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Cycles and Bypass
Cycles and Bypass
Cycles and Bypass
A solution for
Process
POLYSIUS S.A.
Lets talk about bypass
POLYSIUS S.A.
What happens in the system ?
Grinding Heating up
Volatilization
Clinkerization
Clinker
POLYSIUS S.A.
What are the minor elements ?
Although some have no impact on the chemical process, others might lead to major
troubles.
POLYSIUS S.A.
What are some elements doing ?
Problem with volatile elements
Flowing with
gases
PROBLEMS
POLYSIUS S.A.
What are some elements doing ?
Volatilization temperature
+
Condensation temperature
2 Cases
Internal External
Cycle Cycle
POLYSIUS S.A.
Internal and External Cycles
POLYSIUS S.A.
Internal and External Cycles
POLYSIUS S.A.
Definition of the Volatility
Volatility of a component
QVolatilized
Volatility
QTotal
Component
POLYSIUS S.A.
Definition of the Volatilization
Volatilization of a component X in the kiln
Recirculation part
X Ck
Volatiliza tionX 100 1
X Hm
Note: Calculation done LOI free
POLYSIUS S.A.
Volatility or Volatilization ?
Volatility
Volatilization
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Different behaviors
Conclusion :
POLYSIUS S.A.
The salt formation
K 2O 2Cl 2KCl
Na2O 2Cl 2NaCl Chlorines
Formation order
K 2O CO2 K 2CO3
Carbonates
Na2O CO2 Na2CO3
POLYSIUS S.A.
Calculation of the salt concentration
POLYSIUS S.A.
Calculation of the salt concentration
149 100
Quantity of KCl formed : KCl a
94 100 e
71 100
Cl used during the reaction : ClKCl a
94 100 e
71 100
Cl remaining after the reaction : ClR1 c a
94 100 e
POLYSIUS S.A.
Calculation of the salt concentration
62
Quantity of Na2O that can be used with Cl : Na2O ClR1
71
117
NaCl formed during the reaction : NaCl ClR1
71
100 62
Na2O remaining after the reaction : Na 2OR 2 b ClR1
100 e 71
POLYSIUS S.A.
Calculation of the salt concentration
142
Quantity of Na2SO4 formed with Na2O : Na2SO 4 Na2OR 2
62
80
SO3 used during the reaction : SO3 Na 20 R 2
62
100 80
SO3 remaining after the reaction : SO3R 3 d Na 2OR 2
100 e 62
POLYSIUS S.A.
Why do we need such calculations ?
POLYSIUS S.A.
What is the bypass system ?
Process
Cycles creations
Bypass system
Salt formation
Troubles
POLYSIUS S.A.
What is the bypass system ?
Separation
Electro filter
POLYSIUS S.A.
How much bypass ratio ?
The bypass
Decreases the concentration of minors in the
kiln inlet by taking a part of the kiln gas
Taking part of the heat
Taking part of the production
POLYSIUS S.A.
Two different ways
1 - Assuming that
Bypass % Cl % input (free of LOI) x 100
POLYSIUS S.A.
POLYSIUS process of decision for BP%
SO3, Cl, X% BP X% BP
Na2O, K2O
Yes <4%
Bypass > 4%
Cl < 1%
Calculation % Salts in hot meal
hot meal
X%
< 6%
> 6%
< 60%
% CaSO4
> 60%
X% BP
POLYSIUS S.A.
Example of decision
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Calculation of the bypass ratio
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Definition of the Bypass Ratio
VBypass
BypassRati o
VKi ln
POLYSIUS S.A.
Definition of the calculation parameters
WD
to
VBP
to
VAF
WD to
t1
VA
VBP to
t1
VAF
t1
%O2(BP)
Va
ta
%O2(k), Vk
POLYSIUS S.A.
Calculation of V Kiln
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Calculation of V Comb
C + O2 CO2
S + O2 SO2
H2 + O2 H2O
CXHY with Y = 2x + 2
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Calculation of V Comb
VCombCO 2
CO CO2 x.CxHy Wg
100
y
H 2 H 2S H 2O .CxHy Wg
2
VComb H 2O
100
VComb SO 2
H 2S Wg
100
y
2,381 CO 2,381 H 2 7,143 H 2S 4,762 O 2 4,762 x .CxHy Wg
4
V Air min
100
POLYSIUS S.A.
Calculation of V Comb
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Calculation of V CO2
CaO MgO
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Calculation of V Ex
O2 Air
%O 2 ( k )
VEX x (VCO2 VCOMB )
21 - %O 2 ( k )
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Calculation of V Kiln
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Calculation of V BP
INPUTS WD
to
OUTPUTS VBP
to
VAF
WD to
t1
VA
VBP to
t1
VAF
t1
%O2(BP)
Va
ta
%O2(k), Vk
POLYSIUS S.A.
Calculation of V BP
INPUT
VBP x CPGAS x (t1 20)
+ Va x CPAIR x (ta 20)
+ WD x CPdust x (t1 20)
+ VFA x CPair x (ta 20)
OUTPUT
VBP x CPGAS x (t0-20)
+ Va x CPAIR x (t0-20)
+ WD x CPdust x (t0 20)
+ VFA x CPair x (t0 20)
K
%O2 ( BP ) %O2 ( Ki)
VFA K VBP
21 %O2 ( BP )
POLYSIUS S.A.
Calculation of VBP
As far as
Inputs = Outputs
VBP
POLYSIUS S.A.
Calculation of the bypass ratio
VBypass
BypassRati o
VKi ln
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Conclusion
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Questions and/or comments ?
POLYSIUS S.A.