Pyroprocessing

Trapping : Impact on Process

 Pyroprocessing - Trapping

Contents

 General notions on Trapping

 Coating Risks

 PH BuildUp

 Sulfate Ring

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 Pyroprocessing - Trapping

General notions on trapping : Outlines

 Maximum level

 Condensation on Dust

 Type of Coating

 Specific case of Chlorine

 Trapping in clinker and refractory

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Trapping- Coating Risk

 Maximum level in the kiln load entering the burning zone :

 SO3<4 to 5 % (Exp.: < 3,5%)
 Na2Oeq<4 %
 Cl<1% (Exp.: < 2,5 [%])

ABOVE THESE --> Build-ups, Balls and

Rings formation

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 Pyroprocessing - Trapping

Trapping occurs on:

 Kiln dust

 Kiln load

 Refractory lining

 Clinker

 On walls : Buildups & rings

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Trapping Main mechanism :
Condensation on dust

 Gaseous volatile + Dust = Condensation

 After condensation of the volatile, the dust gets sticky --> rings and
build-ups
 The dust is much richer in volatile than any other material flow
 Part of the dust goes back with the kiln load
 Part of the dust can be wasted (recycled in the cement)
 Promoted by dust curtain (preheaters), chain system

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 Pyroprocessing - Trapping

Trapping in Kiln Load

 Probably marginal compared to condensation on dust

 Promoted by dust curtain (preheaters), chain system

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Trapping in refractory

 Volatiles are found in the bricks, shells ...

 Alkalis may react with the refractory  expansion

 Migration through the bricks and chemical attacks of the shell and
anchors (corrosion/oxidation)

Infiltration SO3

Infiltration chlore

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Trapping - Retention in clinker

 The more important way of volatiles output

  Trapping in clinker =  recycling load/ volatiles recirculation, then...

 Low recycling load: reduction of rings and build-ups formation,

improved kiln stability

 Reduction of walls corrosion and attacks to the brickwork

 Emission reduction at the stack

 Quality monitoring improved

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 Pyroprocessing - Trapping

Trapping in Clinker

Type of kiln SO3 K2O Na2O Cl-

v t v t v t v t
Wet kiln without dust wasting 0.59 0.76 0.45 0.81 0.12 - 0.99 -
Wet kiln with dust wasting 0.72 0.63 0.53 0.51 0.24 0.68 0.99 -
Long dry kiln 0.65 0.87 0.65 0.81 0.21 0.45 0.99 -
Preheater kiln 0.8 0.9 0.69 0.96 0.26 0.79 0.99 0.99
Precalciner kiln 0.55 0.96 0.49 0.98 0.55 0.6 0.99 0.99
(Prepared from average volatile balances made within Lafarge)

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Trapping on Walls

 2 types:
 Trapping in tower from condensation
• Build-ups (same as condensation on dust)
• Trapping in kiln  rings

 Types of rings
 Ash
 Sulfate
 Clinker

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Trapping - BuildUp zone

Condensation + Analyze the

reactions with dust built up
lead to build-ups, material!
rings , etc. Chlorine
Build-up
Zones
Blocks dust flow,
restricts draft,
destabilizes, cuts
output SO3
Build-up
Zones ESP fouling

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Types of build-up and rings

description kiln type position/ zone gas ?C° material?C°

coating all kilns ID 120-400 -

slory ring wet kiln drying 150-300 <100
coating PH cy 3/4 700-1100 700-900
coating grill PH walls and roof 1000-1100 -
coating short dry kiln inlet 1000-1100 800-1000
raw meal ring all dry kilns calcination 1100-1400 800-1200
balls all kilns calcination <1400 <1200
sinter ring all kilns beginn sinter 1400-1600 1250-1350
coating all kilns sinter 1600-1800 1250-1450
CK ring all kilns end sinter 800-1600 1200-1400
snowman cooler beginn 600-1000 1200
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Case of chlorine

