TRANSLATION

GERMAN ASSOCIATION OF CEMENT WORKS (VDZ)
Tannenstrasse 2 4 Düsseldorf Germany

Execution and Evaluation of Kiln Performance Tests

PROCESS TECHNOLOGY COMMITTEE KILN PERFORMANCE TESTS TASK FORCE

May 1992

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TABLE OF CONTENTS

1. 2.
2.1 2.2

PRELIMINARY REMARKS ...........................................................................7 DESCRIPTION OF THE CLINKER BURNING PROCESS ...........................8
Reactions of the kiln feed............................................................................................................... 8 Burning process............................................................................................................................ 10

3.
3.1 3.2

EXECUTION OF KILN PERFORMANCE TESTS .......................................16
Mode of operation of the kiln system.......................................................................................... 16 Duration of the performance test................................................................................................ 16

3.3 Measuring methods ...................................................................................................................... 17 3.3.1 Solid substances.................................................................................................................... 17 3.3.1.1 Sampling .......................................................................................................................... 17 3.3.1.2 Analysis ........................................................................................................................... 18 3.3.1.3 Mass flows ....................................................................................................................... 25 3.3.2 Gases..................................................................................................................................... 27 3.3.2.1 Sampling .......................................................................................................................... 27 3.3.2.2 Analysis ........................................................................................................................... 28 3.3.2.3 Volume flows................................................................................................................... 28 3.3.3 Liquids.................................................................................................................................. 30 3.3.3.1 Heating oil ....................................................................................................................... 30 3.3.3.2 Water................................................................................................................................ 30 3.3.4 Temperatures ........................................................................................................................ 31 3.3.5 Pressures ............................................................................................................................... 32 3.3.6 Strokes and rotational speeds................................................................................................ 32 3.3.7 Electricity consumption ........................................................................................................ 33 3.3.8 Ambient conditions............................................................................................................... 33 3.3.9 Ensuring the precision of the measurements and analyses ................................................... 34

4.

EVALUATION OF KILN PERFORMANCE TESTS.....................................35

4.1 Balancing of the entire system..................................................................................................... 35 4.1.1 Solid substance mass flows .................................................................................................. 40 4.1.2 Gas volume flows ................................................................................................................. 42

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4.1.2.1 Dry gas............................................................................................................................. 42 4.1.2.1.1 Minimum air volume flow.......................................................................................... 42 4.1.2.1.2 Air proportionality factor............................................................................................ 45 4.1.2.1.3 Infiltrated air at the kiln hood ..................................................................................... 46 4.1.2.1.4 Secondary air .............................................................................................................. 47 4.1.2.1.5 Cooler intake air ......................................................................................................... 48 4.1.2.1.6 Raw gas ...................................................................................................................... 48 4.1.2.1.7 Gas downstream from the burning area ...................................................................... 50 4.1.2.1.8 Gas downstream from the rotary kiln (kiln inlet) ....................................................... 50 4.1.2.2 Water vapor...................................................................................................................... 51 4.1.2.2.1 Humidity in the air...................................................................................................... 51 4.1.2.2.2 Water from the kiln feed............................................................................................. 51 4.1.2.2.3 Water from the fuel..................................................................................................... 52 4.1.2.2.4 Injection water ............................................................................................................ 52 4.1.2.3 Moist gas.......................................................................................................................... 52 4.1.2.3.1 Air............................................................................................................................... 52 4.1.2.3.2 Raw gas ...................................................................................................................... 53 4.1.3 Liquid mass flows................................................................................................................. 53 4.1.4 Energy flows......................................................................................................................... 53 4.1.4.1 Energy input..................................................................................................................... 53 4.1.4.1.1 Fuel ............................................................................................................................. 53 4.1.4.1.2 Kiln feed ..................................................................................................................... 57 4.1.4.1.3 Air............................................................................................................................... 60 4.1.4.1.4 Injection water ............................................................................................................ 62 4.1.4.1.5 Mechanical performance ............................................................................................ 62 4.1.4.2 Energy output................................................................................................................... 62 4.1.4.2.1 Reaction enthalpy of the kiln feed .............................................................................. 62 4.1.4.2.1.1 C3S, C2S, C3A and C4AF in the clinker ............................................................... 64 4.1.4.2.1.2 CaCO3 and MgCO3 in the kiln feed and in the raw gas dust ............................... 65 4.1.4.2.1.3 CaCO3 and C2S in the bypass dust....................................................................... 66 4.1.4.2.1.4 Balance equations ................................................................................................ 66 4.1.4.2.2 Water evaporation....................................................................................................... 70 4.1.4.2.3 Waste gas losses ......................................................................................................... 70 4.1.4.2.4 Dust losses .................................................................................................................. 71 4.1.4.2.5 Incomplete combustion............................................................................................... 72 4.1.4.2.6 Clinker ........................................................................................................................ 72 4.1.4.2.7 Radiation and convection ........................................................................................... 74 4.1.4.2.8 Uncoupled heat ........................................................................................................... 78 4.1.4.3 Energy balance................................................................................................................. 79 4.2 Balancing of the partial systems.................................................................................................. 80 4.2.1 Clinker cooler ....................................................................................................................... 80 4.2.1.1 Solid substance mass flows.............................................................................................. 83 4.2.1.2 Gas volume flows ............................................................................................................ 84 4.2.1.3 Energy flows ........................................................................................................................... 84 4.2.1.3.1 Energy input ............................................................................................................... 84 4.2.1.3.1.1 Hot clinker ........................................................................................................... 84 4.2.1.3.1.2 Cooler intake air .................................................................................................. 85 4.2.1.3.1.3 Injection water ..................................................................................................... 85 4.2.1.3.1.4 Mechanical performance ..................................................................................... 85

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4.2.1.3.2 Energy output ............................................................................................................. 85 4.2.1.3.2.1 Clinker, clinker dust ............................................................................................ 85 4.2.1.3.2.2 Radiation and convection .................................................................................... 86 4.2.1.3.2.3 Uncoupled heat .................................................................................................... 86 4.2.1.3.2.4 Cooler vent air, secondary air, tertiary air ........................................................... 86 4.2.1.3.2.5 Water evaporation................................................................................................ 86 4.2.1.3.3 Energy balance ........................................................................................................... 86 4.2.1.4 Evaluation quantities........................................................................................................ 87 4.2.1.4.1 Pre-cooling zone ......................................................................................................... 87 4.2.1.4.2 Energy loss flow of the cooling area .......................................................................... 89 4.2.1.4.3 Cooling area efficiency............................................................................................... 89 4.2.1.4.4 Cooler efficiency ........................................................................................................ 90 4.2.2 Calcinator (only for kiln system with cyclone preheater)..................................................... 90 4.2.2.1 Determination of the degree of precalcining.................................................................... 92 4.2.3 Preheater (only for kiln system with cyclone preheater) ...................................................... 93 4.2.3.1 Degree of separation of individual cyclone stages........................................................... 94

5. 6.
6.1 6.2 6.3 6.4 6.5 6.6 6.7

EVALUATION OF THE SUBSTANCE CIRCULATION SYSTEMS ............98 EVALUATION OF THE CEMENT CLINKER ..............................................99
Degree of burning......................................................................................................................... 99 Particle-size distribution.............................................................................................................. 99 Grindability ................................................................................................................................ 100 Chemical composition ................................................................................................................ 100 Phase composition ...................................................................................................................... 103 Microscopic examination........................................................................................................... 103 Cement testing ............................................................................................................................ 104

7. 8. 9.
9.1 9.2

EVALUATION OF THE EMISSIONS ........................................................105 FORMULA SIGNS AND INDICES ............................................................106 LITERATURE REFERENCES...................................................................112
General literature references .................................................................................................... 112 Technical literature references.................................................................................................. 113

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10. EVALUATION EXAMPLE 1 (KILN SYSTEM WITH A CYCLONE PREHEATER, CALCINATOR AND TERTIARY AIR DUCT) ...........................118
10.1 Balancing the entire system .................................................................................................. 118 10.1.1 Solid substance mass flows ................................................................................................ 118 10.1.2 Gas volume flows ............................................................................................................... 119 10.1.2.1 Dry gas ...................................................................................................................... 119 10.1.2.1.1 Minimum air volume flow...................................................................................... 119 10.1.2.1.2 Air proportionality factors ...................................................................................... 120 10.1.2.1.3 Infiltrated air at the kiln hood ................................................................................. 120 10.1.2.1.4 Secondary air .......................................................................................................... 121 10.1.2.1.5 Cooler intake air ..................................................................................................... 121 10.1.2.1.6 Raw gas .................................................................................................................. 122 10.1.2.1.7 Gas downstream from the burning area .................................................................. 123 10.1.2.1.8 Gas downstream from the rotary kiln (kiln inlet) ................................................... 124 10.1.2.1.9 Infiltrated air (preheater)......................................................................................... 125 10.1.2.1.10 Infiltrated air (calcinator)...................................................................................... 125 10.1.2.2 Water vapor............................................................................................................... 125 10.1.2.2.1 Humidity in the air.................................................................................................. 125 10.1.2.2.2 Water from the kiln feed......................................................................................... 126 10.1.2.2.3 Water from the fuel................................................................................................. 127 10.1.2.2.4 Injection water ........................................................................................................ 127 10.1.2.3 Moist gas (examples) ................................................................................................ 128 10.1.3 Liquid mass flows............................................................................................................... 128 10.1.4 Energy flows....................................................................................................................... 128 10.1.4.1 Energy input.............................................................................................................. 128 10.1.4.1.1 Fuel ......................................................................................................................... 128 10.1.4.1.2 Kiln feed ................................................................................................................. 129 10.1.4.1.3 Air........................................................................................................................... 130 10.1.4.1.4 Injection water ........................................................................................................ 130 10.1.4.1.5 Mechanical performance ........................................................................................ 130 10.1.4.2 Energy output ............................................................................................................ 131 10.1.4.2.1 Reaction enthalpy of the kiln feed .......................................................................... 131 10.1.4.2.1.1 C3S, C2S, C3A and C4AF in the clinker ........................................................... 131 10.1.4.2.1.2 CaCO3, and MgCO3 in the kiln feed and in the raw gas dust........................... 132 10.1.4.2.1.3 CaCO3 and C2S in the bypass dust................................................................... 132 10.1.4.2.1.4 Balance equations ............................................................................................ 132 10.1.4.2.2 Water evaporation................................................................................................... 134 10.1.4.2.3 Waste gas losses ..................................................................................................... 134 10.1.4.2.4 Dust losses .............................................................................................................. 135 10.1.4.2.5 Incomplete combustion........................................................................................... 136 10.1.4.2.6 Clinker .................................................................................................................... 136 10.1.4.2.7 Radiation and convection: ...................................................................................... 137 10.1.4.2.8 Uncoupled heat ....................................................................................................... 137 10.1.4.3 Energy balance .......................................................................................................... 137 10.2 Balancing of the partial systems........................................................................................... 138 10.2.1 Clinker cooler ..................................................................................................................... 138 10.2.1.1 Solid substance mass flows ....................................................................................... 138

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10.2.1.2 Gas volume flows...................................................................................................... 138 10.2.1.3 Energy flows ............................................................................................................. 139 10.2.1.3.1 Energy input ........................................................................................................... 139 10.2.1.3.2 Energy output ......................................................................................................... 139 10.2.1.3.3 Energy balance ....................................................................................................... 141 10.2.1.4 Evaluation quantities................................................................................................. 142 10.2.1.4.1 Pre-cooling zone ..................................................................................................... 142 10.2.1.4.2 Energy loss flow of the cooling area ...................................................................... 142 10.2.1.4.3 Cooling area efficiency........................................................................................... 143 10.2.2 Calcinator ........................................................................................................................... 143 10.2.3 Preheater ............................................................................................................................. 144 10.3 10.4 Estimation of error................................................................................................................ 145 Tables...................................................................................................................................... 146

this specification. but also to create a reliable foundation for the optimization of individual system components. including significant remarks pertaining to measurement technology. as well as for the reduction of the level of emissions. specific fuel-energy consumption). The practical feasibility of the evaluation is always the main priority in the formulation of the numerical value equations. This specification deals primarily with energy and mass balances. The units indicated in Section 8 apply to all numerical value equations. of the operation and of the cement quality.May 1992 Specification Vt 10 Page 7 1. stroke numbers and rotational speeds as well as on the consumption of electricity. Information on pressure levels. in addition to the evaluation. . only serves to assess the kiln operation. The evaluation equations are employed in two practical examples in Sections 10 and 11. kiln performance tests not only serve to gather data on the performance of the kiln system (clinker output. in contrast. For this reason. Preliminary remarks In cement plants. specifically contains information for carrying out performance tests. Additional information in this context would be necessary in order to obtain a precise measurement. The important aspect here is the absolute value of the measured values.

clay and sand.Schematic representation of the clinker formation reaction. The oxidic main components are calcium oxide (CaO). silicon dioxide (SiO2). some of them consecutively.1 Description of the clinker burning process Reactions of the kiln feed Portland cement clinker is made from a finely-ground raw material mixture consisting of limestone. marl. aluminum oxide (Al2O3) and iron oxide (Fe2O3). The raw material mixture is heated up and burned in the rotary kiln to form clinker. and some of them in parallel to each other (see Figure 1).May 1992 Specification Vt 10 Page 8 2. Figure 1 . . 2. a process in which several chemical reactions take place.

however. • starting at 1250°C [2282°F]. crystallization of the melt to form C3A and C4AF. the formation of the dicalcium silicate (2CaO · SiO2. In this process. which practically takes place between 800°C and 900°C [1472°F and 1652°F]. clay minerals (SiO2-Al2O3-H2O) and iron ore (Fe2O3). • upon cooling. • once a maximum of 1200°C [2192°F] is reached. various calcium aluminate and calcium ferrite compounds are formed as transition phases which. quartz (SiO2). it reaches a fraction of about 20% to 30% by weight. C2S) already starts at about 700°C [1292°F]. This is followed by the calcination (decarbonation. activation of the silicates through water expulsion and modification change.May 1992 Specification Vt 10 Page 9 The clinker formation reactions can be depicted as a model broken down into the following temperature stages: • starting composition: calcite (CaCO3). Moreover. Fe2O3 as well as of activated SiO2 and CaO. calcination of the CaCO3 and concurrent binding of Al2O3. dissociation) of the calcium carbonate into CaO and CO2. in short. First of all. After the complete decarbonation. Owing to solid-state reactions. • between 700°C and 900°C [1292°F and 1652°F]. The melt plays a significant role in the finishing burn of the clinker. and forced above 1300°C [2372°F] due to melt formation. • up to about 700°C [1292°F]. while the chemically bound water is removed up to a temperature of about 700°C [1292°F]. the formation of belite (“C2S”) from SiO2 on CaO (“free lime”) is completed. the kiln feed has lost about 35% of its dry weight. the alite and the belite remain virtually unchanged in their form and composition. reaction of the belite with the remaining free lime to form alite (“C3S”). disintegrate again once the clinker melt starts to form at about 1280°C [2336°F]. since it pro- . At a sintering temperature of around 1450°C [2642°F]. the physically bound water is removed when the kiln feed is preheated.

May 1992 Specification Vt 10 Page 10 motes the formation of tricalcium silicate (3CaO · SiO2. In order to reach the sintering temperature of about 1350°C to 1500°C [2462°F to 2732°F] that is necessary for the formation of the clinker phase and in view of the unfavorable heat-conduction conditions in the kiln feed. Rotary kilns with preheaters located upstream have a length that is 10 to 17 times longer than their diameters. the cooling rate should not be so high that the melt becomes glassy as it solidifies. in short. brick-lined tubes. in short. C4AF) crystallize out. On the other hand. C3S) from solid dicalcium silicate and CaO. In this context. burning tempera- . which is indispensable for the strength properties of the cement. the kiln feed coming from the preheater moves towards the main burner of the rotary kiln. in short. which are operated at 1.5 to 3 rpm.2 Burning process In Germany nowadays.0°. Rotary kilns are fire-proof. and the tricalcium aluminate crystallizes with the finest grain possible. After completion of the sintering. Consequently. the cooling of the cement clinker has to be optimally harmonized with the required clinker properties. which is located at the lower end of the rotary kiln. 2. C3A) and aluminate ferrite (4CaO · Al2O3 · Fe2O3. As a result of the inclination and rotation. the cement clinker has to be cooled off so quickly that the tricalcium silicate does not disintegrate. 6-9 and 11-15]). qualitative differences occur which depend on the composition of the kiln feed [48-53]. As the melt cools down. cement clinker is produced in rotary kiln systems with kiln feed preheaters located upstream and clinker coolers located downstream (for other process techniques. having diameters of up to 6 meters and inclined at an angle ranging from about 2.5° to 4. see [2-4. essentially tricalcium aluminate (3CaO · Al2O3.

the gas is once again blown from the top to the bottom through the moist granules in the dry chamber. it re-enters the gas stream prior to the next-lower cyclone stage. afterwards. which usually consist of 10 satellite tubes attached around the periphery of the rotary kiln. After the coarse dust has been separated out. satellite coolers and rotary coolers are employed as clinker coolers in the cement industry. Grate-type preheaters consist of a traveling grate on which the kiln feed that has been made into granules or briquettes travels through a closed tunnel that is divided into a hot chamber and a dry chamber. With grate-type coolers. Grate-type coolers. the combustion air is preheated to about 600°C to 1000°C [1112°F to 1832°F] in a clinker cooler located downstream from the sintering process. The dry. An intermediate gas fan blows the process gas of the rotary kiln from the top to the bottom through the layer of granules in the hot chamber. and it is once again separated from the gas in the cyclones. . the clinker dissipates its energy to the cooling air that is flowing in a cross current or countercurrent. When it comes to kiln systems. In the case of the rotary coolers or satellite coolers. and it is then fed to the rotary kiln burner as so-called secondary air. a distinction is made as to whether they are operated with a grate-type preheater or with a cyclone preheater. depending on the clinker output. raw meal mixture is fed into the waste gases prior to entering the uppermost cyclone stage. the clinker that drops out of the rotary kiln after the sintering operation is cooled in a crosscurrent.May 1992 Specification Vt 10 Page 11 tures ranging from 1800°C to 2000°C [3272°F to 3632°F] or even higher are needed. The cyclone preheater essentially consists of four to five cyclone stages arranged one above the other in a tower that is 50 to 100 meters high. In order to be able to reach such high temperatures. The process gases coming from the rotary kiln flow through the cyclone preheater from the bottom to the top.

depending on the number of stages and capacity flow ratio. As a function of the process. the waste gases have a temperature of around 290°C to 400°C [554°F to 752°F]. Upon leaving the cyclone preheater. the process gas from the rotary kiln has a temperature of about 1000°C to 1200°C [1832°F to 2192°F].Schematic representation of a cement rotary kiln system with cyclone preheaters and waste gas utilization. Figure 2 shows a schematic representation of a cement rotary kiln system with a cyclone preheater and waste gas utilization. The kiln feed entering the rotary kiln reaches temperatures of 820°C to 850°C [1508°F to 1562°F] at precalcining degrees of up to about 90%.May 1992 Specification Vt 10 Page 12 Both with cyclone preheater systems and with grate-type preheater systems. . Figure 2 . the waste gases of the grate-type preheater have a temperature of about 90°C to 120°C [194°F to 248°F]. Figure 3 schematically shows a rotary kiln system with a grate-type preheater.

the further development of kiln systems has led to the process involving precalcining. This method is employed with old systems in particular. which leads from the clinker cooler past the rotary kiln. For this purpose. and from there to the secondary burner. In this process.May 1992 Specification Vt 10 Page 13 Figure 3 .Schematic representation of a cement rotary kiln system with a grate-type preheater. In the case of new systems with cyclone preheaters. The principle involved in both techniques for conveying the combustion . that is to say. the so-called “tertiary air duct”. the fuel energy is divided up over two burners and. with the secondary burner located between the rotary kiln and the preheater. The combustion air for the secondary burner can be conveyed through the rotary kiln. which is designated as the calcinator. however. the amount of energy supplied is such that 70% to 95% of the calcium carbonate of the kiln feed has already decarbonated by the time it enters the rotary kiln. together with the waste gas from the main burner. the combustion air is conveyed in a separate gas duct. new systems with cyclone preheaters are provided with an enlarged combustion chamber between the rotary kiln inlet and the lowermost cyclone. Since about 1970.

