1) Snow balls form in the transition zone of cement kilns where the temperature is around 1100°C. Low melting compounds like alkalies and sulfides melt at this temperature and bind with raw meal to form balls.
2) Excess alkalis in the clinker can melt in the transition zone and cause raw meal to form balls (snow balls). Using petcoke fuel can help reduce excess alkalis and liquid.
3) To reduce snow ball formation, the flame length should be shortened to decrease the back end temperature and liquid content in the transition zone. Ring formation should also be reduced.
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.
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.
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.
Rotary kiln design is a complex process, with a variety of factors and material characteristics influencing the sizing and design. This presentation gives an overview of the sizing and design process, including the many factors that will need to be considered during the design stage.
The ppt is useful for basic information on Cement, glass & refactories.
All above materials are used as Civil engineering materials.
Study group: Polytechnic level, For First Year students.
Pelletization of iron ores and the type of wear liners used in thier eqipmentsGulshan Kumar Singh
Now a days about 60% of iron ore converted to fines during mining, handling and transporting so pellet is a process of utilizing iron ore fines up to size of 0.15 microns. i investigate its process,equipment used in process, wear and other problems in them and its future scope
barch_building material-1_Types of lime, Classification of lime, comparison between fat lime and hydraulic lime, Manufacturing
process slaking, Hardening – Testing and Storage, Lime putty, Precautions in handling and uses of
lime.
MANUFACTURING AND UNDERSTANDING ABOUT CEMENT ITS COMPOSITION, INTERNAL MECHANICS, VARIOUS METHODS OF MANUFACTURING, USES AND VARIOUS COMPOUNDS PRESENT IN CEMENT AND ITS IMPORTANCE
CHECKOUT MY YOUTUBE CHANNEL
http://www.youtube.com/c/beaCIVILEngineergovindsir_onlineclasses
why we use fly ash in concrete , production of fly ash, how it improve the fresh and harden properties of concrete
how it react when mix with concrete.
Digital Transformation and IT Strategy Toolkit and TemplatesAurelien Domont, MBA
This Digital Transformation and IT Strategy Toolkit was created by ex-McKinsey, Deloitte and BCG Management Consultants, after more than 5,000 hours of work. It is considered the world's best & most comprehensive Digital Transformation and IT Strategy Toolkit. It includes all the Frameworks, Best Practices & Templates required to successfully undertake the Digital Transformation of your organization and define a robust IT Strategy.
Editable Toolkit to help you reuse our content: 700 Powerpoint slides | 35 Excel sheets | 84 minutes of Video training
This PowerPoint presentation is only a small preview of our Toolkits. For more details, visit www.domontconsulting.com
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Sustainability has become an increasingly critical topic as the world recognizes the need to protect our planet and its resources for future generations. Sustainability means meeting our current needs without compromising the ability of future generations to meet theirs. It involves long-term planning and consideration of the consequences of our actions. The goal is to create strategies that ensure the long-term viability of People, Planet, and Profit.
Leading companies such as Nike, Toyota, and Siemens are prioritizing sustainable innovation in their business models, setting an example for others to follow. In this Sustainability training presentation, you will learn key concepts, principles, and practices of sustainability applicable across industries. This training aims to create awareness and educate employees, senior executives, consultants, and other key stakeholders, including investors, policymakers, and supply chain partners, on the importance and implementation of sustainability.
LEARNING OBJECTIVES
1. Develop a comprehensive understanding of the fundamental principles and concepts that form the foundation of sustainability within corporate environments.
2. Explore the sustainability implementation model, focusing on effective measures and reporting strategies to track and communicate sustainability efforts.
3. Identify and define best practices and critical success factors essential for achieving sustainability goals within organizations.
CONTENTS
1. Introduction and Key Concepts of Sustainability
2. Principles and Practices of Sustainability
3. Measures and Reporting in Sustainability
4. Sustainability Implementation & Best Practices
To download the complete presentation, visit: https://www.oeconsulting.com.sg/training-presentations
Buy Verified PayPal Account | Buy Google 5 Star Reviewsusawebmarket
Buy Verified PayPal Account
Looking to buy verified PayPal accounts? Discover 7 expert tips for safely purchasing a verified PayPal account in 2024. Ensure security and reliability for your transactions.
