Process Optimization-Pyrosection

© Confederation of Indian Industry

 Contents
 About Preheater system
 Pressure drop and velocity profile across Preheater
 Challenges in Pyrosection
 Concept of minimum air combustion
 Concept of excess of air
 Heat loss due to CO
 Importance of recuperation air
 Impact of secondary air on Flame
 Burner pipe centering methodology
 Challenges in cooler operation
© Confederation of Indian Industry
 Contents
 Cooler efficiency calculations
 Energy balance across cooler
 Cooler efficiency curve
 Function of MFR (Cross Bar)
 Conada Effect in IKN
 CFD Study
 Thermal efficiency Calculations
 Low NOx burners
 Latest development in cyclones
© Confederation of Indian Industry
 Contents
 Raw mix & Importance of liquid phase
 Kiln challenges during petcoke operation
 Important Case Studies
 Thumb rules
 Key points

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 Preheater Systems
 Reduction of losses in Preheater system
 No of stages – By design
 Operation of Preheater – Air infiltration

 Number of stages
 4 stages – 725 kcal/kg
 5 stages – 700 kcal/kg
 6 stages – 685 kcal/kg

© Confederation of Indian Industry

 Beauty of PH system ..

 PH – Basically meant for Heat Recovery

 80% in Ducts
 20% in Cyclones

 Why not have a long duct & 1 Cyclone ?

© Confederation of Indian Industry

 Beauty of PH system ..
 PH System – Heat Recovery
 Co-current – Ducts
 Counter Current – Cyclones (Little !!)
 Key Attributes
 Overall – Counter current
 Stage wise – Co-current
 Material to next stage – Encounters higher
temperature air !!

© Confederation of Indian Industry

 Pre-heaters
 Latest pre-heaters are designed with high efficiency low
pressure drop cyclones and efficient heat transfer
 Minimum observed pressure drop in PH tower
 470 mmwg for 6 stage pre-heater

 Best observed top stage cyclone efficiency-97%

 Lowest observed pre-heater exit temperature- 245 0C
 Minimum observed false air in pre-heater- 5%

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 Pressure drop & Velocity profile Across Preheater

Temp-259 degree C Kiln Feed

-457 mmwg-Top Temp-416

Duct velocity-17 m/s 1
degree C

Temp-418 degree C 2 -373 mmwg-2nd

O2-5% -365 mmwg-3rd
Temp-794
3 Temp-650 degree
Fan Inlet degree C C
4
pressure-500 -221 mmwg-5th -323 mmwg-4th
mmwg PH FAN 5
O2-2.5% Temp-923 degree
C
6
-161 mmwg-6th
Calcine
r

kiln
© Confederation of Indian Industry
How to Calculate pressure Drop across preheater?
 Pressure drop across 6th stage-5th Stage
= (-161)-(-221)
= 60 mmwg To be
corrected
 Similarly for other cyclones by CFD
Temp-418 degree C Study
 6th -5th=60 mmwg
-365 mmwg-3rd
 5th-4th =102 mmwg
Some thing wrong-
 4th-3rd = 42 mmwg No heat transfer

 3rd -2nd = 8mmwg………………… Temp-416 degree C

-373 mmwg-2nd
 2nd-1st=84 mmwg
 Total pressure drop=296 mmwg+161=457 mmwg
 Acceptable pressure drop across latest cyclones=50-60 mmwg
© Confederation of Indian Industry
How much saving by reducing pressure drop across
Preheater?

 Fan inlet Pressure = -530 mmwg

 Fan outlet = -45 mmwg
 Electrical power = 1500 kW
Reduction in Pressure drop = 50 mmwg
Saving = 50 X1500
(-45)-(-530)
= 154 kW
Therefore, checking the pressure profiling across the preheater
is very important activity.

© Confederation of Indian Industry

 Velocity Profile Across Pyro section
 Riser Duct:-80% heat transfer takes place
 15-17 m/sec
 Down comer duct
 15-17 m/s
 TAD duct
 25 m/s
 Hood & cooler grate
 5 m/s
 Under cooler bull nose
 15 m/s
 Burning zone-9.5 m/s© Confederation of Indian Industry
FEW MAJOR PROBLEMS IN PYRO PROCESS

 High Pre-heater fan power consumption

 High Pre-heater cyclones pressure drop
 High specific fuel consumption
 High Cooler loss
 Difference in Clinker Quality

© Confederation of Indian Industry

 PROBLEMS IN PYRO PROCESS

1. High Pre-heater fan power consumption

Reasons :-
 Low Fan efficiency
 High pre-heater pressure drop
 High dust recirculation
 High False entry (excess air)

© Confederation of Indian Industry

 PROBLEMS IN PYRO PROCESS

2. High Pre-heater Cyclone Pressure drop

Reasons :-
 Basic design
 Coating or material accumulation
 High velocity or flow
 Cyclone Erection made to suit at site
 Improper gas distribution

© Confederation of Indian Industry

 PROBLEMS IN PYRO PROCESS
3. High Specific fuel consumption
Reasons :-
 Change in quality of fuel
 Low Cooler efficiency
 Low heat recuperation
4. High Cooler loss
Reasons :-
 Low heat recuperation

© Confederation of Indian Industry

 Parameters Affecting SEC of PH fan

 Pressure drop across preheater of Fan

 Depend upon no of stages
 Best observed value 470 mmwg for 6 stage
 Fan efficiency
 Fan design and operating parameters
 Losses in speed Control
• VFD : 98% efficiency
• SPRS : 95% efficiency
• GRR : 90% efficiency

Lowest observed SEC of PH fan : 3.81 kWh/MT clk

© Confederation of Indian Industry

 Low Pressure Drop Cyclones
 Typical pressure drops - Latest PH with PC
 4 Stage – 310 to 360 mmwg
 5 Stage – 350 to 400 mmwg
 6 Stage – 450 mmwg

© Confederation of Indian Industry

 Heat Losses in Pre-heater exit gas

Factor affecting the Heat loss in PH exit gas

 PH EXIT GAS VOLUME- Depends upon the gas temp. &
false air infiltration
• Best observed value : 1.37 Nm3/kg clinker

 PH EXIT GAS TEMP.- Depends upon the PH heat transfer

efficiency
• Best observed value : 245 0C

Lowest observed heat loss in PH exit gas : 120 kcal/kg clk

© Confederation of Indian Industry
 How to calculate minimum air for
combustion?
 Lmin = 1.293 X (32/12 x % C + 16/2 x %H -% O +%S + 32/14 x %N)
1.429 x 21
Lmin = Kg air/kg Fuel
How to convert Kg air/kg fuel into Nm3/kg fuel?
Dividing by 1.29 kg/Nm3
Sample calculation:-
C-85.8%
Hydrogen-11%
Oxygen:-0.4%
Nitrogen:-0.8%
© Confederation of Indian Industry
Sulphur:-2%
 How to calculate minimum air for
combustion?
 Lmin = 1.293 X (32/12 x 85.8 + 16/2 x 11 -0.4+2+ 32/14 x 0.8)
1.429 x21
Lmin = Kg air/kg Fuel
= 13.76 kg air/kg fuel
Nm3/fuel = 13.76/1.29
= 10.66 Nm3/kg fuel

