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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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

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

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

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

and the tricalcium aluminate crystallizes with the finest grain possible.2 Burning process In Germany nowadays. As the melt cools down. in short.5° to 4. see [2-4.5 to 3 rpm. Consequently. essentially tricalcium aluminate (3CaO · Al2O3.0°. Rotary kilns with preheaters located upstream have a length that is 10 to 17 times longer than their diameters. As a result of the inclination and rotation. the cooling of the cement clinker has to be optimally harmonized with the required clinker properties. C4AF) crystallize out. the kiln feed coming from the preheater moves towards the main burner of the rotary kiln. in short. 2. which is located at the lower end of the rotary kiln. C3S) from solid dicalcium silicate and CaO. In this context. Rotary kilns are fire-proof. which is indispensable for the strength properties of the cement. After completion of the sintering. 6-9 and 11-15]). qualitative differences occur which depend on the composition of the kiln feed [48-53].May 1992 Specification Vt 10 Page 10 motes the formation of tricalcium silicate (3CaO · SiO2. C3A) and aluminate ferrite (4CaO · Al2O3 · Fe2O3. in short. On the other hand. the cement clinker has to be cooled off so quickly that the tricalcium silicate does not disintegrate. cement clinker is produced in rotary kiln systems with kiln feed preheaters located upstream and clinker coolers located downstream (for other process techniques. which are operated at 1. 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. brick-lined tubes. having diameters of up to 6 meters and inclined at an angle ranging from about 2. burning tempera- . the cooling rate should not be so high that the melt becomes glassy as it solidifies.

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. which usually consist of 10 satellite tubes attached around the periphery of the rotary kiln. . The process gases coming from the rotary kiln flow through the cyclone preheater from the bottom to the top. it re-enters the gas stream prior to the next-lower cyclone stage. 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. raw meal mixture is fed into the waste gases prior to entering the uppermost cyclone stage. the gas is once again blown from the top to the bottom through the moist granules in the dry chamber.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 dry. When it comes to kiln systems. afterwards. the clinker that drops out of the rotary kiln after the sintering operation is cooled in a crosscurrent. satellite coolers and rotary coolers are employed as clinker coolers in the cement industry. 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. With grate-type coolers. After the coarse dust has been separated out. 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. and it is then fed to the rotary kiln burner as so-called secondary air. and it is once again separated from the gas in the cyclones. 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. the clinker dissipates its energy to the cooling air that is flowing in a cross current or countercurrent. In the case of the rotary coolers or satellite coolers. In order to be able to reach such high temperatures. Grate-type coolers.

. the waste gases have a temperature of around 290°C to 400°C [554°F to 752°F]. 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 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%. As a function of the process. depending on the number of stages and capacity flow ratio. Figure 2 . Figure 2 shows a schematic representation of a cement rotary kiln system with a cyclone preheater and waste gas utilization.May 1992 Specification Vt 10 Page 12 Both with cyclone preheater systems and with grate-type preheater systems.Schematic representation of a cement rotary kiln system with cyclone preheaters and waste gas utilization. the process gas from the rotary kiln has a temperature of about 1000°C to 1200°C [1832°F to 2192°F]. Upon leaving the cyclone preheater.

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

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

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

3. the mass flow of the kiln feed. out. The essential operating data (for instance. 3. in cases of major changes vis-à-vis normal operations. by changing the mixed bed). composition of the kiln feed. The latter has to be safeguarded by means of appropriate measures. type of combined drying and grinding operation) should already have been determined during the planning phase of the performance test and.May 1992 Specification Vt 10 Page 16 3. 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. the energy fraction of the secondary fuel. Possible criteria for interrupting the performance test should also be laid down in advance.2 Duration of the performance test A kiln performance test should last for at least 24 hours. partial load). the performance test should preferably last 72 hours. should already have been established one week prior to the start of the performance test. preferably 48 or 72 hours. If the type of combined drying and grinding operation changes (in. types of fuel. .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.

3.5 ≥ 0.3 Measuring methods 3. the sampling amount and the sampling frequency have to be adapted to the prevailing test conditions.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.5 ≥ 0.1.Sampling amount and sampling frequency in rotary kiln performance tests. 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. then this non-homogeneity has to be taken into consideration by enlarging the scope of the sampling.3. that is to say.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 . for instance.1 Solid substances 3. The safety regulations that apply in such cases must be observed. Table 1 . 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. which could give rise to insufficient blending by the time the sampling site is reached. conveyor belt. Thus.May 1992 Specification Vt 10 Page 17 3. at the discharge end of the conveyors (for instance. the hot-meal pipe of a cyclone). The samples are taken from the belt (for instance.5 ≥ 0.5 ≥ 0. Sampling amount in kg ≥1 ≥ 0. apron conveyor).5 ≥ 0. screw conveyor) or from the meal pipes (for example.5 ≥ 0. when two partial streams having different concentrations of the component to be examined are combined. Table 1 shows an example of a sampling plan. every 12 hours. bucket elevator.

tertiary air dust) can also be taken by means of isokinetic suction of a partial stream.May 1992 Specification Vt 10 Page 18 A partially decarbonated kiln feed should be cooled off rapidly and air-tight so as to avoid. . As a matter of principle. As a matter principle. clinker). further decarbonation of CaCO3 or a residual burn-out of carbon. the average sample is subsequently formed on the basis of the pre-dried individual samples. This ensures that the best suited decomposition and analysis methods will be selected for each particular case. 3. For practical reasons. homogenized and combined to form a weighed average sample for the duration of the performance test. for example. In this process.3. the laboratory should be informed about the source and presumed composition of the samples. the samples can also be taken at time-staggered intervals.1. in the raw material) should be determined on larger individual samples. Samples of solid substances from flowing gases (raw gas dust. care should be taken to ensure that the suction is representative. High levels of moisture (for instance. The individual samples are pre-comminuted (for example.2 Analysis Table 2 shows an example of an analysis plan. the individual and average samples should be stored air-tight in order to avoid a falsification of the H2O and CO2 contents.

ISO 3733 DIN EN 7 DIN 51721 1) DIN EN 41. ISO 1928 DIN 51777.Analysis and analysis method for rotary kiln performance tests. 0. tertiary air dust sample preparation loss on ignition . ISO 348. ISO 562 DIN 51721. ISO 1171 DIN 51729 DIN 51720. ISO 351 DIN 51727. ISO 331. 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 1015 DIN 51719. ISO 2309 DIN 51900.May 1992 Specification Vt 10 Page 19 Table 2 . ISO 579.09 mm (for CaOfree 0. Material Coal dust Analysis sampling. DIN 51400 DIN 51722 1) subtraction DIN 51872 DIN 51856 DIN 51855 Grinding for complete passage through the sieve. ISO 609. ISO 687. ISO 333 subtraction DIN 51570 (Parts 1 to 3) DIN 51900.063) 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 1928 DIN 51718. ISO 587 DIN 51722 (Part 1). ISO 1988. ISO 352. ISO 589. ISO 334. ISO 625 DIN 51724 (Part 1).

absorption) a) method according to Franke b) method according to Schläpfer and Bukowski Depending on the boundary conditions.1% by weight of LiF + 8. dilution of 1:10). flame photometry (emission.L. K2O and Na2O with other analytical methods. Na2O CaOfree a) fluxing agent tablet (≤ 1000°C [1832°F]. 100% by weight of Li2B4O7 as the decomposition agent. hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7. 90% by weight of Li2B4O7 + 10% by weight of LiF as the decomposition agent.9% by weight of SrO + 2% by weight of V2O5 as the decomposition agent. dilution of 1:5 to 1:20). Smith decomposition. analysis including SO3 and alkali b) fluxing agent tablet (1050°C [1922°F].May 1992 Specification Vt 10 Page 20 X-ray fluorescent full analysis 2) Cl – (including Br and I) 3) Σ SO3 K2O. Measurement of the SO2 by means of an IR detector or else iodometrically J. 81% by weight of Li2B4O7 + 8. determination of SO3. dilution of 1:5). determination of SO3. K2O and Na2O with other analytical methods. subsequent correction of the results c) fluxing agent tablet (1200°C [2192°F]. the results can deviate from one method to another . 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.

determination of SO3. dilution of 1:5 to 1:20). 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 . 90% by weight of Li2B4O7 + 10% by weight of LiF as the decomposition agent. determination of SO3. subsequent correction of the results c) fluxing agent tablet (1200°C [2192°F]. 81% by weight of Li2B4O7 + 8. K2O and Na2O with other analytical methods. dilution of 1:5). 0. 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. 100% by weight of Li2B4O7 as the decomposition agent. analysis including SO3 and alkali b) fluxing agent tablet (1050°C [1922°F].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. drying at 110°C [230°F]. K2O and Na2O with other analytical methods.1% by weight of LiF + 8. 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].May 1992 Specification Vt 10 Page 21 Kiln feed sample preparation CO2 Grinding for complete passage through the sieve. dilution of 1:10).

Smith decomposition.L. 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. hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7. 0. absorption) Dissolution with hydrochloric acid containing SnCl2 in the presence of Cr (metallic). thermal reaction of the carbon compounds in an oxygen stream a) gravimetric b) coulometric c) IR detection . Na2O J. iodometry Grinding for complete passage through the sieve.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. Measurement of the SO2 by means of an IR detector or else iodometrically K2O. flame photometry (emission.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.

