By Pass System in The Dry Process

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By pass system in the dry process

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Contents [hide]
1 By pass system in the dry process

2 Introduction
3 Circulation phenomenon
3.1 1. Internal and External Circulation Phenomena
3.2 2. The limits of chlorine and sulfate input in the kiln feed
[on loss on ignition free basis]
3.3 3. Maximum allowable input of volatiles in kiln with
precalciner: [loss on ignition free]
http://www.cementequipment.org/production-engineering/pass-system-dry-process/ 3/22/2018
3.4 4. Circulation Mechanism

3.5 5. Evaporation Rates of Different Elements
3.5.1 Solution
3.6 6. Molecular Ratio of Sulfur and Alkalis
3.7 7. Optimum range of molecular of sulfur and alkalis in
the presence of chlorine
3.8 8. Coating and Ring Formation in Kiln and Preheater
3.9 9. Where does the build-up occur in the kiln and
preheater system?
3.9.1 9.1 Kiln
3.9.2 9.2 Cyclone preheater
3.10 10. Behaviour of Volatile in Preheater with Precalciner
3.11 11. The Relation between Kiln System and the Volatile
Matters
3.12 12. What is the reason that makes suspension-
preheater-kilns with precalciners more sensitive to the volatiles
problem than the suspension –preheater kilns?
3.13 13. How to Decrease the Effect of Volatile Matters on the
Kiln System?
3.14 14. Measures to Overcome the Circulation Problem
4 By –pass installation in dry process
By pass system in the dry process
Introduction
It is well known that cement is made mainly from limestone and

clay. Both contain the essential oxides: silicon dioxide, calcium
oxide, aluminum oxide, and iron oxide needed to form the clinker
4 major components in the rotary kiln. These four oxides exist in
limestone and clay in different percentages. Limestone and clay
have also other minerals that contain some elements that are not
required in the process of forming clinker main components. Some

of these minerals exist in different percentage. If these
percentages exceeded certain limits then it creates trouble for the
burning process especially in the preheater lower stages before
and after the precalciner, in the kiln inlet area and sometimes in
kiln tube itself.
These elements and components are called process adverse

materials.
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These harmful materials are sulfur, chlorine and alkali elements

i.e. sodium and potassium. Their behaviour in the kiln and
preheater atmosphere leads to build-up of layers of these
components and trapping huge quantity of kiln dust. This build-up
forces the kiln operator to shutdown the kiln system to clear this
build-up that in most cases makes the operation next to the
impossible. The kiln operation suffers because the build-up in the
riser pipes and cyclones increases pressure drop in the system, so
maintaining draft in the kiln becomes harder and more difficult.
This obliges the kiln operator to work with less excess air in the
kiln, which makes things worse since the circulation of sulfur highly
increases at low oxygen level and the problem becomes worse in
the kiln and the build-up of accretion becomes very quick and its
nature will be stronger and harder i.e. the build-up will be harder
to clean. This leads directly to a decrease in kiln production and
eventual shut down of the system.
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The second result of working with higher levels of sulfur circulation

is the formation of a very dusty clinker. This leads to deterioration
of the heat profile of the kiln and preheater system because high
amount of heat will be lost with the dust transported with the kiln
exhaust gas.
This will shift the heat upward away from burning zone affecting
the coating condition in the kiln-burning zone. The kiln then will
have a long zone of unstable coating at the upper transition zone
before the burning zone leading directly to brick in this area, since
with every cycle part of the brick that is approximately 10 mm will
be lost.
The only real and final remedy for this phenomena preventing it
from troubling the burning process is to install a by-pass system.
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The sole and major job of this installation i.e. by-pass installation
is to control these elements to the degree that permits for smooth
operation. Therefore, a universal fact should be noted that the by-
pass system does not eliminate the circulation problem of volatile

matters but just controlling it to the degree that makes the kiln
operation smooth and economical. This section is devoted to study
in detail the problem of the volatile matters in the raw materials
and the by-pass system and how to make it work smoothly.
Circulation phenomenon
This term is used to represent the phenomena caused by the

presence of the volatiles in the system i.e. alkali chlorides,
Sulphates and other related components in the dry kiln system
with preheater and precalciner.
Why this phenomenon is called circulation phenomenon? The

