Volatiles Cycle

8/18/2019 Volatiles Cycle

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FIRING

VIII – VOLATILES CYCLE


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Introduction

Control Parameters

Consequences of volatilization

Preventive actions and possible optimizations

Influence in the quality of the finished product

CONTENTS


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Introduction

Control ParametersControl Parameters

Consequences of volatilizationConsequences of volatilization

Preventive actions and possible optimizationsPreventive actions and possible optimizations

Influence in the quality of the finished productInfluence in the quality of the finished product

CONTENTS


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Volatile elementsSulfur (S 3! S 2" #

$l%alis (& 2 e 'a 2 #Chlorine

This minority elements are extremely variable in thecomposition of raw materials and fuels.

a) Clin%er

Loss Fuel

ven concentration

condensation volatilization

Pre Gas Fuel

Conditions for the existence of the recirculation heno!enon

*+chan,e of heat in counter flo)

-edia. solid and ,aseous

peratin, temperature intervals that facilitate the circulation of volatileelements. condensation and volatilization/

Circu!stances that fa"or the #existence$ of this heno!enonVOLATILES

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T% es of C%cles

VOLATILES

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IntroductionIntroduction

Control Parameters




CONTENTS


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If this relation is > 1, meaning that there are sulphates in excess and there is preferentialformation of calcium sulfate, SO !a "ote# in oxidants conditions SO !a starts to become volatile at 1450 ºC

If this relation is = 1 the potassium sulphate, SO $ %, is &fixed' by the clin(er

If this relation is < 1 , part of the al(alis are &fixated' by the !)*

Control &ara!eters

%SO 3 / ! %Na #O/$# %& #O/'( " %Cl/)1

Relation 'et(een SO)*Al+alis in hot !ealRelation 'et(een SO)*Al+alis in hot !eal

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Reference "alueReference "alue ,, ϕ - ./0 1- ./0 1

2e3ree of "olatili4ation2e3ree of "olatili4ation 55ϕ

uel

Clin*er

+CL

5ot mealc 67

-

CL

+

+1

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Control &ara!eters


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O erationro'le!s

O erationro'le!s

6ot !eal co! osition8Reference "alues6ot !eal co! osition8Reference "alues

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O erationro'le!s

Nor!al noencrustation

ro'le!s


ro'le!s


Control &ara!eters


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I. ortant ara.eters in the o0en assa eI. ortant ara.eters in the o0en assa e

Gas velocity Temperature of the firing +one *tmosphere of the firing +one elation between SO ) - *l(alis egree of volatili+ation

There is a +riti+al 2one in hi+h a s.all te. erat4re 0ariation+reates a si nifi+ant +han e in the ele.ents 0olatili2ation5

/ SOSO )) and al(alis, the critical temperature is close to the temperature ofand al(alis, the critical temperature is close to the temperature of

clin(er formation.clin(er formation./ !hlorine, the temperature is 0%112!./ !hlorine, the temperature is 0%112!.

Control &ara!eters

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Consequences of volatilization



CONTENTS


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$ctions

*liminate false air entries and dead zones/9se lo) porous concrete/Install air canons/Systematically control the volatile cycle → Include in the control of the processparameters the determination of S 3 ! &2Cl" in the hot meal/

ProblemsProduction. encrustation in the fumechamber! bloc%a,e of the cyclones andformation of a rin, in the entry :oint/Chemical attac% in the refractory and in the%iln shell/

Alkalis create the expansion of the refractory.

The migration through the refractory createscorrosion and oxidation in the kiln shell.in,s inside the oven. the formation of

spurrite! 2C 2S/CaC 3! )ith the presence ofe+cess sulfur and al%alis stabilizes in theform of sulfate spurrite at 7288;C/

3ncrustation in the pre/calcinator and pre/heater

Conse9uences of "olatili4ation

VOLATILES

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!ollage clin(er4si la temp est trop haute5

6o7te

4si la phaseli8uide est excessive5

!oncr9tions sulfates8ui peut boucher la goulotte

*nneau sulfate4accentu9 par les fuites au :oint5

$%SO condens9 sur les murs4si les envol9es poussi;res trop faibles5

!oncr9tionschlorures

!oncr9tions!aSO


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!ollage clin(er4si la temp est trop haute5

6o7te4si la phaseli8uide est excessive5

!oncr9tions sulfates8ui peut boucher la goulotte

*nneau sulfate4accentu9 par les fuites au :oint5

$%SO condens9 sur les murs4si les envol9es poussi;res trop faibles5

!oncr9tionschlorures

!oncr9tions!aSO &re:calcinator < « Key points »

