DOPOL® ’90 preheater

and PREPOL® calcining system.

PREPOL®-CC with separate
combustion chamber (picture at top).
Split tertiary air supply of the
PREPOL®-MSC process.

PREPOL®-CC

In order to improve the burnout rate

when using non-reactive fuels,
Polysius developed the PREPOL®-CC
(Combustion Chamber). The calcining
system achieves outstanding results
when raw materials with poorly com-
bustible constituents are used and in
cases where high internal alkali cycles
may arise in the kiln plant due to the
fuel and raw material compositions,
resulting in impairment of the
combustion.

The separate combustion chamber,

which is connected to the calcining
loop by a gas duct, is the main feature
of the PREPOL®-CC. Providing the
possibility to influence the combustion
temperature, it ensures calciner
efficiency when using solid fuels.

PREPOL®-MSC-CC
PREPOL®-MSC proved that, depending on the fuel, system installed in
the NOx emission rate is reduced by the USA.
The PREPOL®-MSC calciner is the up to 50 %.
standard calcining system for reducing
NOx emissions. The MSC (Multi Stage PREPOL®-MSC-CC
Combustion) process is based on the
split feeding of fuel, tertiary air and To reduce operating costs, it has today
raw meal. The effect is only achieved become common practice to operate
by means of this special mode of the calciner with fuels which have poor
operation. This means that the operat- burnout behaviour, as well as with
ing costs are no higher than those of secondary fuels. limit values for nitrogen oxide emis-
classical calcining processes. sions. To enable nitrogen oxide reduc-
At the numerous MSC plants installed At the same time, many plants have tion while maintaining the flexibility of
all around the world it has been to observe regulations stipulating low fuel usage, Polysius developed the
PREPOL®-MSC-CC process.
Selection matrix for calciners
This combines the combustion cham-
ber of the PREPOL®-CC process with
PREPOL® type AS CC MSC MSC-CC
the split introduction of fuel, tertiary air

tk
Fuel High ash content xx xx xx xx and raw meal that is characteristic of
proper- the PREPOL®-MSC process.
ties Non-reactive x xx x xx
The kiln inlet is equipped with a kiln
inlet burner for reducing the nitrogen
Flexible change of fuel x xx xx xx
oxide created in the clinkering zone of
the kiln. The greater portion of the fuel
Emission reduction X X xx xx
is fed into the combustion chamber. A company

Suitability for bypass xx xx x x That leads into the MSC calciner,

of ThyssenKrupp
Technologies
Polysius
where there is a further split infeeding
x x Very suitable x Well suited X Suitable of air and raw meal.
 For every requirement an optimally customised
DOPOL® / PREPOL® concept.

Innovation is at the centre of the Polysius com- Special PREPOL® calcining systems for different
pany philosophy. This means purposive inno- requirement profiles.
vation as an answer to concrete requirements of
the industries we serve. The calciner fulfils the func- with great flexibility, in order
tions of heating-up and calcin- to cope with the wide range of
In the case of the cement industry, today's ing the raw material and of fuel grades used (from highly
Advantages of PREPOL® calcining systems:
requirement profile for the manufacturing pro- burning the supplied fuel. The reactive to extremely unreac-
cess is directed at high production capacities burning of the different types tive). x uniform kiln operation, thanks to extensive precalcination of the raw meal,
with low operating and capital expenditure. of fuel takes significantly more x long refractory lining service life in the rotary kiln, as a result of the low thermal
time than heating-up and Today, great importance is loading,
For this reason, multistage cyclone preheaters placed on systems incorporat-
calcining the raw meal and is
with integral calciner and tertiary air duct are ing primary measures for emis-
x minimal coating formation in the preheater, due to the low circulation of alkalis,
therefore the determining factor 4,000 t.p.d. grey cement
indispensable components of modern kiln lines. sion reduction, and this trend is production line in Vietnam with x low pressure drop in the preheater because of the optimum flow-dynamic design of
for the dimensioning of the 5-stage DOPOL® ’90 preheater
calciner. increasing. and PREPOL®-CC system the calciner, and
Polysius offers preheater/calciner concepts
(for anthracite firing).
that are innovative and nevertheless technically x superior economy of operation thanks to the high fuel flexibility.
In addition to assuring com- For such requirements Polysius
mature for the production of white and grey plete combustion of the fuel, has developed the PREPOL®-
cement; for new plants as well as plant con- the calciner has to function MSC-CC system in addition to
versions, and tailored to the desired production the proven PREPOL®-MSC
capacity – no matter whether this is less than calciner. This system permits
1,000 or more than 10,000 the use of unreactive fuels and
5-stage DOPOL® ’90 preheater
tonnes per day. including PREPOL®-CC-MSC simultaneously reduces the
calcining system for 2,600 t.p.d. of nitrogen oxide emissions.
The heat produced by the cement clinker in Spain.
burning process in the rotary The Polysius PREPOL®-AS cal-
kiln and calciner is used for ciner programme (AS stands
preheating the raw material. DOPOL® ’90: the economical preheater generation: for Air Separate; a concept
which all PREPOL® types share)
The preheating and extensive The first of two 10,000 tpd kiln lines
The number of cyclone stages of the heat consumption). thus includes a selection of with 5-stage DOPOL® ’90 and PREPOL®-MSC
precalcination of the raw
is selected to suit the individual versions, -CC, -MSC and calciner to be constructed in China.
material shorten the burning
application. Due to to the optimum flow- -MSC-CC, in order to optimally
process.
As a rule, the throughput and dynamic design, the pressure fulfil individual requirements
moisture content of the raw drop of the preheater system is 5-stage DOPOL® ’90 / PREPOL®-AS 3-stage DOPOL® ’90 with
The high degree of heat utili- with regard to operating relia-
preheater calciner combination in Saudi Arabia; PREPOL®-MSC-CC calciner White cement production line
sation reduces the fuel materials and fuels, which have small, minimising the electrical designed for a daily production rate of bility, product quality, flexibility in the USA; output: 2,700 tpd in Spain with 6-stage
requirement and the capital to be dried by the remaining energy requirement for the 3,500 tonnes of grey cement clinker. and emission reduction. of grey cement clinker. DOPOL® ’90 preheater.

