19 Jonathan Forinton ATEC

PREHEATER BLOCKAGES
By Pedro Montes de Oca and Jonathan Forinton

p.montesdeoca@atec-america.com
j.forinton@atec-america.com
EVENT:
PLACE:
DATE:
FICEM-APCAC Technical Conference

Montego Bay, Jamaica
2010sep08
Priviledged Information not to be copied. All rights reserved.
PREHEATER BLOCKAGE SCENARIOS
2 types of cause:
1- mechanical
- design of ducts/cyclones
- equipment damage
2- chemical
- chlorine
- sulphur
BLOCKAGES: MECHANICAL ASPECTS

Care taken at the inlet to
lower cyclones
Preferably the
cyclone cone has
20 to vertical
Dip tubes or refractory pieces

can block cyclone cones.
Standard test is to throw a light
bottle down. No steel balls!
3
The inlet from

Combustion
Chamber to kiln riser
is a known issue
Chemical Causes
A) Chemistry of buildups
DEFINITION OF BUILDUPS
Buildups are caused by melt formation
followed by solidification that
acts as binder for dust particles
to agglomerate
agglomeration due to the

presence of molten alkali chlorides
Consequence: preheater blockages
Composition of Buildups:
Analysis leads to cause of formation

formation is dependent on
the presence of molten

salts, especially alkali sulfates and chlorides.
Samples show that the alkali, S and Cl concentration in the
build-up material is significantly higher than in the kiln feed
Deposits and link to operation

Mineral
deposited
Ternesite
Anhydrite
Langbeinite
Chemical
Possible link to kiln operation
Formula
C5(SiO4)2SO4 High sulphur recirculation in flue gas,
CaSO4
high sulphur fuel utilization
K2Ca2(SO4)3
Sylvite
Halite
KCl
NaCl
K2SO4
Arcanite
Aphthitalite K3Na(SO4)2
thernadite Na2SO4
High chlorine concentration in the fuel or

raw materials /high accumulationrecirculation rate
Low or no alkali bypass flow rate,
high alkali concentration in raw materials
Affinity
1: Alkalis
Combine with
Chlorine
2: Remaining
alkalis will
combine with
sulphur
3.-Remaining
sulphur will
combine with
calcium
Chlorine
Cl
Alkalis
Na, K
Sulphur
S
Calcium
Ca
Alkali Chlorides
NaCl. KCl
Alkali Carbonates,
OxidesKOH,Na2CO3
Alkali Sulphates
Na2SO4, K2SO4
4.-Alkalis in
Excess of S,
combination
with CO3, OH
Calcium Sulphates
CaSO4
Affinity
Alkalis will preferentially combine with any chloride present.
Best A/S ratio is when there is just enough sulfur present to combine
stochiometrically with the remaining alkalis.
excess of sulfur, CaSO4 formation sulphur in CaSO4 will volatilize
completely.
excess of alkalis alkali aluminate can form stiffening problems in concrete
and mortar.
Bypass alkali in excess possible low alkali cement + no stiffening problems
no sulphur excess problems.
Chemical Causes
B) Volatility
10
Melting and Boiling points

Component
Melting point C
Boiling point C
Volatiliy %
KCl
776
1400
60 - 80
NaCl
801
1413
40 - 60
K2SO4
1069
1669
50 -60
CaCl2
772
1935
35 - 50
Trapped in kiln system due to physical

properties
11
Recirculation of volatiles
Input
800 C:
Condensation Cl
Recirculation
Output
1200 C:
Evaporation Cl
12
Effects :
Transfer of Thermal profile of kiln

