Pyro 2. Kiln Feeding Systems

Pyroprocessing 2.
Gravimetric Feeding Systems
Pyroprocessing in cement kilns

2. Gravimetric Feeding Systems for kiln feed
In the preceding session we have made the point that the reactions between free
CaO and SiO2 to form C2S and C3S in a cement kilns are energy releasing or
exothermic reactions. This makes a major contribution to heating and
maintaining the temperature in the kiln.
Because of this exothermic reaction, a cement kiln is partially self-fuelling,

provided that the temperature is kept above 1400°C, which is the threshold
temperature for C3S formation. If the temperature falls below 1400°C the C3S
formation stops, the exothermic contribution is lost and the kiln very quickly cools
down and blacks out.
This is one of the main reasons why stable feed

composition and control are vital for cement kilns.
It is also the reason why accurate feeding systems
for kiln feed and fuels are vital for cement kilns.
We must accurately balance the thermal energy
input in the fuels with the energy requirements of
the process for the conversion of the raw minerals
in the kiln feed into the clinker minerals. We must
also ensure that there is sufficient thermal energy
input to maintain the heat capacity in the system
and the temperatures in the burning zone of the
kiln at above 1400°C so that the C3S formation
takes place releasing thermal energy to partially
fuel the kiln.
Preheater Precalciner Rotary Cooler

Kiln
The feeders for kiln feed and solid fuels delivered to a cement kiln normally
operate on gravimetric principles, i.e. they accurately measure and control the
weight or mass of feed of fuel delivered into the kiln.
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Pyroprocessing 2. Gravimetric Feeding Systems
Obvious exceptions would be a long-wet kiln

where the slurry feed to the kiln is delivered
by pumps and the volume of slurry delivered
to the kiln is measured and controlled. In this
case the moisture content of the slurry must
also be accurately controlled in order that the
solid weight of feed can be calculated from
the volume of slurry feed to the kiln.
When feeding dry raw mix as a powder

to modern dry process cement factories
equipped with preheaters it is normal to
combine a mass flow measuring device
with a feed bin mounted on load cells Load Cell Load Cell
ahead of that mass flow measuring
device. This means that the mass flow
measuring device can be calibrated at
any time by interrupting the feed to the
feed bin for a period and then monitoring
Load Cell
the loss in weight of the feed bin as the
kiln feed is extracted and delivered to
the kiln. The feed rate measured by the
mass flow measuring device must equal
the rate of loss in weight of the feed bin.
If not then the mass flow measuring
device is adjusted.
The mass flow measuring device might be belt scales where the speed of the
belt and the weight on the belt are both measured to allow the amount of feed
delivered to the kiln in unit time to be calculated. With such belt scales the feed
rate to the kiln can be adjusted either by varying the speed of the belt with
nominally the same quantity (material depth) of feed on the belt, or by varying the
quantity (material depth) on the belt while maintaining the belt speed constant.
An advantage of the use of belt scales as the

mass flow measuring device is the quoted
accuracy of such devices of +/-0.5%. A
disadvantage of the use of belt scales is the
Load Cell Load Cell space required for the installation. An
alternative is to use an impact solids flow
meter as commonly found for measuring the
grit returns on closed circuit ball mills. The kiln
Load Cell feed is extracted from the feed bin and falls
onto an inclined impact plate. The force of the
impact is measured by a load cell attached to
the impact plate and is proportional to the
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mass flow of kiln feed. The accuracy of such devices is +/-2%, which is
acceptable in combination with the continuous calibration provided by the loss in
weight of the feed bin mounted on its load cells. Such an arrangement requires
that the flow rate of kiln feed be controlled by an adjustable extraction rate from
the feed bin as there is no means to vary the speed of travel of the feed after it
has been extracted.
A further alternative to belt scales as the

mass flow measuring device is the Polysius
“Poldos” system, which measures the
pressure at the bottom of their “Aeropol”,
Load Cell Load Cell vertical pneumatic conveyor vessel. The
pressure is measured by a capillary tube
below the aeration pad of the Aeropol and is
proportional to the mass flow of kiln feed.
The Polysius Aeropol system is an example of a

