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Optimisation of The Rotary Kiln
Optimisation of The Rotary Kiln
SUBMITTED BY
BALAJI.A
BALAMURASU.R
SAMPATHKUMAR.G
AYYAPAN.S
SUBMITTED IN PARTIAL FULFILMENT FOR THE AWARD OF THE
DEGREE OF
BACHELOR OF ENGINEERING
IN THE
CHEMICAL ENGINEERING BRANCH
SCHOOL OF CHEMICAL AND FOOD SCIENCE
KONGU ENGINEERING COLLEGE
(AUTONOMOUS)
PERUNDURAI-638052
APRIL 2011
BONAFIDE CERTIFICATE
(07CHR009)
BALAMURASU.R
(07CHR011)
SAMPATHKUMAR.G (07CHR040)
AYYAPPAN.S
(07CHR008)
SIGNATURE
Dr.K.SARAVANAN
HEAD OF THE DEPARTMENT
Department of chemical engineering
School of chemical and food science
Kongu engineering college
Perundurai
Erode -638 052
SIGNATURE
Dr.K.CHANDRAMOHAN
GUIDE
Professor, Dep of Chemical Eng
School of chemical and food science
Kongu engineering college
Perundurai
Erode-638052
CERTIFICATION OF EVALUATION
College Name
Branch
: Chemical Engineering.
Semester
Sl.No
: VIII.
Title of the
project
with designation
1.
Balaji. A
(07chr009)
2.
Balamurasu.R
(07chr011) Optimisation of
3.
Sampathkumar.G (07chr040)
4.
Ayyappan.S
(07chr008)
Dr.K.ChandraMohan
rotary kiln in
Professor
paper mill
Department of
chemical
The reports of the project work submitted by the above students in partial
fulfilment for the award of Bachelor of Engineering in Chemical Engineering
was evaluated and confirmed to be reports of the work done by the above
students.
(EXAMINER I)
(EXAMINER II)
ACKNOWLEDGEMENT:
We
wish
to
express
our
sincere
thanks
to
our
correspondent
CONTENTS
PAGE NO.
SYNOPSIS
LIST OF FIGURES
II
CHAPTER 1
INTRODUCTION
1.1 ABOUT THE COMPANY
1.2 EXPANSION/MODERNISATION PROJECT
1.3 ENVIRONMENTAL PROTECTION
1.4 CHEMICAL RECOVERY PROCESS
1.5 ORIGINOF PAPER
1.6 OVER ALL PAPER MANUFACTURING PROCESS IN SPB
1.7 MANUFACTURE OF PAPER
1
2
2
3
4
5
CHAPTER 2
LITERATURE SURVEY
2.1 ROTARY LIME KILNS
2.2 NECESSITY OF ROTATION IN ROTARY LIME KILN
11
11
11
12
13
13
14
15
16
17
10
18
CHAPTER. 3
DESIGN CALCULATION OF LIME KILN
3.1. MASS FLOW RELATIONSHIPS
3.2
LIST OF FIGURES
GF
G CaO
G co2
GW
Gi
Ga
Gcp
HR
HHV
LHV
Tp
T ref
= Reference temperature
Tge
Tsh
= shell temperature, 0C
FLHV
f cp
hgc
Qsh
hi
= Excess air
= Mud solids
= Lime availability
= Dust loss
Gm
Cps
sh
= Shell emissivity
= Residence time, hr
D =Kiln outside diameter, m
V = Wind velocity, m/s
L = Length, m
= Angle of inclination, degrees
q c = Convection heat transfer , W/m2
q r = Radiation heat transfer , W/m2
CHAPTER-1
INTRODUCTION
1.1
1.2
EXPANSION/MODERNISATION PROJECT
The Company Embarked On An Expansion / Modernization Project To
Enhance Its Production Capacity From 60000 Tons Per Annum, To 1, 15,000
Tons Per Annum And To Upgrade Some Of The Existing Facilities, At An
Estimated Cost Of Rs 1890 Millions.
The Said Expansion / Modernization Project Was Completed In December 2010
After Successful Trials, the Commercial Production Out Of the New Paper
Machine Commenced On July 1, 2010.
The Current Installed Capacity of the Company Stands at 1, 15,000 Tons
per Annum.
