BACKGROUND OF THE INVENTION

Plants for heat treating granular raw material such as cement raw meal often include one or more vertical multi-stage suspension preheater strings each of which includes a plurality of serially connected cyclone separators that receive cement raw material at the top and hot exhaust gases from the rotary kiln at the bottom with countercurrent flow of the hot gases and the cement raw meal through the preheater to thereby preheat the raw cement feed for the rotary kiln. A typical calcining cement suspension preheater string such as disclosed, for example, in U.S. Pat. Nos. 3,891,383; 3,904,353 and 3,914,098 may include four serially connected cyclone separators interconnected by heat exchanger conduits and meal pipes to achieve four stages of heat exchange. Each cyclone separator has an inlet for hot gas and suspended raw meal, an outlet at its upper end for separated hot gases connected to a stage above, and an outlet at its lower end for separated raw cement meal connected to a stage below. The cyclone separators in the suspension preheater string are spaced apart vertically, and the raw cement meal flows by gravity through meal pipes interconnecting the cyclone separators while kiln off gas is moved upwardly through the separators and heat exchange conduits by suction from an induced draft fan.

Cement plants of such multi-stage preheater strings are of extreme vertical height, for example, 190 feet height for a four stage cyclone-type suspension preheater, and the vertical dimension of each cyclone separator contributes significantly to the undesirable height of a conventional cyclone-type suspension preheater tower.

A conventional cyclone separator has a relatively high gas pressure drop and relatively high friction loss which result in high energy losses in the calcining cement suspension preheater and necessitate use of high horsepower induced draft fans. Power consumption in a cyclone type preheater results principally from moving the gas against the pressure differential of the cyclone separators. A major portion of the gas pressure drop in a cyclone separator results from: (a) the energy required to draw the relatively low whirl velocity gas at the cyclone body diameter into the higher whirl velocity of the gas exit pipe diameter, and (b) the unrecovered energy of the higher whirl velocity of the exit gas stream. Cyclone separator type suspension preheater strings are usually limited to four stages because of height and pressure drop limitations.

U.S. Pat. No. 3,049,343 to Helming discloses a cement plant preheater wherein the axes of the cyclone separators are inclined at a 45 degree angle to the horizontal for the purpose of reducing the height of the preheater tower, but such arrangement has not proven commercially successful and has the above discussed disadvantage of cyclone separators.

U.S. Pat. No. 3,358,426 to Husbjerg discloses apparatus for preheating cement raw meal and separating the hot meal particles from the gas after heat transfer which utilizes centrifugal force to throw the meal particles against the outer wall of a curved pipe and precipitate them from the gas, but the apparatus disclosed in this prior art patent has only a single stage of heat transfer and would be capable of carrying out only a relatively small percent of the calcination of the cement meal.

OBJECTS OF THE INVENTION

It is an object of the invention to provide an improved multi-stage suspension preheater for a cement calcining plant which is more compact and substantially reduced in height in comparison to a preheater using cyclone operators. Another object is to provide an improved multi-stage suspension preheater for a cement calcining plant which is more compact and substantially reduced in height in comparison to a preheater using cyclone separators. Another object is to provide such an improved multi-stage suspension preheater which permits a reduction of up to forty percent in the height of a suspension preheater tower in comparison to a conventional suspension preheater using cyclone separators. Still another object is to provide such an improved suspension preheater which has more stages than, but is approximately of the same height and pressure drop as, a conventional four stage preheater of the cyclone separator type to thereby increase preheating of the meal and reduce fuel requirements.

It is a further object of the invention to provide an improved multi-stage suspension preheater for a cement calcining plant which requires substantially less total system energy to operate than a conventional suspension preheater using cyclone separators and which also permits use of fans which develop substantially less power than fans used with conventional suspension preheaters of the cyclone separator type. Another object is to provide such an improved multi-stage suspension preheater which permits use of induced draft fans having a horsepower rating of approximately one half that of fans used with cyclone type suspension preheaters of the same capacity.

