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preheater process
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 1
Krupp Polysius Corp.
Preheater and Calciner
Process Training
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 2
Krupp Polysius Corp.
CM
The modern kiln plant
Raw mill
Clinker cooler
Calciner
Rotary kiln
Preheater
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 3
Krupp Polysius Corp.
Preheater
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 4
Krupp Polysius Corp.
DOPOL 90
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 5
Krupp Polysius Corp.
Gas and material flow in a preheater
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 6
Krupp Polysius Corp.
DOPOL 90 B-type cyclone
1
2
3
4
5
1 Cyclone 2 Intermediate piece3 Dip pipe4 Gas duct 5 Meal chute
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 7
Krupp Polysius Corp.
Calciner cyclone
System cyclone
DOPOL® 90
Dedusting cyclone
Cyclone types
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 8
Krupp Polysius Corp.
CM
The modern kiln plant
Raw mill
Clinker cooler
Calciner
Rotary kiln
Preheater
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 9
Krupp Polysius Corp.
DOPOL 90 - preheater design
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 10
Krupp Polysius Corp.
Number of cyclone 4 5 6Exhaust gas
- temperature °C 370 315 280
- volume Nm³/kg clinker 1,372 1,353 1,345
- dust relative to clinker % 8 6,5 5
- pressure loss mbar 33 38 45
Fuel consumption kcal/kg clinker 740 718 705
Cooler efficiency % 74,6 73,1 72,1
Clinker temperature °C 100 100 100
Cooling air Nm³/kg clinker 1,7 1,7 1,7
Cooler vent air
- volume Nm³/kg clinker 0,84 0,87 0,88
- temperature °C 295 305 312
Electrical power consumption
- for exhaust gas fan kWh/t clinker 5,6 5,7 6,1
- for total kiln plant kWh/t clinker 15,1 15,2 15,7
Permitted RM moisture
- exhaust gas only (with coal mill) % 7,6 5,6 4,3
- exhaust gas only % 8,5 6,5 5,3
- exhaust gas with exhaust air % 11 9,5 8,7
Technical data
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 11
Krupp Polysius Corp.
Drying capacities - preheater systems
AS 6 AS 5 AS 4 AS 3 AS 2
700 750 800 850 9000
100
200
300
400
500
600
0
4
8
12
16
20
24
Fuel consumption [ kcal/kg cli ]
Exh
aust
gas
tem
p. [
°C
]
Dry
ing
cap
acit
y [
% -
H2O
]
PH exhaust only -->
PH + cooler exhaust-->
<-- PH exhaust temp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 12
Krupp Polysius Corp.
Calciner
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 13
Krupp Polysius Corp.
PREPOL AS PREPOL MSCPREPOL AS-CC PREPOL MSC-CC
Calciner types
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 14
Krupp Polysius Corp.
PREPOL AT
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 15
Krupp Polysius Corp.
TA-duct
Fuel injection
Calciner loop
PREPOL AS
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 16
Krupp Polysius Corp.
PREPOL AS-CC
TA-duct
Calciner loop
Combustion chamber
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 17
Krupp Polysius Corp.
CC-Chamber outlet(Connection tothe calciner)
Tertiary duct
Tangential inlet fortertiary air inlet
Central inlet for tertiary air
Burner
Meal inlet
Meal inlet
Tangential inlet fortertiary air inlet
Combustion - Chamber (CC)
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 18
Krupp Polysius Corp.
PREPOL MSC
Kiln inlet burner
PC - burner
Meal stagingTertiary air duct
Top air duct
Deflection chamber
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 19
Krupp Polysius Corp.
PREPOL MSC-CC
Kiln inlet burner
PC - burner
Deflection chamber
Top air duct
Tertiary air duct
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 20
Krupp Polysius Corp.
Tertiary air duct
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 21
Krupp Polysius Corp.
MSC Calciner with Tire Feed Chute
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 22
Krupp Polysius Corp.
Tertiary air from cooler
w < 8 m/s w < 6 m/s
w > 26 m/s
w < 8 m/s
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 23
Krupp Polysius Corp.
w < 5 m/sw < 5 m/s
w > 26 m/s
Tertiary air from kiln hood
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 24
Krupp Polysius Corp.
kiln hood cooler measures
secondary air temperature lower higher
thermal stress on outlet segments + lower better cooling andform of segments- higher
burn out in the calciner + better - worse
- lower + higher
- higher
- higher + lower
+ lower
CC - Calciner
adapted dimensionnig and quality of refractory
optimized burner adjustment
precalcination rate
- higher + lowerbypass losses
- higher + lowerload of sintering zone
thermal stress on tertiary airflap and refractory
- bigger + smallersize of kiln hood
- longer + shorterlength of burner
(+ lower) (- higher)NOx - formation
Investment cost
Tertiary air connection
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 25
Krupp Polysius Corp.