At Present Five Machines Produce An Average Of 330 Tpd of Paper. To
Meet its Pulp Requirement, SPB Produce About 235 Tpd Of Wood And Bagasse
Unbleached Pulp And Balanced Is Purchased. SPB Has Four Stationary
Digesters, Brown Stack Washing (BWS), Screening & Centri Cleaning And
Bleaching System (CEPHH) For Production of Bleached Wood Pulp
1.3 ENVIRONMENTAL PROTECTION
The Company attaches paramount importance to the conservation and
improvement of the environment. In its efforts to improve the environmental
protection measures, the Company has installed:
RAW MATEIALS:
Hard wood and Bagasse are the two basic raw materials mostly
used in SPB for manufacturing paper. Following steps are involved in the
paper making.
Some modern plants use totally enclosed pressure diffusion washers following
O2 delignification to further reduce toxic effluent.
It involves increased substitution of chlorine dioxide for chlorine gas.
Chlorine dioxide does not release the chlorine ions responsible for forming
dioxin. Although chlorine dioxide is more expensive to produce, it requires
2.5~3 times less to bleach the same amount of pulp. Some processes which use
O2 delignification prior to bleaching have achieved 100% substitution of
chlorine dioxide.
Although many changes have evolved which have decreased dioxin
emissions, the future continues to hold change. Federal and state regulatory
agencies continue to disagree on allowable emission limits. Future technology
will continue to move toward zero discharge limits for dioxins and other byproducts of the bleaching process.
Step -5: STOCK PREPARATION
The stock is prepared is a series of steps that converts logs to a suitable
form for use in the pulp mill.
Logs from the forest are usually received from a truck, rail car, or barge.
Large overhead cranes are used to unload and sort the logs into piles for long or
short logs. Logs may pass through a slashed if a certain length is required.
The next step involves debarking which removes both dirt and bark from the
logs. The most common method employed is mechanical debarking via a
barking drum.
Logs are fed into the rotating cylinder and the rotating/tumbling action
rubs the bark from the logs. The bark falls out of the cylinder via slots and
debarked logs exit the opposite end of the cylinder. Bark is used as fuel for the
power boiler.
Following debarking, the logs are fed to the chipper. The chipper uses
high speed rotating blades to reduce the logs to chips of a suitable size for
pulping. Chips are then screened for acceptable sizes by passing them over a set
of vibratory screens. The rejects are returned for further chipping and acceptable
chips stored in large outdoor piles or silos for pulp mill use.
Step-6: PAPER MACHINING
The Paper Machine is a very large piece of machinery. A typical machine is
about the length of two football pitches and around 4 meters wide. It can run up
to speeds of 2000 m per minute - or 60 miles per hour! The machine itself
consists of 7 distinct sections. The flow box, wire, press section, drier section,
size press, calendar and reeling up.
The first section of the machine is called the 'Wet End'. This is where the
diluted stock first comes into contact with the paper machine. It is poured onto
the machine by the flow box which is a collecting box for the dilute paper stock.
A narrow aperture running across the width of the box allows the stock to flow
onto the wire with the fibers distributed evenly over the whole width of the
paper machine.
Step 7: CHEMICAL MEASURING METHOD (KAPPA NUMBER)
The Kappa number is an indication of the residual lignin content
or bleach ability of wood pulp by a standardized analysis method.
Measuring method
The Kappa number is determined and applicable to all kinds
of chemical and semi-chemical pulps and gives a Kappa number in the range of
1-100.
The
Kappa
number
is
measurement
of
how
much
CHAPTER 2
LITERATURE SURVEY
LIME KILN PRINCIPLES AND OPERATIONS
2.1 ROTARY LIME KILNS
Rotary lime kiln are large steel tubes that are lined on the inside with
refractory bricks. They are slightly inclined from the horizontal and are slowly
rotated on a set of riding rings. Lime mud is introduced at the uphill, feed end
and slowly makes it away to the discharge end due to the inclination and
rotation. A burner is installed at the downhill or discharge end of the kiln fuel is
burned to from an approximately cylindrical flame. Heat transfer from this
flame and the hot combustion gases that flow up the kiln dries, heats, and
calcines the counter-flowing lime solids. Rotary kiln in the pulp and paper
industry range in size from 7 ft (2.1m) in diameter by 175 ft (53m) long to 13.5
ft (4m) in diameter by 400ft (122m) long . The refractory lining is from 6 in
(15.2cm) to 10 in (25.4cm) thick. Production capacities for these units range
from 50 tons/day of capacity for these units range from 50 tons /day of Cao (45
metric tons/day) to 450 tons/day of Cao (400 metric tons/day).
