The Design of Rotary Kiln With Cyclonic Heat Exchangers

18.
THE DESIGN OF ROTARY KILN WITH CYCLONIC HEAT

EXCHANGERS
Odigure J. O. First National competition on Design of Process Equipment and Process Plants.
RMRDC, Abuja, 2004. “The Design of Rotary Kiln with Cyclonic Heat Exchangers”.
EXECUTIVE SUMMARY
The numerous economic incentives of the Federal Government of Nigeria aimed at facilitating
rapid industrial growth of the nation, are added advantages to investors in the solid mineral
sector. There is an overwhelming need and market for the processed solid minerals. One of such
is high quality quicklime; the focus of this presentation. Lime is commonly used in most process
industries, the likes of paint, construction, pharmaceutical, agriculture, etc.
The major objective of this design is to develop a cost effective, environmentally friendly
process that takes into consideration the technological development of our economy and market
structure. Dominant technologies for the production of lime include the shaft furnace and the
rotary kiln of various modifications based. They are foreign designs with visible advantages and
disadvantages when considered within our context. There is the need to develop an indigenous
technology that takes into consideration the specific technological and human characteristics of
our nation. Such technology should be a synthesis of the characteristics of the rotary kiln and
shaft furnace. This idea has led to the conceptualization and design of the rotary kiln with
preheating cyclonic heat exchangers.
Comparative analysis of the designed process show that it is suitable for grain sizes below
30mm. The calculated heat utilization is lower than that of the traditional rotary kiln without heat
exchangers by 12.8% and falls within the range of the shaft furnace. Considerable reduction of
heat lost to the surrounding was achieved. The design is time intensive reducing the material
retention time by more than 300%.
The economic analysis considerable allowed for execution of social services. In fact it was
considered as part of raw material cost. This is to ensure smooth civil relationship with the host
communities and consequently eliminate civic disturbances; a phenomena rapidly determining
the industrial structure of the nation. The project is quite profitable with a rate of return on
investment of 30% and pay back period of 3 years.
PROCESS DESIGN
Introduction
Lime is produced from limestone. The production technology is based on
burning/decarbonization of limestone at temperature of about 1200oC, until the complete
removal of carbon dioxide. The clayey impurities concentration must not exceed 6 – 8% as
higher concentration it hydraulic activeness. Other impurities associated with limestone are
silicon, iron pyrite, gypsum, etc. The raw materials commonly used in the production of lime are
various kinds of calcium magnesia carbonate, dolomite, etc. They are mainly of sedimentary
origin. Typical examples of lime raw materials is presented in Table 7.2
Joseph O. Odigure: Selected Publications: Mathematical Modelling, Cement Technology and Process Design
Table 7.2. Some common examples of raw materials for the production of lime brands.
Raw material Composition, mass % Lime type
CaCO3 MgCO3 Clayey impurities
Limestone
Pure 95 – 100 0 – 3 0 – 2.5 Rich, low magnesia
Ordinary 87 – 95 0–3 3–8 Lean, low magnesia
Dolomitic 75 – 90 5 – 20 0–8 Magnesia
75 – 90 0–5 8 – 25 Hydraulic
Dolomite 55 – 75 25 – 45 0 – 8 Dolomitic
In their pure state calcium-magnesia carbonates (limestone, chalk, etc.) are white in colour,
however they are normally coloured due to the presence of various impurities. The quantity and
type of impurities, their distribution or homogenization, often influence the choice of lime
production technology; choice of furnace and optimum burning temperature, productivity and
properties of the final product. Limestone with lesser impurities content and high density
requires higher burning temperature 1100 – 1250oC. The burning temperature could be reduced
to 900 – 1150oC for limestone with high impurities content.
The physico-chemical properties of calcium magnesia carbonate also influence the choice of
technology. Raw materials that are hard with mechanical strength of 20 –30MPa are better burnt
in shaft furnace, however they must be equal sized and not likely to disintegrate during burning.
Soft raw material such as chalk and even hard ones likely to disintegrate during burning to
crystals 1 – 3mm in size are preferably burnt in furnace where they are not subjected to serious
milling like the rotary kiln. In Nigeria the available materials are poorly characterized and
classified and therefore not always suitable for shaft furnace technology. The most suitable,
based on our technological development is the preheater/shaft - rotary kiln combination; which is
the focus of this project. The proposed preheater/shaft – rotary kiln combination is a synergy of
the shaft and rotary kiln technologies. It will allow for wider utilization of available sometimes
poorly processed raw materials and is energy saving. However, material to be burnt using the
designed technology must not exceed 30mm in size. A schematic presentation of the combined
technology is presented in Figure 6.1.
Design condition
The technological conditions used for the design process is as follow:
Furnace productivity, G, kg/hr of quicklime 25.2T/hr (7kg/s)
Concentration of CaCO3 in raw material (dry mass) %, 93
Moisture content of raw material wr, % 23
Moisture content of raw material at dryer outlet, % 0
Initial temperature of material To. oC 10
Firing temperature Tf, oC 1200
Temperature of material at dryer outlet T, oC 1000
Temperature of quicklime at furnace outlet Tq, oC 1000
o
Temperature of quicklime at cooler outlet Tc, C 100
Temperature of ambient air Ta, oC 20
o
Temperature of flue gases from furnace Tg, C 1100
Temperature of gases from the dryer Td, oC 150
o
Temperature of gases from the cooler outlet Tgc, C 160
Joseph O. Odigure: Selected Publications: Mathematical Modelling, Cement80
Lime activeness A, % Technology and Process Design
Fuel natural gas Qn, kJ/nm3 35615
Burning of Fuel
1. Composition of natural gases, %: CO2 –0.1, N2 – 1.0, CH4 – 98.3, C2H6 – 0.33, C3H8
– 0.12, C4H10 – 0.15.
2. Amount of air required theoretically to burn 1m3 of natural gas Voa , m3/m3.
Voa = 1/21[0.5H2 + 0.5CO +2CH4 + 3.5C2H6 + (m + n/4)CmHn +1.5H2S – O2]
1/21[2x98.3 + 3.5x0.33 + (3 + 8/4)x0.15] = 9.5
3 Theoretical product output VoRO2 m3/m3
VoRO2 = 0.019CO2 + CO + CH4 + 2C2H6 + mCmHn + H2S)
= 0.01(0.1 + 98.3 +2x0.33 + 3x0.12 +4x0.15) = 1
H 2O
Vo = 0.01[H2 + 2CH4 + 3C2H6 + (n/2)CmHn + H2S + 0.124(dr + Voa da)]
= 0.01[2x98.3 + 3x0.33 + 4x0.12 + 5x0.15 + 0.124910 + 9.5x160]
= 2.19
N2
Vo = 0.79V Voa + 0.01N2 = 0.79x9.5 + 0.01x1 = 7.51.
Total Vo = 1 + 2.19 + 7.51 = 10.70m3
4 At excess air coefficient  = 1.15 the actual amount of air utilized and gaseous
product produced is equal to:
V a =  Voa (1 + 0.016) = 1.15x9.5(1 + 0.016) = 11.1m3
V N 2 = VoN 2 + 0.79( V a - Voa ) 7.51 + 0.79(11.1 – 9.5) = 8.8
where 0.016 = da – air moisture content g/m3.
V RO2 = VoRO2 = 1 (It is not affected by excess air).
V H 2O = VoH 2O = 2.2
O2
Vexcess = 0.21( V a - Voa ) = 0.21(11.1 – 9.5) = 0.3
Total gaseous products = 8.8 + 1 + 2.2 + 0.3 = 12.3m3
Material balance
1. Quantity of undissociated CaCO3 in the limestone x, %
A (CaCO3  x)0.56 0.56(93  x ) 80

  ; x = 5.28
100  A xI x7 100  80
where I – impurities %.
CaCO3  x 93  5.28
2. Extent of dissociation   = = 0.94
CaCO3 93
Table 7.3. Theoretical Material balance, % dried mass
Type Percentage Type Percentage
CaCO3 93.0 CaO (93 – 5.28)0.56 49.10

