Full-scale investigations of initial deposits formation in a cement plant co-fired with coal and SRF

This work investigates the initial (short-term) deposit formation in a cement calciner co-fired with coal and SRF (Solid Recovered Fuel). The main objective was to evaluate and compare the tendencies of deposit formation (i.e. material deposition rate and composition) at different locations (heights) in the calciner system, during different operation conditions. A steel probe was used to collect initial deposits from four different sampling locations: ⁱ⁾ in the kiln riser (two sampling locations), ⁱⁱ⁾ in the mid calciner, and, ⁱⁱⁱ⁾ at the outlet from the bottom stage preheater cyclone (C5). After an exposure time of the probe between 1 and 20 min, the collected deposit samples were weighted and characterized by SEM-EDX, ICP-OES/IC, and XRD. Plant operation data, measured gas temperatures, as well as gas phase composition data (i.e. KCl(g) and SO₂(g)), supported the evaluation of deposit formation. Due to high particle flux (up to approx. 61,000 kg/(m²·h) in the riser duct), the average net deposit formation rate was around 500 kg/(m²·h) for 1 min exposure time, decreasing to <100 kg/(m^2·h) for exposure times ≥4 min (due to spontaneous shedding and erosion). The deposits contained primarily five crystalline phases (CaO, CaCO₃, Ca(OH)₂, KCl, and SiO₂), which is in general consistence with the composition of the admitted preheated raw meal (C4 meal) at measurement locations, with a slight enrichment in KCl, suggesting some condensation of volatile elements from the high-temperature gas phase on the surface of the somewhat colder deposit particles. Further, the deposit samples obtained in the kiln riser had a higher degree of calcination (higher proportion of CaO as compared to CaCO₃) as compared to the admitted C4 meal, suggesting carry-over of dust from the kiln feed pipe, or fast calcination of the riser meal due to high temperature.

The collected short-term deposits differ significantly from long-term (mature) deposits, which have previously been collected from the site, in terms of chemical and physical properties. Compared to short-term deposits, which had a content of KCl in the range of approx. 3–5 wt%, the content of KCl in the mature deposits increased substantially from around 2 wt% in samples from the kiln riser area to a level of >20 wt% in the calciner and C5 cyclone area, implying significant accumulation of KCl caused by volatile circulation and condensation from the hot gas on surfaces with locally lower temperatures. The most prevalent crystalline phases in the mature deposits were KCl, CaCO₃, and the mineral spurrite (Ca₅(SiO₄)₂CO₃). The presence of spurrite implied that SiO₂ reacts with CaCO₃, or with CaO and gaseous CO₂, to form spurrite during long-term deposit build-up and maturation.

Overall, the results from this work suggest that the short-term deposit formation in the cement calciner is dominated by impaction. The composition of the short-term deposits is quite similar to the composition of the entrained C4 meal particles; while the build-up of mature deposits is influenced greatly by local temperature gradients and long-term fluctuations. I.e. in zones with locally lower temperatures, such as cold area of calciner walls (< ∼850 °C), heterogeneous condensation and/or thermophoresis of KCl from the high-temperature flue gas is facilitated.