Precalcining process with and without tertiary air duct. rotary kiln.May 1992 Specification Vt 10 Page 14 air is shown in Figure 4. . calcinator. is shown in Figure 5. up to 60% – of the total fuel energy needed can be employed in the secondary burner. In rotary kiln systems having a calcinator but without a tertiary air duct. Figure 4 . up to 30% – in systems with a tertiary air duct. consisting of a fourstage cyclone preheater. A rotary kiln system with precalcining. reciprocating grate-type cooler and tertiary air duct.

calcinator and tertiary air duct.Schematic representation of a cement rotary kiln system with a cyclone preheater.May 1992 Specification Vt 10 Page 15 Figure 5 . .

types of fuel. type of combined drying and grinding operation) should already have been determined during the planning phase of the performance test and. by changing the mixed bed).2 Duration of the performance test A kiln performance test should last for at least 24 hours. If the type of combined drying and grinding operation changes (in. should already have been established one week prior to the start of the performance test. in cases of major changes vis-à-vis normal operations. The latter has to be safeguarded by means of appropriate measures. Neither shortly before nor during the performance test should there be any changes in the composition of the kiln feed or of the fuel (for example. 3. out.May 1992 Specification Vt 10 Page 16 3. partial load). the energy fraction of the secondary fuel. composition of the kiln feed. the mass flow of the kiln feed.1 Execution of kiln performance tests Mode of operation of the kiln system The considerations elaborated upon below apply exclusively to the stationary operation a kiln system. Possible criteria for interrupting the performance test should also be laid down in advance. The essential operating data (for instance. preferably 48 or 72 hours. 3. the performance test should preferably last 72 hours. .

every 12 hours.1 Solid substances 3. Thus.5 ≥ 0.5 ≥ 0. screw conveyor) or from the meal pipes (for example. for instance.5 ≥ 0. Table 1 shows an example of a sampling plan. conveyor belt.5 ≥ 0.3 Measuring methods 3. The samples are taken from the belt (for instance.5 Sampling frequency every hour every four hours every four hours every four hours every four hours 1) every four hours 1) every two hours every four hours . It must be ensured that the sample is taken over the entire width of the material stream in order to take into account possible de-mixing phenomena.5 ≥ 0. which could give rise to insufficient blending by the time the sampling site is reached. Table 1 .May 1992 Specification Vt 10 Page 17 3. bucket elevator. at the discharge end of the conveyors (for instance.1 Sampling The objective of sampling is to obtain a random sample of each solid substance mass flow that is representative of the parent population being examined. Sampling amount in kg ≥1 ≥ 0.1. when two partial streams having different concentrations of the component to be examined are combined.3. The safety regulations that apply in such cases must be observed. the sampling amount and the sampling frequency have to be adapted to the prevailing test conditions.Sampling amount and sampling frequency in rotary kiln performance tests.3. then this non-homogeneity has to be taken into consideration by enlarging the scope of the sampling. that is to say. apron conveyor). Material clinker coal dust (main burner) coal dust (secondary burner) kiln feed raw gas dust tertiary air dust bypass dust Kiln feed in the preheater 1) With partial-stream suction.5 ≥ 0. the hot-meal pipe of a cyclone).

clinker). for example.May 1992 Specification Vt 10 Page 18 A partially decarbonated kiln feed should be cooled off rapidly and air-tight so as to avoid.1.3. Samples of solid substances from flowing gases (raw gas dust. care should be taken to ensure that the suction is representative. in the raw material) should be determined on larger individual samples. High levels of moisture (for instance. . the average sample is subsequently formed on the basis of the pre-dried individual samples. The individual samples are pre-comminuted (for example. This ensures that the best suited decomposition and analysis methods will be selected for each particular case. the individual and average samples should be stored air-tight in order to avoid a falsification of the H2O and CO2 contents. further decarbonation of CaCO3 or a residual burn-out of carbon. the laboratory should be informed about the source and presumed composition of the samples. 3. homogenized and combined to form a weighed average sample for the duration of the performance test. In this process. tertiary air dust) can also be taken by means of isokinetic suction of a partial stream. As a matter principle. For practical reasons. the samples can also be taken at time-staggered intervals. As a matter of principle.2 Analysis Table 2 shows an example of an analysis plan.

sample preparation calorific value H 2O ash ash composition volatile components C and H S Cl N O – Analysis method DIN 51701 (Part 3). ISO 1928 DIN 51777. ISO 609. ISO 331. ISO 1988. ISO 3733 DIN EN 7 DIN 51721 1) DIN EN 41. ISO 579. ISO 587 DIN 51722 (Part 1). ISO 589.May 1992 Specification Vt 10 Page 19 Table 2 . ISO 1015 DIN 51719.063) 1000°C [1832°F] ± 25 K (10 min) or 950°C [1742°F] ± 25 K until weight constancy is achieved Oil sampling calorific value H 2O ash C and H S Cl N – Natural gas composition O S Clinker. ISO 333 subtraction DIN 51570 (Parts 1 to 3) DIN 51900. ISO 334. ISO 2309 DIN 51900. ISO 687. ISO 348. ISO 1171 DIN 51729 DIN 51720. Material Coal dust Analysis sampling. ISO 562 DIN 51721. DIN 51400 DIN 51722 1) subtraction DIN 51872 DIN 51856 DIN 51855 Grinding for complete passage through the sieve. ISO 1928 DIN 51718. ISO 352.09 mm (for CaOfree 0. 0.Analysis and analysis method for rotary kiln performance tests. ISO 351 DIN 51727. ISO 625 DIN 51724 (Part 1). tertiary air dust sample preparation loss on ignition .

absorption) a) method according to Franke b) method according to Schläpfer and Bukowski Depending on the boundary conditions. 90% by weight of Li2B4O7 + 10% by weight of LiF as the decomposition agent.1% by weight of LiF + 8. K2O and Na2O with other analytical methods. 100% by weight of Li2B4O7 as the decomposition agent.May 1992 Specification Vt 10 Page 20 X-ray fluorescent full analysis 2) Cl – (including Br and I) 3) Σ SO3 K2O. hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7. Smith decomposition. determination of SO3.L. subsequent correction of the results Decomposition: a) nitric acid (1 part of concentrated nitric acid + 19 parts of water) b) acetic anhydride (7+6) c) thermal reaction in a moist O2 stream at 1000°C [1832°F] so as to form hydrogen chloride Analysis: a) potentiometric titration with silver nitrate b) titration according to Volhardt c) introduction of the hydrogen chloride into an acetic silver nitrate solution and coulometric titration The weighed-in amount has to be adapted to the low Cl – content of the clinker (5 to 10 g) a) gravimetric b) thermal reaction of the sulfur compounds with additives in the oxygen stream. the results can deviate from one method to another . 81% by weight of Li2B4O7 + 8. Measurement of the SO2 by means of an IR detector or else iodometrically J. Na2O CaOfree a) fluxing agent tablet (≤ 1000°C [1832°F]. dilution of 1:5).9% by weight of SrO + 2% by weight of V2O5 as the decomposition agent. determination of SO3. subsequent correction of the results c) fluxing agent tablet (1200°C [2192°F]. K2O and Na2O with other analytical methods. flame photometry (emission. analysis including SO3 and alkali b) fluxing agent tablet (1050°C [1922°F]. dilution of 1:5 to 1:20). dilution of 1:10).

subsequent correction of the results c) fluxing agent tablet (1200°C [2192°F].May 1992 Specification Vt 10 Page 21 Kiln feed sample preparation CO2 Grinding for complete passage through the sieve. analysis including SO3 and alkali b) fluxing agent tablet (1050°C [1922°F]. 100% by weight of Li2B4O7 as the decomposition agent. 81% by weight of Li2B4O7 + 8. K2O and Na2O with other analytical methods. dilution of 1:10). 0. dilution of 1:5 to 1:20).1% by weight of LiF + 8. determination of SO3. drying at 110°C [230°F]. K2O and Na2O with other analytical methods. dilution of 1:5). determination of SO3. 90% by weight of Li2B4O7 + 10% by weight of LiF as the decomposition agent. cooling in a desiccator.9% by weight of SrO + 2% by weight of V2O5 as the decomposition agent. thermal reaction of the carbon compounds in an oxygen stream a) gravimetric b) coulometric c) IR detection a) fluxing agent tablet (≤ 1000°C [1832°F]. subsequent correction of the results H2O < 110°C [230°F] 4) Σ H 2O Corg X-ray fluorescent full analysis 2) Cl – (including Br and I) 3) Decomposition: a) nitric acid (1 part of concentrated nitric acid + 19 parts of water) b) acetic anhydride (7+6) c) thermal reaction in a moist O2 stream at 1000°C [1832°F] so as to form hydrogen chloride .09 mm Thermal degradation in the inert gas stream at 1000°C [1832°F] or chemical degradation with acid a) gravimetric b) coulometric c) IR detection Weighing. weighing Thermal desorption in an inert gas stream at 1000°C [1832°F] a) KF titration b) IR detection c) gravimetric Decarbonation with hydrochloric acid.

hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7.09 mm Thermal degradation in an inert gas stream at 1000°C [1832°F] or chemical degradation with acid a) gravimetric b) coulometric c) IR detection S2– Raw gas dust 5) (cyclone preheater kiln) sample preparation CO2 Σ H 2O Thermal desorption in an inert gas stream at 1000°C [1832°F] a) KF titration b) IR detection c) gravimetric Corg Decarbonation with hydrochloric acid. iodometry Grinding for complete passage through the sieve. Na2O J. Smith decomposition. pick-up in a cooled (≤ 15°C [59°F]) ammoniacal ZnSO4 or CdCl2 solution. gravimetric b) thermal reaction of the sulfur compounds with additives in the oxygen stream. 0.May 1992 Specification Vt 10 Page 22 Analysis: a) potentiometric titration with silver nitrate b) titration according to Volhardt c) introduction of the hydrogen chloride into an acetic silver nitrate solution and coulometric titration The weighed-in amount has to be adapted to the low Cl – content of the clinker (5 to 10 g) Σ SO3 a) oxidation with bromine water. thermal reaction of the carbon compounds in an oxygen stream a) gravimetric b) coulometric c) IR detection . flame photometry (emission. Measurement of the SO2 by means of an IR detector or else iodometrically K2O. absorption) Dissolution with hydrochloric acid containing SnCl2 in the presence of Cr (metallic).L.

9% by weight of SrO + 2% by weight of V2O5 as the decomposition agent. Smith decomposition. dilution of 1:10). subsequent correction of the results Decomposition: a) nitric acid (1 part of concentrated nitric acid + 19 parts of water) b) acetic anhydride (7+6) c) thermal reaction in a moist O2 stream at 1000°C [1832°F] so as to form hydrogen chloride Analysis: a) potentiometric titration with silver nitrate b) titration according to Volhardt c) introduction of the hydrogen chloride into an acetic silver nitrate solution and coulometric titration The weighed-in amount has to be adapted to the low Cl – content of the clinker (5 to 10 g) a) oxidation with bromine water. flame photometry (emission. analysis including SO3 and alkali b) fluxing agent tablet (1050°C [1922°F]. Measurement of the SO2 by means of an IR detector or else iodometrically J. iodometry Cl – (including Br and I) 3) Σ SO3 K2O. K2O and Na2O with other analytical methods. absorption) Dissolution with hydrochloric acid containing SnCl2 in the presence of Cr (metallic). subsequent correction of the results c) fluxing agent tablet (1200°C [2192°F]. gravimetric b) thermal reaction of the sulfur compounds with additives in the oxygen stream. dilution of 1:5 to 1:20). Na2O S2– . pick-up in a cooled (≤ 15°C [59°F]) ammoniacal ZnSO4 or CdCl2 solution. 100% by weight of Li2B4O7 as the decomposition agent. K2O and Na2O with other analytical methods. dilution of 1:5). 90% by weight of Li2B4O7 + 10% by weight of LiF as the decomposition agent. hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7.May 1992 Specification Vt 10 Page 23 X-ray fluorescent full analysis 2) a) fluxing agent tablet (≤ 1000°C [1832°F].1% by weight of LiF + 8. determination of SO3.L. determination of SO3. 81% by weight of Li2B4O7 + 8.

L. flame photometry (emission. Measurement of the SO2 by means of an IR detector or else iodometrically Σ H 2O Corg K2O. hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7. Na2O Cl – (including Br and I) 3) Σ SO3 S2– Dissolution with hydrochloric acid containing SnCl2 in the presence of Cr (metallic). gravimetric b) thermal reaction of the sulfur compounds with additives in the oxygen stream. thermal reaction of the carbon compounds in an oxygen stream a) gravimetric b) coulometric c) IR detection J. Smith decomposition. 0. iodometry .09 mm Thermal degradation in an inert gas stream at 1000°C [1832°F] or chemical degradation with acid a) gravimetric b) coulometric c) IR detection Thermal desorption in an inert gas stream at 1000°C [1832°F] a) KF titration b) IR detection c) gravimetric Decarbonation with hydrochloric acid.May 1992 Specification Vt 10 Page 24 Bypass dust 5) Kiln feed in the preheater5) Raw gas dust 5) (grate-type preheating kiln) sample preparation CO2 Grinding for complete passage through the sieve. absorption) Decomposition: a) nitric acid (1 part of concentrated nitric acid + 19 parts of water) b) acetic anhydride (7+6) Analysis: a) potentiometric titration with silver nitrate b) titration according to Volhardt c) coulometric titration d) gravimetric a) oxidation with bromine water. pick-up in a cooled (≤ 15°C [59°F]) ammoniacal ZnSO4 or CdCl2 solution.

dirt). < 105°C [221°F]. An interim result should be determined every 4 to 6 hours in order to obtain information about the time course of the mass flow. for instance. every 4 hours with different clinker production. CaO. The duration of the clinker weighing can differ from the performance test duration.) Nitric acid extraction does not always dissolve all of the halides out of the sample matrix.3 Clinker: Mass flows The clinker is loaded onto trucks or railroad cars and weighed on calibrated scales (for example. K2O. clinker contains FeO and MnO. MgO. The maximum error is smaller with a duration of 48 hours. . several measuring intervals are needed. 3) 4) 5) 3. Continuously operating clinker scales can be adjusted by the above-mentioned method. Na2O. the solid materials might also contain fluoride. Mn2O3. even over shorter periods of time. barium oxide and strontium oxide or S2–. the weighing procedure should be checked. the examinations should be performed in the delivery state.3. The measured value from the performance test is then multiplied by the resulting correction values. Prior to the test. but it should not be shorter than 24 hours. Na2O should be checked by other analytical methods.1. This can lead to erroneously low results at low levels of Cl– in the raw material. P2O5. In addition to the above-mentioned compounds. the analysis method for fuels is employed. shipping scales).May 1992 Specification Vt 10 Page 25 1) 2) Since there are no specifications for mineral oils. (Σ SO3. K2O. During the reducing burning process. TiO2. SiO2. (NH4)2SO4. the trucks or railroad cars are weighed both empty and fully loaded (varying amounts of fuel in the tank. Dust as well as the kiln feed in the preheater can also contain highly volatile compounds such as. the laboratory should be informed to this effect. SO3. For this purpose. Al2O3. Alternatively. If this is already known to be so. In the case of sensitive samples that are hygroscopic or that react during the drying process. In each case. Fe2O3. for example.

1. Dust: Dust is preferably weighed on calibrated scales (for example.4. If weighing is not possible. Here. the dust mass flow is determined by means of an isokinetic partial stream suction (in this context. Kiln feed: The kiln feed mass flow is calculated.May 1992 Specification Vt 10 Page 26 In the case of immediately consecutive kiln performance tests. a second clinker weighing procedure is not necessary if it is ensured that all of the dust mass flows remain constant. shipping scales). It results from the component balance of the sum of the non-volatile substances (see Section 4. . care should be taken to ensure that the cleaning of the filter is switched to continuous operation before the dust is discharged.1).1. The following relationship applies: Fuels: Fuels are weighed on industrial scales which have been previously adjusted. the fuel energy consumption is usually balanced by means of a comparison of the energy output with the energy input (see Section 4. For this reason. also see the VDZ Specification titled “Dust quantity measurements in cement plants” [17]).3). However. Translator’s note: See Section 8 for the list of abbreviations used in the formulas. the precision levels achieved in this manner are often not sufficient for evaluating the kiln system.

