Process Design Notes
Process Design Notes
Process Design Notes
Ovality (%) 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
Retention time (min) 150-200 120-160 110-140 95-120 70-85 40-45 20-25 20-30 20-25
Hertz pressure 62,000 62,000 62,000 62,000 62,000 62,000 59,000 59,000 59,000
-1
SHC (kcalkg KK ) 1300-2000 1150-1450 1050-1150 1000-1100 900-1000 750-860 750-860 750-860 720-780
KEG temperature (C) 250-300 550-600 650-700 750-800 900-950 1000-1100 1000-1100 1000-1100 1050-1200
Feed moisture (%) 28-35 0.5 0 0 0 0 0 0 0
-1
KEG velocity (ms ) 4-5 4-5 8-10 8-10 8-10 8-10 4-5 4-5 4-5
-1 -2
BZ load (Gcalh m ) 5-6 5-6 4.75-5.75 4.5-5.5 4.25-5.25 4-5 2.5-3.5 2.5-3.5 2-3
Stage 1 exit gas T (C) --- --- 400-425 375-400 375 350 375 375 325-350
Chain section Yes Yes Yes (short) Yes (short) No No No No No
1
Process Design Notes
Raw Grinding
VRM vibration:
Frame/reducer mounted sensor: 3 mm/s
Housing mounted sensor: 10 mm/s (e.g. Loesche)
Power consumption:
VRM: 3-12 kWh/ton (=f(material grindability))
BM: 9-17 kWh/ton
2
Process Design Notes
Dew point:
Minimum 40F < dry bulb T
Pyroprocess
False air = (O2(final) O2(initial)) / (20.9 O2(final)) 100% Note: w/ respect to inlet gases
False air = (O2(final) O2(initial)) / (20.9 O2(initial)) 100% Note: w/ respect to outlet gases
Hood velocity:
5-8 m/s (FLS)
5-6 m/s (MMcCabe)
4 m/s (KHD)
Cyclone p:
1st stage: 5-6 inWG
2nd stage: 8-10 inWG
3rd stage:8-10 inWG
4th stage: 10-12 inWG
Bypass:
-
Heat penalty (4-stage SP): 5% BP 1% KF
-
16,000-22,000 Btu/tonKK per % BP
Volatiles:
-
KK S/Alk molar ratio 0.8-1.2 (can be higher as long as sulfur (SO3) comes out in KK)
-
Typical equilibrium time = 150 kiln retention time [LSingh]
-
Volatilization approx. 15-20 gr/ft3
-
Chlorides:
o < 0.015-0.040% of inputs (raw basis)
3
Process Design Notes
4
Process Design Notes
Total chain wt
% of daily production (ton/d) 8.0 12.0
ton chains / ton KK 2.1 to 2.5
Specific surface area (ft2 / ft3 of chain zone) 2.6 to 3.7
Length of dust curtain chains (ft / ft kiln ) 0.66 to +0.77
30
25
20
Normal T calciner
%R 90 m
15 High T calciner
Kiln burner
10
0
0 5 10 15 20 25 30 35 40 45 50
% Volatiles (ash and m oisture free)
5
Process Design Notes
Microscopy:
Heating rate = f(alite size); target = 15-35 m
Small = too fast
Large = too slow
Residence time = f(belite size); target = 25-40 m
Small = too short
Large = too long
Maximum temperature = f(alite birefringence); target > 3.6
Cooling (quenching) rate = f(belite color); target > 3.6
Calcination:
Reaction starts ~ 700C (1,292F)
Reaction fully underway ~ 800C (1,472F)
Secondary firing:
1 s retention time in preheater 20% back end firing
6
Process Design Notes
Finish Grinding
7
Process Design Notes
Slot sizes:
C1: 6-8 mm
C2: 8-10 mm
Fluorescein mixture:
2 g fluorescein per Mg/h total mill feed
600-800 ml alcohol
2.5 kg mill feed (proportioned for raw KK, gyp and returns)
Fluorescein analysis:
100 ml beakers (10-20)
5 g material
50 ml distilled water
8
Process Design Notes
Dust Collection
Air-to-cloth ratio:
Pulse Jet (process D/C): 4.0-4.5 acfm/ft2
Pulse Jet (nuisance D/C): 5.0-6.0 acfm/ft2
R/A: 2.0-2.5 acfm/ft2
Star bags: 4.0-4.5 acfm/ft2
Pleated elements: 4.0-4.5 acfm/ft2
D/C p:
Pulse Jet: 3.5-4.5 inWG (bags blinded at 7 inWG)
R/A: 2.0-3.0 inWG (bags blinded at 5 inWG)
Star bags: 4.0-5.0 inWG (bags blinded at 7 inWG)
D/C off-time: 8-15 s (higher the better; low off-time contributes to internal bag wear)
D/C on-time: 0.10-0.12 s (dependent on bang)
Blow pipes:
Number of holes per pipe 16
Hole : hole areas pipe cross-sectional area
1 pipe (sched 40): I.D. = 1.610, A = 2.036 in2
1 pipe (sched 40): I.D. = 1.380, A = 1.496 in2
1 pipe (sched 40): I.D. = 1.049, A = 0.864 in2
pipe (sched 40): I.D. = 0.824, A = 0.533 in2
Stagger firing sequence: e.g. 1-4-7-10-2-5-8-11-3-6-9-12-etc.
9
Process Design Notes
Cyclone dimensioning:
4V
d
2.6 n3,600
Fans
Fan power:
P [kW] = Q [m3/s] p [kPa] / [%]
BHP [hp] = Q [cfm] SP [inWC] / 6356 / [%]
( = static efficiency)
Fan laws:
Note: valid only for speed changes up to 25% because of assumption that fan efficiency remains constant
Tip speed, u:
u [fpm] = D [ft] N [rpm]
Rule of thumb for calculating fan total pressure w/ straight impeller vanes:
0.6 u 2
p total
g
Wheel inertia:
wr2 [lbmft2] = W [lbm] (0.35 D [ft])2
Dr 1.2655
ab 3
ab
10
Process Design Notes
Environmental
SNCR:
Up to 85% NOx reduction
0.40-0.80 USD/tonKK
Auxiliary Equipment
Engineering / Miscellaneous
Pipe conveying velocities: 3,500-4,000 fpm (18-20 m/s) to transport fine material (raw meal, clinker dust, cement)
11
Process Design Notes
Motors:
If designed for 0.8 PF () and a given hp, can incr to 1.0 and get more hp as long as stay below FLA
kVA = 3 E I /1000
kW = 3 E I /1000
= kW / kVA = cos ( = phase angle)
Hardness scales:
Solid fuels: Hardgrove grindability index (HGI) lower value represents harder to grind material
Minerals: Mohs scale (1 = talc, 10 = diamond)
Metals and alloys (penetration tests):
Brinell hardness number (HBN)
Rockwell hardness test (Rc) [note: scales A, B, C, D, E, F, G) higher value = harder
Also: Vickers, Meyer, Meyer-Vickers, Knoop
Md
d 3
0.2 K d
12