THE BYPASS

A solution for
Process

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 Lets talk about bypass

What happens in the system ?

What are the minor elements ?
What do the minor elements do ?
Why do we need a bypass system ?
What is the bypass system ?
What are the calculations ?

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 What happens in the system ?

Grinding Heating up

Raw Meal Hot Meal

Raw Materials

Volatilization

Clinkerization

Clinker

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 What are the minor elements ?

They are chemical components of the raw materials with a

low concentration towards the other components.

Although some have no impact on the chemical process, others might lead to major
troubles.

In the cement industry, Cl, SO3, Na2O and K2O are,

among others, particularly monitored

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 What are some elements doing ?
Problem with volatile elements

Low volatilization Condensation on

temperature cooler particles

Extraction from Increase of

material local
concentration

Flowing with
gases
PROBLEMS

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 What are some elements doing ?

Volatilization temperature
+
Condensation temperature

2 Cases

Internal External
Cycle Cycle

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 Internal and External Cycles

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 Internal and External Cycles

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 Definition of the Volatility

Volatility of a component

QVolatilized
Volatility
QTotal

Component

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 Definition of the Volatilization
Volatilization of a component X in the kiln

Recirculation part

Hot meal Clinker

X Ck
Volatiliza tionX 100 1
X Hm
Note: Calculation done LOI free

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 Volatility or Volatilization ?

Volatility

is a physical property of a component

?
is depending on the temperature
Is depending on the crystallographic structure

Volatilization

is depending on the considered area

is depending on the operation

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 Different behaviors

Chloride start evaporate around 650C

Alkalis start evaporate around 900C
Sulfur start evaporate around 1000C

Conclusion :

The various content of element is different according to the

analyzed area (kiln feed, meal cyclone 2, hot meal,
clinker,).

Nevertheless, most of the highest concentrations are

located at the kiln inlet, depending on the salt formation.

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 The salt formation

K 2O 2Cl 2KCl
Na2O 2Cl 2NaCl Chlorines
Formation order

CaO 2Cl CaCl2

K 2O SO3 K 2SO4
Na2O SO3 Na2SO4 Sulfates
CaO SO3 CaSO4

K 2O CO2 K 2CO3
Carbonates
Na2O CO2 Na2CO3
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Calculation of the salt concentration

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Calculation of the salt concentration

Reaction 1 K 2O 2Cl 2KCl

94 71 149

149 100
Quantity of KCl formed : KCl a
94 100 e

71 100
Cl used during the reaction : ClKCl a
94 100 e

71 100
Cl remaining after the reaction : ClR1 c a
94 100 e

With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI

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 Calculation of the salt concentration

Reaction 2 Na2O 2Cl 2NaCl

62 71 117

62
Quantity of Na2O that can be used with Cl : Na2O ClR1
71

117
NaCl formed during the reaction : NaCl ClR1
71

100 62
Na2O remaining after the reaction : Na 2OR 2 b ClR1
100 e 71

With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI

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 Calculation of the salt concentration

Reaction 3 Na2O SO3 Na2SO4

62 80 142

142
Quantity of Na2SO4 formed with Na2O : Na2SO 4 Na2OR 2
62

80
SO3 used during the reaction : SO3 Na 20 R 2
62

100 80
SO3 remaining after the reaction : SO3R 3 d Na 2OR 2
100 e 62

With a= K2O% b= Na2O% c= Cl% d= SO3% e= LOI

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 Why do we need such calculations ?

Better understanding of the cycles with the analysis

Better understanding of the build ups
Criteria of decision for a bypass system

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 What is the bypass system ?

Raw Material composition Volatility of some

in minor elements elements

Process

Cycles creations
Bypass system
Salt formation

Troubles

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 What is the bypass system ?

Clean gas emission

Separation
Electro filter

Cooling Dust collection

Quenching chamber
Conditioning tower

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 How much bypass ratio ?

The bypass
Decreases the concentration of minors in the
kiln inlet by taking a part of the kiln gas
Taking part of the heat
Taking part of the production

What has to be the bypassed gas quantity ?

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 Two different ways

1 - Assuming that
Bypass % Cl % input (free of LOI) x 100

2- Complete calculation of the salts, taking into

account the volatility, the type of system (kiln,
preheater). Using the whole chemical theory.

