Course 3 – Clinker Production

3.5 Bypass Systems

Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 78–1
Fax: +49 211 45 78–296
info@vdz-online.de
www.vdz-online.de

info@elearning-vdz.de
www.elearning-vdz.de

Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Construction and Operation............................................................................ 1
2.1 Gas Bypass.......................................................................................................... 4
2.2 Hot Meal Bypass................................................................................................. 6
2.3 Dust Bypass ........................................................................................................ 6
2.4 Designs ............................................................................................................... 6
2.5 Relief of Circulating Chlorine and Sulfur Systems using Bypasses................... 8
2.6 Exhaust Gas Routing and Utilization ................................................................. 9
2.7 Bypass Gas Dedusting ........................................................................................ 10
2.8 Dust Transport and Storage ................................................................................ 11

3 Plant Operation and Quality ........................................................................... 12

4 Environmental Protection ................................................................................ 12

5 Health and Safety Practices ............................................................................. 13 i
6 Questions on Course LB 3.5 – Bypass Systems.............................................. 13

Solutions............................................................................................................................... 15
Glossary ............................................................................................................................... 17

Index..................................................................................................................................... 18

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1 Introduction

Due to the counter-current flow process, circulating systems may occur during clinker Circulating Systems
production as a result of vaporization and subsequent condensation. The circulation of the
following substances is of particular relevance to the operation of the plant:
 alkalis,
 chlorides and
 sulfates.
Alkalis can vaporize in the kiln from temperatures above about 800 ◦ C (Tab. 1.0-1). The »Internal
vaporized alkalis pass with the gas into the cooler zones of the preheater where they con- AlkaliCirculating
System«
dense on the kiln feed. The condensed alkalis then pass back with the kiln feed into the
region of higher temperatures, where they vaporize again, thus producing an »internal
alkali circulating system«.
There is also an »external circulating system« between the preheater, raw mill and exhaust »External Circulating 1
gas filter. In this instance volatile components, such as highly volatile sulfur compounds System«

and/or mercury, condense on the dust that is in turn collected in the filter and fed back into
the process with the raw meal.

Compound Melting Point [◦ C]

potassium chloride (KCl) 768

potassium carbonate ("potash", K2CO3) 894

potassium sulfate (K2SO4) 1074

sodium chloride ("common salt", NaCl) 801

sodium carbonate (Na2CO3) 850

sodium sulfate (Na2SO4) 884

Table 1.0-1: Melting Points of AlkaliCompounds.

Increased levels of circulating elements, such as chlorine and sulfur, may cause serious Coating Formation
disruption in the kiln system. This is attributed to the fact that circulating sulfur systems,
together with chlorine and alkali circulating systems, may lead to increased coating for-
mation in the kiln inlet, gas riser pipe and lower cyclone stages. The extent of coating
formation depends in particular on the existing circulation situation. If the inputs exceed
certain limits a »bypass« must be used to relieve the circulating system.
In this course you will learn more about the designs of bypasses in the field of clinker
production. In particular you will learn about the operating principles of and the need for
gas, hot meal and dust bypasses in rotary kiln plants.
Course Summary

2 Construction and Operation

In the technical sense of the word, bypass means that part of a flow of material is
diverted from the main flow and carried past it.

Three different types of bypass are used in practice: Types

 gas bypass for reducing chlorine and, to a limited extent, sulfur

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 2 Construction and Operation

 hot meal bypass for reducing chlorine

 dust bypass for reducing heavy metals
Fig. 2.0-1 shows the importance of bypass systems. Initially, the amount of material fed
(fuel and feed material) is greater than the amount of material discharged (raw gas, raw
gas dust and clinker). The circulating system (e.g. of sulfur) increases until it reaches a
critical level, represented by increasing ring thickness. Circulation movement stops and
leads to a (cyclone) blockage, symbolized by a flash.
At this point in the online course you would see an animation instead of this picture.

Figure 2.0-1: Preheater Rotary Kiln without Bypass System.

In Fig. 2.0-2 the amount of material fed is initially greater than the amount of material
discharged until an equilibrium position is achieved or a steady-state condition is main-
tained by the bypass offtake.
At this point in the online course you would see an animation instead of this picture.