Impurities 7.0 Impurities 7.00
CaCO3 5.28
CO + vapour  38.62
Joseph O. Odigure: Selected Publications: 2Mathematical Modelling, Cement Technology and Process Design
Total 100 100
3. Utilization coefficient: mass of material required to produce 1kg of quicklime

100
G1  = 1.63kg/kg.
61.38
4. Mass of limestone required assuming the amount of limestone particles (dust) in the flue gases =
12%
1.63x100
G2  = 1.85kg/kg
88
Mass lost in form of dust y = 1.85 – 1.63 = 0.22kg/kg.
5. At moisture content of limestone = 23% the amount necessary to produce 1kg CaO
100
G3  G 2 = 1.85/.77 = 2.40kg/kg
100  w
Mass of vapour = 2.40 – 1.85 = 0.55kg/kg.
6. Mass of technological CO2 assuming that the amount of quicklime in the flue gases =
10%
0.44 44
G 4CO2  G1 (CaCO3  x)  0.1 y = 0.65kg/kg
100 56
Table 7.4 Material balance for the production of 7kg/s quicklime

Type Mass flow Type Mass flow
rate, kg/s rate, kg/s
CaCO3 Limestone 16.80 CaO (93 – 5.28)0.56 7.0
Impurities 0.17 Impurities 0.168
CaCO3 / dust 1.54
Moisture 3.85
CO2 4.55
Total 16.97 17.10
Heat balance
The calculation is based on heat required to or lost during the production of 1kg CaO of lime.
Heat received
1. Heat received from fuel burning including its initial heat content
Q1  G xf (Qo  cTo )  G xf (35615  1.59 x10)  35631G xf kJ

where c – heat capacity of fuel, kJ/m3. oC.
2. Initial heat content of air
Q2  G xf V a c aT  G xf 11.1x1.3 x10  144.3G xf kJ
where ca – heat capacity of air kJ/3.oC.
3. Initial heat content of raw material entering the rotary kiln
Q3  G m c mTo = 1.85x1.08x1000 = 1198.8kJ
Heat Lost.
4. Heat spent during dissociation of CaCO3 in material and flue gases
Q4  GCaCO3  1660
where 1660 – reaction heat effect kJ/kg
Q4 = (1.63x0.93x0.94
Joseph O. Odigure: + 0.22x0.1x100/56)1660
Selected Publications: =2430kJ
Mathematical Modelling, Cement Technology and Process Design
5. Heat lost via technological gases – CO2.
G
Q5  4 cTg =(0.65/1.92)x2.25x1100 = 837.9kJ
 CO2
6. Heat lost with the flue gases
Q6  G xf (V N 2 C N 2  V RO2 C RO2  V H 2O C H 2O  VO2 C O2 )Tg
= G xf (8.8x1.40 + 1.0x2.25 + 2.2x1.75 + 0.3x1.49)1100 = 20757 G xf .
7. Heat lost with dust particles
Q7 = ycTg = 0.22x0.90x1100 = 217.8kJ.
8. Heat lost through lime from cooler
Q8 = 1cTc = 1x0.79x100 = 79kJ
9. Heat lost to the surrounding. This assumed to be about 12% of heat received.
Q9 = 012Q1 = 0.12x35631 G xf = 4275 G xf kJ.
Heat Received = Heat Lost

35631 G xf + 144.3 G xf + 1198.8 = 2430 +837.9 + 20757 G xf + 217.8 + 79 + 4275.7 G xf
The quantity of natural gas required to produce 1kg of quicklime
G xf = 2365.9/10742.6 = 0.22m3/kg
The volumetric flow rate of gases in the kiln = 12.3x0.22 = 2.71m3/s.
The heat balance for the process is presented in Table 7.5.
Table 7.5 Heat balance for the process per kg lime.
Heat received Q, kW Heat lost Q, kW

Burning of fuel, Q1 7838.82 Dissociation of CaCO3 Q4 2430.62
Initial heat content Loss from technological gas
of air Q2 31.75 to wall Q5 837.90
Initial heat content With flue gases Q6 4566.54
of raw material Q3 1198 With dust Q7 217.80
With exit lime Q8 79.00
To surrounding Q9 940.65
Total 9068.57 Total 9072.51
Design of decarbonization unit –rotary kiln
The calculation of the design parameters will be based on iteration technique, as most
data are not experimentally verified. The basic principle of the furnace components
selection is that minimum heat loss of not more than 900kW will be allowed to the
surrounding. This is higher than Q5.
Q = KFT
Where K – overall heat transfer coefficient, kW/m2.oC
F – heat transfer surface area, m2.
T – mean temperature at ambient temperature of 20oC.
K is a function of the kiln construction material – low carbon steel sheet (Type 430),
refractory and insulator (asbestos). The basic characteristics of these materials can be obtained in
standard handbook.
1
K
1 1  2
 
 1 1  2
where 1 – heat transfer coefficient from the steel surface to the air. It approximate value with
temperature variation can be determined as
1 = 9.3 + 0.058Tw = 9.3 + 0.058x180 = 19.74W/m.oC, where Tw is the kiln wall temperature.
!80o was chosen based on our lack of experience in refractory production/installation technique.
1 = asbestos insulator thickness = 20mm
1 - heat transfer coefficient of insulator = 0.144W/m.oC
2 – refractory - fireclay thickness = 180mm (3 layer thickness).
2 – heat transfer coefficient of refractory = 1.51W/m.oC
1
K = 3.237
1 0.02 0.18
 
19.74 0.144 1.51
At kiln outlet temperature of 700oC
T 
1200  20  700  20 =
500
= 907.44oC
1200  20 0.551
2.3 lg
700  20
Q 900000
F = = 306.40m2
KT 3.237 x907.44
K
Check: Tw = 20 + T

20 + (3.237x907.44)/19.74 = 168.8oC < 180 oC.

T = 1023.89oC.
F = 271.55m2.
Check: Tw = 187.90oC  180oC.

T = 1078oC
F = 257.92m2
Check: Tw = 196.77 > 180oC
The obtained results are presented in Table 7.6.
Table 7.6 Relation between kiln characteristics and its outlet temperature
Q = 900kW
Toutlet T, oC F, m2 Tw oC
700 907.44 306.40 168.80
900 1023.89 271.55 187.90
1000 1078 257.92 196.77
Table 7.6 shows that the higher the outlet temperature the smaller the dimensions of the kiln, but
more efficient cooling system will be required. Heat transfer coefficient for fireclay has been
chosen allowing for local sourcing of refractory materials.
From the above Table 4 a surface area of 271.55m2 for the entire kiln aggregates is
recommended. This includes F for the preheating, decarbonization and cooling units.
The kiln inner diameter based on the refractory lining could be determined as
g
Dr 
0.785v
where g – volumetric flow rate of the flue gases = 3m3/s, v – allowed gas velocity, m/s. v for
counter current motion is taken as 2m/s.
Dr = 1.55m.
The total thickness of the refractory and insulating linings = 0.2m.
Therefore the calculated kiln diameter Dc = 1.95m
From standard values a kiln diameter of Dk = 2.2m is adopted.
For cylindrical shaped rotary furnace
F = 0.785 Dw2 L = 271.55

