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- 1. 06-08-28 Cement Plant Cement PlantPyro Pyro- -Technology Technology Palle Grydgaard MSc, Chem. Eng. Head of Process, PD1-P1 F.L.Smidth A/S Vigerslev Allé 77 • DK-2500 Valby • Copenhagen • Denmark Tel +45 36 18 10 00 • Direct line +45 36 18 20 63 Fax +45 36 17 10 91 palle.grydgaard@flsmidth.com
- 2. 06-08-28 Trends in cementprocess: Trends in cement process: • dry process • larger production units > 5.000 t/d up to 12.000 t/d • lower energy consumption <720 kcal/kg (<90 l oil/t) and <90 kWh/t • more alternative materials and fuels waste (pet coke, tyres, solvents, bone meal etc.) • more automation for better quality • more focus on the environment emissions (NOx, SOx, dust, noise etc.)
- 3. 06-08-28 Wet Kilns 1898: 1.8x18m 35tpd 1967: 7.6x232 m 3500 tpd Preheater kilns 1970: 6.0x96 m 4000 tpd Precalciner kilns 1984: 5.0x80 m 5500 tpd 1990: 6.0x96 m ≥10,000 tpd 2006: 6.6x93 m >12.000 tpd History of kiln capacity development History of kiln capacity development
- 4. 06-08-28 Rotax Rotax- -2 kiln for5500 tpd 2 kiln for 5500 tpd
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- 6. 06-08-28 Kiln heat consumption(1 kcal/kg = 4.18 kJ/kg) Process kcal/kg Wet process with chains +/- cross ~1400-1600 Long dry process with chains +/- cross ~1100 1-stage cyclone preheater ~1000 2-stage cyclone preheater ~900 4-stage cyclone preheater ~800 4-stage preheater+precalciner+SFcooler ~735-750 5-stage preheater+precalciner+SFcooler ~710-730 6-stage preheater+precalciner+SFcooler <700
- 7. 06-08-28 Main Raw Material:Limestone
- 8. 06-08-28 TYPICAL Values Clinker Raw MixLimestone Clay Iron ore Mix %dry 83.92 13.31 2.77 SiO2 % Al2O3 % Fe2O3 % CaO % MgO % K2O % Na2O % LOI % 21.06 4.87 4.70 64.39 1.94 0.57 0.34 13.77 3.19 3.07 42.11 1.27 0.37 0.22 34.61 5.19 1.41 1.34 49.48 1.11 0.16 0.07 39.73 64.06 13.96 5.95 2.18 1.42 1.72 1.03 9.51 32.20 5.22 41.91 10.69 5.41 0.33 1.03 Total 98.83 98.83 98.69 100.00 97.37 LSF % MS MA 95.00 2.20 1.04 95.00 2.2 1.04 289.92 1.89 1.05 1.09 3.22 2.36 8.65 0.68 0.12 C3S % C2S % C3A % C4AF % 62.8 13.2 4.95 14.3
- 9. 06-08-28 Calcination Reactions CaCO3 =CaO + CO2 Al2O3, 2 SiO2, 2 H2O = Al2O3, 2 SiO2 + 2 H2O
- 10. 06-08-28 Chemical changes duringburning Liquid phase Free CaO CaCO3 Quartz Clays C S 2 C S 3 C A 3 C AF 4
- 11. 06-08-28 ILC ILC - - In In- -LineCalciner Line Calciner
- 12. 06-08-28 SLC SLC- -D Separate D SeparateCalciner Calciner - - Downflow Downflow
- 13. 06-08-28 Modern Dry ProcessKilns Plant Name Kiln size DxL, m L/Di Load t/d/m3 Prod. t/d Heat Cons. Kcal/kg Remarks Ozarow 5.75x92 17 4.3 8500 ~750 4 stage preheater + ILC + 3 supports + grate cooler Siam City 6.0x96 17 4.3 10000 ~720 5 stage preheater + SLC + 3 supports + grate cooler Zuari 4.55x68 16 5.7 5200 ~730 4/6 stage preheater + SLC + 3 supports + grate cooler Sean Quinn 4.55x54 13 5.2 3800 ~735 5 stage preheater + ILC + 2 supports + grate cooler Saloniki 4.55x58 14 4.5 3500 ~720 5 stage preheater + ILC + 2 supports + SF cooler Ramos 4.55x56 13.5 4.2 3150 ~700 6 stage preheater + ILC + 2 supports + SF cooler
