Documentos de Académico
Documentos de Profesional
Documentos de Cultura
In this module...
DESCRIPTION OF THE PROCESSES
UNDERSTANDING OF THE IMPORTANT PROCESSES
ZONES OF ROTARY KILN
TYPES OF KILN SYSTEMS
MAJOR COMPONENTS OF KILN SYSTEM
CHEMICAL PROCESSES
INTRODUCTION
CHEMICAL TRANSFORMATIONS
REACTIONS IN BURNING ZONE
MODIFICATIONS TO MINERAL STRUCTURES
DEHYDRATION OF ARGILLACEOUS MINERALS
DECOMPOSITION OF CARBONATES
REACTION BETWEEN SOLID PHASES
REACTION IN THE PRESENCE OF LIQUID PHASES
a.MELT FORMATION
b.ALITE FORMATION
REACTION DURING COOLING
CLINKERIZATION
LIMESTONE LOADING
LIMESTONE TRANSPORT
TO CRUSHER
SEM
I DR
YK
ILN
VRM - I
QUARRY
CRUSHING
CRUSHER
DRY
PH
&
VRM - II
CEMENT DESPATCH
PACKING
CEMENT GRINDING
WAGON LOADING
BALL MILL
PACKING
MACHINE
LORRY LOADING
CEMENT
VERTICAL
ROLLER MILL
PC
KIL
N
Temperature
Natural minerals
Hydraulic mixture
Time, Pressure
atmosphere
Reducing atmosphere will yield a brownish clinker
having quicker setting and lower strength.
Mineralogical factors
Physical factors (fineness, particle size distribution)
Homogeneity of rawmeal
CaCO3
MgCO3
Mineral
Calcite
Decomposition
Temperature
890 degC
Dolomite
745 degC
2(AL2O3.2SiO2) + 4 H2O
400 - 750 C
Metakaolinite
influenced by
CaCO3
Alumina Modulus
AM = AL2O3 / Fe2O3
Silica Modulus
SM = (SiO2) / (AL2O3 + Fe2O3 )
Optimum value of alumina modulus is
around 1.38
Amount of liquid is increased by reducing
the silica modulus
Liquid phase
CaO + 2CaO.SiO2 -------------> 3CaO . SiO2
C3S (Solid)
t >1250
Sensitive Areas
Selection of the bricks based on the specific load
based on our experience
Heat consumption assured by the designer
Tyre
CZ
Falling of
Coating
Unstable
Coating
SZ
Temperature
Thermal
Shock
Ring
Formation
Abrasio
n
KCl
K,
C
Na,
MZ
Cl,
K2SO
S
Clinker
Melt
Infiltratio
n
Sulfates
,
Chloride
s,
Infiltration
CALCINING ZONE
HEATING ZONE
LIQUID ZONE
SINTERING ZONE
COOLING ZONE
BURNING
ZONE
HEATING ZONE
After calcining zone and up to the liquid zone
Located behind the flame where the bed of the kiln
charge has dark colour
Reaction between Lime & Alumina and Lime and Iron
are taking place to form temporary intermediate products
As there is no heat consumption in this zone, the
temperature raises rapidly
Temperature reaches 13000 C at the end of the heating
zone
Formation of a hard and dense coating begins
Formation of liquid phases starts
COOLING ZONE
Material starts to solidify and agglomeration
occurs due to cooling
If the cooling is slower, C3S decomposes to back to
C2S and free CaO
Free CaO reacts with unstable C-A minerals to
form C3A
Grindability of clinker is improved in rapid cooling
Rapid cooling is achieved by locating the MZ near
the discharge end
In rapid cooling, clinker exit temperature is high
followed by a sudden cooling the first compartment
of cooler
CZ - Calcining Zone
HZ - Heating Zone
LZ - Liquid Zone
MZ - Max Temp Zone
AZ - Cooling Zone
The reduction of AM, SM or LSF will produce as
easily burnable rawmix
Change in rawmix burnability will affect the relative
lengths of the zones
Heat of Reaction
Kcals / Kg
clinker
Evaporation of combined
water
20
Decomposition of clay
minerals
Decomposition of
carbonates
Heat of formation of
clinker minerals
Total heat of reaction
35
475
-130
400
ADVANTAGES
Protection and safety of working personnel
Continuous stable operation of kiln
Production of well burnt good quality of clinker
maximum production with energy efficiency
longer life of kiln refractory
Lesser heat consumption
SP kiln
SP kiln
ILC E kiln
ILC E kiln
ILC kiln
ILC Kiln
Calciner vessel is built into the kiln riser pipe
Through the calciner, the kiln exit gas as well as the
tertiary air from grate cooler passes through
Degree of calcination is around 90 - 95% as the
temperature is in the range of 870 - 900 degC
Gas velocity is in the range of 5-7m/sec and
retention time is around 3.3 seconds
Secondary air is around 900-1100 degC and Tertiary
air around 750 -900 degC
CO and O2 analysers are provided at kiln inlet, PC
exit and Preheater exit
ILC kiln
SLC D kiln
SLCD kiln
SLC kiln
SLC kiln
SLC I kiln
SLC I kiln
SLC Vs ILC
ILC Calciner
SLC Calciner
SLC D Calciner
Kiln Dimensioning
VOLUMETRIC LOAD
Expressed as production in TPD clinker per m3
of kiln volume inside the lining (tpd / m3)
BURNING ZONE LOAD
Expressed as Kcal / hr released through the kiln
burner per m2 cross sectional area of the kiln
inside the lining ( 106 kcal/h/m2)
Cyclone design
Developments in Preheater
Technology
Increased retention time in precalciner
Retrofitting of existing cyclones by
# modifying the cyclone inlet cross section
# angle of entry
# altering the shape of immersion tube
Reduction in pressure drop by 20-25% and
reduction in gas temperature by around 40
degC (20-30kcals / kg of clinker)
Sixth stage preheater brings down the exit
temperature by another 25- 30 degC
Degree of Filling
P
%F =
------------Di3 x % I x Rev
where % F = Filling degrees in Kiln (%)
P = Kiln production (TPD)
Di = Internal Diameter of kiln (m)
%I = Inclination of kiln (%)
Rev = Kiln speed (Rpm)
normal value 15% to 20 %