Smith decomposition. 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. dilution of 1:5 to 1:20). determination of SO3. K2O and Na2O with other analytical methods. pick-up in a cooled (≤ 15°C [59°F]) ammoniacal ZnSO4 or CdCl2 solution.May 1992 Specification Vt 10 Page 23 X-ray fluorescent full analysis 2) a) fluxing agent tablet (≤ 1000°C [1832°F]. dilution of 1:10). determination of SO3. dilution of 1:5). iodometry Cl – (including Br and I) 3) Σ SO3 K2O. flame photometry (emission. Measurement of the SO2 by means of an IR detector or else iodometrically J. 100% by weight of Li2B4O7 as the decomposition agent. 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. K2O and Na2O with other analytical methods. 81% by weight of Li2B4O7 + 8.9% by weight of SrO + 2% by weight of V2O5 as the decomposition agent. Na2O S2– . 90% by weight of Li2B4O7 + 10% by weight of LiF as the decomposition agent.1% by weight of LiF + 8. hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7. analysis including SO3 and alkali b) fluxing agent tablet (1050°C [1922°F]. absorption) Dissolution with hydrochloric acid containing SnCl2 in the presence of Cr (metallic).L.

pick-up in a cooled (≤ 15°C [59°F]) ammoniacal ZnSO4 or CdCl2 solution.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. Smith decomposition. hydrofluoric acid decomposition / perchloric acid decomposition (observe the safety regulations!) or melt decomposition (< 1000°C [1832°F]) with Li2B4O7. 0.L. gravimetric b) thermal reaction of the sulfur compounds with additives in the oxygen stream. Measurement of the SO2 by means of an IR detector or else iodometrically Σ H 2O Corg K2O.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. Na2O Cl – (including Br and I) 3) Σ SO3 S2– Dissolution with hydrochloric acid containing SnCl2 in the presence of Cr (metallic). 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. thermal reaction of the carbon compounds in an oxygen stream a) gravimetric b) coulometric c) IR detection J. iodometry . flame photometry (emission.

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

shipping scales).1.4. a second clinker weighing procedure is not necessary if it is ensured that all of the dust mass flows remain constant. It results from the component balance of the sum of the non-volatile substances (see Section 4.3). the fuel energy consumption is usually balanced by means of a comparison of the energy output with the energy input (see Section 4.1. For this reason. care should be taken to ensure that the cleaning of the filter is switched to continuous operation before the dust is discharged. 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. also see the VDZ Specification titled “Dust quantity measurements in cement plants” [17]). The following relationship applies: Fuels: Fuels are weighed on industrial scales which have been previously adjusted. the dust mass flow is determined by means of an isokinetic partial stream suction (in this context. . Here. Translator’s note: See Section 8 for the list of abbreviations used in the formulas.1). the precision levels achieved in this manner are often not sufficient for evaluating the kiln system. If weighing is not possible. Dust: Dust is preferably weighed on calibrated scales (for example. However.

O2.3. 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]). Table 3 . the time intervals at which the probes need to . O2. CO CO2. CO – – – – – – Discontinuous measurement is often sufficient.2 Gases For the gas analysis. CO 1) CO2.Volume flow measurement and gas analysis in rotary kiln performance tests. 3. Table 3 shows an example of a measurement plan. O2. in the case of double-string cyclone preheaters. In the gas downstream from the burning area. there are also differences in the individual strings. more information can be obtained from the VDZ Specification titled “Continuous gas analysis in cement plants” [20]).1 Sampling In the raw gas. Moreover. 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.May 1992 Specification Vt 10 Page 27 3. CO CO2.3. O2. various gas compositions can occur over the cross section of the duct. O2. in the bypass gas and in the gas downstream from the burning area.2. CO 1) CO2.

2 Analysis The gas analysis should be carried out continuously. the sampling probe should be built laterally into the refractory brickwork. it is not possible to specify a representative measuring site.3. cooler vent air). that is to say. The probe should be cooled.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 CO2.5 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. With volumes flows that fluctuate markedly (for instance.2. Since the measuring site is also frequently exposed to falling material. At the very least. the process gas usually displays great differences in concentration. In the rotary kiln inlet.2. the pitot tube should be installed in the . without injection water or scrubbing water. So as to prevent falsifications of the concentration values due to the scrubbing out of individual gas components. 3.3.3 Volume flows The volume flows are primarily measured with a pitot tube. Sampling sites in the upper third of the rotary kiln cross section are recommended. For this reason. The sampling opening should project about 0. O2 and CO are required. 3. both with respect to location and to time. The probe in the gas downstream from the burning area should be cooled. the measuring gas should be sampled dry.

b) fan characteristic curves (only possible for fans with adjustable rotational speeds). deflection of the gas upstream from the measuring site. only possible if clean gases of the kiln can be detected in their entirety. . 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. 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. There are three methods for measuring the volume flow of the cooler intake air: a) inlet nozzles (often very imprecise). The bypass gas volume flow prior to the admixture is derived from the gas analysis before and after the admixture of the cooling air. b) calculation on the basis of a CO2 and an H2O balance of the kiln system (imprecise when secondary fuels are used) [30]. this is often very imprecise). expensive but accurate). substantial pressure fluctuations or a high amount of dust [for instance. 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. 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). for example. > 50 g/m³].

.3.2 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. which changes as a function of the temperature. Moreover.3. 3.3). 3.1. The cross-sectional surface area is either measured or estimated.3 Liquids 3. of the kiln feed is derived from the nominal data of the fan. the result that is read off the meter has to be corrected by means of a calibration curve. it is necessary to take into account the density. 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.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. Heating gas that has been measured volumetrically has to be converted to the standard conditions.3.1 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. In order to determine the actual volume flow that passes through. if applicable.3.3. The conveying air volume flow of the coal dust and.2.

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 . kiln feed) Measuring device compensation temperature in adiabatic vessel.Temperature measurement in rotary kiln performance tests. hot meal) bypass dust raw meal (for instance.g. Measuring site cold clinker hot clinker kiln feed in the preheater (e.May 1992 Specification Vt 10 Page 31 3.9) partial-radiation pyrometer (ε = 0. Table 4 .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 .4 Temperatures Table 4 shows the example of a measuring plan.9) partial-radiation pyrometer (ε = 0. 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.rotary kiln surface temperature .9) partial-radiation pyrometer (ε = 0.

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

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

Table 5 . platinum resistance thermometer) black body radiator tungsten band lamp (only above 500°C [932°F]) liquid pressure gage (for instance. . 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. Table 5 provides an overview of possible comparative measuring methods. Checks and corrections should be documented and should be indicated on the measuring equipment used. In addition to regularly checking the status and settings during the performance test. Status checks should be made every hour and setting checks should be carried out at least before and after the performance test.3. it is also necessary to routinely replace wearing parts as preventive maintenance and to conduct function tests with comparative measured values (calibration).May 1992 Specification Vt 10 Page 34 3.9 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. 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. 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. together with the date.

Figure 6 shows the balancing space of a kiln system with a cyclone preheater (V). as a result of which a separate presentation has not been provided. since there are interactions between both of these as a result of chemical reactions. the gas and solid substance mass flows should be balanced together.May 1992 Specification Vt 10 Page 35 4. tertiary air duct (T).1 Evaluation of kiln performance tests Balancing of the entire system When the mass balance is drawn up. With other kiln types. rotary kiln (D) and cooler (K) with the mass and energy flows that exceed the balance limit as an example. calcinator (C). 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. the changes are only gradual. .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.

while the formula sign V designates the volume flow related to standard conditions after removal tr of the water-vapor fraction. 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.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. C & VFl. 1013 & hPA). .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]. D & VFl.

S & ∆H V. D & H Fl. V & ∆H R. K for the uncoupled heat (cooler) .C & H Fl.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. 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.

C & Q W.May 1992 Specification Vt 10 Page 38 & ∆H R. 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) . V & Q W.CO & Q W.T & Q W. D & 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.

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

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. 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 analogously: The kiln feed mass flow necessary for the clinker burning process then results from Equation (2): As an approximation.

1 Dry gas Minimum air volume flow In order to calculate the dry. burner air (secondary burner). cooler intake air (see Section 3.3). sulfide sulfur) of the kiln feed also have to be taken into account. . conveying air (kiln feed). the combustible components (organically bound carbon. minimum air volume flow.1. For this reason.1 4. the burning of all combustible substances has to be taken into consideration.2. in addition to the fuel mass & & flows m B7 and m B3 . bypass gas.2.1. burner air (main burner).2.May 1992 Specification Vt 10 Page 42 Analogously. infiltrated air. cooler vent air (if present). the following applies: 4.1.2 Gas volume flows Measured quantities: fuel (main burner). secondary air. fuel (secondary burner).3.1. raw gas. Operands: 4.

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

the numerical value equation is the following: For oil and coal. lmin can be calculated as an approximation using the lower calorific value of the fuel *).May 1992 Specification Vt 10 Page 44 Accordingly. *) 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. Calorific value-related combustion gas quantities of secondary fuels can differ markedly from the indicated uppermost and lowermost values.

