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Rotary Kiln

Rotary Kiln

Rotary kiln is also known as lime rotary kiln.

Product specification:Φ2.5×40m-Φ6.0×95m

Production capacity:168-10000t/h

Rotation speed:0.1–5 r/min

Applied materials: roasting cement clinker in the industries of metallurgy, refractory matter and chemical plant.

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waste heat recovery in cement plant - ijert journal

The vertical preheater is one of the main equipment of the cement plant equipment. The main function of the cement preheater is to send the upper limestone material to the preheater body and use the high temperature exhaust gas (850 ℃) discharged from the kiln after calcination. The preheater will preheat the material evenly above 800 ° C. During the preheating process, 30% CaCO3 is decomposed in the preheater and then pushed by the hydraulic fader into the preheater. This calcination process not only makes limestone greatly shorten the time calcined in the kiln, but also obtain a higher degree of activity of lime

The vertical preheating is a device that is outside the kiln, and the cooling equipment is a separate device outside the kiln. The preheater is a heat exchange device that causes the temperature of the exhaust gas to drop rapidly and the temperature of the raw material powder rises rapidly, thus reducing the heat Consumption, improve production and quality, energy conservation, comprehensive utilization. For example, the suspension preheater, which is characterized by dry raw powder and rotary kiln hot gas, in the suspended state for heat exchange. In the suspension preheater, the raw material powder is evenly dispersed in the air flow, the surface of the raw material powder particles directly contact with the hot air, heat exchange area is very large, the heat transfer effect is good. Moreover, because the raw material particles are small, heat quickly from the surface to the center. Therefore, the heat transfer speed is also very fast, raw materials can be increased to 750 ゜ C above in the tens of seconds from the normal temperature. Since the suspension vertical preheater is a highly efficient heat exchange device, so this kiln type of heat is very low, only 3140 ~ 3560 kJ / kg clinker

The vertical preheater is used with rotary kiln, make the high temperature air from kiln tail fully utilize, play a role in saving energy and reducing consumption, it’s an energy saving and environment - friendly product.  

waste heat recovery in cement plant - ijert journal

preheater temperature. - international cement review

To summarise: (i) NOx has reduced, (ii) kiln speed has been reduced, (iii) kiln has dust, (iv) meal chute temperatures have risen. This sounds to me that there are reducing burning conditions explaining why the NOx has reduced and the kiln has dust (also why there is high free CaO in clinker on occasion). The higher meal chute temp might be caused by unburnt fuel being carried out of the calciner into the bottom stage cyclone and continuing to burn in the meal chute. If a sample is taken from the meal chute can you see it "sparkling" as you bring the sample into the air? The unburnt fuel might be the result of, or a cause of the reducing burning conditions. You need to check coal fineness in the first instance.

   In addition to What Dr Michael Clark  said, Have you checked the alkali and sulphur concentration from the meal chute .Higher concentration of any of these may be one of the reason.Also what about the kiln bag filter dust ,Whether you are taking it directly to the kiln at the time of Raw mill stoppage..All these  changes you notice in Clinker HM LSF and are the causes of  kiln operation...As  you said there s change in clinker size (Dusty cooler)which affect the precalciner always.Also Check there is no abnormal coating at the kiln Inlet.Coal fineness also  looks a bit too high

What i understand from your's problem, Mr. M. Clark has clearly communicate you the possible reasons. Please also check the preheater velocity may be there is some short cuircuting, if the O2 at kiln inlet is actual

preheater temperature. - international cement review

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