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Preheater ... AM

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739 views77 pages

Preheater ... AM

Uploaded by

amaralinga chari
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
  • Title Page: Cover page for the document on developments in preheater and calciner technology.
  • Introduction: Introduction to the necessity of developments in preheater and calciner, focusing on energy cost and emissions.
  • Kiln Heat Balance: Detailed table on heat consumption and balance in kilns.
  • Reduction in Energy Cost: Strategies for reducing energy costs in kilns, focusing on gas and power consumption reductions.
  • Emission Standards: Overview of emission standards relevant to kilns and calciner operations.
  • NOx Formation: Explanation of NOx formation processes in the kiln environment.
  • NOx Abatement (Primary): Description of primary methods for NOx abatement.
  • Calciner as Perfect Sulphur Scrubber: Role of the calciner in removing sulfur compounds during kiln operations.
  • NOx Abatement (Secondary): Secondary methods for NOx reduction using SNCR technology.
  • Constraints in Using Alternative Fuels in India: Challenges related to alternative fuel usage in Indian kilns.
  • Developments in PH – PC: Overview of developments in preheater-calciner systems including equipment and optimization.
  • Function of Preheater Cyclone: Describes the functionality and benefits of using preheater cyclones in kiln systems.
  • Suspension Preheater Kiln: Introduction to the suspension preheater kiln design.
  • Basic Requirements of Preheater LP Cyclones: Outlined basic requirements for low-pressure cyclones in preheater operations.
  • Advantages of LP Cyclones: Discusses the advantages of low-pressure cyclones in kiln systems.
  • Developments in Preheaters: Recent advancements in preheater technology and their impacts.
  • Suppliers of Preheater Cyclones: Lists various suppliers known for providing preheater cyclones.
  • FLS LP Cyclone: FLS's low-pressure cyclone design details and benefits.
  • Comparison of FLS Existing Top Plant Stages Efficiency: Comparison chart of efficiency across various FLS plant stages.
  • Humboldt Low Pressure Preheater Cyclones: Features and advantages of Humboldt's low-pressure preheater cyclones.
  • Polysius LP Cyclone: Polysius's approach to low-pressure cyclone design.
  • IKN LP Cyclone: Introduction to IKN's LP cyclone features and advantages.
  • A TEC High Efficiency Cyclone: Details of A TEC's high-efficiency cyclone design.
  • Hurivane: Description and features of the Hurivane cyclone model.
  • Hurriclon with Double Dip Tube: The Hurriclon model featuring a double dip tube for improved efficiency.
  • Operational Details of FLS Low Pressure Preheater: Operational metrics for FLS low-pressure preheater systems.
  • Function of Calciner: Explains the calciner's role in the cement manufacturing process.
  • Main Developments in Calciners: Major developments and innovations in calciner technology.
  • Precalciners: Listing of known precalciner providers and their contributions.
  • Developments in Precalciners: Explores the latest developments in precalciner technology.

DEVELOPMENTS IN PREHEATER

AND CALCINER

Alexander Manomoney
Need for Developments in PH – PC

 Rising Energy Cost


o Fuel
o Power
 Stringent Emission Norms
o NOx
o SOx
o Dust

o CO
 Utilization of Alternate Fuels
 Higher Capacity Kilns
Kiln Heat Balance
REDUCTION IN ENERGY COST

Lower PH exit gas losses


• Lower temperature
• Optimum O2 content
• Minimum CO content

Lower PH Fan power consumption


• Lower pr drop across PH
Emission Standards
NOx Formation
Thermal Nox
N2 (air) + O2 (air) Nox

Fuel Nox
N2 (fuel) + O2 (air) Nox

Both reactions are parallel .


Not possible to analyse independently
NOx Abatement (Primary)

2NO + 2CO N2 + 2CO2

2C + 2NO N2+CO2
Calciner as perfect sulphur scrubber

From raw materials


• in the form of sulfates and sulfite in to Kiln

From Fuel in Kiln


• S + excess free lime in to Kiln
NOx Abatement (Secondary)
Selected Non Catalytic Reeducation (SNCR)

Injection of Ammonia in Calciner

4NO + 4NH3 + O2 4N2 + 6H2O


Constraints in using alternative
Fuels in India

• Continuous supply

• Fluctuating fuels prices


Developments in PH – PC

 Equipments

 Optimization
ILC - KILN
SLC - KILN
Function of Preheater Cyclone

• System/equipment for the heat exchange between kiln hot


gases and kiln feed providing large gas-material contact
area (suspension)
• Utilize the heat in kiln exit gases to
Preheat kiln feed
Reduce kiln exit gas temperature
• Kiln can be short as preheating kiln feed outside kiln
• 80% heat transfer in riser duct
• Material collection in cyclone
• Degree of calcination around 50-60% in SP kiln
SUSPENSION PREHEATER KILN
CONVENTIONAL PH CYCLONE