3 71.021 0.7 22.5 0.332 0.347 0.9 29.382 0.4 8.099 0.92 Coal dust U L 0.5 23.1 0.7 0.098 0.2.024 0.2 19.4 0.370 0. Analyses (raw) in % by weight: L water ash C H O N S 8.392 0.1.8 11.0 25.4 0.0 8.101 0.3 21.05 U 2.339 0. M = mean value.1 27.341 0.9 19.1 65.022 0.339 0.6 7.7 0.096 0.094 0.4 4.8 4.1.3 2.8 3.9 57.6 4. U = uppermost value 4.374 0.2 Lignitic coal dust M 11.6 0.1 3.5 59.9 16.76 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 20.373 0.096 0.May 1992 Specification Vt 10 Page 45 Table 6 .4 56.35 M 1.2 1.016 0.7 2.5 0.22 0.3 1.2 4.6 21.011 0.344 0.80 14.7 3.0 2.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.2 Air proportionality factor The following applies in general: .014 0.375 L = lowermost value.7 4.3 61.

the gas velocity has to be multiplied by a dimensionless factor which lies between 0. the following applies: . Consequently. the equation yields an excessively high gas velocity. as a rule related to dry measuring gas): The expression in the denominator of the lower fraction corresponds to N2.2. The following applies theoretically: Equation (17) presupposes a frictionless flow and an incompressible medium. In reality. neither is present. Here. for actual practice. 4.1.3 Infiltrated air at the kiln hood The volume flow of infiltrated air at the kiln hood can be roughly calculated using the Bernoulli equation. As a consequence. it has been set at 0.1.6 and 0. Thus.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.75.9.

) in kg/m³ = open cross-section area in m² ρL ρ L. tr = volume flow of infiltrated air in m³ (s.1. D. tr can only be calculated very imprecisely.May 1992 Specification Vt 10 Page 47 & With v = V/F for the gas velocity and with the density ratio ρ L /ρ L.1.N F & VFl.2. the density of the ambient air can be taken as the basis for ρ L.)/s As a simplification.c. 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.N for dry air (the water present in the air is ignored here). 4.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.

1.2.5 Cooler intake air The following applies for the volume flow of the cooler intake air (also see Figure 12): 4.1.6 Raw gas 1.2. .S stems from the decarbonation and the combustion of organic components of the kiln feed. The following applies: wherein and & m C. eff.1. Calculation on the basis of the CO2 balance The following applies for the CO2 balance: & VCO 2 . S according to Equation (8).1.May 1992 Specification Vt 10 Page 48 4.

& VCO 2 .01 · 10 – 5 m³ of CO2/kJ for lignitic coal 2 and µCO 2 = 4.87 · 10 – 5 m³ of CO2/kJ for coal.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 49 & VCO 2 . The following applies: If the elementary analysis is not available. B stems from the combustion of the fuel. Equation (26) can be employed: wherein µCO = 5.

8 Gas downstream from the rotary kiln (kiln inlet) & VG6.1. A gas analysis downstream from the burning area is needed for this purpose. tr can be calculated according to [30].1.1. 4.May 1992 Specification Vt 10 Page 50 2. 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.2.1. tr is calculated according to Equations (30) or (31) on the basis of the raw gas volume flow.2. .7 Gas downstream from the burning area & VG2. the calculated values are often very imprecise. CO2 balance: O2 balance: 4. Due to non-representative gas analyses in the kiln inlet.

the following applies for the moisture volume flow of the air: 4. The following applies: wherein xD = water content in kg of H2O/kg of dry air = relative humidity ϕ p and ps (ϑ L.1.2.1 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 4.1.2.May 1992 Specification Vt 10 Page 51 4.U) = saturation pressure of the water vapor in Pa = ambient pressure in Pa Then.2 Water from the kiln feed .2.2.1.2.

1 Moist gas Air The following applies in general: Altogether.2.4 Injection water 4.3 Water from the fuel 4.2. .1.3. λ G1 should be calculated with the gas concentration values which would result after the mixing of raw gas and bypass gas.1.2.3 4.1. is fed into the kiln system.2.2.2.May 1992 Specification Vt 10 Page 52 4.1.

water.2. VH 2 O.1 4. fuel (secondary burner).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.1. 4.4. 4.1.1. 4.3.G5 often equals y H 2 O.1 Energy input Fuel Combustion: .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. y H 2 O.1.4 Energy flows Since standard reaction enthalpies and calorific values are related to 25°C [77°F].10 often equals zero.G6 .1. With grate-type coolers.3 Liquid mass flows Measured quantities: fuel (main burner).4.1.

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

.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 .

Mean specific thermal capacity cp of the fuel gas components (reference temperature = 25°C [77°F]).270 1.918 5.582 2.717 5.2 Kiln feed Sensible enthalpy flows: .402 2.c. s. The following applies here: Table 7 .1.555 1.631 4.4. Fuel gas component Specific thermal capacity cp in kJ/m³ (s.519 2.602 methane ethylene acetylene propadiene n-butane propylene 1) CH4 C2H4 C2H2 C3H4 C4H10 C3H6 H 2S 1.c.246 3.) K 25°C [77°F] 100°C [212°F] 1. = under standard conditions 4.156 4.579 4.700 2.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 7.1.113 1.172 5.137 2.817 2.579 200°C [392°F] 1.101 1.985 2.531 hydrogen sulfide 1) Use C3H6 use for CmHn.

.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 . .

3 Air Sensible enthalpy flows: wherein (For the calculation of cp. As an approximation. j according to Equations (85) through (87).1.1.May 1992 Specification Vt 10 Page 60 4. also see Figure 10).4. it is also possible to use the specific thermal capacity of dry air for the calculation. The following applies in this case: .

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

2. with the standard reaction enthalpies needed in each case (for the additional reaction enthalpies.4. Table 8 is a compilation of the main reactions that take place during the clinker burning process.1 Energy output Reaction enthalpy of the kiln feed For the calculation of the reaction enthalpy of the kiln feed. .4. the degradation reactions of the starting materials and the reactions for the formation of the clinker phases have to be taken into account.1.4 Injection water As a rule. This is particularly true of the intake air fans and of the kiln drive.1.4. 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. The actual reaction enthalpies to be employed result from balance equations. C2S. it is first necessary to calculate the contents of C3S.4. 4.1. C4AF in the clinker. C3A. In simplified form. see [22.1. The data shown in the two right-hand columns are each related to the substance in the left-hand column.2 4. the following applies: 4.1.5 Mechanical performance Within the balancing space.May 1992 Specification Vt 10 Page 62 4. For this purpose. 23 and 25 through 27]). the sensible enthalpy flow of the injection water can be ignored.1.

. Formation of the clinker phases 7. 2. 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. 8. Formation of K2SO4 1) α-K2SO4 Related to the substance in the left-hand column. 9. 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. 5.Reactions of the kiln feed and reaction enthalpies (298 K) during the production of Portland cement clinker. Organic clay components (relative to C) MgCO3 dissociation CaCO3 dissociation Pyrite (FeS2) 2 FeS2 + 5½ O2 α-Fe2O3 + 4 SO2 II.May 1992 Specification Vt 10 Page 63 Table 8 . Formation of C3S 11. 1. 4. 6. Reaction enthalpy 1) at 298 K kJ/kg kJ/mole Reaction Reaction equation I.

1.4.May 1992 Specification Vt 10 Page 64 4. C3A and C4AF in the clinker For normal Portland cement clinker or tertiary air dust.85 ⋅ x K 2 O. S10 . C3A and C4AF (TM > 0.2.1 C3S.1. 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. S10 > 0. C2S. C2S. The following applies: For x SO 3 .85 ⋅ x K 2 O.292 ⋅ x Na 2 O. the following applies: For x SO 3 . which consists primarily of C3S. the following applies: The following results from this: . S10 ≤ 0. S10 + 1. S10 . S10 + 1.292 ⋅ x Na 2 O.64). In this context. the clinker phases can be calculated according to Bogue [45 and 46].

2. the following applies in the case of 1.2 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.1.274 · x CO 2 > x CaO : and . Assuming that the CO2 is primarily bound to the CaO.May 1992 Specification Vt 10 Page 65 4.4.1.274 · x CO 2 ≤ x CaO : and in the case of 1.

1. St5 = 0 5) The formation enthalpy of C4AF and of C12A7 in the bypass dust is negligibly small.1. it is assumed that Al2O3 and Fe2O3 have completely reacted with CaO to form C4AF and C12A7.1. St5 = 0 4) xS.2.3 CaCO3 and C2S in the bypass dust The content of CaCO3 results from the content of CO2 in the bypass dust.St5 is made according to Equations (55) or (56). St5 = 0 2) xC. The following then applies: The calculation of x CaOSO3 .4.2.4.4 Balance equations The balance equations are based on the following assumptions and simplifications: 1) x H 2 O. For purposes of calculating the C2S content. St5 = 0 3) x MgCO3 . 7) The fuel ash is present in the form of oxides.1. 4.May 1992 Specification Vt 10 Page 66 4. . 6) The starting materials as shown in Table 8 are present.

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: .

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

3 Waste gas losses Raw gas: wherein The following approximation equations apply for the essential components of the waste gas (also see Figure 10): .4.May 1992 Specification Vt 10 Page 70 The following applies to the sum of the reaction enthalpies of the kiln feed: 4.2.1.2.2 Water evaporation Evaporation enthalpy for cooler injection water: 4.1.4.

1.May 1992 Specification Vt 10 Page 71 Bypass gas: Cooler vent air: 4.2. ϑ St1 = ϑ G1).4.1.4 Dust losses Raw gas dust: (for cSt1.4.2. . see Section 4.1.

4.5 Incomplete combustion In cases of high energy losses due to incomplete combustion (for example. 4.1. see Section 4.1.2.May 1992 Specification Vt 10 Page 72 Bypass gas dust: (for cSt5.1. yCO. ϑ St5 = ϑ G5).2.6 Clinker . an analyzer that operates continuously should be used for the calorific value of the gas for the balancing. see Equation (95).1. 4. ϑ St12 = ϑ L9).4.G1 > 0. Discharged tertiary air dust: (for cSt12.2. Losses due to cooler vent air dust are usually negligibly small.4.01).

