HGRS MASTER

Operation Area: Clinker Production

Category : Equipment
Module: Kiln Bypass
Unit: Bypass Principle 01 o 0!
"ersion: 1#0 $%&0'&0(
Bypass Principle
Purpose: A )ypass creates a *al*e or circulating elements in t+e kiln and remo*es elements suc+ as Cl,
sulur and alkalis until t+e coating-clogging situation in t+e pre+eater-kiln )ecomes controlla)le
.it+ t+e +elp o cleaning#
A )ypass is used or t+e remo*al o alkalis in case lo.&alkali cement is )eing produced
Function/
Description:
/+e kiln gases containing t+e *olatili0ed elements 1see unit circulation p+enomena2 are e3tracted
at t+eir point o +ig+est concentration, i#e# t+e kiln inlet# /+is pre*ents t+em rom condensing in
t+e pre+eater to.er and creating cyclone )lockages t+ere#
4t can roug+ly )e stated t+at or eac+ 100g-t cli o c+lorine o total input, 15 o )ypass rate is
necessary#
6ue to t+e )ypass t+e +eat consumption o t+e kiln system is roug+ly increased )y 10 k7-kg cli
or precalciner kilns and $0 k7-kg cli or pre+eater kilns per percent o )ypass rate#
/+e eiciency o )ypass installations is most eicient or Cl and muc+ less or 8 and alkalis#
/+ereore Cl )ypass rates are muc+ smaller t+an ot+er )ypass rates#
Ater t+e )ypass t+e +ot kiln gases are quenc+ed in a mi3ing c+am)er .it+ t+e +elp o quenc+ing
air alone or .it+ quenc+ing air and .ater in9ection# /+is quenc+ing +as t.o main reasons:
6ue to t+e cooling do.n o t+e gases t+e gaseous *olatile elements solidiy and
condense on t+e kiln dust and is e3tracted as )ypass dust# /+is dust can )e separated
rom t+e gas stream and remo*ed rom t+e kiln system#
/+e +ot kiln gases 1ca# 11:0;C2 are cooled do.n to 1:0&(:0;C 1according to t+e ilter
type used2 in order not to damage t+e ilter 1e#g# )ag ilters2 and-or in order to impro*e
t+e eiciency o t+e ilter 1e#g# Electrostatic precipitators2
/+e quenc+ed gases are introduced into a ilter .+ere t+e )ypass dust is separated rom t+e
gas# /+e gas is lead to t+e main or a separate )ypass stack or is reintroduced into t+e kiln
system 1cooler, pre+eater, ra. mill, etc#2#/+e potential or t+e e3traction o *olatiles .it+ a )ypass
is gi*en )y:
*olatile e3traction potential < dust quantity = *olatile&concentration
/+e collected )ypass dust is used or instance in cement as a iller or t+e *olatile elements can
)e .as+ed out and remo*ed, t+e rest o t+e dust )eing reused as ra. material#
Impact if not
correctly
functionin
Clogging in t+e pre+eater to.er or ring ormation in t+e kiln
E*entually kiln s+ut do.n
Cement quality pro)lems in case o lo.&alkali cement production
!auses of
malfunctions
4nadequate )ypass rate 1too lo.2
/oo lo. alkali *olatili0ation and .it+dra.al 1lack o c+lorine added2
Erroneous +ot meal analysis o *olatile elements
Pre"enti"e
actions
Correct +ot meal analysis o *olatile elements at least once per s+it
Ad9ustment o t+e )ypass rate according to t+e +ot meal analysis
See site specific unit for a##itional information$ respecti"e correcti"e
actions an# applica%le safety instructions&
'M( #enotes maintenance issue

AD)*+,&#sf / -ma ./&+&*.
0uenc1 air
fan
0uenc1
c1am%er
clin2er
intro#uction
into t1e cement
%a filter
coolin to3er
%ypass
%a filter
%ypass fan