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Transcript of Volatiles Cycle
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FIRING
VIII – VOLATILES CYCLE
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Introduction
Control Parameters
Consequences of volatilization
Preventive actions and possible optimizations
Influence in the quality of the finished product
CONTENTS
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Introduction
Control ParametersControl Parameters
Consequences of volatilizationConsequences of volatilization
Preventive actions and possible optimizationsPreventive actions and possible optimizations
Influence in the quality of the finished productInfluence in the quality of the finished product
CONTENTS
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Volatile elementsSulfur (S 3! S 2" #
$l%alis (& 2 e 'a 2 #Chlorine
This minority elements are extremely variable in thecomposition of raw materials and fuels.
a) Clin%er
Loss Fuel
ven concentration
condensation volatilization
Pre Gas Fuel
Conditions for the existence of the recirculation heno!enon
*+chan,e of heat in counter flo)
-edia. solid and ,aseous
peratin, temperature intervals that facilitate the circulation of volatileelements. condensation and volatilization/
Circu!stances that fa"or the #existence$ of this heno!enonVOLATILES
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T% es of C%cles
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IntroductionIntroduction
Control Parameters
Consequences of volatilizationConsequences of volatilization
Preventive actions and possible optimizationsPreventive actions and possible optimizations
Influence in the quality of the finished productInfluence in the quality of the finished product
CONTENTS
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If this relation is > 1, meaning that there are sulphates in excess and there is preferentialformation of calcium sulfate, SO !a "ote# in oxidants conditions SO !a starts to become volatile at 1450 ºC
If this relation is = 1 the potassium sulphate, SO $ %, is &fixed' by the clin(er
If this relation is < 1 , part of the al(alis are &fixated' by the !)*
Control &ara!eters
%SO 3 / ! %Na #O/$# %& #O/'( " %Cl/)1
Relation 'et(een SO)*Al+alis in hot !ealRelation 'et(een SO)*Al+alis in hot !eal
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Reference "alueReference "alue ,, ϕ - ./0 1- ./0 1
2e3ree of "olatili4ation2e3ree of "olatili4ation 55ϕ
uel
Clin*er
+CL
5ot mealc 67
-
CL
+
+1
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O erationro'le!s
O erationro'le!s
6ot !eal co! osition8Reference "alues6ot !eal co! osition8Reference "alues
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O erationro'le!s
Nor!al noencrustation
ro'le!s
Nor!al noencrustation
ro'le!s
Nor!al noencrustation
Control &ara!eters
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I. ortant ara.eters in the o0en assa eI. ortant ara.eters in the o0en assa e
Gas velocity Temperature of the firing +one *tmosphere of the firing +one elation between SO ) - *l(alis egree of volatili+ation
There is a +riti+al 2one in hi+h a s.all te. erat4re 0ariation+reates a si nifi+ant +han e in the ele.ents 0olatili2ation5
/ SOSO )) and al(alis, the critical temperature is close to the temperature ofand al(alis, the critical temperature is close to the temperature of
clin(er formation.clin(er formation./ !hlorine, the temperature is 0%112!./ !hlorine, the temperature is 0%112!.
Control &ara!eters
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IntroductionIntroduction
Control ParametersControl Parameters
Consequences of volatilization
Preventive actions and possible optimizationsPreventive actions and possible optimizations
Influence in the quality of the finished productInfluence in the quality of the finished product
CONTENTS
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$ctions
*liminate false air entries and dead zones/9se lo) porous concrete/Install air canons/Systematically control the volatile cycle → Include in the control of the processparameters the determination of S 3 ! &2Cl" in the hot meal/
ProblemsProduction. encrustation in the fumechamber! bloc%a,e of the cyclones andformation of a rin, in the entry :oint/Chemical attac% in the refractory and in the%iln shell/
Alkalis create the expansion of the refractory.
