over floor level to protect feet and legs. ‘When opening a cleaning door in a cyclone pre-heater remember that hot dust is Present and therefore the scaffolding/staging must NOT be constructed out of inflammable material. Ifa platform is used it must be constructed as a grating, as that wil allow material to fall through. wo PSTIONOT © FL Smidth & Co. A'SFS Course Name: Mechanical Maintenance of Kiln Systems Page 24 . Module 14: Preheater and Precalciner Remember. materials can move quickly and quietly and can damage cables, tools or other items. ‘Take all possible precautions to protect with barriers and screens around the affected area. After every inspection of cyclones, riser and feeder pipes ALL cleaning doors, hatches and every opening MUST be securely fastened. 14.241.3 ‘Checking of condition Steel plates and weldings are to be inspected with regard to wear and corrosion. The Wear rate of steel plate can be measured using ultra sound measuring equipment. (These measuring techniques are discussed in chapter 3 of this training material). If the wear rate is exceptionally high the production staff should be consulted. Excessive wear is probably an indication of abnormalities in the production process. 14244 Repair, replacement and intemal cleaning All weld seams are to be at least of 4 mm root except where otherwise stated on drawings. To avoid heat and stress deformations when welding, use appropriate tools jigs and fixtures. Painting is to be repaired in accordance with painting specification or instructions. When performing intemal cleaning the safety measures to be observed are as for inspection but with the following additions: wp WPSTAOMIOT © FLL Smidth & Co. ASAg Course Name: Mechanical Maintenance of Kiln Systems Page 25 fla Module 14: Preheater and Precalciner ‘When cleaning a cyclone in operation - ALL personnel must know the escape routes. Heaps of dust must be removed - Clean through the inspection peephole. Use an air lance to remove dust heaps. ‘Warning: Hot material may fall from cyclones positioned higher in the system can ‘occur during cleaning operations, 14.2.1.5 Performance test Measurement of pressure and flow by means of appropriate pressure gauges and flow meters. If the pressure moves towards zero it is probably an indication of clogging. (Check also the moverents of the double flap gate (tulip flap gate). 14.2.2 CYCLONES WITH LINING AND PRECALCINER ‘The procedures the same as described for cyclones without lining, but the inspection, Concition check, repair and replacement must, of course, include the lining. Ths is to be inspected and checked for wear and oracks. Any repair and replacement is to be in accordance with the specific instructions for that type of lining. Correct storage of e@ lining materials is also an important matter, which is offen not appreciated. The instructions given by the supplier must be adhered to. It must be emphasized, however, that the decision on when repair shall be carried out can only be taken by plant management itself In the following pages examples of maintenance routines for specific machines will be given. While the methodology will be similar for all makes of equipment, it should be noted that the specifics given below are of course not generally applicable. WS WPSTIONNOT © FL. Smith & Co. WSFig Course Name: Mechanical Maintenance of Kiln Systems Page 26 LE Module 14: Preheater and Precalciner 14.23 DMDING GATES Text 1 2 3 4 5 6 Dividing gate-Pos 00 2A A A ‘Supporting rollers- 06 2A Guide rollers- 07 2A Geared motor- 09 ‘See separate instruction manual 1 = Lubrication D = per 8 hour operation 2 = Cleaning S = Weekly 3. = Inspection & adjustment M= Monthly 4 = Checking of condition A= Yearly 5 = Replacement (including lubricants) T = See text in instruction manual 6 = Performance test Anumber in front of a letter indicates frequency of procedure - i.e. 2A = Twice a year. sath il products are to be selected in accordance with the machinery supplier's instructions for the lubrication of the specific parts and components. While the product can probably be supplied from more manufacturers than one, itis important to ensure that the chosen lubricants have the required properties. ‘95 UPSTIOMNKOT ‘© FL Smidth & Co. AS.AS Course Name: Mechanical Maintenance of Kiln Systems Page 27 Ha Module 14: Preheater and Precalciner Guide and supporting rollers Lubricate the rollers with grease selected as defined in Figure 14.11 points (06) and (07). Clean the gate and the surrounding area, with particular emphasis on the geared motor, gear unit and position transmitter. 