Cemeng Pyro Processors

For clinker production in a Cement Plant

D S Venkatesh, Freelance Industrial Consultant
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We have to think out of box solutions to simplify the entire pyro processing system to reduce the
inter-material transfers, purge air leakages to maximum extent, reduce the amount of cooling air,
avoid excess air and limit the addition of auxiliary equipment far as possible. Cemeng Pyro Calciner
is one such innovative approach that needs attention from Pyro processing industries, especially
Cement plants.
1.0 Introduction:
Cement plants have pioneered over decades to graduate to the present level of employing suspension
preheater/precalciner, along with short rotary kiln and latest generation of clinker grate coolers with several
fans achieving high thermal efficiency and enhanced clinker output. However, additional auxiliary
equipment have to be installed to condition the exhaust gases and excess air to meet stringent
environmental standards and to harness waste heat from these sources involving higher investment . In
addition, maintaining these auxiliary equipment in efficient working condition calls for a lot of operational
expenditure. While Rotary kiln proper has reached a higher level of optimization, there is room for
improvement in the preheater/precalciner and clinker cooler equipment Cemeng Pyro Calciner described
here is an innovative approach that needs attention from Pyro processing industries, especially Cement
plants.

2.0 Cemeng Pyro Processor:

Cemeng Pyro Processor is a novel concept of a rotary kiln integrated with reverse pitch spirals, stationary
or rotating, within an insulating heat resisting planetary cellular lining and an inner working refractory
layer forming two contiguous concentric cylindrical surfaces extending from feed end to the discharge end
of the unit. The insulating cellular lining will serve as cooler for clinker and made of calcium silicate or
heat resisting steels of different grades to resist abrasion and wear. Generally the thickness of work
refractory will be between 180 to 220 mm and the height of planetary cells will be 400 to 600 mm
depending upon kiln diameter. Whenever required, the external surface of the Pyro Processor is air or water
cooled without affecting the process air flow through the cooler and rotary kiln.
As in case of planetary coolers, the number of cells circumferentially is varied to suit the clinker output,
with one or two spirals in each cellular row... The radial walls of cells are cut out to allow flow of clinker
from one row of cells to the next row, if so required, to result in uniform clinker distribution to every row.
The reverse pitch spiral provides a central open circular area of approximately one-third its diameter. This
results in higher retention time as also higher output and cooling efficiency. A heavy duty chain drive with
multi-sprockets arrangement is employed to drive the spirals simultaneously...

Schematics of Cemeng Pyro Processor and Heat transfer in Rotary kiln

The cooling air can be admitted at both ends for increased heat capture and bettering cooler efficiency. The
air pipe within the spiral acts as additional heat exchanger, and the hot air flowing within the pipe is
directed to inside of the rotary kiln after the burning zone to provide additional heat for pre calcination.
The required cooling air is admitted from a stationary Air Chamber cum clinker discharge hood. . The
discharge hood will have leaf spring sealing arrangement.

Detail of Shaftless Spiral functioning within Planetary Cells

The feed and discharge ends of the Pyro processor are similar: The Planetary cells, in this zone, have no
radial walls, thus forming a circular trough to receive the hot clinker and slides as a bed without any lift up.
Discharge openings are thus kept minimal in the steel shell. Air chamber cum discharge hood, as explained
above, is located over the openings. At the burner end, these openings are fitted with bolt on covers,
envelopes the openings at the burner end where the clinker enters the cooler cells, the discharge openings
are provided with quick opening covers to discharge any oversize clinker pieces whenever required. The
processor shell can be externally cooled by blowing ambient air alternatively water spray can also be
carried out.
The only wearable part of the planetary cells would be spirals. As the speed is low, the wear rate shall also
be low thus providing long life. In case of any need for replacement, the spiral in a particular planetary cells
row can be replaced easily by withdrawing from, especially, the burner end. As usual both the kiln ends are
open through which maintenance within can be carried out.
3.0 Sizing of Pyro Processor:
As is known, a rotary cooler will be of similar volume as that of short rotary kiln. This means that the Pyro
Processor corresponds to twice the volume of rotary kiln. As the Pyro Processor divides the clinker stream
just as in case of Planetary Coolers, Pyro Processors are sized with specific volume rates of 3 to 4t/d per
cum of cooler volume based on the annulus i.e. Planetary cells height with various internals to achieve
clinker discharge temperature below 200 deg C. Unit volume of air in nm3/kg clinker and the retention time
are two relevant factors to be considered in sizing the Pyro Processor. The increased diameter of the Pyro
Processor will provide the necessary structural rigidity to enable employ only two supporting stations, but
yet achieve longer rotary kiln length similar to that of a conventional 3 support kiln arrangement.

