PG 1992 2025 KilnSystems Overview Text

"Holderbank" Cement Seminar 2000
Process Technology
Kiln
Systems
II
Kiln
Systems
Overview
Urs Gasser
PT 99/1 4501 /E
1.
2.
PROCESS REQUIREMENTS FOR

PROCESS TYPES
WET PROCESS
3.3
15
Kilns
Kilns with Slurry Preheaters
16
18
WET PROCESS
General
18
4.2 Semi
Wet Process Long
4.3 Semi
Wet
18
Kilns
18
Grate Preheater Kilns
4.4 Semi-Wet Suspension Pre-heater Kiln
20
SEMI DRY PROCESS
22
5.1
6.
Wet Process
Wet Process
SEMI
4.1
.....14
General
3.2 Long
5.
10
10
3.1
4.
SYSTEMS
General
2.1
3.
KILN
Semi-Dry Process Long
22
Kilns
5.2 Semi-Dry Process Grate Pre-heater Kilns
22
DRY PROCESS
26
6.1
Long Dry
26
6.2
Raw
Kilns
Meal Suspension Preheater Kilns
26
26
6.2.1
General
6.2.2
One and two Stage Cyclone
6.2.3
Four Stage Cyclone Pre-heater Kilns
28
6.2.4
Precalciner Kilns
30
Holderbank
Management &
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Pre-heater Kilns
27
Page 5
^^
-'Holderbank" Cement Seminar 2000

Process Technology
II
Systems
Kiln
SUMMARY
Today's
kiln systems for burning cement clinker of major importance use a rotary kiln.
Exceptions are vertical shaft kilns still used in certain geographical areas. With very rare
exceptions, new plants use the dry process. However, there are still important markets
where older wet process plants are predominant (USA, Russia).
first
<
water
the water content of the
kiln
feed:
dry-process
10...
12%
water
semi-dry-process
17...
21%
40%
water
semi-wet-process
water
wet-process
25...
made based on
classification of the process can be
Dry-Process
Precalciner kiln with 4 to 6 cyclone stages (contemporary technology):

*
Separate tertiary air duct
*
50 - 60% fuel to the precalciner
*
Large capacities possible > 1 0000 t/d
*
Up
*
*
Heat consumption < 3000 kJ/kg possible (6 stages)

Sensitive to circulation phenomena (-> kiln gas bypass!)
to
4000
t/d
in
string
4-stage cyclone pre-heater
Cyclone stages (co-current
*
*
*
*
Large application world wide

Capacities of up to 4500
Heat consumption: 31 50
Sensitive to circulation
t/d
to
(standard technology 1970 to 1980):
kiln
flow) for
raw meal preheating
technically possible
3350 kJ/kg
phenomena
2-stage cyclone pre-heater
cli
(-> kiln
gas bypass!)
kiln:
phenomena than 4-stage pre-heater
Less
Higher heat consumption than pre-heater with more stages
sensitive to circulation
Shaft pre-heater
kiln:
Counter current heat exchange between hot gas and raw meal
Practical efficiency inferior to cyclone pre-heater
Long-dry-kiln:
Rather simple equipment

High dust emission from kiln tube
Without heat exchange internals: high heat consumption of up to 5100 kJ/kg
With chains and/or crosses: 4200 kJ/kg
Page 6
cli
cli
achievable
Holderbank Management & Consulting, 2000
'HOLDERBANK"
Process Technology
II
Kiln
Systems
Semi-dry and semi wet process
Grate pre-heater kiln (LEPOL, ACL):

*
Raw meal must be suitable to be nodulised with water (semi-dry)
*
3450 kJ/kg
Long
*
cli
(no waste heat available for primary raw material drying)
kiln and suspension preheater:

cakes fed or slurry injection into vertical dryer; rather rare cases
rotary
Filter
Wet-process
Long wet kiln:

Fed with raw meal
*
*
*
*
*
slurry of approx.
32
42%
water content
Internal heat transfer improved by chains
High heat consumption of 5300
to
Heat consumption reduced by

Slurry preheaters can reduce kiln
6300 kJ/kg
cli
due
to evaporation of
slurry thinners for a slurry with

size and improve heat exchange
water
25
30% H20
Page 7
IMLHrWÎT

Process Technology
II
Kiln
Systems
PROCESS REQUIREMENTS FOR
1.
KILN
SYSTEMS
to be designed to cope with the requirements of the chemical

clinker.
which
the kiln feed material is converted into cement
during
temperatures
of
This process as a whole is endothermic and takes place at maximum material
generated by
Receiving
thermal
energy
from
hot
gases
of
up
to
2000C
its
1450C.
combusting fuels, it is also referred to as pyroprocess.
of reactions
Type of reaction and temperature development are compiled in "sequence
kiln system has
The
process
of
occurring in a rotary kiln" (table 1) and graphically as the "quasi-qualitative variation

minerals with temperature" (figure 1).
is converted to
The chemical process taking place in the kiln system where raw meal (input)
cement clinker (output) can be subdivided into the following five steps:
1.
Drying
2.
Preheating
3.
Calcining
4.
Sintering
5.
Cooling
equipment has been developed and improved

Process andthese
performing
steps forever improved economy, which
High
availability
Low
heat consumption
Low power consumption
Higher
Stable
Good, uniform
Table
capacity
unit
kiln
operation
clinker quality
Sequence
with the aim at
means
Temperature
range (C)
of Reactions occurring in a Rotary Kiln
Type
of reaction
Heating Up
20-100
Evaporation of free
100-300
Loss
400 - 900
>500
Removal
Structural changes
600
Dissociation of carbonates
900
of physically
H20
absorbed water
of structural
H20 (H20 and OH

in silicate
>800
>1250
Formation of
Formation of
approx. 1450
Completion of reaction and
belite,
liquid
groups) from clay
minerals
minerals
C02
driven out)
intermediate products, aluminate and
phase (aluminate and
ferrite
ferrite melt)
re-crystallisation of alite
and
belite
Cooling
1300-1240
Page 8
Crystallisation of liquid
phase
into mainly aluminate
and ferrite
Holderbank Management
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Process Technology
Kiln Systems
II
Heat exchangers
in
kiln
system
CaCO
CO
C3 S
Spurrite
Quarz
C,A
Liquid phase
Clays
200
H
400
800
600
1000
1200
1400
1400
C AF
4
1200C
Cooling
Hj
IPi
r\
m&Bal&
HOLDERBANK'
CC-99064.dsf
Kma
Process Technology
22.2.99
&
Consulting,
2000
Page
:MI.d:M.MCT

