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The cooling air can be admitted at both ends for increased heat capture and bettering cooler efficiency. The
air pipe within the spiral acts as additional heat exchanger, and the hot air flowing within the pipe is
directed to inside of the rotary kiln after the burning zone to provide additional heat for pre calcination.
The required cooling air is admitted from a stationary Air Chamber cum clinker discharge hood. . The
discharge hood will have leaf spring sealing arrangement.
Kiln Diaxlg
m
3.0 x 41
3.2 x 43
3.4 x46
3.6 x 48
3.8 x 50
4.0 x 52
4.2 x 55
4.4 x 57
4.6 x60
4.8 x 63
5.0 x 65
Kiln Refract.
lining, mm
180
180
180
200
200
200
200
200
220
220
220
Drive KW
Installed
240
300
370
440
540
2 x 315
2 x 390
2 x 440
2 x 520
2 x 610
2 x 720
Production,
tpd
1000
1200
1400
1700
2000
2400
2800
3300
3800
4400
5000
Slope of the Pyro Processor: 3.5 %. Kiln speed: 3.55rev/min The Drive KW is likely to be lower than
indicated. If necessary, next higher pyro diameter can be employed with kiln of lower diameter, say
instead of 3.8 x 41 we can employ 4.0 x41 along with 3.0 x 41 m lg kiln.
Achieve the benefit of a 3-support rotary kiln with a 2-support Cemeng Rotary Pyro Processor
4.0 Cemeng Pyro Processor with Preheater/Precalciner:
Cemeng Pyro Processor has versatility with respect to clinker output, as it can be integrated with
conventional Cyclone Preheater/Precalciner for pre calcination and the kiln furnace capacity can be fully
utilized for enhanced output. Especially, it would be advantageous to employ Cemeng Dragon Calciner
along with Cemeng Pyro Processor set up: The fuel required for calcination and the air for combustion will
not pass through the Pyro Processor, which is the main advantage. The required fuel can form part of raw
meal and the required air can be blown via the tubular heat exchanger incorporated with the Dragon
Calciner. A multi-stage blower (instead of a Roots Blower) can pump the conveying air through the heat
exchanger to carry raw meal and the raw meal borne hot air passes through the dragon calciner .At the
discharge end of the Calciner, we have precalcined material and this is fed into the Pyro Processor. The
indirect and direct heat transfer affected in the Dragon Calciner results in higher thermal efficiency and thus
lowers specific fuel consumption. There is no additional burner required. As can be seen, the dragon pipes
arrangement can be duplicated by perpendicular inlay of the pipes without the need for enlarging the
dimensions of the Dragon Calciner.
Schematics of Dragon Calciner with Kiln Inlet and Burner Ends of Pyro Processor:
In view of the clinker discharge nearer the kiln feed end, the exhaust gases from the Cemeng Dragon
Calciner set up can be partially recycled to act as cooling gas, as the heat carrying capacity of exhaust gases
are higher than that of ambient air. However, partial pressure of CO2 has to be balanced with external air
5.0 Advantages of Cemeng Pyro Calciner:
Cemeng Pyro Processor can be either girth gear driven or by friction drive.
Process fans are minimal and have variable speed drives.
Reverse flow spirals can be stationary or driven by chain and sprocket drive
Inlet and Burner ends are similar, as also the Air chamber cum clinker discharge hoods.
Cemeng Pyro Processor has only two supporting roller stations close to ground level
Does not require heavy foundations and requires least civil engineering works.
The foot print of the unit is minimal
Least number of material transfer points and handling equipment.
Minimal gas/air ductings reducing pressure drops and insulation.
Clinker discharge temperature is controlled as required.
Improved specific fuel consumption due to high thermal efficiency
Recycling of Preheater/Precalciner exhaust for clinker cooling made simple
6.0 Summary:
Cemeng Pyro Processors can replace industrial processes wherever the rotary kiln and cooler systems with
Multi-auxilary equipment are employed for reducing investment and achieves enhanced thermal efficiency.
We can provide required technical know-how and manufacturing drawings to machinery manufacturers,
cement, lime and other mineral based industries.
D.S. Venkatesh,
Freelance Industrial Consultant,