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    Bowmanville Cement Technology - Kiln Systems

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    Mohamed Saad
    This document discusses kiln systems used in cement production. It describes the processes that occur as raw materials pass through a kiln system, including drying, preheating, decarbonation, melting, and cooling. Key reactions like the decarbonation of calcium carbonate and the formation of clinker are explained. Common kiln technologies like suspension preheaters, precalciners, and coolers are introduced. A temperature profile illustrates how material and gas temperatures change throughout the kiln system. Large commercial plants employing multiple kiln lines with daily production capacities up to 10,000 tons are noted.

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    Bowmanville Cement Technology - Kiln Systems

    Uploaded by

    Mohamed Saad
    169 views16 pages
    This document discusses kiln systems used in cement production. It describes the processes that occur as raw materials pass through a kiln system, including drying, preheating, decarbonation, melting, and cooling. Key reactions like the decarbonation of calcium carbonate and the formation of clinker are explained. Common kiln technologies like suspension preheaters, precalciners, and coolers are introduced. A temperature profile illustrates how material and gas temperatures change throughout the kiln system. Large commercial plants employing multiple kiln lines with daily production capacities up to 10,000 tons are noted.

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    kiln systems

    Original Title

    Kiln System Intro-Bow

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    This document discusses kiln systems used in cement production. It describes the processes that occur as raw materials pass through a kiln system, including drying, preheating, decarbonation, melting, and cooling. Key reactions like the decarbonation of calcium carbonate and the formation of clinker are explained. Common kiln technologies like suspension preheaters, precalciners, and coolers are introduced. A temperature profile illustrates how material and gas temperatures change throughout the kiln system. Large commercial plants employing multiple kiln lines with daily production capacities up to 10,000 tons are noted.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    169 views16 pages

    Bowmanville Cement Technology - Kiln Systems

    Uploaded by

    Mohamed Saad
    This document discusses kiln systems used in cement production. It describes the processes that occur as raw materials pass through a kiln system, including drying, preheating, decarbonation, melting, and cooling. Key reactions like the decarbonation of calcium carbonate and the formation of clinker are explained. Common kiln technologies like suspension preheaters, precalciners, and coolers are introduced. A temperature profile illustrates how material and gas temperatures change throughout the kiln system. Large commercial plants employing multiple kiln lines with daily production capacities up to 10,000 tons are noted.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 16
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    The document discusses the various components and processes involved in cement kiln systems, including preheaters, precalciners, rotary kilns, and coolers. It describes the chemical reactions that occur as raw materials pass through the system and the temperature profiles at different stages.

    The main components of a cement kiln system are the rotary kiln, preheater/precalciner, and cooler. The preheater/precalciner raises the temperature of the raw materials before they enter the rotary kiln. The rotary kiln facilitates the high-temperature reactions. The cooler lowers the temperature of the clinker before storage.

    The main chemical reactions that occur in the kiln are drying/preheating, decarbonation, and formation of clinker phases. Decarbonation, where calcium carbonate decomposes, is the most energy-intensive reaction. Other reactions include formation of melts and fluxes and conversion of tricalcium silicate.

    Bowmanville Cement Technology -

    Kiln Systems
    Kiln Systems
    An Introduction

    Production level
    Limitations
    Drying/heating
    Kiln Chemistry
    Drying and preheating
    Dry process kilns have very little free water
    associated with the kiln feed, a small amount of water
    is also usually bound inside the shale or clay
    minerals present. This requires energy to release. In
    a pre-heater or pre-calciner kiln, this occurs in the
    upper stages of the tower.
    Drying/heating
    Decarbonation (800C)
    Kiln Chemistry
    Decarbonation
    Decarbonation or calcination as it is sometimes
    termed, is the primary energy intensive reaction of
    cement kilns. During this process, Calcium Carbonate
    is dissociated into Calcium Oxide (lime) and Carbon
    Dioxide according to the reaction:
    CaCO3 CaO + CO2
    This reaction absorbs around 400 kcal/kg of heat. The
    degree to which this reaction occurs within the pre-
    heater tower is the principal difference between pre-
    heaters and pre-calciners.
    Drying/heating
    Decarbonation
    Heat/melts (1250 C)
    Drying/heating
    Decarbonation
    Heat/melts
    Clinker (1450C)
    Drying/heating

    Decarbonation
    Heat/melts
    Clinker
    Cooling
    Kiln Chemistry
    Reactions in the Kiln system
    Raw meal/slurry undergoes a series of chemical changes as
    it passes from the kiln inlet to the cooler. These changes or
    reactions occur in approximately the following order:
    Drying and pre-heating.
    De-carbonation.
    The formation of low temperature melts and fluxes.
    C2S formation
    C2S converting to C3S
    Temperature profiles of gas and material in a rotary kiln

    2000
    System boundary
    Gas commencement of
    decarbonation
    1500
    Material

    1000

    500

    cooling burning decarbonation preheating drying

    Main thermal Subsidiary thermal


    system system
    Cooler Kiln
    Precal Suspension Preheater
    Suspension Preheater

    Material temp 850C Gas temp: 1150C


    Kiln Feed

    Suspension Preheater
    and kiln

    Gas handling

    Firing System
    Cooler
    Calciner Kiln Plant
    Kiln Process Overview

    Chemistry of the clinker making processes


    Suspension preheater
    Precalciner
    Clinker coolers
    Flames
    Large Plant ?

    Kiln 1: 3500t/day

    Kiln 2: 4000t/day

    Kiln 3: 5500t/day
    Kiln 4: 5500t/day
    Kiln 5: 10,000t/day
    Kiln 6: 10,000t/day

    Total: 11.9million t/year

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