Process Technology
II
2.
PROCESS TYPES
2.1
General
The
Kiln
Systems
criterion normally used to distinguish the process types
is
the moisture
defined:
material. Four basically different process types for clinker burning can be
Process Type
Dry process
Feed
Semi dry process
Nodules
Semi wet process
Filter
Wet
Slurry
Raw
process
Cons.
Material
Feed Moisture
Dry
meal
cake, nodules
feed
of the kiln
Feed System
<1%H20
Mechanic, pneumatic
Moist
12% H20
Mechanic, pneumatic
Moist
17.-21% H20
= 25... 40% H20
Mechanic, pneumatic
10...
Liquid
Hydraulic
for
1 gives a general survey of the various rotary kiln systems in operation

Table
industrial
clinker production. Shaft kilns, which are still used in China or experimental
systems such
as
in
We
the scheme.
sintering grates or fluidised beds, are not considered
can
distinguish
a)
Long
b)
Short or
two main groups
of
systems:
heat exchanging
kilns with or without internal
medium
kiln
kilns with external
installation
preheaters
(e.g. suspension preheaters, grates or external slurry preheaters)
The heat consumption
of burning
This can be illustrated by
wet
The
depends
strongly
on the water content of the
the typical specific heat consumption:
The
fuel
kiln
feed
consumption
of
kilns.
kilns is nearly twice as high as for modern dry process suspension pre-heater
(dry
clearly:
comparison of the heat economy within each process group
or wet) shows
The more
intensive the heat-exchange for drying
and
the heat
preheating, the lower
consumption.
Other than based on

Process Type
the feed moisture,
Mode
systems can be grouped
>25% H20 in feed

17-21%H20infeed
10-12%H2Oinfeed
wet
semi wet
semi dry
<1%H20infeed
dry
Production
kiln
< 200
batch+cont.
t/d
2900
(
kJ/kg
Power Consumption
700 kcal/kg cli)

> 6000 kJ/kg cli
Page 10
20
to
65 kWh/t
ways:
Slurry
nodules from slurry

nodules from meal
raw meal
shaft kilns
state of the art
cli
(> 1400 kcal/kg
different
rotary kilns
continuous300t/d-10'000t/d
Heat Consumption
in
system
long wet or dry kilns,

not optimum operation
cli)
kiln
cli
feed to clinker cooler
&
Consulting,
2000

Process Technology
OVERVIEW OF
General Overview
Holderbank
of
II
KILN
Systems
AND PROCESS TYPES
Process Types and Rotary
Management &
Kiln
!M|.H;i:M.Mr
Kitn
Systems
Consulting,
2000
Page
11

Process Technology
When the
II
Kiln
Systems
concept for a new plant
possible future developments of
The
is
all
developed, not only the present situation but also

relevant factors
must be taken
into
account.
following main parameters must be considered when selecting the
Raw
*
*
*
*
*
*
system:
material:
grindability
homogeneity
number
of deposit
of components for raw mix
chemical composition (sulphur, chlorides, alkalis, organic compounds

filtration properties of slurry (for semi-wet process only)
Plant installation and operating costs
Requirements
Aspects
Technical standard of the country
Long wet (and

internal
kiln
moisture content
cement
the
for clinker quality (e.g.
alkali clinker)
of environmental protection (emission of dust,
dry) rotary kilns are the oldest
clinker.
low
The
equipment
to
pyroprocess takes place
improve heat
etc)
SOx, NOx,
and most simple type

in
transfer, and, in
etc)
of installation to
produce
a long rotating tube, which has usually

loss. Unit
wet kilns, to reduce dust
capacities of up to 2000 t/d are typically achieved, higher outputs are possible, however,
they require kilns of gigantic dimensions.
Today, economy
requires plants for
3000
to 10'000 t/d. Therefore
new
plants are almost
cooler.
always based on the dry process with preheater, pre-calciner and reciprocating grate
The semi wet process for a new plant could be preferred in special cases, e.g. where raw
material with a high natural moisture must be used (e.g. quarry below water
The
level).
three following graphs illustrate the development of the significance of the various
processes within the Holderbank group, which can be considered representative
of
the
global situation.
Page 12
:Mi.]=N:M?rTaa

Process Technology
Kiln Systems
II
Kiln
Systems
in
the "Holderbank" Group
70ts
60
S-50
0)
S40-
=S30a
wet
semi wet
semi dry
Hdry
12010-
1981
1983
1985
Kiln
1987
1989
Systems
in
1991
1993
1995
1997
II
140m120
100?
3*
BO-
'S
Long wet
Long semi wet

Long dry
Grate preheate
SP
60f:
401
SP-PC
201
0-P
1981
1983
1985
1987
1989
1991
1993
1995
1997
Page 13
!MI.:i=M?ITga

Process Technology
Kiln Systems
II
Systems
Kiln
in
III
| Total
. avg
1983
1981
1985
3.
WET PROCESS
3.1
General
The wet process was

all
plants
higher
1989
1991
the liquid slurry
was done
lining
wear
The disadvantage
Today, with
efficient
new
in
1995
corrective addition
in
the past
good batch-wise blending.

