BURNING AND COOLING

PROCESS

By:
Raheel Memon

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 Pyroprocessing (0verview)
The homogenous raw meal is preheated in Preheater.
The material is then calcined upto 90% in Calciner.
The Calicined raw meal is sintered into clinker in a
rotary Kiln.
Fuel (Coal , Oil) is fired into Kiln to sinter the raw meal
(Sintering).
Red hot Clinker is cooled in cooler.
The cooled clinker is crushed in Clinker breaker &
stored in silo or Gantry for Finished grinding.

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 Pyroprocessing
Pyroprocessing OR Clinkerization
Main Purpose of pyroprocessing is to produce Clinker
from Raw meal in energy efficient manner
Kiln Operation can be in following mode

1. Wet Process : Kiln Feed Water 30 - 40%

2. Semi Dry/Wet process
3. Dry Process : Kiln Feed Water 2 - 3%

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Raw materials are ground to powder and blended.

Source: PCA, 2003

Raw materials are ground, mixed with water to form slurry,

and blended.

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 Burning changes raw mix chemically into
cement clinker.

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 Pyroprocessing
The choice of the process to be used depends upon a
complex combination of different factors this includes:

The nature of the raw materials.

The thermal efficiency of the different processes and
their variations
Fuel and other energy prices

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 Pyroprocessing
Wet Process Dry Process

1. Moisture content of the slurry is 35- Moisture content of the pellets is 2-3%
40%

2. Size of the kiln needed to manufacture Size of the kiln needed to manufacture
the cement is bigger the cement is smaller

3. The amount of heat required is higher, The amount of heat required is lower, so
so the required fuel amount is higher the required fuel amount is lower

4. Less economically More economically

5. The raw materials can be mix easily, Difficult to control the mixing of raw
so a better homogenous material can be materials process, so it is difficult to
obtained obtain homogenous material

6. The machinery and equipment do not The machinery and equipment need more
need much maintenance maintenance
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 Clinker Manufacture
Mineral Phases in Raw Meal Mineral Phases in Clinker

• Calcite – CaCO3 • Alite

• Belite
• Dolomite –CaMg(CO3)2
• Aluminate
• Quartz–SiO2 • Ferrite
Temperature
• Clay minerals Pressure
• Free lime (unwanted)
• Periclase (unwanted)
• Micas Time
• Alkali Sulfates
• Feldspars (unwanted)
• Aluminum oxide
• Pyrite
• Iron oxide

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 COMPOSITION OF CLINKER
Oxides interact with eachother in the kiln to form more
complex products (compounds). Basically, the major
compounds of clinker for portland cement can be listed as:
Name Chemical Formula Abbreviations

Tri Calcium Silicate (Alite) 3CaO.SiO2 C3 S

Di Calcium Silicate (Belite) 2CaO.SiO2 C2 S

Tri Calcium Aluminate (Aluminate) 3CaO.Al2O3 C3 A

Tetra Calcium Alumino Ferrite 4CaO.Al2O3.Fe2O3 C4AF

(Ferrite)
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 Process of Clinker Production

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  The degree to which the potential reactions
can proceed to “equilibrium” depends on:

1) Fineness of raw materials & their

intermixing.
2) The temperature & time that mix is held in
the critical zone of the kiln.
3) The grade of cooling of clinker may also be
effective on the internal structure of major
compounds.

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 Influence of Compound Composition
on Characteristics of P.C.
 When water added in cement, the compounds in the
cement undergo chemical reactions with the water
independently, and different products result from these
reactions.

  C3S C2S C3A C4AF

Rate of Reaction Moderate Slow Fast Moderate

Heat Liberation High Low Very High Moderate

Early Cementitious Value Good Poor Good Poor

Ultimate Cementitious Value Good Good Poor Poor

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Methods of Determining Compound Composition

 Each grain of cement consists of an intimate

mixture of these compounds.

 They can be determined by:

1) Microscopy (SEM)
2) X-Ray Diffraction

 But due to the variabilities involved the compound

composition is usually calculated using the oxide
proportions.

3) Calculations (Bouge’s Equations)

Assumptions

1) The chemical reactions in the kiln proceeded to

equilibrium.
2) Compounds are in pure form such as C3S & C2S
3) Presence of minor compounds are ignored.
4) Ferrite phase can be calculated as C4AF
5) All oxides in the kiln have taken part in forming the
compounds.
 Microphotograph of clinker

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 Bouge’s Equations

 %C3S=4.071(%C)-7.6(%Si)-6.718(%A)-1.43(%F)-2.852(%S)

 %C2S=2.867(%S)-0.7544(%C3S)

 %C3A=2.650(%A)-1.692(%F)

 %C4AF=3.043(%F)

Where;
CaO (C), SiO2(Si), Al2O3 (A), Fe2O3(F), Sulphur(S)
Example: Given the following oxide composition of a
portland cement clinker.
CaO=64.9% SiO2=22.2%
Al2O3=5.8% Fe2O3=3.1% MgO=4%

Using Bogue’s equation, calculate the compound

composition of
the Portland cement clinker?
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 Influence of Kiln Speed on Klin Operation
Lower rpm, High % of High rpm, Low % of
filling, Less active layer, filling, more active layer,
High free lime, High Low free lime, Low
radiation losses. radiation losses.

Optimum % filling = 8 – 13 with raw meal retention time 20 -25

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minutes
• Kiln speed should be such that volumetric loading is within the range 8-13% .
• Cyclone preheater kilns rotate at 2-2.5rpm.
• Precalciner kilns rotate at 3.5-4.5rpm (Retention time in Preheater is 20-40secs).

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 High degree of filling brings the surface of Charge (feed
material) closer to the flame envelope (covering zone). In this
case, there is a chance of chars trapped inside the charge., which
causes in reduction local condition and increase the volatile
cycle.

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 COOLING
1. The hot clinker is discharged from klin is further treated in
clinker cooler.
2. The clinker cooler serves to cool clinker from the 1200°C at
which it leaves the kiln to less than 100°C by exchange of heat
with ambient air which is, thereby, preheated before entering
the kiln (or precalciner) as combustion air.
3. Water as a direct cooling medium for clinker is used only in
the manufacture of special types of clinker.
4. Air as a Indirect cooling, with separating walls dividing the
clinker from the air flow passages, is sometimes used only for
after cooling.

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 Grate Cooler

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 Cooler
Aim
Recover Maximum Heat from Clinker
Maintain Clinker Quality
Minimize Clinker Temperature

Operational Values
Maximum Heat Recovery in first few compartments is
achieved by keeping high bed height of Clinker
Lower Clinker temperature is achieved in last few
compartments by Low Clinker bed height & High Air volume
 Cooling
As the clinker cools, the main liquid phase crystallizes to
form aluminate phase, ferrite and a little belite.
Fast cooling of clinker is advantageous - it makes for
more hydraulically-reactive silicates and lots of small,
intergrown, aluminate and ferrite crystals.
Slow cooling gives less hydraulically-reactive silicates
and produces coarse crystals of aluminate and ferrite -
over-large aluminate crystals can lead to unreliable
cement setting characteristics.
Very slow cooling allows alite to decompose to belite
and free lime.
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 Influence of cooling on clinker phase
Fast cooling well distributed small Slow cooling larger crystals
crystals

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