Selection of Cemeng Pyro Processor

Pyro Diaxlg
m
3.8 x 41
4.0 x 43
4.2 x46
4.4 x 48
4.6 x50
4.8 x52
5.0 x55
5.2 x 57
5.4 x60
5.6 x 63
5.8 x65

Kiln Diaxlg
m
3.0 x 41
3.2 x 43
3.4 x46
3.6 x 48
3.8 x 50
4.0 x 52
4.2 x 55
4.4 x 57
4.6 x60
4.8 x 63
5.0 x 65

Kiln Refract.
lining, mm
180
180
180
200
200
200
200
200
220
220
220

Kiln Crosssectional load

182.7
189.4
192.9
211.4
220.3
235.8
246.9
262.6
279.6
294.7
306.1

Drive KW
Installed
240
300
370
440
540
2 x 315
2 x 390
2 x 440
2 x 520
2 x 610
2 x 720

Production,
tpd
1000
1200
1400
1700
2000
2400
2800
3300
3800
4400
5000

Slope of the Pyro Processor: 3.5 %. Kiln speed: 3.55rev/min The Drive KW is likely to be lower than
indicated. If necessary, next higher pyro diameter can be employed with kiln of lower diameter, say
instead of 3.8 x 41 we can employ 4.0 x41 along with 3.0 x 41 m lg kiln.

Achieve the benefit of a 3-support rotary kiln with a 2-support Cemeng Rotary Pyro Processor
4.0 Cemeng Pyro Processor with Preheater/Precalciner:
Cemeng Pyro Processor has versatility with respect to clinker output, as it can be integrated with
conventional Cyclone Preheater/Precalciner for pre calcination and the kiln furnace capacity can be fully
utilized for enhanced output. Especially, it would be advantageous to employ Cemeng Dragon Calciner
along with Cemeng Pyro Processor set up: The fuel required for calcination and the air for combustion will
not pass through the Pyro Processor, which is the main advantage. The required fuel can form part of raw
meal and the required air can be blown via the tubular heat exchanger incorporated with the Dragon
Calciner. A multi-stage blower (instead of a Roots Blower) can pump the conveying air through the heat
exchanger to carry raw meal and the raw meal borne hot air passes through the dragon calciner .At the
discharge end of the Calciner, we have precalcined material and this is fed into the Pyro Processor. The
indirect and direct heat transfer affected in the Dragon Calciner results in higher thermal efficiency and thus
lowers specific fuel consumption. There is no additional burner required. As can be seen, the dragon pipes

arrangement can be duplicated by perpendicular inlay of the pipes without the need for enlarging the
dimensions of the Dragon Calciner.

Schematics of Dragon Calciner with Kiln Inlet and Burner Ends of Pyro Processor:
In view of the clinker discharge nearer the kiln feed end, the exhaust gases from the Cemeng Dragon
Calciner set up can be partially recycled to act as cooling gas, as the heat carrying capacity of exhaust gases
are higher than that of ambient air. However, partial pressure of CO2 has to be balanced with external air
5.0 Advantages of Cemeng Pyro Calciner:

Cemeng Pyro Processor can be either girth gear driven or by friction drive.
Process fans are minimal and have variable speed drives.
Reverse flow spirals can be stationary or driven by chain and sprocket drive
Inlet and Burner ends are similar, as also the Air chamber cum clinker discharge hoods.
Cemeng Pyro Processor has only two supporting roller stations close to ground level
Does not require heavy foundations and requires least civil engineering works.
The foot print of the unit is minimal
Least number of material transfer points and handling equipment.
Minimal gas/air ductings reducing pressure drops and insulation.
Clinker discharge temperature is controlled as required.
Improved specific fuel consumption due to high thermal efficiency
Recycling of Preheater/Precalciner exhaust for clinker cooling made simple

6.0 Summary:
Cemeng Pyro Processors can replace industrial processes wherever the rotary kiln and cooler systems with
Multi-auxilary equipment are employed for reducing investment and achieves enhanced thermal efficiency.
We can provide required technical know-how and manufacturing drawings to machinery manufacturers,
cement, lime and other mineral based industries.

Please refer your specific enquiry to:

D.S. Venkatesh,
Freelance Industrial Consultant,

# 682, 17th Cross, Phase 6, J P Nagar, Bangalore 560078

E-mail: dsvenkatesh40@yahoo.com /dsvenkatesh40@gmail.com