BY

Y PASS SYSTEM
 BY PASS
SS S
SYSTEM
S

z CIRCULATION PHENOMENON
 Kiln Che
emistry
Kiln Volattile Cycles
Normal atmospherre Reducing atmos
l 96--99
96 99%
% 97--99
97 99%
%
O3 60--90
60 90%
% 90--100
90 100%
%

2O
30--70
30 70%
% 30--70
30 70%
%

a2O 20--40
20 40%
% 20--40
20 40%
%
 Preheaater exit g
gas Preheater exit gas 4
360 C

Normal operation Abnormal opera

760 net kccal/kg clinker 830 net kcal/kg c

Calciner ex
xit gas 880 C Calciner exit gas 1
Back-eend Fuel

Kiln f

High BET and risk of blockag

ges
 PREH
HEATER
P.H.
P H
PH VOLATILES

HORNO
KIL
LN

PRECALCINE
ER

VOL
LATILES
P.C,
PH

HIGHER
CONCENTRATION
BY
P/CPASS
OF VOLATILES
Air Se
eparate Pre
Pre--Calciner

Calciiner vessel

Ba
ack-end Fuel

Tertiary Air duct

 AND KILN
N BACK-END

UPPER STAGE 3 UPPER STAGE 3

MEAL FEED MEAL FEED

EFFECT OF LO
OWER
ENTRY FOR STAGE
3 MATERIAL

BUILD UP
P AREAS
 Five stage
330 - 360 °C 310

530 - 560 °C
C
490

680 - 720 °C 630

800 - 840 °C 750

820
1010 - 1100 °C
1000-1100
000 00
 Build-ups
p
500-550 °C

650-700 °C

Chlloride based build-up

800-850 °C

Sulphur based Build-up

1150-1200 °C 1500-1600 °C

Ash rings
 process adve
d rse materials
t i l
These harmful materials are sulfur,, chlorine and
alkali elements i.e. sodium m and potassium.
potassium. Their
behaviors in the kiln and preheater atmosphere
eads to build-
build-up
p of layer
y rs of these components
p
and trapping huge quanttity of kiln dust. This buil
up forces the kiln operato or to shutdown the kiln
system
y to clear this build
d-up.
p The kiln operation
p
suffers because the build d-up in the riser pipes an
cyclones increases pressu ure drop in the system
 Circulation
Ci l ti phenomenon
ph
his term is used to reppresent the
phenomena caused byy the presence of the
volatiles in system i.e. alkali chlorides,
chlorides,
Sulphates and other related components i
he dry kiln system wiith preheater and
p
precalciner
 Internal and External Circulation
Phenoomena
1-INTERNAL CIRCULA ATION PHENOMENON
between preheater towwer lower stages and
the kiln-
kiln-burning zone.
zone.

2-EXTERNAL CIRCULA ATION PHENOMENON

Their cycle from prehe eater to electrostatic
precipitator to kiln fee
ed and back again to
the kiln system
y
% By
By--pass = % chlorine as Cl in
the raw matterials x 100
This procedure is applied to chlorine
because it is nearly im
mpossible to control th
evaporation of chlorinne in the kiln burning
zone or control its con
ncentration in the
process by any mean.
mean.
 Exam
Exam
mple
l
The raw materials con
ntain chlorine [raw
meal basis] =0
=0.25 %. What is the bypass
%?

Th required
The i d bypass%
b % = 0.25
25xx100
100==25
25%%
Th main
The i compo
ounds
d made
d are:
Alkali sulfate [K, Na]2
Na]2 SOSO4
4
Alkali chloride KCl,, NaCl
Alkali carbonate [K,
[ Na]2
Na]]2 CO3
CO3
Calcium sulfate Anhydrite CaSO4
CaSO4
Sulfate spurrite 2C2 S CaSO4
CaSO4
Sulfo--spurrite
Sulfo [K, Na] 2 SO4
SO4
 Circulatio
on Mechanism