The migration through the refractory createscorrosion and oxidation in the kiln shell.in,s inside the oven. the formation of
spurrite! 2C 2S/CaC 3! )ith the presence ofe+cess sulfur and al%alis stabilizes in theform of sulfate spurrite at 7288;C/
3ncrustation in the pre/calcinator and pre/heater
Conse9uences of "olatili4ation
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!ollage clin(er4si la temp est trop haute5
6o7te
4si la phaseli8uide est excessive5
!oncr9tions sulfates8ui peut boucher la goulotte
*nneau sulfate4accentu9 par les fuites au :oint5
$%SO condens9 sur les murs4si les envol9es poussi;res trop faibles5
!oncr9tionschlorures
!oncr9tions!aSO
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!ollage clin(er4si la temp est trop haute5
6o7te4si la phaseli8uide est excessive5
!oncr9tions sulfates8ui peut boucher la goulotte
*nneau sulfate4accentu9 par les fuites au :oint5
$%SO condens9 sur les murs4si les envol9es poussi;res trop faibles5
!oncr9tionschlorures
!oncr9tions!aSO &re:calcinator < « Key points »
=urn )here necessary>educe the emissions of ' +
Control.Te! eratureTi!e of co!'ustion *residenceTur'ulence
Ox%3en saturationFuel fineness
Consequences of absent control9n"burnt solid particlesC emissions
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Conse9uences of "olatili4ation
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IntroductionIntroduction
Control ParametersControl Parameters
Consequences of volatilizationConsequences of volatilization
Preventive actions and possible optimizations
Influence in the quality of the finished productInfluence in the quality of the finished product
CONTENTS
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Increase theconcentration of dust inthe s!o+e cha!'erE.g.:
Meal curtain (part of themeal of the last cycloneenters the smokecham er at lo!temperature"#$nstall ele%ators at the%ice&s entrance 'oint orrefractory system insidethe o%en.
Reduce the te! erature
in the firin3 4oneLi!it the false air inlets
Install a '% ass
O ti!i4e the firin3ara!eters
&re"enti"e actions
!%
!0
pre"calcinator
$ir 3;
uel in:ection
-eal cu rtain educin, zone
+idizin, zone
orno
&re:calcinator&re:calcinator
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O"erall !easures ;S!art< cleanin3
&ro'le!s (ith chlorine
&ro'le!s (ith sulfur
&ro'le!s (ith al+alis
A3ainst incrustationsA3ainst incrustations
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&re"enti"e actions
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O"erall !easures
educin, the entry of volatile elements
a) feed uel ptimized conduction of the %iln stability
e,ular inputs of ra) feed and fuel Conduction by e+pert system
$dequate selection of the $
;S!art< !easures
Prevent condensation in the riser duct of the fumes chamber -eal curtain in the %iln entrance Pendulum valves in the meal drop of the cyclones
Inclination of the meal ducts (? 00@# Aide cyclone e+it $void Bdead zones Install sli,htly impermeable refractory $void false air
&re"enti"e actions
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&re"ention a3ainst condensation&re"ention a3ainst condensation
Fonte: Holcim 2001
B ptimal point for the entrance of the meal in the pre
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&re"enti"e actions
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7eal C%clones7eal C %clones
Pendulum valve in the drop of the ra) meal
Dispersion chambers
Incorrect
Correct
Source: Holcim 2001
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&re"enti"e actions
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;S!art< !easures5 cont.
Cleanin, of the critical pointsE installation of cleanin, doors
Installation of air cannonsE cardo+ Cleanin, )ith hi,h pressure pump Cleanin, accordin, to the pressure profiles
Asment Temara CJO
Alhandra
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&re"enti"e actions
Cordoba
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Chlorine &ro'le!
=%:&ass → if the content of Cl " ? 2F than there is the need toinstall
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,!>x/?@ nafarinha 9uente1
'%: ass
$r frio
)*+, GC
*
!ax/ .@ Cl :
Ghe * does not perform )ith anhi,her value! problems )ithresistivity>
-** )**+, (max. -)*+,#
E/3/B A7CC and ACC E3% t
&ilnVOLATILES
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Chlorine &ro'le!
,!ax ?@ inRa( !eal1
Cold air
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&ol%sius solutions for o ti!i4ation of the '%: ass5 =& .
/ Installin3 a s lash late on the !eal dro at the entrance of the+iln → allo!s to create a mixture of the meal of the entrance of the kiln!ith the dustings.
?/ An uni9ue chi!ne%5 =& ra(*+iln → dilution of the dustin3sD
3/ Reduce the te! erature at the exit of the TC u to ?. C/ $nstall dual fluid no//les !ith compressed air.
4/ Reduce the 3as "elocit% in the s!allest section of the 3as entr% atthe =&D0ecommended %elocity of * m1s2 recommended %elocity for gases at the,3 4* 4) m1s
This solution !ill e tested at the E,,&s 5ine )
Chlorine &ro'le!
