DOPOL® ’90 preheaterand PREPOL® calcining system.
PolysiusA companyof ThyssenKrupp
Technologies
tk
PREPOL®-MSC
The PREPOL®-MSC calciner is the standard calcining system for reducingNOx emissions. The MSC (Multi StageCombustion) process is based on thesplit feeding of fuel, tertiary air and raw meal. The effect is only achievedby means of this special mode of operation. This means that the operat-ing costs are no higher than those ofclassical calcining processes. At the numerous MSC plants installedall around the world it has been
PREPOL®-CC
In order to improve the burnout ratewhen using non-reactive fuels, Polysius developed the PREPOL®-CC(Combustion Chamber). The calciningsystem achieves outstanding resultswhen raw materials with poorly com-bustible constituents are used and incases where high internal alkali cyclesmay arise in the kiln plant due to thefuel and raw material compositions,resulting in impairment of the combustion.
The separate combustion chamber,which is connected to the calciningloop by a gas duct, is the main featureof the PREPOL®-CC. Providing the possibility to influence the combustiontemperature, it ensures calciner efficiency when using solid fuels.
proved that, depending on the fuel, the NOx emission rate is reduced by up to 50 %.
PREPOL®-MSC-CC
To reduce operating costs, it has todaybecome common practice to operatethe calciner with fuels which have poorburnout behaviour, as well as with secondary fuels.
At the same time, many plants have to observe regulations stipulating low
limit values for nitrogen oxide emis-sions. To enable nitrogen oxide reduc-tion while maintaining the flexibility offuel usage, Polysius developed thePREPOL®-MSC-CC process.
This combines the combustion cham-ber of the PREPOL®-CC process withthe split introduction of fuel, tertiary airand raw meal that is characteristic ofthe PREPOL®-MSC process.
The kiln inlet is equipped with a kilninlet burner for reducing the nitrogenoxide created in the clinkering zone ofthe kiln. The greater portion of the fuelis fed into the combustion chamber.That leads into the MSC calciner,where there is a further split infeedingof air and raw meal.
PREPOL®-CC with separate combustion chamber (picture at top).
Split tertiary air supply of the PREPOL®-MSC process.
PREPOL®-MSC-CC system installed in
the USA.
Selection matrix for calciners
PREPOL® type AS CC MSC MSC-CC
xxHigh ash content xx xx xx
xNon-reactive xx x xx
x xx xx xx
X X xx xx
xx xx x x
Flexible change of fuel
Emission reduction
Suitability for bypass
xx Very suitable x Well suited X Suitable
Fuelproper-ties
Our new name is
ThyssenKrupp Industrial Solutions
www.thyssenkrupp-industrial-solutions.com
Innovation is at the centre of the Polysius com-pany philosophy. This means purposive inno-vation as an answer to concrete requirements ofthe industries we serve.
In the case of the cement industry, today'srequirement profile for the manufacturing pro-cess is directed at high production capacitieswith low operating and capital expenditure.
For this reason, multistage cyclone preheaterswith integral calciner and tertiary air duct areindispensable components of modern kiln lines.
Polysius offers preheater/calciner concepts that are innovative and nevertheless technicallymature for the production of white and greycement; for new plants as well as plant con-versions, and tailored to the desired productioncapacity – no matter whether this is less than
1,000 or more than 10,000tonnes per day.
The heat produced by the burning process in the rotarykiln and calciner is used forpreheating the raw material.
The preheating and extensiveprecalcination of the raw material shorten the burningprocess.
The high degree of heat utili-sation reduces the fuel requirement and the capitalexpenditure for the rotary kiln.
Moreover, it is possible to uselow-priced substitute fuels andmaterials in the calciner and topositively influence the NOxand CO emissions – an additio-nal plus point for operatingeconomy and environmentalcompatibility.
To assure correct dimensioningof the various preheater/calci-ner systems, the properties ofthe raw materials and fuels aretested in the central researchcentre of the Polysius Group.
This ensures that all thesystems and plant componentsare optimally harmonised.
For every requirement an optimally customisedDOPOL®/ PREPOL® concept.
5-stage DOPOL® ’90 preheater including PREPOL®-CC-MSC
calcining system for 2,600 t.p.d. of cement clinker in Spain.
5-stage DOPOL® ’90/PREPOL®-AS preheater calciner combination in Saudi Arabia; designed for a daily production rate of 3,500 tonnes of grey cement clinker.
4,000 t.p.d. grey cement production line in Vietnam with 5-stage DOPOL® ’90 preheater and PREPOL®-CC system (for anthracite firing).
3-stage DOPOL® ’90 with PREPOL®-MSC-CC calciner
in the USA; output: 2,700 tpdof grey cement clinker.
White cement production line in Spain with 6-stage DOPOL® ’90 preheater.
The first of two 10,000 tpd kiln lines with 5-stage DOPOL® ’90 and PREPOL®-MSC
calciner to be constructed in China.
