Hello GKS,

Due to the use of high sulphur petcoke and insufficient alkalis in the raw materials, your alkali/SO3 ratio in both hotmeal and clinker is far too low (~0.5 in both cases).

To balance the sulphur you will need to increase your alkali content in the raw mix by a factor of two or so, either by selective mining at the quarry or adding a high alkali corrective such as potassium/sodium feldspar.

Regards,

Ted.

Thank you sir,

    But adding K and Na element not balance hot meal to react to form stable componet to come out with clinker. But some time KCL like salt formed which caused heavy corrosion effect.So3 will increased upto 3.0 % in hot meal and k2o will reach upto 2.0 % .

We have used feldspar ( Caf2 ) for reduced  combinibilty temp . for incresed C3s in clinker with pet coke ( 100%) but Hot meal not control and kiln not running  normal,

Best regards

GKS

Hello GKS,

I think you mean fluorospar (CaF2). Feldspars are silicates of potassium, sodium or calcium and are commercially used to balance sulphur  in kilns burning a high proportion of petcoke as fuel.

However, it's not enough to simply balance the sulphur with alkalis. You must also ensure that there is enough oxygen at the kiln inlet so that the sulphur can react with the alkalis to form alkali sulphate compounds which are less volatile, otherwise the alkalis and sulphur cannot escape and will continue to cause blockages.

With petcoke, you need to have significantly higher O2 content in the gas stream at the kiln inlet, due to the higher sulphur loading... say 4-6% O2 instead of 2-3%,  or sometimes even higher.

Also the petcoke needs to be ground fine enough to ensure rapid combustion, otherwise an oxygen deficiency (CO) in the kiln inlet may result, increasing sulphur volatility and again causing blockages.

Regards,

Ted.

Sir,

             We have sufficient  O2 level ( 5.0 %) with high flame momentum ( 8.0 N /MW) and fine coal residue on 90 micron 2.0 % .

 But input  s from pet coke  4.5 to 6.5 % . 

To control  VF we have reduced KF feed upto 10 to 20 tph for last to result become  normal and avoid co formation at kiln inlet and riser duct & timely cleaned  coating formation zone by water jet and air blaster.

I want to know  any other process in kiln operation for help to avoid  blockage.

With best regards

GKS