.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 .

0 .m of the tube element and of the ambient temperature ϑ L. the heat flow of individual tube elements is calculated on the basis of the mean circumferential temperature ϑ W.4.May 1992 Specification Vt 10 Page 74 4.U: wherein and αconv results from approximation equations.1.2.3 a0 = 4. The following applies for wind velocities w ≤ 2 m/s: wherein a = 0.7 Radiation and convection Rotary kiln: First of all.

May 1992 Specification Vt 10 Page 75 a1 = 3.27 5.83 0.227 .75 7.25 6.92 0.70 b1 0.93 0.0.0.00 b1* .076 Scope of validity: w ≤ 2 m/s 100°C [212°F] ≤ ϑ W.75 4.66 5.18 2.0.25 5.227 .75 6.97 1.98 5.11 2.25 6.11 5.85 a3 = 0.25 5.05 5.0.25 3.40 5.75 5.25 4.79 0.98 1.75 5.75 4.5 a2 = -0.83 b0 4.238 .25 4.233 .48 5.75 3.19 5.220 .236 .37 2.25 3.27 2.244 .88 0.243 .73 0.0.0.75 ≤ Da < 3.0.97 0.75 6.25 b 2.m ≤ 500°C [932°F] 2 m ≤ Da ≤ 8 m 10°C [50°F] ≤ ϑ L.219 .93 1.0.U ≤ 30°C [86°F] The following applies for wind velocities w > 2 m/s: wherein Diameter range in m 2.05 1.0.87 1.

75 m ≤ Da ≤ 7.m ≤ 500°C [932°F] 2.9 σ = 5.m = mean surface temperature in K TL.U = ambient air temperature in K & The radiation and convection loss flow Q W.25 m 10°C [50°F] ≤ ϑ L.May 1992 Specification Vt 10 Page 76 Scope of validity: 2 m/s < w ≤ 10 m/s 100°C [212°F] ≤ ϑ W. 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].U ≤ 30°C [86°F] The following applies for αStr: wherein ε W = 0.67 · 10 – 8 W/(m² · K4) TW. .

Moreover. 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. an empirical factor of 1. the satellite temperatures as well as the temperatures in the interstitial spaces.May 1992 Specification Vt 10 Page 77 Cooler: Equations (96) through (101) can be employed directly for the rotary cooler.m is calculated as an arithmetic mean value of all of the individual temperature meas- ured values calculated over the circumference. . it is recommended to employ the imaginary surface area of a cylinder surrounding the satellite cooler as the heat-transfer surface area. For satellite coolers. In such cases. The mean circumferential temperature ϑ W. that is to say.6 should be used for the calculation of the heat flow. the surface temperature should be measured only on the side facing away the wind. 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). Equation (104) yields a heat loss flow that is too low.9 At higher wind velocities.

8 Uncoupled heat The following applies as an approximation for the heat uncoupling via a cooling chute: wherein c H 2O ≈ 4. 4. The following applies for the heat uncoupling through the cooling of the cooler circulation air: .4.2.May 1992 Specification Vt 10 Page 78 Preheater and calcinator: Equations (104) should be employed accordingly.1.2 kJ/kg K for 0°C [32°F] < ϑ < 100°C [212°F]. Tertiary air duct: Equations (96) through (102) should be employed accordingly.

1. Since the reaction enthalpy flow of the fuel as energy input can often only be determined very imprecisely. Usually the input and the output do not offset each other completely. however. it is also designated as fuel energy consumption. it should be calculated on the basis of the difference between the energy output and the other energy input values according to Equation (109). the energy input and the energy output are compared to each other. . so that a balance deficit remains which.May 1992 Specification Vt 10 Page 79 4.3 Energy balance The following applies for the sum of the energy input and energy output: and With kiln performance tests. should not make up more than ± 3% of the total energy output.4.

the hot clinker temperature can only be measured in a very imprecise manner.2 Balancing of the partial systems 4. For this reason.May 1992 Specification Vt 10 Page 80 4.2. Figure 12 .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. . Moreover.Balancing space of the cooler with the incoming and outgoing mass and energy flows. the fact that considerable dust circulation can occur between the rotary kiln and the clinker cooler has to be taken into account.

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. Thus. for example.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. the exhaust air volume flow. 10 for the cooler injection water . has to be set as zero. several exhaust air flows can be discharged from the cooler. In the case of rotary and satellite coolers. in contrast.

May 1992 Specification Vt 10 Page 82 Incoming energy flows: & H S8 & H L10 & H H 2 O. K & Q K. 10 Pmech. H 2 O for the evaporation enthalpy of the cooler injection water . 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 & ∆H V.

this value can rise to more than 200 g/m³.2. discharged and returned tertiary air dust. secondary air dust.1 Solid substance mass flows clinker. 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. the dust concentration is about 30 to 50 g/m³. hot clinker. The following applies for the hot clinker mass flow: . With a “clear” kiln discharge. the dust concentration in the secondary air should be estimated.1. In the case of a pronounced dust circulation.May 1992 Specification Vt 10 Page 83 4. 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.

Measured quantities: Operands: The secondary air volume flow results from Equations (20) and (38). The water vapor from the water injection should also be taken into account.3.May 1992 Specification Vt 10 Page 84 4.1.3 Energy flows A reference temperature of 25°C [77°F] is selected for the calculation of the individual energy flows. 4.2. cooler intake air. secondary air. .2. and the cooler intake air volume flow results from Equations (21) and (38).3. tertiary air.1.2.1 Hot clinker (cS8 according to Equation (95) or Figure 11).2.1 Energy input 4.1.2 Gas volume flows cooler vent air (if present). 4.1.1.

1.1.4. clinker dust See Section 4.3. .3.2.6.4 Mechanical performance 4.2.1.3. 4.2.1.2 Cooler intake air 4.1.1.3.4.2.3 Injection water See Section 4. This error increases as the temperature drops and the particle size increases.2 Energy output 4.2.1 Clinker.4.1. the calculated hot clinker energy flow is fundamentally too low.1. Therefore.2.1. 4. the hot clinker energy flow is associated with a high level of uncertainty.1.May 1992 Specification Vt 10 Page 85 Only the surface temperature of the hot clinker can be measured by means of instruments. Therefore.3.1.2.

3.2. tertiary air See Section 4. secondary air.7. 4.1. As a rule.2.May 1992 Specification Vt 10 Page 86 4.2.4 Cooler vent air.2.1.1.3 Uncoupled heat See Section 4.2.3. The following then applies: . 4.3 Energy balance If a reliable measured value for the secondary air temperature is available.2.2. 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.1.2.3.2.2 Radiation and convection See Section 4.2.1.1.2.3.3.1. with sound-over-time measurement or a suction-type thermometer).2.2. the hot clinker & enthalpy flow H S8 can be calculated on the basis of the energy balance.4.5 Water evaporation See Section 4.1.4.1. 4.8.2.4.3. 4.4.

1 Pre-cooling zone For the evaluation of the clinker cooler.4). in the so-called pre-cooling zone.1.1. . it is necessary to take into account the fact that the first cooling of the clinker already takes place inside the rotary kiln.2.4.4 Evaluation quantities 4.Balance limits of the burning area and cooling area. Figure 13 .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.2.1. 4. of the pre-cooling zone as well as of the cooler with the example of a kiln system with a rotary cooler. which is where radiation and convection losses occur.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.

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

U) stands for the specific enthalpy at the ambient air temperature. & The energy loss flow Eloss. In this context.4.1. cooling area is the sum of the heat and enthalpy flows that are released by the cooler into the atmosphere. h(ϑ L.May 1992 Specification Vt 10 Page 89 4. for the clinker and cooler vent air. which has to be replaced by fuel energy.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: .2.2. The fraction that is not recovered constitutes the energy loss of the cooling area.4.2 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. In this equation.3 Cooling area efficiency For comparisons. 4. 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.

2. at this site. 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. the equilibrium temperature of the calcium carbonate dissociation sets in at the lowermost stage.1. In contrast. 4. 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. since it is in these aggregates that the essential reactions of the kiln feed and of the fuel take place. which should prevail at the site of transition from the burning area to the cooling area.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). 4.4 Cooler efficiency The efficiency values of the cooler are described in the VDZ Specification titled “Gratetype.2. the calcinator is often balanced together with the rotary kiln. Thus. a sintering temperature of 1450°C [2642°F] was presupposed. irrespective of the burning or pre-heating conditions. the waste gas acquires a chemically determined temperature that is very well-suited for determining this balance limit. satellite and rotary coolers in the cement industry” [33].May 1992 Specification Vt 10 Page 90 For the sake of harmonization.3.2. The lowermost stage of the cyclone preheater counts as part of the calcinator. The limitations outlined in Section 4. With degrees of precalcining below approximately 90%. The cooling area efficiency makes it possible to thermally evaluate the cooling in the entire process. .1 apply when using the formulas.1.1.4.

