Suspension Preheater Kilns

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 Suspension Preheaters
1885 Ransome kiln
1934 SP kiln patent
1951-3 First SP kiln
3.2m by 40m for 300 tpd

1959 Total of 10 SP plants

Mid60s -all major suppliers

offer SP kiln systems Blue Circle Training
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Suspension Preheater

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Gas out Material in Gas out Material out

Material out Gas in Material in

Gas in
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Counter current 4
Co-current
 Heat exchange
Gas temp in

Material temp out

Material temp in

Co-current flow counter current flow

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Gas out Material in Gas out Material out

Material out Gas in Material in

Gas in
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Counter current 6
Co-current
 Suspension Preheater
THIS REPLACED BY THIS

Hot Gas

Raw Meal - surface

400 - 500 m2/kg

Raw Meal in

Raw Meal - exposed surface

around 2.7 m2/kg Blue Circle Training Hot Gas

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 Suspension Preheater
Cleaned gas

Cyclone inlet

Vortex finder

Meal to next riser

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Increase velocity = Increased efficiency Increase velocity = Increased pressure drop
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D
o
p
o
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Miag preheater

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G
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P
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 High efficiency
top stage
Preheating

Lower efficiency
stages Calcining - 25 to 30 %
decarbonation

Remaining decarb. plus clinkering

Kiln hearth Blue Circle Training

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 Suspension Preheater
Meal ex. Stage 3
Hearth enlargement
Residence time
Meal pick up
Meal distribution across duct
Meal/gas separation
Limitations

Combustion gas

Meal ex. Stage 4

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Feeding into a riser

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Material short circuit 16
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Feeding into a riser

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Feeding into a riser

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 Suspension Preheater
Poor Heat exchange
Generally due to poor dispersion or short
circuit of material
Dispersion achieved by either
Splash plate (adjustable but prone to wear)

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 Suspension Preheater
Splash box (outside riser but not adjustable)
Short circuiting can be a problem at start-up
when gas velocity is low
Long term solution is to fit a constriction
below the box to accelerate the gas

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 Gas flow into cyclone
Gas short circuit

E from 65 to 85
Saving 15 kcal/kg
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 Suspension Preheater
Deficient heat exchange due to vortex:
If vortex finder is not of sufficient length then
gas can bypass cyclone from inlet to outlet,
carrying heated meal to colder part of process.

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Dip tubes-1

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Dip tubes-2

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 Four stage preheaters: why?
Four stage preheaters: why?

Pressure drop ?

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Widen inlet to
decrease velocity

Slope shelf to reduce

build up

Increase wrap round to

improve gas swirl

Widen diameter of
outlet

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 Pressure drop(mmWG)

% Modern PH
Ex stage 1 860 35 500 (min 300mm)
ex stage 2 540 20 340
ex stage 3 370 20 230
ex stage 4 220 20 130
kiln hearth 50 5 40

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Fifth stage: -25kcal/kg

Sixth stage: -15kcal/kg

Waste gas

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 Drying capacity

Materials moisture % No. of stages

0 to 3 5 or 6
0 to 5 5
0 to 8 4 or 5
0 to 12 3 or 4
12 to 16 2 or 3
16 to 22 1 or 2
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 Five stage
330 - 360 C 310
490
530 - 560 C

630
680 - 720 C

750
800 - 840 C
820
1010 - 1100 C 1000-1100

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Conventional Temperatures
 Volatile components
Boil C Melt C

KCl 1200 740

SO3
NaCl 1200 800
K2O
K2SO4 1690 1075
Na2O
Na2SO4 -- 939
Cl
CaSO4 1350 1295

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 350-400 C

Build-ups
500-550 C

650-700 C

Chloride based build-up

800-850 C

Sulphur based Build-up

1150-1200 C 1500-1600 C

Ash rings
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 TABLE 6 : MELTING & BOILING POINT DATA

Melting Point Boiling Point Dissociation

O O O
C C C

Sodium:
Chloride 800 1440-1465 Over 1200
Sulfate 884
Carbonate 850-854 dissociates
Hydroxide 319-328 1390

Potassium:
Chloride 700-768 1407-1411 Over 1200
Sulfate 1075 1689
Carbonate 894-897 dissociates
Hydroxide 320 1320

Calcium Sulfate 1297 1350

Chloride 2000 5000

K2O 200 650
Na2O 150 200
SO3 200 800

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 Kiln Chemistry
Kiln Volatile Cycles
Reducing atmosphere
Normal Atmosphere
Cl 97-99%
96-99%
SO3 90-100%
60-90%
K2O 30-70%
30-70%
Na2O 20-40%
20-40%
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 What can we do

Quarry
Chemist
Control kiln conditions
Work hard
Blasters
Bleed
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Bleeds

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How can production levels be
increased ?

Bigger fan ?
Reduced pressure drop?
Improved fuel consumption?
Reduce gases from kiln ?

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 Free lime

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 Summary
Range in sizes 300 to 4500tpd
Typical L/D 17:1
4000tpd unit: kiln 6m by 100m
Commonest size about 2000tpd(4.75m by 75m)
Can be one or two string preheaters
Change over around 2000 to 2500tpd, but twin streams do exist as
low as 1500tpd.
Fuel consumption -4 stage: 730 to 800kcal/kg
Fuel consumption -5stage: 700 to 750 kcal/kg

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 Fuel savings/penalties
5th stage -25kcal/kg
6th stage -10 to 15kcal/kg
-4th stage +35kcal/kg
BET+10C: +7 to 10kcal/kg
BEO2 +1%: +5 to 6kcal/kg
front seal +0.1kg/kg: +11 to 14kcal/kg
back end seal +0.1kg/kg:+17 to 20kcal/kg
Bypass +1%: +2.5kcal/kg
Cooler efficiency +10%: -45 to 50kcal/kg

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