circulating elements are sulfur and chlorine and the other two
elements are sodium and potassium.
Fractions of these four elements first evaporate in the kiln burning

zone depending on the degree of volatility of the component then
carried away by kiln gas in the direction of the kiln inlet and
condensate and precipitate on the kiln feed particles in the
preheater lower stages and in the kiln inlet then return back to the
kiln burning-zone again and volatile again.
So they start to circulate in the system between the kiln and

preheater stages and will continue endlessly to evaporate in the
burning zone of the kiln then precipitate in the preheater. They
return again to kiln burning zone with the fresh material containing
fresh supply of these elements in addition to what is precipitated
on them in the preheater. However, we have to note here that part
of these elements leaves the system with the clinker, the
preheater chimney, preheater electrostatic precipitator dust, the
by-pass’s chimney, and by-pass electrostatic precipitator dust.
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These cycles continue as long as the kiln is in operation and the

process is called Circulation Phenomenon.
These cycles increase the concentration of the alkali sulfates and

chlorides in the system to a very high level as the operation of the
kiln continue. Such concentration increases to fifty times its
original concentration when the kiln is just started.
1. Internal and External Circulation Phenomena
The INNER-CIRCULE of volatile matters or INTERNAL

CIRCULATION PHENOMENON is between preheater tower lower
stages and the kiln-burning zone.
As for the volatile matters that condensate on the material

particles of the kiln feed and have the chance to leave the kiln
system with the kiln gas leaving the upper most cyclones, they
precipitate in the preheater electrostatic filter and eventually
returning back to the kiln with the fresh feed but they just enrich
the feed with these volatile matters to some degree. Their cycle
from preheater to electrostatic precipitator to kiln feed and back
again to the kiln system is called the EXTERNAL CIRCULE of
volatile matters or EXTERNAL CIRCULATION PHENOMENON.
At a certain concentration, the system atmosphere becomes

saturated to the degree that permits for the precipitation of the
volatile matters in the melted phase condition that will lead to the
formation of build-ups and rings in the lower part of the preheater

system and the kiln inlet and in calcining zone in the kiln.
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If the concentration of the volatile matters becomes dangerously

high either because of high input of volatile matters to the system
or due to high volatility of these matters, then the installation of a
by-pass system is a must.
2. The limits of chlorine and sulfate input in the

kiln feed [on loss on ignition free basis]
There are two limits, the normal limit which is applied when the
kiln feed has moderate to normal silica modulus and normal value
of free lime will be accepted in the clinker, while the high limit is
applied when the kiln feed is easy to burn i.e. have low silica
modulus accepting higher free lime in the clinker and/or the
alkali/sulfur ratio in the kiln feed is ideal [this will be discussed
later].
The high limits should not also be applied when the condition in
the burning zone require very strong flame e.g. as in high silica
ratio in kiln feed or the kiln feed has a relatively high volatiles
content and we need to produce low alkali clinker cement from this
feed with concentration of volatile matters in the kiln feed higher
than the ideal concentration needed for low alkali clinker.
3. Maximum allowable input of volatiles in kiln

with precalciner: [loss on ignition free]
If these limits are surpassed and the total input of volatiles are
higher, the precalciner kiln should be provided with a by-pass
system by which a part of the kiln gas can by-pass the preheater
altogether. This process decreases the concentration of volatile
matters leaving the kiln to the preheater and precalciner.
The by-pass percentage of the kiln gas can be calculated in the

following way.
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% By-pass = % chlorine as Cl in the raw materials [raw

meal basis] x 100
This procedure is applied to chlorine because it is nearly impossible

to control the evaporation of chlorine in the kiln burning zone or
control its concentration in the process by any means.
Example
The raw materials contain chlorine [raw meal basis] =0.23 %.