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

the degree of precalcining can also be determined on the basis of the solid substance analyses. & Provided that the raw gas dust mSt1 has the same chemical composition as the kiln feed & mS1 . It is designated as the apparent degree of precalcining ϕ apparent.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. The actual degree of precalcining ϕ actual is defined according to Equation (120) as the ratio of the carbon dioxide mass flow & mCO 2 . In this context.2.1 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. As a simplification. and by ignoring the dust in the rotary kiln inlet gas.2. 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): .May 1992 Specification Vt 10 Page 92 4. 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. More details on this can be found in literature reference [30]. VC that has escaped from the kiln feed in the preheater and in the calcinator to the & carbon dioxide mass flow mCO 2 .

however. the following relationship exists between the apparent and the actual degree of precalcining: 4. 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. As a rule. If the dust mass flows mSt4 and mSt6 have been completely decarbonated. 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.3 Preheater (only for kiln system with cyclone preheater) Figure 15 shows the balancing space of the preheater.May 1992 Specification Vt 10 Page 93 & & In reality.2. For this reason. the apparent degree of precalcining ϕ apparent calculated according to Equation (121) generally simulates a higher & & decarbonation of the kiln feed. .

May 1992 Specification Vt 10 Page 94 Figure 15 . 4. the following applies for the degree of separation: .Balancing space of the preheater with incoming and outgoing mass and energy flows.3.1 Degree of separation of individual cyclone stages Figure 16 shows the incoming and outgoing solid substance mass flows of a preheating stage.2. According to it.

& & Equations (124) and (125) yield the mass flows mS. 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. . i and mSt.May 1992 Specification Vt 10 Page 95 & & The mass flows mS. In this context. i +1 result from the mass and energy balance of the ith stage. i and mSt. it is assumed that there is temperature equilibrium between the gas and the kiln feed in the cyclone stage. i stands for the radiation and convection loss flow of the ith cyclone & stage and ∆H R. As a rule. i stands for the reaction enthalpy flow of the raw material in stage i. Q W. this is the case with the uppermost cyclone stages (ϑ < 600°C [1112°F]).

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

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

May 1992 Specification Vt 10 Page 98 5. 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. .

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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.

(for ϑ S = 1338°C [2440.4°F] and TM > 1. (for ϑ S = 1400°C [2552°F]). . (for ϑ S = 1450°C [2642°F]).38).May 1992 Specification Vt 10 Page 102 The sulfatization degree (SG) indicates the percentage of alkalis in the clinker.38).4°F] and TM < 1. 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.

the constitution and distribution of the clinker compounds and their coalescence. constitution and distribution of the clinker compounds. the structure.May 1992 Specification Vt 10 Page 103 xMgO enters into the formulas with xMgO = 0. 6.5 Phase composition The phase composition of the clinker can be calculated on the basis of the values of the chemical analysis. 6. .02 at the maximum.6 Microscopic examination The microscopic examination of the clinker provides information about the type. at higher contents. according to equations (54) through (60). For these reasons. the calculation only provides an approximation of the actual clinker composition [7]. that is to say. 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. for instance. Whereas the type of the compounds depends primarily on the chemical composition of the kiln feed. xMgO = 0.02. provide information about the preparation of the raw material mixture and about the conditions during the burning and cooling of the clinker. However. not only at the sintering temperature but also and especially when they crystallize during the cooling procedure.

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. . They are of decisive significance for the optimization of operations.

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

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 4.2.1.2.c.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.) / kg of fuel mass flow in kg/s molecular weight in kg/mole stage number in the cyclone preheater. chamber number in the grate-type cooler pressure in Pa .May 1992 Specification Vt 10 Page 106 8.7) total alkali fraction in kg/kg factor (Section 4.4.c.4.) 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.

relative humidity .c.) / 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 = 5.67 · 10 – 8 ϕ W m2 K 4 degree of precalcining.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.

1. 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. vapor under standard conditions (0°C [32°F] and 1013 hPA) effective balance input inlet . carbon rotary kiln.1.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.4) 0 through 12 balance limits 1 preheater (kiln feed.2.4.

sulfide sulfur satellite cooler dust radiation (rad) actual theoretical .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. loss on ignition surrounding cylinder variable cooler.) (0°C [32°F] and 1013 hPA) sum of non-volatile substances at constant pressure reaction clean gas grate-type cooler saturation apparent solid.c. uncoupled clinker convection air mean value maximum mechanical minimum standard conditions (s.

atomic water potassium oxide potassium sulfate magnesium carbonate . 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.May 1992 Specification Vt 10 Page 110 tr T U Um V loss pre-cool W dry tertiary air duct ambient circulation air preheater.

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 .

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

Stoffmengen und Hilfsgrößen. J. pp. Execution of kiln performance tests [16] VDZ-Merkblatt “Mengenmessung von Gasen durch Geschwindigkeitsmessung”.: Messen. Steuern und Regeln in der Chemischen Technik. H. Messung von Stoffeigenschaften und Konzentrationen. Springer-Verlag..: Brennverfahren. B.: Precalciners today . July (1985) pp..: Einfluß des Ofensystems auf die Klinkereigenschaften. S.. Vol. [15] Rosemann... und Winkler.: Technologische Probleme beim Brennen des Zementklinkers.1982.: Theoretische und betriebliche Untersuchungen zum Brennstoffenergieverbrauch von Zementofenanlagen mit Vorcalcinierung. Düsseldorf 1961. Th. Verein Deutscher Zementwerke e.. O. Steuern und Regeln in der Chemischen Technik. Sturm. 3. J. Zement-KalkGips 38 (1985) Vol. O. 48.. [14] Bonn.a review.M.V. Rock Products. .1987. Berlin 1980.2 Technical literature references Description of the clinker burning process [11] Sprung. Band 1. Vol. Messung von Zustandsgrößen. pp. [17] VDZ-Merkblatt “Staubmengenmessungen auf Zementwerken”. Schriftenreihe der Zementindustrie.: Messen. Ursache und Lösung. Düsseldorf 1990. A. [20] VDZ-Merkblatt “Kontinuierliche Gasanalyse in Zementwerken”. [13] Wolter. und Winkler.May 1992 Specification Vt 10 Page 113 9. Zement-Kalk-Gips 39 (1986) Vol. [19] Hengstenberg. [18] Hengstenberg.. H. 105-114. Band 11. Verein Deutscher Zementwerke e. Berlin 1980.V. Springer-Verlag. 39-61. Schriftenreihe der Zementindustrie. 612-614. W. und Lang. 43. B. Verein Deutscher Zementwerke e. Düsseldorf 1962. [12] Garrett.V. 10. Sturm.

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

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

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

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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

0006 1 − 3.N = 1. tr.G1 = 0.0489) λG1 = λG2 = 1 = 1.2.2 Air proportionality factors yCO 2 .0005 − 0.0489 yO 2 .G6 = 0.G1 = 0.3843 0.May 1992 Specification Vt 10 Page 120 10.2925 − 0.2925 yCO 2 .0318 yO 2 .G2 = 0.2.762 (1 − 0.G2 = 0. tr.G6 = 0.G1 = 0.1. from the burning area and from the rotary kiln (Equation 16): 1 = 1.3 Infiltrated air at the kiln hood F ≈ 0. tr.0489 − 0.0007 − 0.0006 − 0.1745 0.2108 yCO.G2 = 0.5 ⋅ 0.762 (1 − 0.0007 1 − 3.29 kg/m³ .3290 yCO 2 .0005 1 − 3.0302 Air proportionality factors in the waste gas downstream from the preheater.0318 − 0.0318) λG6 = 1 = 1. tr. tr.5 ⋅ 0.G2 = 0.0007 y CO.762 (1 − 0.1.2278 0. tr. tr.3290 − 0.0005 yO 2 .25 m² ∆p = 5 Pa p = 1010 hPa ϑ U = 5°C [41°F] ρ L.0302) 10.1.5 ⋅ 0. tr.0302 − 0. tr.1.0006 y CO.2108 − 0.

2.1.4 Secondary air λ G6 = 1.1. tr ≈ ⋅ 5 ⋅ 1.18 m³/s 10. D. tr = 1. D.268 ⋅ 2 = 0. tr = 7. tr =7.39 m³/s & VFl.May 1992 Specification Vt 10 Page 121 Density of the ambient air: ρ L = 1.39 – 0.25 & VFl.29 · 5.268 kg/m³ 1013 277 Infiltrated air volume flow (Equation 19): 0.29 kg/s lmin.5 Cooler intake air & VL8.75 ⋅ 0.73 + 23.1. tr = 23.1745 · 1. tr = 0.998 – 1.52 m³/s Secondary air volume flow (Equation 20): & VL8. tr = 6.18 m³/s & VL9.17 = 37.17 m³/s Cooler intake air volume flow (Equation 21): & VL10.29 · 1010 273 ⋅ = 1.08 m³/s .73 m³/s & VL11.1.998 m³/kg & VL7.52 m³/s 1.52 = 7. tr = 1. B7 = 5.1745 & m B7 = 1.29 10.18 + 6.2.

0489 yCO2 . tr.01 · 10 – 5 · 22684 = 2.eff.G1 = 0.S = 28.24) · 5.May 1992 Specification Vt 10 Page 122 10.3380 = 0.S1 x CO 2 .0411  12.S & m B7 & m B3 = 28.42 m³/s yO2 .1426 1. B3 = 22684 kJ/kg (lignitic coal) = 22684 kJ/kg (lignitic coal) & VG5.24 kg/s = 0 x CO 2 .55 kg/s = 0.55 · 0.01  1. tr.2.0007 yCO2 . pure gas = 0. tr.88 m³/s .84 kg/s = 0 = 0.3256 not applicable h u.97  CO2 from the fuel (Equation 26): & VCO2 .376 + 0.G1 = 0.84 · 0.1. tr. pure gas = 0.29 kg/s = 1. tr yCO 2 .29 + 1.eff.G5 not applicable yCO.84 m³/s VCO 2 .3380 – 0.1. B = (1. tr.376 kg/s CO2 from the kiln feed (Equation 23): 44. tr = 60. B7 h u.St5 = 0.2925 & Vpure gas. tr.St1 x CO 2 .G1 = 0.6 Raw gas & mS1 & mSt1 & mSt5 & mC. tr.1262 yO2 .01  1  & = 4.3256 = 9. y CO.S =  9.G5 . Calculation on the basis of the CO2 balance: Carbon dioxide mass flow (Equation 24) effectively fed in with the kiln feed: & mCO 2 .0411 kg/s = 1.