It is only possible to discharge alkalis, chlorine and sulfur with the clinker to a limited
extent. As a result, these materials accumulate in the plant if they are not selectively
removed.
Volatility, The ratio of the circulating materials to one another basically determines the volatility
ConcentrationProfile of the resulting compounds. It should be assumed that chlorides are in principle more
volatile than sulfates. Since calcium sulfate vaporizes at temperatures above 1,200 ◦ C and
alkali sulfates vaporize around the sintering temperature (i.e. at approximately 1,450 ◦ C),
operational parameters such as burner setting, flame shape and burner position (inclination
towards the kiln feed, position in the kiln) also play a part. Furthermore, uniform kiln
operation is important since fluctuations in operation contribute to temporary overheating

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 3

Figure 2.0-2: Preheater Rotary Kiln with Bypass System .

of the sintering zone and of the kiln feed, and therefore contribute to a greater vaporization
rate of the circulating materials. In all kiln plants a characteristic concentration profile is
established across the entire plant as a result of these influencing variables.

Interruption of a circulating material system is generally most effective if it is carried out

at the point of maximum accumulation as this makes it possible to minimize material,
gas and heat losses.

For this purpose it is necessary to know the concentration profile of the circulating system
over the entire kiln plant, which can be determined by taking measurements.
However, operational measures to relieve material circulation should be exhausted first: Alternatives
 reducing the input of materials that form circulating systems
 reducing the rate of vaporization (sulfur)
 expert cleaning of the parts of the plant that are at risk

Hot meal from the bottom cyclone stage is a suitable practical indicator for assessing Indicators
the circulating systems. As far as possible it should not contain more than 5 mass %
SO3 or 2 mass % Cl (after ignition); the thresholds are even lower when both materials
are present simultaneously.

Fig. 2.0-3 shows the chloride and sulfate contents in the hot meal of different kiln plants
and the areas of potential coating formation. It shows that kiln plants with a high tendency
to form coating are particularly sensitive to an additional increase in the internal circulating
systems.
In rotary kiln plants with cyclone preheaters three measures for relieving the circulating Measures for
systems have proved to be effective depending on the level of circulation and the volatility CyclonePreheaters

of the circulating materials:

1 a gas bypass is installed at the kiln inlet for instances of high volatility, i.e. in partic-
ular to reduce chlorine levels.
2 a hot meal bypass in which, in principle, meal can be removed from each cyclone
stage, may be installed in order to draw off materials that are less volatile.

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 2 Construction and Operation

4,0

3,5 high coating

SO3 in hot meal in mass %

tendency
3,0

2,5

2,0

1,5

1,0

0,5 low coating average coating

tendency tendency
0,0
0,0 0,5 1,0 1,5 0 2,0

4 chloride in hot meal in mass %

Figure 2.0-3: Tendency to Coating caused by Circulating Sulfur and Chlorine Systems .

3 filter dust can be removed during direct operation when circulation is low or less
volatile substances are present (dust bypass).
In all the above cases circulation may be interrupted continuously or discontinuously. In
the first instance the level of circulation is kept at a practically constant level that depends
on the bypass rate. A dust bypass is generally operated discontinuously in kiln plants with
a cyclone preheater as it is only appropriate during direct operation of the kiln plant.

2.1 Gas Bypass

It is possible to reduce circulating elements by creating a partial gas offtake (bypass),
through which some of the kiln exhaust gas is drawn off at the bottom of the gas riser pipe
(directly above the kiln inlet housing).

The bypass should be designed in such a way that it provides maximum relief of the
circulating system with minimum loss of heat and meal.
Principle
Fig. 2.1-1 shows a schematic view of a gas bypass system. A partial low-dust gas stream
is taken from the kiln inlet and sent to a mixing chamber (1). Within the mixing chamber,
the gas is quenched with cold air (2). Slaked lime can be fed into the mixing chamber to
increase the capture rate of sour gas like SO2. To allow the dedusting, the gas is cooled
down with an evaporative cooler (3). Subsequently, raw meal can be fed into the gas
stream to improve the precipitation of condensated matter (4). The sulphur and chlorine
compounds are removed from the gas within the dedusting equipment (5). Finally, the
cleaned gas is released through the stack (6).
Dust containing The difficulty of handling dust with high chloride concentrations places limits on the by-
Chloride pass. However, a high level of relief can be obtained at a comparatively low bypass rate
since the chloride is almost completely vaporized in the rotary kiln.
BypassRate A bypass rate between approximately 3 and 10 % is set in most applications, i.e. the
volume of gas drawn off is 3 to 10 % of the total flow. The kiln plant consumes more heat
energy and electrical energy when the bypass is operated.
EnergyConsumption The additional consumption of thermal energy differs from plant to plant and may range

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 2.1 Gas Bypass

5 3

1 bypass mixing chamber 1

2 air, lime hydrate
3 conditioning tower kiln inlet
4 raw meal
5 fabric filter 2
6 to the exhaust gas chimney

Figure 2.1-1: Schematc View of a Bypass System.

