Preheaters & Precalciners
Summary: Priority study results
Oct 1993 - Jan 1995
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Objectives:
Preheater & precalciner study
Present the state of art for preheaters
Performance expectations
low pressure drop - investment, operating cost
capacity flexibility
number of stages
combustion eff. with low cost fuels
NOx reduction
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Low Tower Pressure drop
Designs of major suppliers very similar
Most suppliers have upgraded design
state-of-the-art cyclones, duct, splash box
have decreased Tower dP
without negative effect on separation eff.
Dimension ratios must be maintained
cyclone inlet and outlet area, etc.
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Cyclone Dimensioning
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Tower Design
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Tower Pressure Drop
Tower dP directly related to:
cyclone & duct size
capacity
Cyclone chosen according to desired dP
standardized ranges (steps of approx. 7%)
no compromise between dP & separation eff.
Min. dP required to avoid upset conditions within a range or
operation (80-100%)
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Tower Pressure Drop
Minimum dP
dP process stage = 22 inWG, 550 mmWG
dP dedusting stage = 4 inWG, 100 mmWG
Richmond
contract = 23.5 inWG, 597 mmWG
actual is better than guarantee
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Specifying Pressure Drop
Flexibility
Capacity increase: dP = kQ2
Capacity decrease
smaller sized cyclone selection is better
Costs
very low dP is expensive (payback = 8-10 years)
suppliers will suggest “middle” dP
higher dP = more flexibility to reduce capacity
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Tower - Number of Stages
5th stage - yes
payback = 5-11 years
fuel cost dependant
6th stage - no
only justified under special conditions
elimination of conditioning tower, bag filter
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Precalciners
Precalciner retro-fits
capacity increase
SHC similar; only 10 kcal/kg less
Preheater kilns
difficulty to control & maintain f-CaO > 0.5%
Current Precalciner designs
fuel oil design residence time = 1.8 s
required solid fuel residence time = (min 3.5 s
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Precalciner combustion
Higher combustion Temp. is better
Min. solid fuel fineness is required
R90um = 0.5%VM
Preheater NOx = 1200- 1300 mg
Europe norms: NO2 @ 10% O2
existing - NOx = 800 mg
existing - NOx = 500 mg
RMD permit = 450; actual = 200
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Low NOx Principle
Reduction Zone
breakdown NOx
Post-combustion oxidation zone
to burn all combustibles, reduce CO emissions
Hot Core
If Temp. increases 850°C to 1200°C
NOx reduced by 50%
CONCLUSION: SEPARATE COMBUSTION CHAMBER
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N2 Fuel
Fuel NOx cannot be ignored
N2 content
ability to form radicals for NOx reduction
High N2 fuels may be limited in future
pet-coke
high N2 coals
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Conclusions
Cyclone dimension ratios determine dP
Low dP vs. cost, capacity flexibility
not selection efficiency
Precal vs. preheater
capacity, clk quality, fuel cost, NOx, not SHC
Good combustion: high temp, & min. fuel fineness
Modern precal’s required for new emission reg’s.
Hot core, reduction zone followed by oxidation
Fuel characteristics important (N2 fuels)
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