1423.4 (Checking of condition Check the gate lining through the inspection hatch. Check the seals around the moving parts (08). The packing (gasket) cord is a ceramic fibre material, heat resistant up to 1250°C. ‘Check the sheet plate for corrosion. ‘Check that supporting (06) and centering rollers (07) can rotate easily. 14.2.3.2 Performance test Check the performance of the limit stop switches. 8 PSTN © FLL. Smidth & Co. WSFis ‘Course Name: Mechanical Maintenance of Kiln Systems Page 28 Module 14: Preheater and Precalciner i) ® DQ ®) @® DOF Ps oO EN @ ®@ TAGE @ i: Fa @ @ iE e 12) ©) ; B= ® / e@ Figure 14.11 Dividing Gate 01 Inlet cone 07 Guide roller (centering roller) 13. Posiiontransrritter 02 Rotary part «08 Sealing arrgt. 14° Sealing flange 03 Bottom part «09. Geared motor 15 Eccentric nut 04 Bracket 10 Roller chain 16 Brace 05 Bracket (frame) 11 Safety limit stop switch 17 Runaway 06 Supporting roller 12 Coupling ‘w95 UPSTIONOT © F.L. Smidth & Co. A/SAS ‘Course Name: Mechanical Maintenance of Kiln Systems Page 29 . Le 7 Module 14: Preheater and Precalciner 14.24 SLIDE GATE 14244 Operational checks It is essential to check the exit air temperature at least once for every 8 hours of operation, (see Item 12 in Fig, 14.12) . In case the temperature rises to a level above 128° ©, this is probably an indication that the heat-resistant lining of the tongue has been damaged. The tongue must then be replaced at the earliest opportunity. 14.2.4.2 Preventive maintenance- survey Pos Text 1] 2] 3]4]s5]6 00 | Slide M en camper 06 M air outlet 10 | Link bearing | M | M 11 | Compressed M air outlet 13 | RACOmotor| mM | M M A (Step motor) 15 Lubrication D_ = per 8 hour operation 2 = Cleaning S = Weekly 3 = Inspection & adjustment M_ = Monthly 4 = Checking of condition A = Yearly 5 = Replacement (including lubricants) T = See text in instruction manual 6 = Performance test ‘Anumber in front ofa letter indicates frequency of procedure - ie. 2A = Twice a year. wes PsTaOMHO © FL Smidth & Co. A/SAS Course Name: Mechanical Maintenance of Kiln Systems Page 30 L: Module 14: Preheater and Precalciner 14.2.4.3 Lubrication Oil products are to be selected in accordance with the machinery supplier's instructions for the lubrication of the specific parts and components. RACO-motor (step motor) (13) and link bearing (10) Fill grease via the grease nipples (19). Grease quality and quantity is selected as mentioned above. 14244 Clearing Slide damper (00) Remove dust from the RACO-mators and the spindles. Check and clean the air outlets (06) and (11) if necessary. 14.245 Inspection and adjustment Compressed air outlets (06) and (11) Inspect the compressed air outlets, and clean them if necessary. 95 VPSTIONOT © FL Smidth & Co. A/SAS Course Name: Mechanical Maintenance of Kiln Systems Page 31 . LE . Module 14: Preheater and Precaiciner 14.246 ‘Checking of condition Slide damper (00) Check the condition of the slide damper during routine cleaning of riser pipe and also during a kiln shutdown Check the tongues (05) for cakings . Clean if necessary. Check that the tongue's heat resistant lining is intact, ‘Check the nose (03) and the guide bushing (04) for wear and damage. Replace defective parts. It is recommended to always have one set of spare parts readily available. ‘The set should consist of: ‘One complete tongue (05) ‘One guide bushing (04) One RACO-motor. 