DOPOL® ’90: the economical preheater generation:
The number of cyclone stagesis selected to suit the individualapplication. As a rule, the throughput and moisture content of the rawmaterials and fuels, which haveto be dried by the remainingexhaust gas heat, decide whether 2, 3, 4, 5 or 6 cyclonestages are used. The cyclonesand gas ducts have a refrac-tory lining, which keeps the ra-diation losses low (below 2 %
of the heat consumption).
Due to to the optimum flow-dynamic design, the pressuredrop of the preheater system issmall, minimising the electricalenergy requirement for theexhaust gas fan.
The high collection efficiency of the cyclones ensures thatthe exhaust gas has a low dustcontent.
Special PREPOL® calcining systems for different requirement profiles.
The calciner fulfils the func-tions of heating-up and calcin-ing the raw material and ofburning the supplied fuel. Theburning of the different types of fuel takes significantly moretime than heating-up and calcining the raw meal and istherefore the determining factorfor the dimensioning of the calciner.
In addition to assuring com-plete combustion of the fuel,the calciner has to function
with great flexibility, in order to cope with the wide range offuel grades used (from highlyreactive to extremely unreac-tive).
Today, great importance is placed on systems incorporat-ing primary measures for emis-sion reduction, and this trend isincreasing.
For such requirements Polysiushas developed the PREPOL®-MSC-CC system in addition tothe proven PREPOL®-MSC calciner. This system permitsthe use of unreactive fuels andsimultaneously reduces thenitrogen oxide emissions.
The Polysius PREPOL®-AS cal-ciner programme (AS standsfor Air Separate; a conceptwhich all PREPOL® types share)thus includes a selection ofversions, -CC, -MSC and -MSC-CC, in order to optimallyfulfil individual requirementswith regard to operating relia-bility, product quality, flexibilityand emission reduction.
Advantages of the DOPOL® ’90 concept:
x Minimal power requirement due to highdegree of heat recuperation and low pressuredrop.
x High efficiency – low heat consumption due to high cyclone collection rate and uniform meal distribution over the gas ductcross-section.
x High availability thanks to the proven, reliable design and construction.
Advantages of PREPOL® calcining systems:
x uniform kiln operation, thanks to extensive precalcination of the raw meal,
x long refractory lining service life in the rotary kiln, as a result of the low thermal loading,
x minimal coating formation in the preheater, due to the low circulation of alkalis,
x low pressure drop in the preheater because of the optimum flow-dynamic design ofthe calciner, and
x superior economy of operation thanks to the high fuel flexibility.
Innovation is at the centre of the Polysius com-pany philosophy. This means purposive inno-vation as an answer to concrete requirements ofthe industries we serve.
In the case of the cement industry, today'srequirement profile for the manufacturing pro-cess is directed at high production capacitieswith low operating and capital expenditure.
For this reason, multistage cyclone preheaterswith integral calciner and tertiary air duct areindispensable components of modern kiln lines.
Polysius offers preheater/calciner concepts that are innovative and nevertheless technicallymature for the production of white and greycement; for new plants as well as plant con-versions, and tailored to the desired productioncapacity – no matter whether this is less than
1,000 or more than 10,000tonnes per day.
The heat produced by the burning process in the rotarykiln and calciner is used forpreheating the raw material.
The preheating and extensiveprecalcination of the raw material shorten the burningprocess.
The high degree of heat utili-sation reduces the fuel requirement and the capitalexpenditure for the rotary kiln.
Moreover, it is possible to uselow-priced substitute fuels andmaterials in the calciner and topositively influence the NOxand CO emissions – an additio-nal plus point for operatingeconomy and environmentalcompatibility.
To assure correct dimensioningof the various preheater/calci-ner systems, the properties ofthe raw materials and fuels aretested in the central researchcentre of the Polysius Group.
This ensures that all thesystems and plant componentsare optimally harmonised.
For every requirement an optimally customisedDOPOL®/ PREPOL® concept.
5-stage DOPOL® ’90 preheater including PREPOL®-CC-MSC
calcining system for 2,600 t.p.d. of cement clinker in Spain.
5-stage DOPOL® ’90/PREPOL®-AS preheater calciner combination in Saudi Arabia; designed for a daily production rate of 3,500 tonnes of grey cement clinker.
4,000 t.p.d. grey cement production line in Vietnam with 5-stage DOPOL® ’90 preheater and PREPOL®-CC system (for anthracite firing).
3-stage DOPOL® ’90 with PREPOL®-MSC-CC calciner
in the USA; output: 2,700 tpdof grey cement clinker.
White cement production line in Spain with 6-stage DOPOL® ’90 preheater.
The first of two 10,000 tpd kiln lines with 5-stage DOPOL® ’90 and PREPOL®-MSC
calciner to be constructed in China.
