Professional Documents
Culture Documents
By Dr Y C Naidu
Precalcination
Definition Precalcination is the addition of a second firing point and combustion chamber at the base of preheater with separate ducting of hot air from clinker cooler through Tertiary air duct.
Precalcination
Definition Precalcination is the addition of a second firing point and combustion chamber at the base of preheater with separate ducting of hot air from clinker cooler through Tertiary air duct.
Factors Influencing the Decarbonation Rate Temperature Heat Transfer Area Mineral Composition
Factors Influencing the Combustion of Coal Surface area of the coal particle Volatile matter of the coal Partial pressure of oxygen
In a typical precalciner both combustion and decarbonation are occurring simultaneously. Rate of combustion and rate decarbonation influence each other. of
Raw meal is suspended in a rising stream of hot gases resulting from combustion.
Calcination at Constant Temperature It is critical to regulate the temperature. Cement plants employ a PID loop between precalciner temperature and coal feed rate. Precalciner temperature is controlled at 5C.
The quantity of fuel fired in the kiln is therefore is independent of variation in the kiln output. The heat requirement for entire production are met by increasing fuel to the precalciner. Maintain constant precalciner temperature through PID controller at varying output
Air Control
PH air by rpm Cooler vent air by rpm
Mechanical control
Kiln rpm
TEMPERATURE PROFILE OF HUMBOLDT KILN SYSTEM WITH PYROCLON LOW NOX CALCINER
Cooler Control
Cooling fan air volumes Cooler strokes Cooler bed through speed of grates Air Blasters
* Bed thickness, mm
* Grate width loading, tpd/m
CONSIDERATIONS FOR PROCESS DESIGN OF GRATE COOLER For given clinker to recuperation air (secondary air + tertiary air) ratio in terms of Nm3/Kgcl heat recuperation depends on * bed depth * average cooling air velocity through grate (m3/m2/min) * air distribution over the grate. Higher the clinker temperature, maintaining higher bed depth and higher cooling air velocity will increase heat recuperation. For given average air velocity and distribution over the grate limiting clinker bed height exists beyond which further heating of air does not take place. Contd..
Contd.. Compartmentalization to prevent excessive shot circuiting through cooled clinker on downstream side. Minimum cooling air velocity required to prevent thermal over - loading and over heating of grate. Cooling air should not fluidize clinker or form blow chimneys. High bed thickness, high clinker temperature and high air velocity require high air pressure. Very high air pressure can lead to leakages through gaps between grates and side walls etc. Temperature of clinker leaving the cooler depends on downstream equipment safety.
: 500 mm
: 700 mm
: 800 mm
FAN PRESSURES
Fan pressures for conventional coolers: First fan Last fan : : 750 mmWG 300 mmWG
First fan
1000 mmWG
Red River
- Narrow stream of uncooled red hot fine clinker flowing down the cooler.
- Red river occurs due to uneven depth and size segregation of clinker across the width of cooler resulting in :
* Diversion of cooling air through bed of coarse clinker and less bed thickness. Fluidisation of fine clinker and air slide effect.
Snowman Formation
Discharge of sticky clinker containing residual liquid from kiln causing buildup at cooler inlet. Clinker with relatively high content of alkali or sulphate.