14.247 Performance test RACO-motors (13) Check that the motor's limit switches and position sensors function correctly. pS vPSTIOMOS © F.L. Smidth & Co. ASAis ‘Course Name: Mechanical Maintenance of Kiln Systems Page 32 . . Module 14: Preheater and Precalciner Figure 14:12 Side gate Key 01 Housing 11 Compressed air outlet (tongue) s Retainer plate 02 Cleanout hole 12 Temperature sensor 22 Packing cord 03 Nose 13. RACO-motor 23 Spindle 4 Guide bushing 14 Compressed ar sup (bushing) 24 Cooling air ring 05 Tongue 15 Cover plate 25. Suspen. irons for 24 06 Comp. air out. 16 Housing for tongue 26 Distribution pipe 07 Cap 17 Compressed a sup (ergue) 27 ‘Suspen. irons for 26 08 Stroke/insert 18 Bracket for 13 8 Hose coupling 09 Bott 19 Grease nipple 29 Hose 40 Linkage 20 Tiling pad bearing 30. Bearing housing for 23 vos wPstramot © FL Smidth & Co. ASFS Course Name: Mechanical Maintenance of Kiln Systems Page 33 . Module 14: Preheater and Precalciner 1425 CHANGE OVER GATE Pos | Text aj2{/3]a]s |e 00 | Change-over 2A A A gate 06 | Supporting rollers | 2A 07 | Guide rollers 2A 09 | Geared motor | See supplier's separate instr. manual 10 | Chain drive 2A ia 1 = Lubrication D_ = per 8 hour operation 2 = Cleaning S = Weekly 3 = Inspection & adjustment M = Monthly 4 = Checking of condition A = Yearly 5 = Replacement (including lubricants) T = See text in instruction manual 6 = Performance test * = Also at each plant stop A number in front of a letter indicates frequency of procedure - ie. 2A = Twice a year. 14.25.14 a Oil products are to be selected in accordance with the machinery suppliers instructions for the lubrication of the specific parts and components. wesaPsTranso © F.L Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 34 . Module 14: Preheater and Precalciner Guide rollers (07) and supporting rollers (06) Lubricate with grease selected as mentioned above. Chain drive (10) Lubricate with grease selected as mentioned above. 14.252 Cleaning Clean the gate and the surrounding area, with particular emphasis on the geared motor, gear unit and position transmitter. 14.253 Checking of condition Check the gate lining through the inspection hatch Check the seals around the moving parts. The packing (gasket) cord (08) is a ceramic fibre material, heat resistant up to 1250°C. During replacement the material must be compressed by approximately 40% when inserting it in the sealing rings. Check the sheet lining for corrosion. Check that supporting and centering rollers can rotate easily. 14.2.5.4 Performance test ‘Check the performance of the limit stop switches. ‘wp PSTN © F.L Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 35 . L: . Module 14: Preheater and Precalciner 04) (06) (07) (01 0S 08) (14) (04 ! i Ch i [ac Lu ® = i 7 2 I ! © ! i i Figure 14.13 Changeover gale Key 01 Inlet cone 06 Supporting roller 11. Safety limit switch 02 Rotary part 07 Guide roller 12 Runway 03 Bottom part 08 Sealing arrgt. 13. Pos. trans.(not shown) 04 Bracket 09 Geared motor 14_—_Sealing flange 05 Bracket (w. frame) 10 Chain drive 15 Eccentric nut ‘np UPSTROUNO © FLL. Smidth & Co. A'SAS ‘Course Name: Mechanical Maintenance of Kiln Systems Page 36 LE: Module 14: Preheater and Precalciner 14.2.6 MATERIAL CHUTES AND RISER DUCTS. The preventive maintenance of material chutes and riser ducts is very similar to that of cyclones. They can also be divided into those with linings and those without. The same safety measures also apply. Defective bellows in the expansion joints cannot be repaired; they must be replaced! W98 UPSTIRNNAOT © FL Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 37 . L: 7 Module 14: Preheater and Precalciner 14.3. PRECALCINER 14.3.1 PROCESS DESCRIPTION In the buming of raw mix to cement clinker, the process may be divided into several steps. 1. Drying of the raw mix. 2. Heating up to 800 - 200 °C. e 3. Calcination (CaCO, + heat -> CaO + CO,) The required heat is approx 475 kcal/kg clinker. 4, Further heating up to approx 1500 °C, formation of liquid phase. 5. Formation of clinker (Buming zone). 