- 14. 06-08-28 Heat Consumption kcal/kg (kJ/kg) SURFACE HEATLOSS FROM KILN 30 (125) SURFACE HEAT LOSS FROM PREHEATER 35 (146) COOLER LOSS 115 (481) EXIT GAS HEAT LOSS 145 (606) HEAT OF REACTION 400 (1673) FREE INPUT WITH RAW MEAL + FUEL - 25 (- 105) NET HEAT CONSUMPTION 700 (2927) TYPICAL HEAT BALANCE: 6-STAGE MODERN KILN SYSTEM
- 15. 06-08-28 Maximum utilization ofkiln exhaust gases - 100 % to raw mill 5 stage ILC 6 stage ILC Kiln heat consumption 725 kcal/kg cl 700 kcal/kg cl Exhaust gas temperature 312 0C 280 0C Exhaust gas quantity 2.18 kg/kg cl 2.16 kg/kg cl Drying capacity in a vertical roller mill running 20 hours/day (ambient temperature of 15 0C) 8.6 % H2O 7.3 % H2O Drying capacity in a vertical roller mill running 20 hours/day (ambient temperature of 0 0C) 7.4 % H2O 6.2 % H2O
- 16. 06-08-28 High- temperature ILC low-NOx Calciner Reduction zone (1100°C) Airfrom cooler (3’ air) Kiln gas High-temperature oxidation zone (1100°C) Calcination zone (900°C) CO eliminating duct Stage 2 cyclone Stage 3 cyclone Stage 4 cyclone (880°C) Calciner fuel input
- 17. 06-08-28 Two string Two string ILCLow ILC Low- - NOx NOx precalciner precalciner
- 18. 06-08-28 Upgrading of Upgrading of 3500tpd 3500 tpd preheater kiln to preheater kiln to two two- -string ILC string ILC Low NOx Low NOx precalciner precalciner system system designed for designed for 8500 tpd 8500 tpd
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- 22. 06-08-28 FLS Standard RotaryKiln Dimensions FLS Standard Rotary Kiln Dimensions FLS 2-base kiln FLS 3-base kiln 13 x D inside lining 2.3 x D 6.8 x D 3.6 x D 17 x D inside lining 1.3 x D 5.3 x D 6.4 x D 2 x D ø D ø D
- 23. 06-08-28 Inlet & OutletLamella Seals Inlet & Outlet Lamella Seals
- 24. 06-08-28 Duoflex kiln burner Duoflexkiln burner Primary air inlet Burner trolley Burner pipe with refractory Valve for radial air Valve for axial air
- 25. 06-08-28 waste oil wood chips orplastic chips fuel oil pulverised coal plastic chips or oil contaminated refuse >>> DUOFLEX BURNER FOR ALTERNATIVE FUELS DUOFLEX BURNER FOR ALTERNATIVE FUELS
- 26. 06-08-28 Waste Fuel: Anopportunity Waste Fuel: An opportunity
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- 28. 06-08-28 Stationary and MoveableCross-Bars
- 29. 06-08-28 Stationary and MoveableCross-Bars
- 30. 06-08-28 Air flow through Airflow through holes in tongue holes in tongue Air flow through Air flow through idle hole idle hole Air flow through Air flow through gaps gaps AIR DISTRIBUTION PLATE WITH MFR AIR DISTRIBUTION PLATE WITH MFR ∆P ρ ξ Q A A Q ρ ξ ρV ξ ∆P 2 2 1 2 1 2 2 & & = ⇒ ⎟ ⎟ ⎠ ⎞ ⎜ ⎜ ⎝ ⎛ = =
- 31. 06-08-28 Mechanical Flow Regulators MechanicalFlow Regulators HIGHER VALVE dP LOW BED RESISTANCE HIGH BED RESISTANCE LOWER VALVE dP C O N S T A N T A I R F L O W
- 32. 06-08-28 5 stage ILCkiln Fuel Type Bituminous Coal Heavy Fuel Oil Natural Gas Net Heat Value kcal/kg fuel 6430 9780 11300 Kiln Heat Cons. kcal/kg clinker 727 720 731 CO2 from Raw Mat. kg/kg clinker CO2 from Fuel kg/kg clinker 0.540 0.281 0.540 0.230 0.540 0.174 Total CO2 kg/kg clinker 0.821 0.770 0.714
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