What is the bypass %?
The required bypass% = 0.25×100=25%
4. Circulation Mechanism
The circulation mechanism of circulating elements; potassium,

sodium, chlorine, and sulfur can be explained in the following
manner:
The circulating elements enter the kiln with the kiln feed that
travels through the preheater to the kiln inlet.
Starting from lower most cyclones the temperature starts reaching

800ºC in the kiln system. From this temperature, part of these
elements is volatilized i.e. dissociated and becomes part of the kiln
atmosphere.
As the temperature starts to rise more and more the rate of

volatilization increases.
In the kiln atmosphere the fuel will add to the kiln atmosphere
additional sulfur after combustion. When the material reaches
burning zone, all the chlorine will be evaporated with part from
sulfate, sodium, and potassium [the harder the kiln feed to burn
the higher will be the evaporation rate of the volatiles and this
takes place also in case of a very strong flame in the main burner]
and transported along with the kiln gas back to the areas of lower
temperature. Because of this cyclic mechanism, the circulating
elements increase in progression.
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This enrichment continues until the total quantity of circulating

elements brought into the kiln system corresponds to the total
quantity carried out of it.
The dissociated components become then capable of reacting with

other compounds in the kiln-gas, kiln-dust and burning material.
The main compounds made are:
1. Alkali sulfate [K, Na]2 SO4

2. Alkali chloride KCl, NaCl
3. Alkali carbonate [K, Na]2 CO3
4. Calcium sulfate Anhydrite CaSO4
5. Sulfate spurrite 2C2 S CaSO4
6. Sulfo-spurrite [K, Na] 2 SO4
Chloride reacts primarily with the alkalis, forming NaCl and KCl.
Any excess of chlorides will react with calcium oxide available in
the system to form CaCl2. A part of the alkalis in excess of chloride
combine with sulfur to form Na2SO4, K2SO4 and double salts as
Ca2K2(SO4)2. Alkalis not combined with chloride or sulfur are
present as Na2O and K2O embedded in the clinker mineral.
Sulfur in excess of alkali combines with CaO to form CaSO4.
At temperatures between 800 and 1200ºC, these compounds

condensate on the burning materials, kiln dust or on the walls of
kiln and preheater system, some of them in a melted phase. The
circulating elements, which condensate on the walls in the
preheater and kiln tube and on the burning materials and some of
these on the dust, reach areas of high temperature again, together

with the burning material stream, where once again some are
volatilized and transported back with the kiln gas.
As an example of how the concentration of a certain volatile

element changes through the process:
If we introduced 1 kg of potassium each hour with the feed and

when the reactions achieve a state of equilibrium of volatiles in the
system, then we will have the following condition:
1. 811 kg of potassium will leave with the clinker

2. In the system the concentration of potassium will be 2.573 kg
3. In the by-pass dust the concentration of potassium will be
0.221 kg.
4. In the exhaust gas dust the concentration will be 0.042 kg of
potassium.
The explanation is the following:
The first, 0.189 kg will remain from one kg, this will start making
accumulation and continue on for hours with addition of new
supply from the fresh material. When the concentration in the kiln
atmosphere reaches the concentration of 2.573 kg/h then what is
coming out from the by-pass system dust will be 0.221 kg and
with E.P dust 0.042 kg/h
The second, the volatility of potassium permits for the remaining

of 0.811 kg/h in the clinker coming out from the kiln while only
0.189 kg remained in the system but eventually it will return back
to the system with the kiln feed enriching the system with
potassium to reach higher concentration of that element and
eventually will reach saturation level if the by pass system is not
applied.
Third, the by-pass system permits only for controlling the volatile
elements but not eliminating them from the system, since the
concentration of the potassium coming out with kiln by-pass dust
is only 0.042 kg /hour for each one kg added to the system
through the fresh feed, while nearly 0.800 kg is going out with the
clinker.
That indicates the less the volatility of the element in the raw mix
in the kiln, the better will be the condition regarding the circulation
phenomena.
5. Evaporation Rates of Different Elements
Each of these elements will have its evaporation rate or volatility.
Volatility or evaporation factor defined as E of a volatile element or

compound means that part of this element evaporates in the kiln
burning zone instead of leaving the kiln with the clinker produced
in the kiln burning zone where this element is evaporated
Example: 1
The concentration of the sulfate in the clinker in one sample is

1.05 %, SO3 concentration in cyclone 4 materials which is collected
from the material pipe of cyclone 4 to the kiln inlet is 2 % and the
loss on ignition of this same sample is 3.5%
What is the evaporation factor of sulfate [SO3] in this system?
Solution
% SO3 at the kiln inlet loss on ignition free basis=
= = 2.0725
Evaporation factor E = 1 – = 1 – 0.507 = 0.493
This calculation can be applied to any of the other volatile

elements as potassium, sodium, or chorine.
Example 2
The loss on ignition of the sample for chlorine is 3.8 %. Its

concentration in the clinker is 0.03 % and its concentration in the
hot meal [kiln feed] from cyclone 4 to the kiln inlet is 0.65 %.
What is the evaporation factor of chlorine in this system?
Solution
% Chlorine at the kiln inlet loss on ignition free=
Evaporation factor E of chlorine = 1- = 1 – 0.04=0.96
Example 3
The loss on ignition of the sample for potassium in kiln feed is