28 m³/s 0. tr = 60.1.42 = 26.G1 = 0.21 − 0.2925 & VG2.42 = 25. tr.7 Gas downstream from the burning area yCO2 .2925 b) O2 balance: 0.0318 & VG1. tr.68 m³/s Gas volume downstream from the burning area (Equations 30 and 31): a) CO2 balance: 0.1426 & VG1.2.1262 & VG1.3290 yO2 .May 1992 Specification Vt 10 Page 123 Raw gas volume flow (Equation 29): 4.0489 yO2 .1.83 m³/s 0.07 m³/s 0.2925 + 0.33 m³/s 0.88 − 0 & VG1. tr = 0.21 − 0. tr = = 26. tr = 60. tr.3290 .G2 = 0. tr = 25.68 m³/s 10.28) = 25.5 (26.84 + 2.0007 2.07 + 25.G2 = 0.68 = 22. tr.2925 yCO2 . Calculation on the basis of the clean gas volume flow: Raw gas volume flow (Equations 30 and 31): a) CO2 balance: 0. tr = 25.G1 = 0.0489 The following applies: & VG1.

68 = 23.2.88 m³/kg = 3.0007  0.0005 lmin.G6 = 0.B3 lmin.G6 = 0.May 1992 Specification Vt 10 Page 124 b) O2 balance: 0. tr = 25.24 kg/s = 0. tr = 25.0489 & VG2.0107 kg/s yO2 .0302   1 − 0.0007 yO2 .21   0 .G1 = 0.21   = 9.32 m³/kg yO2 .1.8 Gas downstream from the rotary kiln (kiln inlet) yCO2 .5   0.2108 & m B3 & mC. tr.G1 = 0.998 m³/kg = 8.998 + 0.tr.0318 The following applies: & VG2.24 ⋅ 5. tr 0.C lmin.79 1. eff.1.68 m³/s yCO.22) = 23. tr = 0. eff. tr.21   = 0.0302   1 − 0.G6 = 0.21   .2108 −  0.2925 & VG1. tr.22 m³/s 0.5 (22. S & mS.0489 yCO2 .0302 Gas volume flow downstream from the rotary kiln [30]: & VG6.88 + 0.21 − 0.0107 ⋅ 3.03 m³/s 10.0007 −  0.32 m 3/s − 0.S = 5.21 − 0.68 1 − 0.2108 −  0.G1 = 0.83 + 23.68 ⋅ 0. S = 1.32 − ⋅ 25.2925 − 0.0411 kg/s = 0. tr. tr.0489   25.0411 ⋅ 8.

2°F] ϕ = 0.32 – 6.88 + 0.2. tr.2 Water vapor 10. tr = 25.B3 = lmin. eff.0107 · 3.0318 0.1. eff.tr = yO2 .G2 = 0.03 m³/s = 9.24 · 5.60 m³/s 10.2.32 · 0.9 Infiltrated air (preheater) & VGl.C = (23.0302 0.0411 · 8.2.24 kg/s = 0.19 m³/s & VG2.03 m³/s 10.2.03 · (0.998 + 0.G6 = & VL3.May 1992 Specification Vt 10 Page 125 10. S = 1.0302) + 1.1.1 Humidity in the air p = 101000 Pa ϑ L. tr.0107 kg/s = 23.tr & VG6.0006) – 9.73 m³/s lmin.4 .21 0.1.S = = 5. tr.tr & VL4.0006 Infiltrated air volume flow (calcinator) according to [30]: 1 & VFl. tr.0318 – 0.U = 4°C [39.10 Infiltrated air (calcinator) & m B3 & mC.0411 kg/s = 0. S & mS.68 m³/s & VG2.1.2.tr yO2 .88 m³/kg 3.1.32 m³/s = 6.998 m³/kg 8.5 · 0.1.19 = 3.32 m³/kg 0.C lmin. tr = 23.03 m³/s & VL1 = 1.G2 = yO2 .73 – 0.

5 + 43. S1 = 0.tr · 1.84 kg/s x H2O.998 · 1.0204 x H2O. L = λG1 ⋅ VL. min.4 Humidity volume flows (Equation 34): a) downstream from the preheater & & VH 2 O. L = 1.877 · 10 – 4 · 44 + 10 – 6 · 45 = 812.2.002 = 0.608 · 0.8 kg/m³ .87 · 4 + 1.608 · 0.470 · 42 + 2.06 m³/s c) downstream from the rotary kiln (kiln inlet) & VH 2 O.2.U) = 611.2278 · 15.55 kg/s = 0.0020 kg/kg 101000 − 812.608 · xD = 1.29 · 5.2 = 0.May 1992 Specification Vt 10 Page 126 Saturation pressure of the water vapor at ambient temperature (Equation 33): ps (ϑ L.07 m³/s b) downstream from the burning area & VH 2 O.0190 ρH 2O.3843 · 15.2 Pa Water content of the dry air (Equation 32): xD = 0. St1 = 0.58 · 1.2 Water from the kiln feed & mS1 & mSt1 = 28.58 · 1.1.1745 · 1. L = 1.608 · 0.564 · 10 – 5 · 43 + 2. D = 0.002 = 0.622 812.03 m³/s 10.002 = 0.2 0 .

29 kg/s 1.80 m³/s VH 2 O.087 x H.71 m³/s 0 .019) ⋅ = 0. B7 = 0.1.087 + 0.087 x H2O.8  b) Secondary burner 18  1  & = 0. B7 x H.0453  2  0 . S = (28.087 + 0.2.0204 − 0.0453  2  0 .24 kg/s x H2O.8 10. 10 = 0 .4 Injection water & m H 2 O.0453 = 0.1.2.0453 Moisture volume flows (Equation 36): a) Main burner 18  1  & = 0.May 1992 Specification Vt 10 Page 127 Moisture volume flow from the kiln feed (Equation 35): 1 & VH 2 O.24  0.55 ⋅ 0.3 Water from the fuel & mB7 & mB3 = = 1.2.8  10. B3 = 1.29  0. B7 = 1.77 m³/s VH 2 O. B3 = 0.2.84 ⋅ 0. B3 = 0.

4.1 Energy input 10.80 = 10.May 1992 Specification Vt 10 Page 128 10.77 = 28.1 Fuel & m B7 = 1. B3 = 0.6°F] x H 2 O.2.07 + 0.03 + 0.1.03 m³/s Volume flow downstream from the burning area: & VG2 = 23.71 + 0.66 m³/s Volume flow downstream from the rotary kiln (kiln inlet): & VG6 = 9.15 m³/s 10.3 Liquid mass flows Does not apply.80 + 0.087 . B7 = x H 2 O.68 + 0.77 = 24.087) ϑB7 = 32°C [89. B7 = x F.80 + 0.1. 10.1.29 kg/s & m B3 = 1.24 kg/s h u.06 + 0.1.1. B7 = 22684 kJ/kg h u.1.32 + 0. B3 = 22684 kJ/kg x F.03 + 0. B3 = 0.6°F] ϑB3 = 32°C [89.4 Energy flows 10.3 Moist gas (examples) Raw gas volume flow (Equation 40): & VG1 = 25.496 (1 − 0.4.

May 1992 Specification Vt 10 Page 129 Mean specific thermal capacity for dry lignitic coal (Equation 43): 0. tr ≈  0.1.496   –3 – 10 3 c B.5 · 10 · 32 – 8 · 10 · 32 ) = 1.846 +  (1 + 1.1.2 Kiln feed & mS1 = 28.087) · 1.803 ⋅ 0.592 kJ/kg K Reaction enthalpy flow of the fuel (Equation 41): & ∆H R.6 ·10 – 7 · 632 + 5.29 + 1.24) · 1. B = (1.844 kJ/kg K Enthalpy flow of the kiln feed (Equation 48): & H S1 = 28.3 ·10 – 4 · 63 – 4.344 kJ/kg K 1 − 0.844 · (63 – 25) = 916 kJ/s .592 · (32 – 25) = 28 kJ/s 10.2 · 10 – 11 · 633 = 0.4°F] Mean specific thermal capacity of the kiln feed (Equation 49): cS1 ≈ 0.24) · 22684 = 57391 kJ/s Sensible enthalpy flow of the fuel (Equation 42): & H B = (1.8 + 7.2 = 1.2 kJ/kg K Mean specific thermal capacity for moist lignitic coal (Equation 44): cB7 = cB3 = (1 – 0.087 · 4.55 · 0.29 + 1.344 + 0.087   Mean specific thermal capacity for the water in the coal: c H 2O ≈ 4.4.55 kg/s ϑS1 = 63°C [145.