Where L – kiln length m.
271.55
L = 71.47m
0.785 x 2.2 2
This is quite long. The calculated material retention time in this kiln is about 300min
(Teterevkov and other, 1984).
Based on the choice of the kiln diameter the expected length should be 71.47m. Figure 1 shows
the typical zones in a rotary kiln: zone of preheating (drying) l1, zone of decarbonization l2 and
the remainder the cooling zone. The length of these zones is a function of the adopted
technology. For most existing kiln without separate preheating and cooling zones the relative
percentages of these zones are about 20, 60 and 20.
Gear motor ring
l1 l2 binding ring
lo l l3 l2
l1
FigureO.
Joseph 7.1Odigure:
Existing rotaryPublications:
Selected kiln schematic diagram Modelling, Cement Technology and Process Design
Mathematical
The concept of this design is that the preheating and cooling zones are separated from the
decarbonization zone. Material will be arriving in the decarbonization zone at a relatively higher
temperature of 1000oC and leaving at 1000oC, unlike existing ones of about 900 and 600oC
respectively (Figure 7.2). Consequently, a decarbonization zone length of 15m is chosen.
From the above the surface area of the decarbonization zone Fd = 0.785x 2.22 x15 = 57m2.
The rotation velocity n is determined as (Teterevkov and others,1984)
3.08 x10 3 x (  24) L 3.08 x10 3 (45  24) x15

n = = 0.727 rev/min.
Dr tg 1.55 x54 x 0.0524
1- Pre heating zone
100oC 23 oC
300 oC
400 oC
100 oC
600 oC
800 oC
2 – Decarbonization zone
950oC
3 – Cooling zone
Figure 7.2 Schematic diagram of a Rotary Kiln.
where 3.08x10-3 – coefficient dependent on the material regime,  - angle of natural fall of the
material in the kiln, oC,  - angle of kiln inclination oC
The coefficient of kiln loading (volume occupied by the material)  can be determined as
G 54 x60 x 7.
 2
= = 0.35
0.785 Dr L m 0.785 x1.55 2 x15 x 2100
where m – apparent mass of the material, kg/m3.

Mass of refractory material is determined as
G r  0.785 r ( Dw2  Dr2 )
where r – density of refractory = 2270 kg/m3 for fireclay
G r  0.785 x 2270 x(2.2 2  1.8 2 ) = 3632kg/m.
Mass of the material in the kiln
Gm = 0.785xD2m = 0.785x1.82x0.35x2100 = 18694kg/m
ROTARY COOLER
Based on the calculations for the rotary kiln, the followings were accepted as input data for the
design of the rotary cooler:
Productivity, G, kg/day 25200 (7kg/s)
Inlet temperature of quicklime, oC 1000 (1273K)
o
Outlet temperature, C 100 (373K)
Inlet air temperature 30 oC 30 (303K)
Surface area of cooling zone is taken as 20% of calculated surface area = 0.2x271.54 =
54.31m2.
Based on standard values a rotary cooler with the following characteristics was chosen: Diameter
D = 2500mm, Length = 14000mm
Therefore F = 0.785D2L = 0.785x2.52x14 = 68.69m2
Heat lost by quicklime Q = GcT = 7.0x0.92x(1273 – 373) = 5796kW
For effective heat recovery the cooler chamber is divided into 2.
70% of the heat will be removed in the first chamber. This amount is based mainly on technical
ability of heating the incoming air.
Using a fan with productivity Qf = 8m3/s
The final temperature of air – coolant Ta
Q 4057.2
Taf  Tao   303  = 782K
KQ f  a c 0.9 x8.0 x1.28 x0.92
where Tao initial temperature of cooling air, oC, K – coefficient accounting for dust content in
coolant, a – mean air density, kg/m3, c – mean heat capacity of quicklime, kJ/kg.K
The required heat transfer surface area for the cooling air
Q
F
KT
T 
509  20   30  20 = 123.3
509  20
2.3 lg
30  20
The K value is taken as 19.74 based on earlier calculation.
Therefore for the first chamber F = 1667.2m2.
Fireclay refractory material will be required for the first chamber. Mass of the refractory Gr =
0.785x2270x(2.52 – 2.422) = 4910kg.
Similarly for the second chamber the temperature of the outgoing air T = 166.4oC and F =
1727.2m2.
PREHEATING ZONE
The concept of this unit is to ensure adequate preparation of material quicklime before entering
the rotary kiln. Material is heated a semi-fluidized state to ensure better heat transfer and
minimum loss with the outgoing flue gases.
The heat lost by the carrier gas is determined

Q = KFT
Where K – overall heat transfer coefficient, kW/m2.oC
F – heat transfer surface area, m2.
T – mean temperature at ambient temperature of 20oC.
K is a function of the preheater construction material – low carbon steel sheet, refractory
and insulator (asbestos). The basic characteristics of these materials can be obtained in standard
handbook.
1
K
1 1  2
 
 1 1  2
where 1 – heat transfer coefficient from the steel surface to the air. It approximate value with
temperature variation will be determined for each unit. At steady state the heat received by the
preheater goes mainly to the raw material and maintaining the equilibrium state between it, the
construction material and the surrounding.
First Preheater
1 = 9.3 + 0.058Tw = 9.3 + 0.058x40 = 11.62W/m. oC
1
K = 3.778
1 0.02 0.06
 
11.62 0.144 1.51
T 
400  20  100  20  =
300
= 192.75oC
400  20 1.556
2.3 lg
100  20
The heat received by the material can be determined as

Qm = GO.mcT
Joseph = 17x1.08x(400
Odigure: – 100) =Mathematical
Selected Publications: 5508kW Modelling, Cement Technology and Process Design
Q 5508
F = = 7.56m2
KT 3.778 x192.75
17kg/s
100oC
400 oC
2
600 oC
3
800 oC
` 4 Material at 1000 oC to kiln

Flue gases at 1100oC – from kiln
Figure 7.3 Proposed Schematic diagram of the Preheating Unit
The length diameter relation for the cylindrical part will be taken as L = 2D.
The top and bottom will be shaped to allow for easy flow of material. Provisions will be made
for the materials.
F = 0.785x2D3 = 7.56
D = 1.69m
L = 3.38m
Mass of refractory assuming a cylindrical shaped preheater

   
M r  0.785 r D 2  Dr2  0.785 x 2270 1.69 2  1.57 2  697kg /m
Second Preheater
1 = 9.3 + 0.058Tw = 9.3 + 0.058x80 = 13.94W/m. oC
1
K = 3.447
1 0.02 0.12
 
13.94 0.144 1.51
T 
600  20  400  20 =
200
= 473.5oC
600  20 0.422
2.3 lg
400  20
Qm = GmcT = 17x1.08x(600 – 400) = 3672kW

Q 3672
F = = 2.25m2
KT 3.447 x 473.5
F = 0.785x2D3 = 2.25
D = 1.13m
L = 2.26m
Mr = 863.9kg/m
Third Preheater
1 = 9.3 + 0.058Tw = 9.3 + 0.058x80 = 13.94W/m. oC
1
K = 3.447
1 0.02 0.12
 
13.94 0.144 1.51
T 
800  20   600  20 =
200
= 675.8oC
800  20 0.296
2.3 lg
600  20
Qm =O.GOdigure:
Joseph mcT = 14.6x1.08x(800 – 600)
Selected Publications: + 1.4x0.92x(800
Mathematical – 600)
Modelling, = 3411.2kW
Cement Technology and Process Design
Q 3411.2
F = = 1.46m2
KT 3.447 x675.8
F = 0.785x2D3 = 1.46
D = 0.98m
L = 1.95m
Mr = 728.0kg/m
Fourth Preheater
1 = 9.3 + 0.058Tw = 9.3 + 0.058x80 = 13.94W/m. oC
1
K = 3.032
1 0.02 0.18
 
13.94 0.144 1.51
T 
1000  20  800  20  =
200
= 877.2oC
1000  20 0.228
2.3 lg
800  20
Qm = GmcT = 3.4x1.08x(1000 – 800) + 4.2x0.92x(1000 – 800) = 1507.2kW

Q 1507.2
F = = 0.57m2
KT 3.032 x877.2
Taken a decarbonisation unit of D = 0.8m
F = 0.785xLxD2 = 0.57
D = 0.8m
L = 1.15m a length of 1.2 was considered for convenience.
Mr = 855.3kg
PIPING DESIGN
The temperature change by material during transfer from one preheater to the other is taken to be
not more than 20o. The pipe diameter will be the same as much as practicable to allow for easy
material selection, interchangeability of accessories and aesthetics (Fig.7.3).
Material movement from:
First preheater to the second.