which consume 30%, less energy than dry ball mills, but
of the
kiln,
wet process
is
the difference
the high heat consumption.
is
more than 2000
Compared
kJ/kg clinker or 60 to
dry homogenising technology available, the wet process
control
(alkali
in
wet
for preferring the
wet process
in
the past
content < 0,6%) and the fact that
kilns.
at
is
to e.g.
70%!
no longer
as well as operating costs of a wet system are higher than
systems of the same output. Technical development allows using more

systems even where wet plants would have been built in earlier times.
cement
and almost
were no problem;
rates.
plants. Investments
Another reason
cap
1997
for dry
kiln
kiln
the slurry tanks provides very
in slurry mills,
suspension preheater
applied for
1993
the most important process for clinker burning
were wet. Heterogeneous quarries and
stirring of
Grinding
1987
Group
Today secondary
firing
was
efficient
the production of low alkali
difficult circulation
problems are easier to
or efficient bypass installations with precalciner
are possibilities to keep these problems under control also
in
modern
kiln
systems.
Because of the lower specific gas volume and the shorter rotary part, rotary kiln dimensions
as well as gas handling, dedusting and fuel preparation can be designed accordingly
smaller. Although
important role
Page 14
in
new wet
the
US
kilns are
as well as
in
no longer considered
many
for
new
countries of Eastern
plants, they still play an

Europe and Central Asia.
&
Consulting,
2000
.:J=MJIT

Process Technology
Kiln Systems
II
Long Wet Process Kilns
3.2
Long wet kilns have been the most commonly used burning reactors for a very long time,
because of the high water content of the feed, their heat consumption is up to twice as
but
high as for modern dry systems.
The
and homogenised raw
milled
42% and
is
pumped
material
is
slurry with
a water content
of typically
32
to
to the kiln inlet.
In the first zone heat transfer for the evaporation of water is always increased by means of
chain systems (extended surface, higher relative velocities, increase of turbulence). The
chain systems should also reduce the dust losses and clean the
kiln shell.
These
internal
heat exchanger installations require very special know-how, based to a large degree on
experience (see separate paper 'chain systems').

In
order to decrease fuel consumption the water content should be kept as low as possible.
The
limit
is
normally the pumpability of the
slurry.
It
is
basically possible to further
reduce the
technology has been successfully applied and

adequate quantities are available at low cost, e.g. as
slurry moisture by using slurry thinners. This

will
provide an economical advantage
if
industrial by-product.
Example: Beauport (Canada):
28%
feed moisture
Production of Cement by the Wet Process
CC-9S7.dsl
Kma
17.2.99
Holderbank
Management &
Consulting,
2000
Page 15
:r.U.l=N:M;iTSM

Process Technology
Wet
II
Kiln
Systems
are relatively insensitive to circulation problems because the critical temperature

in the rotary part of the kiln (see also 'circulation phenomena').
kilns
ranges are
Low
alkali clinker can be produced from high alkali raw material simply by selectively
wasting of dust: The highest enriched kiln dust (e.g. from the last precipitator compartment)
removed from the process (i.e. dumped onto a dust pile) as necessary. The rest of the
dust can be reintroduced to the kiln by dust scoops or insufflation into the burning zone.
is
Today, discarding dust creates increasing problems because
of restrictive permitting of dust
piles.
Note:
Kiln dust cannot just be blended to the slurry because
it
would react and thicken the
slurry.
Typical technical data for long wet kilns with chains:

5'000
Heat consumption q
gas temperature
Kiln exit
in
0,5... 1,0
of clinker production
Probably the largest wet process
kiln in
Wet Process
3.3
of 7,6
is
(1'200.
1'500kcal/kgcli)
kPa
100%
5...
the world
(Michigan USA). This kiln has a diameter

capacity of about 3'600 1.
cli
250C
150...
System pressure drop

Dust emission
6'300 kJ/kg
...
installed at
and a
Holnam's Clarksville plant
length of
232
with
daily
Kilns with Slurry Preheaters
External Slurry Preheaters

order to improve the heat exchange between gas and slurry and to reduce the kiln size,
external slurry preheaters have been developed by MIAG (Kalzinator) and Krupp
In
(Konzentrator). Both of
have about
The
the
same
them are
revolving
diameter as the
capacity of these machines
problems
arise.
Very
is
drums
kiln, its
with special internal packing.
These drums
length being slightly smaller than the diameter.

-1
limited to
often, external preheaters
800
were
000
large
t/d
and frequently operating
sources
of false air.
Internal Slurry Preheaters

F.L. Smidth designed a slurry pre-heater system integrated into the kiln compartment, which
should avoid the disadvantage of external slurry preheaters. In practice, this construction
turned out to be very sensitive to clogging.
better system developed by Fives Cail
Lifting
Babcock
is
installed
in
the three kilns at
Obourg.
buckets and chain curtains produce a slurry curtain that keeps back a high amount of
dust and improves heat exchange.
Page 16
>
&
Consulting, 2000
!MJ.:i:MJIT

Process Technology
II
Kiln
Systems
Wet process
kiln
Fuel Dosing
liiiiuir
^-"'
z'
Slurry Basin
Dust Discarded
Slurry Dosing
Oust
Syphon
Insufflation
Dust Scoops
Burner
Clinker
Reciprocating
Storage
Grate Cooler
CC-990G2.d*f
Km
Burning Zone
Drying Zone
17.2.90
Wet process
kiln
dust: 0.15 kg/kg
5500kJ/kg
Cl
!Jl|
3.0Nm3/kg,
Installed
'
Capacity
20'C
operation:
23
Diameter
Length
Length/Diameter
Kiln load (inside lining)
BZ
CC-99072.aU
Knu
Holderbank
load (Inside lining)
100
2.5
40
30
0.4
40
7.5
230
38
m
m
0.8 t/m3d
Vd
3600
100
Vm2d
Kiln feed
Kiln circumferential speed

Kiln slope
Total chain weight
Dust losses
Specheat consumption
slurry
28
43
10
20
2.5
10
15
7000
0.05
5000
%H20
nVmin
%
%
rel.
0.25 kg/kg
kJ/kg
to
capacity
cli
cli
172.99
Management &
Consulting,
2000
Page 17
l?W-H*H.-IW
-HolderbankCemen. Seminar 2000