 It will condense in the lower temperature area in the kiln and

will create build ups

 [600 ºC - 800 ºC] - Maximum at 750 ºC

 Either
• salts formation (KCl, NaCl, CaCl2)
 Or
• entering the minerals

 Lowers the temperature of decarbonation

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 Pyroprocessing - Trapping

Contents

 General notions on Trapping

 Coating Risks

 PH BuildUp

 Sulfate Ring

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Coating Risk Indexes

 S Index

 Coating Index

 S/Cl curve

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S-Index

 S-index or “Stickiness” index

 Under development since 2001

 Appears related to coating, snowmen & ring problems (front of

kiln) & fine dusty clinkers
 Fine clinkers sticks to cooler walls, burner pipes & nosering castings
 Also causes problems with IKN KIDS & coolers in general
 Want well formed clinkers for good cooler operations

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S-index
C3S X AR + Liq1340 X K2SO4
S-Index = - (Liq1450-22)
8X 0.31(LSF-100) +2.18(SR-1.8)
Relative Free Lime

 Target to be above 10
 Determined from clinker chemistry

 A measure of risk:
 The lower the S-index the greater the chance of a ring forming
• But burn just right & no ring will form
 The higher the index the lower the risk
• But not impossible, operator has to go out his way

 Does make correlations difficult

 If Relative fCaO<0.1 AND Liq1340>21, then S-index = 0

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S Index : explanation 1
 Liquid at 1340C
 Right amount critical to starting clinker nodulization
• Otherwise fine dusty clinker results
 Operator reaction is to burn hotter which makes

dustiness & stickiness worse. (FLS research)

 Nodulization efficient @ 1330C-1350C
 Coating more strongly related to Liq1340C

 C3S
 High C3S PLUS high BZ temp results in Alites sintered
together into bigger coarse Alites (particles)
 FLS says as long as particles remain fine, good nodulization
can occur. When particles get too coarse – dusty clinker
results – despite amount of liquid present.
 Long BZ + high BZT encourages bigger Alites but dustier
clinker & pumice like coating (FLS)
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2. S Index : explanation 1
 Alumina Ratio
 Proper amount promotes more melt content above 1350°C & more
viscous, better nodulization (at high temp)
 1300C-1340C, AR = 1.6 considered ideal (FLS- although we tend to
favor closer to 1.5)
• Affects rate of alite formation at this temp
• Therefore influences nodulization
 AR too high or too low does not promote nodulization

 Relative Free Lime

 Assuming constant quartz, calcite, argil sizes, predicts amount of free
lime @ 1400C
 The higher the value the harder the burning that will be required
• FLS has similar equations (see notes)

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2. S Index : explanation 1
 K2SO4
 The higher the value the easier the burnability or combinability
 Alkali levels & burner settings are factors

 Liquid at 1450C
 Linked to scale overall stability & adherence to refractory

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S index : Locations Tried

 Developed for Joppa
• Cross check mix designs

 Used by Bath
• Used to monitor closely – AR sensitive, but now generally
good all of the time (except for excursions)

 Used by Exshaw
• Periodically gets into trouble – low LSF – perhaps raise
C3S target – large ash variations makes targeting tough

 Tulsa
• Historical problem with ring formation

 All found good correspondence to ring formations

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Coating Index

C.I. = C3A + C4AF + 0.2*C2S + 2*Fe2O3

 Must be between 28 – 30

 Focuses on flux & liquid contributors, but not burnability

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S/Cl curve (hot meal analysis) : Build ups Risk

% Cl

3
Quick build ups problems

Acceptable
1 build ups

Minor
build ups
0
1 2 3 4 5 6
SO3 (% )

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Indexes

Recommendations
 S-index, coating index and SO3/Cl curve appear to give chemical
conditions that could promote easy formation of rings & heavy
front end build-up
 Can be used as a diagnostic tool to determine what target
adjustments are needed to help avoid rings in the future
 All plants should track those indexes

Remember
 Build-Up/Ring/snowman formations are a 2 sided coin

 It happens only if:

 You have the right chemistry (S-index/Coating Index/SO3/Cl curve)
 You have to high volatilization