The heat gained by the material is determined as
Qp1 =O.GOdigure:
Joseph mcT = Selected
17x1.08(400 – 380)Mathematical
Publications: = 367.2kW Modelling, Cement Technology and Process Design
At equilibrium the same amount of heat is lost be the system. Therefore to maintain the required
equilibrium it is necessary that the material of construction enhance the state of equilibrium.
Same material of construction as that of the preheater will be used for the pipes.
K – same as the 1st preheater = 3.778kW/m2.oC.
T 
400  20  380  20  = 370.0
400  20
2.3 lg
380  20
Consequently, F = 367.2/(3.778x370.3) = 0.262m2
The length of the required pipe was estimated from the dimension of the preheaters. Therefore a
pipe length of 2.5m was chosen.
The pipe diameter was calculated as
D= 0.7852.5D2 = 0.262
D = 0.365m = 365mm.
This is the outer diameter.
The inner diameter Dinner = 205mm.
The required refractory material for lining Gr = 0.785x2270(0.3652 – 0.2052) = 162.5kg/m

Similarly from the 2nd preheater to the 3rd
Qp2 = 17x1.08(600 – 580) = 367.2kW
T = 570.6
K = 3.447kW/m2. oC.
F = 0.19m2
D = 0.365m
L = 1.82m
Gr = 233.8kg/m.
From 3rd to 4th

Qp2 = 14.2x1.08(800 – 780) + 1.4x0.79x20 = 341.1kW
T = 770.8
K = 3.447kW/m2. oC.
F = 0.128m2
D = 0.365m
L = 1.22m
Gr = 282.9kg/m.
From 4th to rotary kiln

Qp2 = 3.4x1.08(1000 – 980) + 4.2x0.92x20 = 151kW
T = 971.1
K = 3.032kW/m2. oC.
F = 0.051m2
D = 0.44m
L = 0.34. A pipe of length 0.5m will be considered.
Gr = 191.2kg/m.
Total length of the material pipe = 2.5 + 1.82 + 1.22 + 0.5 = 6.04m
The quantity
Joseph of Selected
O. Odigure: heat required by theMathematical
Publications: preheating unit QT is the
Modelling, sum Technology
Cement of the heatand required byDesign
Process each
o
unit, the piping area and the outgoing flue gases at temperature 150 C.
The heat lost with the outgoing flue gases can be determined as
Q6  [G xf (V N 2 C N 2  V RO2 C RO2  V H 2 O C H 2O  VO2 C O2 )  VCO 2 C CO 2 ]Tg
VCO2 accounts for CO2 from decarbonization reaction.
= [0.22(8.8x1.1.315 + 1.0x1.928 + 2.2x1.564 + 0.3x1.376) +0.35x1.928]150 =
572.65+101.22 = 678.87kW/kg.
This is equal to 4717.09kW for 7kg production rate.
The overall heat requirement for the preheating unit is presented in Table 7.5.
Table 7.5 Energy requirement for the Preheating Unit

Heat utilized Heat received,
Heater Pipe from kiln flue gases, kW
st
1 5508 367.2
2nd 3672 367.2
rd
3 3411.2 341.1
4th 1507.2 151.0
Outgoing flue gases 4717.1
Total 14098.4 5943.6 20042
Piping for gaseous product
The required pipe diameter for each section will be defined by volume of gaseous product,
however the length must be determined based on the geometry of the heat exchangers and the
already determined material pipe length.
The total heat required by the preheating unit = 20042kW.

1m3 gas will generate 35615kJ
Therefore 20042kW will require 0.563m3 of natural gas or 1.564x10-4 m3/s
The amount of gaseous product generated = 1.563x10 -4 x12.65 = 0.002m3/s.
The gaseous path length from the 4th heat exchanger to the rotary kiln is fixed as 0.5m.
Therefore the required pipe diameter = [0.002/ (0.785x0.5)]0.5 = 0.071m.
The larger pipe diameter for the gaseous product than that required for the material (0.044m) will
ensure that no dead zone will be formed in the pipe and decarbonization unit. The pipe diameter
for gaseous product will be taken as 0.351m for all connections. For connections from the 4th to
the 3rd and the 3rd to the 2nd cyclones the insulation and refractory layer thickness shall be 0.02
and 0.12m respectively. For the 2nd to the 1st and out an insulation and refractory layer thickness
of 0.2 and 0.06m shall be provided.
Geometrical calculation using an elbow of 45o and taking the material pipe length as the
hypotenuse gave the following dimensions 6.3, 4.58 and 3.08m for the 1 st, 2nd and 3rd inter heater
connections respectively. Total length = 14.3m. An allowance of 30% was given for possible
deviation.
The outgoing flue gases will be used in the rotary dryer.
Design of the Rotary dryer.

Productivity = 18kg/s
Heat available = 4717kW
Final temperature
Joseph of material
O. Odigure: Selected = 100oC.Mathematical Modelling, Cement Technology and Process Design
Publications:
o
Initial temperature = 15 C
Heat required by the material McT = 18x2.27x85 = 3473.1kJ/s
Drying gas initial temperature 150oC
Final temperature = 30oC
T 
150  20  30  20  = 46.8
150  20
2.3 lg
30  20
The material of construction will be the same as the 1st preheater K = 3.778kW/m2.oC
The surface area of the rotary dryer F = 4717.09/(3.778x46.8) = 26.7m2.

Therefore a rotary dryer of dimension 1.6 x 14m will be adequate.
Calculation of Pressure Drop and Gases Velocity

The pressure drop P along the preheating cyclone is calculated based on Perry, 1998. The basic
characteristics of the cyclone used are the same Dc/De ratio = 2.
2
 4A 
The cyclone friction loss Fc is related to the pressure drop as Fc  P  1   c2 
 De 
Where De – gas exit dust diameter cm and Ac cyclone inlet area cm/s.
Taking Fc = 8,
2
 4 x 0.393 x0.785 
For the first cyclone 8 = P + 1 -    P  1  0.25
  0.785 
P = 7.25kPa
2
 4 x0.22 x 0.44 
For the second cyclone 8 = P  1   
  0.44 
P = 7.078kPa
2
 4 x0.153 x0.305 
For the third cyclone 8 = P  1   
  0.305 
P = 7.038kPa
For the fourth cyclone

2
 4 x0.08 x 0.02 
8 = P  1   
  0.04 
P  Fc It indicates that the structure is not different from a normal tube. It reality, a
decarbonization unit is a pipe in which intensive heating is performed.
n
The total pressure loss  P = P1 + P2 + P3 +P4 + Pfittings + Ppipes
1
= 7.25 +7.078 + 7.038 + 7.003 + 14x0.19 + 20.18x 0.07 =
= 32.44kPa
Joseph O. Odigure: Selected Publications:
The average inlet velocity of the gas in Mathematical Modelling,
the first cyclone Vc isCement as and
Technology
calculated P Process Vc2 =
 0.024Design
0.024x1.23V2
For the first cyclone Vc = 32.44 = 0.024V2 = 33.15cm/s = 0.33m/s
For the second cyclone 24.01 = 0.024V2. V= 0.29m/s
2
For the third cyclone 22.8 = 0.024V . V= 0.28m/s
2
For the fourth cyclone 21.64 = 0.024V . V= 0.27m/s
Total drop in velocity = 1.17m/s
An initial velocity of 2.0m/s is suitable for the draught system.
SUMMARY OF FINDINGS FROM PROCESS DESIGN CALCULATIONS
The basic characteristics of the preheating heat exchangers are presented in Table 7.6
Table 7.6 Characteristics of Preheater unit

Pre % Limestone F, P, Area of Refractory mass,
Heater decarbonization + CaO kg/s m2 MPa Preheater kg/m
DxL, m2 Preheater Pipe
1 0 17 7.56 7.25 1.69x3.38 697.0 162.5
2 0 17 2.25 7.078 1.13x2.26 863.9 233.8
3 20 14.6 + 1.4 1.46 7.038 0.97x1.94 728.0 282.9
4 80 3.4 + 4.2 0.57 7.003 0.8x1.20 855.3 191.2
Rotary Cooler
Diameter and Length, 14x2.5m
Angle of inclination 1o
Rotation velocity 6rev/min

