Preheater calciner systems

Successful on every level

Key benefits An optimal process

Today’s modern plant preheats raw
Proven NOx reduction from high
temperature “stage-less” combustion
- Effective emission control meal to calcination temperature in a is incorporated into the standard
multi-stage cyclone preheater.
preheater. Most design of the ILC preheater. It’s
It’s a very
ve ry
- Easy operation of the calcination process takes place uncomplicated and effective way to
in a separately fired, stationary calciner, create low NOx emissions with only
- Highly reliable while the remaining calcination and one firing location, one meal split and
clinkerization process takes place in one tertiary air stream entering
- Optimised fuel and power
a rotary kiln. tangentially to the calciner.
calciner.
consumption

- Excellent suitabilit
suitability
y for FLSmidth has precisely what cement Our design is based on dividing the
producers need to make it an optimal meal from the second-lowest stage
low-grade fuels
process. With its low emissions, cyclone to the kiln riser and the calciner.
- Flexibile design for easy flexibility and ease of operation, These feed points are separated by an
upgrades the FLSmidth In-Line Calciner (ILC) expanded riser duct that forms a NO x
preheater has been a success since reducing zone. That is, the calcining
its debut in 1976. And thanks to chamber is built (at least partially) into
our continual development of the the kiln riser. All of the calciner fuel is
system ever since, the ILC is still at introduced to the kiln riser duct with
the forefront of technology. Flexible less oxygen than required for complete
enough to meet future demands as combustion, thereby forming a reducing
well, the ILC can help plants stay in atmosphere.
the lead for many years to come.
Above the reduction zone is the main
How the ILC preheater works calciner vessel, which is divided into
Raw meal is introduced at the inlet gas two or more sections separated by a
duct to the Stage I (top) cyclones. It is notch. The changes in cross-sectional
subsequently preheated by hot, areas create turbulence that ensures
countercurrent gas flow as it is effective mixing of fuel, raw meal and
continuously collected and passed gas, improving heat transfer and
down the other cyclone stages in the combustion. The calciner outlet loop
preheater to the calciner. Fuel is burned duct ensures optimum gas retention
in the calciner to achieve 92-95% of time, further mixing and complete fuel
the total material calcination before combustion.
collection in the bottom cyclone and
entrance into the kiln. Combustion air Optionally,
Optionally, the second- or third-lowest
for the calciner is taken from the kiln stage cyclone material can be further
via the riser duct and through a separate split to allow for diversion of a portion
tertiary air duct from the cooler.
cooler. of the meal directly into the upper
 3

section of the calc iner.

iner. This creates a 1 Calciner outlet loop duet
“hot zone” in the lower section of the
calciner that is conducive to burning 2 Meal dividing gate
difficult fuels and further NOx for “hot zone”
reduction.
3 Meal dividing gate for
NOx reducing zone
Design characteristics
• Full capacity range of today’s
today’s 4 Calciner vessel notch
plants of 13,000 tpd or more
• Built with single or multiple 5 Optional “hot zone”
preheater strings with up to 6
6 Tertiary air inlet 1
cyclone stages
• Ratio of firing in calciner: 55-65% 7 NOx reducing zone
• Calcination at kiln inlet: 92-95%
• Allowable bypass of kiln gas: 0-60%
0-60% 8 Optional kiln gas bypass
• For bypass of kiln gas up to 100%,
9 Calciner firing point
special ILC version applies
• Optional “hot zone” in lower
section of calciner 2
• Available with or without the
HOTDISC™ combustion device
reactor for burning coarse
alternative fuels

Operating characteristics
• High-efficiency cyclones with low 3
4
pressure drop resulting in low fuel
and power consumption
• Lowest NOx emission from unique
high-temperature reduction zone
• Simultaneous low CO emission 5
specially due to calciner notch
and outlet loop duct
• Uncomplicated operation with 6
single entry locations of calciner
7
fuel and tertiary air
• Suitable for firing both traditional
8 9
and alternative fuels 5 stage In-Line Calciner
(ILC) preheater 
4

