A Model for Predicting the Erosion Rate Induced by the Use of a Selective Catalytic Reduction Denitrification Technology in Cement Kilns Flue Gas

Selective catalytic reduction(SCR)is a technology by which nitrogen oxides are converted with the aid of a catalyst into diatomic nitrogen and water.It is known that the catalyst can be easily eroded if a cement kiln with a high-dust content is considered.To understand this process,numerical simulations have been carried out considering a single catalyst channel in order to study the collision and erosion of fly ash and catalysts at meso scale.Based on a response surface methodology,the effects of five factors on the erosion rate have been studied,namely,the catalyst particle velocity,the particle size,the particle concentration,the incidence angle and the catalyst porosity.The results show that the influence of particle velocity,particle size and particle concentration is statistically significant and the particle size and incidence angle have a significant effect on the erosion rate.A quadratic polynomial prediction model for the erosion rate of honeycomb catalysts in cement kiln SCR reactors is finally proposed to support the future optimization of these systems.

Effects of Municipal Sewage Sludge on Fixation of Cr,Ni,Cu,and Zn during Co-processing of Heavy Metal-containing Waste in Cement Kilns

Cement raw meal with MSS and different heavy metals was blended to examine the fixation ratios, chemical species, and cement crystalline phases in clinkers. The results showed that blending MSS could decrease the fixation ratio of Cr, Ni, Cu, and Zn in the produced clinker by 5% to 25%. And Cr, Cu, and Zn were mainly incorporated into clinkers as metal silicates, Ni was mainly solubilized in Mg O to form magnesium nickel oxides, and the transition phases were mainly metal aluminum oxides as indicated by X-ray diffraction. The reduction of fixation ratios was likely attributed to the presence of impure elements, such as sodium and phosphorus in MSS. In addition, high concentrations（eg, 1.7 wt%） of chlorine in MSS led to metal chloride formation that could vaporize Cu, Cr, Ni, and Zn. To summarize, introducing MSS would decrease the fixation ratios of heavy metals due to the presence of impure elements, such as sodium and phosphorus and chlorine.

Present Synthesizing Situation and Application Mechanism of Hercynite in Cement Kilns

The magnesia -hercynite bricks offer a new lining to rotary cement kiln. They are well adopted and widely used in the high temperature zone of cement kiln, and have obtained good performance at rigorous and severe working conditions. The synthesis of hercynite requires a suitable atmosphere with proper O2 partial pressures which makes sure FeO can stably exist at the synthesizing temperature. Current industrial production of hercynite mainly adopts fused method. The other method, sinte- ring method, is not mature and needs further research. The magnesia - hercynite brick shows high hot toughhess, high adhesion strength to kiln crust, and good corrosion resistance to alkali salt in cement kilns. The mismatching of thermal expansion between magnesia and hercynite can improve the thermal shock resistance of the bricks, but the oxidation of partial Fe^2＋ , the high temperature solution, and low temperature exsolution of transgranular secondary spinel lead to cubical expansion, .formation of more cracks, and poor thermal shock resistance of the bricks.

Assessment of popular techniques for co-processing municipal solid waste in Chinese cement kilns

Cement kiln co-processing techniques have been developed in the past 20 years in China,and more than 60 factories now use fermentation,screening,and gasification pre-treatment techniques to coprocess municipal solid waste(MSW).There three complete MSW pre-treatment techniques,coprocessing procedures,and environmental risk assessments have been described in few publications.In this study,we assessed the effectiveness of each technique.The results suggested that the pollutant content released by each pre-treatment technology was lower than the emission standard.To reveal the mechanisms of pollutant migration and enrichment,the substances in the kiln and kiln products are investigated.The input of co-processing materials(Co-M)produced by fermentation caused formation of polychlorinated dibenzo-p-dioxins and dibenzoftiran(PCDD/Fs)in the bypass flue gas(By-gas)in excess of the regulatory standard.The Co-M input produced by the screening and gasifier technologies caused the total organic carbon(TOC)concentration to exceed the standard.In addition,the NOx,TOC,and PCDD/Fs in the By-gas exceeded the regulatory standard.Raw meal was the primary chlorine and heavy metals input stream,and clinker(CK)and cement kiln dust(CKD)accounted for>90%of the total chlorine output stream.Flue gas and CKD were the primary volatile heavy metal(Hg)output streams.Greater than 70%of the semi-volatile heavy metals(Cd,Pb,T1 and Se)distributed in hot raw meal and bypass cement kiln dust.The low-volatility heavy metals were concentrated in the CK.These results indicated that co-processing techniques used in China still require improvement.