3.5% and the concentration of potassium in the clinker 0.29% and
its concentration in the hot raw meal from cyclone 4 to the kiln
inlet 0.39%. What is the evaporation factor of potassium in this
system?
Solution:
The % of potassium at the kiln inlet loss on ignition free =
Evaporation factor E of potassium=1 – = 1 – 0.725 = 0.275
But we have to indicate what is the meaning of the value obtained

from the previous examples:
When E = 1 indicate that all volatile elements evaporate and

none leave with the clinker
This is clearly indicated in the case of Example 2 of chlorine

where the solution proved in a very unmistakable way this fact. [E
in the example is nearly one].
When E = 0 indicate that none of the volatile elements

evaporate and all leave with the Clinker.
This is clearly indicated in the case of Example 3 of potassium

where the solution proved in a very unmistakable way this fact. [E
in the example is very small].
Average evaporation factors
Average values for the evaporation factor of various volatiles

element compounds are:
Evaporation factor E
K2O free from chlorine 0.1-0.4
Na2O 0.1-0.25
Alkali SO3 0.2-0.9 [have a relatively high melting

point of 1074ºC, boiling at 1689ºC]
Excess SO3 0.75
Cl 0.990-0.996
KCl 0.990-0.996 [have low melting

point of 768ºC, boil at 1411ºC]
The volatile matters escape through the preheater dust

[preheater valve].
K2O free from chlorine 0.15
Na2O 0.05-0.20
Alkali SO3 0.05-0.25
Excess SO3 ———
Cl 0.05
KCl 0.05
The volatile matters escape through the preheater chimney

[preheater filter valve]
K2O free from chlorine 0-0.10
Na2O 0-0.15
Alkali SO3 0-0.20
Excess SO3 ———
Cl 0-0.10
KCl 0-0.10
Chloride compounds KCl, CaCl2 and NaCl are seen to have an

evaporation factor of 0.990-0.996 in the kiln at 800ºC. These
compounds melt and boil at 1400ºC.
But sulfate compounds with alkali as K2 SO4 [potassium sulfate]

and Na2SO4 [sodium sulfate] will be more stable than CaSO4
[calcium sulfate]. The last component is formed when there is
excess sulfur that cannot react with the alkali in the system.
Alkali sulfates have evaporation factors from 0.2 to 0.90 but they
are mostly in the lower part of the range, while excess sulfur that
cannot find alkali to react with has an evaporation factor of 0.75,
therefore it is best that all sulfur react with alkalis to the highest
extent.
6. Molecular Ratio of Sulfur and Alkalis
The concentration of sulfur which may build up in the system

through its circulation and its components causes huge trouble for
kiln operation. The total quantity of sulfur or the deficiency of
alkalis may be the cause. Sulfur that has not been combined with
the alkalis present in the system is responsible for causing huge
trouble to kiln operation than the other sulfate components such as
potassium sulfate and sodium sulfate.
If the alkalis are in the right proportion with the sulfur in the
system, both will combine together and become built in salts in the
clinker minerals. But in the absence of alkalis i.e. if there is excess
sulfur in the system, the more volatile calcium sulfate will be
formed in the kiln system, and it has a higher evaporation factor.
The following equation is used for the estimation of

optimum molecular ratio between sulfur and alkalis in the
system:
If the sulfur and alkalis ratio exceeds 1.1 it means that the amount
of sulfur present in the kiln feed material that react with the alkalis
is in excess and the remaining excess sulfur will react to form
CaSO4.
Example 1
A kiln feed sample contains the following concentration
SO3=0.45 % K2O=0.37 % Na2O=0.38 %
What is the sulfur and alkalis molecular ratio in this system?
Solution
The result is indicating that there is no excess sulfur in the system.
Example 2
A kiln feed sample contain the following concentration
SO3=0.57% K2O =0.21 % Na2O=0.15 %
What is the sulfur and alkalis molecular ratio in this system?
Solution
The result is indicating that there is excess sulfur in the system