Creating a system that

meets unique needs

Burn coarse alternative fuels 1. Number of stages/cyclones 3. Size of cyclones

Increasingly,
Increasingly, plants are burning solid FLSmidth’s
FLSmidth’s preheater calciner The selection of cyclone sizes is a
waste fuels to achieve a variety of systems are equipped with up to balance of having the smallest
benefits. By integrating the ILC with six stages of cyclones. The number cyclone dimensions while
our HOTDISC combustion device, it is of stages is normally determined by maintaining the lowest overall
possible to achieve unsurpassed fuel the drying requirements in the pressure drop through the
flexibility with minimal impact on different grinding systems. preheater.
preheater. This is to minimise the
process stability and performance. Emission requirements or other use induced draft (ID) fan power
of the preheater exit gas can also consumption – the most power-
The HOTDISC is a safe, simple and affect the number of stages, as can consuming part of a kiln system.
effective combustion device that has practical matters such as local
proven to be the best available building codes/height restrictions. The size of cyclones relates to the
technology for substituting calciner maintaining of desired gas velocity
fuel with coarse alternative fuels. 2. Number of strings criteria and efficiency.
efficiency.
With the HOTDISC, plants can burn The number of strings of cyclones
all kinds of solid waste in sizes up to is generally related to the plant’s
plant’s Increasing the preheater cyclone
1.2 metres. This eliminates the need capacity requirements – the more dimensions reduces the pressure
for expensive shredding of lumpy capacity needed, the more strings drop. But for any given cyclone
waste material. typically needed. Most commonly,
commonly, geometry,
geometry, stable preheater
the system encompasses one or operation (without raw meal falling
An optimal solution two strings, but more may be through the riser ducts) requires a
Preheater and calciner design has a considered for the largest of certain minimum gas velocity.
velocity.
strong influence on operational plants. A transition from one to
efficiency,
efficiency, emissions and ability to two strings relates to the size of
effectively burn different types of the cyclones and the resulting
fuels. Every FLSmidth preheater volume of the preheater Preheated raw
calciner system is optimised for the construction. meal inlet 
Emergency cold
individual situation in which it is to be  Alternative
raw meal inlet 
used. FLSmidth’s decades of fuel inlet 
HOTDISC™  Ashes/residues
experience in this area enables us to combustion Kiln gases
deliver solutions that are ideal for device

each plant’s specific challenges. Tertiary

air 
These are some of the key
factors that go into designing
Kiln riser duct 
an optimal solution:
Rotating disc 
Scraper 
 5

Typical process flowsheet

of an ILC kiln system

-465 mm WG (4.5 kPa)

293  C
°

material  1 Raw meal feed

478  C
°
gas 2 Exhaust gas
3 Kiln gas bypass, if any
fuel 
4 Clinker
5 Kiln burner
650  C
°
6 Calciner burners
7 Tertiary air duct
8 Tertiary air duct damper
9 Cooler excess air
799  C
°

890  C
°

1000  C
°

280  C
°

100  C
°
6

Preheater components

Cyclones Central pipes

FLSmidth preheaters have been Central pipes (thimbles) are standard
based on proven low pressure loss in all cyclone stages to provide high
(LP) cyclones. The unique design of separation efficiency. The lowermost
the LP cyclone ensures high thermal cyclones feature a cast, segmented
efficiency and low pressure drop while design with a hanging suspension
enabling a flexible and space-saving system and common elements
layout. LP cyclones have no horizontal throughout. This enables easy
surfaces on the inside for material to installation and maintenance.
Cast segmented central pipe
accumulate, thereby securing stable
operation. The top stage has a special Sluice flaps and distribution
geometry to provide the lowest dust boxes
loss while maintaining low pressure To prevent gas from bypassing up
drop. LP cyclones are not just for through the material pipes between
completely new preheaters but may the cyclone stages, the pipes are
be individually fitted to upgrade equipped with sluice flaps (tipping
existing preheaters. valves) designed for full opening.
Good meal distribution in the cyclone
riser ducts is ensured by adjustable
spreader plates in the distribution Material pipe sluice flaps
boxes.

Dividing gates
Robust dividing gates are used to
precisely and consistently distribute
meal to the different sections of the
riser duct and ca lciner.
lciner. One gate i s
capable of dividing meal into two,
three, or four different streams.

Tertiary air duct damper Meal dividing gate

To balance the combustion air flow
between the kiln and calciner, a
tertiary air duct damper is provided
for reliable regulation of the tertiary
air gases. The damper design features
Typical LP a solid refractory blade for long,
cyclone reliable life.

Tertiary air duct damper 

 7

Upgrades and
special solutions

ILC upgrades Choose it as a new system, or quickly

It is possible to upgrade virtually any upgrade an existing ILC or SP
existing kiln system into the modern preheater.
ILC – regardless of whether it comes
from FLSmidth or another supplier. The separate-line features of this
This includes not only conventional system enable a substantial portion of
suspension preheaters (SP) and other the total retention time to be located
calciner systems, but also complete parallel to the kiln riser duct. The
transformations of long dry and wet placement of the combustion chamber
kiln systems. outside the preheater structure makes
this calciner design well suited for
SLC-D preheater calciner system upgrades, since downtime is minimal.
As an optional preheater calciner system,
FLSmidth also offers the SLC-D. With The SLC-D combines the advantages
its high-temperature pre-combustion of separate-line calciners with the low
chamber,
chamber, the SLC-D (Separate-Line NOx features of the in-line calciner
with Downdraft Calciner) offers unique when a portion of the calciner fuel is
flexibility in fuel use. directed to the kiln riser duct.

Example of an ILC upgrade

into an existing preheater 
1

1 Primary firing point

2 Pre-combustion chamber
3 Tertiary air
4 Optional firing point

4
3

SLC-D type calciner 

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