Training OHORONGOFA

Pyroprocessing components and operation

Part 1

Polysius Academy
Neubeckum, June 2010
Pyroprocessing components and operation
10.11.20
Training
1 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line

Pyroprocessing components and operation

10.11.20
Training
2 Polysius
Overview - production sequence in a cement plant

... from raw material through raw meal and clinker to cement ...

Pyroprocessing components and operation

10.11.20
Training
3 Polysius
Overview - production sequence in a cement plant

6
10
5
1 2
6
3 4 7 8 9 11 12

1. Crushing
7. Preheating and calcining
2. Material analysis
8. Burning
3. Intermediate storage and
9. Cooling
blending
10. Storage
4. Proportioning
11. Grinding
5. Grinding
12. Storage, packing and loading
6. Homogenising
Pyroprocessing components and operation
10.11.20
Training
4 Polysius
Overview - process functions of plant sections
•Water evaporation
•Dehydration of clay
•Preheating of raw meal
•Cooling of exhaust gases
•Conveyance of gas and meal
•Partial decarbonization of raw meal
•Heating of raw meal
•Combustion
•Decarbonization
•Combustion
•Conveyance of gas and
meal
•Clinker cooling
•Conveyance of meal and gas •Preheating
•Residual decarbonization Combustion air
•Granulation of meal/clinker •Conveyance of
•Clinker mineral formation clinker and air
•Combustion

Pyroprocessing components and operation

10.11.20
Training
5 Polysius
Overview - basic temperatures and flows
80 °C 340 °C; To raw mill
and / or EP

Pre heater
Calciner
900 °C
Tertiary Air Duct
Fuel
55 – 60 %

1700 °C Fuel 280 °C; to EP

860 °C Rotary kiln
40 – 45 %

350 °C
1400 °C
Clinker cooler
80 - 100 °C

Pyroprocessing components and operation

10.11.20
Ambient air temp.
Training
6 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / Calciner

Rotary kiln

Cooler

Operation of the kiln line

OHORONGOFA 24.05.2010
Pyroprocessing components and operation
10.11.20
Training
7 Polysius
Preheater / calciner - topics

Gas and material flow

Cyclon functioning

Double rotary airlock feeder

Pneumatic flat slide gate

Hot meal pendulum flap

Calciner types

Pyroprocessing components and operation

10.11.20
Training
8 Polysius
Gas and material flow

Meal

Gas
Material Gas

Secondary firing

Gas
Meal
Pyroprocessing components and operation
10.11.20
Training
9 Polysius
Cyclone functioning

Pyroprocessing components and operation

10.11.20
Training
10 Polysius
Cyclone functioning

Pyroprocessing components and operation

10.11.20
Training
11 Polysius
Cyclone functioning

= 85 micra

= 71 micra

= 57 micra

Pyroprocessing components and operation

10.11.20
Training
12 Polysius
Double rotary airlock feeder

Pyroprocessing components and operation

10.11.20
Training
13 Polysius
Pneumatic flat slide gate

Pneumatic
cylinder

Valve

Air supply
system

Pyroprocessing components and operation

10.11.20
Training
14 Polysius
Hot meal pendulum flap

Pyroprocessing components and operation

10.11.20
Training
15 Polysius
Calciner types

Pyroprocessing components and operation

10.11.20
Training
16 Polysius
PREPOL MSC

Pyroprocessing components and operation

10.11.20
Training
17 Polysius
Cyclone preheater DOPOL 90 & PREPOL calcinator

Pyroprocessing components and operation

10.11.20
Training
18 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line OHORONGOFA 24.05.2010

Pyroprocessing components and operation

10.11.20
Training
19 Polysius
Rotary kiln - topics

Kiln types and tertiary air duct

Kiln shell

Reactions and mineral formations

Technological kiln design

Low dust kiln inlet

Examples

Pyroprocessing components and operation

10.11.20
Training
20 Polysius
Rotary kiln

Gas
Meal
Fuel

Pyroprocessing components and operation

10.11.20
Training
21 Polysius
Rotary kiln development

5 - support kiln

3 - support kiln

2 - support kiln

Pyroprocessing components and operation

10.11.20
Training
22 Polysius
3-support kiln vs. 2-support kiln

3-support kiln 2-support kiln

Statically undefined Statically defined

• possibility of • constant support loading

- extreme overload
- plastic deformation • elastic deformation only

• requirement for • no sensitivity to misalignment

- extra safety margin
- regular adjustment
Pyroprocessing components and operation
10.11.20
Training
23 Polysius
Tertiary air duct

Pyroprocessing components and operation

10.11.20
Training
24 Polysius
Functions of the kiln shell

• Conveys material
• Guides gas from cooler to kiln
• Creates a constant moving material bed
• Allows heat exchange between gas
and material
• Holds the brick lining

Pyroprocessing components and operation

10.11.20
Training
25 Polysius
Reactions and mineral formations

Preheater Kiln

Calciner
Raw meal

Clinker
Clay minerals

Temperature [°C]