that will react to form CaSO4
The amount of excess sulfur is expressed in gram SO3 per 100kg

clinker and calculated according to the equation.
E.S = 1000x SO3 –850x K2O – 650x Na2O [gram SO3/100kg

clinker]
The limit on the excess sulfur is given to be in the range of 250-

600g/100clinker
For easy burning kiln feed, the high value of 600gram SO3/100kg
clinker will not cause any problem for the kiln operation, but for
hard burning kiln feed, the lower value is the limit. Above these
limits the coating formation starts in the preheater tower and kiln
by-pass system.
Example
A kiln feed sample contain the following concentration
SO3=0.57% K2O =0.21 % Na2O=0.15 %
Solution
E.S = 1000 x SO3 –850x K2O – 650 x Na2O [gram SO3/100kg

clinker]
E.S = 1000x 0.57 – 850 x 0.21 –650 x 0.15
= 570 – 178.5 –97.5
= 294 gram SO3/100kg clinker
This kiln feed contains a relatively small amount of excess sulfur.

But if the material of the kiln feed is hard to burn or the flame is
very strong a coating problem may cause some trouble due to
build-up in the preheater and the pressure loss may increase in the
preheater.
7. Optimum range of molecular of sulfur and

alkalis in the presence of chlorine
Since the chlorine affinity for reaction with alkalis is higher than
the sulfate therefore the following equation is applied to determine
the optimum sulfate alkali ratio where the chlorine is subtracted
from the alkalis
Therefore the optimum range is nearly 0.8 to 1.1.
8. Coating and Ring Formation in Kiln and

Preheater
By the condensation of the volatilized circulating elements, salt

melts are formed when the temperature of the material in the
system reaches 700ºC and more. The melt starts to trap particles
of dust binding these materials together, and the build-up starts to
exist in the system. Thus, the principal cause of build-up is the
adhesion of the melt to the walls of the preheater and kiln.
In certain stage of build-up a new material starts to exist and

causes more trouble in the system. The formation of spurrite [2
C2S . CaCO3] and sulfo spurrite [2 C2S . CaSO4] in case of the
excess sulfur will exist in abundance. The formation of these
compounds is promoted and made possible only by the presence of
the alkalis, chlorine, and sulfur in the raw material of the kiln feed.
The last mentioned build-up will not be due to the present melt but
due to kiln mating together of the needle shaped spurrite crystals.
9. Where does the build-up occur in the kiln and

preheater system?
9.1 Kiln
If there is a ring in the kiln related to the circulating elements it

will exist in the calcining zone and its position will be 7 to 13 times
kiln inner diameter from the kiln outlet (7:13 Di). These rings will
contain enrichment of circulating elements, spurrite and sulfate-
spurrite. In most cases the sulfo-spurrite will be the dominant
component in this build-up.
However, these rings are not very dangerous to the kiln and can
be detected from outside the kiln by the kiln hand pyrometer or by
shell scanner. These rings always fall by themselves due to the
rotation of the kiln and the fluctuation in the temperature inside it.
9.2 Cyclone preheater
The build-up can occur in the connection area between the

preheater and kiln riser duct.
Cyclone gas-duct i.e. riser-ducts and the cones of lowest cyclones.

Coating in these areas can contain from 8 to 60%circulation
elements compounds.
The diameters of the gas ducts decrease by the coating formation.

In the area of the cyclones cones the build-up will end in closing
the material pipes at the bottom of the cone and the eventual
result will be the filling of the cyclone by materials and hours will
be lost in clearing the material from the cyclone.
Also the crusts that may occur in the cyclones riser ducts may fell
down closing the material pipe at the bottom of the cyclone.
It should be noted that the 4, 5, or 6 cyclone stages preheater

with precalciner are very susceptible to the build-up caused by
volatile materials. This can be attributed to the presence of
secondary firing system in the precalciner and due to the
temperature profile in such type of system which induce such type
of build –up and the high circulation of dust in the lower part of the
preheater.
10. Behaviour of Volatile in Preheater with