© Confederation of Indian Industry

 Lmin Values for different types of Coal(kg/1000 kcal)
Lignite :- 1.388
Bituminous :- 1.398
Anthracite :- 1.412
Petcoke : 1.407
Diesel : 1.408
Lmin Flow = Lmin x Heat consumption x Production per dayx1000
24 x 1000
Heat Consumption = kcal/kg clinker
Production = TPD
Lmin Flow = kg/hr
© Confederation of Indian Industry
 Excess Air Concept
 Air requirement for complete combustion process across the
pyro section is 10 percent of Lmin .
For example :-Pet coke
Air Requirement = 1.10 X 1.407
= 1.54 kg air/1000 kcal
For anthracite coal:-
= 1.41x1.10
= 1.55
Note:-But generally due to Sulphur dilution ,the amount of excess
air is increased in the case of pet coke.
© Confederation of Indian Industry
Excess Air Concept

© Confederation of Indian Industry

 Standard Values
 Kiln Inlet :- 2% O2
 Calciner Outlet :- 2% O2
 Preheater outlet :- 3-4% O2
 Preheater Flow :- 1.30-1.50 Nm3/kg Clinker in case of normal coal

:- 1.45-1.55 Nm3/kg clinker in case of pet coke

Recuperation Air :- 0.75 Nm3/kg Clinker for normal coal
:- 0.80 Nm3/kg Clinker for pet coke

© Confederation of Indian Industry

 Excess Air Calculation
 How to find excess air?(approximate & when CO formation is min)
= O2 percentage X 100
21 –O2 percentage
= (5/21-5) x100
= 31.25%
Oxygen :-2% at kiln inlet –Find excess air?
= (2/21-2) X100
= 10.52%

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Heat loss due to excess Air

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 Numerical No1
Heat Loss due to excess Air
 Preheater gas flow = 1.30 Nm3/kg clinker
 Excess air = 10%
 Then Volume:
= 1.10 x 1.30
= 1.43 Nm3/kg clinker
= 1.43-1.30
= 0.13 Nm3/kg clinker
Preheater gas temp-250 degree C
= 0.13x1.42x0.23x250
= 10.60 kcal/kg clinker loss
© Confederation of Indian Industry
 Heat loss due to CO formation?
C + O2 – CO2 + 8084 kCals/kg of Carbon

2C + O2 – 2 CO + 2430 kCals/kg of Carbon

2H2 + O2 – 2H2O + 28,922 kCals/kg of Hydrogen

S + O2 - SO2 + 2,224 kCals/kg of Sulphur

 Each kilogram of CO formed means a loss of 5654 kCal of

heat (8084 – 2430)

© Confederation of Indian Industry

 Importance of Recuperation Air
 Recuperation Air:-Secondary Air + Tertiary Air
 Secondary Air:-
 It is the main part of the combustion air (85 – 95% of total
air fed).
 Flame direction is usually affected by the buoyancy of
secondary air.
 Lower temperature of secondary air causes increase in
velocity of secondary air as a consequent the mixing of
air with coal is in efficient which makes the lengthy flame.

© Confederation of Indian Industry

Which is the correct flame?

Flame no1

Flame No2

Flame No3

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 Which is the correct flame?
Long Flame, unstable coating, high back end
Flame no1
temp, low shell temperature

Short Intense divergent flame, low back end

Flame no2
temp, high shell temperature, poor refractory
life, good for burning

Convergent flame, low shell temperature,

Flame no3 good refractory life, good for burning, stable
coating.

Flame no3 is the correct one

© Confederation of Indian Industry

Effect of Secondary Air on Flame

© Confederation of Indian Industry

Impact of Secondary Air velocity on flame length

 Higher the secondary Velocity

longer is the flame, hence to
increase the flame momentum by
increasing primary air velocity at the
burner tip as a result the overall
heat consumption would be
increased.

© Confederation of Indian Industry

 Impact of Secondary Air velocity on
flame length
Q = A XV
Q is directly proportional to V as a result Q will be increased
and finally affects the heat consumption
 Higher secondary air velocity that causes the lower the hot
air pressure region, therefore, we have to increase the
pressure drop at the tip to pull back more secondary air
towards the flame.
 Secondary Air Velocity:-5-6 m/s

© Confederation of Indian Industry

 Burner Pipe Centering

 Position 7,4,1,2& 3 are away from

material inside the kiln.

 Position 9 & 8 are very close to the

charge.

 Only 5 is close to the material as well

as with refractory & this position is best
because it gives the uniform thermal
distribution .

© Confederation of Indian Industry

 Burner Pipe Centering

 Why we are not considering 7,4,1,2,&3 position?

 These positions are very close to the refractory and it can

damage the refractory through burning.
 some times flame is disturbed
 Position 8 & 9 is Very close to the material
 if coal is trapped it has serious negative impact.

© Confederation of Indian Industry

Impact of Primary Air on Fuel Consumption

© Confederation of Indian Industry

 Challenges in Cooler Operation
 Snowmen formation
 Red river
 Low Efficiency of Cooler
Reason for Snowmen:-
 Dusty operation of the kiln
 Fine particles formation
 Cooling air face more resistance in case of fine particle
 Kiln overheated
 Melting condition inside the kiln
 Change in burner pipe position which affects the cooling zone
inside the kiln
 Raw mix design © Confederation of Indian Industry
 Challenges in Cooler Operation
Reason for red river:-
 Fine dusty clinker
 Segregation in kiln due to wide range in particle size.
 Material characteristics , and rotation of kiln
 Cooler design, air flow distribution Non-uniform
clinker bed
 Operation and maintenance of cooler

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Cooler Efficiency curve

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Cooling Air resistance

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Effect of resistance grates

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 Cooler Efficiency trends
(conventional to 3rd generation)

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 Cooler Efficiency Calculations
Calculate total input air in kg air /kg clinker.
 Total Input air= Cooler Vent Air + Recuperation Air(all value on
mass basis)
Cooler vent Air Recuperation air

ESP

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 Energy Balance of Cooler
Radiation &
Cooler Vent Convection
4
Air losses

SA+TA
COOLER

Input Heat
heat losses
from from
clinker Input heat clinker
from
cooling air

© Confederation of Indian Industry

 Cooler Efficiency Calculations
Input Heat from clinker = 0.2733 x(Inlet Clinker Temp-Refrence T )
Inlet Clinker temp = 1400 degree C
Input heat from clinker = 382.6 kcal/kg clinker
Input heat Cooling air = 17.9 kcal/kg clinker(ABC plant)
Total input Heat = 400.5 kcal/kg clinker--------
Heat Output
Heat through Vent Air = 92.2 kcal/kg clinker----------1
Heat through clinker = 26.9 kcal/kg clinker----------2
Radiation & Convection = 5 kcal/kg clinker---------------3
Heat through Water Spra = 37.7 kcal/kg clinker…………4

© Confederation of Indian Industry

 Importance of cooler Efficiency
Heat through Secondary & TA = Input Heat-(1+2+3+4)
= 400.5-161.80
= 239 kcal/kg clinker
Cooler recuperation efficiency
= Heat through Secondary & tertiary Air x 100
Input heat from cooler
= 60 %

© Confederation of Indian Industry

 Important Facts-Cooler

 The hotter the inlet temperature the hotter the

clinker outlet temperature.
 The hotter the cooling air temperature the hotter the
clinker outlet temperature.
 The longer the air/material contact time the cooler
the clinker outlet temperature.