CO CO2. while information on volume flow measurement is to be found in the VDZ Specification titled “Quantity measurement of gases by means of velocity measurements” [16]). In the gas downstream from the burning area. more information can be obtained from the VDZ Specification titled “Continuous gas analysis in cement plants” [20]). in the bypass gas and in the gas downstream from the burning area.May 1992 Specification Vt 10 Page 27 3. 3.2 Gases For the gas analysis. O2.Volume flow measurement and gas analysis in rotary kiln performance tests. Moreover. O2. O2.3. Measuring site raw gas bypass gas (with cooling air) bypass gas (without cooling air) downstream from the burning area kiln inlet tertiary air cooler intake air cooler vent air burner air (main burner) burner air (secondary burner) conveying air (kiln feed) 1) Volume flow measurement pitot tube pitot tube – – – pitot tube – pitot tube pitot tube + rated values pitot tube + rated values rated values Gas analysis CO2. O2. Table 3 . CO – – – – – – Discontinuous measurement is often sufficient. in the case of double-string cyclone preheaters.2. O2. Table 3 shows an example of a measurement plan. CO CO2. various gas compositions can occur over the cross section of the duct. CO 1) CO2.3. the time intervals at which the probes need to . CO 1) CO2.1 Sampling In the raw gas. there are also differences in the individual strings.

O2 and CO are required. At the very least.2 Analysis The gas analysis should be carried out continuously. For this reason. Since the measuring site is also frequently exposed to falling material.5 m into the rotating part of the kiln in order to avoid falsifications of the measured results due to infiltrated air that gets into the inlet gasket or as a result of falling kiln feed material.2. 3. the pitot tube should be installed in the . that is to say. The probe should be cooled. With volumes flows that fluctuate markedly (for instance. cooler vent air). The probe in the gas downstream from the burning area should be cooled. the sampling probe should be built laterally into the refractory brickwork. both with respect to location and to time. So as to prevent falsifications of the concentration values due to the scrubbing out of individual gas components. it is not possible to specify a representative measuring site. the measuring gas should be sampled dry. In the rotary kiln inlet.May 1992 Specification Vt 10 Page 28 be cleaned can be extended by placing the measuring gas sampling opening as far as possible from the meal inlet pipes. determinations of CO2. without injection water or scrubbing water. The sampling opening should project about 0. Sampling sites in the upper third of the rotary kiln cross section are recommended. the process gas usually displays great differences in concentration.3 Volume flows The volume flows are primarily measured with a pitot tube.3.2. 3.3.

There are three methods for measuring the raw gas volume flow: a) direct measurement with a pitot tube (in the case of unfavorable measuring conditions. . for example. There are three methods for measuring the volume flow of the cooler intake air: a) inlet nozzles (often very imprecise). b) calculation on the basis of a CO2 and an H2O balance of the kiln system (imprecise when secondary fuels are used) [30]. c) conversion of the clean gas volume flow to raw gas conditions using an O2 or CO2 balance or an H2O balance (additional gas analysis and measurement of the volume flow in the clean gas is necessary. c) air balance of the cooler (often the most precise way with continuous volume flow measurement of the cooler vent air after the dust removal). only possible if clean gases of the kiln can be detected in their entirety. expensive but accurate). b) fan characteristic curves (only possible for fans with adjustable rotational speeds). The bypass gas volume flow prior to the admixture is derived from the gas analysis before and after the admixture of the cooling air. deflection of the gas upstream from the measuring site. substantial pressure fluctuations or a high amount of dust [for instance. this is often very imprecise). > 50 g/m³]. The bypass gas is measured with a pitot tube after admixing the cooling air.May 1992 Specification Vt 10 Page 29 gas duct and the differential pressure as well as the appertaining temperature should be recorded continuously.

Heating gas that has been measured volumetrically has to be converted to the standard conditions.3. the result that is read off the meter has to be corrected by means of a calibration curve.1.2.1 Heating oil Heating oil can be sampled either by means of an automatic sampling system or else a sample is taken from the oil tank. of the kiln feed is derived from the nominal data of the fan.3. 3.3 Liquids 3.3. it is necessary to take into account the density.May 1992 Specification Vt 10 Page 30 The volume flow of infiltrated air at the kiln hood is calculated on the basis of the open cross-sectional area and of the differential pressure at the kiln hood (see Section 4. if applicable. The conveying air volume flow of the coal dust and. Moreover.2 Water The water mass flow of a cooling chute (cooling water) or into the clinker cooler (injection water) is measured with water meters that have to be installed in advance. 3. . The cross-sectional surface area is either measured or estimated.3. The amount of oil that passes through the burner nozzle per unit of time is for the most part measured volumetrically by means of an oil meter. In order to determine the actual volume flow that passes through. which changes as a function of the temperature.3).3.

9) partial-radiation pyrometer (ε = 0.May 1992 Specification Vt 10 Page 31 3.9) partial-radiation pyrometer (ε = 0.cooler kiln hood calcinator preheater 1) continuously continuously continuously once per day continuously continuously 1) continuously once per day once per day – twice per day once per day 2) twice per day 3) once per day once per day once per day if available with grate-type coolers 3) with rotary coolers or satellite coolers . kiln feed) Measuring device compensation temperature in adiabatic vessel.rotary kiln surface temperature .9) 2) Frequency every hour continuously twice per day once per day once per day fuels once per day raw gas bypass gas (with cooling air) gas downstream from the burning area tertiary air upstream from the preheater tertiary air downstream from the cooler cooler intake air cooler vent air burner air (main burner) burner air (secondary burner) conveying air (kiln feed) surface temperature .4 Temperatures Table 4 shows the example of a measuring plan.3. Table 4 . Pt 100 quotient pyrometer NiCr Ni Pt 100 or NiCr Ni Pt 100 or surface temperature of the conveying line with partial-radiation pyrometer Pt 100 or surface temperature of the conveying line with partial-radiation pyrometer Pt 100 or NiCr Ni Pt 100 or NiCr Ni NiCr Ni NiCr Ni NiCr Ni meteorological station Pt 100 or NiCr Ni Pt 100 or NiCr Ni Pt 100 or NiCr Ni like kiln feed partial-radiation pyrometer (ε = 0.Temperature measurement in rotary kiln performance tests.g. Measuring site cold clinker hot clinker kiln feed in the preheater (e. hot meal) bypass dust raw meal (for instance.9) partial-radiation pyrometer (ε = 0.9) partial-radiation pyrometer (ε = 0.

• downstream from the waste gas fan.6 Strokes and rotational speeds In order to evaluate the kiln operation. • grate-type preheater. 3. • bag house fan / ESP fan. the following differential pressures should be measured or recorded by the operating measuring pick-ups: • cooler (chambers 1 through N). • kiln outlet. • kiln inlet. • bypass fan. • kiln.3. .3. The above-mentioned differential pressures have to be measured with damped measuring pick-ups.5 Pressures In order to evaluate the kiln operation.May 1992 Specification Vt 10 Page 32 3. • upstream from the waste gas fan. • preheater (stages 1 through N). • cooler vent fan. the strokes and rotational speeds of the following aggregates should be measured or recorded by the operating measuring pick-ups: • cooler. • waste gas fan.

8 hours. • kiln feed feeding system. • rotary kiln drive. . Consequently. • fuel feeding system.3.May 1992 Specification Vt 10 Page 33 3. The following consumers should be taken into consideration: • cooler fans. • cooler vent fan.3. for example.7 Electricity consumption In order to evaluate the kiln operation. • cooler drives. • waste gas fan. when the balancing space is calculated. the energy distribution should be measured with prong-type instruments. If several consumers are connected to one meter. A large proportion of the electricity is converted into heat in the kiln system. the consumption of electricity should be considered as an input item of the energy balance. the meter readings of the main consumers should be recorded at intervals of. 3. pressure and relative humidity of the ambient air are recorded by a meteorological station. • burner air fan. • bypass fan.8 Ambient conditions The temperature.

May 1992 Specification Vt 10 Page 34 3. In addition to regularly checking the status and settings during the performance test. Checks and corrections should be documented and should be indicated on the measuring equipment used. Status checks should be made every hour and setting checks should be carried out at least before and after the performance test. The time schedule for replacing wearing parts and for the function tests with comparative measured values depends on the measuring instruments and should be laid down appropriately.3. . Table 5 provides an overview of possible comparative measuring methods. platinum resistance thermometer) black body radiator tungsten band lamp (only above 500°C [932°F]) liquid pressure gage (for instance. Table 5 . miniscope or U-tube) sealed container with several aqueous saturated salt solutions The solid substance analyses have to be conducted by a laboratory that has sufficient experience with the execution of the analyses listed in Table 2.9 Ensuring the precision of the measurements and analyses The precision of a kiln examination depends on the systematic maintenance and upkeep of the measuring instruments. together with the date. it is also necessary to routinely replace wearing parts as preventive maintenance and to conduct function tests with comparative measured values (calibration). Measuring instrument gas analyzer gas meters thermal elements resistance thermometer pyrometer pressure transducer humidity measuring device Comparative measuring instrument or method gas analyzer with another measuring principle wet-chemical analysis testing by the Board of Weights and Measures test thermometer and normal thermometer (for instance.Comparative measuring instruments or method for rotary kiln performance tests.

With other kiln types. the gas and solid substance mass flows should be balanced together. . as a result of which a separate presentation has not been provided. Figure 6 shows the balancing space of a kiln system with a cyclone preheater (V). the changes are only gradual. tertiary air duct (T).C raw gas dust for the discharged tertiary air dust (only relevant in kiln systems with a tertiary air duct and high levels of dust in the tertiary air) *) Liquid or gaseous fuel can also be fed in. since there are interactions between both of these as a result of chemical reactions. 4. rotary kiln (D) and cooler (K) with the mass and energy flows that exceed the balance limit as an example.1 Evaluation of kiln performance tests Balancing of the entire system When the mass balance is drawn up.May 1992 Specification Vt 10 Page 35 4. The following mass and energy flows have been taken into account: Incoming solid substance mass flows: & mS1 & m B7 & m B3 for the kiln feed for the fuel (main burner) *) for the fuel (secondary burner) *) Outgoing solid substance mass flows: & mS10 & mSt5 & mSt1 & mSt12 for the clinker for the bypass dust & for H Fl. calcinator (C).

May 1992 Specification Vt 10 Page 36 Incoming gas volume flows **) & VL10 & VL7 & VL3 & VL1 for the cooler intake air for the burner air (main burner) for the burner air (secondary burner) for the conveying air (kiln feed) for the infiltrated air (kiln hood) for the infiltrated air (calcinator) for the infiltrated air (preheater) & VFl. D & VFl. while the formula sign V designates the volume flow related to standard conditions after removal tr of the water-vapor fraction. . 1013 & hPA). C & VFl.10 for the cooler injection water Incoming energy flows: & H S1 & H B7 & H B3 for the kiln feed for the fuel (main burner) for the fuel (secondary burner) **) & The formula sign V below designates the volume flow related to standard conditions (0°C [32°F]. V Outgoing gas volume flows: & VL11 & VG1 & VG5 for the cooler vent air for the raw gas for the bypass gas Incoming liquid mass flows: & m H 2 O.

10 Pmech Outgoing energy flows: & H S10 & H St5 & H St1 & H St12 & H L11 & H G1 & H G5 for the clinker for the bypass dust for the raw gas dust for the discharged tertiary air dust for the cooler vent air for the raw gas for the bypass gas for the reaction enthalpy of the kiln feed & ∆H R.May 1992 Specification Vt 10 Page 37 & H L10 & H L7 & H L3 & H L1 for the cooler intake air for the burner air (main burner) for the burner air (secondary burner) for the conveying air (kiln feed) for the infiltrated air (kiln hood) for the infiltrated air (calcinator) for the infiltrated air (preheater) for the reaction enthalpy of the fuels for the cooler injection water for the mechanical performance & H Fl. H 2 O for the evaporation enthalpy of the cooler injection water & Q K. B & H H 2 O.S & ∆H V. D & H Fl. V & ∆H R. K for the uncoupled heat (cooler) .C & H Fl.

T & Q W. K for the incomplete burning for radiation and convection losses (preheater) for radiation and convection losses (calcinator) for radiation and convection losses (rotary kiln) for radiation and convection losses (tertiary air duct) for radiation and convection losses (cooler + kiln hood) .May 1992 Specification Vt 10 Page 38 & ∆H R.C & Q W. D & Q W. V & Q W.CO & Q W.

tertiary air duct. rotary kiln and cooler with incoming and outgoing mass and energy flows.May 1992 Specification Vt 10 Page 39 Figure 6 . calcinator. .Balancing spaces for preheater.

it is only partially used as such with gratetype coolers. discharged tertiary air dust. TiO2. Al2O3. raw gas dust. The following applies: *) The formula sign x below stands for the mass concentration of the solids at the balance limit (= delivery condition in the laboratory).1 Solid substance mass flows Measured quantities: clinker. the waste gas is designated as “raw gas” and the dust as “raw gas dust”. CaO. whereas in contrast. Mn2O3. excess cooling air is released as cooler vent air. Therefore. bypass dust.1. some of the cooler vent air can be returned to the cooler as intake air via a fan once the dust has been removed and cooled (duothermal configuration). With grate-type coolers. K . it still contains relatively large amounts of dust. Fe2O3. a component balance is drawn up of the sum of the non-volatile substances (for example. In the case of the latter. Cooler vent air dust has not been taken into account. Operands: In order to balance the mass flows. This & was taken into consideration in the figure by the uncoupled heat flow Q K. MgO) whose mass concentration in the individual substance flows is designated by xNF *). When the waste gas leaves the preheater. fuel (main burner). the cooling air volume flow is used completely as combustion air in the process.May 1992 Specification Vt 10 Page 40 With rotary and satellite coolers. P2O5. 4. SiO2. fuel (secondary burner). mass flow of the kiln feed. .

By using xG to designate the mass concentration of the substances that are released during calcination at about 1000°C [1832°F] until weight constancy is achieved. the following applies to the kiln feed mass flow that actually becomes clinker (including discharged tertiary air dust): The ratio of kiln feed to clinker necessary for the clinker burning process then results from Equation (4): .May 1992 Specification Vt 10 Page 41 The loss on ignition can also be used for a rough estimate. the following applies analogously: The kiln feed mass flow necessary for the clinker burning process then results from Equation (2): As an approximation.

3. Operands: 4. conveying air (kiln feed).1. burner air (main burner). fuel (secondary burner). in addition to the fuel mass & & flows m B7 and m B3 . cooler intake air (see Section 3. burner air (secondary burner). the combustible components (organically bound carbon.1 Dry gas Minimum air volume flow In order to calculate the dry. .1 4.May 1992 Specification Vt 10 Page 42 Analogously. the burning of all combustible substances has to be taken into consideration. minimum air volume flow. infiltrated air. bypass gas. secondary air. For this reason.1.2. sulfide sulfur) of the kiln feed also have to be taken into account.1. cooler vent air (if present).2 Gas volume flows Measured quantities: fuel (main burner).1. the following applies: 4.3). raw gas.2.2.

This value can be calculated on the basis of elementary analyses of the fuel according to Equation (11): . S effectively fed into the kiln system: & Analogously. eff. the carbon content of the raw gas dust as xC.St5 and x S. min to burn all of the combustible substances then amounts to the following: lmin is the minimum air demand of the fuel in question in its raw state. the following results & for the carbon mass flow mC. St5. The minimum air volume flow & VL.eff.S1.St5 are approximately zero. x C. S : Frequently. the following applies for mS.May 1992 Specification Vt 10 Page 43 By designating the carbon content of the kiln feed as xC. St1 and the carbon content of the bypass dust as xC.

*) The formula sign hu below stands for the lower calorific value of the coal at the balance limit threshold (= delivery condition in the laboratory). The following applies: For lignitic coal and coal: For heating oil: Table 6 shows examples of elementary analyses and calorific value-related combustion gas quantities of lignitic coal and coal. the numerical value equation is the following: For oil and coal. Calorific value-related combustion gas quantities of secondary fuels can differ markedly from the indicated uppermost and lowermost values.May 1992 Specification Vt 10 Page 44 Accordingly. . lmin can be calculated as an approximation using the lower calorific value of the fuel *).

7 0.011 0.1.2 Air proportionality factor The following applies in general: .094 0.096 0.339 0.1 3.332 0.6 0.Elementary analyses of lignitic coal dust and coal dust with the combustion gas quantities calculated therefrom and related to the lower calorific value in the raw state.80 14.3 71.5 59.05 U 2.4 8.0 8.3 2.3 1.375 L = lowermost value.4 4.9 57.101 0.3 61.0 2.099 0.7 2.347 0.382 0.2.1 65.5 23.92 Coal dust U L 0.7 22.9 29.7 4.7 3.6 4. M = mean value.2 19.35 M 1.22 0.374 0.4 0.6 21.1 27.0 25.3 21.392 0.021 0.8 11.096 0.016 0.5 0.4 0.May 1992 Specification Vt 10 Page 45 Table 6 .370 0.1 0.344 0.5 0.9 19.2 4.7 0.098 0.76 calorific value (raw) in MJ/kg: Calorific value-related combustion gas quantity in kg/MJ: minimum air demand carbon dioxide water vapor moist flue gas 20. Analyses (raw) in % by weight: L water ash C H O N S 8.9 16.2 1.022 0.339 0.014 0. U = uppermost value 4.2 Lignitic coal dust M 11.8 3.4 56.341 0.6 7.1.8 4.024 0.373 0.

neither is present.1. The following applies theoretically: Equation (17) presupposes a frictionless flow and an incompressible medium. the gas velocity has to be multiplied by a dimensionless factor which lies between 0.75. the following applies: .May 1992 Specification Vt 10 Page 46 The air proportionality factor in the waste gas results as an approximation from the values of the gas analysis (in the case of Orsat analyses and measuring methods that work with extraction. for actual practice. Here.1. Consequently.2.6 and 0. the equation yields an excessively high gas velocity. Thus. As a consequence.3 Infiltrated air at the kiln hood The volume flow of infiltrated air at the kiln hood can be roughly calculated using the Bernoulli equation.9. as a rule related to dry measuring gas): The expression in the denominator of the lower fraction corresponds to N2. it has been set at 0. In reality. 4.

) in kg/m³ = open cross-section area in m² ρL ρ L.1. the density of the ambient air can be taken as the basis for ρ L.c.4 Secondary air The following applies for the volume flow of the secondary air (also see Figure 12): & Due to non-representative gas analyses in the kiln inlet. VL8.N for dry air (the water present in the air is ignored here). tr = volume flow of infiltrated air in m³ (s.2.May 1992 Specification Vt 10 Page 47 & With v = V/F for the gas velocity and with the density ratio ρ L /ρ L.N F & VFl.)/s As a simplification. tr can only be calculated very imprecisely. . the result is a calculation equation for the volume flow of infiltrated air: wherein ∆p = differential pressure at the kiln hood in Pa = density of the air in the cross section F in kg/m³ = density of the ambient air under standard conditions (s. 4.1. D.c.

