PROCESS & KILN SYSTEMS AND

BASIC PRINCIPLES OF OPERATION

ECONOMIC SUCCESS OF THE PLANT

CONTINUOUS OPERATIO N
TROUBLE FREE OPERATION

DESCRIPTION OF THE PROCESSES

UNDERSTANDING OF THE IMPORTANT PROCESSES
 CHEMICAL PROCESSES
INTRODUCTION
CHEMICAL TRANSFORMATIONS
REACTIONS IN BURNING ZONE PROCESS
MODIFICATIONS TO MINERAL STRUCTURES
DEHDRATION OF ARGILLACEOUS MINERALS
DECOMPOSITION OF CARBONATES
REACTION BETWEEN SOLID PHASES
REACTION IN THE PRESENCE OF LIQUID PHASES
a.MELT FORMATION
b.ALITE FORMATION
REACTION DURING COOLING
PROCESS RELATED TO KILN ZONES

CALCINING ZONE
HEATING ZONE
LIQUID ZONE
HIGH TEMPERATURE ZONE
COOLING ZONE
 CHARACTERIZED BY PRODOMINENT
PHYSICAL AND CHEMICAL PROCESSES

UNIFORM AND PREDICTABLE QUALITY

WITH MINIMUM ENERGY CONSUMPTION
FULL UTILIZATION OF THE CAPACITY

UNDERSTANDING OF THE PROCESS PARAMETERS

 CALCINING ZONE
TEMPERAURE 820 C TO 900 C
DECARBONATION AND CO2
PARTIAL PRESSURE
MATERIAL RUSH
 HEATING ZONE
TEMPERATURE 900- 13000 C
UPPER TRANSITION ZONE - DARK COLOUR
FORMATION OF COATING
SUDDEN RISE IN TEMPERATURE
FORMATION OF INTERIM PHASES
FORMATION OF LIQUID PHASES STARTS
LIQUID ZONE
TEMPERATURE 1300 TO 1350 0 C
NODULIZATION BEGINS
FORMATION OF C3S STARTS BUT SLOW
HIGH TEMPERATURE ZONE
FORMATION AND GROWING OF C3S
SINTERING OF THE SOLID PHASES

COOLING ZONE
AGGLOMERATION DUE TO COOLING
C3S TO C2S AND CAO
CAO REACTS WITH CA TO FORM C3A
GRINDABILIT OF THE CLINKER
SP kiln
ILC E kiln
ILC kiln
SLCD kiln
SLC kiln
SLC I kiln
ILC Calciner
ILC I Calciner
SLC Calciner
SLC D Calciner
Cyclone design
Immersion tube
 INEFFICIENT SEALS
=
ENERGY LOSS +
PRODUCTION CAPACITY LOSS

HOT SECONDARY AIR IS REPLACED WITH

COLD OUTSIDE AIR

KILN DISCHARGE SEAL

 INEFFICIENT SEALS
=
ENERGY LOSS +
PRODUCTION CAPACITY LOSS

HOT GASES ARE REPLACED WITH

COLD OUTSIDE AIR

FEED END SEAL

 INEFFICIENT SEALS
=
ENERGY LOSS +
PRODUCTION CAPACITY LOSS

LAMELLAR SEAL
 INEFFICIENT SEALS
=
ENERGY LOSS +
PRODUCTION CAPACITY LOSS

REVERSE LAMELLAR SEAL

 INEFFICIENT SEALS
=
ENERGY LOSS +
PRODUCTION CAPACITY LOSS

FLOATING RING +
PNEUMATIC PISTON TYPE SEAL
DISCHARGE SEAL
DESIGN FEATURES

As an option it is possible to install

a new nose ring segment cooling
system with multiple nozzles
 INLET SEAL
DESIGN FEATURES

Graphite blocks are air cooled Excess dust is evacuated through a hopper