297 · (4 – 25) = -1223 kJ/s 10.17 m³/s xD = 0. tr = 23.U = 4°C [39.1.4.1.tr = 15.88 · 1.88 m³/s i Mean specific thermal capacity of the air fed in (Equation 52): cp. total = 44. air-intake fan = 337 kJ/s Mechanical performance (Equation 53): Pmech = (337 + 117) · 0.3843 & VL.297 kJ/m³ K Enthalpy flow of the air fed in (Equation 50): & H L.L.May 1992 Specification Vt 10 Page 130 10.06 · 10 – 8 · 42 – 2.2°F] Sum of the air volume flows fed in (Equation 39): & ∑ VLi = (1.3843 · 15.75 · 10 – 5 · 4 + 8.608 · 0.002) = 44. 10. kiln drive = 117 kJ/s .58 + 23.002 kg/kg ϑ L.4 Injection water Does not apply.4.tr = 1.1.1.5 Mechanical performance Pmech.3 Air λG1 = 1.58 m³/s & VL11.9 = 409 kJ/s Pmech. min.86 · 10 – 11 · 43 = 1.1.1.297 + 5.4.17) (1 + 1.

2137 – 0.043 · 0.1. 10.0067 The following then results: x CaOSO .1 C3S.1.692 · 0.2137 – 1.S10 = 4.563 x C 2S.188 x C3A.071 .1 Reaction enthalpy of the kiln feed Chemical analyses of the solid substance average samples. S10 = 0. C2S.0010 = 0.S10 = 2.0143 – 0 = 0.071 · 0.4.868 · 0.602 · 0.S10 = 2.4.0234 = 0.65 · 0.43 · 0.85 · 0.S10 = 3.718 · 0.1.0083 > 0.0083 + 1.563 = 0.1.2.2.0234 = 0.754 · 0.0632 = 0.S10 = 0 3 CaO bound in the clinker phases (Equation 54): x CaO* .0234 – 6.May 1992 Specification Vt 10 Page 131 10. C3A and C4AF in the clinker SO3 bound to the CaO in the clinker (Equation 55 or 56): 0.4.0632 – 1.2 Energy output 10.6498 Clinker phases (Equations 57 through 60): x C 3S.292 · 0. each according to Table 10.128 x C 4 AF.6498 – 7.6641 – 0.

1.7683 x MgCO3 . 10.2 CaCO3.1.May 1992 Specification Vt 10 Page 132 10.1.4235 The following then results: x CaCO3 .274 · 0.00 kg/s & mSt12 = 0 kg/s Reaction enthalpy flows (Equations 67 through 79): 1) Evaporation of H2O: & ∆H R1 = 2446 (0.4304 = 0.2.785 · 0.4 Balance equations & mS1 = 28.S1 = 1.1.4.274 · 0.0190 · 0.4.4.916 · (0.St1 = 2.55 kg/s & mSt1 = 0.274 · 0.3256 = 0.2.0003 b) raw gas dust (Equations 61 through 64): 1.3256 = 0.1.84) = 1386 kJ/s .4306 > 0.S1 = 1.1.0204 · 28.785 · 0.7404 x MgCO3 .4148 < 0.3 CaCO3 and C2S in the bypass dust Does not apply.2.3380 = 0.4304 The following then results: x CaCO3 .55 – 0.4304) = 0.St1 = 0 10.3380 – 0.84 kg/s & mSt5 = 0 kg/s & mS10 = 18. and MgCO3 in the kiln feed and in the raw gas dust a) kiln feed (Equations 61 through 64): 1.

00 = -86 kJ/s 8) Formation of C3A: & ∆H R8 = 74 · 0.0004 · 28.7404 · 0.84) = 978 kJ/s 3) Organic clay components: & ∆H R3 = -32786 (0.0015 · 28.55 – 0.84) = -139 kJ/s 7) Formation of C4AF: & ∆H R7 = -67 · 0.84) = 37895 kJ/s 6) Pyrite: & ∆H R6 = -12914 (0.0499 · 0.84) = -1346 kJ/s 4) MgCO3 dissociation: & ∆H R4 = 1396 (0.00 = -2369 kJ/s .0021 · 0.0008 · 0.071 · 18.May 1992 Specification Vt 10 Page 133 2) Decomposition of clay: assumption: 100%-illite & ∆H R2 = 884 (0.188 · 18.7683 · 28.55 – 0.84) = 12 kJ/s 5) CaCO3 dissociation: & ∆H R5 = 1778 (0.128 · 18.0402 · 28.55 – 0 · 0.00 = 170 kJ/s 9) Formation of β-C2S: & ∆H R9 = -700 · 0.55 – 0.0003 · 28.55 – 0.

0014 · 0.0010 · 28. G1 y N 2 . G1 = (1 – 0.84 – 0.2680 yO 2 .2.2.55) = -903 kJ/s Sum of the reaction enthalpy flow of the kiln feed (Equation 80): & ∆H R.S = 1386 + 978 – 1346 + 12 + 37895 – 139 – 86 + 170 – 2369 – 5016 – 903 = 30582 kJ/s 10. G1 = 0.1.03 m³/s & VL11 = 23. G1 = (1 – 0.2680 – 0.4.25 m³/s ϑ G1 = 330°C [626°F] ϑ L11 = 278°C [532.0838) · 0.4°F] y H 2O.2 Water evaporation Does not apply.3 Waste gas losses & VG1 = 28. 10.6034 .2925 = 0.4.0838 – 0.0067 · 18.0448 = 0.May 1992 Specification Vt 10 Page 134 10) Formation of C3S: & ∆H R10 = -495 · 0.0489 = 0.0448 = 1 – 0.1.563 · 18.00 + 0.00 = -5016 kJ/s 11) Formation of K2SO4: & ∆H R11 = -9690 (0.0838) · 0.0838 yCO 2 .

633 + 9.52 · 10 – 5 · 330 + 2.4.904 kJ/m³ K c p.90 · 10 – 11 · 3303 = 1.3 · 10 – 4 · 330 – 4.2 · 10 – 11 · 3303 = 0. H 2O = 1.304 + 1.497 kJ/m³ K Enthalpy flow of the raw gas (Equation 82): & H G1 = 28.021 · 10 – 7 · 3302 – 7.84 kg/s ϑ St1 = 330°C [626°F] Mean specific thermal capacity of the raw gas dust (Equation 49): CSt1 ≈ 0.301 + 3. N 2 = 1.297 + 5.366 kJ/m³ K c p.1.489 + 9.319 (278 – 25) = 7759 kJ/s 10.320 kJ/m³ K c p.06 · 10 – 8 · 2782 – 2.O 2 = 1.904 + 0.631 · 10 – 4 · 330 – 4.606 · 10 – 7 · 3302 + 8.May 1992 Specification Vt 10 Page 135 a) Raw gas Mean specific thermal capacity of the raw gas (Equations 83 through 87): c p.35 · 10 – 11 ·3303 = 1.540 kJ/m³ K c p.993 kJ/kg K .G1 = 0.6034 · 1.0838 · 1.4 · 10 – 9 · 3302 – 1.916 · 10 – 4 · 330 – 9.32 + 0.2.05 · 10 – 5 · 330 + 9.03 · 1.86 · 10 – 11 · 2783 = 1.54 + 0.6 · 10 – 7 · 3302 + 5.75 · 10 – 5 · 278 + 8.497 (330 – 25) = 12798 kJ/s b) Cooler vent air Mean specific thermal capacity of the cooler vent air (Equation 52): cp.4 Dust losses & mSt1 = 0.01 · 10 – 11 ·3303 = 1.65 · 10 – 8 · 3302 – 3.22 · 10 – 11 ·3303 = 1.25 · 1. L11 ≈ 1.268 + 1.CO 2 = 1.8 + 7.366 = 1.0448 · 1.319 kJ/m³ K Enthalpy flow of the cooler vent air (Equation 89): & H L11 = 23.

May 1992 Specification Vt 10 Page 136 Enthalpy flow of the raw gas dust (Equation 90): & H St1 = 0.5 Incomplete combustion & VG1.CO = 25.0007 · 12645 = 227 kJ/s 10.84 · 0. tr = 25.369 · 10 – 7 · 1202 + 2.2.68 · 0.tr.1.68 m³/s y CO.2.6 Clinker & mS10 = 18.793 (120 – 25) = 1355 kJ/s .921 · 10 – 4 · 120 – 5.00 · 0.729 + 5.4.00 kg/s ϑ S10 = 120°C [248°F] Mean specific thermal capacity of the raw gas dust (Equation 95): CS10 = 0.G1 = 0.793 kJ/m³ K Enthalpy flow of the clinker (Equation 94): & H S10 = 18.4.124 · 10 – 10 · 1203 = 0.0007 Reaction enthalpy flow (Equation 93): & ∆H R.993 (330 – 25) = 254 kJ/s 10.1.

V = 720 kJ/s & Q W.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.1.7 Radiation and convection: For calculation examples.8 Uncoupled heat Does not apply.2. K = 252 kJ/s 10. B = 59059 – 28 – 916 + 1223 – 409 = 58929 kJ/s Balance deficit: 58929 – 57391 = 1538 kJ/s This corresponds to 2.4. 10.1.4.May 1992 Specification Vt 10 Page 137 10.6% of the balance sum.2.C = 360 kJ/s & Q W.T = 486 kJ/s & Q W. see [31]: & Q W. D = 4266 kJ/s & Q W. .1.4.