© Confederation of Indian Industry

 Latest Generation of Coolers

 FLS SF cross bar cooler

 IKN pendulum cooler

 Claudius Peters ETA (ɳ)cooler

 CemProTec Revolving Disc Cooler (RDC)

© Confederation of Indian Industry

 Major Developments

SF Cross Bar Cooler- The 4 Innovative features:

 Fixed grate line for air distribution

 Conveying system separate from Cooling

system

 Grate plates with individual regulators for

cooling air-Cooling Techniques – Unique

 Modular design
© Confederation of Indian Industry
 Mechanical Flow Regulation (MFR)
 Classical compartment
aeration
 Each plate equipped with
a mechanical flow
regulator
 Pressure drop across
perforated plate controls
regulator opening
 Gives constant flow
independently of clinker
resistance
 Eliminates need for air
beam

© Confederation of Indian Industry

Operation of the (MFR)

© Confederation of Indian Industry

Effect of resistance grates

© Confederation of Indian Industry

Working of MFR

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Case Study of Cooler Upgrade with Cross Bar
Cooler
Parameter Unit Before After

Production TPD 3150 3400

Cooler loss Kcal/ Kg Cl 135 98

SPC kWh/MT 5.7 5.17*

Clinker Deg C 195 98

temp
•Power includes Cooler Fans, cooler drives & HRB

© Confederation of Indian Industry

11/26/2020
 Hot Air Recirculation

+20-25%
More heat

Waste Heat Recovery Maximised

without compromising Recuperation Efficiency

© Confederation of Indian Industry

Waste Heat Recovery with hot air recirculation

Secondary +
Tertiary air
Mid air / WHR
Vent air

© Confederation of Indian Industry

 IKN Pendulum Cooler

 Pendulum cooler – IKN

 Unique features
 Stationary inlet
 Coanda nozzle
 Oscillating frames

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 Coanda Nozzles
 Narrow, inclined and curved slots in
transport direction of clinker
 Narrow sharp jet of air – 40 m/sec
(Horizontal)
 Fines are swept to the clinker bed
surface, Coanda nozzles are completely
engulfed by the cooling air
 Fines always on top – Fluidized
 Coarser pushed mechanically at the
bottom
 No Red river problem
© Confederation of Indian Industry
Oscillating Frames

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 Features of IKN Cooler
 Low Air requirement
 Specific power consumption
< 4 units/ton
 Lower clinker temperatures
< 100C

© Confederation of Indian Industry

Operating results before and after the IKN
upgrade
Before After
Production rate (TPD) 5550 5750
TA Temp (oC) 760 930
Sp. Heat Consumption 710 690
(kcal/kg clk)
Power in cooler section 4.47 3.88
(kW/MT clk)
Cooler vent air temp (oC) 220 200
Clinker temp (oC) 152 132

© Confederation of Indian Industry

Revolving Disc Cooler (RDC)- 5th Generation
Cooler

© Confederation of Indian Industry

Revolving Disc Cooler (RDC)- 5th Generation
Cooler
 Introduced by CemProTec, Germany
 Operates according to the “revolving disc” principle
 The travelling grate is replaced by revolving disc
 Under trial, results are being awaited

© Confederation of Indian Industry

Revolving Disc Cooler (RDC)- 5th Generation
Cooler
 Revolving disc – speed 30 min per round
 High efficiency- 100% cross flow heat exchange
 Low cooling air volume and hence exhaust air
 No clinker spillage- Dust handling & transport
system not required
 100% transport efficiency
 Very limited wear & maintenance

© Confederation of Indian Industry

 Benefits of Latest Generation High efficiency
cooler
 Better clinker properties
 Lower exit gas and clinker temperature
 Lower cooling air requirement
 Total heat loss of latest generation cooler is less than 110
kcal/kg clk
 Recuperation efficiency 75-80%
 Retrofitting of existing conventional cooler with latest
generation cooler offers significant potential for electrical and
thermal energy saving

© Confederation of Indian Industry

 Cooler Vent Fan
 Typical power consumption
 0.5 to 1.0 kW/ton
 Typical pressure drops required
 40 – 50 mmWC
 Fan design (Head) very important
 Natural draught available
 Example 220C, 55 m height

© Confederation of Indian Industry

 Cooler vent fan
PARAMETERS AFFECTING THE SEC OF COOLER VENT FAN
 PRESSURE AT FAN INLET- Depends upon the pressure drop in
cooler ESP and duct
• Best observed value : 40 mmWc

 EFFICIENCY OF FAN- Depends upon the fan design and operating

parameters

 CHIMNEY EFFECT- Depends upon the chimney height & dia.

 LOSSES IN SPEED CONTROL- Depends upon the type of control

installed

Lowest observed SEC of Cooler vent fan : 0.13 kWh/MT clk

© Confederation of Indian Industry
 How to choose best cooler System?

 Minimum specific power consumption of cooler fans and

vent fan
 Cooler fans:-3-3.5 kWh/ton clinker
 ESP Fans:-0.5-1.0 kWh/ton of clinker
 Cooler recuperation efficiency should be greater than 70 %
 Cooler Efficiency:-70-77%
 Total losses:-110 kcal/kg clinker
 (Cooler Vent + Radiation+Clinker)
 Should be good in terms of maintenance point of view also

© Confederation of Indian Industry

 Numerical No
N1:-A grate cooler with cooler recuperation efficiency of 44% is
to be replaced with high efficient cooler of 77% efficiency then
calculate the benefit in terms of kcal/kg clinker?
Also estimate the benefit in vent losses
Present SEC-760 Kcal/kg clinker

© Confederation of Indian Industry

CFD Study & Thermal Efficiency
Calculations

© Confederation of Indian Industry

 Application of CFD to Improve Efficiency

 Computational Fluid Dynamics (CFD)

• Predicting the fluid flow related problem by
solving mathematically, the equations which
govern the process.
• Numerical calculation method for solving
fluid flow problems as possible, in solving
practical engineering flow, heat transfer
problem
© Confederation of Indian Industry
CFD – Application Areas

Cyclone Ducts

Electrostatic
Baghouse
Precipitators (ESP)

Raw Mill/ Coal Mill Kiln/ Calciner

Gas Conditioning
Tower

© Confederation of Indian Industry

 Application of CFD to Improve Efficiency
 CFD study identifies the region offering high
pressure drop, improper flow distribution, high
velocity region etc.
 Benefits of CFD study:
Reducing the high pressure drop in pre-heater
cyclones
Reducing the high pressure drop in ducts
Improving the cyclone efficiency
© Confederation of Indian Industry
 Thermal Efficiency Improvement in PH System

Reasons for High PH Exit

Temperature are
 Improper material distribution
 High velocity
 High excess air
 High return dust (low cyclone
efficiency)

Heat Transfer Analysis in Riser Duct for Flue gas with

Particles elaborates the Temperature

© Confederation of Indian Industry

 Thermal Efficiency Improvement in PH System

By CFD analysis, the Exit Temperature Can Reduce &

Reduction in Heat consumption about 5-20 kcal / kg clinker is
possible.

By means of

 Modification in Riser Duct

 Modification in Spreader Box & Feed Pipe

 Modification in Cyclones

© Confederation of Indian Industry

 Thermal Efficiency Improvement in Calciner
 Benefits by CFD analysis in the Cal
 Improvement in coal particle
distribution
 Improvement in flow
Distribution of Velocities
which improves the combustion

 Reduces the high concentration

of Temperature near the wall.

 Improvement in residual time

of the Particle
Particle Trajectory Velocity Distribution
 Overall improvement in in Calciner in Calciner
calcinations

© Confederation of Indian Industry

Cyclone Performance Analysis

Pre-modified duct

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CFD Analysis PH system

Reduction in Pressure drop up to

20mm WC

Streamlines plot at the inlet duct of III stage cyclone

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 CFD Analysis for PH system

Project Completed and analysis report shows pressure drop up to 25mm WC

© Confederation of Indian Industry
 Cyclone Performance Analysis

Pre-modified Cyclone analysis Modified Cyclone analysis with

with ductReduced pressure drop by duct
60 mm WC(10%
reduction in Fan Power).
Energy savings 50 KW/h.

