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Optimisation of combustion and technology process in a vertical shaft kiln

Conference Paper · October 2017

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 12th CONFERENCE ON SUSTAINABLE DEVELOPMENT
OF ENERGY, WATER AND ENVIRONMENT SYSTEM
October 4-8, 2017, Dubrovnik, Croatia

Optimisation of combustion and technology

process in a vertical shaft kiln
Risto V. Filkoski, Ilija J. Petrovski and Zlatko Gjurchinovski
University “Sts Cyril and Methodius”, Faculty of Mechanical Engineering,
Skopje, R. Macedonia

1. INTRODUCTION 3. OPTIONS FOR OPTIMISATION OF THE KILN ENERGY

 Calcination is an essential part of the technological process of dolomite refractory PERFORMANCE
materials production from dolomite stone. It takes place in vertical shaft kilns, where
the dolomite stone (CaMg(CO3)2), as it flows downward by gravity, passes through  Five different optionsfor optimisation were analysed: (1) Preheating of a raw
several phases of thermal processing. material, (2) Preheating of fuel - heavy oil, (3) Preheating of combustion
 The objective of the work was to assess the possibilities for utilisation of waste (primary) air, (4) Preheating of combustion (primary) air and raw material and (5)
heat of exhaust gas from the shaft kilns. It was found that there is a relatively large Preheating of air for combustion and for drying of a raw material (Fig. 6).
amount of waste heat in the exhaust gases of the shaft kilns

2. METHODOLOGY dolomite

2.1. Description of the shaft kiln and

the technology process
exhaust gases

In a vertical (shaft) kiln, the dolomite, as it

flows downward by gravity, passes through
three operating zones: (1) preheating, (2)
reaction and (3) cooling zone. The preheating
zone is the part of the kiln where the dolomite fuel

is heated to its dissociation temperature. The fuel

reaction zone is the part of the kiln in which cooling media

return

process of calcination and process of fuel cooling media

supply

combustion air

combustion take place. The cooling zone is the

part of the kiln in which the sintered dolomite
emerging from the reaction zone is cooled
before discharge from the bottom of the kiln.
cooling air

The calcination or burning of dolomite is product

sinter dolomite

highly endothermic reaction, requiring about Fig. 1. Schematic presentation of vertical

3202 kJ of heat input to produce one kg of shaft kiln and cross-section of a vertical shaft
sintered dolomite (CaO∙MgO). When heated, kiln. (a) Preheating zone; (b) Reacting zone;
the carbonates decompose according to the (c) Cooling zone
reaction: Fig. 6. Schematic presentation of the option utilisation of exhaust gas energy for
CaMg(CO3)2 + Heat = CaO∙MgO + 2CO2 preheating of air for combustion and for drying of raw material

The burner lances, located at two levels

(Fig. 1), protrude into the hot bed of 4. RESULTS
material at different depths to enable an
optimum fuel distribution over the whole
cross section of the kiln (Fig. 2). Fig. 2. The burner system Option Utilised Energy Fuel saving, % of fuel
Exhaust Dolomite
heat, saving, t/year; chemical
gas
HEAT DEMAND FOR: kW MWh/year Cost saving, energy
Euro/year
- Evaporation of water
Preheating - Preheating of dolomite
1. Preheating of raw material 135;
zone - Heat loss to surroundings
183.3 1283 101250 4.7
CaCO3·MgCO3 º 2. Preheating of heavy fuel oil 16.0 (light oil)
CaO + MgO + 2CO 2
- Calcination of MgCO3 22 160 15870 0. 6
C+ O2 º CO2 Reaction and CaCO3
H2 + ½O2 º H2O zone - Reaction enthalpies
- Heat loss to surroundings
3. Preheating of combustion 73;
S+ O2 º SO2
(primary) air 95 693.5 54700 2.4
Primary air
Heavy fuel oil 4. Preheating of combustion 149;
Cooling
zone
Heat loss to surroundings
air and raw material 194 1416.2 112000 4.9
5. Preheating of air for
combustion and for drying 238 1737.4 183; 6.1
of raw material 137250
Secondary Sintered
air dolomite

Fig. 3. Main zones, chemical reactions and energy use Fig. 4. Temperature profiles in the shaft kiln
CONCLUSION
 The option (5) was selected by the company management team as the most
2.2. Energy balance of the reaction and cooling zones of the kiln attractive and therefore it was analysed in more details.
 According to the calculations, as a conservative approach, the annual energy
saving would be 1737.4 MWh/year, or transformed to equivalent heavy fuel oil,
about 180-190 t/year per one shaft kiln.
Table 2.1. Basic geometry data of the kiln  The simple payback period on investment for this option, without purchasing new
compressor units, which would be significant item in the specification list, but are not
- Total furnace height 9.69 m necessary, is less than two years.
- Funnel cooling height 2.0 m
- Height from the furnace bottom up to:
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