Process Design Notes.doc

Process Design Notes

Kiln Comparison Data 3-Stage SP* 2-Stage SP   Conversion 4-Stage SP

SF  

SF  Conversion

Short*  L/D Kiln

1.5-!.0

3.0-4.0

3.0-3.5

3.5-4.7

!3-!'

15-18

15-18

15-!!

10-1!

1.4

1.5

1.'

!.8

!.8-3.8

!.1

1.7

1.7

1.75

1.

3.3

3.3-4.5

!.5

3.'5

3.0-4.0

3.0-4.0

3.0-4.0

4.0

4.0

3.0-4.0

3.5

10-13

10-13

10-13

10-13

10-13

10-13

10-13

10-13

10-14

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

150-!00

1!0-1'0

110-140

5-1!0

70-85

40-45

!0-!5

!0-30

!0-!5

'!000

'!000

'!000

'!000

'!000

'!000

5000

5000

5000

1300-!000

1150-1450

1050-1150

1000-1100

00-1000

750-8'0

750-8'0

750-8'0

7!0-780

!50-300

550-'00

'50-700

750-800

00-50

1000-1100

1000-1100

1000-1100

1050-1!00

!8-35

0.5

0

0

0

0

0

0

0

K $locity (m·s -1)

4-5

4-5

8-10

8-10

8-10

8-10

4-5

4-5

4-5

6 load (cal· -1·m-!)

5-'

5-'

4.75-5.75

4.5-5.5

4.!5-5.!5

4-5

!.5-3.5

!.5-3.5

!-3

*tag$ 1 $it gas 9 (C)

---

---

400-4!5

375-400

375

350

375

375

3!5-350

Cain s$ction

:$s

:$s

:$s (sort)

:$s (sort)

;o

;o

;o

 ;o

 ;o

Wet

Long Dry

1-Stage SP

3-Stage SP* 2-Stage SP   Conversion 4-Stage SP

SF  

SF  Conversion

Short*  L/D Kiln

Capacity (l%m·d -1·
!8-44

!8-44

47-53

5'-'!

'!-81

4-1!5

187-!50

187-!18

!18-!3

"#D (insid$ %ric&)

38-44

3'-41

30-40

3!-34

!3-!'

15-18

15-18

15-!!

10-1!

Kiln sp$$d op$r (rpm)

1.!

1.35

1.4

1.4

1.5

1.'

!.8

!.8-3.8

!.1

Kiln sp$$d ma (rpm)

1.4

1.'

1.7

1.7

1.75

1.

3.3

3.3-4.5

!.5

*lop$ (+)

3.'5

3.'5

3.0-4.0

3.0-4.0

3.0-4.0

4.0

4.0

3.0-4.0

3.5

,ill (+)

10-13

10-13

10-13

10-13

10-13

10-13

10-13

10-13

10-14

ality (+)

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

0.!0

150-!00

1!0-1'0

110-140

5-1!0

70-85

40-45

!0-!5

!0-30

!0-!5

$rt pr$ss2r$

'!000

'!000

'!000

'!000

'!000

'!000

5000

5000

5000

*C (MM6t2·tonKK -1)

4.7-7.!

4.1-5.!

3.8-4.1

3.'-4.0

3.!-3.'

3.'-4.0

3.'-4.0

3.'-4.0

3.8-4.3

K t$mp$rat2r$ (,)

500-'00

1000-1100

1!00-1300

1400-1500

1'50-1750

1400-1'00

1400-1'00

1400-1'00

1300-1450

!8-35

0.5

0

0

0

0

0

0

0

K $locity (
800-1000

800-1000

1'00-!000

1'00-!000

1'00-!000

1'00-!000

800-1000

800-1000

800-1000

6 load (MM6t2· -1·
1.84-!.!1

1.84-!.!1

1.75-!.1!

1.''-!.03

1.57-1.4

1.47-1.84

0.!-1.!

0.!-1.!

0.74-1.11

*tag$ 1 $it gas 9 (,)

---

---

750-800

700-750

700

'50

700

700

'00-'50

Cain s$ction

:$s

:$s

:$s (sort)

:$s (sort)

;o

;o

;o

 ;o

 ;o

Wet

Long Dry

1-Stage SP

0.45-0.70

0.45-0.75

0.75-0.85

0.-1.0

1.0-1.3

38-44

3'-41

30-40

3!-34

Kiln sp$$d op$r (rpm)

1.!

1.35

1.4

Kiln sp$$d ma (rpm)

1.4

1.'

