1/23/23, 5:23 PM Mail - Siddharth Singh - Outlook

Subject: Introducing the concept for regular and continuous monitoring of Alkali-Sulphur or Sulphur alkali ratio with chloride in hotmeal, with the
introduction why this is important nowadays
 
Dear Team,
As we all know that the usage of alternative fuel and raw material (AFR’s) has been increased in Cement industries due to the higher cost of
conventional energy, some environmental concerns and for achieving cement sustainability mission through low carbon technology. This concept
is very important and we encourage its use in the cement industries with sufficient knowledge for its impact analysis on process and quality.
Looking this area very lucrative in cost economics, fair knowledge with regular monitoring of Alkali-Sulphur Ratio or Sulphur-Alkali ratio is
required keeping it in the ideal range to make us in Win-Win situation.
 
Let us understand the concept: AFR’s are composed of many minor elements especially alkali, sulphur and heavy elements. The molar
balance between alkalis and Sulphur in clinker is a critical facet to consider and optimize clinker due to its significant impacts on both kiln
operation and clinker quality. The  principal volatile elements are K, Na, Cl, S.  In  the  case of raw materials, certain sulphur compounds
(sulphides or organics) can readily decompose/volatilise below 600°C, but most volatile compounds in raw materials only evaporate partially
and at higher temperatures as the feed passes towards the kiln burning zone.
 
These Evaporated volatiles travel back up the kiln with the combustion gases and condense as inorganic compounds (liberating latent heat):
i) on the feed, forming the basis of a recirculating internal volatile load
ii) as a fine dust or fume which is finally trapped in the gas cleaning system or raw mill and becomes part of an external volatile cycle, as dust
is partly or wholly returned to the system
iii) on colder surfaces in the system, forming the basis of build-ups.
 
Kiln Recirculating loads form because of partial volatilisation in the burning zone and are often implicated information of build-ups, coating
and blockages in cooler parts of the process. Differences arise between plants from design features and from characteristics of raw materials
and fuels.
 
Alkalis and sulfates entering the burning zone in practice largely form a separate molten sulfate phase, immiscible with the principal ferrite
flux. The level of volatiles in recirculation is significantly greater than their total rate of introduction and the substances in the vapours phase
can be in various states of dissociation and recombination. In general, the preferred chloride compound is potassium chloride and only when
there is an excess of chlorine for chemical combination with potassium will sodium chloride be formed as a recirculating volatile species.
Alkali sulfates (Na2S04, K2SO4) evaporate congruently, disappearing entirely when heated for a long period. CaS04 decomposes and leaves
residual CaO (in oxidising conditions), so that CaO:CaS04 melts can form.
 
Typical recirculating volatile loads expressed as % of the total quantity introduced are as follows as per thumb rule:
 
                             %                                                                                                            %
        Cl                5000                                                                                     Na2O        150-200
        K2O            200-650                                                                                SO3           200-800 
 
                                                                            

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1/23/23, 5:23 PM Mail - Siddharth Singh - Outlook

The purpose of this ASR/SAR ratio is to predict the likely hood of alkali or sulphur related buildups in the kiln inlet. In particular, sudden
increases in this ratio can indicate lack of oxygen in the back end of the kiln and impending sulphur buildups. The ASR results will help to
better understand the influence of alkali and sulphur in AFR on clinker properties with proper modelling of this parameters with its continuous
monitoring at Hot meal stage and its analysis to ensure smooth running of the Kiln achieving ideal clinker parameters supporting the proactive
decision based on the hot meal analysis results.
 
 
 

    or Molal ratio (MR)

S/A=SO3/80/K2O/94+Na2O/62−Cl/71
 
 
 
 
In this equation, chloride is first subtracted from the alkali molar total because alkali chlorides are far more volatile than alkali
sulphates. Over 99% of alkali chlorides (particularly KCl) are re-evaporated in the high temperature of the burning zone and return
to the kiln inlet with the kiln gases where they condense on the incoming hot meal, completing the cycle.
 
The above equation is based on the reactivity of the components, is derived as follows.
 
All chloride is assumed to be combined with alkalis. Residual alkali is combined with SO3 to form alkali sulfates.
Thus MRs/a would be unity if there were no SO3 remaining to combine with CaO.
 
When MR = 1 all SO3 leaves the kiln in the form of low volatility alkali sulfates. If inputs of sulfur compounds, whether in raw
materials or fuels can be controlled to give ASR or MRs/a between 0.8 and 1.2 it is likely that the sulfur cycle will be within manageable
limits. If MRs/a is < 0.8 there may be alkali build-ups within the kiln in the form of rings located in the upper third of the kiln.
 
Solution: To avoid any negative consequences from imbalance of ASR in hotmeal/clinker, strict monitoring of its value in the
ideal range must be maintained by the use of either Alkali or Sulphur containing Alternate raw materials/fuels which can be
case specific.

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1/23/23, 5:23 PM Mail - Siddharth Singh - Outlook

Looking into the subject compliance, let us start monitoring the ASR or MRs/a value in hotmeal. These will help us in smooth
Kiln operation within ideal operating range which finally can affect the clinker quality and the process operation, causing build-ups
and blockages.
Will share the format for continuous monitoring of the hotmeal ASR or MRs/a value analysis to see the measure and control
the Kiln jamming or coating tendency.
 
Example: Acceptable values range
 

 
 
 
 
 
Thanks and regards,
Dr Abhishek Kumar Rai
 
 

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