Payback period less than

4 months.
© Confederation of Indian Industry
Dust loss from Pre-heater system/Improvement of
Cyclone Efficiency By CFD study

Dust loss – 30 tph

275°C
 Top cyclone eff
 Design – 96 %
Feed 300 tph
75°C
 Actual – 90 %

PH & PC  Equivalent heat loss

– 10 kcal /kg

© Confederation of Indian Industry

 Dust loss from Pre-heater system / Improvement of Cyclone
Efficiency By CFD study

 Pre-heater dust loss – 10 %

 Dust goes out at about 275ºC

 Fresh feed enters at 75ºC

 Material heat loss alone – 10.0 kcal/kg

 Top cyclone efficiency increase of 3 % means -3.0

kcal/kg

© Confederation of Indian Industry

 Dust loss from Pre-heater system / Improvement of
Cyclone Efficiency By CFD study

 Excellent opportunity

 CII had discussions with consultants on reducing dust

loss thro CFD analysis & retrofit

 Consultant positive on dust loss reduction without

increasing pressure drop

 Has been successful in several Cement plants

© Confederation of Indian Industry

Improvement of Cyclone Efficiency By CFD study
Present Cyclone Efficiency = 90%
Design Efficiency = 96%
Kiln feed to clinker Factor = 1.6
Fresh Feed enters at temperature 75 degree C
Present dust loss = 0.10X1.60
= 0.16 kg material

Present heat loss = 0.16x0.23x275

= 10 kcal/kg clinker

© Confederation of Indian Industry

 Improvement of Cyclone Efficiency By
CFD study
Recoverable is 3%
Improving in efficiency by CFD study(Considering 93%)
= 0.07*1.60
= 0.112
Benefit in dust loss = 0.16-0.112
= 0.048 kg material
Heat improvement = 0.048xspecific heat of flue
gasesxT
Q = 0.048x0.23x(275-0)
= 3.03 kcal/kg clinker
© Confederation of Indian Industry
 Calculations
Thermal cost = RS 1100 Mkcal
(Million kilo calorie)
Clinker production :- 4500 ton/day;
NCV of coal = 7000 kcal/kg coal
Overall Heat saving per day
= 3x4500x1000
= 13.5 Mkcal per day

© Confederation of Indian Industry

 Calculations
13.5 Mkcal per day/
In terms of coal = 1.92 ton of coal in a day
No of days per annum = 300
= 13.5x300
= (4050) Mkcal
- Energy saving per annum

= 4050 x 1100
Savings = Rs 44.55 lakhs per annum
Investment = 20 lakhs
Payback = 20 X12
44.55
= 6 months

© Confederation of Indian Industry

Dust loss from Pre-heater system/ Improvement of
Cyclone Efficiency By CFD study
 I Step
 Conducted CFD analysis for top cyclone
 Implement retrofits to improve efficiency
 Target efficiency - 93 %
 Improvement in efficiency – 3 kcal / kg clinker

Saving - Rs. 44.50 lakhs

Investment - Rs. 20 lakhs
Payback - 6 months

© Confederation of Indian Industry

Minimize Heat Loss in Tertiary Air Duct

840oC

950oC PC

Cooler Heat Loss

•Air infiltration in TA duct
•Surface Heat Loss
© Confederation of Indian Industry
TA Duct – Thermograph Images

© Confederation of Indian Industry

TA Duct – Thermograph Images

© Confederation of Indian Industry

 Minimize heat loss in TA Duct
 Air infiltration
 Atmospheric air entry
 Reduces Air intake from Cooler
 Cooler vent – higher temperature
 Arresting air infiltration
 Lower ambient air ingress
 Increases cooler air utilization (at Temp of
about 500 Deg C)

© Confederation of Indian Industry

 Minimize heat loss in TA duct
 Surface insulation
 Hot spots observed > 200 Deg C
 Significant drop between cooler & PC

 Radiation loss estimated > 5 kCal/kg Cl

 Loss due to air infiltration ~ 3 kCal/kg Cl

 TARGET – 30-40oC drop between cooler exit and PC

© Confederation of Indian Industry

 Calculations
Present Temperature Drop:-
= 950-840
= 110 oC
Margin in temperature = 110-40
= 70 oC
Considering recuperation air = 0.80 Nm3/kg clinker
Total air requirement for calciner
= 0.60 x 0.80
= 0.48 Nm3/kg clinker
Mass = 0.48 x1.29
= 0.6192 kg air/kg clinker
= 0.6192 x 0.25x 70
= 10.836 kcal/kg clinker benefit
© Confederation of Indian Industry
 Calculations
Thermal cost
= Rs 1100 Mkcal
(million kilo calorie)

Clinker production = Rs 4500 ton/day

NCV of coal = 7000 kcal/kg coal

Overall Heat saving per day
= 10.836x4500x1000
= 48.76 Mkcal per day/ In terms
of coal
= 6.96 ton of coal in a day
© Confederation of Indian Industry
 Calculations
 No of days per annum:= 300
= 48.76x300
= (14628) Mkcal
Energy saving per annum
Annual Saving
= 14628 x 1100
= Rs 160.90 lakhs per annum
Investment = 70 lakhs
Payback = 70 X 12
160.96
= 6 months

© Confederation of Indian Industry

 Minimize heat loss in TA duct

 Annual Saving - Rs 160.90 Lakhs

 Investment - Rs 70.0 Lakhs
 Payback period - 6 Months

© Confederation of Indian Industry

 Reduce PH exit temperature
293 oC
325 oC Case stufy plant profile
Standard profile

1A 1B 478 oC
1A 1B 502 oC

2
2 650 oC
659 oC

3
3 799 oC
815 oC

890 oC
893 oC
4
4
5
5

ILC ILC
© Confederation of Indian Industry
Lower Dispersion Box in riser ducts and increase
heat transfer

 PH system – heat transfer

 Overall – Counter current
 Each Stage – Co-current
 Maximum heat transfer in riser ducts
 Separation of material & air in cyclones
 Very little heat transfer in cyclones

© Confederation of Indian Industry

Lower Dispersion Box in riser ducts and increase
heat transfer
 Latest approach
 Locate feed pipe as low as possible
 Increases heat transfer in riser ducts
 Lowers PH gas exit temperature
 Discussions with Suppliers & other Cement Plants
 Favor this step (Upto 1 m, easy)
 Implemented in several plants

© Confederation of Indian Industry

© Confederation of Indian Industry
 Present System
Kiln String Calciner String

Dispersion Total Riser Dispersion Total Riser

Box Height Height Box Height Height
5.055 16.932 2.953 14.570

3.0 12.8 2.947 12.392

5.435 12.78 3.335 13.2

2.1 12 3.053 12.918

4.435 13.4 4.7 -

© Confederation of Indian Industry
Lower Dispersion Box in riser ducts and increase
heat transfer
 Good potential to lower the feed point
 Discussion with supplier before implementation
 Saving of 10-15oC
 2.5 - 3 kCal / kg of clinker, At least
 Recommended to take up one by one
 Monitor temp & pressure profiles closely

© Confederation of Indian Industry

Lower Dispersion Box in riser ducts and increase
heat transfer

Annual Saving - Rs 34.98 Lakhs

Investment - Rs 6.0 Lakhs
Payback period - 2 Months

© Confederation of Indian Industry

 Reduce cold air entry into system
 Cold air entry in Kiln and Pre-heater system
 Coal conveying
 Primary air
 Coal conveying offers a good potential for energy
saving
 Presently coal conveying air – ~ 16.0 tph
 Same irrespective of type of coal used
 Equivalent heat loss with air finally going out at
265°C is – 1.50 kcal/kg
© Confederation of Indian Industry
 Reduce cold air entry into system..
 Phase density for FK pumps – up to 7 possible
 Present phase density – 2 to 2.5
 Varies depending on the coal used and the fineness
 Good potential to reduce
 Install VFD for all four coal conveying blowers
 Reduce rpm in a phased manner
 5 % steps and observe performance
 Target speed reduction – 20 - 25%

