Professional Documents
Culture Documents
Dirk Basten
Illustration of an entire installation
1000
Temperatur / °C
Temperature / °C
900
Temperature
30 °C/h
800 bis zur Einsatztemperatur
up to temp. of application
700
600 Heating-up 10 h / 500 °C
500
400 Drying out 25 °C/h
300
200 20 h / 110 - 150 °C
min. 24 h Erhärtungsdauer 15 °C/h
100 min. 24 hrs setting time
0
0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs Time after installation / hrs
How much water has to be removed?
Rough estimation:
concrete weight (in tonnes) x 10% Æ total water amount (in tonnes)
Two different kinds of water are found:
Acc.V Spot Magn Det WD Exp Acc.V Spot Magn Det WD Exp Acc.V Spot Magn Det WD Exp
25.0 kV 4.0 540x SE 9.8 17 CRB Analyse Service GmbH 25.0 kV 4.0 10000x SE 9.9 13 CRB Analyse Service GmbH 25.0 kV 4.0 7800x SE 9.6 17 CRB Analyse Service GmbH
In the drying process a distinction is made between two essential steps:
1000
Temperatur / °C
Temperature / °C
900
Temperature
30 °C/h
800 bis zur Einsatztemperatur
up to temp. of application
700
600
10 h / 500 °C
500
400 Drying out 25 °C/h
300
200 20 h / 110 - 150 °C
min. 24 h Erhärtungsdauer 15 °C/h
100 min. 24 hrs setting time
0
0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs Time after installation / hrs
Behaviour of drying rate
Behaviour ofasdrying rateofas
a function a function
drying time of drying time
100
Phase 1 Phase 2
90
Drying rate (weight/hr)
80
70
60
Drying rate
10
0
1 2 3 4 5
tkn
6 7 8 9 10 11 12 13
Dryiing time
Drying time (hr)
1500
1400 Aufheizdiagramm feuerfester Massen (LCC, MCC, SC, JC)
Drying out and heating-up diagramm of refractory concretes/castables
Heating diagramm of refractory concretes (LCC, MCC, SC, JC)
1300
(RCC, MCC, LCC, SC, JC)
1200
1100
Phase 1 Phase 2
/ °C
1000
Temperatur / °C
Temperature / °C
900
Temperature
30 °C/h
800 bis zur Einsatztemperatur
up to temp. of application
700
600
10 h / 500 °C
500
400 Drying out 25 °C/h
300
200 20 h / 110 - 150 °C
min. 24 h Erhärtungsdauer 15 °C/h
100 min. 24 hrs setting time
0
0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs Time after installation / hrs
Phase 1: Initial phase:
Phase 1 20 0.02
50 0.12
Phase 1 100 1
150 5
200 15
250 40
300 86
350 165
Drying phase 1: Initial phase
100°C
/1 bar
∆P≈ 1 bar
20°C
/0.02 bar
Phase 1: Pmeniscus > Poutlet
Gas Flow
Inlet Outlet
T [°C]
100°C Poutlet
/1 bar
∆P≈ 1 bar
Pmeniscus
20°C
/0.02 bar Pcapillary
Saturation vapour pressures vs temperature
250
S a t u r a t io n va p o u r p r e s s u r e (b a r )
200
150
100
50
1bar (Atmospheric Pressure)
0
0 50 100 150 200 250 300 350 400
T e m pe ra t ure (°C )
1000
Temperatur / °C
Temperature / °C
900
Temperature
30 °C/h
800 bis zur Einsatztemperatur
up to temp. of application
700
600
10 h / 500 °C
500
400 Drying out 25 °C/h
300
200 20 h / 110 - 150 °C
min. 24 h Erhärtungsdauer 15 °C/h
100 min. 24 hrs setting time
0
0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs Time after installation / hrs
Phase 1: Pmeniscus > Poutlet Phase 2: Pmeniscus < Poutlet
Gas Flow
Inlet Outlet
T [°C]
100°C Poutlet 350°C Poutlet
/1 bar /165 bar
alumina bricks
gear basic bricks
tyre
All elements have to be treated as a whole system since they closely coexist
to each other and are integrated therein accordingly.
Temperature distribution in brick and kiln shell during heating-up
Kiln Shell
Time in hrs
Heating-up is limited by the tyres and other mechanical parts
To protect the refractory lining in the rotary kiln, whole time for drying
out and heating-up is limited to 72 hours.
(Drying out should take max. 36 hours.Heating-up is to start immediately
afterwards and is to be finished after 72 hours).
T2
ILC
T3
RRiser
Steig-
schacht T1
i
Kiln
Drehofen
s
Cooler e
Kühler r
FLS Kuwait
Drying out and heating-up using exclusively the central burner
Kiln: Puttalam, Sri Lanka (Holcim)
1500
1400
1300
1200
1100
1000
Temperature / °C
900
800
700
600
500
400
300
200
100
0
0 10 20 30 40 50 60 70 80
Raw meal feeding is started in KHD and Polysius plants if the inlet chamber
temperature exceeds 850 °C.
FLS Kuwait
2. Drying out and heating-up using exclusively the calciner burner
Drying out and heating-up time is limited (see process with central burner)
Advantages:
clean and easy flame control
Disadvantages:
distribution of gas in the plant needs a lot of safety precautions
Typical auxiliary burner assembly situation for light oil
Auxiliary burner for light oil
Advantages:
oil storage and distribution relatively easy
Disadvantages:
high development of smoke Æ eventually cleaning of building
4.1. Plants without tertiary air duct
When applying this method, drying will take longer than with the main burner
method and is therefore advantageous to the kiln lining.
Heat distribution in all vessels is very equal, particulary drying in the cooler can be
commenced at its optimum.
Total drying and heating-up time is limited and any interruption after drying
is not possible.
Drying and heating time is not limited but recommended to range between
100 and 125 hours.
0
100
200
300
400
500
600
.0 07
48
5.
20 :0
31 03 7:
.0 22
03
5.
20 :2
01 03 1:
.0 12
39
6.
20 :2
01 03 1:
.0 03
39
6.
02 200 :33
.0 3 :5
4
6. 18
02
20 :
03 15:1
.0 08 8
6.
20 :1
03 03 5:
.0 22
18
6.
20 :3
04 03 1:
.0 12
28
6.
20 :3
03 6:
00
03
:5
3:
03
Sollwert
TC 5 Meßstelle 5
TC 4 Meßstelle 4
TC 3 Meßstelle 3
TC 2 Meßstelle 2
TC 1 Meßstelle 1
Drying out curve with actual temperatures measured during the process
2. Drying out and heating-up using exclusively a calciner burner