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Control the le"el of OControl the le"el of O ?? in the +ilnin the +iln
Ghe volatilization of Sulfur depends of the level of 2 in the %iln
C O – O ? *SO ) Ra( !eal
Recirculation ro'le! of sulfur
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$d:ust the molar ratio $l%alisHSulfur 7
&eep the JS as lo) as possible (S in =elite#
-odify the silica module! -S! smaller! for better suitability tothe firin, and ,ranulation
-inimize fluctuations (chemical#
Chan3in3 the co! osition of the ra(Chan3in3 the co! osition of the ra(
Exception : The need to produce a clinker !ith lo! le%el of alkalis !t is necessar" to increase the #olatili$ation o% the al&alis' Ho()
0educing the introduction of sulfur Elongating the flame 0educing the firing&s aptitude (increase the M6# 0educing first the air $ntroducing chlorinated elements2 e.g.: sol%ents
Recirculation ro'le! of sulfur
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Firin3 o ti!i4ation
&ara!eters to 'e o ti!i4ed in the firin3 4one&ara!eters to 'e o ti!i4ed in the firin3 4one
< u r n i n g = e v e l4 F r e e = im e 5T > T P O b :
< u r n a b i l i t y4 a w m i x d e s ig n 5
T e . / e r a t 4 r e
$ i ln S p e e d
< u r n e r P i p e4 . e s i g n , S e t t i n g s 5
L e n 1 h
O % = e v e l4 S O ) m a i n l y 5
? % O4 * l ( a l i s 5
A t . o s / h e r e T h e r . a l L
6 o la t i l i+ a t i o n i n t h e< u r n i n g @ o n e
Volatilization
irin, Kone
Gemperature Jen,th $tmosphere Ghermal load
-a+imize free lime ↑
C3S ↑
Improve.
7 / irin, aptitude
2 / a) composition
(variability#
=urner re,ulator
(ma+imize air 7; ↑ #
=urner parallel tothe %iln alliance
&iln Velocity
↑ 2 and S 3 ↓
5 2 and $l%alis ↑
-a+imize loadat the pre ↑
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2
. o u b l e s a l t s4 f r o m r e c i r c u l a t i o n 5s t a r t v o l a t i l i + i n ga t A 1 1 / A B 1 !
T e . / e r a t 4 r e
T h e s h o r t e r t h e b e t t e r
7 e s i 6 e n + e T i . e
, e d u c i n gc o n d i t i o n s4 l o w " O x P r e c a s 5
F u e l s o f S u b s t i t u t i o n4 T i r e s 5
F u e l F i n e n e s s
A t . o s / h e r e
6 o l a t i l i + a t i o n i n t h e! a l c i n i n g @ o n e
o r - a n dt h e P r e c a l c i n e r
&ara!eters to 'e o ti!i4ed in the re:&ara!eters to 'e o ti!i4ed in the re:calcinatorcalcinator
Volatilization
Pre"calciner and pre"heaterPre"calciner and pre"heater
Gemperature Permanence time $tmosphere
educin, conditions
9se of tyres
uel fineness(lo)er ,radin,#
$s brief as possible88 < 08 ;C
? 08 ;C!
Volatilization restarts
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Gas retention time# 0,A secsDaterials retention time# secs
Gas retention time # ) to ,B secsDaterials retention time #0B secs
)
( 1! 3!$
(!
3!
#!
1!
!
#! 8! 1!!
Volatile .aterials
7etention ti.e 9se+s:
7 '! ;. .B ).B %.B 0.B%
atio bet)een the retention timeand the characteristics of the fuel
Firin3 o ti!i4ation
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&ara!eters to 'e o ti!i4ed in the re:&ara!eters to 'e o ti!i4ed in the re:calcinatorcalcinator
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7ea+ti0e ra7ea+ti0e ra Reacti"e Clin+er
Controlled firin3
& I < 1(
7e 4lar ra7e 4lar ra
E!ission accordin3 tothe nor!
-S 9# # " # 8:Eas? firin ra
Eas? firin ra
Ra( co! osition influence
VOLATILES
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i h C 3S.ore C 3A than C ( A
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IntroductionIntroduction
Control ParametersControl Parameters
Consequences of volatilizationConsequences of volatilization
Preventive actions and possible optimizationsPreventive actions and possible optimizations
Influence in the quality of the finished product
CON
TENTS
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SOSO )) Clin+erClin+er SO ) L more reactive clin%er
hi,her mechanical resistance at 2 and days faster cementMs hydration velocity
Al+alis Clin+erAl+alis Clin+er 2 types of sulphates.S 4&2 → hi,her )ater solubility → etter hydrationS 4Ca → combines )ith the phases of the clin%er/
,u ic , 7 A → orthorhom ic8 less reacti%e#
Ghe al%alis reduce the mechanic resistance to 2 days and the chlorinespeeds up the settin, and corrodes the concrete reinforcement/
If the sulphates are trapped in the clin%er! there is a lo)er volatilesMcirculation/
Influence in the 9ualit% of the finished roduct
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O ti.i2e the in 4t7a an6 f4el
@S.art re0ention .eas4res
O ti.i2e the firin ara.eters
Su!!ar%
-easures to minimize the recirculation phenomenon of the volatile elements-easures to minimize the recirculation phenomenon of the volatile elements
VOLATILES
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