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  • KilnOpBasics - Pyroprocessing 2

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    This document provides an overview of kiln operation basics and pyroprocessing. It discusses the major equipment in a kiln system, including preheaters, precalciners, kilns, and coolers. It focuses on preheaters and cyclones, explaining how they work via heat exchange principles and the flow of gas and materials. Key components of cyclones like the cylinder and cone are described. The document also outlines pyroprocessing zones and temperature diagrams.

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    KilnOpBasics_Pyroprocessing 2

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    This document provides an overview of kiln operation basics and pyroprocessing. It discusses the major equipment in a kiln system, including preheaters, precalciners, kilns, and coolers. It focuses on preheaters and cyclones, explaining how they work via heat exchange principles and the flow of gas and materials. Key components of cyclones like the cylinder and cone are described. The document also outlines pyroprocessing zones and temperature diagrams.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    243 views86 pages

    KilnOpBasics - Pyroprocessing 2

    Uploaded by

    mustaf
    This document provides an overview of kiln operation basics and pyroprocessing. It discusses the major equipment in a kiln system, including preheaters, precalciners, kilns, and coolers. It focuses on preheaters and cyclones, explaining how they work via heat exchange principles and the flow of gas and materials. Key components of cyclones like the cylinder and cone are described. The document also outlines pyroprocessing zones and temperature diagrams.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 86

    Kiln Operation Basics

    Pyroprocessing 2
    Kiln Operation Basics – Pyroprocessing 2

    Content

    • Introduction
    • Pyroprocessing: Different types of process
    • Zoom on preheaters / precalciners
    • Pyroprocessing zones
    • LT diagrams
    • Major equipment description
    • Preheater & Cyclone
    • Precalciner
    • Kiln
    • Cooler

    EVA Communication kit February 2008 - 2


    Kiln Operation Basics – Pyroprocessing 2

    Kiln system

    EVA Communication kit February 2008 - 3


    Kiln Operation Basics – Pyroprocessing 2

    Major equipment description

    • Let’s now look at the kiln system in order to:


    • List their main components
    • Describe their function
    • Describe their specificities

    EVA Communication kit February 2008 - 4


    Kiln Operation Basics – Pyroprocessing 2

    Content

    • Introduction
    • Pyroprocessing: Different types of process
    • Zoom on preheaters / precalciners
    • Pyroprocessing zones
    • LT diagrams
    • Major equipment description
    • Preheater & Cyclone
    • Precalciner
    • Kiln
    • Cooler

    EVA Communication kit February 2008 - 5


    Kiln Operation Basics – Pyroprocessing 2

    Cyclone preheater
    • Do you know how a
    preheater works?

    • Do you know how a


    cyclone works?

    EVA Communication kit February 2008 - 6


    Kiln Operation Basics – Pyroprocessing 2

    Preheater & Cyclone

    • Heat exchanges principles


    • Heat exchanges in the cyclone
    • Gas & material flow in the tower
    • Temperatures in the tower
    • Pressures in the tower
    • Preheater sensors & critical sensors

    EVA Communication kit February 2008 - 7


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 8


    Kiln Operation Basics – Pyroprocessing 2

    Objective:

    Function
    of the
    heat
    exchange:

    EVA Communication kit February 2008 - 9


    Kiln Operation Basics – Pyroprocessing 2

    Heat exchange

    • In order to optimize the thermal transfer in a


    preheater, the heat exchange between gases &
    material has to be progressive

    Material

    Gas

    EVA Communication kit February 2008 - 10


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 11


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 12


    Kiln Operation Basics – Pyroprocessing 2

    Do you need a calculator?

    EVA Communication kit February 2008 - 13


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 14


    Kiln Operation Basics – Pyroprocessing 2

    585°C is the right answer! When they separate, gas &


    material are practically at the same temperature.
    However, in practice, material temperature is slightly lower

    EVA Communication kit February 2008 - 15


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 16


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 17


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 18


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 19


    Kiln Operation Basics – Pyroprocessing 2

    The separation takes place inside


    the cyclone. Let’s now look at a
    cyclone more in detail

    * Example of 4 stages preheater

    EVA Communication kit February 2008 - 20


    Kiln Operation Basics – Pyroprocessing 2

    Preheater & Cyclone

    • Heat exchanges principles


    • Heat exchanges in the cyclone
    • Gas & material flow in the tower
    • Temperatures in the tower
    • Pressures in the tower
    • Preheater sensors & critical inspections

    EVA Communication kit February 2008 - 21


    Kiln Operation Basics – Pyroprocessing 2

    Do you know the different components of a


    cyclone?
    1. Cylinder
    2. Cone
    3. Tipping valve
    4. Entry feed
    Chute
    5. Splash box
    6. Dip Tube
    7. End Feed
    chute
    8. Outlet Duct
    9. Air cannons
    10. Inlet Duct

    EVA Communication kit February 2008 - 22


    Kiln Operation Basics – Pyroprocessing 2

    Cyclone components

    Dip
    tube
    Dip
    tube

    Air
    cannons

    EVA Communication kit February 2008 - 23


    Kiln Operation Basics – Pyroprocessing 2

    How does a cyclone work?

