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The Design Considerations of A Rotary Kiln Are
The Design Considerations of A Rotary Kiln Are
The Design Considerations of A Rotary Kiln Are
1.77×√Q×L×F
Retention time (in minutes) = S×D×n
2.29×4.5×n
L= 1.77×√35×1
t = p×d×N
where, t – Residence time (mins) L- Length of kiln (m) p- Slope of kiln
(degrees) d- Diameter (m)
N-revolutions per minute
Θ-angle of repose (degrees)
Therefore length is given by
L =
Taking t = 35, p=9, d=3.2, n= 0.6
L = 35 x 9 x 3.2x0.6
1.77 x 6
L= 56.01 m
Kiln diameter:
The following rotary kiln slopes were found in cement plant operation handbook.
5% slope for kilns with diameters up to 2.8m
4% slope for kilns with diameter from 3-3.4m
3%slope for kilns with diameter above 3.4m
Therefore kiln slope of 4% the diameter of the kiln is taken to be:
Kiln diameter = 3.2m.
=
Percent filling (hb)
To keep the difference between temperature at surfaces of material and its core, to a minimum it is desirable to keep
degree of filling between 4-6 %
1.667×𝑇×𝑄×𝑎
Percentage filling (%) = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑘𝑖𝑙𝑛×𝑏
T = retention time in minutes
Q = Capacity of clinker in tph
a = Ratio of raw meal feed/ product
=
b= for clinker 1.2 t/m3
1.667×𝑇×𝑄×𝑎
Percentage filling (%) =
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑘𝑖𝑙𝑛×1.2
% of filling level =
Assuming 16% filing level,
Kiln speed =
Kiln speed = 0.6 rpm
Heat loads(z
Heat required in raising the feed to 14000C
Q = m Cp ∆T
Q = 11.64kg/s x 0.88 kJ/kgoC x (1400-25)0C Q = 14084 KJ
Kiln power
1. Friction power (PI) and
2. Load power (P2)
Where, W = Total weight of rotating parts including weight of refractory and charge
in kiln in tons
Dt, Db and Dr are diameters of tyre, bearing and roller respectively (m)
n = Speed (rpm)
H = friction factor (usually 0.018 for kilns)
It is a cylinder shaped vessel slanted somewhat to the level which is pivoted gradually about its
axis. The material to be processed is bolstered into the upper end and may experience a specific
measure of blending. Hot gases go along the oven inverse way to the procedure material (counter
current). Hot gases are created by a flame inside the furnace.
Kiln shell material
This is made from rolled mild steel plate welded to form a cylinder .Mild steel is used because of
its good thermal conductivity, resistant corrosion and can withstand high stresses.
This is also true of all round vessels like caiciners, ducts like t.a. ducts.
Ready reckoner tables or graphs can be built up to estimate weight of refractory for kilns of
different diameter
Refractory bricks called andalusite based fire bricks are used in lining to insulate the steel shell
from the high temperatures inside the rotary kiln, and to protect it from the corrosive properties
of the process material. The refractory selected depends upon the temperature inside the kiln and
the chemical nature of the material being processed. The thickness of the lining is 200 mm.
Minimum thickness =
Thickness =
Thickness = 200mm
Stress Analysis
The stresses that act on the rotary kiln are axial and compressive stresses Axial stress =
where;
p- Density of mild steel Di – inner diameter t- Thickness
C- Corrosion allowance
Assuming a corrosion allowance of 3mm,
Axial stress =
Axial stress = 518.2 N/m2
Longitudinal stress due to pressure
Where,
P- Design pressure
Di – inner diameter
t- Thickness
Kiln slope 4%