This document discusses considerations for firing petcoke in kilns. It notes that petcoke has higher sulfur content than coal which can increase build-ups in the kiln system. It also has lower volatiles and ash. The document provides rules for utilizing petcoke, including maintaining appropriate alkali to sulfur ratios and ensuring proper coal and petcoke preparation and feeding. It discusses grinding petcoke to a finer particle size. Combustion considerations include maintaining sufficient oxygen levels. Refractory failures can result from high temperatures or sulfur/alkali effects from burning petcoke. Denser refractories with additions like zircon or AZS castables can improve buildup resistance.
ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILNISA Interchange
This paper highlights the efforts taken by the author in developing an Energy Model for the pyro-processing of Clinker production in a dry-process rotary cement kiln. In this paper this Energy Model is applied to a state of the art cement plant in a Far East Asian country. However this Energy Model is also applicable to all the modern dry process cement kilns. This model is based on actual field input data and site observations.
The Indian cement industry today stands at
260 MTPA capacity, with greater growth prospects
and promising future ahead. Cement industry has
been an excellent example of a fast growing sector
showing consistent and steady reduction in its
energy consumption. This has largely been
possible by steady and continuous improvement
across all equipments in cement manufacturing
process.
Installation of Refractory Materials in Rotary Kilns ”Essential principles"Refratechnik Group
This guide provides a brief overview of the steps for the installation materials in rotary kilns.
Please note that this guide does not claim to be complete, especially with regard to work safety and prevention of accidents.
For any further questions you may have, please do not hesitate to contact your local Refratechnik representative.
ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILNISA Interchange
This paper highlights the efforts taken by the author in developing an Energy Model for the pyro-processing of Clinker production in a dry-process rotary cement kiln. In this paper this Energy Model is applied to a state of the art cement plant in a Far East Asian country. However this Energy Model is also applicable to all the modern dry process cement kilns. This model is based on actual field input data and site observations.
The Indian cement industry today stands at
260 MTPA capacity, with greater growth prospects
and promising future ahead. Cement industry has
been an excellent example of a fast growing sector
showing consistent and steady reduction in its
energy consumption. This has largely been
possible by steady and continuous improvement
across all equipments in cement manufacturing
process.
Installation of Refractory Materials in Rotary Kilns ”Essential principles"Refratechnik Group
This guide provides a brief overview of the steps for the installation materials in rotary kilns.
Please note that this guide does not claim to be complete, especially with regard to work safety and prevention of accidents.
For any further questions you may have, please do not hesitate to contact your local Refratechnik representative.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
A cupola furnace is a melting device used in foundries that can be used to melt cast iron, Ni resist iron and some bronzes
Cupola furnace is employed for melting scrap metal or pig iron for production of various cast irons.
2024.06.01 Introducing a competency framework for languag learning materials ...Sandy Millin
http://sandymillin.wordpress.com/iateflwebinar2024
Published classroom materials form the basis of syllabuses, drive teacher professional development, and have a potentially huge influence on learners, teachers and education systems. All teachers also create their own materials, whether a few sentences on a blackboard, a highly-structured fully-realised online course, or anything in between. Despite this, the knowledge and skills needed to create effective language learning materials are rarely part of teacher training, and are mostly learnt by trial and error.
Knowledge and skills frameworks, generally called competency frameworks, for ELT teachers, trainers and managers have existed for a few years now. However, until I created one for my MA dissertation, there wasn’t one drawing together what we need to know and do to be able to effectively produce language learning materials.
This webinar will introduce you to my framework, highlighting the key competencies I identified from my research. It will also show how anybody involved in language teaching (any language, not just English!), teacher training, managing schools or developing language learning materials can benefit from using the framework.
Instructions for Submissions thorugh G- Classroom.pptxJheel Barad
This presentation provides a briefing on how to upload submissions and documents in Google Classroom. It was prepared as part of an orientation for new Sainik School in-service teacher trainees. As a training officer, my goal is to ensure that you are comfortable and proficient with this essential tool for managing assignments and fostering student engagement.
The Roman Empire A Historical Colossus.pdfkaushalkr1407
The Roman Empire, a vast and enduring power, stands as one of history's most remarkable civilizations, leaving an indelible imprint on the world. It emerged from the Roman Republic, transitioning into an imperial powerhouse under the leadership of Augustus Caesar in 27 BCE. This transformation marked the beginning of an era defined by unprecedented territorial expansion, architectural marvels, and profound cultural influence.
The empire's roots lie in the city of Rome, founded, according to legend, by Romulus in 753 BCE. Over centuries, Rome evolved from a small settlement to a formidable republic, characterized by a complex political system with elected officials and checks on power. However, internal strife, class conflicts, and military ambitions paved the way for the end of the Republic. Julius Caesar’s dictatorship and subsequent assassination in 44 BCE created a power vacuum, leading to a civil war. Octavian, later Augustus, emerged victorious, heralding the Roman Empire’s birth.