The following applies: wherein and & m C. S according to Equation (8).6 Raw gas 1.May 1992 Specification Vt 10 Page 48 4.1. .2.1.1. Calculation on the basis of the CO2 balance The following applies for the CO2 balance: & VCO 2 .5 Cooler intake air The following applies for the volume flow of the cooler intake air (also see Figure 12): 4. eff.2.S stems from the decarbonation and the combustion of organic components of the kiln feed.1.

May 1992 Specification Vt 10 Page 49 & VCO 2 . Equation (26) can be employed: wherein µCO = 5. The following applies: If the elementary analysis is not available. B stems from the combustion of the fuel.87 · 10 – 5 m³ of CO2/kJ for coal. & VCO 2 .01 · 10 – 5 m³ of CO2/kJ for lignitic coal 2 and µCO 2 = 4.G5 results from the gas analysis and from the measurement of the gas volume flow in the bypass gas: With the result is the calculation equation for the raw gas volume flow: .

May 1992 Specification Vt 10 Page 50 2. tr can be calculated according to [30]. CO2 balance: O2 balance: 4.1.2.7 Gas downstream from the burning area & VG2. the calculated values are often very imprecise. 4.8 Gas downstream from the rotary kiln (kiln inlet) & VG6.1.1. tr is calculated according to Equations (30) or (31) on the basis of the raw gas volume flow. A gas analysis downstream from the burning area is needed for this purpose.2. Due to non-representative gas analyses in the kiln inlet. Calculation on the basis of the clean gas volume flow This calculation is only possible if the entire clean gas volume flow of the kiln system can be determined and if no auxiliary burner is operated in the combined drying and grinding mill. .1.

2 Water from the kiln feed .2.2.1.May 1992 Specification Vt 10 Page 51 4. The following applies: wherein xD = water content in kg of H2O/kg of dry air = relative humidity ϕ p and ps (ϑ L.U) = saturation pressure of the water vapor in Pa = ambient pressure in Pa Then.2.2.1.2. the following applies for the moisture volume flow of the air: 4.1.1 Water vapor Humidity in the air The humidity in the air results from the relative humidity and from the saturation pressure of water-vapor at ambient temperature.2 4.

May 1992 Specification Vt 10 Page 52 4.1 Moist gas Air The following applies in general: Altogether. .1.3 Water from the fuel 4.2.4 Injection water 4.2.2. λ G1 should be calculated with the gas concentration values which would result after the mixing of raw gas and bypass gas. is fed into the kiln system.2.2.1.1.1.3 4.3.2.

1. VH 2 O.4.4.1.3 Liquid mass flows Measured quantities: fuel (main burner).1.10 often equals zero.2 Raw gas λ G1 should be calculated with the gas concentration values which would result after the & mixing of raw gas and bypass gas.1.May 1992 Specification Vt 10 Page 53 4. a reference temperature of 25°C [77°F] was likewise selected for the calculation of the individual enthalpy flows. 4. 4.G5 often equals y H 2 O. 4.2.4 Energy flows Since standard reaction enthalpies and calorific values are related to 25°C [77°F]. water.1. With grate-type coolers. y H 2 O.1 Energy input Fuel Combustion: .1.1 4. fuel (secondary burner).G6 .3.

the following applies (also see Figure 7): wherein xF. Equation (43) also applies. The following then applies: wherein c H 2 O ≈ 4. however. ϑ .B = sum of the volatile components in the coal. Here.2 kJ/kg K for 0°C [32°F] < ϑ < 100°C [212°F].May 1992 Specification Vt 10 Page 54 Sensible enthalpy flows: *) For dry coal. as an approximation. *) The formula sign c or cp below stands for the mean specific thermal capacity c p 25°C [77° F] . to dry lignitic coal. the water content of the lignitic coal has to be taken into account. The following applies in the case of oil (also see Figure 8): wherein ρ = density of the oil in kg/m³ at 15°C [59°F].

May 1992 Specification Vt 10 Page 55 Figure 7 .Mean specific thermal capacity of dry coal (reference temperature = 25°C [77°F]). .

Mean specific thermal capacity of oil (reference temperature = 25°C [77°F]).May 1992 Specification Vt 10 Page 56 Figure 8 . .

817 2.1. Fuel gas component Specific thermal capacity cp in kJ/m³ (s.602 methane ethylene acetylene propadiene n-butane propylene 1) CH4 C2H4 C2H2 C3H4 C4H10 C3H6 H 2S 1.156 4.Mean specific thermal capacity cp of the fuel gas components (reference temperature = 25°C [77°F]).270 1.555 1. The following applies here: Table 7 .631 4. = under standard conditions 4.c.717 5.113 1.May 1992 Specification Vt 10 Page 57 The specific thermal capacity of the heating gas is calculated on the basis of the mean specific thermal capacities of the individual gas components according to Table 7.) K 25°C [77°F] 100°C [212°F] 1.2 Kiln feed Sensible enthalpy flows: .700 2.246 3.579 4. s.579 200°C [392°F] 1.402 2.531 hydrogen sulfide 1) Use C3H6 use for CmHn.c.519 2.4.1.137 2.985 2.918 5.101 1.172 5.582 2.

.May 1992 Specification Vt 10 Page 58 The following applies as an approximation for the commonly employed composition of the kiln feed: The specific thermal capacities of individual components of the kiln feed are shown in Figure 9.

Mean specific thermal capacity of kiln feed components (reference temperature = 25°C [77°F]).May 1992 Specification Vt 10 Page 59 Figure 9 . .

May 1992 Specification Vt 10 Page 60 4.4.1. it is also possible to use the specific thermal capacity of dry air for the calculation. As an approximation. The following applies in this case: . also see Figure 10).1.3 Air Sensible enthalpy flows: wherein (For the calculation of cp. j according to Equations (85) through (87).

.May 1992 Specification Vt 10 Page 61 Figure 10 .Mean specific thermal capacity of gas components (reference temperature = 25°C [77°F]).

For this purpose.5 Mechanical performance Within the balancing space.May 1992 Specification Vt 10 Page 62 4.1. Table 8 is a compilation of the main reactions that take place during the clinker burning process. C3A. the contents of CaCO3 and MgCO3 in the kiln feed and in the raw gas dust as well as the contents of CaCO3 and C2S in the bypass dust. the mechanical performance of the electric drives has to be taken into consideration. C2S. with the standard reaction enthalpies needed in each case (for the additional reaction enthalpies.2 4.4.1.1.1 Energy output Reaction enthalpy of the kiln feed For the calculation of the reaction enthalpy of the kiln feed. C4AF in the clinker. the following applies: 4.4. .4.1. 4. the degradation reactions of the starting materials and the reactions for the formation of the clinker phases have to be taken into account. The data shown in the two right-hand columns are each related to the substance in the left-hand column.4.2.4 Injection water As a rule.1. This is particularly true of the intake air fans and of the kiln drive. 23 and 25 through 27]). the sensible enthalpy flow of the injection water can be ignored. see [22. In simplified form.1. it is first necessary to calculate the contents of C3S. The actual reaction enthalpies to be employed result from balance equations.

Formation of C3S 11. 4. Reaction enthalpy 1) at 298 K kJ/kg kJ/mole Reaction Reaction equation I. 9.May 1992 Specification Vt 10 Page 63 Table 8 . 6. 8. Organic clay components (relative to C) MgCO3 dissociation CaCO3 dissociation Pyrite (FeS2) 2 FeS2 + 5½ O2 α-Fe2O3 + 4 SO2 II. 5. . 1. Formation of the clinker phases 7. Formation of K2SO4 1) α-K2SO4 Related to the substance in the left-hand column.Reactions of the kiln feed and reaction enthalpies (298 K) during the production of Portland cement clinker. 2. Formation of oxides and degradation reactions Evaporation of H2O Decomposition of • kaolinite (relative to Al2O3) • montmorillonite (relative to Al2O3) • illite (relative to Al2O3) kaolinite α-Al2O3 + 2 · β-SiO2 + H2O (fl) montmorillonite α-Al2O3 + 4 · β-SiO2 + n · H2O (fl) illite α-Al2O3 + 4 · β-SiO2 + m · H2O (fl) C + O2 MgCO3 CaCO3 CO2 MgO + CO2 CaO + CO2 + 1519 + 744 + 884 – 32786 + 1396 + 1772 – 6902 + 155 + 76 + 90 – 394 +118 + 178 – 828 H2O (fl) H2O (g) + 2446 + 44 3. Formation of C4AF Formation of C3A Formation of β -C2S 4 CaO + α-Al2O3 + α-Fe2O3 3 CaO + α-Al2O3 2 CaO + β -SiO2 3 CaO + β -SiO2 K2O = SO2 + ½ O2 C3A C4AF – 67 + 74 – 700 – 495 – 4452 – 33 + 20 – 121 – 113 – 776 β-C2S C3S 10.

S10 . S10 + 1.1 C3S.292 ⋅ x Na 2 O. the clinker phases can be calculated according to Bogue [45 and 46].64). The following applies: For x SO 3 .4. S10 + 1. C3A and C4AF in the clinker For normal Portland cement clinker or tertiary air dust. the following applies: The following results from this: . C2S.2. the following applies: For x SO 3 .85 ⋅ x K 2 O.1. S10 ≤ 0. S10 .1.292 ⋅ x Na 2 O. In this context. C2S. C3A and C4AF (TM > 0.May 1992 Specification Vt 10 Page 64 4.85 ⋅ x K 2 O. which consists primarily of C3S. S10 > 0. the value employed for the CaO bound in the clinker phases is the one that is obtained after the subtraction of the free CaO and of the CaO bound to SO3.

the following applies in the case of 1.1. Assuming that the CO2 is primarily bound to the CaO.4.May 1992 Specification Vt 10 Page 65 4.2 CaCO3 and MgCO3 in the kiln feed and in the raw gas dust The content of CaCO3 and MgCO3 of the kiln feed results from the content of CO2 and CaO.274 · x CO 2 ≤ x CaO : and in the case of 1.2.274 · x CO 2 > x CaO : and .1.

1. St5 = 0 2) xC.4. it is assumed that Al2O3 and Fe2O3 have completely reacted with CaO to form C4AF and C12A7.3 CaCO3 and C2S in the bypass dust The content of CaCO3 results from the content of CO2 in the bypass dust.1.1.2. 7) The fuel ash is present in the form of oxides.St5 is made according to Equations (55) or (56).4.4 Balance equations The balance equations are based on the following assumptions and simplifications: 1) x H 2 O. 4. St5 = 0 4) xS. St5 = 0 5) The formation enthalpy of C4AF and of C12A7 in the bypass dust is negligibly small. St5 = 0 3) x MgCO3 . For purposes of calculating the C2S content. 6) The starting materials as shown in Table 8 are present.2. . The following then applies: The calculation of x CaOSO3 .1.May 1992 Specification Vt 10 Page 66 4.

May 1992 Specification Vt 10 Page 67 According to Figure 6. the following applies for the balance equations: 1) Evaporation of H2O: 2) Decomposition of clay: 100%-kaolinite: 100%-montmorillonite: 100%-illite: 3) Organic clay components: .

May 1992 Specification Vt 10 Page 68 4) MgCO3 dissociation: 5) CaCO3 dissociation: 6) Pyrite: 7) Formation of C4AF: 8) Formation of C3A: .

or of a clinker from a kiln feed with calcareous fly ash. in the case of fly ash and blast-burner slag. Moreover. assumptions also have to be made pertaining to the devitrification enthalpies.May 1992 Specification Vt 10 Page 69 9) Formation of β-CsS: 10) Formation of C3S: 11) Formation of K2SO4: In Equation (79).64. or of a clinker from a burning process involving other substance flow configurations. In order to calculate the reaction enthalpy of a special clinker. blast-burner slag or gypsum from flue gas desulfurization plants. . for instance. TM < 0. the balance equations need to be changed or supplemented. the actual SO3 contents (without sulfide sulfur) should be used.

May 1992 Specification Vt 10 Page 70 The following applies to the sum of the reaction enthalpies of the kiln feed: 4.2.1.3 Waste gas losses Raw gas: wherein The following approximation equations apply for the essential components of the waste gas (also see Figure 10): .2.2 Water evaporation Evaporation enthalpy for cooler injection water: 4.4.4.1.

4.4.1. . ϑ St1 = ϑ G1).1.4 Dust losses Raw gas dust: (for cSt1. see Section 4.May 1992 Specification Vt 10 Page 71 Bypass gas: Cooler vent air: 4.1.2.2.

5 Incomplete combustion In cases of high energy losses due to incomplete combustion (for example.4. yCO. ϑ St5 = ϑ G5).4.May 1992 Specification Vt 10 Page 72 Bypass gas dust: (for cSt5. see Equation (95). see Section 4.1.1.1. 4.4. an analyzer that operates continuously should be used for the calorific value of the gas for the balancing. Losses due to cooler vent air dust are usually negligibly small. Discharged tertiary air dust: (for cSt12. 4. ϑ St12 = ϑ L9).2.01).6 Clinker .2.G1 > 0.1.2.

Mean specific thermal capacity of Portland cement clinker (reference temperature = 25°C [77°F]). .May 1992 Specification Vt 10 Page 73 The following applies for the specific thermal capacity of the clinker (also see Figure 11): Figure 11 .

3 a0 = 4. the heat flow of individual tube elements is calculated on the basis of the mean circumferential temperature ϑ W.0 .May 1992 Specification Vt 10 Page 74 4.2.4.U: wherein and αconv results from approximation equations.7 Radiation and convection Rotary kiln: First of all.m of the tube element and of the ambient temperature ϑ L.1. The following applies for wind velocities w ≤ 2 m/s: wherein a = 0.

25 4.75 3.66 5.233 .0.75 4.98 1.244 .83 b0 4.98 5.25 4.27 5.70 b1 0.05 1.75 6.0.236 .73 0.75 5.19 5.25 3.238 .May 1992 Specification Vt 10 Page 75 a1 = 3.40 5.83 0.0.243 .25 b 2.93 0.18 2.227 .75 6.25 6.0.00 b1* .25 3.79 0.93 1.219 .85 a3 = 0.48 5.25 5.75 ≤ Da < 3.11 2.05 5.5 a2 = -0.076 Scope of validity: w ≤ 2 m/s 100°C [212°F] ≤ ϑ W.75 4.0.97 1.0.25 5.88 0.U ≤ 30°C [86°F] The following applies for wind velocities w > 2 m/s: wherein Diameter range in m 2.37 2.227 .87 1.m ≤ 500°C [932°F] 2 m ≤ Da ≤ 8 m 10°C [50°F] ≤ ϑ L.92 0.75 5.75 7.0.220 .0.25 6.27 2.11 5.0.97 0.

.U = ambient air temperature in K & The radiation and convection loss flow Q W.m ≤ 500°C [932°F] 2.75 m ≤ Da ≤ 7. D for the entire rotary kiln results from the addition of the radiation and convection loss flows of the individual tube elements: More details on the calculation of the radiation and convection loss flow can be found in literature references [28 and 31].m = mean surface temperature in K TL.May 1992 Specification Vt 10 Page 76 Scope of validity: 2 m/s < w ≤ 10 m/s 100°C [212°F] ≤ ϑ W.U ≤ 30°C [86°F] The following applies for αStr: wherein ε W = 0.67 · 10 – 8 W/(m² · K4) TW.25 m 10°C [50°F] ≤ ϑ L.9 σ = 5.

the satellite temperatures as well as the temperatures in the interstitial spaces. Equation (104) yields a heat loss flow that is too low. The following applies: The following applies as a good approximation for the grate-type cooler and the kiln hood: wherein αconv = 7 W/(m²·K) ε W = 0.m is calculated as an arithmetic mean value of all of the individual temperature meas- ured values calculated over the circumference. The diameter of this surrounding cylinder can then be used to calculate the heat-transfer coefficient αtotal as an approximation according to Equations (98) through (101). that is to say. The mean circumferential temperature ϑ W. Moreover. In such cases.6 should be used for the calculation of the heat flow.May 1992 Specification Vt 10 Page 77 Cooler: Equations (96) through (101) can be employed directly for the rotary cooler.9 At higher wind velocities. For satellite coolers. the surface temperature should be measured only on the side facing away the wind. . it is recommended to employ the imaginary surface area of a cylinder surrounding the satellite cooler as the heat-transfer surface area. an empirical factor of 1.

May 1992 Specification Vt 10 Page 78 Preheater and calcinator: Equations (104) should be employed accordingly. The following applies for the heat uncoupling through the cooling of the cooler circulation air: .4.2 kJ/kg K for 0°C [32°F] < ϑ < 100°C [212°F].1.8 Uncoupled heat The following applies as an approximation for the heat uncoupling via a cooling chute: wherein c H 2O ≈ 4. 4. Tertiary air duct: Equations (96) through (102) should be employed accordingly.2.

.May 1992 Specification Vt 10 Page 79 4. so that a balance deficit remains which. Since the reaction enthalpy flow of the fuel as energy input can often only be determined very imprecisely. however.1. should not make up more than ± 3% of the total energy output. it should be calculated on the basis of the difference between the energy output and the other energy input values according to Equation (109). Usually the input and the output do not offset each other completely. it is also designated as fuel energy consumption.3 Energy balance The following applies for the sum of the energy input and energy output: and With kiln performance tests. the energy input and the energy output are compared to each other.4.

Moreover. For this reason. Figure 12 .2 Balancing of the partial systems 4. the hot clinker temperature can only be measured in a very imprecise manner. the fact that considerable dust circulation can occur between the rotary kiln and the clinker cooler has to be taken into account. .2.Balancing space of the cooler with the incoming and outgoing mass and energy flows.1 Clinker cooler A complete mass and energy balance can only be drawn up for the clinker cooler within the limits set by its design.May 1992 Specification Vt 10 Page 80 4.

in contrast. Thus. 10 for the cooler injection water . has to be set as zero. for example. The following mass and energy flows have been taken into consideration: Incoming solid substance mass flows: & mS8 for the hot clinker Outgoing solid substance mass flows: & mS10 & mSt8 & mSt9 for the clinker for the secondary air dust for the tertiary air dust Incoming gas volume flows: & VL10 for the cooler intake air Outgoing gas volume flows & VL8 & VL9 & VL11 for the secondary air for the tertiary air (cooler) for the cooler vent air Incoming liquid mass flows: & m H 2 O. In the case of rotary and satellite coolers. the exhaust air volume flow.May 1992 Specification Vt 10 Page 81 Figure 12 shows the balancing space of a clinker cooler with the mass and energy flows that exceed the balance limit. several exhaust air flows can be discharged from the cooler.