*lop$ (+)

3.'5

,ill (+) ality (+)

Capacity (Mg·d-1·m-3) "#D (insid$ %ric&)

/$t$ntion tim$ (min) $rt pr$ss2r$ *C (&cal·&gKK -1) K t$mp$rat2r$ (C) ,$$d moist2r$ (+)

/$t$ntion tim$ (min)

,$$d moist2r$ (+)

1

=roc$ss D$sign ;ot$s

/a> rinding ?/M nol$ ring $locity (@Cin-,att)A 80-0 m#s (>#o $t$rnal r$circ) B15750-17700 # som$ mat$rial r$co$ry ( 15+)) B1!800 # $t$rnal r$circ (  !5+)) B700-8850 (=olysi2s)A 1.'4 &ggas#&gm$al ?/M i%rationA ,ram$#r$d2c$r mo2nt$d s$nsorA 3 mm#s o2sing mo2nt$d s$nsorA 10 mm#s ($.g. "o$sc$) ?/M (># dynamic classi$r cons2mptionA ?/MA 3-1! &G#ton (E<(mat$rial grinda%ility)) 6MA -17 &G#ton 9ypical <$$d si$A ?/MA 3-5 6MA 1H ma to 80+ -I 9ypical <$$d moist2r$A ?/MA J !4+ 6MA !-3+ >#o drying capa%ility '-8+ ># drying capa%ility 9ypical prod2ct $$p (@Cin-,att)A  ;ot air-s>$ptA 0.8-1.5 m#s *$mi air-s>$ptA !.0-3.5 m#s ,2lly air-s>$ptA 3.5-'.0 m#s p$rating rotational sp$$d (+ o< critical)A 70-7!+

!

=roc$ss D$sign ;ot$s

D$> pointA Minim2m 40, L dry %2l% 9

=yroproc$ss Clin&$r prod2ction incr$as$ E <() or <(*=)A KK ! E KK 1 F (*=! # *=1)N KK ! E KK 1 F (! # 1) *p$ci (E<(*C <2$l caract$ristics))A 780-830 &cal#&gKK  (!.8-3.0 MM6t2#tonKK )A 1.5-!.15 &g#&gKK  B1.35-1.50 ;m3#&gKK  830-80 &cal#&gKK  (3.0-3.! MM6t2#tonKK )A !.10-!.30 &g#&gKK  B1.45-1.'0 ;m3#&gKK  Kiln $it static pr$ss2r$A 1.5-!.5 inG (s2ction)

 L!  KF  + Calcination E

100   L!  KF 



 L!  sample 100   L!  sample

 L!  KF 

 100+

100   L!  KF  c$ss air E  !(# r$sp$ct to inl$t gas$s ,als$ air E ( !(
;ot$A ># r$sp$ct to o2tl$t gas$s

*= op$ration (com%2stion # $plosion)A *$t P !5+ o< lo>$r
$at p$nalty (4-stag$ *=)A 5+ 6= R 1+ K, 1'000-!!000 6t2#tonKK  p$r + 6=

?olatil$sA -

KK *#@l& molar ratio 0.8-1.! (can %$ ig$r as long as s2l<2r (*3) com$s o2t in KK) 9ypical $S2ili%ri2m tim$ E 150 F &iln r$t$ntion tim$ B"*ing ?olatiliation appro. 15-!0 gr# %asis) o

3

=roc$ss D$sign ;ot$s

o o o o

L 1.0+ o< &iln inl$t (ra> %asis) L 0.07+ in <2$l &iln inl$t appro. 50 FTs inp2ts  pr$cipitat$ # cond$ns$ P 00-1!00, (475-'50C)

Clin&$r cool$r cooling air r$S2ir$m$ntA /$ciprocating grat$ cool$rA !.8-3.! &g air #&gKK  *-, cross-%ar cool$rA !.! &g air #&gKK  (as ad$rtis$dU r$alistically !.5) *$condary ( t$rtiary) air mass (E<(1 air ;C@ *C @))A Dir$ct-irl airA 50-0 m#s asA !00 m#s 9ypical &iln <$$d d$nsiti$s (=$ray p. 178)A =r$$at on$ 75 l%#$igt (p$r Magott$a2)A I F 3 XA 5. l%#
4

!0 O 30 1.0 O !.0

=roc$ss D$sign ;ot$s

9otal cain >t + o< daily prod2ction (ton#d) ton cains # ton KK *p$ci
8.0 O 1!.0 !.1 to !.5 !.' to 3.7 0.'' to 0.77

