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Bowmanville Cement Kiln Technology Guide

This document discusses kiln systems used in cement production. It describes the processes that occur as raw materials pass through a kiln system, including drying, preheating, decarbonation, melting, and cooling. Key reactions like the decarbonation of calcium carbonate and the formation of clinker are explained. Common kiln technologies like suspension preheaters, precalciners, and coolers are introduced. A temperature profile illustrates how material and gas temperatures change throughout the kiln system. Large commercial plants employing multiple kiln lines with daily production capacities up to 10,000 tons are noted.

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Mohamed Saad
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403 views16 pages

Bowmanville Cement Kiln Technology Guide

This document discusses kiln systems used in cement production. It describes the processes that occur as raw materials pass through a kiln system, including drying, preheating, decarbonation, melting, and cooling. Key reactions like the decarbonation of calcium carbonate and the formation of clinker are explained. Common kiln technologies like suspension preheaters, precalciners, and coolers are introduced. A temperature profile illustrates how material and gas temperatures change throughout the kiln system. Large commercial plants employing multiple kiln lines with daily production capacities up to 10,000 tons are noted.

Uploaded by

Mohamed Saad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
  • Bowmanville Cement Technology - Kiln Systems
  • Kiln Systems Introduction
  • Kiln Chemistry: Drying and Preheating
  • Kiln Chemistry: Decarbonation
  • Reactions in the Kiln System
  • Temperature Profiles
  • Suspension Preheater and Kiln
  • Kiln Process Overview

Bowmanville Cement Technology -

Kiln Systems
Kiln Systems
An Introduction

Production level
Limitations
Drying/heating
Kiln Chemistry
Drying and preheating
Dry process kilns have very little free water
associated with the kiln feed, a small amount of water
is also usually bound inside the shale or clay
minerals present. This requires energy to release. In
a pre-heater or pre-calciner kiln, this occurs in the
upper stages of the tower.
Drying/heating
Decarbonation (800C)
Kiln Chemistry
Decarbonation
Decarbonation or calcination as it is sometimes
termed, is the primary energy intensive reaction of
cement kilns. During this process, Calcium Carbonate
is dissociated into Calcium Oxide (lime) and Carbon
Dioxide according to the reaction:
CaCO3 CaO + CO2
This reaction absorbs around 400 kcal/kg of heat. The
degree to which this reaction occurs within the pre-
heater tower is the principal difference between pre-
heaters and pre-calciners.
Drying/heating
Decarbonation
Heat/melts (1250 C)
Drying/heating
Decarbonation
Heat/melts
Clinker (1450C)
Drying/heating

Decarbonation
Heat/melts
Clinker
Cooling
Kiln Chemistry
Reactions in the Kiln system
Raw meal/slurry undergoes a series of chemical changes as
it passes from the kiln inlet to the cooler. These changes or
reactions occur in approximately the following order:
Drying and pre-heating.
De-carbonation.
The formation of low temperature melts and fluxes.
C2S formation
C2S converting to C3S
Temperature profiles of gas and material in a rotary kiln

2000
System boundary
Gas commencement of
decarbonation
1500
Material

1000

500

cooling burning decarbonation preheating drying

Main thermal Subsidiary thermal


system system
Cooler Kiln
Precal Suspension Preheater
Suspension Preheater

Material temp 850C Gas temp: 1150C


Kiln Feed

Suspension Preheater
and kiln

Gas handling

Firing System
Cooler
Calciner Kiln Plant
Kiln Process Overview

Chemistry of the clinker making processes


Suspension preheater
Precalciner
Clinker coolers
Flames
Large Plant ?

Kiln 1: 3500t/day

Kiln 2: 4000t/day

Kiln 3: 5500t/day
Kiln 4: 5500t/day
Kiln 5: 10,000t/day
Kiln 6: 10,000t/day

Total: 11.9million t/year

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