May 1992 Specification Vt 10 Page 138 10.002) = 7.00 kg/s & mSt9 = 0.20 m³/s .08 m³/s xD = 0. tr = 7.18 m³/s & VL10.0020 kg/kg Secondary air volume flow (Equation 38): & VL8 = 7. tr = 7. tr = 6.20 m³/s Cooler intake air volume flow (Equation 38): & VL10 = 37. tr = 37.73 m³/s Secondary air dust mass flow (Equation 110): & mSt8 = 0.35 ⋅ 7.2.002) = 37.73 Hot clinker mass flow (Equation 111): & mS8 = 18.08 (1 + 1.18 = 0.37 kg/s 6.35 kg/s & VL8.608 · 0.2.1.1 Clinker cooler 10.2 Gas volume flows & VL8.72 kg/s 10.1 Solid substance mass flows & mS10 = 18.2 Balancing of the partial systems 10.35 + 0.37 = 18.18 (1 + 1.1.2.00 + 0.18 m³/s & VL9.608 · 0.

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

2) (200 – 4) 1 = 122 kJ/s 1000 10.076   = 9.85   + 0.168 W/m² K 100  100   100  αrad = 0.667 · π · 3.1 Pre-cooling zone LB = -0.4 Evaluation quantities 10.2 m Da = 3.4.9 · 5.2°F]: & H L11 (4°C [39.2 m ϑ W.2°F]) = 25.2°F] Heat-transition coefficients (Equations 98.2 (3.2°F]) = 18.499 = 20.5 – 0.667 W/m² K Radiation and convection loss flow of the pre-cooling zone (Equation 117): & Q W.499 W/m² K 473 − 277 αtotal = 9.1. 99 and 101): 200  200   200  αconv = 0.2°F]: & H S10 (4°C [39. pre − cool = 20.25 · 1.2 – 0.2 + 4.731 · (4 – 25) = -276 kJ/s Enthalpy flow of the cooler vent air at 4°C [39.00 · 0.168 + 11.298 · (4 – 25) = -688 kJ/s .2 Energy loss flow of the cooling area Enthalpy flow of the clinker at 4°C [39.3 · 3.May 1992 Specification Vt 10 Page 142 10.1.1.0 + 3.2.2.67 · 10 – 8 2 3 4734 − 277 4 = 11.4.2.m ≈ 200°C [392°F] ϑ U = 4°C [39.

3380 0.0532 = 1 − 0.6316 ϕ apparent .0532 xCO2 .S1 = 0.00 · 1.3380 xNF.3 Cooling area efficiency Enthalpy flow of the clinker at 1450°C [2642°F]: & H S10 (1450°C [2642°F]) = 18.May 1992 Specification Vt 10 Page 143 Energy loss of the cooling area (Equation 118): & Eloss.6316 (sum 1 to 8 in Table 10) Apparent degree of precalcining of the kiln feed at the kiln inlet (Equation 121): 0.S6 = 0.89 0.2 Calcinator xCO2 .635 28370 + 276 10.4.106 · (1450 – 25) = 28370 kJ/s Cooling area efficiency (Equation 119): η cooling area = 1 – 10452 = 0.1.2. cooling area = 1355 + 276 + 7759 + 688 + 252 + 122 = 10452 kJ/s 10.S6 = 0.9016 (sum 1 to 8 in Table 10) xNF.2.S1 = 0.9016 = 0.

(126). (127). (130) and (131). 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. 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. .2. 3) The infiltrated air volume flow of the preheater is uniformly distributed over the four stages. 7) The dust from the rotary kiln and from the tertiary air duct contains 10% alkalis and 90% non-volatile components. 2) One-fourth of the moisture volume flow from the kiln feed is desorbed in each of the four uppermost stages.3 Preheater Calculation of the mass flows and degrees of separation according to Equations (123). 6) The cyclone of the calcinator is assigned the number 5.

110 – – & VG – 28.67 49.03 23.3 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).844 0.80 0.619 – – & QW – 180 180 180 180 – – & ∆H R – 223 223 223 223 – – & mS 28.87 0. Thus.84 – 7.67 48.26 – – – & mSt – 0.497 1.02 25.97 25.92 3.87 ξ – 0.555 1.55 – 34.43 6.595 1.69 0.993 1.53 25.55 43.96 21.62 62.98 0. .35 – 10.31 28.19 21.050 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. the table provides information about the necessary measuring precision for the individual measured quantities during a performance test.14 34.092 1.26 – & mSt – 0.55 – – & mS 28.G – 1.84 15.09 – – cp.

May 1992 Specification Vt 10 Page 146 10.4 Tables (The operands are printed in boldface!) Table 9 .35 .Solid substance mass flows (kiln system with a cyclone preheater.4 107.29 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 18.0 – 30 28.55 1.24 0.00 – – 2466 111. calcinator and tertiary air duct).84 – 0.3 73.

31 – 33.56 0.92 0.70 – 42.30 1.61 – 0.75 63.01 0.08 66.03 0.32 0.03 0.05 0.22 34.91 4.31 – 0.10 70.57 0.72 0.85 100.76 – – – 3 14.76 5.45 – 0.96 – Raw gas dust 14.57 0. calcinator and tertiary air duct).58 – 45.45 0.48 – – – 4 15.68 0.51 99.05 0.34 – 66.37 6.76 – 31.58 100.60 – 0.65 3.63 0.54 0.16 0.99 – – 1.57 0.75 98.46 97.64 0.44 – 0.15 0.13 – – 1.41 1. No.90 90.80 – – – 1b 13.25 48.12 4.12 – – 1.07 – – – – – Kiln feed downstream from the cyclone 1a 14.10 99.04 0.64 99.25 27.22 0.57 0.14 – – 1.51 – 43.64 0.57 0.51 – 43.54 17.62 – 47.22 7.15 – 61.30 34.008 0.06 64.75 64.84 4.02 12.80 0.80 – – – 2 14.25 4.35 0.32 – – – 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 .04 0.51 – 42.04 – – 0.14 0.16 0.36 0.85 0.30 – 33.27 62.72 4.10 0.26 34.70 0.May 1992 Specification Vt 10 Page 147 Table 10 .15 33.16 – 5.40 – – – 5 19.21 35.42 – – 1.67 – 0.43 100.08 0.49 – 0.23 31.07 1.26 99.81 80.82 – – 2.72 100.08 1.00 99.47 1.001 0.59 – – 1.45 – 0.13 3.23 – 27.83 – Clinker 21.50 – 43. Components Kiln feed 13.45 2.10 0.13 – 33.32 – – 2.60 0.02 0.83 0.23 0.30 6.85 4.15 0.23 35.43 Fuel ash 8.77 0.72 0.42 1.10 61.95 – – 1.78 0.Chemical analyses of the solid substance average samples in % by weight of the substance entailing loss on ignition (kiln system with a cyclone preheater.02 – – 1.31 34.

684 8.00 60.74 49.May 1992 Specification Vt 10 Page 148 Table 11 .-% Fuel (main burner) 22. calcinator and tertiary air duct).70 4.27 0.20 4.53 0.60 Fuel (secondary burner) 22.56 21.70 4.27 0.60 Relative to the dry substance.-% wgt.20 4.56 21.-% wgt.74 49.Fuels (kiln system with a cyclone preheater.00 60.53 0.-% wgt.-% wgt. .-% wgt.-% wgt.684 8.-% wgt. Designation lower calorific value water ash carbon hydrogen sulfur nitrogen oxygen volatile components 1) 1) Unit kJ/kg wgt.

Temperatures (kiln system with a cyclone preheater. 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] .4°F] 1024°C [1875.2°F] 845°C [1553°F] 853°C [1567.8°F] 278°C [532.May 1992 Specification Vt 10 Page 149 Table 12 . calcinator and tertiary air duct).4°F] 744°C [1371.2°F] 901°C [1653.2°F] 32°C [89.4°F] 330°C [626°F] 480°C [896°F] 638°C [1180.6°F] 32°C [89.2°F] 1389°C [2532.

19 1.20) 6.03 24.18 3.73 23.32) (7.62 29.68 23.19 1. = under standard conditions .26 4.)/h 67. calcinator and tertiary air duct).8 8.42 m³(s.90 21.89 3.06 0.25 32.02 CO vol-% 0.)/h 60.75 23.52 3800 (10900) 1900 1. related to dry gas m³(s. Designation Dry gas Moist gas Gas composition.76 CO2 12.07 0.08 O2 14.c.25 133600 5800 700 5000 37.03 (9.39 air with 0.0 92400 82900 (33600) (25900) 24200 83400 25.08 1.c. s.03 0.6 8. but often very imprecise since gas analysis at the kiln inlet is not representative.52 Calculated.Gas volume flows and composition (kiln system with a cyclone preheater.c.66 (10.May 1992 Specification Vt 10 Page 150 Table 13 .61 0.15) (7.)/h 244000 m³(s.20 1.60 0.03) 0.05 217500 10.3 vol-% of H2O 3800 (10900) 1900 1.05 (3.05 (3.4 6.04) 0.39 134000 5800 700 5000 37.17 100900 88700 36500 (26000) 24300 83700 28.c.18) 6.)/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.c.

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 .May 1992 Specification Vt 10 Page 151 Table 14 .Energy balance of the kiln system (kiln system with a cyclone preheater. calcinator and tertiary air duct).

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 0.635 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]) .Energy balance of the cooler (kiln system with a cyclone preheater.May 1992 Specification Vt 10 Page 152 Table 15 . calcinator and tertiary air duct).

24 Translation by: Duvekot Translators 2219 Brackenville Road Hockessin.42 2.74 0.09 0.Influence of measuring errors on the calculated fuel energy consumption (kiln system with a cyclone preheater.May 1992 Specification Vt 10 Page 153 Table 16 .08 0.28 1.51 –0.15 0.com .12 1.43 0. calcinator and tertiary air duct).3 0.29 1.27 0.93 0.22 –1. 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.

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