The weight of the kiln is supported on the riding rings that encircle kiln.
These riding rings contact carrying rolls supported by concrete piers. A large
electric motor operating through a reducing gear box and pinion drives a main
gear attached to the kiln. Typically the kiln is driven at speeds of 0.5 to 2 RPM,
often with variable speed arrangements. Typically transit times for the lime
through the kiln are from 1.5 hours to 4 hours under normal operating
conditions. This is set by the speed and by the slope of the kiln, which is
between 1.50 and 3 0 (5/16 to 5/8 inches/foot).
efficiency and refractory service life. However, irrespective of the shape, the
flame must not touch the refractory, or serious refractory washing will occur.
out of the cold end of the kiln. The ID fan is used to control the total air flow
into the kiln for combustion so controls the excess air or excess oxygen in the
flue gas from the kiln.
Fans, draft and O2
PA fan only for flame shaping
ID fan is main air moving fan
- Use ID fan to control O2
- Often limited production capacity
- Wet scrubber is main for restriction
The capacity of the ID fan often limits the production capacity of the kiln.
When the ID fan reaches its maximum capacity, no more combustion air can be
brought into the kiln. This limits the fuel firing rater and the lime production
rate. For many installations the wet scrubber that follows the ID fan in the flue
gas system is the biggest resistance to flue gas flow, so scan limits the ID fan
capacity. Changes in wet scrubber pressure-drop for emission control or changes
in fuel type can decrease the ID fan capacity and kiln production capacity.
2.9. LIME KILN HEAT RATE
The energy efficiency of lime kilns is expressed as the heat Rate. Heat
is the reciprocal of energy efficiency, and is usually expressed as MM Btu/ton of
CaO. or as GJ/tone of CaO. Lower values of Heat Rate indicate more efficient
operation.
The main chemical reaction in a lime kiln is calcining, the conversion of the
calcium carbonate (Caco3) in the lime mud into calcium oxide (Cao) in the kiln
product. Energy is required to cause this endothermic reaction to occur, but
there are other energy components to the overall energy demand of the kiln.
Lime Kiln Energy Balance Components
Drying
Calcining :CaCO3 + heat-> CaO +CO2
Losses
Heat loss through shell
Heat loss in hot lime product
Heat loss with gas and dust exiting at cold end
A portion of fuel higher heating value is unavailable
IIIIV is measured and reported
Only Lower Heating Values (LHV) is actually available
Net Gas
25TPD
78%
3%
85%
18%
6000F
6000F
11.4 MM Btu/hr
contribution
Heat
fraction
Remedy
Calcining
Rate
2.82
34%
No change possible
reaction
Heat to
evap 1.75
21%
Increase
mud
dry
16%
solids
Decrease
exit
gas
13%
10%
3%
1%
temp
Insulating refractory
Change fuel
Product coolers
Improve chain system
water
Heat in exit gas
1.50
1.10
0.82
0.29
0.11
Base
Nal ZGas
250
Refractory
Nal Gas
250
Fuel Type
Fuel Gas
260
Chains
Net Gas
250
78%
3%
85%
78%
3?%
85%
78%
3%
85%
availability
Dust loss
Product
1`2%
600
18%
600
18%
600
temp,F
Cold and gas 600
475
500
525
temp,F
Shell
6.3
11.4
11.4
Btu/tu
Heat Rate,MM 8.4
7.0
7.4
8.0
Btu/tu
change
-17%
-11%
-4%
19%
600
Heat 11.4
Loss,MM
Improving the Kiln refractory to reduce the shell heat loss obviously has a very
impact on Kiln Heat Rate, but the fuel used in firing the kiln is almost as
important.
Base
Nal ZGas
250
Refractory
Nal Gas
250
Fuel Type
Fuwel Gas
260
Chains
Net Gas
250
Rate TPD
Muddry
75%
78%
78%
78%
solids
Kiln exit o2
Lime
3%
85%
2%
85%
3%
85%
3%
85%
availability
Dust loss
Product
18%
600
18%
600
12%
600
18%
600
temp,F
Cold and gas 600
575
600
600
temp,F
Shell
11.4
11.4
11.4
8.1
8.2
8.2
-3%
-3%
-2%
Heat 11.4
Loss,MM
Btu/tu
Heat
6.4
Rate,MM
Btu/tu
change
Wood and bark powder have been fired directly in kilns as the main kiln fuel.