5

between 16 and 20 kJ/kg clinker for every percent of the bypass rate. The additional
consumption of electrical energy also depends on the type of bypass system and is ap-
proximately 2 kWh/t clinker.
The amount of dust discharged via the bypass is approximately 1 % of the raw meal feed Dust
for every 10 % of the bypass rate.
Example

raw meal
< 200 °C
400 °C 168.000 m3/h
184.000 m3/h M
M

M
< 200 °C
H2O 150.000 m3/h fan design
lime hydrate M < 200 °C
1.100 °C M
180.000 m3/h
20.000 m3/h cold air

M 35 °C
61.000 m3/h

M silo

Figure 2.1-2: Design Data for a Bypass System (Example) .

Fig. 2.1-2 shows the design data for a bypass system (example). The temperature of
the bypass gases at the point of removal is approximately 1,050 to 1,250 ◦ C. The gases
are cooled in a mixing chamber with cold air. The gases can then be dedusted in cy-
clone separators or hot gas filters with no further cooling. If electrostatic precipitators
or fabric filters are used then the gases are passed through a conditioning tower and
cooled with water to a temperature below 200 ◦ C (fabric filter) or 120 ◦ C (electrostatic
precipitator).

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 2 Construction and Operation

The bypass dust containing elevated concentrations of alkalis, chlorine and sulfur may be
added to the cement as process dust within the limits specified by the cement standard.

2.2 Hot Meal Bypass

A hot meal bypass removes a partial flow of the kiln feed that contains elevated con-
centrations of condensed circulating compounds.

In principle a hot meal bypass may be provided via any of the meal chutes in the preheater
if that is where the substances in question accumulate and it is advantageous for plant
operation or for the environment to remove some of these substances. However, the bottom
meal chute is normally used to remove hot meal. The meal may be removed by cooled
screws, either continuously or discontinuously.
The efficiency with which a meal bypass relieves the circulating system is considerably
lower than that achieved with a gas bypass (see also the German Cement Works Asso-
6 ciation Data Sheet SO2 Abatement/Circulating Material Systems). A hot meal bypass is
mainly used to reduce chlorine and sulfur (less effective).

2.3 Dust Bypass

The external material circulating systems between the preheater and mill or exhaust gas
filter can be interrupted by removing dust from the exhaust gas cleaning system, i.e. by
using a »dust bypass«.
CyclonePreheater In a kiln plant with a cyclone preheater a dust bypass only plays a minor role in inter-
rupting chlorine, alkali and sulfur circulation. However, it is associated with considerably
lower costs than other types of bypass.

The main function of a dust bypass is to reduce heavy metals, such as mercury and
thallium, that have accumulated in the external material circulating system.

It is generally only possible to discharge dust discontinuously since this process can only
be carried out efficiently during direct operation of the kiln plant when the raw mill is not
in operation.
Grate Preheater In a kiln plant with a grate preheater a dust bypass (»intermediate gas dust«) is consid-
erably more efficient. Because of the low exhaust gas temperature from the »Lepol kiln«
(grate preheater) the exhaust gas is not generally utilized in the raw mill, so the raw gas
dust can be removed directly.

2.4 Designs
Design Criteria Bypasses are designed in accordance with
 the total input of alkalis, sulfate and chloride, and their molar ratios,
 the burnability of the raw material, and
 the temperature profile in the kiln plant.

The amount of bypass gas drawn off is based on the amount of chloride that needs to be
removed. In German cement plants the bypass rates are approximately 5 to 15 % based
Amount of Gas Offtake on the kiln inlet gas flow.

