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 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
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 Prehater CalcinerPrehater
2 6 7 0
Krupp Polysius Corp.
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
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 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
Krupp Polysius Corp.
Le ng
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 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
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
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
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 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
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 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
Krupp Polysius Corp.
Page 13
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]
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
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
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
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.