6. Cooling of clinker. In the traditional long wet kiln the feed is a slurry containing approx. 30 % of water, thus the first step mentioned above includes the evaporation of this water. However, in the dry kiln types the feed is given in the form of raw meal which is a powder. The residual humidity of this raw meal will normally be around 0.5 %. In the original kiln systems all of the processes took place inside the rotating kiln, but as the demand for higher production and lower fuel consumption increased, the development went in the direction of having more and more of the process taking part ‘outside the rotating kiln. The first kilns with a pre calciner went into production in the late 1970's. In the following table the evolution of the kiln system can be seen. The specific load (here given as tons of clinker per cubic meter of kiln per 24 hours) has increased from approx. 0.5 to approx. 4. The kiln has also become significantly shorter, as the wo5 VPSTIONNOT © FL Smidth & Co. A'SFs Course Name: Mechanical Maintenance of Kiln Systems Page 38 . Module 14: Preheater and Precalciner length/diameter ratio has been reduced from approx. 35 to 17 or approx. half the original figure. Typical figures for different kiln systems: Kiln system. Specific load LengttvDi {Wounv24h] am. Wet kiins 0.52 - 0.55 30-35 Long dry Kilns 0.55 - 0.70 30-38 e 4 stage suspension preheater kilns 18 -23 y17 “True calciner kilns 36 -48 “7 *) 17 is the LID relation used by some suppliers (e.g. FL.Smidth) for kilns with 3 supports. The kilns may in some special cases be designed with a LID of 10 with 2 supports, but this is normally not recommended. ‘The main purpose of the precalciner is to let the calcination process take place outside the rotary kiln. This causes a significant reduction of the thermal load of the kiln e buming zone, as approximately 60 % of the total fuel is bummed in the calciner. Furthermore the calciner provides the possibility of using fuels of a lesser quality than for a conventional kiln, thus reducing the fuel costs. Some fue! types that have been used are: Coal with a low calorific value and a high ash content, Anthracite, Petrocoke and some types of combustible wastes. The calciner consists of a vessel lined with heat resistant bricks. The calciner has 3 inputs and 1 output (see Figure 14.14): ws PSTIONO! © F.L Smidth & Co. A/S.A ‘Course Name: Mechanical Maintenance of Kiln Systems Page 39 . ao Module 14: Preheater and Precaiciner Input: Fuel Material (preheated to approx 800 °C) Hot gas from kiln and/or cooler, = 800 °C. Output’ Hot gases including combustion products and CO, from the calcination process, and material in form of dust carried with the hot gases. To lowermost cyclone Material Hot air from cooler andjor kiln. Figure 14.14 Diagram of a caliners inputs and outputs The materialigas mixture is then led to a cyclone, where the gas and the material is separated. The material is led into the rotary kiln, and the gases continues upwards through the cyclone preheater where most of the heat is recuperated, exchanging heat with the new material entering into the process. ws PSTN © FL. Smidth & Co. WSAS Course Name: Mechanical Maintenance of Kiln Systems Page 40 LE Module 14: Preheater and Precalciner The size of the calciner vessel is designed to obtain a gas residence time of approx. 3 seconds (for normal fuel types) in order to ensure a complete bur out of the fuel. ‘The different precalciner systems have different details in the design. In some systems only hot gases from the kiln passes through the calciner. There are ‘no hot gases coming from the cooler: 2 To kiln inlet in eS Gas from kiln Figure 14.15 Inline calciner with excess air Figure 14.15 shows an example of this: A calciner where the combustion air comes from the kiln only. wp PSTN © FLL. Smidth & Co. AS.AS Course Name: Mechanical Maintenance of Kiln Systems Page 41 fa Module 14: Preheater and Precalciner In such systems all the oxygen necessary for the combustion must pass through the kiln burning zone, whereby the temperature in this zone is lowered due to the increased quantity of unreacting gases. Normally the percentage of fuel to the calciner will be approx. 