Process Technology
Kiln Systems
II
4.
SEMI WET PROCESS
4.1
General
process
is
considered semi-wet
the
if
feed
kiln
is
produced from wet
water extraction process reduces the water content of the

filter
presses operating batch-wise are
presses or
meal. Feeding
some
filter
band
cakes
filter
is
a straightforward and simple
solution
cakes or dry
used by Italcementi
slurry, filter
and
is
cases.
Semi Wet Grate Preheater Kilns
4.3
Most
systems use a grate preheater
of the semi-wet
grate preheater
where
system includes a short
only calcining
travelling grate
is
and
rotary
sintering take place.
installed in front of the kiln,
For the semi-wet grate
but also continuous
A mechanical
A number of
possible.
heat exchanger crosses can be fed with
Principally, long kilns with
slurry.
feed to 17 to 21 %.
Semi Wet Process Long Kilns
4.2
in
commonly used,
equipment would be
similar
kiln
kiln,
kiln
(similar to
kiln
filter
cakes.
a four stage preheater
kiln)
For drying, preheating and partial calcining, a

where heat of the kiln exhaust gases is used.
must be prepared
the slurry
fed with
in
special
way so
it
can be fed
to
travelling grate:
The pumpable
is
reduced
slurry
to approx.
as
presses where the moisture content

pressure of 15 to 20 bar. In a special type of
cakes are converted into cylindrical nodules (diameter 15 ...
starting material is fed to filter
20%
applying a
filtration
extruder (Siebkneter), the filter

20 mm, length 30 ... 50 mm) and then fed to the preheater-grate. The economy of
of preparation depends strongly on the filtration properties of the slurry.
Operating and performance data are similar

described under 5.2.
to
this
way
the semi-dry grate preheater systems
Characteristic data of a semi-wet grate pre-heater system
Feed Nodules made from
Slurry Filter
Moisture Content of the Feed
10...
Heat consumption q
Exit gas temperature
3770 kJ/kg
AB's
of a semi-wet
kiln
Maximum
Wat
kiln
the
2,6
LEPOL
capacity:
3'600
kPa
t/d
6mx90m
Grate dimensions:
5.6 x 61.7
firing with Fullers
6. 0/5.
earth (special)
(Shut down; replaced by semi wet precalciner
cli)
Lagerdorf plant (Germany)
<p
Page
(D 900 kcal/kg
kiln:
Kiln dimensions:
Secondary
cli
100... 120C
after grate
Example
Cake
12%
kiln in
996)

Process Technology
Kiln Systems
!Ml.:i:M?ITffli
II
Production of Cement by the Semi-Wet Process
CC-99056.dst
Kma
17.2.99
Holderbank
Management &
Consulting,
2000
Page 19
'HOLDERBANK"
Process Technology
II
Kiln
Systems
Semi-Wet Suspension Pre-heater
4.4
The suspension preheater kiln

paper). However, there are some
Kiln
normally fed with dry meal (details see separate
is
cases where suspension preheater kilns are fed

with nodules prepared from slurry. These nodules should not be too strong because
they must be cracked by thermal shock or abrasion before being fed to the kiln system
rare
via top stage of the pre-heater.
two-stage pre-heater
operated with semi-wet nodules
kiln
There, the nodules were cracked
plant.
in
vertical dryer
was
e.g.
the Liesberg
before being fed to the
preheater.
The
FLS
first
in
modern
kiln
system using
Aalborg Cement's
precalciner for a capacity of
4000
has been built in the late 1 980's by

a three stage two string kiln system with
this principle
RORDAL
plant.
t/d.
The
It
is
high operating cost of the
filter
presses has
been avoided by directly injecting the slurry into a drier-crusher followed by a vertical
drier. The semi-wet process was selected because the raw material (chalk) is mined
under water and has very high natural moisture.
From
Example
AB's
the "Holderbank" group:
of a semi-wet pre-heater/pre-calciner kiln:
kiln 11
Maximum
at the Lagerdorf plant (Germany)
kiln
capacity:
4'500
t/d
at
3900 kJ/kg
Kiln dimensions:
04.8x65 m; 2
Preheater:
stages,
Utilisation of various alternative fuels in
Supplied by Polysius; start-up:

Filter
Page 20
cakes produced
in
supports, gearless
friction
drive
strings
both firings
996
already existing filter-presses
&
Consulting,
2000
!|..:i=M?l!a

Process Technology
II
Kiln
Systems
Semi wet process
1P3
P0
^SD ^^)
(with 3-stage
kiln
SP and PC)
Slurry Basin
Burning Zone
Reciprocating Grate Cooler

Clinker
Storage
CC-99061.ds!
Kma
17.2.9
Semi wet process
(with grate preheater
kiln
dust
D.02kgftg
300
Capacity
80'C
Kma
Holderbank
5.6
Diameter
Length
Length/Diameter
45
90
11
IE
Kiln load {inside lining)
1.5
BZ
80
B
load (inside lining)
Grate load
CC.99071.al
t/d
-3000
m
m
Kiln feed
Kiln speed
Kiln slope
"LEPOL")
dust
0.1 kg/kg
18
3600
23
H20
rpm
3.5
4500
kj/kg
cli
22 Vm3d
150
t/m2d
10
t/m2d
17.2.9S
Management &
Consulting,
2000
Page
21
"
i.i
^"
>
'Holderbank" Cement Seminar 2000
Process Technology
5.
II
Kiln
Systems
SEMI DRY PROCESS
The semi-dry process is characterised by the fact that kiln feed nodules are made from
raw meal. Water is added in order to produce nodules with 10 - 12% moisture.
Semi-Dry Process Long Kilns
5.1
There are
by
dry
long kilns with heat
Italcementi
exchanger crosses fed with nodules. This system was applied

similar to an installation for semi-wet feed material.
Semi-Dry Process Grate Pre-heater Kilns
5.2
The
and looks very
grate preheater
kiln
is
by
far the
most popular semi-dry system.
The principle of the grate preheater system

one used for the semi-wet process. What
for the
is
semi-dry process
different
is
is
identical to the
the feed preparation:
The dry raw material is mixed with water (10