Corrosion of Disposing Urban Domestic Wastes on Refractories for Cement Rotary Kilns

Corrosion of burning urban domestic wastes to alkali-resistant bricks and spalling-resistant high alumina bricks was researched by static crucible method and SEM in order to choose refractories for cement rotary kilns for collaboratively disposing wastes. The result indicates that the main corrosion mechanism is slag permeation and corrosion ; the emitted high temperature gases containing alkali, sulfur and chlorine during burning the wastes re- act with refractories forming low melting point sulfate, chloride and compound salts, which metamorphose the refractories, and the loose metamorphic layer is easy to spall under thermal stress. So, corrosion resistance and spaUing resistance shall be taken into account when choosing refractories for cement rotary kilns for collaboratively disposing wastes. It is suggested that decomposition furnaces should adopt spaUing resistant high alumina bricks and anti-coating SiC castables, and preheating equipment should adopt high strength alkali-resistant bricks and castables.

Damage Mechanism of Silicon Carbidemullite Bricks for Transition Zone of Cement Rotary Kilns

In order to improve the service performance and explore the damage mechanism of silicon carbide-mullite bricks for the transition zone of cement rotary kilns,the phase composition and the microstructure of a used brick in the transition zone of a cement rotary kiln were analyzed by XRD,SEM and EDS.The results show that the liquid and alkali vapor phases generated by the reaction between cement materials and the silicon carbide-mullite brick mostly enter the silicon carbide-mullite brick through the pores;meanwhile,Ca+and K+in the cement penetrate through the liquid maintaining a high chemical potential energy to dissolve Al2O3 and SiO2 at the top of the liquid phase thus enhancing the phase penetration;with the decreasing temperature,crystals such as gehlenite,potassium feldspar and potassium chloride are precipitated,which destroy the original structure and increase the difference of thermal expansion coefficient between the high temperature dense end and the metamorphic layer thus resulting in cracks,spalling,and rupture.

Progress of Environment-friendly Basic Refractories for Cement Industry

The chrome pollution from cement industry was introduced briefly,the research on chrome free basic refractories for cement kilns was reviewed,the production technologies of magnesia calcia,magnesium aluminate spinel,magnesia hercynite refractories,etc. were specified,the principles to improve thermal shock resistance and coating adhesiveness of refractories were analyzed,the measures to extend service life by improving production equipment and service conditions of refractories were put forward,the future of chrome free refractories was expected and some developing suggestions were given.

Improvement of geotechnical properties of sabkha soil utilizing cement kiln dust

Improvement of properties of weak soils in terms of strength,durability and cost is the key from engineering point of view.The weak soils could be stabilized using mechanical and/or chemical methods.Agents added during chemical stabilization could improve the engineering properties of treated soils.Stabilizers utilized have to satisfy noticeable performance,durability,low price,and can be easily implemented.Since cement kiln dust(CKD) is industrial by-product,it would be a noble task if this waste material could be utilized for stabilization of sabkha soil.This study investigates the feasibility of utilizing CKD for improving the properties of sabkha soil.Soil samples are prepared with 2% cement and 10%,20% or 30% CKD and are tested to determine their unconfined compressive strength(UCS),soaked California bearing ratio(CBR) and durability.Mechanism of stabilization is studied utilizing advanced techniques,such as the scanning electron microscope(SEM),energy dispersive X-ray analysis(EDX),backscattered electron image(BEI) and X-ray diffraction analysis(XRD).It is noted that the sabkha soil mixed with 2% cement and 30% CKD could be used as a sub-base material in rigid pavements.The incorporation of CKD leads to technical and economic benefits.