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 2.4 Designs

bypass mixed gas bypass mixed gas

bypass-
mixing chamber
riser pipe

bypass-
mixing-
chamber
cooling
cooling air inlet
air inlet

meal -
pipe

rotary 7
kiln
kiln inlet
housing

Figure 2.4-1: Bypass Gas Offtake in Single-String (left) and Twin-String (right) Preheater Plants.

In kiln plants with single-string preheaters the bypass is, if possible, installed at the kiln Installation
end of the riser pipe (Fig. 2.4-1 left). The gas flow is forced against the rear wall here
by the change in direction from the kiln to the gas riser pipe and a low-dust region is
produced. If this is not possible for stuctural reasons then the bypass is attached to the side
of the gas riser pipe.
In multi-string plants, especially precalciner plants, the gas offtake can also be installed in
the arched roof of the kiln inlet (Fig. 2.4-1 right).
The dust content is approximately 150 to 300 g/m3. This should ensure that highly en- High Dust Content
riched dust is removed. If it is necessary to draw off gas with a higher dust concentration
because of its tendency to cause coating then the dust content in the kiln inlet chamber
may be increased using a distributor plate over which the meal from the second-lowest
cyclone stage slides into the riser pipe.
It is always necessary to prevent alkali salts , which condense due to local cooling caused Coating Formation
by cooling air, from contributing to increased coating formation in the region of the partial
gas offtake. The cooling air is blown into the mixing chamber either straight or tangen-
tially so that, as far as possible, any caking on the walls can be avoided. In some plants
water may be injected into the mixing chamber for cooling purposes. The gas temperature
in the downstream filter is adjusted by the amounts of cooling air and, possibly, water that
are injected. The bypass dust is transported pneumatically after the filter and this is not
critical at chloride contents < 10 %. So far no adjustments have been carried out to chlo-
rine bypass systems to improve the removal of sulfur.
Efficient mixing chamber systems are used in order to avoid disruptions to operation
caused by material caking. In modern plant designs the mixing chambers are built di-
rectly at the kiln inlet or are connected to the kiln inlet via a hot gas duct.
The input of volatile constituents into kiln systems has risen sharply due to the increased Increased ChlorideLoad
use of secondary fuels. Chloride in particular is often a limiting factor with respect to pos-

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 2 Construction and Operation

sible quantities of secondary fuels that can be used, so bypass systems of modern design
are being installed increasingly for effective removal of chlorides.

2.5 Relief of Circulating Chlorine and Sulfur Systems

using Bypasses

At identical bypass rates the levels of Cl or SO3 in the hot meal and in bypass dust
that has been removed increase with increasing input of chlorine or sulfur into the kiln
system.
However, in practice there is no consistent correlation between the input and the
concentration in the hot meal due to differing vaporization rates, dust content in the
bypass flow, offtake rates and differing designs of the bypass systems.

Differing Efficiency

8 = 75 % = 50 %
700

600
Cl--removal [mg/kg Kl]

500
= 25 %
400

300

200

100 kiln with gas bypass

kiln with meal bypass
0
0 200 400 600 800 1.000 1.200 1.400 1.600 1.800

Cl--Input [mg/kg Kl]

Figure 2.5-1: Efficiency of the Bypass with respect to Chloride Removal.

Fig. 2.5-1 and Fig. 2.5-2 show the efficiencies of different gas and meal bypass systems in
German cement plants with respect to the removal of chloride and sulfate. In this case
η (pronounced "eeta") denotes the efficiency of the bypass, determined by the ratio of the
amount of material drawn off via the bypass to the input of these substances across all
input materials. In gas bypass systems the amount of sulfur leaving the plant in gaseous
form via the exhaust gas is deducted from the sulfur input since it is not involved in the
internal sulfur circulating system.

The efficiency with respect to removal of chloride based on Cl input lies between 22 and
75 % (Fig. 2.5-1). In contrast, only 4 to 12 % of the sulfur input is discharged via the
bypass (Fig. 2.5-2). The Cl concentrations in the bypass dust are between 2 and 25 times
higher than those in the hot meal, while the concentrations of sulfur are only between 1
and 8 times higher.
The reason for this is that gas bypasses are generally installed at the most dust-free point of

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 2.6 Exhaust Gas Routing and Utilization

☞ = 10 % ☞=5%
1.000
✁✂✂
✄✂✂
SO3 -removal [mg/kg Kl]