12%) and nodulised in a drum or preferably
on a rotating plate (pan noduliser). This system can be used only for raw materials
...
containing plastic components enabling the formation of nodules that are resistant against
plasticity is the mineralogical
thermal shock and abrasion. The main factor influencing

composition, especially the presence of montmorillonite.
On
the grate, heat
approx. 20
cm
exchange from the gas
to
some
the nodules forming
fixed
bed
layer
done
successfully, often using even waste fuels (such as Fullers earth, acid sludge, waste
lubricating oils etc.) utilising secondary firing.
of
thickness
is
excellent. In
grate preheaters, precalcination
is
The only successfully working travelling grate pre-heater was available from Polysius and
became known under the name LEPOL system (American licensee: Allis-Chalmers, ACL
system).
Page 22

Process Technology
II
Kiln
i;mi.:J=mjttm
Systems
Production of Cement by the Semi-Dry Process
CC-99055.dsf
Kma
17.2.99
Holderbank
Management &
Consulting,
2000
Page
23
"HOLDERBANK"

Process Technology
II
Systems
Kiln
LEPOL kiln fed with nodules made out of dry raw meal.
1945 are equipped with two-pass grates; i.e. the exhaust gas is
twice through the nodule bed from top to bottom:
This principle sketch shows a
LEPOL
The
kilns
built
after
led
kiln gas passes first through a bed of dry and preheated nodules and subsequently,
an intermediary dedusting once again trough a layer of moist incoming nodules. It is
believed that the nodules survive throughout the process resulting in a clinker with very
hot
after
uniform size.
Furthermore, dust loads
The
In
in
cases
of
in
only pass the fine dust while the coarse particles are retained.
compound concentrations
the electrostatic precipitator
of the
(especially alkali)
is
system. This effect
makes
the
rather low heat
consumption. For
particularly
the
The
in
LEPOL
this
kiln
reason,
it
the raw material,

them. Only a
in
compounds
has been chosen
in
many
the
cases,
and disadvantages have
be considered:
to
Only raw materials with good plastic properties can be used (semiwet: filter cake nodules -> good filtration properties are required)
The
Uneven temperature
Additional
in
quite suitable to produce a low alkali clinker with
USA.
following limits
grate chain
(partially
low.
largely enriched with
small amount of dust has to be discarded to reduce the balance of these

kiln
system are
kiln
let
increased trace
the fine dust separated
atmosphere and dust emission out
the
nodules on the grate
is
subject to wear.
distribution
heat
theoretical
across the grate can cause
difficulties.
consumption due to the water content
compensated by a low
Exhaust gases cannot be used
exit
in
of
the feed
gas temperature).
drying
and
grinding systems.
Characteristic data of a semi-dry grate pre-heater systems:
Feed nodules made from
dry raw meal
Moisture content of the feed nodules

Specific heat consumption
Exit
gas temperature
after grate
Page 24
10...
12%
3450 kJ/kg
100
2.6
...
cli
(=
820
kcal/kg
cli)
120C
kPa
;M*.;i:MJt?aa

Process Technology
II
Kiln
Semi dry process
Systems
kiln
"LEPOL")
Homogenizing and
Storags
CC-WOMLdtf
Silo
Piocm* Technology
Kmc 17J.K
Semi dry process
kiln
"LEPOL")
100
8
"C
mbar
%02
2.2Nm3/kg
dust: 0.01 kg/kg
dust
0.02kg/kg
dust
0.1 kg/kg
IkgcItSO-C
Capacity
Diameter
2000
4.8
Vd
Length/Diameter
BZ
load (inside lining)
Grate load
CC-M070.df
Kiln feed
150
tfm3d
t/m2d
12
t/m2d
Z2
11
Kiln slope
1.5
60
meal nodules,
Kiln speed
3600
kJflcg cli
Kma 17J.M
Page
25
liHVHHimiL^
-Holderbank" Cement Seminar 2000

Process Technology
Kiln Systems
II
6.
DRY PROCESS
6.1
Long Dry
Without
The
internal
Kilns
heat exchange equipment

is the long dry kiln without any internal heat
With a heat consumption of 5100 kJ/kg cli (1200 kcal/kg
simplest kind of dry process installation
exchange equipment (empty
tube).
or about 90% of the wet process it must be considered very uneconomical. Advantages
might be its simplicity and insensitivity to heavy circulation problems.
cli)
This
for
kiln
type
is
suitable to
power generation.
In that
be used
combination with waste heat recovery steam boilers
in
case, the waste heat contained
in
the hot
kiln
exhaust gases
is
further used to produce valuable energy.

Characteristic
kiln
data:
Heat consumption q
Kiln gas exit temperature

With
450
0,5
6000 kJ/kg cli
...
...
kilns with internal
less
heat exchange equipment (chains or crosses from steel or
can be achieved. Other
Characteristic
kiln
typical operating figures
3800
4500 kJ/kg
...
400
1,0... 1,5
6.2
Raw
6.2.1
General
(910.. .1075 kcal/kg
cli
450C
...
kPa
last thirty
kiln became the dominant clinker

raw meal that is preferably prepared in a
waste gases as a drying medium. This ground and
years, the suspension preheater

is
fed by dry
grinding and drying plant, using the kiln
is homogenised and then fed to the preheater where

is suspended in the
where an extremely effective heat transfer takes place. More information is
dried raw meal
gas
flow,
contained
Page 26
in
cli)
Meal Suspension Preheater Kilns
manufacturing system. This system
kiln
4200 kJ/kg or
are contained in annex 1 0.
of
data:
Heat consumption q
Kiln gas exit temperature
During the
cli)
kPa
1,0
ceramic material) represent a more economical solution. Heat consumption
even
1430 kcal/kg
500C
...
...
(1075
heat exchange equipment
internal
Long dry
4500
it
the special section "Suspension Preheaters".
iMLH^MTTT^
Process Technology
Kiln Systems
II
6.2.2
One and
Characteristic
one stage:
two Stage Cyclone Pre-heater Kilns
kiln data:
Heat consumption q
Kiln
gas
exit
temperature

two stages:
Heat consumption q
Kiln
gas
exit
temperature
3750
400
...
...
1,5... 2,5
3500
400
...
...
1,5... 2,5
4000
kJ/kg
cli
(900
kJ/kg
cli
(850.
950
kcal/kg
cli)
900 kcal/kg
cli)
500C
kPa
3750
450C
kPa
Production of Cement by the Dry Process