Pyroprocessing components and operation

10.11.20
Training
26 Polysius
Technological kiln design - rotary kiln zones

Calcination

Transition

Sintering

Cooling
Preheater

Calciner

2 6 6 1
Calciner kiln
Preheater

7 3 4 1
Preheater kiln
0 Kiln length in D 15
Pyroprocessing components and operation
10.11.20
Training
27 Polysius
Technological kiln design
Test procedure
representative raw material sample
test in gradient furnace
analysis of test results

Characteristic data of raw material

••Fuel
Fuelproperties
properties Computer
••Product
Productquality
Results
quality simulation
••Concept kiln dimensions
Conceptofofkiln
kiln of
line
line kiln speed
burning process

Pyroprocessing components and operation

10.11.20
Training
28 Polysius
Rotary kiln dimensioning

Kiln length (m)

L/D = ~ 12-17 (15,2)
Kiln diameter (m)

Clinker production (t/d)

Spec. volumetric load = ~ 4.0-4.5 (4.12)
Kiln volume (m³)

Energy flow (kJ/h)

Sintering zone load = ~ 12-25*106
Kiln cross section (m²)
(18.8*106)

Pyroprocessing components and operation

10.11.20
Training
29 Polysius
Rotary kiln design
Process - technological dimensions

Kiln with calciner

Kiln with preheater

10 12 14 15 17
L/D ratio

Number of stations and L / D ratio

2 - Stations

3 - Stations
3 - Stations

10 12 14 17
L/D ratio

OHORONGOFA L / D = 54 m / 3,8 m = 14,2

Pyroprocessing components and operation
10.11.20
Training
30 Polysius
Gas velocity in rotary kiln

14
Gas velocity [m/s]

12

10

6 4,0 tpd/m³ 4,5 tpd/m³ 5,0 tpd/m³

2 3 4 5 6 7 8
Kiln diameter [ m ]
Pyroprocessing components and operation
10.11.20
Training
31 Polysius
Low dust kiln inlet

• Controlled inflow of hot meal

• Minimized dust intake into calciner
• Reduction of internal re-circulation

Meal

Gas

Pyroprocessing components and operation

10.11.20
Training
32 Polysius
Examples

DO NOT COPY THESE EXAMPLES

Pyroprocessing components and operation
10.11.20
Training
33 Polysius
Examples

DO NOT COPY THESE EXAMPLES

Pyroprocessing components and operation
10.11.20
Training
34 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line

OHORONGOFA 24.05.2010
Pyroprocessing components and operation
10.11.20
Training
35 Polysius
Cooler - topics

POLYTRACK clinker cooler

Aeration and air distributors

Cooler parameters

Pyroprocessing components and operation

10.11.20
Training
36 Polysius
Cooler

Meal Gas
Pyroprocessing components and operation
10.11.20
Training
37 Polysius
POLYTRACK

Air blast unit

Socket for Upper housing
Bull-nose
cooling

Static Movable grate

grate

Inspection ports Grate equipment

Drive and Lower housing
Grate sub-structure thermo couples
unit

Pyroprocessing components and operation

10.11.20
Training
38 Polysius
POLYTRACK
Clinker
Tetiäry air Waste air
(1400 °C)
(900 °C) (280 °C)
Secondary
air (950 °C)

Static grate

Cooling air Clinker

(25 °C) (80 °C)
Pyroprocessing components and operation
10.11.20
Training
39 Polysius
POLYTRACK

POLYTRACK 5 tracks
2 modules

Pyroprocessing components and operation

10.11.20
Training
40 Polysius
POLYTRACK - mode of working

Example of a POLYTRACK® with 5 transport tracks

M Material flow direction
V Forward stroke
1. 1st return stroke
2. 2nd return stroke
3. 3rd return stroke
Pyroprocessing components and operation
10.11.20
Training
41 Polysius
POLYTRACK - Aeration arrangement

Pyroprocessing components and operation

10.11.20
Training
42 Polysius
POLYTRACK - Air distributors in chambers 1 - 3

Pyroprocessing components and operation

10.11.20
Training
43 Polysius
POLYTRACK - Air distributors in chambers 1 - 3

To replace a pendulum
counterweight, first
remove one of the spring
cotters and then pull out
the pin. Then the
pendulum counterweight
can be removed.
Install analogously in
reverse order.

Pyroprocessing components and operation

10.11.20
Training
44 Polysius
Clinker temperature as function of crushed clinker

Clinker 350
temp.
[°C] 300
250
200
150
100
50
0 10 20 30 40
Amount of crushed clinker [%]

crushed clinker at 400°C crushed clinker at 600 °C

Pyroprocessing components and operation

10.11.20
Training
45 Polysius
Cooler efficiency

Cooler efficiency [%]

82

80

78

76

74

72
Referring to 20 °C ambient air and
70 1400 °C clinker temperature

68
0,75 0,8 0,85 0,9 0,95
Secondary- and tertiary air [Nm³/Kg Cl.]
Pyroprocessing components and operation
10.11.20
Training
46 Polysius