☎✂✂
✆✂✂ kiln with gas bypass
✝✂✂ kiln with meal bypass

✞✂✂
✟✂✂
☞=1%
✠✂✂

100
0 ✁✡✂✂✂ ✁✡✂✂✂
3.000 5.000 7.000 11.000 13.000 15.000 17.000 ☛
9
SO3 -Input [mg/kg Kl]

Figure 2.5-2: Efficiency of Bypass with respect to SO3 Removal.

the kiln inlet in order to remove gaseous alkali chlorides as effectively as possible with low
thermal loss. At these temperatures the alkali sulfates are largely combined with particles
and with a low-dust offtake they generally remain in the kiln system.
There is therefore generally a clear correlation between chloride removal via the bypass
and the bypass rate. In contrast, there is no such correlation for SO3. This effect can be
attributed to the behaviour of chlorides and sulfates that has been described. However, the
specific amounts of bypass dust drawn off have no influence on the removal of chloride
and sulfate. In practice, if there are local reducing zones the conditions in these regions
may not be ideal for sulfur bonding. In this case some of the sulfur may also be present in
gaseous form as SO2.

Kiln plants with precalciners and tertiary air ducts exibit particularly high increases
in concentration so the bypasses are highly efficient. In these plants the vaporized
chloride is »distributed« over approximately half the gas, which facilitates very effective
removal.

2.6 Exhaust Gas Routing and Utilization

The configuration of the exhaust gas routing for the gas bypass and the exhaust gas
utilization system are adapted to suit the respective kiln plants, especially when retrofitting
existing plants with bypass systems. In this instance, the material and heat potential of the
bypass flows must be taken into account over the entire production process so the bypass
system cannot be considered in isolation. In principle it is possible to use the heat potential
to dry the raw materials in tube mills.
The following exhaust gas routing variants have been employed in German cement Variants
works:
 exhaust gas routing with utilization of the bypass waste heat in the tube mill; bypass
dust collection in an electrostatic precipitator

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 exhaust gas routing with utilization of the bypass waste heat for combined drying and
grinding or for drying
 exhaust gas routing without utilization of the bypass waste heat (separate offtake)
 exhaust gas routing without utilization of the waste heat (offtake with exhaust air from
the cooler)
mixed gas
(i.N.) = (standard conditions) control range 300 - 400 °C
max. 23.000 m³/h (i.N.)

hot gas for drying and

grinding of raw materials 320 °C
✑
✌✍✎ ✏ ar
✒ ✔
✍ ✓✎✎✎ ✏ /h (i.N.)

cooling air
V = const
max. 15.000 m³/h (i.N.)
kiln gas
0 – 16 % bypass rate
ca. 8.000 m³/h (i.N.)
1.100°C

10 bypass clinker dust

ca. 1 t/h

clinker silos

Figure 2.6-1: Common Exhaust Gas Routing for the Bypass Gases and the Cooler Exhaust Air in a
KHD Kiln Plant with a Throughput of 2,500 t/d of Clinker.

The exhaust gas routing illustrated in Fig. 2.6-1 has the advantage that the bypass dust,
which has a tendency to stick together, is collected together with the clinker dust from the
cooler exhaust air and is therefore easier to transport and store.

2.7 Bypass Gas Dedusting

The Importance of From a cost perspective the type of filter to be used is of key importance. When using
Filters the bypass flow for drying granulated blastfurnace slag or in a cement mill, cleaning
can be dispensed with entirely under favourable conditions (small variations in the chlo-
ride content in the bypass dust). In the other variants, cleaning, either by an electrostatic
precipitator or a fabric filter and a cyclone, is necessary.
Advantages and Fabric filters can only be used up to temperatures of approximately 200 to 220 ◦ C, but an
Disadvantages of electrostatic precipitator can be used for cleaning in the hot range (280 to 400 ◦ C) and in
Different Filter Types
the cold range (120 to 170 ◦ C). For hot operation it is sufficient to cool the bypass gas with
air but the additional installation of a conditioning tower is required for cold operation. In
this case the precipitator may be smaller.
Trend with Fabric Filters Over the years the ever more stringent demands imposed by environmental legislation and
the increasing use of secondary fuels together with the associated requirements have meant
that the dust limits for kiln exhaust gases, and therefore also for the associated bypass
exhaust gases, have constantly been revised in the direction of lower emission limits.
For this reason there has been an increasing trend in recent years towards the use of fabric
filters for dedusting in new construction projects. Unlike in electrostatic precipitators,
the clean gas dust concentration with fabric filters is not dependent on the water vapour
content of the exhaust gases under the given operating conditions (temperatures of 140 to
approx. 200 ◦ C). With this filter technology it is possible to comply with very low dust
concentration limits of < 10 mg/m3.
Cyclone When using a high-efficiency cyclone as a separator it should be borne in mind that only

