Since meal enters the kiln at about 900 C, (compared with about 20 C in the wet process), the kiln could be shorter and of smaller diameter for exactly the same output. This reduces the capital costs of a brand new cement plant. A dry procedure kiln may be only 70m lengthy and 6m wide but generate a comparable quantity of clinker (normally measured in tonnes per day) as a wet approach kiln of the same diameter but 200m in length. For the same output, a dry procedure kiln with no a precalciner will be shorter than a wet procedure kiln but longer than a dry procedure kiln using a precalciner.

Kiln and preheater tower: raw meal passes down the tower when hot gases rise up, heating the raw meal. At ‘A,’ the raw meal largely decarbonates; at ‘B,’ the temperature is 1000 C – 1200 C and intermediate compounds are forming and at ‘C,’ the burning zone, clinker nodules as well as the final clinker minerals form. A preheater tower is likely to have 4-6 stages, not the three shown right here. Many styles are much more complex but this diagram illustrates the principle. See the ‘Clinker’ pages for far more information and facts on reactions within the kiln.

The kiln is produced of a steel casing lined with refractory bricks. You will find several unique forms of refractory brick and they’ve to withstand not merely the high temperatures within the kiln but reactions using the meal and gases within the kiln, abrasion and mechanical stresses induced by deformation in the kiln shell as it rotates.

Bricks within the burning zone are in a much more aggressive atmosphere compared with those in the cooler end in the kiln (the ‘back end’), so unique parts of the kiln are lined with distinct sorts of brick.

Periodically, the brick lining, or part of it, has to be replaced. Refractory life is lowered by severe alterations in temperature, like happen if the kiln has to be stopped. As the cost of refractories is usually a important expense in operating a cement plant, kiln stoppages are avoided as far as attainable.

As the meal passes through the burning zone, it reaches clinkering temperatures of about 1400 C – 1500 C. Nodules form as the burning zone is approached. When the clinker has passed the burning zone, it begins to cool, slowly at initially, then substantially additional swiftly as it passes over the ‘nose ring’ in the finish in the kiln and drops out into the cooler

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