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THE BYPASS
A solution for
Process
I n t he name of A l l ah, t he Benef i cent , t he M er ci f ul
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Lets talk about bypass
What happens in the system ?
What are the minor elements ?
What do the minor elements do ?
Why do we need a bypass system ?
What is the bypass system ?
What are the calculations ?
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What happens in the system ?
Raw Materials
Raw Meal
Grinding Heating up
Hot Meal
Clinker
Clinkerization
Volatilization
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What are the minor elements ?
They are chemical components of the raw materials with a
low concentration towards the other components.
In the cement industry, Cl, SO3, Na2O and K2O are,
among others, particularly monitored
Although some have no impact on the chemical process, others might lead to major
troubles.
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What are some elements doing ?
Low volatilization
temperature
Extraction from
material
Flowing with
gases
Condensation on
cooler particles
Increase of
local
concentration
PROBLEMS
Problem with volatile elements
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What are some elements doing ?
Volatilization temperature
+
Condensation temperature
2 Cases
Internal
Cycle
External
Cycle
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Internal and External Cycles
This image cannot cur r ently be display ed.
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Internal and External Cycles
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Definition of the Volatility
Volatility of a component
Component
Total
d Volatilize
Q
Q
Volatility =
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Definition of the Volatilization
Hot meal
Clinker
Volatilization of a component X in the kiln
|
|
.
|

\
|
=
Hm
Ck
X
X
X
tion Volatiliza 1 100
Recirculation part
Note: Calculation done LOI free
POLYSIUS S.A.
Volatility or Volatilization ?
Volatility
is a physical property of a component
is depending on the temperature
Is depending on the crystallographic structure
Volatilization
is depending on the considered area
is depending on the operation
?
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Different behaviors
Chloride start evaporate around 650C
Alkalis start evaporate around 900C
Sulfur start evaporate around 1000C
Conclusion :
The various content of element is different according to the
analyzed area (kiln feed, meal cyclone 2, hot meal,
clinker,).
Nevertheless, most of the highest concentrations are
located at the kiln inlet, depending on the salt formation.
POLYSIUS S.A.
The salt formation
KCl Cl O K 2 2 2 +
NaCl Cl O Na 2 2 2 +
2 2 CaCl Cl CaO +
Chlorines
4 2 3 2 SO K SO O K +
4 2 3 2 SO Na SO O Na +
4 3 CaSO SO CaO +
Sulfates
3 2 2 2 CO K CO O K +
3 2 2 2 CO Na CO O Na +
Carbonates
F
o
r
m
a
t
i
o
n

o
r
d
e
r
POLYSIUS S.A.
Calculation of the salt concentration
POLYSIUS S.A.
Calculation of the salt concentration
With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI
KCl Cl O K 2 2 2 +
94
71 149
e
a KCl

=
100
100
94
149
Quantity of KCl formed :
Cl used during the reaction :
e
a Cl
KCl

=
100
100
94
71
Reaction 1
Cl remaining after the reaction :
e
a c Cl
R

|
.
|

\
|
=
100
100
94
71
1
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Calculation of the salt concentration
62
71 117
1
71
62
2
R
Cl O Na = Quantity of Na2O that can be used with Cl :
NaCl formed during the reaction :
1
71
117
R
Cl NaCl =
Reaction 2
Na2O remaining after the reaction :
1 2
71
62
100
100
2
R R
Cl b
e
O Na
|
.
|

\
|

=
NaCl Cl O Na 2 2 2 +
With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI
POLYSIUS S.A.
Calculation of the salt concentration
62
80 142
2
2
62
142
4 2
R
O Na SO Na = Quantity of Na2SO4 formed with Na2O :
SO3 used during the reaction :
2
20
62
80
3
R
Na SO =
Reaction 3
SO3 remaining after the reaction :
2 3
2
62
80
100
100
3
R R
O Na d
e
SO
|
.
|