“Low-dust” kiln inlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 26
Krupp Polysius Corp.
Fuel type PREPOL AS PREPOL AT
Natural gas < 150000 < 100000
Fuel oil < 180000 < 120000
high reaktive Coal < 130000 < 87000
low reaktive Coal < 90000 < 60000
e.g. Pet Coke < 80000
Thermal calciner loading in kcal/m³/h
Calciner volume loading
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 27
Krupp Polysius Corp.
Fuel design and distribution
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 28
Krupp Polysius Corp.
Coal - activity
Time [s]
O2-
conc
entr
atio
n [%
]
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 29
Krupp Polysius Corp.
NOx - generation in clinker burning process
Calciner: Fuel - NOx - exess air - nitrogen content - reactivity
Sintering zone: Thermal NOx - temperature - exess air - retention time
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 30
Krupp Polysius Corp.
Stage 2
Stage 3
Stage 4
Stage 1
0,4 - 0,6 Q
Q = total fuel= excess air figure
Fuel
0,4 - 0,6 Q
> 0,1 Q
> 1,05
0,9 < < 1,05
Air 0,9 < < 1,05
Meal
NO
CHi
NHi
CO2H O2N 2CO
NO
CONO
CHi
CO2N 2
NHiH O2
NOH O2N 2 CO2
Combustion conditions for NO reduction by fuel, air and meal staging
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 31
Krupp Polysius Corp.
NOx and O2 at kiln inlet
O2 at kiln inlet [%]
NO
x at
kiln
inle
t [g
NO
2/kg
cli]
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 32
Krupp Polysius Corp.
NOx - generation and volatiles
Volatile matter in fuel [%]
NO
x -
gene
ratio
n in
cal
cine
r [N
O2/
kgcl
i]
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 33
Krupp Polysius Corp.
NOx and Nitrogen in fuel
Nitrogen in fuel [%]
NO
x [N
O2/
kgcl
i]
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 34
Krupp Polysius Corp.
Nox and calciner temperature
Calciner temperature [ºC]
NO
2 [m
g/N
m3 ]
@ %
O2
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 35
Krupp Polysius Corp.
Operating results MSC plants
NO
x -
emis
sion
[gN
O2/
kgcl
i]
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 36
Krupp Polysius Corp.
0
0.5
1
1.5
2
2.5
NO
x -
Em
issi
on
[g
NO
2/kg
Cli]
AS - operation MSC - operation
800 mgNO2/Nm³(10 % O2)
500 mgNO2/Nm³(10 % O2)
32%
53%
35%
28%
30%
Operating results MSC plants
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 37
Krupp Polysius Corp.
NO
x -
emis
sion
[gN
O2/
kgcl
i]
Operating results MSC plants
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 38
Krupp Polysius Corp.
0
0.5
1
1.5
2
2.5N
Ox
- E
mis
sio
n [
gN
O2/
kgK
l]
KI - AS - operationAS - operation
MSC - operation
800 mgNO2/Nm³(10 % O2)
500 mgNO2/Nm³(10 % O2)
32%53%
35%28%
30%
Plant A B C D E
Fuel 80% Pet Coke20 % Coal
Lignite CoalBleeching Earth
Paper wasteFly Ash
CoalTyresPlastic
OilPaper waste
PlasticCarbon Marl
Volatiles in fuel 15 % 45% 27,3 % ~25 % >40 %
Operating results MSC plants
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 39
Krupp Polysius Corp.
Operating results MSC plantsN
Ox
- em
issi
on [
gNO
2/kg
cli]
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 40
Krupp Polysius Corp.
Operating results MSC plants
0
0.5
1
1.5
2
2.5
NO
x -
Em
issi
on
[g
NO
2/kg
Kl]
KI - AS - operationAS - operation
MSC - operation
800 mgNO2/Nm³(10 % O2)
500 mgNO2/Nm³(10 % O2)
32%53%
35%28%
30%
Plant A B C D E
Fuel 80% Pet Coke20 % Coal
Lignite CoalBleeching Earth
Paper wasteFly Ash
CoalTyresPlastic
OilPaper waste
PlasticCarbon Marl
Volatiles in fuel 15 % 45% 27,3 % ~25 % >40 %
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 41
Krupp Polysius Corp.
NOx - prognosisNOx - emission
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Preheater\preheat_process.ppt 140 TEI, 140 CD
Page 42
Krupp Polysius Corp.
CO - prognosis