Thickness of steel sheet 16mm
Required heat transfer surface area for the cooling air 2720m2
Rotary kiln
Angle of inclination 3o
Rotation velocity 0.737rev/min

Mass of refractory 3632kg/m
Mass of material – lime 1869.4kg/m
Thickness of kiln wall 16mm
MECHANICAL DESIGN
Rotary Kiln
Power Required
The required power to rotate the kiln consists of, W:
Power required lifting the material in the kiln N1
Power required overcoming friction in the trunnion/pivot (gear ring) in the foundation roller N2
Power required overcoming friction in the binding roller bearing N3.
3
3  c 
.8175 D LSelected
N 1  0O.
Joseph Odigure:
r m   sinPublications:
 sin  c Mathematical Modelling, Cement Technology and Process Design
 2
where c central angle inscribed by material movement for most kiln is about 80 – 90o it is taken
as 85o, c angle characterizing the center of gravity of the material rotation 50o,  - angular
velocity of the kiln rad/s.
N1 = 0.8175x1.83 x 15x790x0.077(sin42.5)3sin50 = 1027.6W

4.905 f Gd  G r  G m D1d bL
N2 
d r cos
where Gd – mass of drum kg/m, D1 of binder m, dr diameter of foundation roller belt m,  - ½ of
angle between foundation roller 30o, f – coefficient of friction = 0.025. The relation between the
diameter of the binder to roller D1:dr = 4.2 – 3.7.Based on standard these values were taken as D1
- 2.73, dr - 0.8m, db – 0.25m, mass of kiln – 35000kg = 2333.33kg/m.
4.905 x 0.025 x (2333.33  3632  1869.4) x 2.73 x0.25 x 0.077 x15

N2  = 1092.39W
0.8 x cos 30
9.81Gd  Gr  Gm D1  d r L

N3 
d r cos
where  - coefficient of friction – 0.0008
9.81x7834.73 x2.73  0.8x0.077 x15 x0.0008

N3  = 361.60W
0.8 x0.866
Total power required N
N
 N1  N 2  N 3 

where  - coefficient of excess power – 1.2,  - 0.76
N
1027.60  1092.39  361.81x1.2 = 3918.61W
0.76
Moment and Torque

The drum wall is tested for the bending moment as a result of the uniformly distributed material
and the forces from the rollers
The total bending moment can be calculated as

9.81G d  Gr  Gm Ll1 9.81G d  Gr  Gm L2 (9.81m w l1 )
Mb   
4 8 4
where l1 – distance between the binders m, mb – mass of screw gear kg.
9.81x 7834.73 x15 x10 9.81x 7834.73 x15 2 9.81x 2000 x10
Mb   
4 8 4
= 2882201.3 - 2161650.97 + 49050 = 725455,33 = 0.770MN.m
The torque applied to the rotary kiln/drum

N  N 2  N 3 3918.61
MT  1  = 50891.04 = 0.051MN.m
Joseph O. Odigure:
 Selected Publications:
0.077 Mathematical Modelling, Cement Technology and Process Design
The calculated/design bending moment was calculated as

M c  0.35M b  0.65 M b2  M T2  0.35 x0.725  0.65 0.770 2  0.0512 = 0.254 + 0.500
= 0.754MN.m
At a wall thickness of 16mm, the anti torque was calculated as
W 

 D E4  D 4 
,m3
32 DE
where DE – external diameter of the drum 2.232m
The W 

3.142 2.232 4  2.2 4= 0.0613m3
32 x 2.232
Mc
Therefore the bending stress on the kiln wall  b  = 0.754/0.0613 = 12.30MPa.
W
The stress limit for low carbon steel MS sheet D-1079 of IS: 1852 at 180oC was calculated as
-1 = 0.435[] = 0.435[129] = 56.11MPa
where [] –stress limit at 180oC.
The design b is considerable lower than the allowed limit -1 : 56.11 < 12.3MPa
Verification for sagging

The extent of flexure/sagging during uniform loading and point load can be determined as
5ql14 P l3
f   B 1 ,m
384 Ei 48 Ei
i
 
 D E4  D 4
, m4
64
where q – total mass of the kiln N/m, E – Young module for the steel drum N/m2, I – moment of
inertia for the drum m4, PB weight of screw gear N.
q = 7834.73x9.81 = 76858.70N/m = 0.0769MN/m

i = 3.142(2.2324 – 2.24)/64 = 0.0684m4
Therefore
5 x 0.0769 x10 4 2000 x10 39.81
f   = 0.00077 +0.000031 = 0.0008m
384 x1.91x10 5 x0.0684 48 x1.91x1011 x 0.0684
The sagging limit is determined as

[f] = 0.0003l1 = 0.0003x10 = 0.003m
The drum is strong enough to withstand the applied load.
Verification for foundation roller

The width b1 of the binding belt is verified for allowable load as
R
b1  ,m
[q ]
qL cos 
R
2Z cos
where R –reaction of the foundation roller MN, [q] –allowed specific load MN/m 2.0 –
2.5MN/m, q – total kiln weight, MN/m, Z – number of belt.
0.07834 x15 cos 3

R = 0.339MN
2 x 2 cos 30
b1 = 0.339/2.0 = 0.169m
The foundation roller is verified for concrete strength by determining the bearing stress using
2 RE D1  d r
 c  0.418 .
b1 D1 d r
where E – Young module for foundation roller material, for carbon steel E = 1.99x105MPa.
2 x0.339 x1.99 x10 5 2.73  0.8
 c  0.418 . = 474.8MPa
0.169 2.73x 0.8
The recommended bearing stress [c] lies between 300 – 500MPa. It can be determined as [c] =
KHB, MPa
Where K – coefficient dependent on the type of steel used in constructing the bearing, HB –
Brinell hardness of the roller MPa. For low carbon low alloy case hardening steel (C2M
17Mn1Cr95, 16MnCr5 5115) roller HB = 153 – 179MPa
[c] = 2.7(153 – 179) = 413 – 484MPa
Therefore the obtained bearing stress c = 475 < 483 = [c]

A Ni-hard type 2 steel will be suitable for its construction.
Rotary Cooler
The required power to rotate the cooler consists of, W:
Power required to lift the material in the cooler drum N1
Power required to overcome friction in the trunnion/pivot in the foundation roller N2
Power required to overcome friction in the binding roller bearing N3.
3
3   
N 1  0.8175 D L m  sin c  sin  c
r
 2
where c central angle inscribed by material movement for must kiln it about 122o , c angle
characterizing the center of gravity of the material rotation 35o,  - angular velocity of the kiln
rad/s 0.628.
N1 = 0.8175x2.53 x 15x790x0.628x0.87463x0.5736 = 3232.17W

4.905 f Gd  G m D1d bL
N 2  O. Odigure: Selected Publications: Mathematical Modelling, Cement Technology and Process Design
Joseph
d r cos
where Gd – mass of drum kg/m, D1 of binder m, dr diameter of foundation roller belt m,  - ½ of
angle between foundation roller 30o, f – coefficient of friction = 0.025. Based on standard these
values were taken as D1 – 3.05, dr - 0.8m, db – 0.25m, mass of cooler – 55000kg = 3928.57kg/m.
Gm = 0.785D2m =0.785x2.52 x0.4x790 = 1550.38kg/m
4.905 x0.025 x (3928.57  1550.38) x3.05 x0.25 x 0.628 x14

N2  = 6894.64W
0.8 x cos 30
9.81Gd  Gm D1  d r L

N3 
d r cos
where  - coefficient of friction – 0.0008
9.81x5478.95 x3.05  0.8x 0.628 x14 x 0.0005