10 - 15 % These types of systems are sometimes not considered to be true calciners as the resulting degree of calcination is rather low, only about 40 % ‘comparing to 90 - 95 % in the systems with a separate connection supplying hot gases from the cooler. e@ In the true precalciner system part of (or all of) the combustion air necessary in the calciner is taken from the hot part of the cooler. As the planetary cooler does not include the possibility of teking hot air out, these types of cooler can not be used in conjunction with a true calciner. Figure 14.16 shows a calciner type where all of the kiln gases pass through the calciner, but there is also an intake of hot air from the cooler. The combined gases will then pass through the same preheater cyclones. wos VPSTACNDT © FLL. Smidth & Co. ASAig Course Name: Mechanical Maintenance of Kiln Systems Page 42 . Le 7 Module 14: Preheater and Precalciner Preheated raw meal Air from cooler xX To kiln inlet Gas trom kiln Figure 14.16 In-line calciner. Gases from both kiln and cooler Figure 14.17 shows a calciner type which uses only hot gases from the cooler. It will also be equipped with a separate cyclone preheater string. Figure 14.18 shows a calciner where the hot gases are taken exclusively from the cooler, but the exit gases are then mixed with the gas from the Kiln before passing through a common cyclone preheater. The inlet of the hot gases into the calciner vessel is normally designed in a way which creates some turbulence, improving the mixing of the fuel, hot air and material. 95 UST © FL Smidth & Co. ASCourse Name: Mechanical Maintenance of Kiln Systems Page 43 Preheater and Precalciner . Module 14: Preheated raw meal from C-string Preheated raw meal from K-string % Air from cooler Figure 14.17 Separate line calciner Preteated raw meal Gas trom kiln % Air trom cooler ‘igure 14.18 Separate line calciner, sharing the cyclone preheater with the kiln gases 95 VPSTIOMO! © FL. Smidth & Co. WSfis ‘Course Name: Mechanical Maintenance of Kiln Systems Page 44 . . Module 14: Preheater and Precaiciner 14.3.1.14 CONTROL OF THE DRAUGHT ‘The draught of air is controlled by a damper and/or by the speed of the fan, in cases where this is variable. In some of the systems, the calciner is a part of the cyclone preheater which is also used for the kiln gases, e.g. FLS ILC, ILC-E and SLC system. In these cases there is an interdependence between the control of the draught in the kiln and of the draught in the calciner. This makes the control a little more complicated. In other systems the calciner has its own cyclone preheater, which is independent of the kiln preheater gas flow. In these cases the control of the gas flow is more simple. 143.1.2 BURNER TYPES “The inlet of the fuel depends on the fuel type. VWhen coal is used the fine coal dust is transported pneumatically to the vessel, where it is introduced via a simple tube into the vessel. There is no bumer as such. IF fuel oil is used then an atomizing bumer is necessary. A typical burner has inlet for oil, atorrizing air (compressed air) and cooling/primary air. The bumer may also have different designs for the nozzles depending on the angle of injection and of the spreading angle. It must be emphasized that there is no actual flame formation in the calciner, as the heat resuiting from the combustion is taken up by the calcination process immediately. Wp VESTN © FL. Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 45 fa 14.3.1.3 NEWER DEVELOPMENTS: Module 14: Preheater and Precalciner In many countries governments are planning to reduce the permissible outlet of NO, in the exit gases. A way to reduce the formation of NO, in the calciner is to introduce ammonium into the calciner vessel. Another concept is to have two combustion zones in the vessel, one with a reducing and another with an oxidizing atmosphere. Both these concepts are being used in cement plants on an experimental basis, and r ) are expected to be more common as the environmental restrictions becomes more strict. 