=urn )here necessary>educe the emissions of ' +

Control.Te! eratureTi!e of co!'ustion *residenceTur'ulence

Ox%3en saturationFuel fineness

Consequences of absent control9n"burnt solid particlesC emissions

VOLATILES

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Conse9uences of "olatili4ation


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Preventive actions and possible optimizations


CONTENTS


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Increase theconcentration of dust inthe s!o+e cha!'erE.g.:

Meal curtain (part of themeal of the last cycloneenters the smokecham er at lo!temperature"#$nstall ele%ators at the%ice&s entrance 'oint orrefractory system insidethe o%en.

Reduce the te! erature

in the firin3 4oneLi!it the false air inlets

Install a '% ass

O ti!i4e the firin3ara!eters

&re"enti"e actions

!%

!0

pre"calcinator

$ir 3;

uel in:ection

-eal cu rtain educin, zone

+idizin, zone

orno

&re:calcinator&re:calcinator

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O"erall !easures ;S!art< cleanin3

&ro'le!s (ith chlorine

&ro'le!s (ith sulfur

&ro'le!s (ith al+alis

A3ainst incrustationsA3ainst incrustations

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&re"enti"e actions


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O"erall !easures

educin, the entry of volatile elements

a) feed uel ptimized conduction of the %iln stability

e,ular inputs of ra) feed and fuel Conduction by e+pert system

$dequate selection of the $

;S!art< !easures

Prevent condensation in the riser duct of the fumes chamber -eal curtain in the %iln entrance Pendulum valves in the meal drop of the cyclones

Inclination of the meal ducts (? 00@# Aide cyclone e+it $void Bdead zones Install sli,htly impermeable refractory $void false air

&re"enti"e actions

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&re"ention a3ainst condensation&re"ention a3ainst condensation

Fonte: Holcim 2001

B ptimal point for the entrance of the meal in the pre

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&re"enti"e actions


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7eal C%clones7eal C %clones

Pendulum valve in the drop of the ra) meal

Dispersion chambers

Incorrect

Correct

Source: Holcim 2001

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&re"enti"e actions


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;S!art< !easures5 cont.

Cleanin, of the critical pointsE installation of cleanin, doors

Installation of air cannonsE cardo+ Cleanin, )ith hi,h pressure pump Cleanin, accordin, to the pressure profiles

Asment Temara CJO

Alhandra

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&re"enti"e actions

Cordoba


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Chlorine &ro'le!

=%:&ass → if the content of Cl " ? 2F than there is the need toinstall

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,!>x/?@ nafarinha 9uente1

'%: ass

$r frio

)*+, GC

*

!ax/ .@ Cl :

Ghe * does not perform )ith anhi,her value! problems )ithresistivity>

-** )**+, (max. -)*+,#

E/3/B A7CC and ACC E3% t

&ilnVOLATILES

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Chlorine &ro'le!

,!ax ?@ inRa( !eal1

Cold air


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&ol%sius solutions for o ti!i4ation of the '%: ass5 =& .

/ Installin3 a s lash late on the !eal dro at the entrance of the+iln → allo!s to create a mixture of the meal of the entrance of the kiln!ith the dustings.

?/ An uni9ue chi!ne%5 =& ra(*+iln → dilution of the dustin3sD

3/ Reduce the te! erature at the exit of the TC u to ?. C/ $nstall dual fluid no//les !ith compressed air.

4/ Reduce the 3as "elocit% in the s!allest section of the 3as entr% atthe =&D0ecommended %elocity of * m1s2 recommended %elocity for gases at the,3 4* 4) m1s

This solution !ill e tested at the E,,&s 5ine )

Chlorine &ro'le!

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Control the le"el of OControl the le"el of O ?? in the +ilnin the +iln

Ghe volatilization of Sulfur depends of the level of 2 in the %iln

C O – O ? *SO ) Ra( !eal

Recirculation ro'le! of sulfur


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$d:ust the molar ratio $l%alisHSulfur 7

&eep the JS as lo) as possible (S in =elite#

-odify the silica module! -S! smaller! for better suitability tothe firin, and ,ranulation

-inimize fluctuations (chemical#

Chan3in3 the co! osition of the ra(Chan3in3 the co! osition of the ra(

Exception : The need to produce a clinker !ith lo! le%el of alkalis !t is necessar" to increase the #olatili$ation o% the al&alis' Ho()