PayPal Services Features-
🟢 Email Access
🟢 Bank Added
🟢 Card Verified
🟢 Full SSN Provided
🟢 Phone Number Access
🟢 Driving License Copy
🟢 Fasted Delivery
Client Satisfaction is Our First priority. Our services is very appropriate to buy. We assume that the first-rate way to purchase our offerings is to order on the website. If you have any worry in our cooperation usually You can order us on Skype or Telegram.
24/7 Hours Reply/Please Contact
usawebmarketEmail: support@usawebmarket.com
Skype: usawebmarket
Telegram: @usawebmarket
WhatsApp: +1(218) 203-5951
USA WEB MARKET is the Best Verified PayPal, Payoneer, Cash App, Skrill, Neteller, Stripe Account and SEO, SMM Service provider.100%Satisfection granted.100% replacement Granted.
VAT Registration Outlined In UAE: Benefits and Requirementsuae taxgpt
Vat Registration is a legal obligation for businesses meeting the threshold requirement, helping companies avoid fines and ramifications. Contact now!
https://viralsocialtrends.com/vat-registration-outlined-in-uae/
Affordable Stationery Printing Services in Jaipur | Navpack n PrintNavpack & Print
Looking for professional printing services in Jaipur? Navpack n Print offers high-quality and affordable stationery printing for all your business needs. Stand out with custom stationery designs and fast turnaround times. Contact us today for a quote!
3.0 Project 2_ Developing My Brand Identity Kit.pptxtanyjahb
A personal brand exploration presentation summarizes an individual's unique qualities and goals, covering strengths, values, passions, and target audience. It helps individuals understand what makes them stand out, their desired image, and how they aim to achieve it.
Enterprise Excellence is Inclusive Excellence.pdfKaiNexus
Enterprise excellence and inclusive excellence are closely linked, and real-world challenges have shown that both are essential to the success of any organization. To achieve enterprise excellence, organizations must focus on improving their operations and processes while creating an inclusive environment that engages everyone. In this interactive session, the facilitator will highlight commonly established business practices and how they limit our ability to engage everyone every day. More importantly, though, participants will likely gain increased awareness of what we can do differently to maximize enterprise excellence through deliberate inclusion.
What is Enterprise Excellence?
Enterprise Excellence is a holistic approach that's aimed at achieving world-class performance across all aspects of the organization.
What might I learn?
A way to engage all in creating Inclusive Excellence. Lessons from the US military and their parallels to the story of Harry Potter. How belt systems and CI teams can destroy inclusive practices. How leadership language invites people to the party. There are three things leaders can do to engage everyone every day: maximizing psychological safety to create environments where folks learn, contribute, and challenge the status quo.
Who might benefit? Anyone and everyone leading folks from the shop floor to top floor.
Dr. William Harvey is a seasoned Operations Leader with extensive experience in chemical processing, manufacturing, and operations management. At Michelman, he currently oversees multiple sites, leading teams in strategic planning and coaching/practicing continuous improvement. William is set to start his eighth year of teaching at the University of Cincinnati where he teaches marketing, finance, and management. William holds various certifications in change management, quality, leadership, operational excellence, team building, and DiSC, among others.
What is the TDS Return Filing Due Date for FY 2024-25.pdfseoforlegalpillers
It is crucial for the taxpayers to understand about the TDS Return Filing Due Date, so that they can fulfill your TDS obligations efficiently. Taxpayers can avoid penalties by sticking to the deadlines and by accurate filing of TDS. Timely filing of TDS will make sure about the availability of tax credits. You can also seek the professional guidance of experts like Legal Pillers for timely filing of the TDS Return.
RMD24 | Retail media: hoe zet je dit in als je geen AH of Unilever bent? Heid...BBPMedia1
Grote partijen zijn al een tijdje onderweg met retail media. Ondertussen worden in dit domein ook de kansen zichtbaar voor andere spelers in de markt. Maar met die kansen ontstaan ook vragen: Zelf retail media worden of erop adverteren? In welke fase van de funnel past het en hoe integreer je het in een mediaplan? Wat is nu precies het verschil met marketplaces en Programmatic ads? In dit half uur beslechten we de dilemma's en krijg je antwoorden op wanneer het voor jou tijd is om de volgende stap te zetten.