The NPEs in these fuels are usually low enough so that modest increase in like
makeup can control build up of NPEs in the recovery loop.
There are several schemes to separate lignin from the black liquor and use it
as product or as fuel for the like kiln. Tests of lignin as a fuel both in test
facility and in the field have shown this is feasible, though the sulfur content is
relatively high.
Pyrolysis oils have also been proposed for lime kilns but fuel handling problems
need to be overcome to make this attractive.
Other Solid / Liquid Kiln Fuels
Wood not bark powder
- NPEs can be high
Lime purge & makeup sanded to central NPEs
Lignin
sulfur can be high
of
Pyrolysis
Oilsand other materials, which have been used for
On the gasification
wood, coal
many years to provide
fuel-gas for
kilns.issues
The lower cost of the
- clean
Not currently
and,firing
pH &lime
possible
gasification fuel offsets the high capitals cost of the equipment needed to gasify
these fuels. Good, stable operations possible with gasification with production
capacity and Heat Rate similar to that or natural.
Gasification Fuels
Coal, wood and other fuels can be gasified
Fuel-gas can be used to fire kiln
- Similar to natural gas
- Lower inert level, well established technology
- On-line availability 85%
- Wet gasifier feedstocks derate kiln
- Burner and chains must be designed for fuel-gas
The fuels that ate generated in the pulp mill. Turpentine, methanol,
stripper off-gas (SOG), and non condensable gases (NCG) have all been burned
in lime reburning kilns. The energy content of these fuels varies considerably,
but each makes a contribution to over all heat input. These materials contain
some sulphur that can derate the kiln capacity, and all of them lower the Heat
Rate of the kiln.
Fuels from the pulp mill
Turpentine or methanol liquid
Stripper off-gas (SOG)
Non condensable gas (NCG)
- Can be wet and sulfur level can be high
Tall oil and tall oil pitch
- Can fire 100% tall oil, similar to fuel oil
- 16,000Btu/lb and low sulfur
CHAPTER. 3.
DESIGN CALCULATION OF LIME KILN
CALCUATION
3.1. MASS FLOW RELATIONSHIPS
G m=GCaO
1+0.786 a 1
a
d
1+0.7860.85
1
=250+ (
)*( 10.18 )
0.85
G d=G CaO
1+0.786 a d
a
1d
1+0.7860.85
0.18
= 598.31 (
)*( 10.18 )
0.85
1+0.786 a 1 1s
a
1d s
= 598.31*(
1+0.7860.85
1
10.78
)*(
)*(
)
0.85
10.18
0.78
= 168.75 tons/day
Gi=GCaO
1a
a
= 598.31* (
10.85
)
0.85
= 44.12 tons/day
G co 2=G CaO
44
56
44
= 598.31* 56
= 196.428 tons/day
G cp=G f [1+ ( 1+e ) AFS ]
= 432.8 tons/day
3.2
fLHV =
LHV
HHV
7
7
= (4.07 10 )/(4.27 E 10 )
= 0.953
Losses due to flow of combustion products
{ 1+ ( 1+e ) AFS } CpCp ( TgeT ref )
f cp=
HHV
7
= ({1+(1+ 0.20)13.44 }12.67 (17525))/(4.27 10 )
= 0.0762.
Gf
17525
+196.428919 )
+44.12(80-25)*1046
= ( (36.744.27 10 )/ 250
= 6275192 J/kg
3.4. HEAT RATE CALCULATION PARAMTERS
FUEL CONSTANTS
Nat.gas
Fuel oil
Units in SI
HHV
5.37E+07
4.27E+07
J/kg
LHV
4.86E+07
4.07E+07
J/kg
AFS
16.80
13.44
PROPERTIES
Combined product specific heat
Cp Cp
1.267
J/kg/0C
Cp CaO
989
J/kg/0C
Cp co2
919
J/kg/0C
Cp i
1,046
J/kg/0C
Cp s
1,991
J/kg/0C
Heat of calculation
Enthalpy of vaporization
H
r
3,270,045
J/kg
hfg
2,439,465
J/kg
0.35
(Tsh25)
0.35
= 1025.8 W/m2
Shell heat loss, W
n
Q sh=D ( q c+ q r )
= 4704.5 W
3.6. RESIDENCE TIME CALCULATION
L
60 nDtan
= 82/(600.833.52tan ( 6))
= 1.416 hr.