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 Pyroprocessing - Trapping

Contents

 General notions on Trapping

 Coating Risks

 PH BuildUp

 Sulfate Ring

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 Pyroprocessing - Trapping

Build Up in PH : Outline

 Location and type

 Detection

 Build Up Control and Removal

 Main reference : TA BuildUp control

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Build-ups in preheaters
Build ups
CaSO4 from FeS2
dissociation

 SO3 and other volatiles are

trapped on dusts

 The kiln feed becomes more

sticky -> Blockages

Build ups
chlorides

clinker « coatings »
(if temp is too high)

Voûte
(si la phase
liquide est excessive)

K2SO4 condensated on the walls

If the dust concentrations is too low)

Build ups sulfates

Which can block the duct Sulphates rings

(accentuated if the seal is leaking)

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Build-ups type vs temperature

Gas Temperature

1400C

1300C Build-up rate and hardness

Hot core
increases, with increasing
calciner
temperature
maximum 1200C
outlet gas CK
temperatures
1100C
Build-up starts to clinker

SO3 build-up rate and hardness increases

1000C
with increasing temperature
Small
SO3
Calciners 900C
SO3 build-up is soft, easy to clean,
Large 800C occurs slowly
Calciners
700C Cl Chlorine related build-up
Bottom stage
exit gas
maximum 600C
temperatures

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Build Up Detection
 Plugging can be detected in the following ways:
 Nuclear / gamma ray plug detectors (cyclones -
recommended)
 Air pressure rings (cyclones)
 Increasing differential pressure at constant draught
(riser and calciner)
 Significant change in air distribution, tertiary air duct
vs. kiln, given by damper or variable restrictor
position
 Different thermal profile by installed thermocouples
or handheld
 Spikes and sudden short changes of pressures,
indicate falling build up’s in the cyclones, riser ducts,
dip tube or cyclone entry.

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PH BuildUp Control and Removal

1. Primary actions

2. Design and Equipment

3. En-rich condensation on dust : Meal curtain and Durty back end

4. By-pass

5. Removal

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PH BuildUp - Primary Actions (Reminded)

 Kiln feed composition

 Alpena regulates upper and lower bench ratios to limit SO3 input

 Fuel composition
 Bath regulates coke/coal ratio to limit SO3 input

 Sulfur – alkali ratio

 Some plants are looking to raise NaEq to be able to use more coke

 Oxygen level

 Chlorine addition
 Used to pull down alkalis in clinker and raise it in CKD

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PH BuildUp - Design and Equipment

 Dead angles
 Dead angles favour deposit and sticking of build-ps (their
cleaning can be difficult) where recirculation occurs
(turbulences, low velocities)
 Cold Zones – favourable for build-ups generation
 Remove them using refractories (or isolating systems)
 If the origin is cold air in leakage  improve gate sealing.

 Anti-adhesive lining
 Installation of refractory bricks and pieces with high density
(low porosity), limiting buid-ups sticking
 Silicium carbide (SiC)

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PH BuildUp - Design and Equipment

 Air Canons (see removal)

 Others
 Meal pipe dimension is to be adapted to meal flow rate
 Flap design ensuring tight seal (prevent recirculation) &
regular feed rate (smooth opening)
 Suppress inleakage and dead zones  optimal flow design
(no edges, angles of walls > 50°,…)
 Use anti-coating refractory (low porosity)

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Solutions depending on Cl and S

0 1 2 3 4 5 6 7
4 3

3,5
2,5

3 Chlorine Bypass
2
2,5 Cleaning (CARDOX blaster);
Karsdorf Preheater design;
2 Malogoszcz 1,5

Kujawy meal curtain

1,5
Sötenich 1
Combustion optimization,
1
Retznei
Mannersdorf burner, sulphur / alkali ratio
0,5
0,5
Trbovlje Medgidia
Darica Beocin
0 0
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7

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Durty Back End : Dust load at the kiln back end

 Principe
  Dust load =  relative concentrations of sticky materials

 How to do?
 Better design of the last cyclone discharge in order to increase the material
percentage blown by the gases at the kiln exit. ( + splash box if needed)
  Gas velocity in the smoke chamber
Figure B – Kiln Inlet Lifters
Figure C – Kiln Chain
Bypass +
SO3 dust
Bypass +
SO3 dust