Kseniya Leshchenko: Shared development support service model as the way to ma...Lviv Startup Club
Kseniya Leshchenko: Shared development support service model as the way to make small projects with small budgets profitable for the company (UA)
Kyiv PMDay 2024 Summer
Website – www.pmday.org
Youtube – https://www.youtube.com/startuplviv
FB – https://www.facebook.com/pmdayconference
RMD24 | Debunking the non-endemic revenue myth Marvin Vacquier Droop | First ...BBPMedia1
Marvin neemt je in deze presentatie mee in de voordelen van non-endemic advertising op retail media netwerken. Hij brengt ook de uitdagingen in beeld die de markt op dit moment heeft op het gebied van retail media voor niet-leveranciers.
Retail media wordt gezien als het nieuwe advertising-medium en ook mediabureaus richten massaal retail media-afdelingen op. Merken die niet in de betreffende winkel liggen staan ook nog niet in de rij om op de retail media netwerken te adverteren. Marvin belicht de uitdagingen die er zijn om echt aansluiting te vinden op die markt van non-endemic advertising.
2. 2)Presence of volatiles and low
melting compounds alkalies,
sulfur and others ( possible)
1)Flame
length(highly
possible)
3)Chemistry , liquid content etc
( possible due to high Fe2O3 content)
4)Alternate fuels like
Tyres , plastics etc
(Not applicable)
5) Ring formation at the
junction of burning
zone and
Transition zone ( possible)
3. Formation of snow ball formation
Snow ball forms in transition zone where the temperature is around
1100 deg C +/- 50 . Low melting compounds like alkalies , sulfides, sulphites
Melt at this temperature and get agglomerated with the rawmeal and forms balls
called snow balls. In forced kilns the temperature profile becomes flat ie., T between
burning zone temperature and back end temperature is more. This is normally 400 to
450 Deg c . With low momentum flame it becomes 150 to 200 degc. If we use
alternate Fuels like tyres , paint sludge and plastics etc they can add more low melting
compounds in transition zone( not applicable here).But Fe2O3 melts at 1150 deg C.
Snow ball grows as it is rolled upon
liquid and take up more and
more liquid
4. The Ideal Flame
hot !
short !
stable !
T"long" flame
"short" flame
Complete combustion:
- CO = 0
- SO2, NOX ↓
Homogeneous:
- no temperature peaks
- no local CO on the clinker bed
Longer flame increase the back end temperature resulting in
Heat loss at kiln exit and hot meal clogging due to increased length of
transition zone.Pyro rapid kiln which has short burning zone and clinker quenching
gives better quality of clinker .
5. Burning zone, Flame-profile
• Low momentum burner
~23 m Flame ! !
Burner Operation
We are close to here .
• High momentum burner
rings12m (~3xD) burning zone
~16 m Flame !☺☺☺☺!
rings17m (~4xD) burning zone
6. Optimisation of liquid
Normal liquid content in Indian conditions = 28 % +/- 1 %
This liquid is calculated liquid derived from the formula
To make a good clinker the liquid content must beTo make a good clinker the liquid content must be
optimum and with right viscosity.
At our plant the liquid is 29 to 29.5 % and the coating is
stable Hence liquid is optimum.
Observed often lumps discharging from the kiln.(High
Fe2O3 content is one of the reasons)
In the cooler often observed big oval shaped balls with
yellowish brown core.( size 300 mm to 500 mm) This is
because of presence of sulfur and alkalies.
7. It has been found that the calculated liquid is different from actual estimated
by optical micros copy.AR should not be less than 1.2 whereas we have more than
1.2 and forms stable coating formation . If small coating falls and it is obstructed by
coating ring, it melts , soaked inside clinker liquid, densify and becomes big balls.
May be this is the right reason as the balls are solid.
The other types of balls one with yellowish brow core which are soft and
easily breakable , aught to form in transition zone. This is due to presence of alkalies,
sulfur and low melting components .These balls when it is rotated for long time due
to the obstruction of coating ring formed at the junction of
burning zone( or safety zone) and the transition zone grow gradually and becomesburning zone( or safety zone) and the transition zone grow gradually and becomes
big balls called snow balls. This I witnessed in Vikram cements before the spurrite ring
In vikram-3 kiln. Petcoke with 6 % S , was the fuel and the sulfur was excess.
Snow ball formed in the transition zone
Such balls normally melts in burning zone.The
Core Is brownish
coating ball formed in the burning zone
Soaked in the liquid for a long time.