© Confederation of Indian Industry

Reduce cold air entry into system

Saving - Rs. 26.61 Lakhs

Investment - Rs. 30.0 lakhs
Payback - 14 months

© Confederation of Indian Industry

Impact of False Air on fuel & Electrical Consumption
Temp-275
degree C
Measuring Points Kiln
1) Calciner Outlet Feed
1

2) Preheater down
Comer O2-5% 2

3) Fan Inlet 3

Fan Inlet
4
pressure-600
mmwg O2-2.5%
PH FAN 5

Calcine
r

kiln
© Confederation of Indian Industry
 Calculations
 Preheater Down Comer:-5%
 Calciner Outlet:-2.5%
Apply False Air Formula
= (Down Comer oxygen-Calciner outlet) X 100

( 21-calciner outlet oxygen)

= 5-2.5 X 100
21-2.5
= 13.5 %
Consider preheater outlet Temperature :- 275 degree C
Considering Reduction in false air :- 5%
Present Flow: - 1.50 Nm3/kg Clinker
© Confederation of Indian Industry
Impact of False Air on fuel Consumption
Mass Flow Rate = 1.50x1.42
= 2.13 kg gases /kg clinker
Reduction in mass flow by reducing
FA = 0.05x2.13
= 0.1065 kg/kg clinker
Heat Loss = 0.1065xspecific heat of flue
gasesxTemp difference

© Confederation of Indian Industry

Impact of False Air on fuel Consumption

Q = 0.1065x0.23x(275-0)
= 6.73 kcal/kg clinker.
Thermal cost = RS 1100 Mkcal
(million kilo calorie)
Clinker production:- = 4500 ton/day
NCV of Coal = 7000 kcal/kg coal

© Confederation of Indian Industry

 Impact of False Air on fuel Consumption
Overall Heat loss per day
= 6.73x4500x1000
= 30285000 kcal per day
In terms of coal = 4.326 ton of coal in a day
No of days per annum: = 300

= 30285000x300
= (9,085) Mkcal
- energy saving per annum

In terms of Mkcal = (9.085x10^9)/(10^6)

= 9.085x(10^3 )
Cost = 9085 x 1100
Saving = Rs 99.93 lakhs per annum
© Confederation of Indian Industry
 Impact of False Air on Electrical power
Electrical Loss = Percentage of false airX electrical
power of fan
Electrical power = 1400 kW
Power loss = 0.05x1400
= 70 kW
Electrical cost = Rs 5 kWh
No of days per annum: -300
Annual Saving = 135x300x5x24
= 25.2 lakhs per annum
Total Saving = 99.93+25.2
= 125 lakhs
© Confederation of Indian Industry
Impact of False Air on Electrical power
Pay back = (50/125)x12
= 5 months

Saving - Rs. 125. Lakhs

Investment - Rs. 50.0 lakhs
Payback - 5 months

© Confederation of Indian Industry

 Burners
 The ultimate objective of a burner is to provide a
stable short and intense flame for burning of raw
materials to the desired temperature and achieve
heat economy
 More efficient mixing of fuel and air
 Improvement in entrainment of secondary air

© Confederation of Indian Industry

First Generation Burners(conventional)
Advantages
 Burning traditional Fuels
 Good Flame Adjustability
 Good Mixing of the combustion air with the Fuel
Disadvantages
 Generation of high Nitrogen oxides emissions
 Inability to use market dependent alternate fuels

© Confederation of Indian Industry

Second Generation burner(Multichannel)

Duoflex burner:-FLS
Pyrojet:-KHD
Pillard:-Rotaflam
Greco:-Greco

© Confederation of Indian Industry

 How to select best burner for the plant operation?

 Adjustability of the flame shape to suit the kiln operation

and type of fuel
 Operating costs and servicing costs
Other Important process parameters
 Primary air requirement(%) & pressure(effect the energy cons.)
 Flame momentum
 Coal conveying air(solid loading ratio)
 NOX emissions (Low NOX burner)
Emission behavior with respect to NOx emissions
 Flexibility with traditional fuels
 Flexibility with market-dependent alternative fuels
© Confederation of Indian Industry
 NOX Generation
 Thermal NOX
 Form in burning zone and reaction takes place at high
temperature(1400 degree C)
2N2+O2-2NO +N
N+O2-NO+O
 Higher excess air results high amount of NOX
 As Input N2 increases due to excess air
 High residence time in calciner also increase the NOX
formation

© Confederation of Indian Industry

 NOX Generation
Fuel NOX
 Fuel NOx is formed by the oxidation of nitrogen present in
fuel
 A study has indicated that gas-fired, dry-process kilns
typically produce almost three times more NOx than coal-
fired, dry-process kilns
 Fuel NOx predominates NOx generation in the calciner and
at lower-temperature combustion sites.
 Approximately 60% of fuel nitrogen is converted to NOx and
is dependent upon available oxygen in the flame and
temperature profile
© Confederation of Indian Industry
 Low NOx Burners
(Latest generation Burners)
Burner out put(68 MW)
Parameters FLS –Jet Flex Novaflam KHD Pyrojet
Coal or Pet Coal or Pet coke Coal or Pet coke
Type of Fuel
coke
Transport Air volumetric
2805 m3/hr 2135 Nm3/hr 2165 Nm3/hr
flow for pet coke
Solid loading factor-coal 3.8 4.96 kg coal/Nm3 4.90 kg coal/Nm3
Primary air cons(%) 5-6% 6.5% 4.8%
Primary air pressure(mbar) 700 500 Jet-900;swirl-160
Jet-2710m3/hr;swirl:-
Primary air flow 5100 m3/hr. 5500 Nm3/hr
1355 m3/hr

Primary air consumption:-

8-9% in ordinary multichannel burner with low pressure(1500-2500 mmwg).

© Confederation of Indian Industry

 Low NOx burner Concept
 Less primary air means less oxygen and may produce an
initial high-temperature, fuel-rich combustion zone,
followed by a low-temperature fuel-lean combustion zone.
Such a combination is likely to reduce the formation of
NOx.
 Reduce flame turbulence, delay fuel & air mixing and
establish fuel rich zones for initial combustion
 A fuel-rich, oxygen-lean, high temperature combustion
zone is created first by reducing the amount of primary air
in the primary combustion zone and delaying the
combustion of all of the fuel

© Confederation of Indian Industry

 NOX reduction-solutions(Primary level)

 Reducing excess air levels also results in increased

productivity per unit of energy; thus, resulting in the indirect
reduction of NOx emissions per amount of clinker produced.
 Improving burnability of kiln feed & thermal efficiency of the
system
 Reduction in heat consumption
 Installing the low NOX burner
 Change in the preheater system(hot bottom formation in ILC)
 Nitrogen content in the fuel
 Latest developments by technology suppliers

© Confederation of Indian Industry

 Case Study No1
Objective
To reduce the primary air percentage by installing pillard Novaflame
burner
Primary air consumption:-12%
Problems:-
Frequent build up in the 28th m of the kiln
Benefits:-
After changing the burner the coating tendencies are reduced and
plant team are able to increase the petcoke to 100%.

