Page 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.

ppt
140 TEI, 140 CD

Rotary Kiln

Process Training

Krupp Polysius Corp.

 Page 2 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

Krupp Polysius Corp.

 Page 3 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Process - technological kiln design

T
e
st
pro
c
ed
ur
e
r
epr
ese
nta
t
ii
ver
awmat
er
ia
ls
am
pl
e
t
es
ti
n gr
ad
ie
ntf
ur
na
ce
a
nal
ysi
sof
te
str
esu
l
ts

C
h
ar
ac
te
r
is
t
ic
da
t
aof
raw
ma
t
er
ia
l

• Fuel properties C
ompu
te
r
• Product quality R
e
su
l
t
s
• Concept of kiln
s
i
mul
at
io
n k
i
l
n d
i
men
s
io
ns
line o
f k
i
l
n s
p
eed
b
u
rn
i
ngpr
oce
s
s

Krupp Polysius Corp.

Page 4 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

Krupp Polysius Corp.

 Page 5 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Rotary kiln zones

Calcinaton
Transiton
Sintering
Coling
Prehater CalcinerPrehater
2 6 6 1
C
a
l
ci
ner
Ki
ln

7 3 4 1
P
r
eh
ea
t
er
Ki
ln
0 K
i
l
n L
e
ng
t
hi
n D 1
5
Krupp Polysius Corp.
Page 6 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Kiln flame - temperature profile

Krupp Polysius Corp.

 Page 7 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Kiln temperature profils

2400
GasM(l
a o
teG
n ri
a
ga s
)Ml (s
(l
ao h
ten
ori
g
rta
))l (s h o rt )

2200

2000

1800

1600

1400
Temperatue[°C]

1200

1000

800
0 102030405060
K iln L en g

Krupp Polysius Corp.

Page 8 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

Krupp Polysius Corp.

 Page 9 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Kiln inlet temperature & kiln length

T emp erat u re ki
1 ,3 5 0

1 ,3 0 0

1 ,2 5 0

1 ,2 0 0

1 ,1 5 0

1 ,1 0 0

1 ,0 5 0
9 10 1112
1314
151617
L en g t h / d

Krupp Polysius Corp.

 Page 10 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Kiln dimensioning

Le
n
gt
h/
di
ame
t
er N
u
mb
er
ofki
l
n
K
i
l
n S
y
st
em V
o
lu
me
lo
ad
i
ng
rat
i
o su
p
por
ts
t
pd/
m³ -
L
o
ngK
i
l
n
-
wet 0
,
5..
.
0,7 3
0.
.
.40 5
-6
-
dry 0
,
5..
.0,
9 3
0.
.
.40 5
-6
L
e
po
l 1
,
7..
.2,
2 (
10)
13.
.
.17 (
2)3-
4
G
e
po
l 1
,
5..
2,0 1
5.
.
.17 3
-4
Cy
cl
one
pr
ehe
a
te
r
(
DOPOL
)
1
-
st
age 0
,
7..
.1,
0 2
5.
.
.35 5
-6
2
-
st
age 0
,
8..
.1,
2 2
0.
.
.30 4
-5
3
-
st
age 1
,
5..
.2,
0 1
5.
.
.17 3
-4
4
-
st
age 2
,
0..
.2,
5 (
14)
15.
.
.17 (
2)3-
4
5
-
st
age 2
,
0..
.2,
5 (
14)
15.
.
.17 (
2)3-
4
C
al
cin
erK
il
n (
PREP
OL)
-
Prepo
lA
T (2
..
.6
-s
t
age
) 2
,
5..
.3,
5 (
12,
5)1
4.
.
.17 (
2)3-
4
-
Pre
po
lA
S(
2.
..
6-
st
age
) 4
,
0..
.5,
0 (
11)
12.
.
.15
(
17) 2
-3(
4)

Krupp Polysius Corp.

Page 11 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Degree of filling
C
apacit
y t/
d 2
200
N
om .Ki
ln d
iam et
er m 4,
00
D
i
am eter@ i
nlet m 4
,0
A
- Maß mm 2
600
F
F m m 0
,2
L
e
n gt
h m 48
,0
L
/D-i
nner - 1
2,
63
L
/
D -
outer - 1
2,
00
V
ol
um e l
oadi
ng tp
d/
m ³ 4,
50
K
i
lnFu el k
ca
l
/kgCl
i 340
T
her
m alloa
ding k
ca
l/
m ²
h 3
,
06E
+
006
K
i
lnvolum e m³ 489
F
r
ee crosssecti
on m² 1
0,
18
O
uterSurfa
ce m² 603
R
adi
ation k
ca
l/
kgKl 29
,6
Kil
n Fi
ll
ing
K
i
lnincl
inat
i
on [
% ] 3,
50
K
i
lnspee d [
1/mi
n] 3,
00
P
r
o c
es styp
e A
S
D
egree off
il
ling Proc
es
s [
%] 6,
03
D
egree off
il
ling m ec
ha
ni
cal [
%] 8,
41
D
i
fference(> 1,
5 %) [
%] 2
,
378
Krupp Polysius Corp.
 Page 12 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Rotary kiln design

P
r
oc
es
s-
te
ch
n
ol
ogi
cal
dim
en
s
i
ons

K
i
l
n w
i
t
h c
a
lc
i
ner

K
i
l
n w
i
t
h p
r
eh
ea
t
er

1
0 1
2 1
415 1
7
L/
Dra
t
i
o

N
u
mb
er
ofs
t
at
i
ons
an
dL
/Dr
at
i
o

2
-S
ta
t
i
ons

3
-S
t3
-
a
t
i
oS
nt
a
st
i
ons

1
0 1
2 14 1
7
L
/
Dra
t
i
o

Krupp Polysius Corp.

 Page 13 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Thermal loading [kcal/m2/h] Thermal kiln loading

Millions

Kiln diameter [m]

Krupp Polysius Corp.

 Page 14 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Gas velocity in rotary kiln

14

12

10

L
/
D
=
1
4
,
0
Gasvelocity[m/s]

8 @
1
2
0
0
°
C

6 4,0 4,
tp5d5,
t/m
p
0d³t

2 3 4 5 6 7 8
K iln diame

Krupp Polysius Corp.

 Page 15 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Pyroprocessing\Kiln\kiln_process.ppt
140 TEI, 140 CD

Gas velocity in rotary kiln

14

12

10

@
1
2
0
0
°
C
:
Gasvelocity[m/s]

8 4
,
5
t
p
d
/
m
³

6 L/DL=
/D12,
L=
/D5
14

2 3 4 5 6 7 8
K iln diame

Krupp Polysius Corp.