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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Rotary Kiln Process Training

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

The modern kiln plant

Preheater

Calciner
Clinker cooler
C M

Raw mill Rotary kiln

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Process - technological kiln design

T e s t p r o c e d u r e
r e p r e s e n t a t i i v e r a w m a t e r i a l s a m p l e t e s t i n g r a d i e n t f u r n a c e a n a l y s i s o f t e s t r e s u l t s

C h a r a c t e r i s t i c d a t a o f r a w m a t e r i a l

Fuel properties Product quality Concept of kiln line

C o m p u t e r s i m u l a t i o n o f b u r n i n g p r o c e s s

R e s u l t s
k i l n d i m e n s i o n s k i l n s p e e d

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Rotary kiln design

Required kiln parameter: Length and diameter Kiln inclination Degree of filling A-Mass Kiln inlet gas velocity Kiln speed Kiln shell cooling

Kiln static calculation Kiln drive power

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Rotary kiln zones

Calcinaton Transiton Prehater CalcinerPrehater

2 6 7 0
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C a l c i n e r K i l n

P r e h e a t e r K i l n
K i l n L e n g t h i n D

Sintering Coling
6 1 3 4 1 1 5

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Kiln flame - temperature profile

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Kiln temperature profils

2400 2200 2000 1800 1600 1400 1200 1000 800 0 10 20 30 40 50 60

G a s M ( a l o t G e n a rg i s M a )l ( a s ( t l h e o o r n ir a g t) l ) (s h o rt )

Temperatue[C]

K iln
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Le ng

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Kiln dimensions
raw material characteristic moduli: LSF, SM, AM grinding fineness quartz grain distribution homogeneity impurities: alkali, SO3, Cl clinker quality (low alkali) type and quality of fuel fuel preparation alternative fuels fuel flexibility

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Kiln inlet temperature & kiln length

T e mp e r a t u r e
1 , 3 5 0 1 , 3 0 0 1 , 2 5 0 1 , 2 0 0 1 , 1 5 0 1 , 1 0 0

k i

1 , 0 5 0 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7

Le ngt h

/ di

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Kiln dimensioning
K i l n S y s t e m L e n g t h / d i a m e t e r V o l u m e l o a d i n g r a t i o t p d / m L o n g K i l n w e t d r y L e p o l G e p o l C y c l o n e p r e h e a t e r ( D O P O L ) 1 s t a g e 2 s t a g e 3 s t a g e 4 s t a g e 5 s t a g e C a l c i n e r K i l n ( P R E P O L ) P r e p o l A T ( 2 . . . 6 s t a g e ) P r e p o l A S ( 2 . . . 6 s t a g e ) 0 , 7 . . . 1 , 0 0 , 8 . . . 1 , 2 1 , 5 . . . 2 , 0 2 , 0 . . . 2 , 5 2 , 0 . . . 2 , 5 2 , 5 . . . 3 , 5 4 , 0 . . . 5 , 0 2 5 . . . 3 5 2 0 . . . 3 0 1 5 . . . 1 7 ( 1 4 ) 1 5 . . . 1 7 ( 1 4 ) 1 5 . . . 1 7 ( 1 2 , 5 ) 1 4 . . . 1 7 ( 1 1 ) 1 2 . . . 1 5 ( 1 7 ) 5 6 4 5 3 4 ( 2 ) 3 4 ( 2 ) 3 4 ( 2 ) 3 4 2 3 ( 4 ) 0 , 5 . . . 0 , 7 0 , 5 . . . 0 , 9 1 , 7 . . . 2 , 2 1 , 5 . . 2 , 0 3 0 . . . 4 0 3 0 . . . 4 0 ( 1 0 ) 1 3 . . . 1 7 1 5 . . . 1 7 5 6 5 6 ( 2 ) 3 4 3 4 N u m b e r o f k i l n s u p p o r t s

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Degree of filling
C a p a c i t y N o m . K i l n d i a m e t e r D i a m e t e r @ i n l e t A M a F F m L e n g t h L / D i n n e r L / D o u t e r V o l u m e l o a d i n g K i l n F u e l T h e r m a l l o a d i n g K i l n v o l u m e F r e e c r o s s s e c t i o n O u t e r S u r f a c e R a d i a t i o n K i l n F i l l i n g K i l n i n c l i n a t i o n K i l n s p e e d P r o c e s s t y p e D e g r e e o f f i l l i n g P r o c e s s D e g r e e o f f i l l i n g m e c h a n i c a l D i f f e r e n c e ( > 1 , 5 % ) t / d m m m m m m t p d / m k c a l / k g C l i k c a l / m h m m m k c a l / k g K l [ % ] [ 1 / m i n ] [ % ] [ % ] [ % ] 2 2 0 0 4 , 0 0 4 , 0 2 6 0 0 0 , 2 4 8 , 0 1 2 , 6 3 1 2 , 0 0 4 , 5 0 3 4 0 3 , 0 6 E + 0 0 6 4 8 9 1 0 , 1 8 6 0 3 2 9 , 6 3 , 5 0 3 , 0 0 A S 6 , 0 3 8 , 4 1 2 , 3 7 8

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Rotary kiln design

P r o c e s s t e c h n o l o g i c a l d i m e n s i o n s

K i l n w i t h c a l c i n e r K i l n w i t h p r e h e a t e r 1 0 1 2 1 41 5 L / D r a t i o 1 7

N u m b e r o f s t a t i o n s a n d L / D r a t i o
2 S t a t i o n s 3 S t a t i o n s 3 S t a t i o n s 1 0 1 2 1 4 L / D r a t i o 1 7

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Thermal kiln loading

Thermal loading [kcal/m2/h] Millions

Kiln diameter [m]

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Gas velocity in rotary kiln

1 4

1 2

1 0

Gasvelocity[m/s]

L / D = 1 4 , 0 1 2 0 0 C

6 2 3

4 , 0 4 t , 5 p 5 d t , 0 p / m d 4 5 6 7

K i l n

di a m

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L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt 140 TEI, 140 CD

Gas velocity in rotary kiln

1 4

1 2

1 0

Gasvelocity[m/s]

1 2 0 0 C : 4 , 5 t p d / m

6 2 3

L/ D L/ = D L 1 / = D 2 1 , 4 5 6 7 8

K i l n

di a m

Krupp Polysius Corp.