© Confederation of Indian Industry

 Case Study
Project Economics:-
Energy saving:-2 kcal per kg clinker
Total fuel saving:-350 tonnage of coal
Cost :-Rs 6500 per ton of coal
Total cost saving:-Rs 23 lakhs per annum
Investment:-Rs 52 lakhs
Payback:-27 months

© Confederation of Indian Industry

 Case Study No2
 Pyro-Jet Burner was commissioned successfully and
Primary Air consumption reduced by 5% thereby Heat
consumption reduced by 5 Kcal/ kg clinker

© Confederation of Indian Industry

Latest Developments:-KHD Pyroclon-R Low NOx

© Confederation of Indian Industry

 PYROCLON® Redox Reactor-For low NOX

Technology
Main Calciner
 Gasifying reactor between
kiln and calciner.
 Formation of CO by
Boudouard reaction. PYROREDX Reactor

 Reduction of NOx.
 Suppression of fuel NOx
Fuel
formation. ②

© Confederation of Indian Industry

PYROCLON® Redox Reactor-For low NOX

© Confederation of Indian Industry

 Working Principle
Redox reactor inlet Gas Composition:
CO2 19.4 Vol.%
CO 0 Vol.%
100 % Of Calciner Fuel fired in PYROREDOX duct in Kiln Flue gas only,
Without any TERTIARY Air admission hence Reducing atmosphere (
Insufficient Combustion air / Starved O2 Condition ) Created In
PYROREDOX.
Due to reducing atmospheres in PYROREDOX, the CO2 in kiln flue gas react
with fuel C which is sub stoichiometric conditions. The sub stoichiometric
reaction as follows and it produces CO at the same time CO2 content of
flue gas reduces to 8.1 % , hence Conversion of NO into N2 using CO is > 95
%
CO2 + C  2 CO
Boudouard reaction

© Confederation of Indian Industry

 Working Principle

 Redox reactor outlet / Calciner Inlet Gas Composition:

 CO2 8.1 Vol.% `
 CO 21.8 Vol.%
 The above condition is very favorable for DENOX Reaction using CO
as Follows
 2CO + 2NO = 2CO2 + N2
 Final NOX CONCENTRATION IN CALCINER OUTLET IS < 500 mg/Nm3
@ 10 % O

© Confederation of Indian Industry

 Low Pressure Drop Cyclones

 Typical pressure drops - Latest PH with PC

 4 Stage – 310 to 360 mmwg
 5 Stage – 350 to 400 mmwg
 6 Stage – 450 mmwg

© Confederation of Indian Industry

Latest development in Cyclones by KHD
Previous Cyclone High Efficiency (HE)
Design Benefits Cyclone
55% dip tube ratio Based on same capacity Design for > 60% dip
tube ratio
 Dp saving of 1,5 - 2
mbar per cyclone
stage
 Smaller Cyclone size
can be used

 Less equipment and

building expenditure

Inlet cross section 100% New 110%

h/w = 1,6 h/w = 2,0

© Confederation of Indian Industry

 Cyclone Developments –CASE STUDY
Existing design New design
36,6 mbar 7950/5 6852 HE / 5 29,7 mbar
Double Separator:

11,1 mbar 7,1 mbar • increased by one size

System Cyclones:

• reduced by one size

25,5 mbar • new design of gas inlet

22,6 mbar
• increased dip tupe ratio
Reduction building height
Approx. 3 %
Reduction foot print
Approx. 5 %
Reduction building
volume complete
Approx. 10 to 15 %
© Confederation of Indian Industry
 CCX Cyclone by FLS
1. Material top feed
2. Rotating spreader (Counter current
heat exchange) 1

3. Integrated heat exchange and

2
separation
3
4. Light weight lining
5. Central pipe is pointing upwards 4

6. Exit gas outlet naturally pointing 5

downwards 7
7. Reduced civil & Structural loads
6

© Confederation of Indian Industry

CCX Cyclone by FLS

© Confederation of Indian Industry

 CCX Cyclone by FLS
Standard Cyclone HR+ Counter Current Cyclone CCX

Material In
Gas out

Gas In

Material In

Gas In

Gas out
Material Out

© Confederation of Indian Industry

Material Out
CASE STUDY-European Cement Plant

Existing top cyclone modified to CCX 6.3m.

Kiln capacity, clinker Operating at ~ 3300
tpd
Production increase (tpd) ~ 200 tpd
Pressure drop reduction 40%
Recorded gas material 50-60°C
temp. difference
Fuel savings 8-10 kcal / kg cl
Cyclone heat efficiency 1.5
recorded
Load on civil structure > 50%
reduced

© Confederation of Indian Industry

Latest developments in Calciners

© Confederation of Indian Industry

 Requirements for Modern Precalciners

Stable operation for full decarbonation (60 to 65 %

fuel burnt in calciner )
Full combustion of all fuels
Maximum alternative fuels (solid and lumpy)
Control of emissions (NOx, CO , TOC/VOC )

© Confederation of Indian Industry

 FLS In-line calciner
Raw meal duct

Mixing zone Splitter gate

Vmin(ILC) = 6m/s
Restriction area
Retention time
(ILC) = 3.3s

Splitter gate

Reduction zone

Fuel
Kiln riser
Low Nox Calciners for reduced Nox emissions
irrespective of fuel
© Confederation of Indian Industry
 FLS Separate Line Calciner - Downdraft
 Characterizes a special type
of burner arrangement and
flow path. Flow is down draft.
 Geometry is designed for
instant ignition of
combustible.
 Complete burnout of low
volatile fuels high combustion
temperatures
 High material and gas
retention time in the calciner

© Confederation of Indian Industry

144
Developments in KHD Calciner

© Confederation of Indian Industry

PYROCLON® Calciner Technology - Steps of Developments
Pyroclon-R LowNOx
Pyroclon-R LowNOx AF Pyroclon-R LowNOx „LRF“
ILC - staged combustion
ILC - staged combustion Variant for „Low Reactive
„The first LowNOx Calciner and AF utilisation Fuels“ (e.g. Petcoke)
1980“

© Confederation of Indian Industry

PYROCLON® Calciner Technology - Steps of Developments
Pyroclon-REDOX
ILC with
Pyroclon-R Pyroclon-R Pyroclon-R PYROREDOX
LowNOx LowNOx AF LowNOx „LRF“

© Confederation of Indian Industry

 Raw Mix
 To achieve the goal of smooth kiln operation it is
necessary to know
 Which parameters in the raw mix influence kiln
operation?
 How and why they influence operation?
 What can be done about it ?

© Confederation of Indian Industry

 Raw Mix design
 Main Parameters of Raw Mix design
 Lime Saturation Factor
 Silica Modulus
 Alumina Modulus
Range:-
LSF
SM
AM

© Confederation of Indian Industry

 Raw mix design Software
`

- - - - - - - - - RAWMIX DESIGN - - - - - - - - -
LIMESTONE SHALE IRON ORE BAUXITE RAWMEAL

MIX % 82.14 14.13 0.94 2.79 100.00

SiO2 3.24 74.98 9.16 9.00 13.59
Al2O3 0.79 8.80 2.00 50.00 3.30 RAWMEAL
Fe2O3 TARGETS
0.38 6.20 83.04 14.00 2.36
CaO 51.00 0.98 0.06 5.50 42.19
MgO 1.24 0.24 0.41 0.50 1.07 Lime Saturation
K2O 0.50 0.30 0.20 0.10 0.46 97.00
Na2O 0.20 0.20 0.10 0.10 0.20
SO3 0.10 0.20 0.07 0.05 0.11 Silica Modulus
L.O.I. 42.48 8.00 4.65 21.00 36.65 2.40
TOTAL 99.93 99.90 99.69 100.25 99.93
S.R. 2.40 Alumina Modulus
A.R. 1.40 1.40
L.S.F. 97.00