The circulating
g elements enter the kiln with the k
eed that travels through the preheater to the kil
nlet.
nlet
Starting from lower mostt cyclones the temperatu
starts reaching 800
800ºC
ºC in the kiln system. From th
emperature, part of thesse elements is volatilized
and becomes part of the kiln atmosphere.
KCl NaCl
N Cl CaCl2
CaCl
C Cl2
Cl2 K2SOS 4 Na
SO4 N 2SO
Na2 SO44 CaSO
C
CaSO4
SO4
SO4
775 772 801 10069 884 1450
1450ºC
ºC
melting temperature]
 Ci l ti Mechanism
Circulation M h i
When the material rea aches burning zone, a
he chlorine will be evvaporated with part
rom sulfate, sodium, and potassium [the
harder the kiln feed too burn the higher will
be the evaporation rate of the volatiles and
his takes p
place also in
n case of a veryy stron
lame in the main burrner]
 hloride reacts primariily with the alkalis
alkalis,
orming g NaCl and KCl. Anyy excess of
hlorides will react with
h calcium oxide
vailable
il bl in
i the
h systemm to form
f C
CaCl
CaCl2
Cl2. A pa
Cl2
f the alkalis in excess of chloride combine
ith sulfur to form Na2
Na2SOSO4
4, K2
K2SO
SO4 4 and
ouble salts as Ca2
Ca2K2(SO
( 4)2. Alkalis not
(SO4
ombined with chloride e or sulfur is present
a2O and K2 K2O embedd ded in the clinker
mineral
 A Exa
An E ample
l
If we introduced 1 kg of potassium each hour w
the feed and when the reactions achieve a state
equilibrium off volatiles in
n the system, then we w
have the following condition:
0.811 kg of potassium willw leave with the clinker
In the system the concentration of potassium wi
be 2.573 kg
In the by-
by-pass dust the concentration
c of potassiu
will be 0.221 kg.
In the exhaust gas dust the concentration will be
0.042 kg of potassium.
 Evaporation Rates of Different
Elem
ments
or E =
The evaporation facto

1 – ((% within the clinker / % at kiln inlet

oss on ignition free basis )
 Example:
Exam l 1
The concentration
Th t ti off tthe
th sulfate
lf t ini the
th
clinker in one sample is 1.05 %, % SO3
SO3
concentration in cyclo
y one 4 materials which
collected from the ma aterial pipe of cyclone
o the
th kil
kiln inlet
i l t is
i 2 % and d the
th loss
l on
gnition of this same sample
s is 3.5%
What is the evaporatio on factor of sulfate
SO3
SO 3] in this system?
y
 Evaporation Rates of Different
Elem
ments
% SO3
SO3 at the kiln inle
et loss on ignition free
basis = ((2
2/100
0-3.5) * %
= ( 2/96
6.5 ) * %
= 2.07225
E
Evaporation
ti ffactor
t
E = 1 – (1.05
05//2.0725 )
= 1 - 0.507
 Exam
Exam
mple
l 2
The loss on ignition off the sample for
chlorine is 3.8 %. Itss concentration in the
clinker is 0.03 % and its concentration in t
hot meal [kiln feed] frrom cyclone 4 to the
kiln inlet is 0.65 %.
% What
W is the evaporatio
actor of chlorine in th
his system?
y
 S lution
Soluti
% Chlorine at the kiln
n inlet loss on ignition
ree= ( 0.65 / 100-
100-3.8) * %
= ( 0.65/
65/96.
96.2) * % = 0.676
aporation factor E of chlorine
= 1 - ( 0.03/
03/0.676
= 1 - 0.04
= 0.96
 Exam
Exam
mple
l 3
The loss on ignition off the sample for
potassium in kiln feed
d is 3.5% and the
concentration of potasssium in the clinker
0.29
29%% and its concenntration in the hot raw
meal from cyclone 4 tot the kiln inlet 0.39
39%%
What is the evaporatio
p on factor of potassium
p
n this system?
 S l tti
Soluttion:
The % of potassium at a the kiln inlet loss o
gnition free = ((0
0.39/
39/ 100
100--3.5) * 100
= ( 0.39/
39/96
96..5) * 100
= 0.4
vaporation t E off potassium
ti ffactor t i
= 1 – (0.29
29//0.4)
= 1 - 0.725
When E = 1 indicatte that all volatile
elements evaporate e and none leave
with the clinker
This is clearly indicate
ed in the case of
Example 2 of chlorin ne where the solution
proved in a very unmiistakable way this fac
E in the example is nearly
n one].
When E = 0 indicatte that none of the
volatile elements ev vaporate and all
eave with the Clink ker.
This is clearly indicate
ed in the case of
Example 3 of potasssium where the solutio
proved in a very unmiistakable way this fac
E in the example is very
v small )
A
Average
verage evapo
oration
ti factors
f t
Alkali SO3
SO3 0.2 - 0.9
ave a relatively high me
elting point of 1074ºC,
1074ºC,
boiling at 1689ºC]
1689ºC]
E
Excess SO3
SO 3 0.75

