MENGTSEAB INDUSTRIAL AND COMMERCIAL PLC
KUYU CEMENT FACTORY
PRODUCTION DEPARTMENT
ASSIGMENT TWO: ON VERTICAL SHAFT KILN AREA
FOR TRAINEE CHEMICAL ENGINEER
OUT LINE
Process flow description of the system
Aeration system
Vertical shaft kiln
Clinker composition
Bag house
Jaw crusher
PROCESS FLOW DESCRIPTION OF THE SYSTEM
Raw meal enters homo silo via air slide
Blending using aeration lines from root’s blower (411BW01/02).
Material discharged through valve (411EX-01/02-1/2).
Drag chain conveyor (411DC 01/02) directs material.
Two-way valve (411 VV01/02) allows entry to air slide(411AS 09/10) or screw
conveyor.
Material lifted by bucket elevator (411BE01/02).
Transports through air slide (411AS01/02) to kiln top bin.
Raw meal moves through screw conveyor (411SC01/03) to double screw blender
(411BD01/02).
cont.……..
Mixed with water using pipe (411WP01/02).
Processed in nodulizer (411ND01/02) with slicker (411SL01/02).
Nodules formed on rotating pan disc.
Nodules enter vertical shaft kilns #1 and #2.
Clinker formed and cooled by forced draft fans.
Clinkers cooled below 100°C transported by pc (01,02,03,04)to jaw crusher
(411GC01/02).
Material discharged via rotating mechanism (411MD01/02).
Processed clinker conveyed to storage via bucket elevator.
The function of blowers, their capacity
Roots blower: is a device that enhance air flow effectively and efficiently using an
electric motor.
Blowers (BL01/02) capacity information:
Capacity: 13.6m3/min
Speed: 175rp
Motor power: 30kw
Output: 24.5kw
Relief valve (RF01/02): Used for the blower machine safety
Aeration system of Homo Silo
Homo Silo
storage and handling of raw meal.
Function of Aeration system
Reduces friction between particles
Prevents clumping and discharge obstruction
Keeps particles suspended and mixed
Facilitates Smooth Discharge
Reduces risk of blockages from compaction or moisture absorption
Butterfly valve (BF01/02): Used for transfer air across aeration lines by open
and closed manually
Homo Silo Instruments and Devices
Discharge Device (EX01/02)
Control the rate of material release from the silo.
Designed for a discharge rate of 90 tons/hour.
Pneumatic Cylinder Valve (PC01/02)
Controls material flow by opening/closing with compressed air.
Actuators (AU01/02)
Based on production requirements adjust the flowrate of material.
Extraction Gate Control
extraction gate regulates flow rate.
Maintains desired production rates and appropriate material quantities.
Nodulizer and its function
Machine that agglomerate raw materials into nodules, enhancing their handling,
Flowability, Uniformity, Reduce Dust and processing in the kiln.
The nodulizer in KCF has
Capacity: 55t/h Disc diameter: 5m
Output: 55kw Speed of disc: 11r/min
Disc angle: 45-53◦
Effects of Nodule Size During Burning
Smaller Nodules (Less than 5 mm)
Higher Dust Generation: Smaller sizes can lead to increased dust
Rushing occurs: having not sufficient residence time
Fire stops :slow down or stop the movement of flames and heat
Optimal Size (5-10 mm)
Balanced Reaction: It allows for effective heat transfer and reaction kinetics during
the burning process
Consistent Quality: leading to a more uniform clinker quality.
Larger Nodules (Greater than 10 mm): Reduced Reactivity, Heat Transfer Issues
and Increased Risk of Over burning
cont.…
Quality of clinker affected by the following things;
Low O2 supply
Speed of central drive
Nodule size
Cooling system
Raw mix
Double screw
Equipment used to uniformly mix water and raw meal through two mutually spiral
blades that rotates in opposite direction
Increase flow characteristic and reduce dust
Transport it to nodulizer
Forced Draft (FD) Fan and its function
It is used to supply the combustion air needed for the combustion process &
cooling process
Capacity: 48000m3/h
Speed: 2970rpm
Motor power: 560kw
Function of FD Fan
Air Supply for Combustion: Ensures efficient and effective burning
Pressure Maintenance: Controls airflow and stabilizes combustion efficiency
Temperature Control: Regulates air for optimal kiln temperatures and Ensures
quality clinker formation
Vertical Shaft Kiln (VSK)
Is continuous, updraft, moving ware kiln and fire remains stationary
[Link] Current Heat Exchange
Air moves upward and material (feed) moves downward.
[Link] Process
Allows for uninterrupted production and enhances efficiency in thermal
processing.