N3  = 1312.12W
0.8 x0.866
Total power required N
N
 N1  N 2  N 3 

where  - coefficient of excess power – 1.2,  - 0.76
N
3232.17  6894.64  1312.12 x1.15 = 11438.94W
0. 8
Moment and Torque

The drum wall is tested for the bending moment as a result of the uniformly distributed material
and the forces from the rollers
The total bending moment can be calculated as

9.81G d  Gm Ll1 9.81Gd  G m L2 (9.81m w l1 )
Mb   
4 8 4
where l1 – distance between the binders m, mb – mass of screw gear kg.
9.81x5478.95 x14 x10 9.81x5478.95 x14 2 9.81x 2000 x10

Mb   
4 8 4
= 1881197.48 – 1316838.24 + 49050 = 613409.24 = 0.613MN.m
The torque applied to the rotary cooler/drum

N  N 2  N 3 11438.81
MT  1  = 148555.97 = 0.15MN.m
 0.077
The calculated/design bending moment was calculated as

M c  0.35M b  0.65 M b2  M T2  0.35 x0.613  0.65 0.613 2  0.15 2 = 0.221 + 0.631
= 0.852MN.m
At a wall thickness of 16mm, the anti torque was calculated as


 D E4  D 4
W O. Odigure:
Joseph

,m3 Publications: Mathematical Modelling, Cement Technology and Process Design
Selected
32 DE
where DE – external diameter of the drum 2.232m
The W 

3.142 2.532 4  2.5 4= 0.0624m3
32 x 2.532
200
Therefore the bending stress on the cooler wallb = 0.852/0.0624 = 13.65MPa.
0 . 296
The stress limit for low carbon steel MS sheet D-1079 of IS: 1852 at 180oC was calculated as
-1 = 0.435[] = 0.435[129] = 56.11MPa
where [] –stress limit at 180oC.
The design b is considerable lower than the allowed limit -1 : 56.11 < 13.65MPa
Verification for sagging

The extent of flexure/sagging during uniform loading and point load can be determined as
5ql14 P l3
f   B 1 ,m
384 Ei 48 Ei
i
 
 D E4  D 4
, m4
64
where q – total mass of the cooler N/m, E – Young module for the steel drum N/m2, I – moment
of inertia for the drum m4, PB weight of screw gear N.
q = 5478.95x9.81 = 53748.50N/m = 0.0769MN/m

i = 3.142(2.5324 – 2.54)/64 = 0.10m4
Therefore
5 x 0.0769 x10 4 2000 x10 3 x9.81
f   = 0.000524 +0.000021 = 0.000545m
384 x1.91x10 5 x0.10 48 x1.91x1011 x 0.10
-
The sagging limit is determined as
[f] = 0.0003l1 = 0.0003x10 = 0.003m
The drum is strong enough to withstand the applied load.
Verification for foundation roller

The width b1 of the binding belt is verified for allowable load as
R
b1  ,m
[q ]
qL cos 
R
2Z cos
where R –reaction of the foundation roller MN, [q] –allowed specific load MN/m 2.0 –
2.5MN/m, q – total kiln weight, MN/m, Z – number of belt.
0.0769 x14 cos1

R = 0.311MN
2 x 2 cos 30
b1 = 0.311/2.0 = 0.155m
The foundation roller is verified for concrete strength by determining the bearing stress using
2 RE D1  d r
 c  0.418 .
b1 D1 d r
where E – Young module for foundation roller material, for carbon steel = 1.99x105MPa.
2 x 0.311x1.99 x10 5 3.05  0.8
 c  0.418 . = 469.21MPa
0.155 3.05 x0.8
The recommended bearing stress [c] lies between 300 – 500MPa. It can be determined as [c] =
KHB, MPa
Where K – coefficient dependent on the type of steel used in constructing the bearing, HB –
Brinell hardness of the roller MPa. For low carbon low alloy case hardening steel (C2M
17Mn1Cr95, 16MnCr5: 5115) roller HB = 153 – 179MPa
[c] = 2.7(153 – 179) = 413 – 484MPa
Therefore the obtained bearing stress c = 469.2 < 483 = [c]
ELECTRICAL DESIGN/INSTRUMENTATION
The main aim of process instrumentation and automation is to ensure process stability at
optimum technological condition, high productivity at minimum energy utilization and process
safety. The functional schematic diagram of the design process is presented in Figure 5.
The Preheaters and kiln

Analysis of the proposed production technology shows that for efficient operation of this unit the
automation process must guarantee the designed temperature and aerodynamic regimes. In
principle rotary kiln with cyclonic preheaters consists of three main automation mechanism: the
feeder for the limestone, decarbonization and cooling including the draught/respiratory system,
dust collection and transportation. These mechanisms will be remote controlled from the control
board, which could be local (instrument at the point of measurement) or centralized in the control
room.
This automation involves regulation of feed rate of material, stabilization of temperature/ fuel
feed rate and fuel air ratio. The material flow rate is controlled via stabilization of gas/material
velocity/pressure in the pipes before the third, second and first preheating unit. The pressure is
measured with the aid of digital pressure gauge. The signals are then sent to the control board.
The secondary signals are then sent to the regulatory mechanism (metering/weighing machines)
to regulate the material flow rate. The temperature of material in the pipe during stable heat flow
from the kiln is dependent on the material flow rate in the Preheaters. The pressure in the pipe
determines the material flow rate; consequently control of pressure will enhance control of
material flow rate and temperature before and in the Preheaters.
A very important control measure is the regulation of the fuel supply/flow rate to ensure
stabilization of heat distribution in the kiln. The quantity of fuel supplied is determined by the
kiln temperature measure with the help of a digital thermocouple. The signal is sent to the
transducer installed in the control board. From here secondary signal is sent to the regulatory
mechanism to control the flow rate ratio of both the natural gas and air. This is to ensure optimal
burning
Joseph O.regime.
Odigure: Selected Publications: Mathematical Modelling, Cement Technology and Process Design
Regulation of the aerodynamic and temperature in the kiln head is necessary to ensure stability
of the system. Pressure is measured at this point and transferred to the transducer in the control
board. The secondary signal is the sent to the regulatory mechanism (orifice metering machine)
to control the material flow. During abnormal temperature change the signal is sent to the
pressure transducer for onward transfer to the regulatory mechanism at the kiln head to regulate
material flow rate and or control the gas burning rate.
In the burning zone, the rarefaction, temperature of secondary air and temperature of material are
regulated. The signals about the flame brightness, secondary air and material temperature are
sent to the transducers in the control board and secondary signals received by the regulatory
mechanisms ensure stability in the system.
The Rotary Cooler

In the rotary cooler unit automation should ensure effective cooling of the lime to the designed
temperature of 100oC, guarantee the temperature of the secondary air, enhance cooler stability
and life span. Major technological parameters to be controlled include: lime and secondary air
temperature, flow rate (pressure) of primary and secondary coolant (air). All the control
measuring and regulatory digital devices are installed in the control board for easy operation.
The operation of the rotary cooler is synchronized with that of the rotary kiln. The utilization of
the cooler is dependent of the proper functioning of either the kiln or the draught system. For
example in case of faulty draught system supply of lime from the kiln to the rotary cooler is
stopped, however the electric motors will continue to run. The cooling air flow rate and material
flow rate and temperature at the inlet and outlet are very important control parameters to be
monitored.
SELECTION OF ANCILLARY EQUIPMENT

BUCKET ELEVATOR
This has been selected to ensure the required 17kg/s material flow rate.
The basic characteristics are:
Transport height 23m
Mass of material to be delivered 61.56T/hr + 20% = 73.88T/hr
The 20% accounts for non uniform bucket loading and losses
Apparent mass of material 2700kg/m3.
Coefficient of bucket loading 0.85
Step = 0.4m/s
Bucket volume = 0.0108m3
Power required 6kW
ENVIRONMENTAL SAFETY
This was adequately considered in the design. Maximum attention was paid to removal of CaO
by using hydroclone. This is to ensure operational environmentally friendly process.
Purification of cooler air