Under Augustus, the empire experienced the Pax Romana, a 200-year period of relative peace and stability. Augustus reformed the military, established efficient administrative systems, and initiated grand construction projects. The empire's borders expanded, encompassing territories from Britain to Egypt and from Spain to the Euphrates. Roman legions, renowned for their discipline and engineering prowess, secured and maintained these vast territories, building roads, fortifications, and cities that facilitated control and integration.
The Roman Empire’s society was hierarchical, with a rigid class system. At the top were the patricians, wealthy elites who held significant political power. Below them were the plebeians, free citizens with limited political influence, and the vast numbers of slaves who formed the backbone of the economy. The family unit was central, governed by the paterfamilias, the male head who held absolute authority.
Culturally, the Romans were eclectic, absorbing and adapting elements from the civilizations they encountered, particularly the Greeks. Roman art, literature, and philosophy reflected this synthesis, creating a rich cultural tapestry. Latin, the Roman language, became the lingua franca of the Western world, influencing numerous modern languages.
Roman architecture and engineering achievements were monumental. They perfected the arch, vault, and dome, constructing enduring structures like the Colosseum, Pantheon, and aqueducts. These engineering marvels not only showcased Roman ingenuity but also served practical purposes, from public entertainment to water supply.
The Art Pastor's Guide to Sabbath | Steve ThomasonSteve Thomason
What is the purpose of the Sabbath Law in the Torah. It is interesting to compare how the context of the law shifts from Exodus to Deuteronomy. Who gets to rest, and why?
Palestine last event orientationfvgnh .pptxRaedMohamed3
An EFL lesson about the current events in Palestine. It is intended to be for intermediate students who wish to increase their listening skills through a short lesson in power point.
Synthetic Fiber Construction in lab .pptxPavel ( NSTU)
Synthetic fiber production is a fascinating and complex field that blends chemistry, engineering, and environmental science. By understanding these aspects, students can gain a comprehensive view of synthetic fiber production, its impact on society and the environment, and the potential for future innovations. Synthetic fibers play a crucial role in modern society, impacting various aspects of daily life, industry, and the environment. ynthetic fibers are integral to modern life, offering a range of benefits from cost-effectiveness and versatility to innovative applications and performance characteristics. While they pose environmental challenges, ongoing research and development aim to create more sustainable and eco-friendly alternatives. Understanding the importance of synthetic fibers helps in appreciating their role in the economy, industry, and daily life, while also emphasizing the need for sustainable practices and innovation.
Read| The latest issue of The Challenger is here! We are thrilled to announce that our school paper has qualified for the NATIONAL SCHOOLS PRESS CONFERENCE (NSPC) 2024. Thank you for your unwavering support and trust. Dive into the stories that made us stand out!
Unit 8 - Information and Communication Technology (Paper I).pdfThiyagu K
This slides describes the basic concepts of ICT, basics of Email, Emerging Technology and Digital Initiatives in Education. This presentations aligns with the UGC Paper I syllabus.
We all have good and bad thoughts from time to time and situation to situation. We are bombarded daily with spiraling thoughts(both negative and positive) creating all-consuming feel , making us difficult to manage with associated suffering. Good thoughts are like our Mob Signal (Positive thought) amidst noise(negative thought) in the atmosphere. Negative thoughts like noise outweigh positive thoughts. These thoughts often create unwanted confusion, trouble, stress and frustration in our mind as well as chaos in our physical world. Negative thoughts are also known as “distorted thinking”.
5. Petcoke properties
The use of petcoke as a thermal energy source offers potential for
reduction of
thermal energy costs. However Petcoke has different properties from
coal which must be take into account:
• Petcoke has in general a higher sulfur content compared to normal
coal which can enhance the formation of build-ups in the kiln system.
• Petcoke has in general low volatiles and ash content.