K & ∆H V. 10 Pmech. H 2 O for the evaporation enthalpy of the cooler injection water .May 1992 Specification Vt 10 Page 82 Incoming energy flows: & H S8 & H L10 & H H 2 O. K for the hot clinker for the cooler intake air for the cooler injection water for the mechanical performance (cooler) Outgoing energy flows: & H S10 & H St8 & H St9 & H L8 & H L9 & H L11 for the clinker for the secondary air dust for the tertiary air dust for the secondary air for the tertiary air for the cooler vent air for radiation and convection losses (cooler + kiln hood) for the uncoupled heat (cooler) & Q W. K & Q K.

The secondary air dust mass flow then results from the dust mass flow measured in the tertiary air and from the fraction calculated on this basis for the secondary air volume flow: In other cases.May 1992 Specification Vt 10 Page 83 4.1 Solid substance mass flows clinker. Measured quantities: Operands: Only in the case of kiln systems with a tertiary air duct can the secondary air dust mass flow be calculated on the basis of the discharged and returned tertiary air dust assuming equal dust contents in the secondary air and in the tertiary air. With a “clear” kiln discharge. In the case of a pronounced dust circulation. hot clinker.2. the dust concentration is about 30 to 50 g/m³. this value can rise to more than 200 g/m³.1. The following applies for the hot clinker mass flow: . secondary air dust. discharged and returned tertiary air dust. the dust concentration in the secondary air should be estimated.

2.1.2.3.1.1. secondary air. and the cooler intake air volume flow results from Equations (21) and (38).1 Energy input 4.3 Energy flows A reference temperature of 25°C [77°F] is selected for the calculation of the individual energy flows. 4.May 1992 Specification Vt 10 Page 84 4.1. The water vapor from the water injection should also be taken into account. .1 Hot clinker (cS8 according to Equation (95) or Figure 11). Measured quantities: Operands: The secondary air volume flow results from Equations (20) and (38).1.2. cooler intake air. 4. tertiary air.3.2 Gas volume flows cooler vent air (if present).2.

4. the calculated hot clinker energy flow is fundamentally too low.2.2 Energy output 4.1.1.3 Injection water See Section 4.4.1.2.4. Therefore.1.2.3.1.1 Clinker.1.3.2.2 Cooler intake air 4. 4.2. This error increases as the temperature drops and the particle size increases. clinker dust See Section 4.2.1. Therefore.3. 4.6.1.3.1.3.1. .1.4 Mechanical performance 4. the hot clinker energy flow is associated with a high level of uncertainty.2.May 1992 Specification Vt 10 Page 85 Only the surface temperature of the hot clinker can be measured by means of instruments.

2. the hot clinker & enthalpy flow H S8 can be calculated on the basis of the energy balance.1.5 Water evaporation See Section 4.3 Energy balance If a reliable measured value for the secondary air temperature is available.3.1.2.2. 4.2.4.3.2. As a rule. The following then applies: .4.2.May 1992 Specification Vt 10 Page 86 4.1.7.1.2. this is the case whenever tertiary air is removed from the kiln hood (ϑ L9 = ϑ L8) or when the secondary air can be measured error-free (for example. tertiary air See Section 4. 4.3 Uncoupled heat See Section 4.1.3.2 Radiation and convection See Section 4.3.3.4.2.1.2.4.3.2. secondary air.2.1.2.4 Cooler vent air.2.8.2. 4. 4.1.1. with sound-over-time measurement or a suction-type thermometer).

2.2. 4. Figure 13 .4.4). Figure 13 shows the principle of the balance limits of the burning area and of the cooling area and its subdivision into the pre-cooling zone and the cooler.1.1.2.May 1992 Specification Vt 10 Page 87 The hot clinker enthalpy flow calculated according to this equation serves as the basis for the calculation of the cooler efficiency (see Section 4.Balance limits of the burning area and cooling area. it is necessary to take into account the fact that the first cooling of the clinker already takes place inside the rotary kiln.1.1 Pre-cooling zone For the evaluation of the clinker cooler. . of the pre-cooling zone as well as of the cooler with the example of a kiln system with a rotary cooler.4.4 Evaluation quantities 4. which is where radiation and convection losses occur. in the so-called pre-cooling zone.

: wherein Lpre-cool = length of the pre-cooling zone. αtotal stands for the mean heat-transfer coefficient.May 1992 Specification Vt 10 Page 88 In order to calculate the radiation and convection losses in the pre-cooling zone. . it is necessary to know their length Lpre-cool. satellite and rotary coolers in the cement industry” [33]. in m Da = outer diameter of the rotary kiln. the position of the burner lance serves as the reference point for estimating this length (also see Figure 13). in m The estimation according to Equation (116) diverges from that described in the VDZ Specification titled “Grate-type. which can be calculated according to Equations (98) through (101) with a superimposition of the radiation (rad) as well as free and forced convection (conv). It was selected because of the high degree of measuring uncertainty associated with the determination of the hot clinker temperature. & The radiation and convection loss Q W. Since this length cannot be measured and no calculation method is known for this at the present time. in m Lburner = length of the burner in the rotating part of the kiln. pre − cool in the pre-cooling zone of the rotary kiln amounts to the following: Here.

h(ϑ L.1.4.2. cooling area is the sum of the heat and enthalpy flows that are released by the cooler into the atmosphere. which has to be replaced by fuel energy.2 Energy loss flow of the cooling area The energy consumption of a rotary kiln system depends to a decisive degree on the extent to which the enthalpy of the clinker in the cooling area can be recovered for the process. those enthalpy flows that would be released during the cooling procedure from the appertaining outlet temperature to the ambient air temperature should be seen as energy flows. 4.4.May 1992 Specification Vt 10 Page 89 4. & The energy loss flow Eloss. In this context.3 Cooling area efficiency For comparisons.1. it is advantageous to relate the energy loss flow of the cooling area to a theoretical enthalpy flow change on the part of the clinker and thus to define a cooling area efficiency: . for the clinker and cooler vent air. The fraction that is not recovered constitutes the energy loss of the cooling area.2. In this equation.U) stands for the specific enthalpy at the ambient air temperature.

the calcinator is often balanced together with the rotary kiln.4.2. a sintering temperature of 1450°C [2642°F] was presupposed. The cooling area efficiency makes it possible to thermally evaluate the cooling in the entire process. satellite and rotary coolers in the cement industry” [33].2. irrespective of the burning or pre-heating conditions. Future improvements of the burning process or special compositions of the kiln feed could make it necessary to stipulate a sintering temperature that differs from this. 4. In contrast. 4.4 Cooler efficiency The efficiency values of the cooler are described in the VDZ Specification titled “Gratetype.3. With degrees of precalcining below approximately 90%. .2 Calcinator (only for kiln system with cyclone preheater) The balancing space of the calcinator starts at the rotary kiln inlet and ends downstream from the lowermost cyclone (Figure 14). For this reason. this does not apply for the “rotary kiln inlet” balance limit where the energy and mass flows can only be determined very imprecisely.1. The limitations outlined in Section 4.1 apply when using the formulas. The lowermost stage of the cyclone preheater counts as part of the calcinator.May 1992 Specification Vt 10 Page 90 For the sake of harmonization. the equilibrium temperature of the calcium carbonate dissociation sets in at the lowermost stage. at this site. Thus. which should prevail at the site of transition from the burning area to the cooling area.2.1.1. since it is in these aggregates that the essential reactions of the kiln feed and of the fuel take place. the waste gas acquires a chemically determined temperature that is very well-suited for determining this balance limit.

May 1992 Specification Vt 10 Page 91 Figure 14 .Balancing space of the calcinator with incoming and outgoing mass and energy flows. .

0 that was originally bound in the kiln feed as carbonate: The degree of precalcining calculated according to Equation (120) can only be determined by using complete gas or solid substance balances. In this context.May 1992 Specification Vt 10 Page 92 4.1 Determination of the degree of precalcining The degree of precalcining can be used to evaluate the progress of the decarbonation of the kiln feed in the preheater and in the calcinator. the degree of precalcining can also be determined on the basis of the solid substance analyses.2. VC that has escaped from the kiln feed in the preheater and in the calcinator to the & carbon dioxide mass flow mCO 2 . the degree of precalcining refers to the degree of dissociation of the calcium carbonate contained in the kiln feed prior to its entry into the rotary kiln. The actual degree of precalcining ϕ actual is defined according to Equation (120) as the ratio of the carbon dioxide mass flow & mCO 2 . More details on this can be found in literature reference [30]. It is designated as the apparent degree of precalcining ϕ apparent. As a simplification. & Provided that the raw gas dust mSt1 has the same chemical composition as the kiln feed & mS1 . the apparent degree of precalcining ϕ apparent results from the CO2 concentrations x CO 2 and the concentrations of nonvolatile components xNF of the kiln feed (index S1) and of the kiln feed at the kiln inlet (index S6): .2. and by ignoring the dust in the rotary kiln inlet gas.

May 1992 Specification Vt 10 Page 93 & & In reality. it consists of 3 to 5 preheating stages in which gas and the kiln feed are fed in a countercurrent with respect to each other. the following relationship exists between the apparent and the actual degree of precalcining: 4. If the dust mass flows mSt4 and mSt6 have been completely decarbonated. however. the more highly decarbonated dust mSt4 and mSt6 influences the & composition of the kiln feed mass flow mS6 . The degrees of separation of the individual cyclone stages are relevant for an evaluation of the preheater. .2.3 Preheater (only for kiln system with cyclone preheater) Figure 15 shows the balancing space of the preheater. the apparent degree of precalcining ϕ apparent calculated according to Equation (121) generally simulates a higher & & decarbonation of the kiln feed. For this reason. As a rule.

According to it.2.Balancing space of the preheater with incoming and outgoing mass and energy flows.1 Degree of separation of individual cyclone stages Figure 16 shows the incoming and outgoing solid substance mass flows of a preheating stage. 4. the following applies for the degree of separation: .3.May 1992 Specification Vt 10 Page 94 Figure 15 .

i stands for the reaction enthalpy flow of the raw material in stage i. & & Equations (124) and (125) yield the mass flows mS. In this context. i stands for the radiation and convection loss flow of the ith cyclone & stage and ∆H R. i and mSt. . i +1 result from the mass and energy balance of the ith stage. Q W. this is the case with the uppermost cyclone stages (ϑ < 600°C [1112°F]). it is assumed that there is temperature equilibrium between the gas and the kiln feed in the cyclone stage. i +1 : Equations (126) and (127) can be employed in the area of the preheater where hardly any solid/gas reactions (decarbonation) occur. The following applies as an approximation for the solid substance balance: The following applies for the energy balance: & In this context.May 1992 Specification Vt 10 Page 95 & & The mass flows mS. i and mSt. As a rule.

& and if malk. eff stands for the mass flow of alkali compounds that are effectively fed into the system by means of the kiln feed. If the alkali compounds in the kiln feed differ sufficiently. the mass flows can also be ascertained on the basis of component balances.Incoming and outgoing solid substance mass flows of a preheating stage with a cyclone separator. but also to the cyclone separator of the calcinator.May 1992 Specification Vt 10 Page 96 Figure 16 . This generally applies to the lower stages & of the preheater. If m NF. then. eff stands for the mass flow of non-volatile substances effectively fed into the kiln system. it is possible to determine the mass flows of the kiln feed and the dust between the individual cyclone stages: . provided that the dust and solid substance mass flows exiting from each individual stage have the same chemical composition.

N+1 (N= cyclone separator of the calcinator) are very difficult to measure. both concentration values should be pre-defined. but not the absolute value. N+1 and xalk. should be interpreted. for purposes of simplification. as a result of which. as a consequence of which only changes in these operands. Equations (126) and (127) as well as (130) and (131) constitute very rough approximations. between two performance tests. .May 1992 Specification Vt 10 Page 97 From a technical standpoint. for example. xNF.

Evaluation of the substance circulation systems Relevant substance circulation systems should be measured during a kiln performance test or else calculated on the basis of measured and analytical data.May 1992 Specification Vt 10 Page 98 5. .

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6.

Evaluation of the cement clinker

As a rule, new systems are only examined once the clinker properties and thus also the cement properties have been achieving the desired quality requirements for quite some time. In contrast, kiln performance tests with old systems can also serve to optimize the quality of the cement and clinker.

6.1

Degree of burning

The degree of burning of the cement clinker is usually monitored on the basis of the bulk density (weight per unit volume) of a narrow particle range, for instance, 5 to 7 mm, whose values lie between 1.2 and 1.6 kg/dm³. The bulk density, however, is not only dependent on the degree of burning, but also on the chemical composition and on the porosity of the clinker. Moreover, the content of free CaO also provides information about the degree of burning.

6.2

Particle-size distribution

The coarse and fines fractions of the clinker (for example, < 2 mm and > 25 mm) provide information about the kiln operation and the clinker quality. They are ascertained by means of sieve analysis.

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6.3

Grindability

The grindability of the clinker provides information about the necessary work in the cement mill. It is primarily tested with the device according to Zeisel.

6.4

Chemical composition

The chemical composition yields the lime standard (KSt), the silica ratio (SM), the alumina/iron ratio (TM), the sulfatization degree (SG), the total alkali fraction (A) and the melt phase fraction (S). The lime standard indicates the content of CaO actually present in the raw material mixture or clinker as a percentage of the maximum CaO content that can be bound to SiO2, Al2O3 and Fe2O3 under industrial burning and cooling conditions. Several formulas, which do not differ markedly from each other, are commonly employed to calculate the lime standard. According to F.M. Lea and T.W. Parker, for example, the following applies [7]:

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The silica modulus is the ratio of silicon dioxide to the sum of aluminum oxide and iron oxide. The following applies:

Since the silicon dioxide is primarily bound in the solid phases tricalcium silicate and dicalcium silicate at the sintering temperature, but since aluminum oxide and iron oxide are present in the melt, the silica modulus refers to the solid-to-liquid ratio in the sintering zone of the cement kiln. Generally speaking, the silica modulus lies between SM = 1.8 and SM = 3.0, most frequently and most advantageously between SM = 2.3 and SM = 2.8. The alumina/iron ratio (TM) is the ratio of the aluminum oxide content to the iron oxide content. The following applies:

It provides information about the quantity ratio of calcium aluminate to calcium aluminate ferrite and consequently about the clinker melt. With clinker having a commonly employed composition, this value lies between 1.5 and 4.0. With an alumina/iron ratio of 0.638, the calculation indicates that all of the aluminum oxide contained in the clinker is bound as calcium aluminate ferrite having the assumed composition 4 CaO · Al2O3 · Fe2O3.

38). which are present as alkali sulfate: The total alkali fraction (A) results from the conversion of the fraction of potassium oxide into the equivalent sodium fraction according to the following equation: The following applies as an approximation for the melt phase (S): (for ϑ S = 1338°C [2440.May 1992 Specification Vt 10 Page 102 The sulfatization degree (SG) indicates the percentage of alkalis in the clinker. (for ϑ S = 1338°C [2440. (for ϑ S = 1400°C [2552°F]).4°F] and TM > 1. . (for ϑ S = 1450°C [2642°F]).38).4°F] and TM < 1.

May 1992 Specification Vt 10 Page 103 xMgO enters into the formulas with xMgO = 0. that is to say. . according to equations (54) through (60). 6.02 at the maximum. xMgO = 0. for instance. Whereas the type of the compounds depends primarily on the chemical composition of the kiln feed. constitution and distribution of the clinker compounds. provide information about the preparation of the raw material mixture and about the conditions during the burning and cooling of the clinker.02. not only at the sintering temperature but also and especially when they crystallize during the cooling procedure.5 Phase composition The phase composition of the clinker can be calculated on the basis of the values of the chemical analysis. at higher contents.6 Microscopic examination The microscopic examination of the clinker provides information about the type. the constitution and distribution of the clinker compounds and their coalescence. However. the calculation only provides an approximation of the actual clinker composition [7]. it is necessary to assume that the clinker phases have the composition indicated by their formulas and that the clinker melt is in a continuous state of thermodynamic equilibrium with the solid phases of the clinker. 6. the structure. For these reasons.

. They are of decisive significance for the optimization of operations.7 Cement testing The results of the quality tests with the ground-up cement types within the scope of our own as well as outside monitoring also provide essential information about the properties of the cement clinker.May 1992 Specification Vt 10 Page 104 6.

May 1992 Specification Vt 10 Page 105 7. . Evaluation of the emissions Relevant emissions have to be measured and/or recorded during a kiln performance test.

7) mean specific thermal capacity of solids and liquids in kJ/kg K mean specific thermal capacity of gases in kJ/m³ under standard conditions (s.2.) K diameter in m energy flow in kJ/s ratio of kiln feed to clinker in kg/kg of clinker surface area in m² lower calorific value in kJ/kg specific enthalpy in kJ/s sensible enthalpy flow in kJ/s reaction enthalpy flow in kJ/s evaporation enthalpy flow in kJ/s lime standard in % length in m minimum air demand in m³ of air (s.1.May 1992 Specification Vt 10 Page 106 8.2.) / kg of fuel mass flow in kg/s molecular weight in kg/mole stage number in the cyclone preheater.c. Formula signs and indices Roman letters a A b c cp D & E f F hu h & H & ∆H R & ∆H V KSt L lmin & m M N p factor (Section 4.7) total alkali fraction in kg/kg factor (Section 4. chamber number in the grate-type cooler pressure in Pa .c.1.4.4.

) / kJ degree of separation of a cyclone density in kg/m³ Stefan-Boltzmann constant ∆ εW η cooling area ϑ λ µ ξ ρ σ σ = 5. relative humidity .May 1992 Specification Vt 10 Page 107 P & Q S SG SM T TM v & V w x y performance in kJ/s heat flow in kJ/s melt phase content sulfatization degree in % silica modulus absolute temperature in K alumina/iron ratio gas velocity in m/s volume flow under standard conditions (0°C [32°F] and 1013 hPa) in m³/s wind velocity in m/s mass concentration in kg/kg volume concentration in m³/m³ Greek letters α heat transition coefficient in W/m² · K difference emission ratio of the wall surface cooling area efficiency temperature in °C excess air coefficient combustion product per energy unit in m³ (s.c.67 · 10 – 8 ϕ W m2 K 4 degree of precalcining.