DOPOL® ’90: the economical preheater generation:
The number of cyclone stagesis selected to suit the individualapplication. As a rule, the throughput and moisture content of the rawmaterials and fuels, which haveto be dried by the remainingexhaust gas heat, decide whether 2, 3, 4, 5 or 6 cyclonestages are used. The cyclonesand gas ducts have a refrac-tory lining, which keeps the ra-diation losses low (below 2 %
of the heat consumption).
Due to to the optimum flow-dynamic design, the pressuredrop of the preheater system issmall, minimising the electricalenergy requirement for theexhaust gas fan.
The high collection efficiency of the cyclones ensures thatthe exhaust gas has a low dustcontent.
Special PREPOL® calcining systems for different requirement profiles.
The calciner fulfils the func-tions of heating-up and calcin-ing the raw material and ofburning the supplied fuel. Theburning of the different types of fuel takes significantly moretime than heating-up and calcining the raw meal and istherefore the determining factorfor the dimensioning of the calciner.
In addition to assuring com-plete combustion of the fuel,the calciner has to function
with great flexibility, in order to cope with the wide range offuel grades used (from highlyreactive to extremely unreac-tive).
Today, great importance is placed on systems incorporat-ing primary measures for emis-sion reduction, and this trend isincreasing.
For such requirements Polysiushas developed the PREPOL®-MSC-CC system in addition tothe proven PREPOL®-MSC calciner. This system permitsthe use of unreactive fuels andsimultaneously reduces thenitrogen oxide emissions.
The Polysius PREPOL®-AS cal-ciner programme (AS standsfor Air Separate; a conceptwhich all PREPOL® types share)thus includes a selection ofversions, -CC, -MSC and -MSC-CC, in order to optimallyfulfil individual requirementswith regard to operating relia-bility, product quality, flexibilityand emission reduction.
Advantages of the DOPOL® ’90 concept:
x Minimal power requirement due to highdegree of heat recuperation and low pressuredrop.
x High efficiency – low heat consumption due to high cyclone collection rate and uniform meal distribution over the gas ductcross-section.
x High availability thanks to the proven, reliable design and construction.
Advantages of PREPOL® calcining systems:
x uniform kiln operation, thanks to extensive precalcination of the raw meal,
x long refractory lining service life in the rotary kiln, as a result of the low thermal loading,
x minimal coating formation in the preheater, due to the low circulation of alkalis,
x low pressure drop in the preheater because of the optimum flow-dynamic design ofthe calciner, and
x superior economy of operation thanks to the high fuel flexibility.
DOPOL® ’90 preheaterand PREPOL® calcining system.
PolysiusA companyof ThyssenKrupp
Technologies
tk
PREPOL®-MSC
The PREPOL®-MSC calciner is the standard calcining system for reducingNOx emissions. The MSC (Multi StageCombustion) process is based on thesplit feeding of fuel, tertiary air and raw meal. The effect is only achievedby means of this special mode of operation. This means that the operat-ing costs are no higher than those ofclassical calcining processes. At the numerous MSC plants installedall around the world it has been
PREPOL®-CC
In order to improve the burnout ratewhen using non-reactive fuels, Polysius developed the PREPOL®-CC(Combustion Chamber). The calciningsystem achieves outstanding resultswhen raw materials with poorly com-bustible constituents are used and incases where high internal alkali cyclesmay arise in the kiln plant due to thefuel and raw material compositions,resulting in impairment of the combustion.
The separate combustion chamber,which is connected to the calciningloop by a gas duct, is the main featureof the PREPOL®-CC. Providing the possibility to influence the combustiontemperature, it ensures calciner efficiency when using solid fuels.
proved that, depending on the fuel, the NOx emission rate is reduced by up to 50 %.
PREPOL®-MSC-CC
To reduce operating costs, it has todaybecome common practice to operatethe calciner with fuels which have poorburnout behaviour, as well as with secondary fuels.
At the same time, many plants have to observe regulations stipulating low
limit values for nitrogen oxide emis-sions. To enable nitrogen oxide reduc-tion while maintaining the flexibility offuel usage, Polysius developed thePREPOL®-MSC-CC process.
This combines the combustion cham-ber of the PREPOL®-CC process withthe split introduction of fuel, tertiary airand raw meal that is characteristic ofthe PREPOL®-MSC process.
The kiln inlet is equipped with a kilninlet burner for reducing the nitrogenoxide created in the clinkering zone ofthe kiln. The greater portion of the fuelis fed into the combustion chamber.That leads into the MSC calciner,where there is a further split infeedingof air and raw meal.
PREPOL®-CC with separate combustion chamber (picture at top).
Split tertiary air supply of the PREPOL®-MSC process.
PREPOL®-MSC-CC system installed in
the USA.
Selection matrix for calciners
PREPOL® type AS CC MSC MSC-CC
xxHigh ash content xx xx xx
xNon-reactive xx x xx
x xx xx xx
X X xx xx
xx xx x x
Flexible change of fuel
Emission reduction
Suitability for bypass
xx Very suitable x Well suited X Suitable
Fuelproper-ties