• The volatiles of petcoke are not released below 900°C. The volatiles of
petcokeare mainly methane compared to >50% aromatic compounds in
bituminous coals. The aromatic compounds present in the coal combust
more easily
• Petcoke burns from the outside and does not explode. This causes the
problemof precalciner burnout and temperature increase in the bottom
cyclone stage
• The maximum petcoke substitution rate is related to the amount of the
circulating elements - sulfur, alkali and chlorine - which are contained in
the fuel and raw meal inputs
• The Hardgrove index of petcoke is generally lower than of coal
6. Petcoke rules
The following rules are important for the utilization of petcoke in calciner kilns:
• Alkali / sulfur
SO3 inputs <2.0% (clinker basis);
Molar ratio of Alkali / sulfur ≥ 0.4
• Coal / petcoke preparation
Controlled mixing from two feed hoppers
• Coal mill
o Petcoke fineness R 90µm <3% and R 200µm <1%
o Determine the coal mill output by trial (Hardgrove index can be
misleading, greasing effect)
• Kiln feed (raw material)
o Kiln feed uniformity
LSF, STD <1.2
SR, STD <0.04
AR, STD <0.04
o Medium term (10 min) mass-flow fluctuations <±0.5%
• Fine coal dosing
o Short term mass flow fluctuations (10 sec) <±1%
o Fluctuations in calorific value of coal/petcoke mixture <±1%
o Pressure fluctuations in transport duct at burner <±10% of average
pressure
• Combustion
o O2 content at kiln inlet sufficient high,
o O2 target = 3-4% at kiln inlet, CO <0.1% (better CO <0.05%)
10. coal mill
Table rpm =35
Table dia = 2.5 M
Capacity = 50 tph for coal
The hard groove of index of petcok is
about 40 %
And the residue of pet coke is < 3 % on 90
Microns . For this the damm ring has been
Increased by 20 mm (from 120 to 140 mm)
Sometimes the mill operates at 90% of the
Speed to have stable bed.Water spray on the
Grinding track further stabilises the bed to
Improve grinding efficiency
As thumb ruleresidue on
90 microns =volatiles* 0.5,( volatiles=7-8 %)
7*.5=3.5
Dam ring
33. Modern burners are aligned parallel to kiln axis
If it is parallel to kln axis it may impinge the charge
If the flame is short and convergent it may not impinge the flame
48. Pyroclone and
low nox calciner
Firing point
Hgh tertiary air temperature with clnker dust laden
With rich oxygen (21 % ) is more favorable for
Petcoke firing than low NoX calciner ,though it
Has high retention time > 5 -6 seconds.
49.
50.
51.
52. Why we must have O 2 when we
do petcoke firing
65. Longer flame elonagte the burning zone and transition zone where the meal
Has more retention time and make it favorable for more evaporation
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77. REFRACTORY FAILURES
Refractory failures are generally very difficult to identify the root cause failure
mechanism.
The main reasons are:
•Very few people truly understand the non-linear properties of the
•refractory, the thermo-chemical reactions of the refractory with the
•process environment and the thermo-mechanical interactions of the refractory
and steel shell.
•Correct information regarding the service conditions of the existing refractory
is rarely compiled by the plant.
•There are so many variables that could affect the brick reliability during
a typical campaign
•that it would be impossible to isolate the direct effect of any.
•Most refractory (especially kiln brick) failures are a result of a complex
combination of multiple variables.
78. Sulfur / Alkali – The most obvious affects of burning Pet Coke
on cement plant refractory have been the destructive forces
of sulfur / alkali. These destructive forces are seen in brick
spalling, brick capping, shell corrosion, anchor corrosion,
alkali penetration, expansive refractory reactions and direct
damage from buildup removals. Depending on the fuel sources,
pet coke can have anywhere from 1-7 wt% more sulfur and is
typically in the 4-6% range. This change in fuel composition
Creates a large change in the sulfur / alkali ratio and the resulting
cycles.
79. Direct Refractory Damage – “Direct” refractory damages are of a
physical nature due to mechanical forces. These damages and
the failure analysis are usually easily identified and corrected in
a timely manner.
Examples of “direct damage” include the following: Misaligned
kiln, kiln shell damage, incorrect shimming of the kiln tires,
direct flame impingement of a misaligned burner, over-firing a
burner, sulfur ring buildups, abrasion in high wear areas and
normal wear and tear of the system.
Direct Refractory Damages that are related to fuel variations
might include:
•Excessive temperatures (due to coke combustion) in the
“burning zone” brick
•which show 1 ½” to 2” of severe penetration of high liquid phase
is an indication of excessive temperature. This can be accompanied
with thick coating and extremely hard to remove (also indicating high
liquid phase).
• Deep cobbling of brick is a result of excessive temperatures
which left residual stress in the brick.
80. •AZS castables have been found to offer excellent buildup
•resistance in cement application. The AZS grain imparts great
thermal shock (water blasting) resistance, low thermal expansion,
low thermal conductivity and excellent abrasion resistance. The AZS
fused grain products are an upgrade over the products with just the
Zircon additive. Numerous trials have shown that it is more effective to
utilize an AZS refractory rather than Silica Carbide. The AZS refractory
has shown as good if not better results for buildup resistance, lower conductivity
for better designs, and better resistance to alkali/steam reactions that
limit the service life of Silicon Carbide.
•Standard 50-70% alumina products can be upgraded with a zircon
flour addition of 4-8% in the matrix. The zircon addition can fill interstices
sites within the refractory matrix and impart a “non-wetting” type property
to the system to help repeal alkali impregnation.This type of product is
recommended not only in buildup areas of the Tower but also in the Cooler and
Tertiary Air Ducts.
•Denser spinel kiln brick with less porosity / permeability are being evaluated to help
decrease kiln shell corrosion. The trade off is that this type of brick will generally
have a higher modulus of elasticity and may not lead to shorter term reliability.
•Monolithic materials with high percentage of calcium alumina cement should be
avoided in any application above 1400 deg. F.
•Any firebrick should be of the high-fired variety to avoid expansive reactions.