4) 0 through 12 balance limits 1 preheater (kiln feed. raw gas) 2 preheater / calcinator 3 calcinator (secondary burner) 4 calcinator (tertiary air duct) 5 calcinator (bypass) 6 calcinator / rotary kiln 7 rotary kiln (main burner) 8 rotary kiln / cooler 9 tertiary air duct / cooler 10 cooler (clinker.1.1.4. carbon rotary kiln.2. vapor under standard conditions (0°C [32°F] and 1013 hPA) effective balance input inlet .May 1992 Specification Vt 10 Page 108 Indices 0 initial state 0 through 11 reactions of the kiln feed (Section 4. cooler intake air) 11 cooler (cooler vent air) 12 tertiary air duct (discharged tertiary air dust) a Alk out Out B burner C D eff in In outside alkali compounds balance output outlet fuel burner calcinator.

c.May 1992 Specification Vt 10 Page 109 F Fl total G surr i K Kl con L m max mech min N NV p R clean gas grate s app S Sat St Str actual theor sum of the volatile substances infiltrated air total gas.) (0°C [32°F] and 1013 hPA) sum of non-volatile substances at constant pressure reaction clean gas grate-type cooler saturation apparent solid. sulfide sulfur satellite cooler dust radiation (rad) actual theoretical . uncoupled clinker convection air mean value maximum mechanical minimum standard conditions (s. loss on ignition surrounding cylinder variable cooler.

May 1992 Specification Vt 10 Page 110 tr T U Um V loss pre-cool W dry tertiary air duct ambient circulation air preheater. evaporation enthalpy loss pre-cooling zone radiation and convection losses Chemical formula signs C3 A C12A7 C4AF C2 S C3 S Al2O3 C CaCO3 CaO Cl – CO CO2 Fe2O3 H H2 O K2 O K2SO4 MgCO3 tricalcium aluminate (3 CaCO · Al2O3) (12 CaO · 7Al2O3) aluminate ferrite (4 CaO · Al2O3 · Fe2O3) dicalcium silicate (2 CaO · SiO2) tricalcium silicate (3 CaO · SiO2) aluminum oxide carbon calcium carbonate calcium oxide chloride carbon monoxide carbon dioxide iron(III)-oxide hydrogen. atomic water potassium oxide potassium sulfate magnesium carbonate .

May 1992 Specification Vt 10 Page 111 MgO Mn2O3 N2 Na2O O O2 P 2 O5 S2– SiO2 SO3 TiO2 magnesium oxide manganese(III)-oxide nitrogen sodium oxide oxygen. atomic oxygen phosphorus pentoxide sulfide silicon dioxide sulfur(VI)-oxide (sulfate) titanium dioxide .

Vulkan-Verlag. VEB Verlag Technik. J. Brennprozeß und Brennanlagen. Essen 1991. Keil.: Zement-Chemie..D. und Stark. Das Wesen und die Herstellung der hydraulischen Bindemittel. pp. Berlin 1958. Kühl. Band 1. Band 1. Duda. Berlin 1981. Band 1. FDBR-Fachbuchreihe. Brennprozeß und Brennanlagen.May 1992 Specification Vt 10 Page 112 9. Band 3. Baehr. Huckauf.: Technologie der Bindebaustoffe. Internationale Verfahrenstechniken der Zementindustrie. H. 545-574.: Ratgeber für Zementingenieure. .: Bindebaustoff-Taschenbuch. VEB Verlag Für Bauwesen. F: Zement-Herstellung und Eigenschaften. F: Brennstoffe und Verbrennungsrechnung. 9. Band 11. Springer-Verlag. H. Ullmanns Enzyklopädie der technischen Chemie. G. H.. Berlin 1956. H. Seidel. Springer-Verlag. Band 3.: Thermodynamik. Berlin 1978. Verlag Chemie GmbH.: Cement-Data-Book. Labahn.: Zement-Chemie. Berlin 1985. W: Zement. Wiesbaden 1985. und Seidel. Huckauf. H.. VEB Verlag für Bauwesen. G. J. Wiesbaden 1982. W.. VEB Verlag Technik. F.1 Literature references General literature references [1] [2] [3] [4] [5) [6] [7] [8] [9] Kühl. Bauverlag GmbH.H. Berlin 1971. Bauverlag GmbH. Die physikalisch-chemischen Grundlagen der Zement-Chemie. Stark. Locher. O. Weinheim 1983. Band 24. [10] Brandt.

pp. Springer-Verlag. O. 105-114. [19] Hengstenberg. [17] VDZ-Merkblatt “Staubmengenmessungen auf Zementwerken”. 3. Steuern und Regeln in der Chemischen Technik.: Messen.. Schriftenreihe der Zementindustrie. Düsseldorf 1990. pp.. B. [13] Wolter. J. [18] Hengstenberg. Sturm. W. Steuern und Regeln in der Chemischen Technik. Vol.V. Zement-KalkGips 38 (1985) Vol.May 1992 Specification Vt 10 Page 113 9.1987. J. Th. A. Sturm. Verein Deutscher Zementwerke e. Verein Deutscher Zementwerke e.M. Verein Deutscher Zementwerke e. Stoffmengen und Hilfsgrößen. . Messung von Zustandsgrößen. 39-61.. H.V. 43. Düsseldorf 1961. Berlin 1980.. [20] VDZ-Merkblatt “Kontinuierliche Gasanalyse in Zementwerken”.: Precalciners today .: Brennverfahren. und Winkler.. Rock Products.: Theoretische und betriebliche Untersuchungen zum Brennstoffenergieverbrauch von Zementofenanlagen mit Vorcalcinierung. Ursache und Lösung. Vol. Band 1.: Messen. July (1985) pp. Band 11.1982.. Berlin 1980. Schriftenreihe der Zementindustrie. Execution of kiln performance tests [16] VDZ-Merkblatt “Mengenmessung von Gasen durch Geschwindigkeitsmessung”. [14] Bonn. und Lang.V. Zement-Kalk-Gips 39 (1986) Vol. Düsseldorf 1962. Springer-Verlag. [12] Garrett.: Einfluß des Ofensystems auf die Klinkereigenschaften. Messung von Stoffeigenschaften und Konzentrationen. B. 612-614.: Technologische Probleme beim Brennen des Zementklinkers.. [15] Rosemann..2 Technical literature references Description of the clinker burning process [11] Sprung. S. O. H.a review. 10. und Winkler. 48.

O. Teil 1: Grundlagen. . Zement-Kalk-Gips 9 (1956) Vol.E.: Berechnung des Wandwärmeverlustes von Drehöfen und Mühlen.: Beitrag zur Thermochemie von Zementrohstoffen. G. I.: Berechnung des Wandwärmeverlustes von Drehöfen und Mühlen. Berechnungsblätter für den Wärmeübergang. Düsseldorf 1959. [30] Rosemann. O. Springer-Verlag. Supplement. 9. Teil 2: Näherungsgleichungen und Anwendungen. 1. M.. H. Düsseldorf 1983. 465-473. Zement-KalkGips 38 (1985) Vol. 257-262. H.: Thermochemical properties of inorganic substances. Proc. H.O. und Ziegler. pp. A. TonindustrieZeitung 56 (1932) Nr. [26] Barin. H. 8th International Congress on the Chemistry of Cement. und Knacke. E. Knacke.. I. Springer-Verlag. 3.. und Steinbiß. Zement-KalkGips 10 (1957) Vol. 2. [25] Petrosjan. und Gardeik. [22] Schwiete. O.: Rechnergesteuerte Meßdatenerfassung und verarbeitung bei der Durchführung von Ofenversuchen. pp. pp.: Thermochemical properties of inorganic substances. Rio de Janeiro. und Kubaschewski. H. 1986.. Berlin 1977. H. [29] VDI-Wärmeatlas. 22.May 1992 Specification Vt 10 Page 114 Evaluation of kiln performance tests [21] Schwiete.E. [28] Gardeik. Berlin 1966. pp. Zement-Kalk-Gips 37 (1984) Vol.. Berlin 1973. 53-62. Verein Deutscher Zementwerke e. [24] VDZ-Merkblatt “Berechnungsunterlagen für Ofenversuche”. 1-12.V. VEB Verlag für Bauwesen. [27] Barin. [31] Gardeik. und Ludwig.O. 144-149. 89-94. 304-306. pp.: Phase composition of calcined raw meal.: Die spezifische Wärme des Portlandzementklinkers. O. VDI-Verlag GmbH. [23] zur Strassen.: Der theoretische Wärmebedarf des Zementbrandes. H.. H. [32] Wolter. H. Ludwig. 6.. Zement-Kalk-Gips 33 (1980) Vol. pp..: Thermodynamik der Silikate.. pp.

F W.May 1992 Specification Vt 10 Page 115 [33] VDZ-Merkblatt “Rost-.. pp. [37] Sprung. S. Zement-Kalk-Gips 17 (1964) Vol. D. 1-12. Dissertation. [41] Kreft. und Kupper. W: Stoffkreisläufe und Emissionen beim Brennen von Zementklinker. 509-511. [381 Ritzmann. Schriftenreihe der Zementindustrie.und Rohrkühler in der Zementindustrie”. Satelliten. 8. 12. Düsseldorf. S. W: Alkali. 9. 8. Bergakademie ClausthalZellerfeld 1959. [43] Kreft..O. [40] Locher. [36] Weber. [42] Rosemann. pp. 31. pp. Zement-Kalk-Gips 38 (1985) Vol. Sprung. 1960. 215-234. pp. Verein Deutscher Zementwerke e. 9 (1960). Zement-Kalk-Gips 24 (1971) Vol.: Warmeübergang im Drehofen unter Berücksichtigung der Kreislaufvorgänge und der Phasenneubildung. Zement-Kalk-Gips 25 (1972) Vol.: Kreislaufe in Drehofensystemen. 338-343. [35] Goes. F. H. Vol. 565-570. H. pp. D. 1. und Opitz. R.V.: Einflüsse auf die Energieumsetzung in Calcinatoren bei der Vorcalcination von Zementrohmehl. 335-344. 1964.: Ober des Verhalten der Alkalien beim Zementbrennen. 1989. Zement-Kalk-Gips 43 (1990) Vol. 2. pp. . 418-422. Vol. Zement-Kalk-Gips 35 (1982) Vol. 4. Zement-Kalk-Gips. 9. W: Methode zur Vorausberechnung von Schadstoffkreisläufen in Zementöfen. [39] Locher. pp.: Die Bedeutung von Kreislaufbetrachtungen für Produktqualität und Umweltverträglichkeit der Zementherstellung. H.: Reaktionen im Bereich der Ofengase.und Schwefelverdampfung in Zementofen in Gegenwart hoher Chloreinnahmen. C. Zement-Kalk-Gips 36 (1983) Vol. und Gardeik.. Sonderausgabe Nr. R: Alkaliprobleme und Beseitigung bei wärmesparenden Trockenöfen. P. 8. Fortschritte der Mineralogie 60 (1982) Vol. pp. Evaluation of the substance circulation systems [34] Weber. 456-459. [44] Schütte..: Das Verhaften des Schwefels beim Brennen von Zementklinker Schriftenreihe der Zementindustrie.

269-277. F W: Berechnung der Klinkerphasen. [50] Locher.May 1992 Specification Vt 10 Page 116 Evaluation of the cement clinker [45] Bogue.: Erstarren von Zement. pp. [46] Bogue.H. pp. 10. Teil III: Einfluß der Klinkerherstellung.W. [47] Locher.-M. Zement-Kalk-Gips 31 (1978) Vol. [53] Sprung. pp. 669-676. S. ZementKalk-Gips 38 (1985) Vol. Schriftenreihe der Zementindustrie.W: Einfluß der Klinkerherstellung auf die Eigenschaften des Zements.: Einflüsse der Verfahrenstechnik auf die Zementeigenschaften. H. 192-197. and Sylla. H. pp.1962.: The chemistry of portland cement. [52] Locher. 265-272. Industrial and Engineering Chemistry 1 (1929) pp.-M.. F. Vol. 577-585. [51] Sylla.: Einfluß der Klinkerkühlung auf Erstarren und Festigkeit von Zement. H. Zement-Kalk-Gips 31 (1978) Vol. Reinhold Publishing Corporation. New York 1955. Zement-Kalk-Gips 28 (1975) Vol.-M. 6. Zement-Kalk-Gips 28 (1975) Vol. 9. 357-362.H. pp. pp.. 7. 12.: Einfluß der Ofenatmosphäre beim Brennen von Zementklinker. [49] Sylla. R. S. Richartz. [48] Locher. 6. R. W: Verfahrenstechnik und Zementeigenschaften.: Calculation of the compounds in portland cement. 291-293. F. Zement-Kalk-Gips 35 (1982) Vol. . 29. pp. 7-29. F. W. Sprung.

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Evaluation of the emissions
[54] Kroboth, K., und Xeller, H.: Entwicklungen beim Umweltschutz in der Zementindustrie. Zement-Kalk-Gips 39 (1986) Vol. 1, pp. 1-14. [55] Sprung, S.: Spurenelemente - Anreicherungen und Minderungsmaßnahmen. Zement-Kalk-Gips 41 (1988) Vol. 5, pp. 251-257. [56] Locher, F W: Entwicklung des Umweltschutzes in der Zementindustrie. ZementKalk-Gips 42 (1989) Vol. 3, pp. 120-127. [57] Kroboth, K., und Kuhlmann, K.: Stand der Technik der Emissionsminderung in Europa. Zement-Kalk-Gips 43 (1990) Vol. 3, pp. 121-131. [58] Wischers, G., und Kuhlmann, K.: Ökobilanz von Zement und Beton. Zement-KalkGips 44 (1991) Vol. 11, pp. 545-553.

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10.

Evaluation example 1 (kiln system with a cyclone preheater, calcinator and tertiary air duct)
Balancing the entire system

10.1

10.1.1 Solid substance mass flows
& mS10

= 18.00 kg/s

x NF, S10 = 0.9760 x NF, St12 x NF, B7 = x NF, B3 = not applicable x ash, B7 ⋅ x NV, ash = 0.04 · 0.8007 x ash, B7 ⋅ x NF, ash = 0.04 · 0.8007

& mSt12 = 0 kg/s & m B7 & m B3 & mSt1 & mSt5

= 1.29 kg/s = 1.24 kg/s = 0.84 kg/s = 0 kg/s

x NF, St1 = 0.6454 x NF,St5 not applicable

x NF, S1 = 0.6316

Kiln feed mass flow (Equation 4): 18.00 ⋅ 0.976 − (1.29 + 1.24) ⋅ 0.04 ⋅ 0.8007 + 0.84 ⋅ 0.6454 = 28.55 kg/s. 0.6316

& mS1 =

Ratio of kiln feed to clinker necessary for burning clinker (Equation 6): 28.55 = 1.586 kg/kg. 18.00 + 0

fS1 =

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10.1.2 Gas volume flows

10.1.2.1 Dry gas

10.1.2.1.1 Minimum air volume flow

& mS1 = 28.55 kg/s & mSt1 = & m B7 = & m B3 = 0.84 kg/s 1.29 kg/s 1.24 kg/s

x C, S1 = 0.0015 x C, St1 = 0.0021 h u, B7 = 22684 kJ/kg h u, B3 = 22684 kJ/kg

x S, S1 = 0.0004 x S, St1 = 0.0008

The carbon mass flow (Equation 8) and the sulfide mass flow (Equation 9) effectively fed in with the kiln feed: & mC, eff, S = 28.55 · 0.0015 – 0.84 · 0.0021 = 0.0411 kg/s & mS, eff, S = 28.55 · 0.0004 – 0.84 · 0.0008 = 0.0107 kg/s

Minimum air demand of the fuels (Equation 13): lmin, B7 = lmin, B3 = 0.44 + 0.000245 · 22684 = 5.998 m³/kg Minimum air volume flow (Equation 10):

& VL, min, tr = (1.29 + 1.24) · 5.998 + 0.0411 · 8.88 + 0.0107 · 3.32 = 15.58 m³/s

May 1992 Specification Vt 10 Page 120 10. from the burning area and from the rotary kiln (Equation 16): 1 = 1.0005 1 − 3. tr.2.2.2925 yCO 2 .0007 − 0.1.0302 Air proportionality factors in the waste gas downstream from the preheater.0489 yO 2 .G6 = 0.0489) λG1 = λG2 = 1 = 1.3290 yCO 2 .1.1.G2 = 0. tr. tr.3 Infiltrated air at the kiln hood F ≈ 0. tr.2278 0.G1 = 0.G1 = 0.5 ⋅ 0.0005 yO 2 .762 (1 − 0.N = 1.0007 1 − 3.1. tr. tr.0006 y CO.2 Air proportionality factors yCO 2 .3843 0.762 (1 − 0.0007 y CO.G2 = 0.5 ⋅ 0.G2 = 0.G2 = 0.2108 − 0.0006 − 0.G6 = 0.3290 − 0.0318 yO 2 .2925 − 0.2108 yCO.0489 − 0.25 m² ∆p = 5 Pa p = 1010 hPa ϑ U = 5°C [41°F] ρ L. tr.0005 − 0.0006 1 − 3. tr.0318) λG6 = 1 = 1.29 kg/m³ .762 (1 − 0.5 ⋅ 0.G1 = 0.0318 − 0.1745 0. tr.0302 − 0.0302) 10.

52 m³/s 1.52 m³/s Secondary air volume flow (Equation 20): & VL8.1.May 1992 Specification Vt 10 Page 121 Density of the ambient air: ρ L = 1.25 & VFl. tr =7.29 · 1010 273 ⋅ = 1.18 m³/s & VL9. tr = 1.39 m³/s & VFl.268 kg/m³ 1013 277 Infiltrated air volume flow (Equation 19): 0.4 Secondary air λ G6 = 1.39 – 0.29 10.08 m³/s . tr = 6.29 · 5.1.1745 · 1.5 Cooler intake air & VL8.73 + 23.29 kg/s lmin. tr = 7. D.52 = 7. D.2.998 – 1. tr = 1.18 + 6.1. tr = 0. tr ≈ ⋅ 5 ⋅ 1.73 m³/s & VL11. tr = 23.75 ⋅ 0.18 m³/s 10.268 ⋅ 2 = 0.1745 & m B7 = 1. B7 = 5.17 m³/s Cooler intake air volume flow (Equation 21): & VL10.17 = 37.998 m³/kg & VL7.1.2.