Meal
SO2
rich SO2
gas rich
gas
Knotted
kiln
chain
Lifters

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Meal curtain

 SO2 is trapped on cold dust surface

introduced from a higher cyclone stage
and is returned to the riser (no bypass to
the rotary kiln)

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Meal curtain

 About 20 % of stage 3 (for 4 stage preheater) meal is sent to

smoke chamber. Volatile condense on this “cold” meal. This cold
meal mix with the gas to go to the riser (Not in the kiln). SO 3
concentration in hot meal is then reduced so hot meal is less sticky

 There is no reduction of volatilization but reduction of build-up

formation

 If it is not possible to take meal from N-1 cyclone, then N-2 cyclone
could be used. In this case, it deteriorate the efficiency of the
preheater (stage by pass). In that case, flap efficiency is very
important as delta P is much higher.

 The lower the meal curtain is installed, the more efficient. In some
cases, civil works constraints do not allow to install efficient meal
curtain

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Meal curtain

 To be qualified by gas temperature mapping

 Increase the dust concentration in the riser on which volatiles are

then trapped

 Meal curtains allow to create a controlled hot spot section by

splitting meal before and after fuel injection

 Recommendation is to install it
 Systematically for separate line calciners
 As often as possible for in line calciners, in this case
 meal curtain design to be optimised to reduce the amount of meal
sent to the riser to avoid excess of kiln exit gases cooling which
could lead to worse combustion in the calciner and higher
volatilisation.

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To decrease trapping coefficient : Bypass

 Dust wasting (Bath for Cl, Alpena for alkalis/SO3)

 Bypass ESW, DAV (alkali/SO3), SCK (Cl), KdF

 CKD (long kilns)

 ESP Vs. Bag house
 Compromise to find between Kiln Stability & CKD rate

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By-pass
 Partial elimination of gas and or dust (kiln back end)

Input Percentage of by-pass

System 0 5 15 30 60
g/Kg CK CK BP CK BP CK BP CK BP CK BP
SO3 13 13 0 11 2 8 5 7 6 3 10
K20 11 11 0 10 1 8 3 6,5 4,5 4,5 6,5
Na2O 3 3 0 2,8 0,2 2,5 0,5 2,3 0,7 1,9 1,1
Cl2 0,5 0,5 0 0,08 0,42 0,03 0,47

 Extracted dust are either wasted or mixed in cement or used mixed as

hydraulic binders
 Material bypass at the cyclone bottom

 Evacuation of Lepol grate dust

 Method generally used to reduce SO3

 Evacuation of ESP dusts

 Method generally used to reduce alkalis or chlorine levels
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Example: By-pass Le Havre

Max 150°C

Cyclones
Cooler
350°C air-air

Bag filter

Secondary cooling

Raw meal
elevator
450°C Max: 3.7 t/h Max: 505 kg/h

Primary quenching
Max: 9250 Nm3/h
Truck
Transportation Pneumatic
transportation

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Bypass

1.2

1.0
Alkali bypass

0.8

v = 0.5

0.6
Reduction
v = 0.7
in Volatile

0.4

v = 0.9
Cl bypass 0.2 v = 0.95

v = 0.99

0.0
0 10 20 30 40 50 60 70 80 90
% By p ass

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By-Pass - Reduction Rates

100

90 Epsilon Cl = 98 % Cl

80 K2O

Na2O
70
Reduction in %

SO3
60
Epsilon K2O = 60 %
50

40
Epsilon SO3 = 50 %
30

20
Epsilon Na2O = 10 %
10

0
0 10 20 30 40 50 60 70 80 90 100
Bypass-rate in %

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Removal : Automatic Cleaning

 Big blasters:

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Removal : Manual Cleaning Devices

 Success depending a lot on cyclone
dimensions and general
accessability

 Metal bars

 CARDOX

 Air Lances

 Low Pressure Water (6 Bar)

 High Pressure Water (~ 200 Bar)

 SAFETY

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 Pyroprocessing - Trapping

Contents

 General notions on Trapping

 Coating Risks

 PH BuildUp

 Sulfate Ring

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