Sampling
CC-99054.dSl
Kma
Station
17.Z99
&
Consulting,
2000
Page
27
!Ml.H;J:MJrca

Process Technology
II
Systems
Kiln
Four Stage Cyclone Pre-heater Kilns
6.2.3
Until the
mid
980s, this arrangement belong to the systems with the lowest fuel
was offered in several configurations

them being combinations of single or twin cyclone
consumption.
The
if
exit
kiln
the
mill is
with capacities
It
gas includes
enough heat
still
to
up to 4500
t/d,
most
of
stages.
dry raw material up to moisture content of
8%
running during all the kiln operation time. From this point of view, the remaining
relatively high exit
gas temperature cannot be considered
substitute an auxiliary
The
preheater system
120
The
four to six
installed in
(6 stages) above the
loss,
because
it
can
a steel or concrete tower with a height of about 60
kiln inlet,
stages preheater
excessive concentration
as a
raw material drying.
firing for
is
fully
is
depending on capacity and concept.
most susceptible
of circulation
to
to circulation
problems at presence of
in the pre-
compounds causing clogging problems
heater system.
The sketch shows a
conventional four stage cyclone preheater system. In the 1970's,

production lines with more than approx. 2000 t/d had to be built with two parallel preheater
strings. Today, one-string installations are possible for up to 4000 t/d.
Characteristic operating figures of 4-stage pre-heater kilns:
Heat consumption q
small units
3350
...
(= 800
(= 750
kiln exit
gas temperature
320
kiln exit
gas volume
approx.

Dust loss
relative to clinker
Transition
chamber
gas temperature
Material temperature
Page 28
...
...
...
cli
850 kcal/kg
3150... 3350 kJ/kg
large units
kiln
3550 kJ/kg
...
cli)
cli
800 kcal/kg
cli)
350C
1 ,5
Nm3/kg
cli
6 kPa
8...
15%
approx. 1100C
approx. 800C
&
Consulting,
2000
:Ml.:J=M<irSM

Process Technology
Kiln Systems
II
Dry process
kiln
with 4-stage SP)
Conditioning
Tower
Burning Zone
Clinker
Calcining Zone
Reciprocating
Grate Cooler
Storage
CC-99D63.dSt
Kma
Process Technology
17.2.99
Dry process
clinker
kiln
1kg
cli,
secondary air
installed:
1k
500
Capacity
p =30%
NmSykg, 860C
3200
5.5
Length
50
Length/Diameter
14
16
180
BZ
3.5
Kma
0.9
3.0Nm3/kg, 20C
Diameter
1400*C
operation: 2.3
J cli,
CC-99073.dst
with 4-stage SP)
load (inside
lining)
1.5
100
90
speed
t/d
Kiln
m
m
Kiln slope
1.5 -
20
4
3150 -3500
rpm
kJ/kgcli
22 Vm3d
t/m2d
17.2.99
&
Consulting,
2000
Page
29
iM*.U;MMnem

Process Technology
II
Kiln
Systems
Precalciner Kilns
6.2.4
For larger production capacities, a larger portion of the pyroprocess had to be relocated out
of the rotary kiln in order to maintain reasonable kiln diameters without excessive thermal
load of the burning zone.
The process
90%
about
C02
of dissociation of
outside of the rotary
kiln.
Of the
of calcination.
(calcination)
total
00%
suitable to take place
is
kiln
The development
of this reactor started with a secondary firing
35 to
through).
40%
(= tertiary
a static reactor
will
operation (beginning of clinker formation).

in
the
kiln
riser
duct sufficient
calcination of the meal, combustion air still pulled through the kiln tube (=air
therefore referred to as precalciner (PC) type AT. Only when hot cooler air
was
It
air) for
the
PC
the so called tertiary

this type called
fuel (=
PC-AS
secondary fuel) was taken to the calciner in a separate duct,

full benefit of this technology could be used. Today, only
the
air duct,
(=air separate)
precalciner kiln system are explained
The
in
are required to achieve
must be avoided because clogging problems
calcination
seriously disturb
for
65%
heat consumption, 60 to
is
considered a
real precalciner.
The elements
of
the sketch.
in
strongest boost of calciner development
was
the seventies
in
in
Japan, initiated by the
demand
for very large units exceeding the potential of conventional kilns with suspension
preheaters. Only precalciner technology makes today's largest units of 1 0'OOO t/d possible.
Two
process alternatives
are used:
of precalciner
gas
in-line calciner (calciner installed in kiln
separate-line calciner (calciner not passed by
More
The
details
flow)
on calciner technology are contained
kiln
in
gases)
a separate section.
operating data are very close to the ones of the corresponding preheater
In-line calciners
have a tendency
kiln
system.
gas exit temperature and system pressure drop;

