Sir, we are getting more knowledge from your videos. I request to you for adding calculation part in upcoming videos and pyro optimization methods too.
Don't worry I will make future videos in which you will get a lot of calculations and also give you a numerical assignment but before this we have to clear all the technical aspects of Pyrosection.
First calculate recuperation air Now in Case of SLC you can easily calculate the amount of tertiary air based upon the excess oxygen concentration But in the case of ILC you have to make assumptions on the basis of fuel consumption details .The calculation will be shared on upcoming videos.
Sir why hot air recirculation is not given before null point, my Doubt is if this hot air given before null point secondary air and tertiary air will increase hence cooler efficiency will also increase?
No,if it happens then every plant installs HAR before null points...to increase cooler efficiency. HAR is recommended in the following cases 1)If the midpoint temp is less than 350 degree C it generally happens in the old grate cooler because the turbine is generally design around 450 degree C 2) If you install HAR the cooler efficiency is further deteriorated because the clinker temperature will increase. 3) Generally,what is the function of cooling air ? The main function of cooling air in recuperation zone to do quenching...(cooling of clinker in fastest way) now suppose recuperation temperature -1050 degree C and cooling input air-30 degree C in this case the temperature difference=1020 degree Heat transfer is directly proportional to temperature difference Now in case of HAR Input cooling air temperature=100 Recuperation temperature=1050 Temperature difference=950 The amount of heat available for clinker cooling is less as a result it increases the clinker temperature. In my point of view HAR is beneficial only where plant team has been facing the mid point temp. Cooler recuperation efficiency is maximum depends upon the heat transfer rate between cooling air with clinker bed and it depends upon the design. How cooler is effectively to cool the fines tha
Theoretically LSF should be equal to 100 percent but in some plants we are maintaining greater than 100 due to ash content in the coal but in the case of petcoke it should be less than 100 Reason:- When LSF is on the higher side greater than 100 with low ash coal in that case first 100 percentage lime reacts with SiO2 ,Al2O3 and Fe2O3 and form the clinker but whatever excess lime that we have fed into the system remains unburnt as a result free lime content in the clinker will increase despite healthy burning zone condition you will get high free lime content due to improper raw mix formation of kiln which we have fed in to the system. Generally it is recommended to maintain all the moduli in the range so that it should be burnt easily in the burning zone.
Alumina ratio is high causing reduction in viscosity leasing to fine clinker. Low surface tension of liquid phase also causing fine clinker. Hard burning causes large alite and belite crystals leading to dust formation. Highly sulfates clinker also have more dust because of impact on liquid viscosity.
Surface tension is directly proportional to the Alumina ratio..lower the Alumina ratio lower the surface tension and surface tension is directly proportional to the clinker size...this is the correct reason for fine clinker formation.
sir you are excellent in explaining with pure knowledge.
Very good teaching style. Can you please make video for burner calculations, how to take measurements like burner tip velocity calculations
Will upload part 3 and part 4 by today evening
Sir, we are getting more knowledge from your videos. I request to you for adding calculation part in upcoming videos and pyro optimization methods too.
Don't worry I will make future videos in which you will get a lot of calculations and also give you a numerical assignment but before this we have to clear all the technical aspects of Pyrosection.
Thanks
Sir, why are kiln and cooler center kept offset, reason pls
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Sir, How do we cross check the secondary air value getting from heat balance? Calculation please
First calculate recuperation air
Now in Case of SLC you can easily calculate the amount of tertiary air based upon the excess oxygen concentration
But in the case of ILC you have to make assumptions on the basis of fuel consumption details .The calculation will be shared on upcoming videos.
Sir why hot air recirculation is not given before null point, my Doubt is if this hot air given before null point secondary air and tertiary air will increase hence cooler efficiency will also increase?
No,if it happens then every plant installs HAR before null points...to increase cooler efficiency.
HAR is recommended in the following cases
1)If the midpoint temp is less than 350 degree C it generally happens in the old grate cooler because the turbine is generally design around 450 degree C
2) If you install HAR the cooler efficiency is further deteriorated because the clinker temperature will increase.
3) Generally,what is the function of cooling air ?
The main function of cooling air in recuperation zone to do quenching...(cooling of clinker in fastest way) now suppose recuperation temperature -1050 degree C and cooling input air-30 degree C in this case the temperature difference=1020 degree
Heat transfer is directly proportional to temperature difference
Now in case of HAR
Input cooling air temperature=100
Recuperation temperature=1050
Temperature difference=950
The amount of heat available for clinker cooling is less as a result it increases the clinker temperature.
In my point of view HAR is beneficial only where plant team has been facing the mid point temp.
Cooler recuperation efficiency is maximum depends upon the heat transfer rate between cooling air with clinker bed and it depends upon the design.
How cooler is effectively to cool the fines tha
Thank you sir for explanation
Sir if LSF value is high then what it's impact on kiln operations.?
Theoretically LSF should be equal to 100 percent but in some plants we are maintaining greater than 100 due to ash content in the coal but in the case of petcoke it should be less than 100
Reason:-
When LSF is on the higher side greater than 100 with low ash coal in that case first 100 percentage lime reacts with SiO2 ,Al2O3 and Fe2O3 and form the clinker but whatever excess lime that we have fed into the system remains unburnt as a result free lime content in the clinker will increase despite healthy burning zone condition you will get high free lime content due to improper raw mix formation of kiln which we have fed in to the system.
Generally it is recommended to maintain all the moduli in the range so that it should be burnt easily in the burning zone.
Role of Silica modulus and Alumina modulus play an important role to compensate for the Lime saturation factor.
Thank you sir for your guidance.
Can anyone tell me the reason of fine clinker ?
Less flux content
More feed than designed capacity
Less kiln temperatures
ESP efficiency
Fuel grinding
Residence Time Too
Alumina ratio is high causing reduction in viscosity leasing to fine clinker. Low surface tension of liquid phase also causing fine clinker. Hard burning causes large alite and belite crystals leading to dust formation. Highly sulfates clinker also have more dust because of impact on liquid viscosity.
Surface tension is directly proportional to the Alumina ratio..lower the Alumina ratio lower the surface tension and surface tension is directly proportional to the clinker size...this is the correct reason for fine clinker formation.