G1 = 0.88 m³/s .1426 1.42 m³/s yO2 . tr yCO 2 . y CO. tr.1262 yO2 .01  1.24 kg/s = 0 x CO 2 .S & m B7 & m B3 = 28. tr.29 kg/s = 1.G5 .84 kg/s = 0 = 0.3256 = 9.St1 x CO 2 .2925 & Vpure gas.0007 yCO2 . tr.6 Raw gas & mS1 & mSt1 & mSt5 & mC.S =  9. tr.G5 not applicable yCO.3380 = 0.55 kg/s = 0. Calculation on the basis of the CO2 balance: Carbon dioxide mass flow (Equation 24) effectively fed in with the kiln feed: & mCO 2 .376 kg/s CO2 from the kiln feed (Equation 23): 44.24) · 5. tr.29 + 1.97  CO2 from the fuel (Equation 26): & VCO2 .1.84 m³/s VCO 2 .3380 – 0. B7 h u.1.St5 = 0.S1 x CO 2 .376 + 0.May 1992 Specification Vt 10 Page 122 10.G1 = 0. tr.G1 = 0.S = 28.55 · 0. pure gas = 0. tr.01  1  & = 4.84 · 0.0411  12.eff. pure gas = 0. B = (1.eff.01 · 10 – 5 · 22684 = 2.2. tr = 60.0489 yCO2 .0411 kg/s = 1. B3 = 22684 kJ/kg (lignitic coal) = 22684 kJ/kg (lignitic coal) & VG5.3256 not applicable h u.

07 m³/s 0.2925 & VG2. tr.68 = 22. tr = 60.3290 yO2 .0489 yO2 .42 = 25.May 1992 Specification Vt 10 Page 123 Raw gas volume flow (Equation 29): 4.84 + 2.G1 = 0. tr = 25.88 − 0 & VG1.G2 = 0.28) = 25.2925 b) O2 balance: 0.83 m³/s 0.33 m³/s 0. tr = 25. tr.G2 = 0.1426 & VG1.0007 2.3290 .7 Gas downstream from the burning area yCO2 .2.2925 yCO2 . tr = 0.1.2925 + 0.21 − 0.07 + 25.1262 & VG1.28 m³/s 0.0318 & VG1.42 = 26.68 m³/s Gas volume downstream from the burning area (Equations 30 and 31): a) CO2 balance: 0. tr = 60. tr = = 26.G1 = 0.1. Calculation on the basis of the clean gas volume flow: Raw gas volume flow (Equations 30 and 31): a) CO2 balance: 0.0489 The following applies: & VG1.5 (26.68 m³/s 10.21 − 0. tr. tr.

0489 yCO2 .21   = 9.0411 ⋅ 8. tr = 25. tr.88 m³/kg = 3.2108 −  0.0302   1 − 0.5 (22. tr 0. tr.0318 The following applies: & VG2.68 m³/s yCO.2108 & m B3 & mC.21   .May 1992 Specification Vt 10 Page 124 b) O2 balance: 0.S = 5.G1 = 0.8 Gas downstream from the rotary kiln (kiln inlet) yCO2 .G6 = 0.0302 Gas volume flow downstream from the rotary kiln [30]: & VG6.0005 lmin. tr.B3 lmin.68 ⋅ 0.0489 & VG2.G1 = 0.88 + 0. tr = 0. eff.2925 − 0. tr.32 m³/kg yO2 .0302   1 − 0.03 m³/s 10.G6 = 0.21   = 0.83 + 23. tr.0007  0.22) = 23.24 ⋅ 5.79 1.0107 kg/s yO2 .1.998 m³/kg = 8.0107 ⋅ 3. eff.21 − 0.68 1 − 0.G6 = 0.21 − 0.0411 kg/s = 0.2.998 + 0.5   0.2925 & VG1.24 kg/s = 0.32 − ⋅ 25. S & mS.tr.2108 −  0.21   0 .C lmin.0007 yO2 . tr = 25.G1 = 0.32 m 3/s − 0.0489   25.0007 −  0.68 = 23.22 m³/s 0.1. S = 1.

03 m³/s & VL1 = 1.0302 0.1 Humidity in the air p = 101000 Pa ϑ L.tr = yO2 .60 m³/s 10.32 – 6.U = 4°C [39.May 1992 Specification Vt 10 Page 125 10.19 = 3.2°F] ϕ = 0.19 m³/s & VG2.2.1.tr & VL4.24 kg/s = 0.9 Infiltrated air (preheater) & VGl. S = 1.G2 = 0. tr = 25. tr.0006 Infiltrated air volume flow (calcinator) according to [30]: 1 & VFl.0318 – 0.0411 · 8.0107 · 3.03 m³/s = 9. tr.21 0.G2 = yO2 .G6 = & VL3. tr = 23.73 m³/s lmin.32 m³/s = 6. eff.73 – 0.2 Water vapor 10.1.1.4 .24 · 5. S & mS.5 · 0.C lmin.2.1.0107 kg/s = 23.32 · 0.10 Infiltrated air (calcinator) & m B3 & mC.0302) + 1.68 m³/s & VG2.1.S = = 5. tr.2.0006) – 9.tr yO2 .tr & VG6.32 m³/kg 0.88 + 0.998 + 0.2.88 m³/kg 3.0318 0.0411 kg/s = 0. tr.1.2. eff.03 m³/s 10.C = (23.998 m³/kg 8.03 · (0.B3 = lmin.

2 = 0.U) = 611. L = 1.2.55 kg/s = 0. D = 0.29 · 5.0190 ρH 2O.608 · 0.May 1992 Specification Vt 10 Page 126 Saturation pressure of the water vapor at ambient temperature (Equation 33): ps (ϑ L.608 · xD = 1.002 = 0.2 0 .2.622 812.2 Pa Water content of the dry air (Equation 32): xD = 0.1. St1 = 0.0204 x H2O.0020 kg/kg 101000 − 812.002 = 0.58 · 1.470 · 42 + 2.564 · 10 – 5 · 43 + 2. L = 1.2 Water from the kiln feed & mS1 & mSt1 = 28.3843 · 15.002 = 0.07 m³/s b) downstream from the burning area & VH 2 O. S1 = 0.tr · 1.84 kg/s x H2O.2278 · 15.4 Humidity volume flows (Equation 34): a) downstream from the preheater & & VH 2 O. min.608 · 0.1745 · 1.998 · 1.877 · 10 – 4 · 44 + 10 – 6 · 45 = 812. L = λG1 ⋅ VL.58 · 1.8 kg/m³ .06 m³/s c) downstream from the rotary kiln (kiln inlet) & VH 2 O.03 m³/s 10.608 · 0.87 · 4 + 1.5 + 43.

B3 = 0.1. B3 = 1. B7 x H. 10 = 0 .0453 Moisture volume flows (Equation 36): a) Main burner 18  1  & = 0.1.29 kg/s 1.4 Injection water & m H 2 O.2.8 10.55 ⋅ 0.8  10.087 x H2O.0453  2  0 .2.0453  2  0 .087 + 0.087 + 0. B7 = 1.84 ⋅ 0.3 Water from the fuel & mB7 & mB3 = = 1.8  b) Secondary burner 18  1  & = 0.24  0. S = (28.2.71 m³/s 0 .2.0204 − 0. B3 = 0.29  0.77 m³/s VH 2 O.80 m³/s VH 2 O.0453 = 0.019) ⋅ = 0.087 x H.24 kg/s x H2O. B7 = 0.May 1992 Specification Vt 10 Page 127 Moisture volume flow from the kiln feed (Equation 35): 1 & VH 2 O.

087 .1. B3 = 0.68 + 0.4.03 + 0.3 Moist gas (examples) Raw gas volume flow (Equation 40): & VG1 = 25.80 = 10. B7 = x F.24 kg/s h u.6°F] x H 2 O.4 Energy flows 10. B7 = 22684 kJ/kg h u.087) ϑB7 = 32°C [89.06 + 0.1.80 + 0. B3 = 0.80 + 0.3 Liquid mass flows Does not apply.77 = 24.71 + 0.15 m³/s 10.77 = 28.29 kg/s & m B3 = 1. B3 = 22684 kJ/kg x F.6°F] ϑB3 = 32°C [89.496 (1 − 0.1.1.32 + 0.May 1992 Specification Vt 10 Page 128 10.03 m³/s Volume flow downstream from the burning area: & VG2 = 23.2.07 + 0.1.1.1 Energy input 10. B7 = x H 2 O.66 m³/s Volume flow downstream from the rotary kiln (kiln inlet): & VG6 = 9.1 Fuel & m B7 = 1.4. 10.03 + 0.

6 ·10 – 7 · 632 + 5.344 + 0. B = (1. tr ≈  0.1.1.3 ·10 – 4 · 63 – 4.344 kJ/kg K 1 − 0.4.5 · 10 · 32 – 8 · 10 · 32 ) = 1.803 ⋅ 0.8 + 7.24) · 1.2 = 1.844 kJ/kg K Enthalpy flow of the kiln feed (Equation 48): & H S1 = 28.087 · 4.24) · 22684 = 57391 kJ/s Sensible enthalpy flow of the fuel (Equation 42): & H B = (1.087   Mean specific thermal capacity for the water in the coal: c H 2O ≈ 4.592 · (32 – 25) = 28 kJ/s 10.2 · 10 – 11 · 633 = 0.May 1992 Specification Vt 10 Page 129 Mean specific thermal capacity for dry lignitic coal (Equation 43): 0.29 + 1.2 Kiln feed & mS1 = 28.592 kJ/kg K Reaction enthalpy flow of the fuel (Equation 41): & ∆H R.55 kg/s ϑS1 = 63°C [145.844 · (63 – 25) = 916 kJ/s .087) · 1.29 + 1.496   –3 – 10 3 c B.846 +  (1 + 1.2 kJ/kg K Mean specific thermal capacity for moist lignitic coal (Equation 44): cB7 = cB3 = (1 – 0.55 · 0.4°F] Mean specific thermal capacity of the kiln feed (Equation 49): cS1 ≈ 0.

1.U = 4°C [39.297 + 5.L.4 Injection water Does not apply.58 + 23. min.3843 · 15.17) (1 + 1.5 Mechanical performance Pmech. 10.1.88 m³/s i Mean specific thermal capacity of the air fed in (Equation 52): cp.297 · (4 – 25) = -1223 kJ/s 10.3843 & VL. kiln drive = 117 kJ/s .4.17 m³/s xD = 0. total = 44.1.2°F] Sum of the air volume flows fed in (Equation 39): & ∑ VLi = (1.9 = 409 kJ/s Pmech.297 kJ/m³ K Enthalpy flow of the air fed in (Equation 50): & H L.1.75 · 10 – 5 · 4 + 8.tr = 15.1.3 Air λG1 = 1.1. air-intake fan = 337 kJ/s Mechanical performance (Equation 53): Pmech = (337 + 117) · 0.tr = 1.002) = 44.06 · 10 – 8 · 42 – 2.4.88 · 1.4.002 kg/kg ϑ L.May 1992 Specification Vt 10 Page 130 10.58 m³/s & VL11.608 · 0. tr = 23.86 · 10 – 11 · 43 = 1.

0083 + 1.2 Energy output 10.4.563 = 0.6641 – 0.0234 = 0.692 · 0.602 · 0.4.S10 = 4.1 C3S. C2S.1.1.0234 = 0.6498 – 7.S10 = 0 3 CaO bound in the clinker phases (Equation 54): x CaO* .868 · 0.S10 = 2.85 · 0.S10 = 2.65 · 0.0234 – 6.0067 The following then results: x CaOSO .2137 – 1. C3A and C4AF in the clinker SO3 bound to the CaO in the clinker (Equation 55 or 56): 0.S10 = 3.188 x C3A.0143 – 0 = 0. 10.1.1.292 · 0.043 · 0.4.43 · 0.718 · 0.6498 Clinker phases (Equations 57 through 60): x C 3S.May 1992 Specification Vt 10 Page 131 10.0632 – 1.1 Reaction enthalpy of the kiln feed Chemical analyses of the solid substance average samples.2.0632 = 0.0083 > 0.2. each according to Table 10.754 · 0.071 .0010 = 0.2137 – 0.128 x C 4 AF.071 · 0.563 x C 2S. S10 = 0.

3 CaCO3 and C2S in the bypass dust Does not apply.1.785 · 0.7404 x MgCO3 .1.1.84) = 1386 kJ/s .785 · 0.May 1992 Specification Vt 10 Page 132 10.4306 > 0.00 kg/s & mSt12 = 0 kg/s Reaction enthalpy flows (Equations 67 through 79): 1) Evaporation of H2O: & ∆H R1 = 2446 (0.3380 = 0.3256 = 0.2.S1 = 1.1.4304 The following then results: x CaCO3 . 10.2.3256 = 0.1.274 · 0.4.2 CaCO3.274 · 0.55 kg/s & mSt1 = 0.7683 x MgCO3 .S1 = 1.84 kg/s & mSt5 = 0 kg/s & mS10 = 18.4235 The following then results: x CaCO3 .1.2.55 – 0.3380 – 0.4304 = 0.4148 < 0.4 Balance equations & mS1 = 28.916 · (0.0204 · 28.0190 · 0.4.4.St1 = 0 10.4304) = 0. and MgCO3 in the kiln feed and in the raw gas dust a) kiln feed (Equations 61 through 64): 1.0003 b) raw gas dust (Equations 61 through 64): 1.St1 = 2.274 · 0.

May 1992 Specification Vt 10 Page 133 2) Decomposition of clay: assumption: 100%-illite & ∆H R2 = 884 (0.00 = -86 kJ/s 8) Formation of C3A: & ∆H R8 = 74 · 0.0021 · 0.84) = 978 kJ/s 3) Organic clay components: & ∆H R3 = -32786 (0.128 · 18.188 · 18.0003 · 28.0499 · 0.00 = -2369 kJ/s .7683 · 28.071 · 18.55 – 0 · 0.0402 · 28.55 – 0.7404 · 0.84) = 37895 kJ/s 6) Pyrite: & ∆H R6 = -12914 (0.0008 · 0.00 = 170 kJ/s 9) Formation of β-C2S: & ∆H R9 = -700 · 0.0015 · 28.84) = -139 kJ/s 7) Formation of C4AF: & ∆H R7 = -67 · 0.84) = -1346 kJ/s 4) MgCO3 dissociation: & ∆H R4 = 1396 (0.0004 · 28.55 – 0.84) = 12 kJ/s 5) CaCO3 dissociation: & ∆H R5 = 1778 (0.55 – 0.55 – 0.

0838) · 0. 10.2.00 = -5016 kJ/s 11) Formation of K2SO4: & ∆H R11 = -9690 (0.6034 .2 Water evaporation Does not apply. G1 = (1 – 0.4°F] y H 2O.0838 yCO 2 .4. G1 = 0.0838 – 0.0838) · 0.1.03 m³/s & VL11 = 23.May 1992 Specification Vt 10 Page 134 10) Formation of C3S: & ∆H R10 = -495 · 0.0014 · 0.2680 yO 2 . G1 y N 2 .0448 = 1 – 0.4.563 · 18.00 + 0.1.25 m³/s ϑ G1 = 330°C [626°F] ϑ L11 = 278°C [532.2925 = 0.S = 1386 + 978 – 1346 + 12 + 37895 – 139 – 86 + 170 – 2369 – 5016 – 903 = 30582 kJ/s 10.2680 – 0.3 Waste gas losses & VG1 = 28.84 – 0.0489 = 0.0448 = 0.0067 · 18. G1 = (1 – 0.2.0010 · 28.55) = -903 kJ/s Sum of the reaction enthalpy flow of the kiln feed (Equation 80): & ∆H R.

993 kJ/kg K .01 · 10 – 11 ·3303 = 1.301 + 3.90 · 10 – 11 · 3303 = 1.03 · 1. N 2 = 1.CO 2 = 1.6 · 10 – 7 · 3302 + 5.633 + 9.54 + 0.297 + 5.65 · 10 – 8 · 3302 – 3.540 kJ/m³ K c p.25 · 1.0448 · 1.366 = 1.06 · 10 – 8 · 2782 – 2.319 (278 – 25) = 7759 kJ/s 10.22 · 10 – 11 ·3303 = 1.G1 = 0.021 · 10 – 7 · 3302 – 7.916 · 10 – 4 · 330 – 9.1.O 2 = 1.35 · 10 – 11 ·3303 = 1.904 kJ/m³ K c p.05 · 10 – 5 · 330 + 9.304 + 1.32 + 0.497 (330 – 25) = 12798 kJ/s b) Cooler vent air Mean specific thermal capacity of the cooler vent air (Equation 52): cp.3 · 10 – 4 · 330 – 4. H 2O = 1.0838 · 1.75 · 10 – 5 · 278 + 8.4 Dust losses & mSt1 = 0.2.8 + 7.268 + 1.84 kg/s ϑ St1 = 330°C [626°F] Mean specific thermal capacity of the raw gas dust (Equation 49): CSt1 ≈ 0.4 · 10 – 9 · 3302 – 1.366 kJ/m³ K c p.904 + 0.606 · 10 – 7 · 3302 + 8.319 kJ/m³ K Enthalpy flow of the cooler vent air (Equation 89): & H L11 = 23.2 · 10 – 11 · 3303 = 0.52 · 10 – 5 · 330 + 2.May 1992 Specification Vt 10 Page 135 a) Raw gas Mean specific thermal capacity of the raw gas (Equations 83 through 87): c p.489 + 9.320 kJ/m³ K c p. L11 ≈ 1.4.86 · 10 – 11 · 2783 = 1.6034 · 1.631 · 10 – 4 · 330 – 4.497 kJ/m³ K Enthalpy flow of the raw gas (Equation 82): & H G1 = 28.

369 · 10 – 7 · 1202 + 2.4.793 kJ/m³ K Enthalpy flow of the clinker (Equation 94): & H S10 = 18.0007 Reaction enthalpy flow (Equation 93): & ∆H R.84 · 0.00 · 0.124 · 10 – 10 · 1203 = 0. tr = 25.68 m³/s y CO.2.tr.921 · 10 – 4 · 120 – 5.4.6 Clinker & mS10 = 18.G1 = 0.993 (330 – 25) = 254 kJ/s 10.CO = 25.1.00 kg/s ϑ S10 = 120°C [248°F] Mean specific thermal capacity of the raw gas dust (Equation 95): CS10 = 0.1.729 + 5.2.793 (120 – 25) = 1355 kJ/s .May 1992 Specification Vt 10 Page 136 Enthalpy flow of the raw gas dust (Equation 90): & H St1 = 0.68 · 0.0007 · 12645 = 227 kJ/s 10.5 Incomplete combustion & VG1.