Plant Test of Industrial Waste Disposal in a Cement Kiln

Destruction of industrial waste in cement rotary kilns (CRKs) is an alternative technology for the treatment of certain types of industrial waste (IW). In this paper, three typical types of industrial wastes were co-incinerated in the CRK at Beijing Cement Plant to determine the effects of waste disposal (especially solid waste disposal) on the quality of clinker and the concentration of pollutants in air emission. Experimental results show that (1) waste disposal does not affect the quality of clinker and fly ash, and fly ash after the IW disposal can still be used in the cement production, (2) heavy metals from IW are immobilized and stabilized in the clinker and cement, and (3) concentration of pollutants in air emission is far below than the permitted values in the China National Standard-Air Pollutants Emission Standard (GB 16297-1996).

Increasing Plant Availability by Mechanical Checking of the Cement Rotary Kiln Axis

A periodic check of the cement rotary kiln axis is needed withinthe framework of preventive ma- intenance for maintaining high plantavailability. The fourth generation 'KAS-4' measuring system wasdevel- oped by Wuhan University of Technology in 1999. The system canbe carried out with rotating or stationary kiln plant. The same istrue of the measurement of tire and supporting roller diameters, theclearance of tires, the po- sition of rollers, the machining of tiresand rollers, the slops of roller surfaces, the deflection of gear,the axis of kiln. The system has been applied to the measurement for10 set of cement rotary kiln in China.

A New Kind of Eco-Cement Made of Cement Kiln Dust and Granular Blast Furnace Slag

A research project wus conducted to manufacture eco-cement for sustainable development using cement kiln dust（ CKD ） and granular blast furnace slag（ GBFS ）. In the project, the burning process and minerul compositions of CKD dinker were investigated. Different minerulizers such as CaSO4 and CaF2 , sulfur and alkali corttent were coasidered. The strength of CKD and GBFS eco-cement were evaluated. The results indicate the CKD clinker can not only form ordinary cement clinker minerals such as C3 S, C2 S and C4 AF , but also form such high-reuctive minerals as C4 A3 S and C. A7 · CaF2 . The CKD and GBFS eco-cement will have the similar strength to the Portland cement grade 32.5 when blend proportion is properly applied.

Application of the Hand-instrument of Measurement of Tyre Gap and Diameter in Cement Rotary Kiln

This article is concerned with the cement rotary kiln, thehand-instrument of measurements of tyre gap and the outer diameter.The accuracy of measurements of tyre gap and diameter is less than ±1 mm. The hand-instrument wins two patents in China. It has beenapplied to the measurement for 16 sets of cement ro- Tary kiln inChina.

Chrome-free Basic Refractories for Burning Zone of Cement Rotary Kiln

Based on the relevant phase diagrams of ternary system in MgO - CaO - ZrO2 - SiO2 quarternary systems, the phase diagram of Fe - O system and the condensed phase stability area diagram of iron oxides, the corrosion resistance of MgO - CaO - ZrO2 refractories to silicate cement, and the forming conditions and prepar- ing measures of hercynite are analyzed.