0educing the introduction of sulfur Elongating the flame 0educing the firing&s aptitude (increase the M6# 0educing first the air $ntroducing chlorinated elements2 e.g.: sol%ents

Recirculation ro'le! of sulfur

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Firin3 o ti!i4ation

&ara!eters to 'e o ti!i4ed in the firin3 4one&ara!eters to 'e o ti!i4ed in the firin3 4one

< u r n i n g = e v e l4 F r e e = im e 5T > T P O b :

< u r n a b i l i t y4 a w m i x d e s ig n 5

T e . / e r a t 4 r e

$ i ln S p e e d

< u r n e r P i p e4 . e s i g n , S e t t i n g s 5

L e n 1 h

O % = e v e l4 S O ) m a i n l y 5

? % O4 * l ( a l i s 5

A t . o s / h e r e T h e r . a l L

6 o la t i l i+ a t i o n i n t h e< u r n i n g @ o n e

Volatilization

irin, Kone

Gemperature Jen,th $tmosphere Ghermal load

-a+imize free lime ↑

C3S ↑

Improve.

7 / irin, aptitude

2 / a) composition

(variability#

=urner re,ulator

(ma+imize air 7; ↑ #

=urner parallel tothe %iln alliance

&iln Velocity

↑ 2 and S 3 ↓

5 2 and $l%alis ↑

-a+imize loadat the pre ↑

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. o u b l e s a l t s4 f r o m r e c i r c u l a t i o n 5s t a r t v o l a t i l i + i n ga t A 1 1 / A B 1 !

T e . / e r a t 4 r e

T h e s h o r t e r t h e b e t t e r

7 e s i 6 e n + e T i . e

, e d u c i n gc o n d i t i o n s4 l o w " O x P r e c a s 5

F u e l s o f S u b s t i t u t i o n4 T i r e s 5

F u e l F i n e n e s s

A t . o s / h e r e

6 o l a t i l i + a t i o n i n t h e! a l c i n i n g @ o n e

o r - a n dt h e P r e c a l c i n e r

&ara!eters to 'e o ti!i4ed in the re:&ara!eters to 'e o ti!i4ed in the re:calcinatorcalcinator

Volatilization

Pre"calciner and pre"heaterPre"calciner and pre"heater

Gemperature Permanence time $tmosphere

educin, conditions

9se of tyres

uel fineness(lo)er ,radin,#

$s brief as possible88 < 08 ;C

? 08 ;C!

Volatilization restarts


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Gas retention time# 0,A secsDaterials retention time# secs

Gas retention time # ) to ,B secsDaterials retention time #0B secs

)

( 1! 3!$

(!

3!

#!

1!

!

#! 8! 1!!

Volatile .aterials

7etention ti.e 9se+s:

7 '! ;. .B ).B %.B 0.B%

atio bet)een the retention timeand the characteristics of the fuel

Firin3 o ti!i4ation

VOLATILES

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&ara!eters to 'e o ti!i4ed in the re:&ara!eters to 'e o ti!i4ed in the re:calcinatorcalcinator


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7ea+ti0e ra7ea+ti0e ra Reacti"e Clin+er

Controlled firin3

& I < 1(

7e 4lar ra7e 4lar ra

E!ission accordin3 tothe nor!

-S 9# # " # 8:Eas? firin ra

Eas? firin ra

Ra( co! osition influence

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i h C 3S.ore C 3A than C ( A


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Influence in the quality of the finished product

CON

TENTS


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SOSO )) Clin+erClin+er SO ) L more reactive clin%er

hi,her mechanical resistance at 2 and days faster cementMs hydration velocity

Al+alis Clin+erAl+alis Clin+er 2 types of sulphates.S 4&2 → hi,her )ater solubility → etter hydrationS 4Ca → combines )ith the phases of the clin%er/

,u ic , 7 A → orthorhom ic8 less reacti%e#

Ghe al%alis reduce the mechanic resistance to 2 days and the chlorinespeeds up the settin, and corrodes the concrete reinforcement/

If the sulphates are trapped in the clin%er! there is a lo)er volatilesMcirculation/

Influence in the 9ualit% of the finished roduct

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O ti.i2e the in 4t7a an6 f4el

@S.art re0ention .eas4res

O ti.i2e the firin ara.eters

Su!!ar%

-easures to minimize the recirculation phenomenon of the volatile elements-easures to minimize the recirculation phenomenon of the volatile elements

VOLATILES

C YCLE

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Volatiles Cycle

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