Precalciner
The following features characterize the behaviour of such type of

system regarding the circulating elements:
1. Practically all of the amount of the volatile elements enter the

system is trapped and caught within the kiln and preheater
system which leads to considerable build-up of concentration of
these elements in the system.
2. The maximum concentration of these elements will be found in
the area of kiln inlet and at the areas of lowest –cyclones. This
phenomenon takes place because the temperature profile and
the optimal condition for condensation in the area of the lower
most cyclones.
Therefore it is a normal procedure to measure the concentration of

circulating elements in the material coming out of the lowest-
cyclones such as sulfur, chlorine, sodium and potassium. But still
some part of these circulating elements can escape and reach the
top most cyclones i.e. the dust enriched by these elements can
pass through all four cyclones stages and eventually returns back
to the kiln with fresh kiln after precipitating in the electrostatic
precipitator.
11. The Relation between Kiln System and the

Volatile Matters
The behavior of the volatile matters and their effect on operation

can be greatly affected by the process used to burn that material
to change it into clinker. In the long dry kiln the condition will not
permit for high circulation in the system since the kiln dust from
smoke chamber contains small concentration of volatile matters
and the valve of the kiln exhaust fan is for all kiln gas, while in the
4 suspension-preheater system will be less sensitive to the volatile
problem. The suspension preheater kiln with precalciner will be
more sensitive to the volatile matters but both if the limit of the
maximum allowable concentration of volatiles is exceeded the
system should be supplied with by-pass.
12. What is the reason that makes suspension-

preheater-kilns with precalciners more sensitive to
the volatiles problem than the suspension –preheater
kilns?
The reason for higher sensitivity is that in the precalciner kilns the
kiln gas to clinker ratio [expressed as Nm³/kg clinker] in the
precalciner kilns are lower than in the suspension-preheater kilns.
In the precalciner kilns, the quantity of fuel burned in the kiln is
40% of the total fuel of the system i.e.320kcalorie/kg of clinker
which results in higher concentration of volatile matters as
gram/m³ of kiln gas in the kiln inlet smoke chamber reaching
therefore critical values of saturation with less concentration of
volatile matters in the kiln feed. While in the 4-suspension
preheater kiln the fuel in the kiln is 100% required in the system
and this means higher gas to clinker ratio in the kiln inlet smoke
chamber i.e. kiln inlet connecting the kiln tube to the preheater.
That dilutes the concentration of the volatile matters in this area,
and therefore the system can work with higher concentration of
volatile matters in the kiln feed.
13. How to Decrease the Effect of Volatile Matters

on the Kiln System?
The operation of suspension preheater kilns with precalciners

explained before is very sensitive for circulation phenomena
because if this problem is ignored or mismanaged the result will
be :
1. Frequent kiln stops due to cyclones blocking which need

additional time for cooling and cleaning.
2. Higher heat consumption due to this frequent stops, additional
fuel used for reheating the system and higher kiln’s brick
consumption.
3. Reduced kiln production since the operator will try to continue
work with less draft in the kiln and in most cases in reducing
atmosphere with much CO in the system.
14. Measures to Overcome the Circulation Problem
14.1 Interruption of the External Circulation
To reduce the level of circulating matter in the kiln system, the

input of circulation matters can be reduced in some cases by
discarding the fine fraction of the filter-dust; meanwhile, the effect
of such measure will be in most cases very limited on the Internal
Circulation but can be evaluated to determine its effectiveness by
establishing a volatile mass balance.
14.2 Reducing the burning zone temperature
This means the reduction of the volatility of the alkalis, chloride

and sulfate components. This can be done by reducing the burning
zone temperature. The volatility of the sulfur compounds especially
calcium sulfate is a function of the burning zone temperature.
Calcium sulfate starts to decompose at 1220ºC and this thermal
decomposition can be avoided by lowering burning zone
temperature.
This can be done also by other means as :
14.3 Decreasing the silica ratio of the kiln feed and thus
making the kiln feed easier to burn.
14.4 Finer grounding of coarser particles especially the free

silicates if present in the kiln feed therefore easier to burn kiln
feed. The result will be lower sintering temperature in the burning
zone decreasing the volatility .
14.5 Accepting higher free-lime in the clinker. This requires

less fuel in the burning zone, and there will be no overheating of
the burning zone.
14.6 Controlling volatile content in the raw material used for

grinding and used as kiln feed. That means observing the optimum
molecular of sulfur to alkali and ensuring that the excess sulfur is
minimized.
14.7 Controlling Oxidation condition in kiln atmosphere.

