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    PE Pyroprocessing Day 4 Volatilisation Balance Calculation: June 2004

    Uploaded by

    recai
    This document provides information and instructions for an exercise on calculating volatile balances in a cement kiln. It includes input data on mass flows and element compositions. Mass balances are performed on a dry and LOI-free basis to correct for moisture and CO2. A volatile balance is calculated for K2O with corrections made until input and output match. Recirculation coefficients v and t are determined from the corrected K2O balance to model volatile behavior in the kiln.

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    © All Rights Reserved
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    PE Pyroprocessing Day 4 Volatilisation Balance Calculation: June 2004

    Uploaded by

    recai
    134 views18 pages
    This document provides information and instructions for an exercise on calculating volatile balances in a cement kiln. It includes input data on mass flows and element compositions. Mass balances are performed on a dry and LOI-free basis to correct for moisture and CO2. A volatile balance is calculated for K2O with corrections made until input and output match. Recirculation coefficients v and t are determined from the corrected K2O balance to model volatile behavior in the kiln.

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    20030613_GRP_Trainer_Volatilisation-exercise_TEC_PE.ppt

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    This document provides information and instructions for an exercise on calculating volatile balances in a cement kiln. It includes input data on mass flows and element compositions. Mass balances are performed on a dry and LOI-free basis to correct for moisture and CO2. A volatile balance is calculated for K2O with corrections made until input and output match. Recirculation coefficients v and t are determined from the corrected K2O balance to model volatile behavior in the kiln.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    134 views18 pages

    PE Pyroprocessing Day 4 Volatilisation Balance Calculation: June 2004

    Uploaded by

    recai
    This document provides information and instructions for an exercise on calculating volatile balances in a cement kiln. It includes input data on mass flows and element compositions. Mass balances are performed on a dry and LOI-free basis to correct for moisture and CO2. A volatile balance is calculated for K2O with corrections made until input and output match. Recirculation coefficients v and t are determined from the corrected K2O balance to model volatile behavior in the kiln.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 18

    CENTRE TECHNIQUE EUROPE CENTRALE

    PE Pyroprocessing Day 4
    Volatilisation Balance Calculation

    June 2004

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Volatile Balance Calculation

    Field work

    Calculations

    Mass determination
    Sampling
    Mass balance and corrections
    Volatile balance and corrections
    Calculation of v and t coefficients

    Interpretation

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Field work


    Sample

    Stack gas
    & dust

    Flow measurement

    Kiln
    feed
    Fuel

    Precipitator
    Kiln
    gas

    Kiln load

    Clinker

    Waste
    dust

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Definitions

    Mass as received M

    Mass as measured in the field (T/h)

    Mass on dry basis M

    Mass without the moisture content (T/h)


    %H O

    2
    M ' M 1

    100

    Mass at LOI=0 M

    Mass without the CO2 from the kiln feed (T/h)


    %CO2

    M " M ' 1

    100

    Specific mass

    Mass of a component by unit mass of clinker (kg/kg ck or g/kg


    ck)

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Input data - Mass flow


    Flow

    Moisture

    CO2

    (T/h)

    (%)

    (% dry)

    Kiln feed

    48,0

    0,5%

    Coal

    4,5

    4,0%

    Clinker

    30,0

    0,0%

    0,0%

    Waste dust

    4,8

    0,0%

    28,0%

    Stack dust

    0,3

    0,0%

    30,0%

    0,0%

    30,0%

    Kiln load

    33,0%
    -,-

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Input data - Elements


    SO3
    (% dry)
    Kiln feed
    Coal ash

    0,55%
    -,-

    K2O

    Na2O

    (% dry)

    (% dry)

    Cl
    (% dry)

    1,00%

    0,05%

    0,008%

    2,00%

    0,10%

    0,050%

    Clinker

    0,50%

    1,25%

    0,25%

    0,002%

    Waste dust

    4,75%

    3,00%

    0,25%

    2,190%

    Stack dust

    21,25%

    22,00%

    3,50%

    11,400%

    Kiln load

    2,20%

    1,50%

    0,10%

    0,460%

    Coal:

    13% ash (as received)


    4,1% S (as received)

    Stack:

    260,00 kg/h SO2


    6

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise: Calculation Mass Balance (1)


    On dry basis (T/h):
    input

    output

    Kiln feed

    47,76

    Clinker

    30,000

    Coal

    4,32

    Waste dust

    4,800

    Stack dust

    0,300

    Stack gas

    0,325

    Total

    52,08

    Total

    35,425

    Input and output do not match. The difference is CO2

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise: Calculation Mass Balance (2)


