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Principle of Precalciners , Precalciner types , Main Feature of Precalciner , advantages of Precalcination

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

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

Energy Balance of Process Steps for Clinker Burning

AT (Air Through) and AS (Air Separate)

Definitions:

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

Precalciner – Preheater Arrangements

Comparison of Calciner Arrangements

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
• 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
• 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

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

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

O2 Control for PC/BZ: Tertiary Air Damper

O2 Control for PC/BZ: Kiln Riser Orifice

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

Standard Precalciners In-Line and Off-Line AT

FLS, KHD, KSL, Polysius

In-Line Calciners I

In-Line Calciners II

Pre-Combustion Chambers

RSP (Technip), FCB, Polysius, FLS

Calciners with Precombustion Chambers I

Calciners with Precombustion Chambers II

Polysius PREPOL MSC (Multi Stage Combustion)

KHD PYROCLON Low NOx-Topair

FLS, KHD, Polysius a.o.

Precalciners for Lump Fuels(Tires etc): Future Development

PC for Solid AFR: FLS Hot Disc

PC for Solid AFR: BC-Lafarge AFR Ram

Precalciner Video Animation

Tire Skewer for  Cement Kilns

Dimensioning Criteria for Precalciners

Main Benefits of Precalciner Technology