CemNet Training - Course CKPC01

Module 3 - Introduction

Cement Kiln
Process Chemistry
Module 3. Emissions from cement kilns.
3.1 Module 3 - Introduction.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
This attention on kiln emissions
has in part been invited by the
trend to burn alternative fuels in
cement kilns.. ..the same
emissions standards are applied to
cement kilns as incinerators,
despite the different operating
conditions.
Concerns regarding dioxin, furan, mercury and other
heavy metal emissions arise from the trend towards
burning alternative fuels.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
This attention on kiln emissions
has in part been invited by the
trend to burn alternative fuels in
cement kilns..
The normal levels of dioxin, furan
and mercury emission from cement
kilns are minimal. . but if alternative fuels are
going to be burnt then knowledge of the mechanism of their
formation and how to minimise their likelihood is required.

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com

CemNet Training - Course CKPC01

Cement Kiln Chemistry

Module 3 - Introduction

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
Most cement manufacturers will
be aware of the possible global
warming implications of the
CO2 emissions from cement
kilns.. ..in Europe this is at
the top of the agenda due to the
EU Emissions Trading Scheme.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
Current CO2 reduction strategies
involve improved energy
efficiency, replacement of fossil
fuels with biomass fuels and
production of blended cements to
reduce the clinker content of
cement..
.all these will reduce CO2 emissions
and will enable the obligations under the Kyoto protocol to
2012 to be satisfied. .these strategies are not
unpopular because they also reduce costs or increase
revenues for cement companies.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
Current CO2 reduction strategies
involve improved energy
efficiency, replacement of fossil
fuels with biomass fuels and
production of blended cements to
reduce the clinker content of
cement..
.but what about beyond Kyoto?
.when further reductions in CO2 emission from
cement clinker manufacture will require the application of
very expensive technologies?

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com

CemNet Training - Course CKPC01

Cement Kiln Chemistry

Module 3 - Introduction

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
Deforestation and the death of
lakes brought about by acid rain
.coupled with
..
pollution caused by photochemical
smog .have heightened
awareness of the dangers of the
acid gas emissions NOx and SOx.
The deployment of ever more expensive technologies
to reduce or mitigate against NOx and SOx emissions
is demanded of the cement industry.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
Increased environmental
awareness by the public at large
has heightened concerns with any
cement factory emissions plume
.. .explaining this away as
the condensation of water vapour
may not be accepted as
satisfactory .particularly if a haze is visible beyond
the steam plume.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
Increased environmental
awareness by the public at large
has heightened concerns with any
cement factory emissions plume
.. .of course dust emissions
have long been associated with
.although modern electrostatic
cement manufacture
precipitators and bag houses are capable of reducing dust
emissions to a few milligrams per Nm3 of cement kiln exhaust.

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com

CemNet Training - Course CKPC01

Cement Kiln Chemistry

Module 3 - Introduction

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
Increased environmental
awareness by the public at large
has heightened concerns with any
cement factory emissions plume
.. .of course dust emissions
have long been associated with
.in this cement kiln chemistry
cement manufacture
course we will primarily focus on the gaseous emissions from
cement kilns. .although there are chemistry related
issues with the dust and dust handling.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The dust collected from the kiln
exhaust gases has escaped from the
preheater of a modern cement kiln
.. .it is the finest fraction of
the kiln feed which is the most
difficult for the preheater cyclones
to collect.
.this physical separation means that the
dust almost inevitably has a different composition to the kiln
feed.usually it is higher in lime saturation as the silica
concentrates in the coarser fractions of the kiln feed.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The dust collected from the kiln
exhaust gases has escaped from the
preheater of a modern cement kiln
.. .it is the finest fraction of
the kiln feed which is the most
difficult for the preheater cyclones
to collect.
.this physical separation means that the
dust almost inevitably has a different composition to the kiln
feed.where raw materials are dried in a drum dryer
behind the kiln this may not be the case.

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com

CemNet Training - Course CKPC01

Cement Kiln Chemistry

Module 3 - Introduction

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The handling of the dust can
therefore affect the variability of
the kiln feed .. .if added to
the homogenisation silo then the
affect of a layer of dust in the silo
when the raw mill is stopped must
be considered. .returning directly to kiln feed avoids
this problem, but raises concerns of feeding two streams of
material to the kiln .homogenised raw mill product
and dust direct from the collection equipment.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
As cement manufacturing chemists
we must remember that we cannot
create mass .. .whatever
chemical components enter the
system in the raw materials fed to
the raw mill and the fuels .
.must exit the system in the clinker or as gases in the
.the composition of the kiln feed is not
exhausts
important as it contains raw mill product plus the dust
and is the composite material in the external cycle.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
As cement manufacturing chemists
we must remember that we cannot
create mass .. .whatever
chemical components enter the
system in the raw materials fed to
the raw mill and the fuels .
.must exit the system in the clinker or as gases in the
.the inputs to the mass balance are the
exhausts
raw materials and the fuels .chemistry control
should focus on the raw materials and raw mill
product, not the composite including the dust.

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com

CemNet Training - Course CKPC01

Cement Kiln Chemistry

Module 3 - Introduction

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
We saw in session 1.7 that the
alkalis and particularly chlorides
can build up in an external cycle
between the preheater and the dust
collector.
This concentration of alkalis in the
dust affects the performance of
electrostatic precipitators and
baghouses.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The efficiency of electrostatic
precipitators is dependent on the
resistivity of the dust to be
collected.. .among
many other things.
High alkali dust are more difficult to collectmeaning
that the dust from different banks of electrostatic precipitators
may have different alkali contents as the easier to precipitate
low alkali dusts are collected first.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The efficiency of electrostatic
precipitators is dependent on the
resistivity of the dust to be
collected.. .among
many other things.
High alkali dust are more difficult to collecton long
kilns this has been used as a means to selectively extract
alkalis from the process... only the dust from the
final bank of the precipitator was rejected with the dust from
the other banks recycled to the process.

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com

CemNet Training - Course CKPC01

Cement Kiln Chemistry

Module 3 - Introduction

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The efficiency of electrostatic
precipitators is dependent on the
resistivity of the dust to be
collected.. .among
many other things.
If any course participants have analyses of dust from different
banks of their precipitators it would be interesting to see the
results and verify if this affect is present.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The efficiency of baghouses is also
affected by properties of the dust
to be collected..in this case
the hygroscopic characteristics of
high alkali dusts is the concern and
the danger of bags becoming
blinded by the dust absorbing
water vapour.
Thats all we will say regarding dust, we will be focusing
on the gaseous emissions from cement kilns in the
remainder of the course.

Cement Kiln Chemistry

3.1 Introduction

In module 3 of the course we are going to focus on the emissions

a subject which is attracting as
from cement kilns
much attention as energy efficiency, productivity and clinker quality
is many parts of the world.
The efficiency of baghouses is also
affected by properties of the dust
to be collected..in this case
the hygroscopic characteristics of
high alkali dusts is the concern and
the danger of bags becoming
blinded by the dust absorbing
water vapour.
Again I would suggest completion of Quiz 3.1 as a
first step and then repeating later to gauge how
much you have learned from the course.

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com

CemNet Training - Course CKPC01

Module 3 - Introduction

Cement Kiln
Process Chemistry
Module 3. Emissions from cement kilns.
3.1 Module 3 - Introduction.

This document is for the sole use of students enrolled on course CKPC01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd
http://Training.CemNet.com