    Dip
    tube

    Where do you think


    this process takes
    place?

    EVA Communication kit February 2008 - 24


    Kiln Operation Basics – Pyroprocessing 2

    How does a cyclone work?

    Dip
    tube
    MIXING

    EVA Communication kit February 2008 - 25


    Kiln Operation Basics – Pyroprocessing 2

    How does a cyclone work?

    Dip
    tube

    Where do you
    think this
    process takes
    place?

    EVA Communication kit February 2008 - 26


    Kiln Operation Basics – Pyroprocessing 2

    How does a cyclone work?

    Dip
    HEAT
    tube EXCHANGES

    EVA Communication kit February 2008 - 27


    Kiln Operation Basics – Pyroprocessing 2

    How does a cyclone work?

    Dip
    tube

    Where do you think


    this process takes
    place?

    EVA Communication kit February 2008 - 28


    Kiln Operation Basics – Pyroprocessing 2

    Dip
    tube
    SEPARATION

    EVA Communication kit February 2008 - 29


    Kiln Operation Basics – Pyroprocessing 2

    Separation

    • The cylinder & the cone form a « Dropout chamber »


    • Drop in the gas speed

    • Gas speed inversely proportional to the area


    • S cylinder = 4 x S inlet duct => Gas speed in cylinder 4 times
    lower and the large material particles cannot remain suspended

    EVA Communication kit February 2008 - 30


    Kiln Operation Basics – Pyroprocessing 2

    Dip
    tube

    EVA Communication kit February 2008 - 31


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 32


    Kiln Operation Basics – Pyroprocessing 2

    Dip
    tube

    EVA Communication kit February 2008 - 33


    Kiln Operation Basics – Pyroprocessing 2

    Dip
    tube

    EVA Communication kit February 2008 - 34


    Kiln Operation Basics – Pyroprocessing 2

    Preheater & Cyclone

    • Heat exchanges principles


    • Heat exchanges in the cyclone
    • Gas & material flow in the tower
    • Temperatures in the tower
    • Pressures in the tower
    • Preheater sensors & critical inspections

    EVA Communication kit February 2008 - 35


    Kiln Operation Basics – Pyroprocessing 2

    Preheater

    • Material flow • Gas flow


    How long
    does it
    take for
    the
    material to
    go through
    the tower?

    30’’

    EVA Communication kit February 2008 - 36


    Kiln Operation Basics – Pyroprocessing 2

    Preheater & Cyclone

    • Heat exchanges principles


    • Heat exchanges in the cyclone
    • Gas & material flow in the tower
    • Temperatures in the tower
    • Pressures in the tower
    • Preheater sensors & critical inspections

    EVA Communication kit February 2008 - 37


    Kiln Operation Basics – Pyroprocessing 2

    Preheater

    • Work in pairs to do this exercise


    EVA Communication kit February 2008 - 38
    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 39


    Kiln Operation Basics – Pyroprocessing 2

    Preheater & Cyclone

    • Heat exchanges principles


    • Heat exchanges in the cyclone
    • Gas & material flow in the tower
    • Temperatures in the tower
    • Pressures in the tower
    • Preheater sensors & critical inspections

    EVA Communication kit February 2008 - 40


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 41


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 42


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 43


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 44


    Kiln Operation Basics – Pyroprocessing 2

    Just to make sure this


    is clear for all of you:

    EVA Communication kit February 2008 - 45


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 46


    Kiln Operation Basics – Pyroprocessing 2

    Preheater & Cyclone

    • Heat exchanges principles


    • Heat exchanges in the cyclone
    • Gas & material flow in the tower
    • Temperatures in the tower
    • Pressures in the tower
    • Preheater sensors & critical inspections

    EVA Communication kit February 2008 - 47


    Kiln Operation Basics – Pyroprocessing 2

    Basics on sensors

    • Let’s see some basics on sensors


    • Different types of sensors
    • How do they work?
    • What you need to look at?