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 2.8 Dust Transport and Storage

the coarse fractions of the dust, which carry lower concentrations of the substances in
question, will be collected while the fine fractions will pass through the cyclone. A cyclone
may therefore only be used if the exhaust gas is to be re-used or if another filter is installed
for final dedusting. The advantage of using a cyclone as a separator is that the heat loss is
lower since the cyclone can be operated at 500 to 600 ◦ C.

2.8 Dust Transport and Storage

All bypass systems experience considerable problems with dust transport owing to the co- High
hesive properties of the dust that has been collected when the chloride content is high. ChlorideConcentration

High chloride concentrations can be avoided by adding raw meal or clinker dust. By-
pass dust may have a tendency to cake above chloride concentrations of only 5 % so the
transport equipment and storage silos must be designed accordingly.
The bypass dust may be transported away either mechanically using rotary-vane feeders, Transport
heavy duty drag chain conveyors and screw conveyors, or pneumatically using a screw
pump and conveying pipelines. 11

1 2

Figure 2.8-1: Silo for Storing Bypass Dust .

1 Twin screw with intermediate storage container

2 Screw pump and pneumatic conveying equipment

3 Reclaiming screw with central drive

Table 2.8-1: Key to Fig. 2.8-1.

Facilities suitable for storing bypass dust include flat-bottomed silos with mechanical dis- Storage in a Silo
charge equipment. In this instance, the flat base of the silo is equipped with a rotating
reclaiming screw. The screw conveys the material through a central discharge opening
and into an intermediate hopper. The dust is removed from the intermediate hopper under
the reclaiming screw by two screws and fed to a pneumatic conveying pump for onward
transport (Fig. 2.8-1).
In conventional storage silos the base of the silo must be fitted with special aeration devices
to ensure adequate discharge.

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 4 Environmental Protection

3 Plant Operation and Quality

System Breakdown Continuous operation of the bypass system is of vital importance for uniform and trouble-
free operation of the rotary kiln, particularly in view of the increasing use of secondary
fuels. If the bypass system breaks down the circulating elements, such as sulfur and
chlorine, will build up in the region of the kiln inlet and the lowermost cyclone stage. The
rising content of these elements in the hot meal causes caking and this in turn may lead to
a reduction in the flow cross-section in the preheater and therefore to cyclone blockages.

A chloride content above about 8 % in the bypass dust may be detrimental to the func-
tioning of the bypass system since adhesion of the dust may cause conveying equipment
Chloride Content
to become blocked or may make it very difficult to remove the dust from the storage
silos. Clinker meal from the dedusting of the cooler exhaust air or raw meal may be
added to the bypass dust to avoid high chloride concentrations. In addition the size
of the dust particles, moisture content and the chemical composition also influence the
12 adhesion of the bypass dust.

ProductQuality Bypass dust may be added to the cement depending on the maximum chloride content ([Cl-
] < 0.10 mass % ) specified in DIN EN 197. Basic requirements for complying with the
limit are precise gravimetric metering and, in particular, homogeneous dust composition.
This may be achieved, on the one hand, by operational measures such as uniform kiln
operation, constant composition of the raw materials and fuels as well as homogenization
of the dust in appropriate silos and, on the other hand, by adding clinker dust and raw
meal.
Because of their alkali chloride content bypass dusts are generally used as activators for
cements, i.e. reduced setting times and accelerated strength development of the ce-
ments in question can be expected depending on the amount of dust added. Fluctuations
Strength
in final strength can be offset by making corresponding adjustments to the fineness.
Early stiffening may occur when these cements are used in concrete – an undesirable
property in ready-mixed concrete.
On the other hand, bypass dust may be used to produce an appreciable acceleration in the
rate of hydration of cements that are classed as less reactive due to their mineralogy.

