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Kiln Systems

Cement Manufacturing Course 2008

by Urs Gasser (CTS)

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Holcim Group Support

Learning Objectives Kiln Systems

Understand the process of clinker burning

Know how to distinguish the basic process types

Know the typical operating parameters of the mainprocess types

Know main equipment type for clinker burning andunderstand its principle

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Kiln Systems

Process Types

Types of kiln systemswith typical operatingparameters:

Wet processSemi wet processSemi dry processDry process

Critical Process ParametersThe optimum kiln system

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Process Steps Clinker Burning

INPUT: Raw Meal

Drying

Preheating

Calcining

Sintering

Cooling

OUTPUT: Clinker

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CC-99064.dsf / Kma 22.2.99 Process Technology

400 600 800 1000 1200 1400 1400 1200C

Heating Calcining Sintering Cooling

CaCO 3CaCO free C 3 S

C 2S

C 3AC 2 AS

C 3A

C 4 AFC 2F C 4AFCA C 12 A 7

Clays

Quarz

Spurrite

Liquid phase

Q u a n t i t y

200

Heat exchangers in a kiln system

Drying

Process Requirements and Technical Solutions

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Heat Exchangers in a Kiln System

HOT GAS FROM COMBUSTION AIR

HOT GAS FROM COMBUSTION

KILN FEED MATERIAL

ROTARY ROTARY ROTARY ROTARY ROTARY

VERTICAL VERTICAL VERTICAL HORIZONTAL

HORIZONTAL VERTICAL

COOLERDRYER PREHEATER CALCINER KILN

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Typical Process Parameters

Process:

Feed moisture [%H 2O]

Heat consumption [kJ/kg]Exit gas temp [C]

ID fan press [mbar]

Installation:

Max production [t/d]

Kiln dimensions [m]Volume load [t/d m 3]

BZ load [t/d m 2]

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CC-99073.dsf / Kma 17.2.99

Dry process kiln ( with 4-stage SP)

CapacityDiameter LengthLength/Diameter Kiln load (inside lining)BZ load (inside lining)

::::::

5003.5

5014

1.5100

------

32005.5

9016

2.2180

t/dmm

t/m3dt/m2d

Kiln speedKiln slopeSpec.heat consumption

:::

1.53

3150

---

2.04

3500

rpm%kJ/kg cli

3250kJ/kg

1.45 Nm3/kg, 240C

360 C

-50 mbar 3,5 %O21,41 Nm3/kgdust: 0.1kg/kg

550C

720C

830C

1.65kg/kg50 C

1050 C- 3 mbar

2 %O21,2 Nm3/kg

= 30%clinker : 1kg cli, 1400Csecondary air: 0.9 Nm3/kg, 860C

20mbar 50mbar

1kg cli,80C

installed: 3.0Nm3/kg, 20Coperation: 2.3

Dry Process Kiln (with 4-stage SP)

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CC-99079.dsf / Kma 17.2.99

CapacityDiameter LengthLength/Diameter Kiln load (inside lining)BZ load (inside lining)

::::::

15003.5

4010

3185

------

10'0006.2

10516

5.5350

t/dmm

t/m3dt/m2d

Kiln speedKiln slopeSpec.heat consumption

:::

2.53.5

2900

---

4.54

3500

rpm%kJ/kg cli

1,65 kg/kg50C

500C

650C

770C

870C2%O2

0.5Nm3/kg, 1100C

1800 kJ/kg (60%)

310 C-50 mbar

3 %1.30 Nm3/kgStaub: 0.1 kg/kg

1.45Nm3/kg, 240C

1100 C-3 mbar 2 % O20,43 Nm3/kg

= 90%

1200 kJ/kg(40%)

clinker : 1kg cli, 1400Csecondary air: 0.35 Nm3/kg, 1100C

1kg cli,110C

Installed: 2.0Nm3/kg,20C

operation: 1,8

20mbar 50mbar

Dry process kiln (with 5-stage SP and PC)

Dry Process Kiln (with 5-stage SP and PC)

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0 1000 2000 3000 4000 5000 6000 7000 8000

3

4

5

6

7

T h e r m a l

l o a d [ M W / m 2 ]

Kiln capacity t/d

w e t

S P

P C - A T

P C -A S

9000 10000

Large Capacities, BZ Load and Process Type

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0 1000 2000 3000 4000 5000 6000 7000 8000

3

4

5

6

7

K i l n d i a m e t e r

[ m ]

w e t

S P

P C -A T

P C -A S

Large Capacities, Kiln Size and Process Type

9000 10000

Kiln Capacity [t/d]

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The Optimum Kiln System

High availability and rate

No failures Low heatconsumption

Low power consumption

Stable operation

Suitable for variety of

fuels Controlled sufficientquality

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The Optimum Kiln System 2008

7) Pneumatic sealson both ends

1) 5 stage preheater

with low pressuredrop cyclones

2) Low NOxwith staged TAswirl chamber

4) High momentum

multi channel burner

3) Oversized kilnfor AFR

5) High efficiencycooler

8) Splinedtyre fixation

6) Roller crusher

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The Optimum Kiln System 2002

Expected Performance

High avi. And rate > 0.9

Heat consumption < 3000 kJ/kg cli

Power consumption ~ 15 kWh/t cli

174113473-Kilns-Khaled.pdf

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