    On LOI-free basis (T/h):
    input

    output

    Kiln feed

    31,999

    Clinker

    30,000

    Coal ash

    0,562

    Waste dust

    3,456

    Coal SO3

    0,443

    Stack dust

    0,210

    Stack gas

    0,325

    Total

    33,004

    Total

    33,991

    The input and output are much closer but still differ by 0,987 T/h.
    A mass correction is therefore needed.
    Note: Sulphur is considered on SO3 basis
    Conversion:

    %SO3 = % S

    80 / 32

    %SO3 = % SO2 80 / 64
    8

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Calculation Mass Balance (3)


    Mass correction
    Mc = M k (Total output - Total input)
    Weighting adjustment
    coefficients k
    Kiln feed

    1,00

    Coal ash

    0,00

    Clinker

    0,00

    Waste dust

    0,00

    Stack dust

    0,00

    Stack gas

    0,00

    1,00

    input

    output

    Kiln feed

    32,987

    Clinker

    30,000

    Coal ash

    0,562

    Waste dust

    3,456

    Coal SO3

    0,443

    Stack dust

    0,210

    Stack gas

    0,325

    Total

    33,991

    Total

    33,991
    9

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Calculation Mass Balance (4)


    Corrected mass flow (dry basis)
    t/h
    Kiln feed

    kg/kg ck
    49,23

    1,64

    Coal

    4,32

    0,14

    Clinker

    30,00

    1,00

    Waste dust

    4,80

    0,16

    Stack dust

    0,30

    0,01

    Stack gas

    0,33

    0,01
    10

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Volatile balance (1)


    K2O balance
    Corrected mass flows

    % K2O

    t/h
    Kiln feed

    49,23

    1,00%

    Coal ash1

    0,56

    2,00%

    Clinker

    30,00

    1,25%

    Waste dust

    4,80

    3,00%

    Stack dust

    0,30

    22,00%

    Stack gas

    0,33

    0,00%

    %K2O is percentage of ash


    11

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise: Volatile Balance (2)

    K2O balance (kg/h)


    input

    output

    Kiln feed

    492,34

    Clinker

    375,00

    Coal ash

    11,23

    Waste dust

    144,00

    Stack dust

    66,00

    Stack gas

    0,00

    Total

    503,57

    Total

    It does not balance and differs by 81,43 kg/h!

    585,00
    Lets correct it!
    12

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Volatile Balance (3)

    K2O balance correction


    Mc = M k (Total output - Total input)

    Weighting adjustment
    coefficients k
    Kiln feed

    0,45

    Coal ash

    0,00

    Clinker

    0,45

    Waste dust

    0,10

    Stack dust

    0,00

    Stack gas

    0,00

    1,00

    input

    output

    Kiln feed

    528,98

    Clinker

    338,36

    Coal ash

    11,23

    Waste dust

    135,86

    Stack dust

    66,00

    Stack gas

    0,00

    Total

    540,21

    Total

    540,21
    13

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise: Volatile balance (4)


    Corrected K2O composition
    Corrected mass flows

    Corrected

    t/h

    % K 2O

    % K2O

    Kiln feed

    49,23

    1,00%

    1,07%

    Coal ash

    0,56

    2,00%

    Clinker

    30,00

    1,25%

    1,13%

    Waste dust

    4,80

    3,00%

    2,83%

    Stack dust

    0,30

    22,00%

    Stack gas

    0,33

    0,00%
    14

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Kiln load


    An assumption has to be made on the kiln load mass flow rate
    Typical values: 1.2 - 2.0 kg/kg ck
    ASSUME: 1.6 kg/kg ck
    Then
    Kiln load = 1.6 30 = 48 T/h
    Kiln load K2O = 720.0 kg/h

    15

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Volatile recirculation model


    Losses

    trapping

    Gas

    Fuel

    volatilization

    Material

    Kiln load Clinker

    C
    v=1K

    K-M
    t=
    vK + F
    16

    CENTRE TECHNIQUE EUROPE CENTRALE

    Exercise : Coefficients
    K2O coefficients:

    v=1t=
    201,86

    C
    K

    =1-

    338,36
    720,00

    720,00 528,98

    0,53x720,00 + 11,6
    392,88

    191,02

    = 0,53
    = 0,486
    11,23
    381,64

    t = 0,486
    528,98

    v = 0,53
    720,00

    338,36
    17

    CENTRE TECHNIQUE EUROPE CENTRALE

    Coating regions

    Heavy
    coating
    Medium
    coating
    Low
    coating

    18

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