A system consisting of battery cyclone (multiclone), venture scrubber and hydroclone will be
used for the purification of the 2nd secondary air from the cooler.
Input data
Volume of air generated 12m3/s = 43,200m3/hr
Initial temperature 439.4K
Final temperature 333K
A cyclone of productivity 7600m3/hr and volumetric flow rate of 3m3/s was selected. Therefore a
multiclone consisting of 6 units will be required. A six (6) unit venture scrubber and hydroclone
is also required. Outgoing effluent will be used for hydration of the quicklime.
Purification of outgoing flue gases from the 1st preheater

This is a CO2 enriched flue gas stream. It is expected that the flue gases will be sent for further
processing.
Input data
Amount of gaseous product generated per hour = 0.22x12.65x3600x7 =70132m3/hr.
Initial temperature oC 150
Final temperature oC 30
A cyclone of productivity 7600m /hr and volumetric flow rate of 3m3/s was selected. Therefore a
3
multiclone consisting of 10 units will be required. The preliminary cleaned gas stream is then
sent to the CO2 collector for further processing.
The basic characteristics of the purification unit is presented in Table 7
Table 7 Basic Characteristics of the purification aggregates

Parameters Cyclone Venturi Hydroclone Exhaust pipe
scrubber
Diameter, m 1.0 0.25 1 0.9
2
Surface area F, m 0.785 0.049 0.785 13.36
Required units 16 6 6 1
Power, kW 30
ECONOMIC ANALYSIS
EQUIPMENT COST ESTIMATES
Calculation of equipment cost estimates are based on standard procedure for determining cost.
Estimates were based on the cost of the original equipment as at 1991 with appropriate
allowances for inflation, insurance and transportation (Plant Design and Economics, 1991). The
estimated costs of the equipment are presented in Table 8.
Table 8 Bill of Quantity of some major equipment
Equipment Geomet Unit Refractory(+ Productiv Material Unit Total
ry, 0.02m ity Of construction Cost, Cost,
M2 insulator), x103 $x103 $x103
kg kg/hr
1 Rotary dryer, Asbestos, low alloy
indirect heating 26.7 1 Insulator 64.8 iron wall. 20 20
2 Metering machine 1 25.2 35 35
3 Cyclone heat
exchangers 7.56 1 2354.9 Asbestos, Fireclay, 50 50
2.25 1 2246.1 low alloy iron wall. 35 35
1.42 1 1412.3 28 28
0.62 1 1026.3 30 30
4 Bucket elevator 25m 1 73.9 6 6
5 Screw conveyor < 10m 1 73.9 Asbestos, Fireclay, 8 8
6 Pipes, m 0.365 5.54 low alloy iron wall. 15 83.1
0.44 0.5 15 7.5
0.351 14.3 15 214.5
7 Rotary kiln 57 1 28041 25.2 Asbestos, Fireclay,
low alloy iron wall. 40 40
8 Gear motor, kW 1 10 8 8
9 Rotary pump + 1 70.1 6 6
motor
10 Rotary cooler 68.7 1 4910 25.2 Asbestos, Fireclay, 60 60
low alloy iron wall.
11 Gear motor, kW 15 12 12
12 Rotary pump +
motor 69 6 6
13 Dust collector
From cooler:
cyclone 0.785 6 45600 4 24
Venturi scrubber 0.049 6 45600 4 24
Hydroclone 0.785 6 45600 3 18
Exhaust pipe 13.36 1 121600 33 33
Pump + gear motor,
kW 30 1 6 6
14 From Rotary dryer
Cyclone 0.785 10 76000 4 40
Pump + gear motor,
kW 30 1 6 6
15 Tractor shovel 192 1 105HP 75 75
16 Tank trailer 16m3 1 35.7 35.7
Total cost 910.8
Cost estimate of major equipment.
The total estimated cost as at 1990 amounted to $910800.
Allowing for 20% inflation over a 14-year period and 35% for shipment and insurance to
Nigeria, the grand total estimate for equipment = $1,411,740.00
The ratio factors for estimating fixed capital investment items based on the above estimated
delivery equipment cost were used to estimate other parameters (Table 9).
Table 9 Estimated cost of fixed capital investment

Fixed Items Cost, $x103
1 Purchased equipment –delivered, including 1411.74
fabrication locally of some process machinery
2 Purchased equipment installation (45%). 635.28
3 Instrumentation and process control equipment
(11%) 155.29
4 Installation (9%) 127.10
5 Piping, excluding those in the process plant (5%) 70.59
6 Electrical (10%) 141.17
7 Building (25%) 352.94
8 Service facilities (40%) 564.70
9 Land 6% 84.70
Total direct plant cost 3543.51
Engineering and supervision (15%) 531.53
Contractor’s fee (5%) 177.18
Contingency (10%) 354.35
Fixed Capital Investment (FCI) 4606.57
Estimation of Annual Product cost.

The cost of material was estimated based on anticipated Government incentives industrial
structure and prevailing average market price of the finished product. The following were
considered in fixing the cost of raw material – limestone.
Social services – 15% of the average current market price of lime $39/T.
Right of exploitation – 7%.
Therefore raw material cost will consist of 23% of the average current market price of lime
$39/T.
Total annual production material cost = 0.23x7x3600x24x300x39/1000 = $1627516.80
Cost of Energy per day
Average fuel/gas consumption per kg = 4132kJ/kg
1m3 of natural gas will give 36515kJ
Therefore 4132kJ will require 8.619m3
Annual natural gas requirement = Production output 181440x8.619 = 1563885.79m3
Fuel – gas Annual fuel consumption 1563885.79
Cost of gas $0.3/m3
Cost of fuel $469165.73
Allowing for independent market sources of 51% above NNPC official price
The cost of fuel is taken as = $709200.00
Electricity Annual consumption 144x24x300 = 1036800
Cost
Joseph O. Odigure: Selected 0.05/kW.hr
Publications: Mathematical Modelling,$51840.00
Cement Technology and Process Design
Total raw material cost $2388556.80
Operating Labour Cost
The plant production capacity is estimated at 604.8T per day. The manning of the various units
have been estimated generously despite the estimated automation of process control (Table 10)
Table 10 Operating Labour Cost.
Position Grade level Number Qualification Experience, Annual

HATISS required years Salary ($)
General
manager 14 1 B.Eng 12 9000
Production 12 1 B.Eng Chem. 8 7000

manger Engr.
Accountant 12 1 B.Sc 8 7000
Cashier 08 2 HND 2 7000
Technologis 09 3 B.Eng 3 12000

t
7 6 OND in 4 18000
Technician Mech./Electrical
Engr.
Labourer 02 20 NA 40000
Security 1 10 Ex service 20000
Drivers 03 10 Trade test 3 30000

TOTAL 150000
Estimation of Variable Cost.