© Confederation of Indian Industry

Liquid phase variation by Silica& Alumina Ratio

© Confederation of Indian Industry

 Importance of Liquid phase
 SM decreases as liquid phase increases & vice versa
 AM also changes as per liquid content in the clinker
 Significance
 Clinker granulation
 Coating (but also formation of rings)
 Rate of alite formation

© Confederation of Indian Industry

 Importance of Liquid phase

Typical amount 20 –30 %

 Dry: ≤ 23 %
 Normal: 23 – 27 %
 Wet ≥ 27%
Liquid Viscosity:
 Decreases with increasing temperature
 Depending on composition and minor elements
 Reduced by Na2O, CaO, MgO, Fe2O3, MnO
 Increased by SiO2, Al2O3

© Confederation of Indian Industry

C2S,C3S,C3A & C4AF Formation reactions-1300
degree C

© Confederation of Indian Industry

C2S,C3S,C3A & C4AF Formation reactions-1400
degree C

© Confederation of Indian Industry

Formation of clinker

© Confederation of Indian Industry

 Kiln Challenges-Petcoke
 Grinding problems in coal mill
 Minimizing the residue is a difficult task(Lower HGI)
 Low volatile matter
 Requires high flame momentum in kiln
 Chances of refractory damage is high due to FM
 High content of Sulphur
 Condensation of sulphates in preheater(5th & 6th cyclone)
resulting in jamming of process flows , defined as volatile
cycle

© Confederation of Indian Industry

 Recommendations
 Use of high flame momentum burner
 KHD pyrojet, FLS Jet flex ,Novaflam
 Alkalies(K2O,Na2O),lime for raw meal and SO2 from
petcoke
 Optimize alkali Sulphur ratio
 Operate the kiln in oxidizing atmosphere with excess of
oxygen
 Excess oxygen:-4%(kiln inlet for petcoke)

© Confederation of Indian Industry

 Recommendations
 Install UT pump and blasters at kiln inlet
 Reduce filling inside the kiln (12-13%)
 Increase retention time in the calciner
 Avoid CO formation by maintaining the residue below 2% on
90 micron.
 Use Silica Carbide castable at inlet and burner pipes to
reduce coating

© Confederation of Indian Industry

 Alkali Sulphur ratio
Volatile Cycle:-
Sulphur to alkali ratio decide the type of coating formed

Q= %SO3 / 80
Na2O/62 +(K2O/94)-(Cl/71)
Sulphur excess Q>1 = Hard coating

Alkali excess Q<1 = Soft coating

© Confederation of Indian Industry

 Chemistry
 To prevent SO2 gas leave from the kiln, it must be combined
with alkalies(Na,Ca&K) and form sulphates(Na2SO4,K2SO4)
and leave with clinker in the form of sulphates.
 Sufficient amount of liquid is required for above reactions
 AM:-1.2
 Excess oxygen is required for maintaining oxidizing
atmosphere
CaO+SO2+1/2 O2 = CaSO4
 SO3 in clinker may be maintained in the range:1.5-2%

© Confederation of Indian Industry

Rings Formations

© Confederation of Indian Industry

 Important Thumb rules
 10% excess air is equivalent to heat loss of 10
kcal/kg clinker
 False air acceptable range across preheater
system is 6-8%, above it only contributes heat
losses in the system
 Kiln inlet O2:-2% -Normal Coal;O2:-4%:-Pet coke
 Rate of heat transfer increases as the kiln rpm
increases the recommended filling inside the kiln
of normal coal is 14-15 % and for pet coke is 12-
13%.
© Confederation of Indian Industry
 Important Thumb rules
 It is recommended that to reduce the filling in the case of
petcoke due to Sulphur content in it which vaporize in burning
zone and increase the tendency of coating formations at 5th and
6th cyclones.
 Burning zone temperature is directly proportional to square of
diameter of raw meal particle,therefore,another way is to
optimize the process by controlling the residue of raw meal(15-
16%) on 90 micron

© Confederation of Indian Industry

 Important Thumb rules
 Recommended Cooler grate loading:-
 Kiln Loading:-
 Input cooler Air:-1.75 Nm3/kg clinker-Normal Coal
:-1.80 Nm3/kg Clinker-petcoke
 Optimize the cooler vent air by identifying the cooler null
point .
 Heat and mass balance study of pyro section is to be
checked by doing mass balance.

© Confederation of Indian Industry

 Important Thumb rules

 Radiation losses contribute 6-8% of total radiation losses

 Coal conveying pipeline velocity :-25 -26 m/s
 Recommended Phase density :-3-4 kg coal/kg air-Normal Coal
:-4-6 kg coal/kg air-pet coke

© Confederation of Indian Industry

CASE STUDIES

© Confederation of Indian Industry

 Case Study No1
Usage of Pyrolytic Oil for Kiln Light up

Parameter Unit Pyrolytic Oil Diesel

Moisture % 0 0
ASH % 0.025 0
GCV Cal/g 10134 9600
NCV Cal/g 10134 9600
Chloride % 0.23 0.08
Sulfur % 0.69 0.21
Density Kg/m3 0.88 0.83
Flush point Degree C 35 46

© Confederation of Indian Industry

 SOP FOR KILN LIGHT UP THROUGH PYROLYTIC OIL
 Placing of Oil Tanker at safe place( plain & leveled surface)
 Proper dual Earthling for discharging of static charge of oil tanker.
 Direct connection to Pump inlet through a T-joint with manual control
valve.
 First firing started with Diesel and after 4Hrs switch to Pyrolytic oil.
 Diesel firing stopped completely during usage of pyrolytic oil.
 Separate feeding mechanism provided for Pyro-oil firing.
 Two pump provided, in case of one pump failure other will start.
 Oil Flow can be maintained from control valve (MCV1) near pump by
checking pressure in installed pressure gauge.
 Pressure maintained between 6 to 7 bar.
 In case of fluctuation in pressure gauge, filter was clean up which installed
just before pump.
© Confederation of Indian Industry
 SOP FOR KILN LIGHT UP THROUGH PYROLYTIC OIL

 Flow-rate maintained 0.6 KL/Hr. After 36 Hrs. 21.75 KL pyrolytic oil

consumed in kiln light up.
 Recorded the temperature profile hourly.
 Coal firing started after 9 hours by checking kiln inlet temperature

© Confederation of Indian Industry

 Benefits
Tech. Parameter Value Unit
Cost of Diesel 61912 Rs/KL
Cost of Pyrolytic Oil 26800 Rs/ KL
NCV of Diesel 9600 Kcal/Kg
NCV of Py-oil 10134 Kcal/Kg
Replacement Ratio 1.05
Net Cash Benefit (NCB) -26800 Rs/ KL
Substitute benefit (SB) 65355.8 Rs/KL
Gross Added Value 38555.8 Rs/KL
(GAV)

© Confederation of Indian Industry

 Case Study No2:
De-Swirler Installation in PH Top Cyclone of Kiln-4
Observation : In Kiln-4, PH Fan-2 SPC was high up to 4.42 kWh/T Clk
(w/O SPRS Recovery).

Problem : While conducting the pressure profile mapping identified top-

cyclone pressure-drop was in range of 85-90 mmWG.

Solution Adopted : CFD analysis was conducted to identify the regions for
excess pressure drop in cyclone & what rectifications can be initiated to
reduce this.

Modification Done : Based on the recommendations of CFD team, we

modified the dip-tube of top cyclone (shown in figure) to reduce the
vortex formation without affecting the cyclone collection efficiency.