KCl 0.990 - 0.996

ave low melting point of

of 768ºC,
768ºC, boil at 1411ºC
1411ºC
 KCl C
KCl, CaCl
CaCl2
Cl2 and
Cl2 dNNaCl
Cl
Chloride compounds KCl,
K CaCl2 and NaC
CaCl2
are seen to have an evaporation
e factor of
0.990-
990-0.996 in the kiln
n at 800
800ºC.
ºC. These
compounds melt and boil at 1400
1400ºCºC
 Excess
Excesss sulfur
lf
Alkali sulfates have evvaporation factors fro
0.2 to 0.90 but they are
a mostly in the lowe
part of the range, whiile excess sulfur that
cannot find alkali to re
eact with has an
evaporation factor of 0.7575,, therefore it is
best that all sulfur rea
act with alkalis to the
highest extent
olecular
l l Ratio
R ti off S
Sulfur
lf and
d Alk
Alka
f the alkalis are in thee right proportion wit
he sulfur in the syste em, both will combine
ogether and become built in salts in the
clinker minerals.
minerals But in the absence of
alkalis i.e.
i e if there is excess
e sulfur in the
system,
y the more vola atile calcium sulfate w
be formed in the kiln system, and it has a
higher
hi h evaporation ti facf ctor
t
mation of optimum molecular
m ratio betw
r and alkalis in the sys
ystem:
3 /Alk =
( SO3/ 80
0)

K2O /94
/94 + 0.5 * ( Na2O / 62 )
= 1.1
 Estimation of optim
mum molecular ratio
between sulfur and alkalis
a in the system:

f the sulfur and alkalis ratio exceeds 1.1 it

means that the amount of sulfur present in
he kiln feed material that react with the
alkalis is in excess andd the remaining exce
sulfur will react to form CaSO
CaSO44
 Exam
mple 1

A kiln feed sample con

ntains the following
concentration
SO3
SO 3=0.45 % K2O=0O=0.37 % Na2
Na2O=0
O=0.38 %
What is the sulfur and
d alkalis molecular rat
n this
thi system?
t ?
 Solu
ution

he result
h lt iis iindicating
di ti g that
th t there
th is
i no exc
ulfur in the system.
 Exam
Exam
mple
l 2
A kiln feed sample con
ntain the following
concentration
SO3
SO 3=0.57%
57% KK2
2O =0
=0.21 % Na2
Na2O=0
O=0.15 %
What is the sulfur and
d alkalis molecular rat
n this
thi system?
t ?
 S lution
Soluti

esult is indicating that th

here is excess sulfur in t
m that will react to form CaSO4
C
The amount of excess su
ulfur is expressed in gram
SO3
SO3 per 10
00kg
00kg clinker

E.S = 1000
1000x
x SO3
SO3 –850
8 x K2
850x K2O – 650
650x
x
Na2
Na 2O [gram SO
SO33/100
1 kg clinker]
100kg

he limit on the excesss sulfur is given to

e in the range of 250-6
600g/100clinker
 Exam
Exam
mple
l
A kiln feed sample con
ntain the following
concentration
SO3
SO 3=0.57%
57% KK2
2O =0
=0.21 % Na2
Na2O=0
O=0.15 %
 S lution
Soluti
E.S = 1000 x SO3
SO3 –85 50xx K2
50 K2O – 650 x Na2
Na2
gram SO
SO33/100kg
100kg clin
nker]
S = 1000x
1000x 0.57 – 850
8 x 0.21 –650 x 0.1
= 570 – 178
178..5 –97
97..5
= 294 gram SOSO33/100kg
100kg clinker
 comm
mentt
This kiln feed containss a relatively small
amount of excess sulffur
fur.. But if the materia
of the kiln feed is hard
d to burn or the flam
s very strong a coatinng problem may caus
some trouble due to build
b
build--up in the
preheater
p and the pre
p essure loss mayy
ncrease in the prehea ater
Optimum range of molecular of sulfu
nd alkalis in the presence of chlorin

Therefore the optimum

m range is nearly
0 8 to
0.8 t 1.1
1 1.
 comm
mentt
Since the chlorine affinity for reaction with
alkalis is higher than the
t sulfate therefore
he following equation n is applied to
determine the optimum sulfate alkali ratio
where the chlorine is subtracted from the
alkalis
oating and Ring Fo
ormation in Kiln an
Prehe
eater

ertain stage of build-up

build up a new material starts to
and causes more trouble in the system.
formation of spurrite [2 C2S . CaCO3] and sulfo
rite [2 C2S . CaSO4] in case
c of the excess sulfur
in abundance
Where does the build-
build-up
u occur in the kiln an
preheaterr system?