expenditure for the rotary kiln. exhaust gas heat, decide exhaust gas fan.
whether 2, 3, 4, 5 or 6 cyclone
Moreover, it is possible to use stages are used. The cyclones The high collection efficiency
low-priced substitute fuels and and gas ducts have a refrac- of the cyclones ensures that
materials in the calciner and to tory lining, which keeps the ra- the exhaust gas has a low dust
positively influence the NOx diation losses low (below 2 % content.
and CO emissions – an additio-
nal plus point for operating
economy and environmental
Advantages of the DOPOL® ’90 concept:
compatibility.

To assure correct dimensioning x Minimal power requirement due to high

of the various preheater/calci- degree of heat recuperation and low pressure
ner systems, the properties of drop.
the raw materials and fuels are x High efficiency – low heat consumption
tested in the central research due to high cyclone collection rate and
centre of the Polysius Group. uniform meal distribution over the gas duct
cross-section.
This ensures that all the
systems and plant components x High availability thanks to the proven,
are optimally harmonised. reliable design and construction.
 For every requirement an optimally customised
DOPOL® / PREPOL® concept.

Innovation is at the centre of the Polysius com- Special PREPOL® calcining systems for different
pany philosophy. This means purposive inno- requirement profiles.
vation as an answer to concrete requirements of
the industries we serve. The calciner fulfils the func- with great flexibility, in order
tions of heating-up and calcin- to cope with the wide range of
In the case of the cement industry, today's ing the raw material and of fuel grades used (from highly
Advantages of PREPOL® calcining systems:
requirement profile for the manufacturing pro- burning the supplied fuel. The reactive to extremely unreac-
cess is directed at high production capacities burning of the different types tive). x uniform kiln operation, thanks to extensive precalcination of the raw meal,
with low operating and capital expenditure. of fuel takes significantly more x long refractory lining service life in the rotary kiln, as a result of the low thermal
time than heating-up and Today, great importance is loading,
For this reason, multistage cyclone preheaters placed on systems incorporat-
calcining the raw meal and is
with integral calciner and tertiary air duct are ing primary measures for emis-
x minimal coating formation in the preheater, due to the low circulation of alkalis,
therefore the determining factor 4,000 t.p.d. grey cement
indispensable components of modern kiln lines. sion reduction, and this trend is production line in Vietnam with x low pressure drop in the preheater because of the optimum flow-dynamic design of
for the dimensioning of the 5-stage DOPOL® ’90 preheater
calciner. increasing. and PREPOL®-CC system the calciner, and
Polysius offers preheater/calciner concepts
(for anthracite firing).
that are innovative and nevertheless technically x superior economy of operation thanks to the high fuel flexibility.
In addition to assuring com- For such requirements Polysius
mature for the production of white and grey plete combustion of the fuel, has developed the PREPOL®-
cement; for new plants as well as plant con- the calciner has to function MSC-CC system in addition to
versions, and tailored to the desired production the proven PREPOL®-MSC
capacity – no matter whether this is less than calciner. This system permits
1,000 or more than 10,000 the use of unreactive fuels and
5-stage DOPOL® ’90 preheater
tonnes per day. including PREPOL®-CC-MSC simultaneously reduces the
calcining system for 2,600 t.p.d. of nitrogen oxide emissions.
The heat produced by the cement clinker in Spain.
burning process in the rotary The Polysius PREPOL®-AS cal-
kiln and calciner is used for ciner programme (AS stands
preheating the raw material. DOPOL® ’90: the economical preheater generation: for Air Separate; a concept
which all PREPOL® types share)
The preheating and extensive The first of two 10,000 tpd kiln lines
The number of cyclone stages of the heat consumption). thus includes a selection of with 5-stage DOPOL® ’90 and PREPOL®-MSC
precalcination of the raw
is selected to suit the individual versions, -CC, -MSC and calciner to be constructed in China.
material shorten the burning
application. Due to to the optimum flow- -MSC-CC, in order to optimally
process.
As a rule, the throughput and dynamic design, the pressure fulfil individual requirements
moisture content of the raw drop of the preheater system is 5-stage DOPOL® ’90 / PREPOL®-AS 3-stage DOPOL® ’90 with
The high degree of heat utili- with regard to operating relia-
preheater calciner combination in Saudi Arabia; PREPOL®-MSC-CC calciner White cement production line
sation reduces the fuel materials and fuels, which have small, minimising the electrical designed for a daily production rate of bility, product quality, flexibility in the USA; output: 2,700 tpd in Spain with 6-stage
requirement and the capital to be dried by the remaining energy requirement for the 3,500 tonnes of grey cement clinker. and emission reduction. of grey cement clinker. DOPOL® ’90 preheater.