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POLYSIUS process of decision for BP%

SO3, Cl, X% BP X% BP
Na2O, K2O

Yes <4%

Bypass > 4%
Cl < 1%
Calculation % Salts in hot meal
hot meal
X%
< 6%
> 6%

< 60%
% CaSO4

> 60%

X% BP

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 Example of decision

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 Calculation of the bypass ratio

From the measurements done on site

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 Definition of the Bypass Ratio

VBypass
BypassRati o
VKi ln

V Bypass = Volume of gas going to the bypass

V Kiln = Volume of gas going out of the kiln

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Definition of the calculation parameters
WD
to

VBP
to

VAF
WD to
t1
VA
VBP to
t1

VAF
t1

%O2(BP)
Va
ta

%O2(k), Vk

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 Calculation of V Kiln

The volume coming out of the kiln is composed by :

1. The volume of the gas combustion - V Comb

2. The volume of the decarbonation - V CO2
3. The volume of excess air - V Ex

VKi ln VComb VCO 2 VEx

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 Calculation of V Comb

The main combustion equations are :

C + O2 CO2

S + O2 SO2

H2 + O2 H2O

CXHY + (x+Y/4) O2 x CO2 + Y/2 H2O

CXHY with Y = 2x + 2

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 Calculation of V Comb

VCombCO 2
CO CO2 x.CxHy Wg
100

y
H 2 H 2S H 2O .CxHy Wg

2
VComb H 2O
100

VComb SO 2
H 2S Wg
100

0.79 VAir min N 2 Wg

VComb N 2
100 100

y
2,381 CO 2,381 H 2 7,143 H 2S 4,762 O 2 4,762 x .CxHy Wg
4
V Air min
100

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 Calculation of V Comb

CO, CO2, H2, H2S, H2O, O2, N2, CxHy

% from natural gas composition analysis

VComb VCombCO 2 VComb H 20 VCombSO2 VComb N 2

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 Calculation of V CO2

CaO MgO

CO3Ca CO2 + CaO CO3Mg CO2 + MgO

100 44 56 84,3 44 40,3
44 44
CO2 CaO CO2 MgO
56 40,3

0,748 CaO 1.092MgO 100 -

VCO2 ( ) WCK
1,977 100 100

being the carbonation degree

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 Calculation of V Ex

V Comb+ V CO2 V Kiln

V Ex O2 Kiln
inlet

O2 Air

%O 2 ( k )
VEX x (VCO2 VCOMB )
21 - %O 2 ( k )

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 Calculation of V Kiln

The volume coming out of the kiln is composed by :

1. The volume of the gas combustion - V Comb

2. The volume of the decarbonation - V CO2
3. The volume of excess air - V Ex

VKi ln VComb VCO 2 VEx

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 Calculation of V BP
INPUTS WD
to

OUTPUTS VBP
to

VAF
WD to
t1
VA
VBP to
t1

VAF
t1

%O2(BP)
Va
ta

%O2(k), Vk

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 Calculation of V BP
INPUT
VBP x CPGAS x (t1 20)
+ Va x CPAIR x (ta 20)
+ WD x CPdust x (t1 20)
+ VFA x CPair x (ta 20)

OUTPUT
VBP x CPGAS x (t0-20)
+ Va x CPAIR x (t0-20)
+ WD x CPdust x (t0 20)
+ VFA x CPair x (t0 20)

With False Air being calculated with O2 content in the bypass

K
%O2 ( BP ) %O2 ( Ki)
VFA K VBP
21 %O2 ( BP )
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 Calculation of VBP
As far as
Inputs = Outputs

VBP

CPAIR (t 0 - 20) - CPAIR (t a - 20)

Va
CPGAS (t 1 - 20) - CPGAS (t 0 - 20) - K CPAIR (t 0 - 20) - CPAIR (t a - 20)

CPdust (t 1 - 20) - CPdust (t 0 - 20)
WD
CPGAS (t 1 - 20) - CPGAS (t 0 - 20) - K CPAIR (t 0 - 20) - CPAIR (t a - 20)

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 Calculation of the bypass ratio

Finally, knowing V Kiln and V BP

VBypass
BypassRati o
VKi ln

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 Conclusion

Minor elements are to be considered for

operation decisions
Chemistry is able to help for any investigation
concerning the process troubles
The volatilization and cycles of the elements can
be handled through process operation
A good knowledge of the element circulation is
necessary for a good trouble shooting

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 Questions and/or comments ?

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