4 Environmental Protection
Different emission-reducing measures are used depending on the exhaust gas routing of
the bypass system. The filter systems must undergo maintenance at regular intervals in
order to ensure perfect functioning and to comply with the limits set by the authorities.
 With electrostatic precipitators care must also be taken to ensure that the exhaust
gas temperature is higher than the acid dew point since otherwise the filter housing
and internal fittings may be subject to corrosive damage.
 In bag filter systems the temperature in the filter must not exceed the maximum per-
missible temperature for the bags. In addition the bags must be replaced at the correct
time. It is possible to determine when a bag needs replacing either from the increasing
pressure differential before and after the filter or from the increasing cleaning fre-
quency.
lime hydrate SO2 emissions can be reduced by, for example, injecting lime hydrate into the bypass
gas. In this instance it is necessary to ensure that the metering and conveying equipment
function correctly.

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5 Health and Safety Practices
Industrial Safety
Bypass systems consist of a closed system operating under negative pressure up to the
induced draught fan. The gas temperature varies from approximately 1,200 ◦ C at the
offtake point to approximately 100 ◦ C at the chimney. Various measuring devices are used
to monitor the systems:
 temperature measuring equipment
 equipment for measuring negative pressures
 equipment for gas analysis (for example dust measurement, SO2 measurement, CO
measurement)
The bypass dust is also sampled at regular intervals in order to be able to detect any fluc-
tuations in chloride content in good time and take countermeasures.
Generally the same industrial safety requirements as in the entire preheater system are
applicable for the checking and cleaning procedures. Care should be taken to ensure the
suitability of personal protective equipment, in particular when cleaning off caking at the 13
gas offtake point near the kiln inlet chamber. This work is generally undertaken by the
preheater staff and is subject to exactly the same safety precautions as when handling hot
meal (see course 3.3).
Every worker in the hot region must have personal protective equipment:
 protective clothing made of heat-resistant material (Kevlar or a Kevlar-carbon mixture)
 heat protection gloves with tight cuffs Wear Personal
ProtectiveEquipment
 protective hat with a neck guard and face screen
 high, tight safety boots
Danger areas must be clearly marked by appropriate signs, as must the full-body and eye
showers. Communication with lookouts or the control room should be ensured by using
personal mobile radios or mobile telephones.

Health and Safety Practices

Any materials that are hazardous to health in the vicinity of bypass systems are predom-
inantly present in dust form. Bypass dust may cause irritation of the eyes, skin, mucous
membranes and airways owing to its basic constituents (burnt lime, cement clinker and
potassium chloride). Any spilled material should be collected and disposed of in dry form
with as little dust as possible.
From an industrial safety perspective and for health reasons, eye and respiratory protection Respiratory and Eye
should be worn when working in areas with bypass dust. Protection

The following »first aid« measures should be carried out if contamination with bypass dust First Aid
occurs:
 after inhalation: breathe fresh air
 after skin contact: rinse thoroughly with water
 after eye contact: rinse with plenty of water (eye shower), consult an ophthalmologist
if necessary
 after swallowing (large amounts): consult a doctor if you feel unwell

6 Questions on Course LB 3.5 – Bypass Systems

You can test your knowledge by answering the following questions.

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 6 Questions on Course LB 3.5 – Bypass Systems

Question 6.0 A:
1. What causes circulating systems consisting of alkalis, sulfur and chlorine in kiln
plants?
2. How can circulating systems be relieved?
3. Name three operational measures for reducing circulating systems.
4. What is the coating tendency of hot meal dependent on?
5. Why are bypass systems being used increasingly when secondary fuels are used?
6. Why can a high chloride content in the bypass dust be detrimental to the functioning
of the bypass system?
7. Why are chlorides removed more effectively than sulfates when using a gas bypass?
8. How can the bypass gases be dedusted?
9. How is it possible to ensure adequate discharge of bypass dust from storage silos?
10. Name at least three safety measures for eyes, skin, mucous membrane and airways
when handling bypass dust.
11. Name at least three different measuring devices used to monitor the systems.
14 12. Are the safety precautions taken when cleaning off caking in the region of the kiln
inlet chamber identical to those taken when handling hot meal?
13. Which basic constituents of bypass dust may cause irritation of the eyes, skin, mu-
cous membrane and airways?
14. What chloride content in the bypass dust might be detrimental to the functioning of
the bypass system?
15. How can SO2 emissions in bypass gas be reduced?
16. What effect does bypass dust have on cement and how might any variations in this
regard be offset?
17. Can bypass dust be added to cement in large quantities?
Solutions see p. 15

