Precalciners

Cement Manufacturing Course 2003

by Urs Gasser (CTS)

 Learning Objectives Precalciners

 Understand the principle of precalcination.

 Know the basic precalciner types

 Know the main features of the various precalciner types

 Know the advantages of precalcination

 Understand the principle of low NOx precalciners

 Know possibilities and limits of lump fuel in precalciners

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 Precalciners: Content

Content
 Principle and theoretical aspects
 Precalciner design
 ILC precalciners
 Pre-combustion chambers
 Low NOx precalciners
 Solid AFR in PC: priority and new solutions
 Optimization possibilities
 Main Benefits of Precalciner Technology

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 Energy Balance of Process Steps for Clinker Burning
Endothermic Processes: kJ/kg cli kcal/kgcli
Dehydration of clays 165 40
Decarbonisation of calcite 1990 475
Heat of melting 105 25
Heating of raw materials 2050 490
(0 to 1450 °C)
Total endothermic 4310 1030
Exothermic Processes: kJ/kg cli kcal/kgcli
Recrystallistion of dehydrated clay 40 10
Heat of formation of clinker minerals 420 100
Crystallisation of melt 105 25
Cooling of clinker 1400 335
Cooling of CO2 (ex calcite) 500 120
Cooling and condensation of H2O 85 20
Total exothermic 2550 610
Net Theor. Heat of Clinker Formation: kJ/kg cli kcal/kgcli
Endothermic - exothermic 1760 420
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 AT (Air Through) and AS (Air Separate)

Definitions:
PA = Primary Air
SA = Secondary Air
TA = Tertiary Air

TA
PA SA PA

SA

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 Precalciner – Preheater Arrangements
1 or 2 strings 2 strings only

In-Line Off-Line Pre-Combustion Hybrid Separate Line

Chamber
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 Comparison of Calciner Arrangements

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 Requirements I

 Process:
High calcination degree
Good control of calcination degree
No material drop-out (meal, ashes etc)
No build-ups on walls
Simple and rapid start-up procedure
Forgiving operating behaviour
Flexibility regarding fuel ratio BZ / PC
Safe regarding equipment overheating
Minimum primary air requirement
Minimum pressure drop

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 Requirements II

 Combustion:
High burnout degree of fuels
Best mixing of air (O2) with fuel
Instant ignition of all fuels
Direct return of fuel residues to kiln
Optimum combustion monitoring / control
 Fuels:
Suitable for all fuel types (high flexibility)
Insensitive to changes of mix of fuels
Suitable for low reactivity and toxic fuels

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 Requirements III

 Emissions:
Reduction of pollutants from BZ
No (low) generation of pollutants in PC firing
Possibility for SNCR
 Tertiary Air System:
No dust deposits and dust cycles
No hot dust handling
Reliable O2-control for BZ and PC firing
 Design:
Easy integration in preheater
Stepwise upgrading possible

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 Precalciner Control

 Via Fuel Rate

Normally 45% to 60% of total fuel
 According to Calcination Degree
of bottom cyclone hot meal (via LOI);
Normally 85% to 95% apparent calcination degree
 According to Gas Temperature at exit of bottom
cyclone;
Normally 840°C to 890°C

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 True and Apparent Calcination Degree
 True calcination degree:
Degree to which the calcination is completed, i.e. extent
to which the CO2 is dissociated from the CaCO3.
Extremes: Raw meal 0% (LOI=35%)
Clinker 100% (LOI= 0%)
 Apparent calcination degree:
The calcination degree determined from a hot meal
sample taken from the meal duct of the bottom cyclone

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 O2 Control for PC/BZ: Tertiary Air Damper
pID fan

pC5 exit

Var.p1

p2

~pamb 13
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O2 Control for PC/BZ: Kiln Riser Orifice
pID fan

pC5 exit
~pamb

p1

Var.p2
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 Precalciner Elements
 Long tubes “gooseneck type”
 Large volume “vessel type”
 Tertiary air frontal impact
 Tertiary air tangential inlet
 Orifice
 Bends, curves and vessels
 Multiple burners
 Hot spot with and without control
 Precombustion chamber

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 Dimensioning Criteria for Precalciners
1. Gas Retention Time (for combustion in pure air)
decisive for complete combustion
Fuel Reactivity Gas Retention Time
low > 3.5 sec
medium > 2.5 sec
high > 2.0 sec

2. Meal Retention Time Fuel Reactivity Examples:

decisive for complete calcination Low: Petrol coke
Medium: Bituminous coal, natural gas
Actual meal retention times are 6 to 12 seconds,
High: Lignite, fuel oil
at the above gas retention times.

Calcination takes much less than that which Inline Calciners:

means that meal retention time is not a Due to less favourable conditions for combustion
(presence of kiln gas, imperfect mixing of
decisive design criteria.
tertiary air with kiln gas), the following rule of
thumb can be used for sizing this PC type:

Recommended gas retention time + 0.5 to 1 sec

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 Standard Precalciners
In-Line and Off-Line AT

FLS, KHD, KSL, Polysius

 In-Line Calciners I

Polysius PREPOL
gooseneck type
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 In-Line Calciners II

FLS ILC
controlled hot spot
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 Pre-Combustion Chambers

RSP (Technip), FCB, Polysius, FLS

 Calciners with Precombustion Chambers I

Onoda / CLE RSP (~1985)

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 Calciners with Precombustion Chambers II

FLS SLC-D
Downdraft (~2000)
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 Low NOx Precalciners

FLS, KHD, Polysius a.o.

 Low NOx Precalciners

Polysius PREPOL
MSC KHD PYROCLON
(Multi Stage Combustion) Low NOx-Topair
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 Precalciners for Lump Fuels
(Tires etc): Future Development

FLS, Polysius, KHD,

Blue Circle, Ash Grove
 PC for Solid AFR: FLS Hot Disc

FLS
Hot Disc
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 PC for Solid AFR: BC-Lafarge AFR Ram

Ash Grove
Controlled Ram for AFR modules
(Patent 2001)
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 Pre-Calciner: Typical Problems

1) CO at outlet
5) Material
of PC or cyclone
build-ups

6) Refractory
2) Locally too damage
high temp.

7) Tertiary air
3) Unburnt fuel damper failure
particles in
hot meal
8) Tertiary air duct
blockage
4) Too high / low (elbow type only)
calcination
degree
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 Main Benefits of Precalciner Technology
1. More stable kiln operation due to better kiln control via two separate
fuel feed/control points
2. More stable kiln operation due to controlled meal conditions at kiln inlet
3. Reduced thermal load of burning zone
4. Lower refractory consumption as a result of 1. to 3.
5. More than double capacities possible with given kiln (10'000 t/d: 6 x
95m)
6. Possibility of increasing capacity of existing kilns
7. Reduced volatilisation of circulating elements
8. Reduction of cycles (S, Cl, Na2O, K2O) with lower bypass rate / losses
9. Makes short kilns possible with 2 stations, L/D < 12
10. Possibilities of NOx reduction
11. Lump fuel (AFR) utilization (in-line only)
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