pneumatic means of delivering the feed to the kiln. The
simplest pneumatic means of feeding the kiln is via a
pneumatic pump such as an FK pump. These can deliver
the feed directly into the gas riser from the second
uppermost to the uppermost preheater cyclone. This is the
lowest initial capital cost option for feeding a cement kiln.
However, there a number of operating cost disadvantages.
• An airlift will inject ~0.13 kg of air/kg of clinker into the

preheater.
§ This will increase the thermal energy

consumption of the kiln.
§ More importantly the electrical energy consumption of the induced draft
fan of the kiln will be increased.
§ The temperature of the preheater exhaust gases will be reduced by
~10°C.
§ (We will be discussing the reasons and implications for these
drawbacks is greater detail in later sessions of the course).
• Pneumatic means of delivering the feed to the top of the preheater consume
1.1~1.2 kWh/t per 100m of lift.
§ With preheater towers often being >50m in height and ~1.65 tonnes of
feed being required for production of a tonne clinker then transport of
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the feed to the kiln can involve electricity consumption in excess of 1

kWh/t of clinker.
The problem of the injection of transport air into

the preheater can be addressed by collecting the
feed from the transport air at the top of the
preheater and delivering the feed into the
preheater mechanically, with the transport air then
being vented to atmosphere through a dedicated
dust filter. However, this does nothing to reduce
the electricity consumption for kiln feed transport.
The best technology for delivery of the kiln feed to

the top of the preheater is fully mechanically via a
bucket elevator.
The FL Smidth installation shown in the photograph

has 3 bucket elevators with one for kiln feed, one for
transport of the raw mill product to the top of the kiln
feed homogenisation silo, and one standby in the
centre to provide redundancy for both the kiln feed
and raw meal transport systems.
Cement kilns must operate in long, uninterrupted

campaigns to minimise the times which the heat
capacity must be built up to the temperatures
necessary for C3S formation.
Redundancy of feed transport systems is one means

by which such long, uninterrupted campaigns are promoted.
A bucket elevator will consume ~0.2 kWh/t per 100m of lift, meaning that 0.75
kWh/t of clinker, or more will be saved by deploying an elevator rather than a
pneumatic kiln feed transport system.
Alert participants on the course will have picked up an inconsistency between

this session on kiln feeding systems and the course introduction in the preceding
session. In the course introduction we said that “as 44% of the calcium carbonate
will be lost as CO2, a total of 155 kg of raw materials are required to produce 100
kg of clinker”. In this session we have said that “~1.65 tonnes of feed being
required for production of a tonne clinker”. The reason for this discrepancy is that
some of the kiln feed will be lost from the system as dust. We will explain the
reasons for that in the next but one session when we talk about preheaters, but
first we will talk about feeders for solid fuels, as there are some clear similarities
with gravimetric kiln feed systems.
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Pyro 2. Kiln Feeding Systems

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Pyroprocessing 2.

Gravimetric Feeding Systems

Pyroprocessing in cement kilns

Because of this exothermic reaction, a cement kiln is partially self-fuelling,

This is one of the main reasons why stable feed

Preheater Precalciner Rotary Cooler

Obvious exceptions would be a long-wet kiln

When feeding dry raw mix as a powder

An advantage of the use of belt scales as the

A further alternative to belt scales as the

The Polysius Aeropol system is an example of a

However, there a number of operating cost disadvantages.

• An airlift will inject ~0.13 kg of air/kg of clinker into the

§ This will increase the thermal energy

the feed to the kiln can involve electricity consumption in excess of 1

The problem of the injection of transport air into

The best technology for delivery of the kiln feed to

The FL Smidth installation shown in the photograph

Cement kilns must operate in long, uninterrupted

Redundancy of feed transport systems is one means

Alert participants on the course will have picked up an inconsistency between

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