[Link] Management
Effective heat transfer between air and material and optimizes combustion and
material quality
Functions of VSK
Feeding: Raw meal balls are fed into the kiln from the top
Calcining: The raw meal balls move down the kiln while air moves up
Crushing: The material is crushed
Discharging: The material is discharged from the bottom of the kiln
Specification: 4.5*9.50m
Capacity: it depend on speed of main drive, but normal design capacity
28-32t/h
Kiln Controls
Kiln operation can be controlled through the following factors
Feed rate Extraction rate
Air volume
The various zones of reaction starting from top of the kiln
Preheating Zone: The wet pellets are heated by the hot air that flows from bottom
to top
Then the water inside the pellets evaporates
wet pellets change into dry pellets due to rising temperature
the volatile matter in the fuel is constantly escaping
Burning zone: This is the hottest part of the kiln
When the raw material sinks/ move down into the calcining zone, its temperature
continues to rise
Then, clay is decomposed into SiO2 + Al2O3 @ temperature 450-900℃
And limestone is decomposed into CaO + CO₂ at elevated temperatures 900 -
1050 °C
Then, quick lime is reacted with silica, alumina and ferrite
CONT….
Cooling zone: After the clinker is formed, it moves into the cooling zone
it is cooled down before being discharged from the kiln
the air is heated, then rises into the calcining zone to serve as combustion-supporting
air
General the chemical reaction are:
• 2CaO+SiO2--------------------2CaO.SiO2(dicalcium silicates)
• 3CaO+SiO2--------------------3CaO.SiO2(tricalcium silicates)
• 3CaO+Al2O3--------------------3CaO.Al2O3 (tricalcium aluminates)
• 4CaO+Al2O3+Fe2O3-----------4CaO.Al2O3.Fe2O3(tetra calcium alumina
ferrite)
The aluminates and silicates of calcium fuse together to form dark grain called clinkers.
Clinker minerals
Mineral name Chemical Standard KCF Actual value Factor affect
(Common name) formula concentration Concentration %
value %
Belite (C2S) 2CaO·SiO2/ 15-30 19-25 Higher C2S Improves long-term
strength
Ca2SiO4 Low C2S slow down initial
setting times, reduced long-term
strength and conversely with
C3S for early strength may be
insufficient for durability.
Alite (C3S) 3CaO·SiO2 42-53 45-52 Higher C3S Increases early
strength
/ Ca3SiO5 more difficult to grind due to
its hardness
Shortest setting time and
Generates more heat during
hydration
Low C3S Slower early strength
gain and May lead to reduced
CONT…….
Aluminate 3CaO·Al2 5-10 6-9.5 Higher C3A simple react with
(C3A) O3/ water, leading to quick setting times
Ca3Al2O6 and increased risk of cracking
Low C3A Slower setting times and
Lower risk of sulfate-related issues,
but may not achieve desired early
strength as efficiently.
Ferrite 4CaO·Al2 5-15 10- Higher C4AF it affects color
(C4AF) O3·Fe2O3 12.5 it has less impact on strength but
/ can influence the heat of hydration
Ca4Al2Fe2 Higher amounts of C2S and C4AF
O10 can enhance grindability
Low C4AF Less impact on
strength compared to other phases
possible reason for the formation of low-quality clinker
Low-quality clinker can result from several factors.
Improper Raw Material Composition:
Inadequate Homogenization
Incorrect Burning Temperature
Insufficient Residence Time
Poor Fuel Quality
Kiln Operation Issues
Cooling Rate
Moisture Content
Bag house
Bag house :Remove dust and solid particulates from entering the workplace or
being released into the atmosphere
Parameters of bag house
Design parameters: Airflow Rate, Temperature and Humidity, Bag Size and
Configuration
Filter bags: consider particle size of the material, filtration velocity, dust
concentration, Air permeability
Cleaning mechanism: The pulse-jet cleaning mechanism is often considered the
best option
Working principles of kiln bag house
Receives gas from fugitive or process sources
Draws the dusty gas stream into the baghouse through a duct system
The gas stream passes through filters by ID fan using negative pressure
Particles remain on the filter media surface, separating particulates from the air
Over time, dust accumulates and forms a filter cake on the filter surface
Remove dust from filters to maintain efficiency using purging system
working principle of jaw crusher and its capacity
material to be crushed is fed into the top of the jaw crusher through pan conveyor
mechanical pressure are applied using the crusher two jaws i.e Fixed (stationary) and
Movable (reciprocates)
The movable jaw moves back and forth relative to the fixed jaw and crush the material
Cont.……
material is crushed to a size that is smaller than the discharge opening and falls
through the opening and transported to bucket elevator
✓ Material feed: - Clinker
For clinker jaw crusher
✓ Capacity: - 30 T/hr
✓ Motor Power: - 37 KW