\
|

=
With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI
4 2 3 2 SO Na SO O Na +
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Why do we need such calculations ?
Better understanding of the cycles with the analysis
Better understanding of the build ups
Criteria of decision for a bypass system
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What is the bypass system ?
Raw Material composition
in minor elements
Volatility of some
elements
Process
Cycles creations
Salt formation
Troubles
Bypass system
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What is the bypass system ?
Cooling
Quenching chamber
Conditioning tower
Separation
Electro filter
Dust collection
Clean gas emission
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How much bypass ratio ?
The bypass
Decreases the concentration of minors in the
kiln inlet by taking a part of the kiln gas
Taking part of the heat
Taking part of the production
What has to be the bypassed gas quantity ?
POLYSIUS S.A.
Two different ways
1 - Assuming that
Bypass % Cl % input (free of LOI) x 100
2- Complete calculation of the salts, taking into
account the volatility, the type of system (kiln,
preheater). Using the whole chemical theory.
POLYSIUS S.A.
POLYSIUS process of decision for BP%
SO3, Cl,
Na2O, K2O
Bypass
Calculation
X%
Cl < 1%
hot meal
% Salts in hot meal
X% BP
Yes
X% BP
<4%
> 4%
> 6%
% CaSO4
< 60%
X% BP
> 60%
< 6%
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Example of decision
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Calculation of the bypass ratio
From the measurements done on site
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Definition of the Bypass Ratio
ln Ki
Bypass
V
V
o BypassRati =
V
Bypass
= Volume of gas going to the bypass
V
Kiln
= Volume of gas going out of the kiln
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Definition of the calculation parameters
W
D
t
1
V
BP
t
1
V
AF
t
1
%O
2
(BP)
V
a
t
a
W
D
t
o
V
BP
t
o
V
AF
t
o
V
A
t
o
%O2(k), V
k
POLYSIUS S.A.
Calculation of V
Kiln
The volume coming out of the kiln is composed by :
1. The volume of the gas combustion - V
Comb
2. The volume of the decarbonation - V
CO2
3. The volume of excess air - V
Ex
Ex CO Comb Ki
V V V V + + =
2 ln
POLYSIUS S.A.
Calculation of V
Comb
C + O2 CO2
S + O2 SO2
H2 + O2 H2O
C
X
H
Y
+ (x+Y/4) O2 x CO2 + Y/2 H2O
C
X
H
Y
with Y = 2x + 2
The main combustion equations are :
POLYSIUS S.A.
Calculation of V
Comb
( )
100
. 2
2
Wg CxHy x CO CO
V
CO Comb
+ +
=

100
.
2
2 2 2
2
Wg CxHy
y
O H S H H
V
O H Comb

|
.
|

\
|
+ + +
=

( )
100
2
2
Wg S H
V
SO Comb

100
2
100
79 . 0
min
2
Wg N V
V
Air
N Comb

100
.
4
762 , 4 2 762 , 4 2 143 , 7 2 381 , 2 381 , 2
min
Wg CxHy
y
x O S H H CO
V
Air

|
|
.
|

\
|
|
.
|

\
|
+ + + +
=

POLYSIUS S.A.
Calculation of V
Comb
CO, CO2, H2, H2S, H2O, O2, N2, CxHy
% from natural gas composition analysis
2 2 20 2 N Comb SO Comb H Comb CO Comb Comb
V V V V V

+ + + =
POLYSIUS S.A.
Calculation of V
CO2
CO
3
Ca CO
2
+ CaO
100 44 56
CaO CO
56
44
2
=
CO3MgCO2 + MgO
84,3 44 40,3
MgO CO
3 , 40
44
2
=
CaO MgO
CK
W |
.
|

\
|

+
= )
100
- 100
(
100 1,977
1.092MgO CaO 0,748
VCO2

being the carbonation degree

POLYSIUS S.A.
Calculation of V
Ex
V
Comb
+ V
CO2
V
Ex
V
Kiln
O
2
Kiln
inlet
O
2
Air
) V (V x
%O - 21
%O
V
COMB CO2
) (
) (
EX
2
2
+ =
k
k
POLYSIUS S.A.
Calculation of V
Kiln
The volume coming out of the kiln is composed by :
1. The volume of the gas combustion - V
Comb
2. The volume of the decarbonation - V
CO2
3. The volume of excess air - V
Ex
Ex CO Comb Ki
V V V V + + =
2 ln
POLYSIUS S.A.
Calculation of V
BP
W
D
t
1
V
BP
t
1
V
AF
t
1
%O
2
(BP)
V
a
t
a
W
D
t
o
V
BP
t
o
V
AF
t
o
V
A
t
o
%O2(k), V
k
INPUTS
OUTPUTS
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Calculation of V
BP
INPUT
VBP x CPGAS x (t1 20)
+ Va x CPAIR x (ta 20)
+ WD x CPdust x (t1 20)
+ VFA x CPair x (ta 20)
OUTPUT
VBP x CPGAS x (t0-20)
+ Va x CPAIR x (t0-20)
+ WD x CPdust x (t0 20)
+ VFA x CPair x (t0 20)
With False Air being calculated with O
2
content in the bypass
( )
( ) ) ( % 21
) ( % ) ( %
2
2 2
BP O
Ki O BP O
K

=
BP FA
V K V =
POLYSIUS S.A.
Calculation of V
BP
As far as
Inputs = Outputs
| |
| | 20) - (t CP - 20) - (t CP K - 20) - (t CP - 20) - (t CP
20) - (t CP - 20) - (t CP
W
20) - (t CP - 20) - (t CP K - 20) - (t CP - 20) - (t CP
20) - (t CP - 20) - (t CP
V
V
a
AIR
0
AIR
0
GAS
1
GAS
0
dust
1
dust
D
a
AIR
0
AIR
0
GAS
1
GAS
a
AIR
0
AIR
a
BP

=
POLYSIUS S.A.
Calculation of the bypass ratio
Finally, knowing V
Kiln
and V
BP
ln Ki
Bypass
V
V
o BypassRati =
POLYSIUS S.A.
Conclusion
Minor elements are to be considered for
operation decisions
Chemistry is able to help for any investigation
concerning the process troubles
The volatilization and cycles of the elements can
be handled through process operation
A good knowledge of the element circulation is
necessary for a good trouble shooting
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Questions and/or comments ?