The variable cost includes:
(i) Raw material cost per year = $2388556.80
(ii) Cost of maintenance = 8% of fixed capital
Refractory material cost. = 30% of material
Miscellaneous material = 10% of material
Maintenance cost = 8% of FC
= 0.08 x $4606570 = $368525.6
Cost of miscellaneous = 0.1 x $2388556.80 = 238855.7
Refractory = 0.3x2388556.8 = 716567.04
Total variable cost = $1323948.34.
Estimation of Utility Cost.
These include electricity for lightening, electric motors for pumps and energy for control
panel other than those used in the production process.
Utility cost (UC) = 5% of total variable cost
= 0.05 x $1323948.34
= $66197.4
Fixed Cost (to be included in production cost)

These include the following:
(i) Maintenance cost = $368525.6
(ii) Operating Labour cost = $150000.00.
(iii) Plant Over head = 50% of operating labour cost = 75000.000
(iv) Capital charges = 15% fixed capital = $690985.5
(v) Insurance = 1% fixed capital cost = $460657.00
(vi) Land Tax rates = 2% fixed capital cost = $921314.00
TOTAL FIXED COST = $2666482.1
Direct Production Cost (DPC)

= Total variable cost + Total fixed cost + utilities
= 1323948.34 + 2666482.1 + 66197.4 =
= $4056627.74
Annual production rate (APR)

= 7x3600x24x300 = 181440T
Production cost (PC) = APC/APR

= (4056627.84)/( 181440T / year) = $22.36 per ton.
Selling Price.
This is a function of total production cost demand and market forces. The distribution
price of $35.00 per ton would be recommended as the initial price.
Annual product sales (APS)

= $35 x 181440 = $6350400.00
Annual profit before tax = APS – APC

= $6,350,400.00 – 4,056,627.74 = $2293772.26
Profit after tax (40%) = 0.6x2293772.26 = $1376263.36.
Depreciation
Determining the depreciation rate by the straight line method was adopted:
d = (V – Vs) / n
Where d = Annual depreciation $ / year
V = Original value of the property at start of service life period, complete
installed and ready for use.
Vs = Salvage value of property at end of service life.
n = service life period.
Let Vs after 10 years be taken as 15% of FCI = $690985.5

Annual depreciation per year
= ($4606570 - 690985.5)/ 10Years = $391558.45
Pay Back Period (PBP)

This is the minimum length of time required to recover the original capital investment
inform of cash flow based on the total income minus all cost except depreciation.
PBP = (Fixed capital investment) / (Average profit / year + Average depreciation

/ yr)
= 4606570 /($1376263.36 + $391558.45/ year )
= 2.61 years.
Rate of Return on Investment
= Annual profit x 100 / TCI

= (1376263.36 x 100) / 4606570.00 = 29.88%
COMPARATIVE ANALYSIS OF THE DESIGN AND EXISTING SHAFT FURNACE

OR ROTARY KILN
In table 11 the major articles of heat balance required to produce 1kg lime are presented. This
will form the basis of comparison of heat utilization.
Table 11 Heat required for the production of 7kg/s lime
s/No Heat required for some major Theoretical Design

processes calculation, kJ calculation, kJ
1 Dissociation of CaCO3 in the kiln
(only 20% of CaCO3 is left to 17010 3402
decarbonise in the kiln
2 Loss through the kiln wall
(McT = 2333.33x0.00857x160) 5865.3 3182.2
Q5.
3 With flue gases from the kiln to
pre heating unit Q6. 31965.78 20052.8
4 With dust Q7 1519 1734.8
5 With exit lime Q8. 553 553 (max)
Total 63507.58 28924.8
Heat required per kg lime, kJ/kg
Quantity of natural gases, m3/kg 9072.5 4132
8.619
In practice it is well documented that the shaft furnace requires 3820 – 5920kJ/kg and rotary kiln
without pre heating heat exchangers – 4736 – 7696kJ/kg lime. The calculated heat utilization by
the design is lower than that of the rotary kiln by 12.8% and falls in the lower range of the shaft
furnace. However the retention time of material in the design kiln is very low about 80min.
compared to about 24hr for the shaft and about 300min. for a 70m long traditional kiln.
There is a considerable energy conservation considering the fact that deliberate heat loss through
the kiln wall (outer temperature 180oC compared to 90oC normally used) was allowed. This is to
allow for local sourcing of refractory materials and for personnel to acquire necessary experience
The required processing surface area is 68.53m2 compared to 272m2 for the long kiln equivalent
both without the cooling unit. This is about 75% construction materials conservation. The same
is also true for the shaft furnace.
REFERENCES
Bauman V. A., Klushantev B. V., Martinov U. D. (1981). Mechanical Machines for Building
Materials Industry. Machinostroenie, Moscow, 324p.
Dugerov I. G. Matveev G. M., Suxanova V. B. (1987). General Silicate Technology. Stroidat,

Moscpw, 570p.
Gucev, Yu. I., Karacev I. N., and others. (1985). Construction and Calculations for Chemical
Processes Machines. Machinostroenie, Moscow, 408p.
Islamov M. Sh. (1986). Design and Exploitation of Industrial Furnace. Ximiya, Leningrad, 280p.
Odigure J. O. (1995). General Chemical Engineering Technology. Jodigs, Minna, 299p.
Perry R.H. and D.W. Green “Perrys’ Chemical Engineers Handbook”, 7th edition, McGraw-Hill
Book Co., New York, 1997
Plant Design and Economics for Chemical Engineers (1991). 4th Ed. McGraw-Hill Inc. NY. Ed.
B. J. Chark and J. M. Morriss.
Tereovkov A. I., Pechkovskii V. V., Hovosecckaya L. V. (1984). Machines for Inorganic

Compounds. Vishaya scola, Minsk, 196p.

The Design of Rotary Kiln With Cyclonic Heat Exchangers

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18.

THE DESIGN OF ROTARY KILN WITH CYCLONIC HEAT

A (CaCO3  x)0.56 0.56(93  x ) 80

CaCO3 93.0 CaO (93 – 5.28)0.56 49.10

3. Utilization coefficient: mass of material required to produce 1kg of quicklime

Table 7.4 Material balance for the production of 7kg/s quicklime

Q1  G xf (Qo  cTo )  G xf (35615  1.59 x10)  35631G xf kJ

Heat Received = Heat Lost

Table 7.5 Heat balance for the process per kg lime.

Heat received Q, kW Heat lost Q, kW

At kiln outlet temperature of 700oC

At kiln outlet temperature of 900oC

At kiln outlet temperature of 1000oC

The obtained results are presented in Table 7.6.

For cylindrical shaped rotary furnace

F = 0.785 Dw2 L = 271.55

The rotation velocity n is determined as (Teterevkov and others,1984)

3.08 x10 3 x (  24) L 3.08 x10 3 (45  24) x15

1- Pre heating zone

Figure 7.2 Schematic diagram of a Rotary Kiln.

where m – apparent mass of the material, kg/m3.

The heat lost by the carrier gas is determined

The heat received by the material can be determined as

` 4 Material at 1000 oC to kiln

Figure 7.3 Proposed Schematic diagram of the Preheating Unit

Mass of refractory assuming a cylindrical shaped preheater

The heat received by the material can be determined as

Qm = GmcT = 17x1.08x(600 – 400) = 3672kW

The heat received by the material can be determined as

The heat received by the material can be determined as

Qm = GmcT = 3.4x1.08x(1000 – 800) + 4.2x0.92x(1000 – 800) = 1507.2kW

Material movement from:

First preheater to the second.

The required refractory material for lining Gr = 0.785x2270(0.3652 – 0.2052) = 162.5kg/m

From 3rd to 4th

From 4th to rotary kiln

Table 7.5 Energy requirement for the Preheating Unit

The total heat required by the preheating unit = 20042kW.

The outgoing flue gases will be used in the rotary dryer.

Design of the Rotary dryer.

The surface area of the rotary dryer F = 4717.09/(3.778x46.8) = 26.7m2.

Calculation of Pressure Drop and Gases Velocity

For the fourth cyclone

Table 7.6 Characteristics of Preheater unit

Rotation velocity 6rev/min

Rotation velocity 0.737rev/min

N1 = 0.8175x1.83 x 15x790x0.077(sin42.5)3sin50 = 1027.6W

4.905 x 0.025 x (2333.33  3632  1869.4) x 2.73 x0.25 x 0.077 x15

9.81Gd  Gr  Gm D1  d r L

9.81x7834.73 x2.73  0.8x0.077 x15 x0.0008

Moment and Torque

The total bending moment can be calculated as

The torque applied to the rotary kiln/drum

The calculated/design bending moment was calculated as

At a wall thickness of 16mm, the anti torque was calculated as

where DE – external diameter of the drum 2.232m

Verification for sagging

q = 7834.73x9.81 = 76858.70N/m = 0.0769MN/m

The sagging limit is determined as

Verification for foundation roller

0.07834 x15 cos 3

Therefore the obtained bearing stress c = 475 < 483 = [c]

N1 = 0.8175x2.53 x 15x790x0.628x0.87463x0.5736 = 3232.17W