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Research Institute of the Cement Industry
Solutions
Solution for 6.0 A:
1. Because of the high process temperatures involved, circulating systems consisting
of alkalis, chlorides and sulfates may occur during clinker production as a result of
vaporization and subsequent condensation.
2. Circulating systems can be relieved by a bypass by diverting part of the material
flow from the main flow.
There are three types of bypass:
 gas bypass for reducing chlorine and, to a limited extent, sulfur
 hot meal bypass for reducing chlorine
 dust bypass for reducing heavy metals
3. Operational measures for relieving circulating systems:
 reducing the input of materials that form circulating systems
 reducing the vaporization rate (sulfur)
 expert cleaning of the parts of the plant that are at risk 15
4. Due to its content of chloride and SO3 the hot meal from the bottom cyclone stage
can be used as a practical indicator of the coating tendency. The greater the content
of both compounds, the greater is the coating tendency.
5. The input of volatile constituents in kiln systems has increased owing to the use
of secondary fuels. Chloride, in particular, often limits the amount of secondary
fuels that can be used, so bypass systems of modern design are being installed to an
increasing extent for effective removal of chlorides.
6. Bypass dust has a tendency to cake at chloride contents greater than 5 % and this
leads to problems with dust transport.
7. Because chlorides are more volatile than sulfates.
8.  fabric filter
 electrostatic precipitator
 cyclone (only for coarse fractions of the dust)
9. Mechanical discharge by:
 rotary-vane feeders
 heavy duty drag chain conveyors
 screw conveyors
Pneumatic discharge by:
 screw pumps and conveying pipelines
Aeration devices must be fitted in the base of the silo in conventional storage silos
to ensure adequate discharge.
10. Possible safety measures include:
 wearing a protective mask for protecting the eyes and respiratory system
 protective clothing
 in the case of skin contact rinse thoroughly with water.
Possible first aid measures include:
 after inhalation: breathe fresh air
 after skin contact: rinse thoroughly with water
 after eye contact: rinse with plenty of water (eye shower), consult an ophthal-
mologist
 after swallowing (large amount): consult a doctor if you feel unwell
11. Possible measuring devices include:
 temperature measuring equipment
 equipment for measuring negative pressures

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 6 Questions on Course LB 3.5 – Bypass Systems

 gas analysis equipment

12. This work is generally undertaken by the preheater staff and is therefore subject to
exactly the same safety precautions.
13. Basic constituents of bypass dust include:
 burnt lime
 cement clinker
 potassium chloride
14. A content above about 5 % can be detrimental since conveying equipment may
become blocked, for example as a result of caking.
15. SO2 emissions may be reduced by injecting lime hydrate into the bypass gas.
16. The addition of bypass dust may lead to shortened setting times and accelerated
strength development of cement. Variations in final strength can be offset by ad-
justing the fineness.
17. Bypass dust can be added to cement in accordance with the maximum chloride
content specified in DIN EN 197.
Questions see p. 14
16

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Research Institute of the Cement Industry
Glossary
alkali salts
Salts of alkali metals (e.g. lithium, sodium, potassium). One example is sodium chloride (»common salt«, NaCl).
chute
Feed channel or similar filling device
cohesive
cohesion = attraction
lime hydrate
common term for calcium hydroxide as an additive for retaining SO2 emissions.
mass %, M.-%
Abbreviation for percent by mass; measure of the proportion by mass of a component in a mixture
potassium carbonate
K2CO3; potash; potassium salt of carbonic acid
potassium chloride
KCl; potassium salt of hydrochloric acid
potassium sulfate 17
K2SO4; potassium salt of sulfuric acid
sodium carbonate
Na2CO3; calcined sodium carbonate; salt of carbonic acid
sodium chloride
NaCl; common salt; sodium salt of hydrochloric acid
sodium sulfate
Na2SO4; sulfate of soda; sodium salt of sulfuric acid

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 Index

A
alkali salts 7

C
chute 6
cohesive 11

L
lime hydrate 12

M
mass %, M.-% 3, 12

P
potassium carbonate 1
potassium chloride 1
18
potassium sulfate 1

S
sodium carbonate 1
sodium chloride 1
sodium sulfate 1

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