C = 360 kJ/s & Q W.1.1.2. V = 720 kJ/s & Q W.4.4.8 Uncoupled heat Does not apply. see [31]: & Q W. 10.2.1.4. D = 4266 kJ/s & Q W. .T = 486 kJ/s & Q W. B = 59059 – 28 – 916 + 1223 – 409 = 58929 kJ/s Balance deficit: 58929 – 57391 = 1538 kJ/s This corresponds to 2.7 Radiation and convection: For calculation examples. K = 252 kJ/s 10.6% of the balance sum.3 Energy balance Energy output (Equation 108): & E out = 30582 + 12798 + 7759 + 254 + 227 + 1355 + 720 + 360 + 4266 + 486 + 252 = 59059 kJ/s Reaction enthalpy flow of the fuel including the balance remainder (Equation 109): & ∆H R.May 1992 Specification Vt 10 Page 137 10.

1 Clinker cooler 10.18 m³/s & VL9.2.608 · 0. tr = 7.73 Hot clinker mass flow (Equation 111): & mS8 = 18.35 kg/s & VL8.20 m³/s .18 m³/s & VL10.20 m³/s Cooler intake air volume flow (Equation 38): & VL10 = 37.1 Solid substance mass flows & mS10 = 18.08 (1 + 1.May 1992 Specification Vt 10 Page 138 10.18 = 0.002) = 37.37 = 18.00 kg/s & mSt9 = 0.608 · 0.72 kg/s 10.002) = 7.1.2.08 m³/s xD = 0.2 Balancing of the partial systems 10.1. tr = 6.73 m³/s Secondary air dust mass flow (Equation 110): & mSt8 = 0. tr = 37.37 kg/s 6.18 (1 + 1.00 + 0.35 + 0.35 ⋅ 7.0020 kg/kg Secondary air volume flow (Equation 38): & VL8 = 7. tr = 7.2 Gas volume flows & VL8.2.

May 1992

Specification Vt 10

Page 139

10.2.1.3 Energy flows

10.2.1.3.1 Energy input

& VL10 = 37.20 m³/s

ϑ U = 4°C [39.2°F]

Pmech, intake air fan = 337 kJ/s

cp,L10 = 1.297 kJ/m³ K (for the calculation, see above) The enthalpy flow of the hot clinker results from the balance remainder from the energy balance. Enthalpy flow of the cooler intake air (Equation 113): & H L10 = 37.20 · 1.297 (4 – 25) = -1014 kJ/s The enthalpy flow of the injection water does not apply here. Mechanical performance (Equation 114): Pmech, K = 337 · 0.9 = 303 kJ/s

10.2.1.3.2 Energy output

& VL9 & VL8

& = VL4 = 6.75 m³/s = 7.20 m³/s

& & mSt9 = mSt4 = 0.35 kg/s & mSt8 = 0.37 kg/s

ϑ L4

= 853°C [1567.4°F]

& QW,T = 486 kJ/s

May 1992

Specification Vt 10

Page 140

Enthalpy flow of the clinker (for the calculation, see above): & H S10 = 1355 kJ/s Radiation and convection loss flow of the cooler including the kiln hood:

& Q W, K = 252 kJ/s

The uncoupled heat flow does not apply here. Enthalpy flow of the cooler vent air (for the calculation, see above): & H L11 = 7759 kJ/s Enthalpy flow of the tertiary air at the calcinator (Equations 52 and 89): cp,L4 = 1.297 + 5.75 · 10 – 5 · 8.53 + 8.06 · 10 – 8 · 8532 – 2.86 · 10 – 11 · 8533 = 1.387 kJ/m³ K & H L4 = 6.75 · 1.387 · (853 – 25) = 7752 kJ/s Enthalpy flow of the tertiary air dust at the calcinator (Equations 95 and 99): CSt4 = 0.729 + 5.921 · 10 – 4 · 8.53 – 5.369 · 10 – 7 · 8532 + 2.124 · 10 – 10 · 8533 = 0.975 kJ/kg K & H St4 = 0.35 · 0.975 · (853 – 25) = 283 kJ/s Energy balance for the tertiary air duct:

& & & & & H L9 + H St9 = H L4 + H St4 + Q W, T = 7752 + 283 + 486 = 8521 kJ/s

The iterative calculation then results in the following: ϑ L9 = ϑ St9 ≈ 901°C [1653.8°F]

May 1992

Specification Vt 10

Page 141

Enthalpy flow of the secondary air (Equations 52 and 89): Cp,L8 = 1.297 + 5.75 · 10 – 5 · 901 + 8.06 · 10 – 8 · 9012 – 2.86 · 10 – 11 · 9013 = 1.390 kJ/m³ K & H L8 = 7.2 · 1.39 (901 – 25) = 8767 kJ/s Enthalpy flow of the secondary air dust (Equations 95 and 94): CSt8 = 0.729 + 5.921 · 10 – 4 · 901 – 5.369 · 10 – 7 · 9012 – 2.124 · 10 – 10 · 9013 = 0.982 kJ/kg K & H St8 = 0.37 · 0.982 (901 – 25) = 318 kJ/s The evaporation enthalpy flow of the water does not apply here.

10.2.1.3.3 Energy balance

Enthalpy flow of the hot clinker (Equation 115): & H S8 = 8767 + 318 + 8521 + 7759 + 1355 + 252 + 1014 – 303 = 27683 kJ/s Hot clinker temperature:

ϑS8 =

& H S8 + 25 & mS8 ⋅ cS8 & mS8 = 18.72 kg/s

cS8 (1389°C [2532.2°F]) = 1.084 kJ/kg K The following then results: ϑS8 =

27683 + 25 = 1389°C [2532.2°F] 18.72 ⋅ 1.084

499 W/m² K 473 − 277 αtotal = 9.2°F]) = 25.m ≈ 200°C [392°F] ϑ U = 4°C [39.85   + 0.4 Evaluation quantities 10.2 (3.5 – 0.2 – 0.2.2 m Da = 3.25 · 1.2 m ϑ W.2°F]: & H S10 (4°C [39.00 · 0.4.2 Energy loss flow of the cooling area Enthalpy flow of the clinker at 4°C [39.9 · 5.1.May 1992 Specification Vt 10 Page 142 10.2°F] Heat-transition coefficients (Equations 98.168 W/m² K 100  100   100  αrad = 0.67 · 10 – 8 2 3 4734 − 277 4 = 11.168 + 11.4.731 · (4 – 25) = -276 kJ/s Enthalpy flow of the cooler vent air at 4°C [39.0 + 3.667 · π · 3.2.298 · (4 – 25) = -688 kJ/s .667 W/m² K Radiation and convection loss flow of the pre-cooling zone (Equation 117): & Q W.3 · 3.2. 99 and 101): 200  200   200  αconv = 0. pre − cool = 20.499 = 20.2) (200 – 4) 1 = 122 kJ/s 1000 10.076   = 9.2°F]: & H L11 (4°C [39.2°F]) = 18.1 Pre-cooling zone LB = -0.2 + 4.1.1.

S6 = 0.106 · (1450 – 25) = 28370 kJ/s Cooling area efficiency (Equation 119): η cooling area = 1 – 10452 = 0.89 0.6316 ϕ apparent .S1 = 0.635 28370 + 276 10.S1 = 0.0532 = 1 − 0.0532 xCO2 .May 1992 Specification Vt 10 Page 143 Energy loss of the cooling area (Equation 118): & Eloss.00 · 1.3380 xNF.1.9016 (sum 1 to 8 in Table 10) xNF.4.6316 (sum 1 to 8 in Table 10) Apparent degree of precalcining of the kiln feed at the kiln inlet (Equation 121): 0.9016 = 0.3380 0. cooling area = 1355 + 276 + 7759 + 688 + 252 + 122 = 10452 kJ/s 10.2.2 Calcinator xCO2 .3 Cooling area efficiency Enthalpy flow of the clinker at 1450°C [2642°F]: & H S10 (1450°C [2642°F]) = 18.S6 = 0.2.

2) One-fourth of the moisture volume flow from the kiln feed is desorbed in each of the four uppermost stages. (127). 6) The cyclone of the calcinator is assigned the number 5. Assumptions made for the calculations: 1) The conveying air volume flow for the kiln feed enters into stage 1.May 1992 Specification Vt 10 Page 144 10. 3) The infiltrated air volume flow of the preheater is uniformly distributed over the four stages. .2. 4) The following aspects are taken into account for the reaction enthalpy flow in the preheater: • evaporation of H2O • degradation of clay • organic components • MgCO3 dissociation • pyrite 5) The sum of the reaction enthalpy flows in the preheater is uniformly distributed among the four stages. (126).3 Preheater Calculation of the mass flows and degrees of separation according to Equations (123). 7) The dust from the rotary kiln and from the tertiary air duct contains 10% alkalis and 90% non-volatile components. (130) and (131).

55 – 34.53 25.62 62.67 49.97 25.619 – – & QW – 180 180 180 180 – – & ∆H R – 223 223 223 223 – – & mS 28.3 Estimation of error Table 16 provides an overview of how possible errors in the measured or input quantities (column 2) impact on the fuel energy consumption when it is calculated according to Equation (109) or according to Equation (41) and then related to the clinker mass flow (columns 3 and 4).96 21.35 – 10.55 – – & mS 28.555 1.092 1.14 34.84 – 7.03 23. .595 1.19 21.87 0.09 – – cp.84 15.26 – – – & mSt – 0.98 0.92 3.050 1.993 1.55 43. Thus.87 ξ – 0.31 28.43 6. the table provides information about the necessary measuring precision for the individual measured quantities during a performance test.G – 1.80 0.69 0.02 25.844 0.67 48.26 – & mSt – 0.497 1.May 1992 Specification Vt 10 Page 145 Results: energy balance i 0 1 2 3 4 5 6 alkali balance ϑ 63 330 480 638 744 – – cS 0.110 – – & VG – 28.

0 – 30 28.4 107.3 73.24 0.84 – 0.29 1. Designation Clinker Discharged tertiary air dust Kiln feed a) meter status b) calculated lignitic coal (main burner) lignitic coal (secondary burner) Raw gas dust Bypass dust Returned tertiary air dust t/d 1555 – 2506 kg/s 18.35 .55 1.4 Tables (The operands are printed in boldface!) Table 9 .00 – – 2466 111. calcinator and tertiary air duct).May 1992 Specification Vt 10 Page 146 10.Solid substance mass flows (kiln system with a cyclone preheater.

03 0.92 0.54 0.22 34.45 – 0.15 33.64 0.48 – – – 4 15.37 6.10 0.30 – 33.22 7.008 0.43 100.08 0.32 – – 2.001 0.02 0.54 17.61 – 0.64 99.57 0.04 0.51 99.02 – – 1.80 – – – 1b 13.72 100.85 0.60 – 0.23 – 27.76 – 31.81 80.05 0.36 0.04 – – 0.16 – 5.76 5.51 – 43.57 0.21 35.02 12.99 – – 1.58 100.40 – – – 5 19.26 34. calcinator and tertiary air duct).31 – 0.45 – 0.27 62.12 4.44 – 0.31 – 33.80 – – – 2 14.22 0.41 1.06 64.65 3.59 – – 1.42 – – 1.30 34.30 1.75 98.57 0.16 0.58 – 45.12 – – 1.25 4.10 61.72 0.13 3.78 0.23 35.91 4.64 0.08 1.47 1.80 0.May 1992 Specification Vt 10 Page 147 Table 10 .34 – 66.13 – – 1.85 4.43 Fuel ash 8.70 0.31 34.Chemical analyses of the solid substance average samples in % by weight of the substance entailing loss on ignition (kiln system with a cyclone preheater.04 0.15 – 61.26 99.23 0.05 0.46 97.57 0.57 0.51 – 43.35 0. No.95 – – 1.75 64.15 0.85 100.51 – 42.90 90.32 – – – 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 SiO2 Al2O3 TiO2 P2O5 Fe2O3 Mn2O3 CaO MgO SiO3 S 2– Cl – K2O Na2O ignition loss sum 1-14 sum 1-8 C CO2 H2O (< 110°C) H2O (> 110°C) CaOfree .03 0.10 99.00 99.25 27. Components Kiln feed 13.68 0.75 63.30 6.56 0.83 0.63 0.08 66.60 0.72 0.10 70.62 – 47.15 0.25 48.84 4.16 0.45 2.96 – Raw gas dust 14.13 – 33.70 – 42.10 0.01 0.82 – – 2.07 1.67 – 0.76 – – – 3 14.77 0.45 0.49 – 0.42 1.50 – 43.32 0.07 – – – – – Kiln feed downstream from the cyclone 1a 14.14 – – 1.83 – Clinker 21.23 31.72 4.14 0.

Fuels (kiln system with a cyclone preheater.27 0.53 0.-% wgt.-% wgt.70 4.-% wgt.27 0.56 21.-% wgt. calcinator and tertiary air duct).56 21.00 60.-% wgt.70 4.00 60.684 8.20 4.20 4.74 49.-% Fuel (main burner) 22.May 1992 Specification Vt 10 Page 148 Table 11 .-% wgt.60 Relative to the dry substance.-% wgt. Designation lower calorific value water ash carbon hydrogen sulfur nitrogen oxygen volatile components 1) 1) Unit kJ/kg wgt.53 0.684 8.74 49.60 Fuel (secondary burner) 22. .

4°F] 330°C [626°F] 480°C [896°F] 638°C [1180.8°F] 278°C [532.4°F] 744°C [1371.Temperatures (kiln system with a cyclone preheater.2°F] 901°C [1653.4°F] 1024°C [1875. Designation Kiln feed Raw gas Kiln feed (cyclone 2) Kiln feed (cyclone 3) Kiln feed (cyclone 4) Kiln feed (cyclone 5) Tertiary air (calcinator) Kiln inlet gas Hot clinker Secondary air Cooler vent air Clinker Ambient air Fuel (main burner) Fuel (secondary burner) Temperature (°C [°F]) 63°C [145.4°F] 120°C [248°F] 4°C [39.6°F] .2°F] 845°C [1553°F] 853°C [1567.2°F] 32°C [89.2°F] 1389°C [2532. calcinator and tertiary air duct).May 1992 Specification Vt 10 Page 149 Table 12 .6°F] 32°C [89.

08 1.c.62 29.02 CO vol-% 0.89 3.18 3.)/h 244000 m³(s.39 air with 0.32) (7. but often very imprecise since gas analysis at the kiln inlet is not representative.20) 6.60 0.19 1.25 133600 5800 700 5000 37.66 (10.4 6. related to dry gas m³(s.73 23.c.)/h 67.05 (3.05 (3.3 vol-% of H2O 3800 (10900) 1900 1. Designation Dry gas Moist gas Gas composition.42 m³(s. calcinator and tertiary air duct).76 CO2 12.05 217500 10.c.07 0.18) 6.03 0.52 3800 (10900) 1900 1.)/h 60.26 4.20 1.03 (9.03) 0. = under standard conditions .08 O2 14.06 0. s.8 8.68 23.May 1992 Specification Vt 10 Page 150 Table 13 .c.25 32.c.19 1.52 Calculated.04) 0.03 24.15) (7.61 0.17 100900 88700 36500 (26000) 24300 83700 28.90 21.0 92400 82900 (33600) (25900) 24200 83400 25.75 23.6 8.)/h clean gas raw gas gas after burning area kiln inlet gas 1) secondary air 1) tertiary air cooler vent air cooler intake air conveying air (kiln feed) burner air (secondary burner) burner air (main burner) infiltrated air (preheater) infiltrated air (calcinator) infiltrated air (kiln hood) 1) 1) moist gas … – – – – … – – – – H2 O vol-% m³(s.39 134000 5800 700 5000 37.Gas volume flows and composition (kiln system with a cyclone preheater.

May 1992 Specification Vt 10 Page 151 Table 14 . calcinator and tertiary air duct). Designation Input Fuel main burner secondary burner sensible enthalpy balance remainder Kiln feed Air Mechanical performance Sum kJ/s kJ/kg Kl 29262 28129 28 1538 916 –1223 409 59059 1626 1563 1 85 51 –68 23 3281 Output Reaction enthalpy of the kiln feed Water evaporation Waste gas losses raw gas cooler vent air Dust losses Incomplete combustion Clinker Radiation and convection Preheater Calcinator Rotary kiln Tertiary air duct cooler + kiln hood Heat uncoupling Sum Fuel energy consumption including the balance remainder 30582 — 12798 7759 254 227 1355 720 360 4266 486 252 — 59059 1699 — 711 431 14 13 75 40 20 237 27 14 — 3281 58929 3274 .Energy balance of the kiln system (kiln system with a cyclone preheater.

Designation Input Hot clinker (balance remainder) Cooler intake air Mechanical performance kJ/s kJ/kg Kl 27683 –1014 303 26972 1355 252 7759 8521 8767 318 – – 26972 581 0. calcinator and tertiary air duct).Energy balance of the cooler (kiln system with a cyclone preheater.635 1538 –57 17 1498 75 14 431 473 487 18 – – 1498 Sum Output Clinker Radiation and convection Cooler vent air Tertiary air and tertiary air dust Secondary air Secondary air dust Heat uncoupling Water evaporation Sum Evaluation quantities Energy loss of the cooling area in kJ/kg Kl Cooling area efficiency (1450°C [2642°F]) .May 1992 Specification Vt 10 Page 152 Table 15 .

May 1992 Specification Vt 10 Page 153 Table 16 .24 Translation by: Duvekot Translators 2219 Brackenville Road Hockessin.29 1.28 1.93 0.51 –0.com .15 0.Influence of measuring errors on the calculated fuel energy consumption (kiln system with a cyclone preheater.09 0. DE 19707 Phone: (302) 234-0237 Fax: (302) 234-0239 Toll-free: (800) 437-0237 e-mail: ledtrans@compuserve. Input quantity Relative error in the input parameter in % Relative error in the fuel energy consumption in % (Equation 109) Relative error in the fuel energy consumption in % (Equation 41) 2 10 3 Hu fuel Ash content of fuel Mass flow of fuel Mass flow of raw gas dust Mass flow of clinker Volume flow of dry raw gas Volume flow of dry cooler vent air Temperature of clinker Temperature of raw gas Temperature of kiln feed Temperature of cooler vent air Radiation and convection loss of preheater Radiation and convection loss of kiln SiO2 content in the clinker CO2 content in the kiln feed CO2 content in kiln feed and raw gas dust 2 10 10 50 3 10 10 5 2 10 2 50 10 –2 5 5 0 –0.12 1.3 0.42 2. calcinator and tertiary air duct).43 0.08 0.74 0.27 0.22 –1.

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