143.14 CONCLUSION ‘The development of the pre-calciner for the cement kiin has made it possible to let % of the combustion take place outside the rotary kiln. approx. This has made it possible to incr the production for a given kiln size to about the double compared to a conventional dry process kiln with a suspension preheater. The specific heat consumption is also slightly lower than for a conventional dry kiln, ‘The demands for process control are higher, as the process has become faster, but the pre-calciner kiln normally exhibits a more stable operation once the pre-calciner has been put into operation. wp UPSTICANAOT © FL Smidth & Co. A/SAS Course Name: Mechanical Maintenance of Kiln Systems Page 46 L Module 14: Preheater and Precalciner 14.3.2 (CASE STUDY 14.3.2. KILN CONVERSION PROJECT PLANT: St. Lawrence Cement, Mississauga plant BASIS: Upgrading of a pre-calcining system e When the kin system originally was converted from a four stage suspension preheater Kiln into a calciner kiln, the design with two small swirl funace (SF) calciners was adopted as depicted in Figure 14.21 at the end of this section. The kiln was previously provided with a 10% by-pass of kiln gas due to a relatively high content of chloride and alkalies in the raw material. ‘While the clinker production after the modification increased to approximately 4200 tpd, it was necessary to operate with a low oxygen level of 1 to 2 peroent in the exhaust gas from the preheater as not to overload the exhaust gas fan. Operating at this low cnygen level in the exhaust gas, the CO content in the exhaust gas often increased = @ above 1%. In addition, to keep the temperature below 380°C at the exhaust gas fans, it was necessary to inject water in the riser ducts leading to the first stage cyclones. ‘The reason for the high exhaust gas temperature is the low efficiency of the lower stage cyclones combined with incomplete combustion in the precalciner vessels. “The calciners were designed for a gas retention time of 1.2 sec, and a considerable amount of unbumt coal seemed to enter the fourth-stage cyclones with the exhaust gas. From here, part of the residual carbon went to the rotary kiln with the raw meal, Wp PSTIRINAO © FLL. Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 47 Ha Module 14: Preheater and Precalciner and another part left with the gas to the above preheater stages, in which the combustion of the carbon increased the temperature and caused the formation of CO. 143.22 MODIFYING THE CALCINER. ‘When the need arose for a larger and variable kiln by-pass of 10 to 50% of the kiln exhaust gas to produce a low alkali clinker, it was clear that the existing precalciner system would not accept such a highly variable by-pass without modifications. It was decided to replace the two existing calciners with a single, large calciner of the ‘SLC-S type. A new kiln riser duct with a by-pass outlet was also installed, and the inlets to the fourth-stage cyclones were modified to improve the efficiency of this stage. A flow sheet of the modified kiln system is shown in Figure 14.22. ‘The new calciner vessel was erected outside the preheater tower and the tertiary air duct relocated while the kiln was stil in operation. Kiln shutdown was thus limited to less than eight weeks. ‘The 6 x 14.3 meter calciner vessel is connected to the Kiln riser duct by a suspension e transfer duct that serves as an after-combustion chamber. The total calciner volume amounts to 570 m®, resulting in a gas retention time of approximately 3.7 sec at 4200 tpd and 10% by-pass. ‘The ratio of draft to the kiln and calciner is controlled by an adjustable restrictor in the kiln riser pipe. The restrictor is placed above the raw meal inlet in the kiln riser duct and is thus protected against excessive temperatures