5 or 6 preheater stages to compensate for this.
to higher
however, modern units are equipped with
Characteristic operating data of 4 to 6 stage precalciner kilns:
Heat consumption
small units, 4 stage
SP
3350
large units, 5 stage
SP
2900
SP
to
(=
(=
SP
exit
exit
gas temp. 6
800
Dust loss
8...
relative to clinker
...
3550
kJ/kg
cli
850 kcal/kg
3200
kJ/kg
cli)
cli
800 kcal/kg
...
cli)
370C
...
approx.
gas volume
...
...
700
SP 290
st.
...
1 .3
to
1 .5
Nm3/kg
cli
6 kPa
15%
Transition chamber:
kiln
approx. 11 00C
gas temperature
approx. 800C
Material temperature
More data
Page 30
of precalciner
kiln
systems are shown
in
the section "Precalciners".
&
Consulting,
2000
!Ml.:l=MJnai
Process Technology
Kiln Systems
II
Dry process
CC-W06fl.df
Kma
kiln
(with 5-stage
SP and PC)
Process Technology
17.2.99
Dry process
5-stage
kiln (with
SP and PC)
310 'C
mbar
-50
3
1,65 kg/kg
Clinker
secondary
1kg
Installed: 2.0Nm3/kg,
20'C
cli,
110C
operation:
1,8
Kma
air:
cli,
1400C
0.35 Nm3/kg,
1O0C
1500
Capacity
Diameter
3.5
10'000
6.2
Length
40
Length/Diameter
Kiln load (inside
10
BZ load
CC-99079.dsf
1kg
lining)
(inside lining)
Nm3/kg
dust: 0.1 kg/kg
1.30
185
105
16
t/d
Kiln
m
m
Kiln slope
speed
2.5
4.5
3S2900
4
3500
rpm
kJ/kg
cli
5.5 t/m3d
350
tftnZd
17.2.99
Page
31
"HOLDERBANK"

Process Technology
II
Kiln
Systems
HEAT BALANCE
WET/ SEMI-DRY
/4-ST.
PREHEATER
WET PROCESS
Input
Fuel
kJ/kg
kiln
combustion
SEMI-DRY
LEPOL
kJ/kg
kJ/kg
kJ/kg
5560
96.7%
3343
97.6%
3150
97.7%
1180
39.2%
25
0.4%
15
0.4%
13
0.4%
0.2%
PC combustion
sensible heat
cli
4-STAGE SP 6-STAGE SP-PC
cli
sensible heat
Fuel
PREHEATER-PRECALCINER
5-ST.
0.0%
0.0%
1775
58.9%
0.0%
0.0%
0.0%
0.3%
1.7%
45
1.5%
0.4%
30
0.9%
73
1.3%
17
0.5%
67
1.2%
20
0.6%
5750
100%
3425
100%
sensible heat of
cli
0.0%
25
Kiln feed sensible heat
cli
54
0.0%
0.0%
0.2%
0.0%
3223
100%
water
Insufflated air (PA, cooler)
Total inputs
Output
kJ/kg
cli
kJ/kg
cli
kJ/kg
cli
kJ/kg
100%
3013
cli
of formation
1750
30.4%
1750
51.1%
1750
54.3%
1750
58.1%
Water evaporation
2370
41.2%
506
14.8%
13
0.4%
0.3%
Exhaust gas sens, heat
754
13.1%
314
9.2%
636
19.7%
553
18.4%
Exhaust gas dust sens.
25
0.4%
21
0.6%
18
0.6%
29
1.0%
59
1.0%
50
1.5%
63
2.0%
83
2.8%
100
1.7%
276
8.1%
423
13.1%
288
9.6%
Preheater
0.0%
160
4.7%
77
2.4%
60
2.0%
Precalciner (or bottom
0.0%
0.0%
20
0.6%
20
0.7%
Heat
heat
Clinker
Cooler waste
air
Radiation and convection

-
stage)
-
530
9.2%
200
5.8%
200
6.2%
200
6.6%
10
0.2%
92
2.7%
10
0.3%
10
0.3%
cooling
0.0%
42
1.2%
0.0%
Other outputs
0.0%
0.0%
0.0%
Kiln (+tertiary air duct)
Cooler
Water
Rest
Total outputs
Page 32
0.0%
0.0%
152
2.6%
14
0.4%
13
0.4%
12
0.4%
5750
100%
3425
100%
3223
107%
3013
100%
&
Consulting,
2000
:i'U'U:\:iu\7zzm
Process Technology
Kiln Systems
II
**/
x&h^
0)
IV&&
0)
E
(C
"5
c
4
1000
8000
2000
3000
4000
5000
6000
7000
7
.
-^
E
co
'5
'i~'-^r
<S
**$
5
pc-PJS?_j>
3
1000
2000
3000
4000
6000
5000^
7000
8000
Kiln capacity t/d
CC-99080.dsf /
Kma
24.2.99
Process Technology
33
Page
^^

Process Technology
II
Kiln
Systems
Annex
DEVELOPMENT
HISTORICAL
The word cement

as a
more than 2000 years
is
building material.
From
lime.
the medieval ages,
cement was formed out
of lime
impure lime has been used much longer
Romans produced some
lime about 700 B.C. and also the
burned
old, but
established, that the Phoenicians
is historically
It
and
sort of
used a pozzolanic
cement
known that in Holland a type

dome shaped kilns.
is
it
tuff in
or hard
of hydraulic
Our cement, as we know

today, is now more than 200 years old, "invented" by the
Englishman John Smeaton in 1756.
was burned in bottle kilns. The better known inventor
of Portland cement was Joseph Aspdin, who patented his burning process in 1824. He
it
It
also used
dome
approx. 36
kilns of
ft
and 17
height
ft
diameter with a production of 90 bbl (=
per charge, each of which took several days to produce. Fuel consumption was
clinker weight in coal which corresponds to 15'500 kJ/kg cli (= 3'700 kcal/kg cli).
1
In
1)
1880 an
important step forward
was made
with the
development
of the
which had a much better heat economy. An example

was the "Dietzsche Etagenofen" which is shown in Annex 1
working shaft
kiln,
From 1877 experiments have been conducted