Kiln cain >$igt install$d (p$r D2da)A G$t proc$ssA 1!0 &g cain#MgKK #d Dry proc$ssA 105-110 &g cain#MgKK #d ,2$l olatil$ matt$rA D$cr$as$d ?M r$s2lts in d$cr$as$d r$action $rgo incr$as$d C (com%at ia ol$ tir$ ># 13-15+ st$$l) ,2$l oilA 138000 6t2#gal  ;at2ral gasA 1050 6t2#sc
0.70 0.80 0.'0 0.45 0.05

Coal#co&$
20

Normal T calciner 

   0 15    9    R    % 10

High T c alciner  Kiln burner 

5 0 0

5

10

15

20

25

30

35

40

% Volatiles (ash and moistur e fre e)

*olid <2$l
0.5-1.0+ 1.5-!.5+ 8-1!+

5

45

50

=roc$ss D$sign ;ot$s

Coal mill airA<2$l ratio ($r $$p (<2$l %all mill)A *$mi air-s>$ptA 1.0-!.0 m#s (typical 1.5) ,2lly air-s>$ptA 1.0-!.0 m#s (typical 1.5) Bnot$A CMQ 6roo&sill$ 0.5 m#s K?*A !500-3000 /$sid$nc$ tim$ E <(%$lit$ si$)U t arg$t E !5-40 m *mall E too sort "arg$ E too long Maim2m t$mp$rat2r$ E <(alit$ %ir$ay Y 800C (147!,) Com%2sti%l$s in &iln <$$dA rganic (olatil$) C Y !50-350C (48!-''!,) Vnorganic (at$r  Vncr$as$ mill sp$$d

'

=roc$ss D$sign ;ot$s

,inis rinding (6*@1 # 6*@!)n E ton#! # ton#1 E &G#ton1 # &G#ton! n E 1.3 $$n %lad$ top and dr2m co$rA Z-N 6lad$ $t$nsion 2nd$r dr2m co$rA 1N-! *$parator (*) <$$d conc$ntration ( < #a)A -*$paA !.5 &g#m3 B1100 gr#$r %$ca2s$ <2lly air-s>$pt) *$parator circ2lating $nd o< rang$ $r 6lain$) rd 9ypical C $nd o< rang$ $r 6lain$) *$parator (*) $it d2ct grain loading (to D#C)A *lagA 400-500 g#m3 B175-!!5 gr#$st point on c2r$  ;ormal rang$sA * 5-15+ nd !  g $n !0-40+ 1st g$n 30-'0+ 9romp c2r$ sap$ a<<$ct$d %yA Mat$rial loadA $c$ssi$ loading r$s2lts in i ncr$as$d %ypass and lo>$r  al2$ @irA ins2< r$s2lts in ig$r %ypass al2$ and lo>$r  al2$ Circ2lation
7

=roc$ss D$sign ;ot$s

*lot si$sA C1A '-8 mm C!A 8-10 mm *lot op$n ar$aA '-8+ o< $<<$cti$ ar$a (@Cin-,att#,2ll$r) B$cl2ding c$nt$r scr$$n 15+ o< $<<$cti$ ar$a (=@lsop) Bincl2ding c$nt$r scr$$n Mat$rial si$ at diision $adA 4+ !mm (5+ 8M) Mat$rial si$ at mill discarg$A 1'00-1800 cm!#g (appro al< o< $r cons2mption (E<(<$$d si$))A 6MA 3!-3' &G#ton (id$al)U 34-38 &G#ton (typical) B1-1N <$$d ,80 6MA 35-40 &G#Mg (id$al)U 37-4! &G#Mg (typical) B!5-38 mm <$$d ,80 *p$ci$r cons2mption ("*ing)A Mill ># con$ntional s$paratorA Mill ># ig $<# * and roll$r pr$ssA

1.0 F (6*@#100) E &G#ton 0. F (6*@#100) E &G#ton 0.75 F (6*@#100) E &G#ton

,l2or$sc$in mit2r$A ! g KK gyp and r$t2rns) ,l2or$sc$in analysisA 100 ml %$a&$rs (10-!0) 5 g mat$rial 50 ml distill$d >at$r  rinding aid cons2mption (8.5 l%#gal)A 9-VA 0.-1.1 l%m#tonc$m$nt 9-VVVA 1.!-1.4 l%m#tonc$m$nt 9ypical allo>anc$ in t2%$ mill s$ll l$ngt (@Cin-,att)A ,$$d $nd lin$rs 75 mm C$ntral diapragm 500 mm Discarg$ diapragm 350 mm 9ypical s$ll lin$r tic&n$ss (@Cin-,att)A "i
8