yclone preheater
eheater with Precalcciner
 Wh
h ?
hy?
What is the re eason that mak
suspension--preheater
suspension ter--kilns
with precalciner
more sensitive to th
he volatiles proble
th
than the
th suspensioi n –preheater
h t kilns
kil
How to Decrease th
he Effect of Volatil
Matters on the
e Kiln System?
y
Frequent
q kiln stops
p duue to cyclones
y blocking
g
which need additional time for cooling and
cleaning.
l i
Higher heat consumpttion due to this frequen
stops,
p , additional fuel used
u for reheatingg the
system and higher kiln n’s brick consumption.
Reduced kiln productio on since the operator w
try to continue work wwith less draft in the kiln
and in most cases in reducing
r atmosphere w
 Reducing the burning zone
tempe
perature
This means the reducction of the volatilityy o
he alkalis, chloride annd sulfate component
This can be done by reducing
r the burning
zone temperature. Th he volatility of the sulf
compounds especiallyy calcium sulfate is a
unction
ti off ththe bburnin
ing zone temperature.
t t
Calcium sulfate starts to decompose at
1220ºC
1220 ºC and this therm mal decomposition ca
b avoided
be d d byb lowerin
l ng burning
b zone
his can be done also by other mean
as
Decreasing the silica ratio of the kiln feed an
h making
hus ki theth kiln
kil fee
f edd easier
i to
t burn.
b
Finer grounding of coarsser particles especially
he free silicates if preseent in the kiln feed
herefore easier to burn n kiln feed.
feed The result w
be lower sintering temp perature in the burning
zone decreasing
d i the
th vollatility
tilit .
Accepting higher freefree--lime in the clinker. Th
equires less fuel in the burning zone, and ther
will be no overheating of o the burning zone.
zone
 Controlling
C t lli vo
olatile
l til content
t t
Controlling volatile e content in the raw
material used for grinding and used as kiln
eed.
That means observing the optimum
molecular of sulfur to alkali and ensuring
hat the excess sulfur is minimized
Controlling g Oxidation n condition in kiln
atmosphere. When we e have the oxygen leve
n the
th kil
kiln iin the
th higher
hi h side,
id the
th condition
diti ini t
kiln will be oxidation con ndition.
ndition The dissociatio
of sulfate compounds acchieves balance in the
avor of forming alkali sulfate
s in the oxidation
condition in the kiln.
kiln If we
w have reduction
condition the alkali sulfa ate tends to dissociate t
alkali oxide and oxygen.
ontrolling the re
eduction conditio
in the kiln atmosphere
a p
Calcium sulfate + Carrbon → Calcium oxide
+SO2
+SO 2 + Carbon mono o-oxide
Alkali sulfate + Carbon → Alkali oxide + SO
+ Carbon mono-
mono-oxide
e

These reactions increasse sulfur circulation in

the system
 Installation of a kiln By
By--pass
syst
y tem
A modern byy p pass sys
ystem consists of an ai
quench chamber, a sh hut--off valve, a water
hut
quench chamber and a dust collector
collector. The
air quench chamber iss used to mix ambien
air with the kiln gassees to quickly cool the
h
harmful
f l volatile
l til compounds.d The
Th watert
quench chamber is ussed to cool the gases
quickly to lower temperature for dust
collection
ll
The by-
byy-p
pass systems
y installation will
eventually lead to higher power and heat
consumption in the kiln system.
system Also one o
he major losses with this installation is the
dust loss, since the du ust--laden gas streams
ust
are thrown
th outt off th
the system.
t At 30
30%%
bypass the fuel consumption increases by
about 8-1010%
% and matterial loss by about 3
6%.
The chimneyy
The draft-
draft-fan
The electrostatic
electrostatic--preciipitator
Dust handling from the electrostatic
electrostatic--
precipitator collecting screw
screw--conveyor to the
collecting--pin and conssists of: The bucket
collecting bucket--
elevator the dust pin
elevator, pin, and the granulator to
change the dust into dustd balls and the belt
conveyor for
f ththe ddustt balls
b ll to
t the
th truck
t k
Condition-tower for the hot
Condition- h gas from the quench
chamber
h b to t decrease
d tem
t mperature
t off th
the gas ffrom
450ºC
450 ºC to 150ºC
150ºC by wate er spray system.
The quenching chamber for mixing the hot gas w
ambient air,, laden with thet volatile matters from t
kiln riser-
riser-duct and decrease gas temperature from
1000ºC
1000 ºC to 450ºC
450ºC in a ma atter of seconds to freeze
volatile components in itts solid state and prevent
from existing g in the melttingg phase
p in the by-
byy-p
pass
system. This mixing cham mber is always located in
duct ta
taking g tthe
e hot
ot gas from
f o the
t e kiln riser
se duct a an
nearly 800mm
800mm away from m the connecting point to
riser duct.