developed the
These
first
first
with rotary kilns. In
successfully operating unit of this type
rotary kilns
were wet process
kilns with
50% of
continuously
of such a kiln
1897 Hurry and Seaman
America.
in
daily capacity of
50 to
00 tons. Their
9'500
heat consumption was again very high (about 30% of clinker in coal =
kJ/kg cli) and
they had an incredible dust emission (usually more than one third of the whole production). In
order to decrease heat consumption, chain systems were installed in wet kilns to improve
heat transfer during drying. Behind long dry kilns, waste heat steam boilers were arranged
same
for the
purpose.
took almost another 30 years, before a further substantial reduction of heat consumption
could be achieved by reducing the water content of the feed and by a better heat exchange
It
in
the preheating a calcining zone. In 1930 an officer of the
army
of the tsar, Dr. Lellep,
took an important step in this direction. He developed the travelling grate pre-heater,
which is fed with moist nodules. This invention was taken over by Polysius and got the name
LEPOL kiln. Some years later, there was a Czech patent of a cyclone raw meal pre-heater,
and
in
1953 Kloeckner-Humboldt-Deutz
AG
heater system for raw meal. This type of
economy and nowadays
in
kiln
other systems are only
Germany installed the first suspension prenow became dominant because of its heat
chosen
in
special cases. In former
years, the main reason for the selection of the wet process was, that effective
homogenisation of ground raw material was not possible except in the form of slurry. In
developing special techniques for dry material homogenisation such as mix beds, mixing
chamber silos etc., this factor could be eliminated.
Utilising a rather old idea, since about 1966 especially Japanese cement machine
manufacturers have designed several successfully working precalcining kiln systems.
Calcination is already done in a stationary calciner system, where secondary firing is
installed.
By
rotary part
Kiln
this
means,
it
is
possible to design kiln systems with a comparatively small
diameter but a very large capacity up to more than
systems
built after
1990 include 6-stage preheaters
with
0'OOO
t/d.
up to 4000
t/d
per
string,
pure
a variety of fuels and emission control. Using modern low primary

low pressure drop cyclone designs and high recuperation efficiency coolers
air calciners, designed for

air burners,
allow further reduction of heat and power consumption.
Page 34
&
Consulting,
2000
:Mi.H;i=M?nai
Process Technology
Kiln Systems
II
Md
ttta*Gqfef.
Holderbank
Management &
(to*
)*^^v!
Consulting,
2000
DJctiksk'
wiulti sta.f
ah&it
kiln
Page 35
!r..;W:mraa

Process Technology
II
Kiln
Systems
flMS
jliMBL.
.
^tfR
.....i
rSl
""
PM
"
im
Page 36
&
Consulting,
2000
^^M
kiln
slurry
25
slurry
_preheater
preheater
20...
medium
external
i>40()
ext.
exch.
42
lu
i
CO
CO
kiln
40...
heat
5400
a:
a.
long
int.
IS
TJ
CO
C5
to
kiln
to
=j|
-35 !5400^
long
1
V
(0
kiln
42
intcrosses
(Italcementi)
^380()
40...
long
supports
grate
CO
CD
<N
TJ
<=>
CO
hamber
firing
'
2nd
kiln
short
hot
or
in
.19
3
2
precalcination
15.. ^345()
LEPOL
grate
supports
.19
kiln
short
15.. ^3451)
LEPOL
or
-current
change
5
5
C
x.
e>
counter
heat
short
L|
cycl.
supports
^3450^
-17
or
1
shaft
supports
kiln
SP
precalciner
short
10...13
r->
in
^300()
stage
ultra
precalciner
->
preheater
kiln
2 5
firing
2nd
SP
kiln
supports
precalciner
15...17
short
stage
^335()
3 4
jhanga
w
E
1
1
&
rrent
5.
CO
Si
kiln
30
2or3stSP
25...
^3550^
medium
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PG 1992 2025 KilnSystems Overview Text

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"Holderbank" Cement Seminar 2000

PROCESS REQUIREMENTS FOR

Kilns with Slurry Preheaters

Wet Process Long

Grate Preheater Kilns

4.4 Semi-Wet Suspension Pre-heater Kiln

SEMI DRY PROCESS

Semi-Dry Process Long

5.2 Semi-Dry Process Grate Pre-heater Kilns

Meal Suspension Preheater Kilns

One and two Stage Cyclone

Four Stage Cyclone Pre-heater Kilns

-'Holderbank" Cement Seminar 2000

the water content of the

classification of the process can be

Precalciner kiln with 4 to 6 cyclone stages (contemporary technology):

Heat consumption < 3000 kJ/kg possible (6 stages)

4-stage cyclone pre-heater

Cyclone stages (co-current

Large application world wide

(standard technology 1970 to 1980):

raw meal preheating

2-stage cyclone pre-heater

phenomena than 4-stage pre-heater

Higher heat consumption than pre-heater with more stages

Practical efficiency inferior to cyclone pre-heater

Rather simple equipment

With chains and/or crosses: 4200 kJ/kg

Holderbank Management & Consulting, 2000

Semi-dry and semi wet process

Grate pre-heater kiln (LEPOL, ACL):

(no waste heat available for primary raw material drying)

kiln and suspension preheater:

Long wet kiln:

Internal heat transfer improved by chains

High heat consumption of 5300

Heat consumption reduced by

Holderbank Management & Consulting, 2000

slurry thinners for a slurry with

"Holderbank" Cement Seminar 2000

PROCESS REQUIREMENTS FOR

to be designed to cope with the requirements of the chemical

occurring in a rotary kiln" (table 1) and graphically as the "quasi-qualitative variation

equipment has been developed and improved

Low power consumption

with the aim at

of Reactions occurring in a Rotary Kiln

H20 (H20 and OH

Completion of reaction and

groups) from clay

intermediate products, aluminate and

phase (aluminate and

into mainly aluminate

"Holderbank" Cement Seminar 2000

"Holderbank" Cement Seminar 2000

criterion normally used to distinguish the process types

Semi dry process

Semi wet process

1 gives a general survey of the various rotary kiln systems in operation

sintering grates or fluidised beds, are not considered

two main groups

kilns with or without internal

kilns with external