expenditure for the rotary kiln. exhaust gas heat, decide exhaust gas fan.
whether 2, 3, 4, 5 or 6 cyclone
Moreover, it is possible to use stages are used. The cyclones The high collection efficiency
low-priced substitute fuels and and gas ducts have a refrac- of the cyclones ensures that
materials in the calciner and to tory lining, which keeps the ra- the exhaust gas has a low dust
positively influence the NOx diation losses low (below 2 % content.
and CO emissions – an additio-
nal plus point for operating
economy and environmental
Advantages of the DOPOL® ’90 concept:
compatibility.

To assure correct dimensioning x Minimal power requirement due to high

of the various preheater/calci- degree of heat recuperation and low pressure
ner systems, the properties of drop.
the raw materials and fuels are x High efficiency – low heat consumption
tested in the central research due to high cyclone collection rate and
centre of the Polysius Group. uniform meal distribution over the gas duct
cross-section.
This ensures that all the
systems and plant components x High availability thanks to the proven,
are optimally harmonised. reliable design and construction.
 DOPOL® ’90 preheater
and PREPOL® calcining system.
PREPOL®-CC with separate
combustion chamber (picture at top).
Split tertiary air supply of the
PREPOL®-MSC process.

PREPOL®-CC

In order to improve the burnout rate

when using non-reactive fuels,
Polysius developed the PREPOL®-CC
(Combustion Chamber). The calcining
system achieves outstanding results
when raw materials with poorly com-
bustible constituents are used and in
cases where high internal alkali cycles
may arise in the kiln plant due to the
fuel and raw material compositions,
resulting in impairment of the
combustion.

The separate combustion chamber,

which is connected to the calcining
loop by a gas duct, is the main feature
of the PREPOL®-CC. Providing the
possibility to influence the combustion
temperature, it ensures calciner
efficiency when using solid fuels.

PREPOL®-MSC-CC
PREPOL®-MSC proved that, depending on the fuel, system installed in
the NOx emission rate is reduced by the USA.
The PREPOL®-MSC calciner is the up to 50 %.
standard calcining system for reducing
NOx emissions. The MSC (Multi Stage PREPOL®-MSC-CC
Combustion) process is based on the
split feeding of fuel, tertiary air and To reduce operating costs, it has today
raw meal. The effect is only achieved become common practice to operate
by means of this special mode of the calciner with fuels which have poor
operation. This means that the operat- burnout behaviour, as well as with
ing costs are no higher than those of secondary fuels. limit values for nitrogen oxide emis-
classical calcining processes. sions. To enable nitrogen oxide reduc-
At the numerous MSC plants installed At the same time, many plants have tion while maintaining the flexibility of
all around the world it has been to observe regulations stipulating low fuel usage, Polysius developed the
PREPOL®-MSC-CC process.
Selection matrix for calciners
This combines the combustion cham-
ber of the PREPOL®-CC process with
PREPOL® type AS CC MSC MSC-CC
the split introduction of fuel, tertiary air

tk
Fuel High ash content xx xx xx xx and raw meal that is characteristic of
proper- the PREPOL®-MSC process.
ties Non-reactive x xx x xx
The kiln inlet is equipped with a kiln
inlet burner for reducing the nitrogen
Flexible change of fuel x xx xx xx
oxide created in the clinkering zone of
the kiln. The greater portion of the fuel
Emission reduction X X xx xx
is fed into the combustion chamber. A company

Suitability for bypass xx xx x x That leads into the MSC calciner,

of ThyssenKrupp
Technologies
Polysius
where there is a further split infeeding
x x Very suitable x Well suited X Suitable of air and raw meal.