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Influence of Raw Materials Characteristics On Pyroprocessing

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198 views19 pages

Influence of Raw Materials Characteristics On Pyroprocessing

Uploaded by

amaralinga chari
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Influence of raw materials

characteristics
on pyroprocessing
Expectations from the good kiln operation

1.Maximum output

2.Good quality clinker / good burnability

3.Long life of the kiln


process point of view :
1.Easy well burnt(low free lime),
2.Good nodulisation,
3.Adequate density ,
4.Good crushability and grinding,
5.Good coating in burning zone,
6.Good fluidization and heat extraction in coolers,
7.Satisfactory refractory life and low consumption,
8.Low grade fuels
9.Meeting pollution standards –gaseous and solid emissions
Limestone is the major component and its winning and later
preparation decides largely the success of the plant – consistent
quality, trouble free operation of process equipments, plant
output

Thorough geological exploration – quality and quantity, mine


planning, extraction, pre-blending and homogenisation

Good understanding of distribution of minor oxides such as


sulphur, MgO, alkalies and even chloride and any heavy elements
The presence of unbalanced high sulphur or alkali content in raw
mix may result in build up problems in the kiln system.

The SO3/alkali molar ratio near unity are normally considered


preferable to avoid sulphur related build ups in the kiln

Hardness of rock, granulometry, presence of coarse silica and/or


calcite and amount and distribution

All these above ensure the consistent raw mix proportioning


system (rmps)
1.Homogenization is at both chemical and mineralogical levels to
ensure the burning of raw mix is steady and trouble free. even
fuel homogenization may be necessary

2.Burnability of raw mix is seriously affected by the presence of


coarse silica and coarse calcite. they influence the burning zone
temp, clinker formation and mineralogical characteristics of
clinker
Plant’s success depends largely on the the mix design and
burnability

A good mix design ensures right chemical composition, minimum


possible burning temperature, stable coating in the burning zone,
and cost effective overall

Each plant has to contend with its own limestone deposit and
fuel. hence the strategies are different for each plant. Sometimes
the choice may be very limited this is the final control point for QC
chemist. beyond this he has to only pray that the process team
does a good job and efficiently manage any short comings due to
natural causes very effectively
particle size distribution (psd) has enormous bearing on the pyro
processing, clinkerisation and clinker granulometry.

while fineness ( 30 to 75 micron ) gives very improved burning and


lime absorption, the tail end of the distribution namely <10 and
> 90 micron pose serious problems

excessive level of 90 or even 212 micron sizes give rise to coarse


calcite and quartz and affect burnability and the clinker micro
structure adversely. C3Sand C2S sizes and distribution are very
non-uniform. add to this the coarse ash and we end up with poor
quality of clinker

on the other hand, superfines lead to unnecessary dust


recirculation, degradation of high quality heat in the burning zone,
bulid-ups in cyclones, production loss, higher electrical and
thermal consumption
The “ span” may be a good indicator : ( d90 – d10) / d50
based on passing size .

For the multi mineralic system a factor between 2 and 4 will be


satisfactory , the lower the better .

constantly watch on the grinding and separator efficiency.


separator can only separate what the mill provides
Unlike gaseous or liquid fuels ,natural solid fuels are generally
non-uniform in ash and CV. even pre-blending is preferable if
logistics of plant permit

Low or moderate ash coals (20 to 25% ash) have enormous effect
on conserving limestone and the life of the plant

Plants having only marginal grade limestone can survive and even
produce good clinker if high grade – low ash coals are used
low ash coals have the greatest advantage in pyro-processing
1) less unwanted coal conveying air
2) better control of fuel to air ratio and hence burning process
3) higher burning zone temperatures and better flame character
4) better lime absorption and well-nodulised clinker
5) lower heat losses and better thermal and ( electrical) efficiency
6) higher kiln throughput due to stable kiln operation
7) low volatile low ash petcoke or coke dust ( steel plant coke
burners) can be a good choice if sulphur can be taken care
of in the case of petcoke
fuel has to ground finer than raw mix , < 10 % 90 mic +.
adequate

volatile content for stable and good plume in the flame.

Chemical composition

Mineral composition

Fineness

Homogeneity
Factors affecting the burnability

Raw mix 1) mineralogical composition


• Lime components
•Clay components
•Corrective materials
•Modifiers(these are minor components called fluxes
and mineralizers acting in the liquid and/or liquid
solid phase) fluxes lower the temperature at which
the liquid phase appears , mineralizers accelerate
the rate of clinkerziation

CaF2,Na2SiF6,CaSO4 2H2O, Ca3(PO4)2 etc are used in


very small quantity with the raw mix as modifiers
2) Chemical composition
a) main component relations
b)minor non volatile components
c) minor volatile components
3) Granulometric composition
a) fineness
b) particle size distribution
c) Homogeneity and compaction
4) Thermal treatment
a) firing temperature
b) heating rate
c) burning period
d) burning activation
5) liquid phase formation
a) appearance temperature
b)amount
c) viscosity
d) surface tension
e) ionic mobility
6) clinker quality
a) silicate phases
b) alumino-ferrite phases
7) coal ash
a) amount of ash absorbed
b) composition
c) fineness
8) kiln atmosphere
a) oxidation
b) reduction
(exit gases monitoring)
Effects of minor constituents
Non volatiles

•Free Silica : 1. more free silica increases power and fuel consumption
2. Causes difficulty in coating formation
3. Deteriorates refractory lining
4. Increases the radiation of heat from kiln shell
5. Increases kiln exit gas temperature

•Magnesium oxide(MgO) : 1)reduces viscosity and surface tension of clinker liquid


and increases ionic mobility
2)at higher temperatures helps for quick formation of C3S
3)Tends to ball easily in the burning zone which affects
the kiln operation
4)leads to un soundness if it is more than 2%
3) Titanium Di Oxide(TiO2) : 1) Sharp reduction in C3S with equal gain in C2S and
appreciable Variations in other phases
2) Reduces viscosity and surface tension of the melt
3) reduces grain sizes of alite and belite
4) causes slow setting time and lower early strength
5) forms dark colour clinker

4) Manganese Oxide(Mn2O3) : 1) reduces the viscosity of the melt


2) reduces the size of alite crystals
3) reduces early strength
Volatile compounds
Alkalies : 1. improves burnability at lower temperature and deteriorates at
higher temperaturs
2. increases liquid content and coating formation
3. breaks down alite and belite phases
4. creats operational problems due to external and internal alkali cycle
formation
5. causes alkali expansion

Sulphur : 1. Acts as effective mineralizer and modifier of the alkali re cycle by


forming less volatile alkali sulphates
2. lowers the liquid appearance temperature decreases viscosity
and surface tension an increases ionic mobility of oxides
3. decomposes alite at 12500C if alkali sulphates are present
4. above 2.5% causes sulphate expansion
5. improves burning of raw mix at lower temperature and deteriorates
at higher temperature
6. decreases hydraulic and mechanical strengths
Phosphorous pentoxide (P2O5) :
•accelerates the clikerization reaction
•reduces intensity of internal cycle
•reduces early strength
•reduces C3S content

Fluoride (F) :
•lowers the C3S formation temperature
•modifies all the kinetics of all burning reactions
•decreases the mechanical strength of the clinker

Chloride (Cl) :
•forms more volatile alkali chlorides and causes operational
problem due to it’s complete vaporization in the burning zone
•increases ring formation
•by-pass is required if chloride is more than 0.015

Moisture ( H ) :
•increases burnability
•increases fuel consumption

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