Hard and black, even in the core
8. Molar ratio( clinker basis)
K2O = 0.5
SO3 = 0.3
Cl =0.015
ASR = 0.541
This shows there will be excess alkalis which has
ASR ,Alkali – sulfur ratio
This shows there will be excess alkalis which has
volatile recycle. The excess alkali melts in
transition zone and make raw meal balls ( snow
balls). Pet coke firing will help to reduce liquid
and the excess alkali.
9. Stoppage due to clinker discharge got blocked with
clinker balls.( 13-9-10)
If clinker coating lumps falls and unable to come out the kiln due to ash ring
formation in the cooling zone it gets soaked In the liquid and they grow . If the
Ring collapsed the balls roll out of the kiln and block the cooler discharge end.
excessive amount of liquid promotes coalescence to form a solid dense balls
which is blackish in color.
In Grasim cements at Reddipalaym when they used paint sludge as alternate
fuel In 2006 this kind of balls blocked the flame and caused two days stoppage. Itfuel In 2006 this kind of balls blocked the flame and caused two days stoppage. It
was fragmented by pneumatic hammer.
At Ultra tech cements Awarpur I have witnessed 2.5 M dia ball came out of the
kiln .The core part was brown and had rich in sulfur 8 % and 7 % alaklies.
In Vikam Cements , kiln -3,in the calciner retention time was only two minutes
and in the calcining zone there was spurrite ring formation and in front of the
ring there were lot of mud balls or snow balls accumulation.
10. Lin(Counts)
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
C3=C3S
CC=Calcite
B=Brownmillerite (C4AF)
C3S/C2S
C=CaO
A=C3A
C2=C2S
An=Anhydrite [CaSO4]
Coating sample analysed by XRD – ring formation in end of
the Burning zone at 28 M of Vikram Cements Kiln-3Lin(Counts)
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
2-Theta - Scale
11 20 30 40 50 60
C
C
C3
C3/C2
C3/C2
C3/C2
CC/C3
C3
Ar
Ar
C2/CC
CC
CCAn
B/Sp
B
B
B
B
B
B
B
Ar
An
C3S
CC
CC
CC
Q
Q An
Q
C2 C2
C2
C2
An
C3
C2
C2/C3
C2
C2
C2
C2
C2
Ar
Lu
C2
B/C2
Q
B
A/Sp
A
A P
An
An
An
ArAr
Ar
Lu
Ar
Ar=Arcanite [K2SO4]
P=Periclase [MgO]
Lu
Lu
Lu
Lu=Leucite [KAl (Si2O6)]
Q=Quartz [SiO2]
Ar
C2
Sp
Sp
Sp=Spurrite [Ca5 (SiO4)2 CO3]
11. 1. Make the flame shorter which reduces the back end temperature thereby
Reduces the amount of low melting liquid. It reduces ring formation too.
2. Good oxidised condition reduces the alkali and sulfur cycle. The Volatile cycle
enhances unwanted low melting liquid in the calcining and transition zone.
Sulfo Spurrite ring promotes snow balls ( mud balls).Pet coke will reduce the
excess alkali and the liquid . Poor flame makes char entrapment and makes the
volatile active.
3. Fe2O3 must around 4 % and Al2O3 4.5 . We have inherent Fe2O3 in lime
stone and it is difficult for us to reduce. If we can reduce from 4.5 to 4 this solves
most of the problems.
4. Reduce the ring formation by using coating repellant fused magnesia spinel
Conclusion
4. Reduce the ring formation by using coating repellant fused magnesia spinel
bricks at lower and higher transition zone .
5. Live with the problem and reduce the stoppage hours by using water jet
machine with all the safety or Winchester Gun by well trained personnel.
6. Increase the rpm of the kiln which reduces meal retention time but for this we
need high momentum flame to do pyro rapid burning. Otherwise free lime goes
up. Mind raw meal retention time not less than 18 minutes. With the present
operating rpm of 4.8 the retention time is 20.6 seconds. If we increase to 5 rpm
the RT is 19.6 seconds which is close to the acceptable value. If we go to 5.5 rpm
the RT is 17.5 secs for which we need rapid burning with high momentum flame
>2500 % m/s . This is the best option .
12. Thank you for your kind attention
K.P.PRADEEP KUMAR
Sr. G.M.OperationSr. G.M.Operation
Chettinad cements ltd
Ariyalur