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  • Red Rivers of Segregation

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    Syed Kazam Raza
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    9 Ansichten2 Seiten

    Red Rivers of Segregation

    Hochgeladen von

    Syed Kazam Raza
    this is the description

    Copyright:

    © All Rights Reserved
    Als PDF herunterladen oder online auf Scribd lesen
    Markieren Sie unangemessene Inhalte
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    t TECHNICAL FORUM Red rivers of segregation BU Manrelal cake MM Ute atal el fol g lan eae lec me a Me aTel ue el rime (Leese) [ol Ot -Te gle] Coa Pees the clinker cooler. Para ae Ag this month's Technical Forum {focusses on the phenomenon of, segregation in the cement manufacturing process, lets start with a definition of segregation. The Oxford English Dictionary states that segregation is: “The action or state of setting someone or something apart from others" ie, the separation cof people, or separation of objects, I is this separation of objects within a ‘material that we encounter in the cement ‘manufacturing process. Other sources state that the separation of objects can be ‘an enrichment ofa material constituent at a free surface or an internal interface of a ‘material, the tendency of particulate solids tosegregate by size, density, shape and other properties, or magnetic-activated call sorting, a method for separation of various cell populations depending on their surface antigens. ‘The positive side of segregation Inthe cement manufacturing process segregation refers mainly tothe tendency of particulate solids to segregate by ize, density, shape, and other properties the ‘main subject of this Technical Forurn However, there are examples where this tendency is used for sorting. For example, ‘magnetic activated sorting in metal detectors on the feed to vertical roller mills orroll presses is used. n the processing, of alternative fuels such asrefuse-dorived fuels (RDA), different factions are sorted using compressed ar, with the different masses of particles beingrelated to their ‘composition and usefulness Flotation cells mightbe used forthe removal of deleterious fractionsin raw materials. The coal tofire the kilns has probably gone through a coal washing plant where the ash contentis controlled by lating off part of the clay (ash) fraction. These are somewhat exotic examples of sorting by segregation, However, itis common to use the fact that differentsize fractions ofthe primary raw material feed eR MARCH 2016 ST eaee Means Ke oN ‘toacrusher have different compositions. ‘AtHope cement works in the UK the {feed tothe primary gyratory crusher used tobe screened to remove fluoride ‘contamination that concentrated in the finer fractions of the limestone. At the RAK White cement factory, UAE, the feed to the limestone intake was screened to reduce clay input, which concentrated inthe finer fraction. At the Bahau cement plant in Malaysia the product from the primary yratory crushers screened to remove sulphide bearing clay contamination, ‘These are|ustthree examples where the tendency of the composition to segregate by particle size allows the input of contaminating materials to the cement manufacturing process to bereduced and uses the tendency of segregation toimprove the cement manufacturing process. Of course rejecting part ofthe feed or product from a crushing process potentially increases the raw material ‘consumption ofthe process and perhaps ‘the waste from the process, which snot so good. Segregation to avoid (Once the materfals are partofthe cement rmarvfacturing process, segregation becomes more of anissue. critical impli erieneacerna Raw material crushing and blending, Crushed raw materials are carefully stacked on blendingbed, butif that blending bedis longitudinal using the chevron stacking method then the larger particles, wit their different composition, roll down to the base ofthe pile. This does not present any issues ifreciaiming takes place over the entire width ofthe pile until, the end cone is reached, where the larger particles will ave accumulated. Windrow stacking or a circular blending bed will get round this, but both involve higher capital costs. The end cones can also be recirculated to the beginning ofthe next pile, but thatinvolves double-handling ‘them, and there isa cost attached to any double-handling. Premixed material storage and raw mill feed ‘Once reclaimed the premixed materials stored ina premix bin before feeding to the ravi mill to avold the need to continuously run the reclaimer while the raw mills in operation, In addition, to control the chemistry ofthe mill product, the flow rate ‘of the reclaimed material tothe raw mill, needs to be regulated. However the issue is thatthe premixed material segregatesin the premixbin. ‘As the level ofthe material in the premix bin changes so does the composition ofthe ‘material being delivered ta the raw mill, The problem can be resolved by setting the remixbin's high and low filing levelsvery lose together, so thatthe bin level remains ‘almost constant. However, this means that the reclaimer has to run almost all ofthe time while the aw mills operating, Kiln feed segregation in the homogenisation silo and preheater ‘The sameissueis encountered in the homogenization sito, whereby the composition ofthe kiln feed changes as the level ofthe ilo goes down due tothe ‘segregation ofthe material within thesilo, Sotthe homogenisation effect ofthe stois ‘negated by segregation of matcralin the slo. One solution s to reduce the raw mill feed rate to match the kiln feed