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Thermal & Chemical - Kilb 2015
Thermal & Chemical - Kilb 2015
Thermal & Chemical - Kilb 2015
• Thermal aspects
Thermal shock
Specific heat load
• Mechanical aspects
Ovality
Kiln alignment
Critical areas in stationary and
rotating units of a modern cement kiln
Cyclone
Precalciner
10
4
3
6 2
6 3
2 5
5 2
5 4
3 9 7
4 2
5 3
• Cyclone • Safety zone • Main burning zone • Lower transition zone • Cooler side walls
• Calciner • Upper transition zone • Kiln outlet • bull nose
• Inlet housing • Nose ring • Kiln hood
Chemical aspects
Na2O
Na2O
Secondary phases entering the kiln firing unit by alternative fuels and or raw mixes
Tools
Tools – determining chemical conditions cement moduli
Hydraulic Modulus 1.7 – 2.3 ratio of CaO to the hydraulic factors SiO2,
(HM) Al2O3 and Fe2O3
30
by weight
25
20
15
1,5 2 2,5 3 3,5 4
SiO 2
SM =
Al 2 O 3 + Fe 2 O 3
Coating – liquid phase
Coating
20 % 28 %
Liquid phase
Calculation of the Alkali-Sulphate-Ratio (ASR) in Cement Clinker
Na 2 O K O Cl
+ 2 −
Alkali /94Chlorides
62 71
ASR =
ASR =
Sulphates
SO 3
80
<1 1 >1
ASR > 1
Na2, K2 (CrO4)
III VI
MgCr2O4 + Na, K Na2, K2 (CrO4)
Corrosion of chrome ore
Deposit of alkali-chromate
ASR > 1
Alkali attack on alumina bricks and concretes
Formation of new minerals
unaffected microstructure destruction of grains
i.e. feldspar, leucite, calsilite
Volume expansion of up
to 30% causes:
“alkali-bursting”
formula salts
40
30
20
10
AR 0 .4 1 .6 2 .0 2 .4 2 .8
SR 1 .4 2 .2 2 .4 2 .6 3 .8
HM 1 .4 1 .7 2 .0 2 .3 2 .6
ASR 0 .6 0 .8 1 .0 1 .2 1 .4
LSF 85 90 94 98 103
LP 19 22 25 28 31
A c c e p t a b le F a v o u r a b le R a n g e A c c e p t a b le
Range Range
A R = A lu m in a R a t io H M = H y d r a u lic M o d u l L S F = L im e S a t u r a tio n F a c t o r
S R = S ilic a R a t io A S R = A lk a li- S u lp h a te - R a t io L P = L iq u id P h a s e
Clinker analysis reports
Plant A Plant B Plant C
ASR ASR
clinker raw mix
Thermal aspects
Burning zone heat input net burning zone cross section
2000 °C
∆ 600 °C
1450 °C
Heating up in 8 hours
up to 1000°C
Essential control steps for optimal kiln operation