and coating formation by raw meal, which is passed via the material spitter gate below the third-stage last cyclone. pS UPSTIONOT © FLL. Smidth & Co. WSAis ‘Course Name: Mechanical Maintenance of Kiln Systems Page 48 . Module 14: Preheater and Precalciner ‘An important feature of the SLC-S calciner is that the kiln exhaust gas is not routed through the calciner and the combustion of fuel takes place in undiluted hot atmospheric air from the grate cooler. Comparison of design data for the old and new calciner. Old Calciner | New Calciner Calciner dimensions - 6x 143m Calciner effective volume - 570 m> Gas retention time in calciner 12 sec 37 sec Figure 14:19 Comparison of design data. Obtained Resuits. During a test period, all clinker produced was weighed and measurements took place to establish the exact coal consumption, by-pass rate, dust loss etc. In Figure 14.19 above, the results are compared with corresponding values recorded during a perform. ance test before modification. When considering the larger by-pass rate, the production capacity has increased by 100 to 150 tpd and the specific heat consumption decreased by about 36 kcal/kg clinker. This is because the higher degree of combustion obtained in the calciner and the higher cycione efficiency has improved the preheater temperature profile and lowered wa trsTrAMOt © FL Smidth & Co. ASTE ‘Course Name: Mechanical Maintenance of Kiln Systems Page 49 fla Module 14; Preheater and Precalciner the exhaust gas temperature. In addition, the CO content in the exhaust gas has been brought down to a reasonable level, bearing in mind that the high content of carbon in the raw meal of 0.26% will cause some CO formation in the upper cyclone stages. Analysis of material from the fourth-stage cyclones established that the burn-out degree of coal in the new calciner was about 94%. This must be termed satisfactory and is of course a result of the increased gas and material retention time in the calciner. WoE-VPSTIRNMOT © FL Smidth & Co. WSAS Course Name: Mechanical Maintenance of Kiln Systems Page 50 : Le = Module 14: Preheater and Precalciner Comparison of Operational Data before and after Calciner Modification. Before Mod. | After Mod. Production mtpd 4156 4357 Kiln gas by-pass % 6 14 Specific heat consumption keallkg 836 810 e Oy measured after fans % 26 37 CO measured after fans % 05 0.19 Water injection in 1st stage moh 55 0 1 Pressure after preheater mbar 976 95.4 ‘Temperature: After IDfans °C 366 363 After tst stage °C 376 351 After 2nd stage °C 621 590 After 3rd stage °C 805 752 After 4th stage °C 884 868 e After calciner OC 888 868 Figure 14.20 Comparison of operational data. vps WPSTIONOT © FL Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 51 . o Module 14: Preheater and Precalciner 14,3.2.3 CONCLUSIONS Obtained results show that the following improvements were gained by the replacement of the existing small SF calciners with one large SLC-S calciner. c Considering the somewhat smaller by-pass before the modification, the production capacity has increased approximately 100-150 tpd at 10% by- pass. . Areduction of the specific heat consumption by about 38 kcal/kg at 10% kiln gas by-pass. a Elimination of frequent CO peaks in preheater exhaust gas and the possibility of increasing the kiln by-pass rate to 50%. . ‘The new calciner has adequate capacity to allow a further increase in production capacity after future replacement of some of the existing preheater cyclones or the installation of a third preheater string WB PSTN © FLL Smidth & Co. WSAil Course Name: Mechanical Maintenance of Kiln Systems Page 52 Le Moduie 14: Preheater and Precalciner 1 ‘St Canrence Carer Co. - Nisissauga Plant 1 ater conversion fo18 SF Provalsror ‘Wo VPSTIONAOT © FLL. Smidth & Co. ASAS Course Name: Mechanical Maintenance of Kiln Systems Page 53. fla Module 14: Preheater and Precalciner Figure 21.2 St Lawrence Cament Co. - _ sisaiga Part KG after conversion to a SLC-S Precalciner Ki wp PSTN © FLL. Smidth & Co. AS