rate and ‘therefore keep the homogenisation silo level constant. However, that means that ‘the raw mill has to run for more hours and the eleciricity consumed per tonne of feed increases. Once the kiln feed is delivered to the preheater, the cyclones collect the preheated feed from the kiln exhaust gases and pass that feed down to thenext stage ‘of the preheater. The collection efficiency ‘of the cyclones depends on the particle Size ofthe preheated particles being, collected. Coarser, and therefore heavier, particles are more readily collected than fines lighter particles. The coarser particles also have. different composition to the finer particles, being usually higher in silica due to silica being harder to grind than, calcium carbonate. So the dust lost from the top ofthe preheater is predominantly the finer calcium carbonate and therefore hhas a higher lime saturation than the liln feed. The material that is collected and passed down the preheater to make clinker hasa lover lime saturation than the kiln feed ~ an unwelcome example of inadvertent sorting by segregation in the Production process. (Once the dust leaves the preheater itis amalgamated with the raw mill product to form the kiln feed within ‘the homogenisation silo, Theresa cycle between the preheater and the homogenisation silo, and considerations ‘ofa mass balance mean that samples of ‘aw mill product including the dust are not representative ofthe inputs to the process, The weighted composition of the raw ‘material feeds to the raw mill are the true inputs. When the rav mils stopped the “Thankfully, in modern coolers equipped with walking floors, the aeration of the clinker bed and the transport of clinker along the cooler are separated. The transport speed of the floor and clinker across the bed can be adjusted tocombat the tendency to formared river.” dust continues to be lost from the preheater, but theres ro raw mill product to mix \with it How will the dust be handled when the rew mils stopped? Storedin adust bin? Or delivered to the homogenisation silo changing the chemistryin the slo? Or recirculated tothe kiln feed? Each strategy hasits pros and cons, allof which are a consequence o the segregation of the kln feed in the preheater. Red rivers in the coolers Once the feed has passed down the preheater the consequences of segregation ‘are not over. Segregation by particle size continuesin the rotary kiln and this, «an lead to a particulary troublesome consequence inthe process: red river of clinkerin the grate cooler. The moderator witnessed a particularly spectacular example in 2 10,000tpd kin in late 2015, Red rivers are caused by the segregation ofthe clinker falinginto the cooler induced by the rotation oftheklin. Finer clinker climbs the walls ofthe kiln higher with the rotation ofthe Kiln, while coarse clinker rolls down the ascending wall and accumulates atthe bottom ofthe kiln, As the clinker, clscharged into the cooler the coarse clinker is discharged first tothe centre ofthe cooler hile finer fractions re discharged later towvards the edge of the cooler on the rising side of the kiln rotation, This segregation of the clinker provides fr diferent resistance ofthe clinker bed to the cooling ar biown, through. The coarser clinker provides an easier path forthe cooling at, while the fine clinker becomes aerated rather than cooled and lows down the cooler ina red river ‘The ssue with a redriverin the cooler is thatred-hot clinker flows down tothe discharge ofthe cooler. Energy isnt recovered to the combustion airforthe TECHNICAL FORUM kiln, increasing energy losses from the kn and overall kiln fuel consumption. However, much more problematicis that red-hot clinkeris discharged from the cooler. This s no major issue on the metal an conveyors transporting the clinker to storage, but when that still very hot clinkeris extracted from storage there is the danger of res on the rubber belt conveyors transporting the clinker to the cement mills The belts also become cembrittied due to overheating. The cement ‘ills become prone to overheating and the srinding efficiency falls away, Dealing with red rivers How to combat a red river in aclinker ‘cooler? Thankfully, in modern coolers equipped with walking floors, the aeration ofthe clinker bed and the transport of ker along the cooler are separated. The transport speed of the floor and clinker across the bed can be adjusted to combat the tendency to form ared river. With older, chamber-aerated coolers that isnot possible. In this case the best solution sto change the granulometry ofthe clinker tobe coarserand therefore ‘vod fines being segregated tothe kiln rising side ofthe cooler. Changing the grenulometry ofthe clinker requires changes tothe clinker chemistry and ensuring thereis no heavy circulation of, sulphurin the kin, therefore optimising the combustion concitionsin the kiln Adjustment ofslica and alumina modulus will affect the clinkering range inthe ln and, therefore, the granulometry of clinker. Alternatively, the segregation tendency ‘of the clinker can be reduced by slowing the rotation ofthe kil. However, that can lead to problems of overburning ofthe clinker. in general the moderator prefers ‘ constant high rotational speed for precalciner cement kilns. Another possibility isto make physical ‘changes to the cooler to try to push the red Fiver into the centre ofthe cooler and remix the fines with the coarser elinker. One ‘option isto install blank grate plates on the affected side ofthe cooler or refractory dams and deflectors, The moderator does not favour such solutions as they

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