Evaporation
Endothermic
Condensation
Exothermic
T rises
More gas volume,
gas velocity, dp,
Energy Fan
13
T sinks
Flame shape
Fuel Consumption
1. INTRODUCTION ALTERNATIVE FUEL
Kiln Conditions:
Factors that affect volatility
Gas velocity:
A higher gas velocity reduces the vapor pressure of volatiles in the
atmosphere, increasing their volatility.
A higher sinter zone temperature as required for harder burning mix will
increase volatility.
Easier burning material less burning zone temperature less volatility.
Residence time at high temperature: longer time at high temp. increases
volatilities and the amount of volatiles main burner flame shape
A higher CO2 concentration in the kiln will increase volatility of sodium and
potassium.
Reducing conditions will increase the volatility of sulfur, while higher oxygen
levels will decrease it (up till ~2%)
14
Sulphate SO2 equilibrium reaction

Temperature
CaSO4 CaO + SO2 + O2
Almost no
reaction
15
SO2
absobtion
Volatization
Sulphate SO2 equilibrium reaction

Oxygen
Too little excess air and

reducing conditions
Increase of volatility
O2 % in kiln inlet 1-2%
Influence of O2 on Sulphur volatility

only in range: 0 2%
16
Typical Cl - Mass Balance

Raw Meal
Clorine In:
269 kg/h
Input: 269 kg/h Raw Meal

+8 kg/h
Fuel CC
+5 kg/h Fuel MB
=
283 kg/h
Output: 130 kg/h Clinker
Diff:
153 kg/h
Chlorine Out:
130 kg/h
Fuels MB In:
5 kg/h
Fuels
Calciner In:
8 kg/h
17
Operational issues
18
BLOCKAGES AND PERFORMANCE

Build-ups
increasing build-ups cause reduced gas flows at the same ID fan pressure
Fluctuating gas flows

due to fluctuating O2 and heat levels, CO-increases and excess O2 requires ID fan
increase
Fluctuating fuel
fluctuating temps cause fuel increase, thereby increasing S or Cl inputs
Cold Air Ingress

Increasing the ID fan to keep up, kiln inlet under-pressure increase draws in more
false air
Circulating Phenomena
Destablized operation, CO increase and false air cause volatization to spiral out of
control
Blockages
increasing volatization causes more build-ups. Return to the start...
19
INVESTIGATION STEPS
1. General description of situation (position of build-ups, reproducible

conditions that seem to lead to the situation)
2. Ongoing analysis of hot meal (LOI, SO3, Cl, Na2O, K2O, CaO)
3. Pyro-section mass and heat balance
4. Plot ongoing points on Cl-SO3 graph
5. Sample the build-up material (XRF)
6. Analyse Inputs-Outputs for responsible circulating element
20
RESULTS OF BUILD-UPS SEVERE!

1.
2.
3.
4.
5.
6.
Blockages cause unplanned shut-downs and loss of earnings

Constant start-up and stop decreases refractory life
Build-up and dropping off causes mechanical wear of refractory
Severe safety issues involved with cleaning big build-ups
Clinker quality fluctuations + restarts = lots of rejected clinker
Increased heat energy use due to:
a)
b)
dusty clinker reduces radiation inside kiln

more false air and operation at more excess air
7.
8.
9.
10.
Increase shifts to cope with cleaning and higher maintenance

Lower possibility to use alternative fuels because heat levels lower
Clinker cooler instability means increased cement setting times
Lower production level if preheater, kiln inlet, burner, or cooler is the
bottleneck
11. Lower production because away from optimum performance
12. Increase wear on burner and refractories due to dust and velocities
increase
andandand!
21
OPTIMUM EQUIPMENT REDUCES

OPERATIONAL DISTURBANCE
Pendulum flaps
Reliable operation.
Low maintenance.
Increased thermal efficiency.
Expansion joints
improper joints split and let in false air
Splash boxes
Optimized homogenous meal
distribution.
Improved heat exchange.
Dip tubes
Easy to install, long lifetime
22
MAIN BURNER AFFECTS VOLATILITY
23
Chlorine Bypass
24
CL-SO3 balance on fuel change
operation
without bypass
original
operation
operation with
bypass
25
BYPASS TAKE -OFF

Main Advantages:
Big take off area

Low take off velocity
Particles < 10 m
26
No cyclones needed
Gas can be used for raw meal
drying to reduce thermal losses
QUENCH CHAMBER
Made completely of metal