Predictive Model for Cement Clinker Quality Parameters

Managers of cement plants are gradually becoming aware of the need for soft sensors in product quality assessment. Cement clinker quality parameters are mostly measured by offline laboratory analysis or by the use of online analyzers. The measurement delay and cost, associated with these methods, are a concern in the cement industry. In this study, a regression-based model was developed to predict the clinker quality parameters as a function of the raw meal quality and the kiln operating variables. This model has mean squared error, coefficient of determination, worst case relative error and variance account for (in external data) given as 8.96 × 10–7, 0.9999, 2.17% and above 97%, respectively. Thus, it is concluded that the developed model can provide real time estimates of the clinker quality parameters and capture wider ranges of real plant operating conditions from first principle-based cement rotary kiln models. Also, the model developed can be utilized online as soft sensor since they contain only variables that are easily measured online.

Hydrothermal Characteristics of Blended Cement Pastes Containing Silica Sand Using Cement Kiln Dust as an Activator

The hydrothermal reactivity of silica sand was studied using cement kiln dust (CKD) as an activator in addition to the Portland cement fraction of El-Karnak cement (a blend of ordinary Portland cement and ground sand). Autoclaved EI-Karnak cement pastes were studied at pressures of 0.507, 1.013 and 1.520 MPa of saturated steam with respect to their compressive strength, kinetics of hydrothermal reaction and the phase composition of the formed hydrates. The role of CKD in affecting the physicochemical and mechanical properties of EI-Karnak cement pastes was studied by autoclaving of several pastes containing 5, 7.5, 10 and 20% CKD at a pressure of 1.013 MPa of saturated steam. CKD was added either as a raw CKD (unwashed) or after washing with water (washed CKD). The results of these physicochemical studies obtained could be related as much as possible to the role of CKD (raw or washed) in affecting the hydrothermal reactivity of silica sand in EI-Karnak cement pastes.

Anti-hydration Magnesia-spinel Bricks in Cement Industry

Hydration cracks of magnesia-spinel bricks in cement industry have been serious problems for both refractory producers and refractory users for a long time.When magnesia-spinel bricks are kept for more than 6months,the bricks tend to have reaction with water or moisture and result in cracks and loss on their structural strength. Those bricks cannot be used anymore and cause substantial loss for the related parties. In 2013,the Siam Refractory Industry Co.,Ltd.,Thailand,successfully developed and applied a special nano-technology to create ＂Anti-Hydration Magnesia-Spinel Bricks ＂ for cement industry which can have the storage time more than two years even in high humidity areas. The cement producers can ensure that all bricks still have good properties as the new ones.

Adherence Characteristics of Cement Clinker on Basic Bricks

Based on the sandwich test, adherence mechanisms of cement clinker on various basic bricks were tackled by microstructural observations with help of cathodolumi-nescence technique. Doloma based bricks offer sufficient lime to react with clinker, forming C3S rich layer and initializing superior adherence. However, clinker with low silica ratio leads to MgO agglomeration at the interface of doloma bricks, which reduces adherence strength. On magnesia spinel bricks , fine, crystalline spinel easily reacts with lime containing phases from clinker to form low-melting phases and belite zone, which shows high adherence performance. Lack of fine spinel in magnesia spinel bricks results in poor adherence.

A New Type of Cement Kiln——Annular Shaft Kiln

Annular shaft kiln invented by authors is an achievement in scientific research of Wuhan University of Technology. The invention-patent technology has been applyed recently to a φ2.2×7.7m circular shaft kiln of semi-mechnization in Tangshan National Cement Plant. The circular shaft kiln became an annular shaft kiln after a core tube was added in it as an inner annulation. This kiln has been proved to be successful in practice. It’s output after firing on 9th october 1989 has increased by 50%. The average clinker mark of over 525 has

Spalling Resistant Bauxite Based Bricks for Cement Kiln

1 Scope This standard specifies the term, definition, classification, labeling, technical requirements, test methods, inspection rules, packing, marking, transportation, storage, and quality certificate of spalling resistant bauxite based bricks for cement kiln.

Alkali Resistant Bricks for Cement Kiln

This standard specifies the classification, techni- cal requirements, test methods, inspection rules, marking, packing, transportation and storage of alkali resistant bricks.