When we have the oxygen level in the kiln in the higher side, the
condition in the kiln will be oxidation condition. The dissociation of
sulfate compounds achieves balance in the favor of forming alkali
sulfate in the oxidation condition in the kiln. If we have reduction
condition the alkali sulfate tends to dissociate to alkali oxide and
oxygen. Therefore, the oxygen level in the kiln atmosphere should
be maintained at approximately 2%, but increasing oxygen level
beyond 2% will have limited effect on the volatility of the sulfate.
14.8 Controlling the reduction condition in the kiln

atmosphere
Reducing condition in the kiln atmosphere due to incomplete

combustion of the fuel [either due to lower fuel temperature or bad
atomization of the fuel] either in the kiln or in the precalciner
increases the calcium sulfate and alkali sulfate in the presence of
free carbon. The reactions will be as follows:
Calcium sulfate + Carbon → Calcium oxide +SO2 + Carbon mono-

oxide
Alkali sulfate + Carbon → Alkali oxide + SO2 + Carbon mono-oxide
These reactions increase sulfur circulation in the system since this

reaction enhances the decomposition of the stable calcium sulfate
as well as stable alkali sulfate.
Therefore it is of prime importance to maintain carbon mono-oxide

% not more than 0.1% at the kiln inlet and oxygen level >1.5%.
The incomplete combustion of the fuel should be prohibited in all
conditions. This is very important since the high concentration of
sulfur in the system leads to a very dusty clinker from the kiln in
spite of the fuel in the kiln burner or increasing the kiln burning
zone temperature. This ends in a very bad heat profile in the kiln
itself and cyclic kiln operation.
14.9 Installation of a kiln By-pass system
If the total chloride input as indicated before exceeds 0.015% on

raw material basis or 0.023% chlorine on clinker basis then the
installation of a by-pass system is a must.
In such case the by pass system will be used mainly to control the
chlorine and the removal of it from the kiln system. But the
problem of chlorine in the system can’t be blamed alone as the
cause of the problems caused by volatile matters in the suspension
preheater kilns, since in this kiln the volatiles have no escape route
in the kiln system.
This leads in the absence of by-system to formation of low-melting

phases belonging to the CaSO4-Na SO4-Kcl system or the excessive
entrapment of alkali/sulfur in the clinker.
This is partially overcome by the diverting part of the kiln exit

gases with a bypass duct.
A modern by pass system consists of an air quench chamber, a

shut-off valve, a water quench chamber and a dust collector. The
air quench chamber is used to mix ambient air with the kiln gasses
to quickly cool the harmful volatile compounds. The water quench
chamber is used to cool the gases quickly to lower temperature for
dust collection.
The by-pass systems installation will eventually lead to higher

power and heat consumption in the kiln system. Also one of the
major losses with this installation is the dust loss, since the dust-
laden gas streams are thrown out of the system. At 30% bypass
the fuel consumption increases by about 8-10% and material loss
by about 3-6%.
By –pass installation in dry process
The traditional by pass installation consists of
1. The chimney
2. The draft-fan
3. The electrostatic-precipitator
4. Dust handling from the electrostatic-precipitator collecting
screw-conveyor to the collecting-pin and consists of: The
bucket-elevator, the dust pin, and the granulator to change the
dust into dust balls and the belt conveyor for the dust balls to
the truck.
5. Condition-tower for the hot gas from the quench chamber to
decrease temperature of the gas from 450ºC to 150ºC by water
spray system.
6. The quenching chamber for mixing the hot gas with ambient air,
laden with the volatile matters from the kiln riser-duct and
decrease gas temperature from 1000ºC to 450ºC in a matter of
seconds to freeze the volatile components in its solid state and
prevent it from existing in the melting phase in the by-pass
ducts system. This mixing chamber is always located in the duct
taking the hot gas from the kiln riser duct and nearly 800mm
away from the connecting point to the riser duct.
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Posted in CategoriES, key Equipment Working Principles , types , Daily maintenance,

Production Engineering and tagged bypass, bypass system, chlorine and sulfate input in
the kiln feed, Circulation Mechanism, Circulation Phenomena, Coating and Ring
Formation in Kiln, Cyclone preheater, kiln, Molecular Ratio of Sulfur and Alkalis,
volatiles in kiln with precalciner.
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