(no lining required)
27
Cooling in one step to 200 C
Minimum space requirement
Simple functionality
STANDARD BY-PASS FLOWSHEET
Comp. Air
28
Cl REDUCTION
10 % bypass rate is sufficient for chloride bypass systems

29
TYPICAL RESULTS
Kiln gas take off quantity 6000 Nm/h
First stage cooling from 1100 C to 450 C
50% coarse dust removed in cyclone, returned to kiln inlet or circulated
in cyclone riser
Second stage cooling from 450 C to approx 220 C
Gas filtration system with max. dust quantity of 10 mg/Nm is positioned
on top of bypass dust silo
Cleaned bypass gas 59000 Nm/h design is ducted to main stack
100% of dust is transported to special storage area; silo discharge
capacity 30 t/h
30
EXAMPLE INSTALLATION
Advantages:
bypass
cyclone
2nd stage
quench
Reliable operation.
Low maintenance
mixed gas
duct to filter
coarse dust
return
No big civil engineering

No refractory after takeoff
Cheap and simple to install
1st stage
quench
31
A TEC REGIONAL ORGANISATION

HEAD OFFICE
Krems ,Austria
A TEC China
Beijing, China
A TEC AMERICA
Puebla, Mexico
ATEC-GRECO
Sao Paulo, Brasil
32
A TEC ASIA
Kuala Lumpur, Malaysia
THANK YOU FOR YOUR

ATTENTION
Please visit www.atec-ltd.com
A TEC AMERICA
Calz. Zavaleta 1306A /24 suite 5278
Col. Santa Cruz Buenavista
72150 Puebla, PUE, Mexico
Tel.: +52 222 889 7907
E-Mail: inbox@atec-america.com
33

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PREHEATER BLOCKAGES

By Pedro Montes de Oca and Jonathan Forinton

FICEM-APCAC Technical Conference

Priviledged Information not to be copied. All rights reserved.

PREHEATER BLOCKAGE SCENARIOS

Priviledged Information not to be copied. All rights reserved.

BLOCKAGES: MECHANICAL ASPECTS

Dip tubes or refractory pieces

The inlet from

Priviledged Information not to be copied. All rights reserved.

Priviledged Information not to be copied. All rights reserved.

agglomeration due to the

Consequence: preheater blockages

Priviledged Information not to be copied. All rights reserved.

Analysis leads to cause of formation

the presence of molten

Priviledged Information not to be copied. All rights reserved.

Deposits and link to operation

High chlorine concentration in the fuel or

Priviledged Information not to be copied. All rights reserved.

Priviledged Information not to be copied. All rights reserved.

Priviledged Information not to be copied. All rights reserved.

Priviledged Information not to be copied. All rights reserved.

Melting and Boiling points

Trapped in kiln system due to physical

Priviledged Information not to be copied. All rights reserved.

Priviledged Information not to be copied. All rights reserved.

Transfer of Thermal profile of kiln

1. INTRODUCTION ALTERNATIVE FUEL

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Priviledged Information not to be copied. All rights reserved.

Sulphate SO2 equilibrium reaction

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Sulphate SO2 equilibrium reaction

CaSO4 CaO + SO2 + O2

Too little excess air and

O2 % in kiln inlet 1-2%

Influence of O2 on Sulphur volatility

Priviledged Information not to be copied. All rights reserved.

Typical Cl - Mass Balance

Input: 269 kg/h Raw Meal

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Priviledged Information not to be copied. All rights reserved.

BLOCKAGES AND PERFORMANCE

Fluctuating gas flows

Cold Air Ingress

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1. General description of situation (position of build-ups, reproducible

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RESULTS OF BUILD-UPS SEVERE!

Blockages cause unplanned shut-downs and loss of earnings

dusty clinker reduces radiation inside kiln

Increase shifts to cope with cleaning and higher maintenance

Priviledged Information not to be copied. All rights reserved.

OPTIMUM EQUIPMENT REDUCES

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MAIN BURNER AFFECTS VOLATILITY

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