© Confederation of Indian Industry

 Case Study No2:
De-Swirler Installation in PH Top Cyclone of Kiln-4
Impact : Pressure drop in the cyclone is now reduced up to 65 mmwg

Savings Achieved :
Daily Power Savings : 1,050 kWh,
Daily Monetary Savings : Rs 3,990 @ Rs 3.8/kWh,
Rs 13.00 Lacs / Year

Replicability: Cyclones having issues of high pressure drop & maximum

operating temperature range of up to 500 Degree Celsius.

© Confederation of Indian Industry

De-Swirler Installation in PH Top Cyclone of Kiln-4

Parameters Unit Before After

Period Period
Kiln Feed Avg TPH 704 726
Fan Speed 2 RPM 769 766
Load-2 kW 1957 1974
SPC Fan-2 kW/T Clk 4.42 4.32
Avg. Pressure Drop across Top
mmWg 84 65
Cyclone- String 3 & 4
© Confederation of Indian Industry
 Case Study No3
Kiln Radiation Heat Recovery for AC (VAM Chiller)
Observations
1. Kiln Shell Temperature : 200 Deg C
2. Average Radiation Loss :
3. Heat Loss in % : 6%

Action Taken:
1. To Install Radiation Heat Recovery Panels
2. Generation of 100 Deg C Hot Water
3. Operation of VAM Chiller with Hot Water (1 X 85 TR)
4. Stopping of Conventional Chiller (1 X 85TR)

© Confederation of Indian Industry

Kiln Radiation Heat Recovery for AC (VAM Chiller)
Hot Water to VAM Chiller

© Confederation of Indian Industry

 Kiln Radiation Heat Recovery for AC (VAM Chiller)

1. Recovering the Waste Heat from Kiln Shell

2. Operation of VAM Chiller and Stopping Electrical Chiller.
3. Power Saving of 70 KW / Hr.
4. Energy Saving : 1680 Units / Day (5.54 Lakh Units/
Annum)
5. Cost Saving is Rs. 30.25 Lakhs / Annum

© Confederation of Indian Industry

 Case Study-4 Cooler Hot Air Recirculation
Objective: Benefits:
Increase Power Generation of WHRS
To Reroute hot air from Line 1 ESP Stack
by 0.3MW
to cooler inlet.
This will improve line 1 WHRS AQC 1 Power Savings of 23.76 Lacs Kwh
Boiler inlet temperature. Investment of Rs. 200 Lacs

© Confederation of Indian Industry

 Case Study 5
Formation of TAD ramp to increase the oxygen
concentration at kiln inlet
Problem:-
 High CO formation at kiln inlet (ILC KILN)
Reason:-
 There was no damper in TAD because whatever the damper the
plant team installed worn out within 7-8 months as a
consequent CCR operators was not able to pick the kiln due to
CO formation

© Confederation of Indian Industry

 Formation of TAD ramp to increase the oxygen
concentration at kiln inlet

Counter Measures:-
 Installation of ramp inside the TAD which blocks around 40
% area of TAD
 Optimize the raw mix as per pet coke
 Optimize the residue on Petcoke(2-3% on 90 micron)

© Confederation of Indian Industry

 Benefits
 Kiln output has been increased from 220 TPH to 300 TPH
 Smooth kiln operation
 Benefit in specific heat consumption
 Total investment:-Rs 1 lakh(castable & labor)

© Confederation of Indian Industry

 Case Study No 6
MgO added as Mineralizer through Kiln firing
Project Concept

 Clinkerisation is an energy intensive process and it is

influenced to a large extent by the chemistry and mineralogy
of the raw materials used.

 In the burning zone, where the formation of C3S occurs by

diffusion reaction between C2S and free lime, the liquid
phase plays a very important role.
 .

© Confederation of Indian Industry

 MgO added as Mineralizer through Kiln firing

 Many of the problems such as dusty clinker formation,

inadequate porous or excessive coating formation ,high levels
of uncombined lime are attributed to the unfavorable viscosity
of the melt phase especially when Sulphur rich fuels are used
 It is possible to modify the viscosity of the melt phase through
use of various additives including alkalis.

 However, in dry process kilns with suspension preheaters,

there are limitations on the use of alkalis.

© Confederation of Indian Industry

 MgO added as Mineralizer through Kiln firing
Concept & Principle

 The most compatible and least harmful and yet economical

additive is magnesia. It improves the viscosity of the melt
phase and therefore aids in the combinability of lime with
C2S. As a result of this, the free lime is reduced and the C3S
formation is enhanced.

© Confederation of Indian Industry

 MgO added as Mineralizer through Kiln firing
Execution Methodology
 Addition of Dolomitic Limestone with the MgO range of 13 -
15 % at the rate of 1 % with respect to Clinker Production of
7000 TPD.
 Point pile quantity of 3000 Tons was made through LS
Crusher/CPP Crusher
 Crushed material stored in the outside yard and fed to the
Coal crusher along with the Coal pile .
 Fine grinding with PetCoke in Coal Mill then fed to the Kiln
Main burner.
 Reduction in Kiln Primary Fuel and change in raw mix
design with Less iron changed
© Confederation of Indian Industry
MgO added as Mineralizer through Kiln firing

 XRD analysis of clinkers show positive effect of MgO

addition

© Confederation of Indian Industry

 MgO added as Mineralizer through Kiln firing
Benefits

 The MgO modifies the viscosity of the melt phase and

changes the liquid phase composition

 The effect is seen both in terms of reduction in free lime

content and enhancement of C3S contents and its
modification to high temperature polymorphic

 Clinker shown better granulometry and grindability

characteristics as the C3S content is increased with
concomitant reduction in C2S

© Confederation of Indian Industry

 MgO added as Mineralizer through Kiln firing
Results:-

Project involves No Capex or Opex expenditure.

Cost Savings are as follows without any investment :

 Cost savings due to Power - ₹ 1.59 Crores/Annum

 Cost savings due to SHC - ₹ 69.33 lacs/Annum

 Total Cost Savings - ₹ 2.28 Crores/Annum

Replication potential:-

100% replication potential in Cement Sector for all Dry

process Inline Calciner Kilns
© Confederation of Indian Industry
 Key Points
 SEC of Preheater fan can be reduced by minimizing the
pressure drop and optimizing the velocity profile across
preheater system by using efficient cyclones (low pressure
drop) and avoiding the coating formations at kiln inlet &
cyclones(5th & 6th)
 Optimizing the excess air leads to tremendous potential in
thermal energy saving potential
 Excess air 10% is equivalent to loss of 8-10 kcal per kg clinker
 Secondary air temperature plays an important role in
optimizing the flame length
 Recommended Velocity:-5 m/s

© Confederation of Indian Industry

 Key points
 Latest generation coolers have the potential to face the
challenges of snow men formation and red river in the
cooler by installing latest device in the cooler such as MFR
(Mechanical flow regulator) and through conada effect.
 Plant can improve the thermal efficiency of cooler by
reducing vent losses and improving the recuperation air
temperature by avoiding leakages
 Recommended parameters
 70% efficiency
 Cooler losses:-110-120 kcal/kg clinker
 Vent air:-1 Nm3/kg clinker

© Confederation of Indian Industry

 Key points
 CFD study is new era in the field of cement industry through
which lots of modification can be done both thermal as well
as electrical
 Improving Cyclone Efficiency through CFD study
 Reducing the system resistance across ducts &cyclones
 Latest development in cyclones ,Latest generation
burners(Low NOx) and other developments regarding
reducing NOX have increased the productivity as well as
fulfill the environment norms with output
 Latest in-house modifications such as TAD ramp and
utilization of MgO in kiln are the evidences there is enough
potential of improvement in pyro process with low
investment
© Confederation of Indian Industry
 Annexures

© Confederation of Indian Industry

 Annexures

© Confederation of Indian Industry

 THANK YOU !
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© Confederation of Indian Industry