=roc$ss D$sign ;ot$s

9orS2$ $r cons2mption $S2ations) (@Cin-,att)A Classi$r d$sign not$s (@Cin-,att)A ,or dry grinding ra> mill add po>$r $pt ra> mill incr$as$ t$ calc2lat$d po>$r dra> %y 1.08 ,or >$t grinding ra> mill d$cr$as$ t$ calc2lat$d po>$r %y 0.75 to 0. (lo> $r + solids) ,or >$t grinding ra> mill 2s$ %alls no l$ss tan 1^ in !nd compt as $r dra> %y 0.5 9ypical po>$r loss$sA $ar W =inion 3.5+ /$d2c$r 1.5+ Motor 3.0+ 6all ol2m$ (+) R 113 O 1!' F ( # D) 6all mill op$rating rotational sp$$d (+ o< critical)A 75-78+

D2st Coll$ction @ir-to-clot ratioA =2ls$ \$t (proc$ss D#C)A 4.0-4.5 ac o<<-tim$ contri%2t$s to int$rnal %ag >$ar) D#C on-tim$A 0.10-0.1! s (d$p$nd$nt on _%ang) 6lo> pip$sA  ;2m%$r o< ol$s p$r pip$  1' ol$ XA  ol$ ar$as  pip$ cross-s$ctional ar$a 1N X pip$ (sc$d 40)A V.D. E 1.'10 @ E !.03' in! 1H X pip$ (sc$d 40)A V.D. E 1.380 @ E 1.4' in! 1 X pip$ (sc$d 40)A V.D. E 1.04 @ E 0.8'4 in! I X pip$ (sc$d 40)A V.D. E 0.8!4 @ E 0.533 in! *tagg$r p$r mod2l$A !0000 acA 8400 ac$rA improp$r cl$aning ig$rA %lo> gra$l o2t



=roc$ss D$sign ;ot$s

D$sign  pA ra$l %$d d$ptA /a&$ cl$aranc$ a%o$ scr$$nA D$sign inl$t grain loadingA

8- inG (typical is -1! inG) 4.5 in 3#8 in 4-' gr#
Cyclon$ dim$nsioningA # 

4·"   

>$r$A

!.'·  ·n·3('00

#  E nominal cyclon$ diam$t$r Bm "  E total air Bm3·-1 n E n2m%$r o< cyclon$s B---

,ans ,an po>$rA = B&G E  Bm3#s F  p B&=a #  B+ 6= Bp E  BcsA D$nsity Cang$ ! E 1  p! E p1 F (! # 1) =! E =1 F (! # 1)

*p$$d Cang$ ! E 1 F (;! # ;1) p! E p1 F (;! # ;1)! =! E =1 F (;! # ;1)3

*i$ Cang$ ! E 1 F (D! # D1)3  p! E p1 F (D! # D1)! =! E =1 F (D! # D1)5

 ;ot$A alid only # straigt imp$ll$r an$sA 0.'     $ !  p total    g  >$r$A  ptotal  E    E $ E  g  E


G$$l in$rtiaA >r ! Bl%m·
 D r   1.!'5 5

 a&  3 a&

10

=roc$ss D$sign ;ot$s

nironm$ntal Dioin # ,2ran
@2iliary S2ipm$nt Q t2%$ d$signA !000-!500 $rA air-to->at$r pr$ss2r$ ratioA J 1.1A1 ($mpirical P DM) air-to->at$r pr$ss2r$ %iasA 10-35 psi (s2p$rc$d$s a%o$ not$ %as$d on ": W 6@") air rSmtA 5-110 ac
ngin$$ring # Misc$llan$o2s =ip$ con$ying $lociti$sA 3500-4000 m$al clin&$r d2st c$m$nt) =yrolin$ con$ying $lociti$s B=@lsopA ]pp$r limitsA 9ro2g cool$r grat$A Kiln oodA ]nd$r cool$r %2ll nos$A 62rning on$ (1450C)A Kiln <$$d $nd transition (1000C)A =r$$at$r ris$r d2ctA =r$$at$r gas d2ctsA "o>$r limitsA 9$rtiary air d2ctA =2l$ri$d coal con$yingA

5 m#s ' m#s 15 m#s .5 m#s 13 m#s !4 m#s 18 m#s !5 m#s !0 m#s B=@slopU 1' m#s B"a%$ll$ =illard

6all mill con$ying $lociti$s B"a
!3-!5 m#s (ma) 4-5 m#s 10-15 m#s

*t$$l $r$ctionA `3.00#l% st$$l (sti<<$n$rs $tc. m2ltiply %y 1.!5-1.75) B9s$ng /$$r /$$r =o>$r cons2mption %y = (damp$r or ot$r)A &G E  (
11

=roc$ss D$sign ;ot$s

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