100-150 mm WG
BASIC REQUIREMENTS OF PREHEATER
LP CYCLONES

• LOW PRESSURE DROP 50-60mm WG

• HIGH SEPARATING EFFICIENCY

• LOWER PH FAN POWER CONSUMPTION


CONVENTIONAL TO FLS LP CYCLONE
ADVANTAGES OF LP CYCLONES

• REDUCTION IN EXIT GAS TEMPERATURE & PRESSURE

• REDUCTION IN PREHEATER FAN POWER CONSUMPTION

• REDUCTION IN EXIT GAS HEAT LOSSES

• POSSIBILITY OF INSTALLING MORE STAGES

• ABSENCE OF HORIZONTAL SURFACE

• IMPROVED CONE DESIGN TO AVOID PLUGGING


DEVELOPMENTS IN PREHEATERS
• LP CYCLONES
– HEAT RESISTANT DIPTUBES
– FLAP VALVES
– MEAL DISPERSION BOXES

• HURIVANE

• HURICLONE
SUPPLIERS OF PREHEATER CYCLONES

• FLS
• KHD
• POLYSIUS
• LNV
• IKN
• HURIVANE AND HURICLONE
FLS LP CYCLONE
FLS

FLS LP Cyclone
Comparison of FLS existing top plant
Stages efficiency
FLS

Meal Dividing Gate


Cast Segmental Central Pipe Materials Pipe Sluice flaps
lengt
h

FEATURES OF HUMBOLDT LOW


PRESSURE PREHEATER CYCLONES
HUMBOLD LP CYCLONE
Inlet gas flow beside dip tube
for low pressure drop and
improved efficiency

dip tube length =


1/2 gas-inlet height

long distance below the dip


tube for improved gas routing
into dip tube

steep cone of 70 and large


volume for improved meal
discharge

gas velocity 10 . . . 15 m/s

smooth gas stream to prevent


coating and for low pressure
HUMBOLDT SEGMENTED DIP TUBE
POLYSIUS LP CYCLONE
POLYSISUS MULTI ELEMENT HEAT RESISTANT DIP TUBE
LV LP CYCLONE
I KN – LUCY LP Cyclone
A TEC HIGH EFFICIENCY CYCLONE
HURIVANE
HURIVANE
HURRICLON WITH DOUBLE DIP TUBE
OPERATIONAL DETAILS OF FLS LOW
PRESSURE PREHEATER
SLC-KILN 5000 t/d ILC KILN 3000 t/d
(SF COOLER) (SF COOLER)

5- STAGE 6- STAGE 5- STAGE 6-STAGE

K-C K-C

EXHAUST GAS 294 256 293 258


TEMAPERATURE
(oC)
PRESSURE LOSS IN 305 360 305 360
PREHEATER
(mmWG)
PRESSURE LOSS IN 45-140 45-140 160 160
THE REST OF THE
SYSTEM

TOTAL PRESSURE 350-445 405-500 465 520


LOSS (mmWG)
ID FAN(SPOWER 5.0 5.4 5.3 5.7
CONSUMPTION
(kWh/t CLINKER)
Function of Calciner

• Degree of calcination completed > 90%

• 60% fuel burnt in PC and 40% in kiln, kiln thermal


loading will be lower. Refractory service life is longer.

• Utilization of alternate fuels

• Meeting the requirement of Environmental Norms


CONDITIONS FOR COMPLETE
COMBUSTION IN THE CALCINER

• RAPID INITIAL IGNITION

• ADEQUATE RESIDENCE TIME

• INTENSIVE MIXING OF FUEL WITH AIR


MAIN DEVELOPMENTS IN CALCINERS

• COMPLETE COMBUSTION, EVEN OF LESS REACTIVE


FUELS (e.g. Petcoke)
• ABATEMENT OF HARMFUL EMISSIONS (e.g. Nitrogen
oxides)
• Simultaneous use of different fuels of fluctuating
composition with increasing percentage in lumps
form.
• Cost-saving, compact configuration, incorporation
into existing plants
PRECALCINERS

• FLS
• KHD
• Polysius
• RSP
• FCB
DEVELOPMENTS IN PRECALCINERS

• FLS CALCINERS
– ILC – NOX
– SLC-DOWN DRAFT
– HOT DISC
FLS CALCINER SYSTEMS
Low NOx - ILC Calciner
SLC-D Calciner
Latest Low NOx - ILC Calciner
FLS Hot Disc
FLS Hot Disc
FLS Hot Disc
DEVELOPMENT OF KHD PYROCLON
CALCINERS
KHD PYROCLON – R LOW Nox
KHD PYROCLON – R LOW NOX WITH
IGNITION MODULE
KHD PYROCLON – R LOW NOx WITH
COMBUSTION CHAMBER
KHD PYROCLON LOW NOx WITH SNCR
POLYSIUS CALCINERS
POLYSIUS CALCINER DESIGN WITH
TERTIATY AIR AND MEAL SPILT
POLYSIUS MIXING CHAMBER AT TOP
OF THE CALCINER WITH SNCR
POLYSIUS STEP COMBUSTOR
IKN LP Cyclone
POLYSIUS
RSP calciner
LOW NOX - RSP CALCINER

G THE MINOX SYSTEM


J

H K

B
RSP (Reinforced Suspension Preheater)

Feature :
Easy combustion control in
Swirl calciner

Easy and steady kiln


operation

Combustion of hard-to-
burn fuel

Utilization of waste
materials.
FCB ZERO – NOx PRECALCINER
CHAMBER ARRANGEMENT
FCB Precalciner disposition in PH
Modifications in PH – PC

• Installation of LP Cyclone
• Conversion of 4 stage 5 stage
• Conversion of 5 stage to 6 stage
• Riser duct and cyclone entry modification
• Enlarging the down comer
• Lowering the feed pipe
• Installation of NOx Calciner
Optimization
 PH exit gases - T,P O2, CO
 Bottom cyclone outlet gases, T,P ,O2, CO
 Kiln inlet gases T,P ,O2, CO
 Across each cyclone Temp & Pr drop
 Degree of Calcination at kiln inlet material
ILC Calciner
CONVENTIONAL TO FLS LP CYCLONE
FLS SEGMENTAL CENTRAL PIPE (THIMBLE))
TYPES OF PH – PC SYSTEM

• In-line calciner (ILC)


• Separate line Calciner (SLC)
ILC - KILN
FLS - HOT DISC

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