    • Link to ppt on sensors

    EVA Communication kit February 2008 - 48


    Kiln Operation Basics – Pyroprocessing 2

    Preheater tower visit

    • Site visit
    • By workgroups, you will have to:
    • Identify the temperature sensors
    • Identify the preheater sensors
    • Identify the inspection doors
    • Define the list of critical field inspections
    • Inspections done by field operators
    • 1st level running inspections

    EVA Communication kit February 2008 - 49


    Kiln Operation Basics – Pyroprocessing 2

    Preheater tower visit


    • You will locate on this sketch:
    • The Pressure sensors
    • The Temperature sensors (material & gases)
    • Any other relevant information
    • One sketch for pressure sensors, one sketch for
    temperature sensors

    EVA Communication kit February 2008 - 50


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 51


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 52


    Kiln Operation Basics – Pyroprocessing 2

    Preheater: pressure & temperature sensors

    EVA Communication kit February 2008 - 53


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 54


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 55


    Kiln Operation Basics – Pyroprocessing 2

    EVA Communication kit February 2008 - 56


    Kiln Operation Basics – Pyroprocessing 2

    Critical field inspections

    • Safety / Housekeeping
    • Poking holes (sealing)
    • Buildups (check & remove)
    • Flaps (play to check free movement)
    • Tipping valve functioning
    • Air canons (if working)
    • Gas analysers condition
    • Pressure taping points
    • Hot spots at the cyclones / ducts
    • Noise / Vibrations
    • Leakages (oil, material…)

    EVA Communication kit February 2008 - 57


    Kiln Operation Basics – Pyroprocessing 2

    Content

    • Introduction
    • Pyroprocessing: Different types of process
    • Zoom on preheaters / precalciners
    • Pyroprocessing zones
    • LT diagrams
    • Major equipment description
    • Preheater & Cyclone
    • Precalciner
    • Kiln
    • Cooler

    EVA Communication kit February 2008 - 58


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    • Calcining in Preheater Process


    • Precalciner principle
    • Precalciner advantages

    EVA Communication kit February 2008 - 59


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater
    • In order to better understand Precalciner objectives &
    advantages, let’s focus on Calcining step and remind us
    its characteristics for a Preheater kiln

    w e have
    em ber… rlier…
    Rem th is ea
    ed
    cover

    EVA Communication kit February 2008 - 60


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater

    EVA Communication kit February 2008 - 61


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater

    EVA Communication kit February 2008 - 62


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater

    EVA Communication kit February 2008 - 63


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater
    • In a preheater process, the thermal exchange is not
    that efficient
    • Because the material in the kiln presents only a small heat
    exchange surface to the gases and the kiln lining
    • The time for calcination will therefore be quite long: about
    30 minutes

    Exchange
    efficiency

    EVA Communication kit February 2008 - 64


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater

    EVA Communication kit February 2008 - 65


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater

    EVA Communication kit February 2008 - 66


    Kiln Operation Basics – Pyroprocessing 2

    Calcining in Preheater - Conclusion

    The solution: the Precalciner

    EVA Communication kit February 2008 - 67


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    EVA Communication kit February 2008 - 68


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    • Calcining in Preheater Process


    • Precalciner principle
    • Precalciner advantages

    EVA Communication kit February 2008 - 69


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    EVA Communication kit February 2008 - 70


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    3 flows input:

    EVA Communication kit February 2008 - 71


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    EVA Communication kit February 2008 - 72


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    EVA Communication kit February 2008 - 73


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    EVA Communication kit February 2008 - 74


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    EVA Communication kit February 2008 - 75


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    Tertiary air louver

    Diaphragm

    EVA Communication kit February 2008 - 76


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner

    • Calcining in Preheater Process


    • Precalciner principle
    • Precalciner advantages

    EVA Communication kit February 2008 - 77


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner: advantages

    EVA Communication kit February 2008 - 78


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner: advantages

    • Let’s do this exercise again:

    EVA Communication kit February 2008 - 79


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner: advantages

    • Let’s see why…

    EVA Communication kit February 2008 - 80


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner: advantages

    For the same kiln diameter, a


    precalciner allows to increase the
    production rate EVA Communication kit February 2008 - 81
    Kiln Operation Basics – Pyroprocessing 2

    Precalciner: advantages

    • As a result, production is increased!


    EVA Communication kit February 2008 - 82
    Kiln Operation Basics – Pyroprocessing 2

    Precalciner: other advantages

    Use of fuels with a high


    content of ashes

    Decrease volatilisation *

    More stable kiln


    operations

    * Volatilisation will be seen in details later in the course

    EVA Communication kit February 2008 - 83


    Kiln Operation Basics – Pyroprocessing 2

    Precalciner advantages

    EVA Communication kit February 2008 - 84


    Kiln Operation Basics – Pyroprocessing 2

    Content

    • Introduction
    • Pyroprocessing: Different types of process
    • Zoom on preheaters / precalciners
    • Pyroprocessing zones
    • LT diagrams
    • Major equipment description
    • Preheater & Cyclone
    • Precalciner
    • Kiln
    • Cooler

    EVA Communication kit February 2008 - 85


    Kiln Operation Basics – Pyroprocessing 2

    Kiln

    • In CRO Pyroprocessing 3.ppt

    EVA Communication kit February 2008 - 86

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