NOx control approaches applicable to the cement industry may be grouped in three categories: process modifications, combustion control, and NOx reduction controls. One process modification that can be quantified is the CemStar process, which is a small addition of steel slag to the raw kiln feed. Can you provide more information on CemStar?
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TXI have published various papers on their patented Cemstar process. The addition of steel slag or air cooled blast furnace slag boosts the output of the kiln with virtually no increase if fuel consumption as the slags have already effectively been clinkered and contains trace elements that mineralise the combination of the kiln feed into the clinker in the kiln. More product with the same amount of fuel burnt inevitably dilutes the NOx emissions per tonne of clinker produced. The mineralising effect may also lead to lower burning zone temperature, and less thermal NOx formation in the flame. The real crux of the technology is adjusting the chemistry of the kiln feed to maintain the desired clinker mineralogy when the slags are being added t the kiln inlet. With steel slag the iron oxide input is increased and has to be compensated by increasing the alumina and silca modulii. With air cooled blast furnace slag the material is deficient in lime therefore the LSF of the kiln feed has be increased. This inevitably increases the demand for high CaCO3 content in limestone and is often the limiting factor.
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How can we reduce the clinker size -5mm >35 per cent (existing),we want to reduce to under 20 per cent. Our plant is a 1Mta capacity unit. Fuel is pet coke 70 per cent balance Indian coal.
admin
The only way to change the clinker size will be to change the kiln feed chemistry or the operation of the kiln. To have less fines in the clinker you should try to increase the flux content by reducing the silica modulus. Alternatively, adjust the rotational speed of the kiln by slowing slightly to increase the residence time.