SUMMARY OF THE INVENTION

A multi-stage cement calcining plant suspension preheater having a calcining furnace and serially connected heat exchange and gas/meal separator stages for preheating raw cement meal before it is fed to the calcining furnace is characterized in accordance with the invention by helical duct inertial separators in a plurality of the preheater stages each of which comprises a hollow elongated continuous duct having its longitudinal axis disposed generally along a downwardly inclined helical path with its inlet end at a higher elevation than its outlet end and having a gas inlet opening in a vertical plane for receiving a horizontal stream of gas with cement meal suspended therein, means including a downwardly inclined upper wall and a concave outer side wall for deflecting the gas stream into a downwardly inclined helical path within said duct, a generally horizontal bottom wall in the path of the helically downward directed gas stream, a meal exit opening in the bottom wall and a gas exhaust opening in the top wall adjacent the outlet end of the duct, whereby the helically downward directed gas stream impinges on the bottom wall and is deflected upward and drawn by suction toward the gas exhaust opening while the heavier meal is precipitated from the gas stream and flows under centrifugal and inertial forces along the bottom wall into the meal exit opening. In comparison to conventional cyclone separators, the helical duct inertial separators are substantially reduced in height and have substantially lower pressure drop across the separator, thereby reducing the height of the suspension preheater and the horsepower capacity of the induced draft fan which draws the gas through the separators. A suspension preheater embodying the invention is further characterized in that the uppermost stage has a cyclone separator and that the calcining furnace has a combustion gas and calcining cement outlet connected to the gas inlet opening of a helical duct inertial separator of the lowermost stage and also has a preheated cement meal inlet connected by a feed pipe to the meal exit opening of a helical duct inertial separator of the stage immediately above the lowermost stage.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described in connection with the attached drawing wherein:

FIG. 1 is a schematic front view of a cement calcining plant having a multi-stage suspension preheater string embodying the invention;

FIGS. 2, 3 and 4 are front, top and side views respectively of the helical duct inertial separators shown in FIG. 1;

FIG. 5 is a front view of a single stage heat exchanger and meal/gas separator of the type used in the FIG. 1 embodiment;

FIG. 6 is a graph plotting pressure drop versus volume of raw cement meal flow per unit time in a conventional cyclone separator and in a helical duct inertial separator of the type illustrated in FIGS. 2-4; and

FIGS. 7 and 8 are front and top views respectively of a cement calcining plant dual multi-stage suspension preheater embodiment of the invention having four stages.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates a cement calcining plant including a rotary cement clinkering furnace, or kiln 10, a single multi-stage cement suspension preheater string 11 embodying the invention and including a calcining combustor, or calcining furnace 12 for substantially completely calcining the preheated raw cement meal before it is fed to kiln 10, and a clinker cooler 14 coupled after the kiln 10 for cooling the product treated in the kiln.

Suspension preheater 11 is shown as having connected in series an upper stage I having a cyclone separator 17, three serially flow-connected meal/gas separator stages II, III and IV each having an inertial helical duct separator 15 of the type disclosed in my copending application Ser. No. 222,034 entitled Helical Duct Inertial Separator filed Jan. 2, 1981 and designated 15II, 15III, and 15IV respectively, and a calcination stage V including calcining combustor 12 and such a helical duct inertial separator designated 15V. Suspension preheater 11 has an inlet pipe 16 for cement raw meal at the top thereof and an outlet meal pipe 18 connecting calcination stage V to the cement meal inlet end 20 of rotary kiln 10.

The cement meal inlet end 20 if kiln 10 may communicate with guide means such as a hood 23 having an opening in a vertical plane surrounding kiln inlet end 20. The clinker discharge end 24 of kiln 10 may communicate with a casing 25 which at its lower end joins cooler 14 which may be of the grate type. Cooler 14 receives the hot clinker discharged from kiln 10 through casing 25, and the hot clinker is cooled and the cooling air is heated. Hood 23 has a restricted furnace gas conduit 27 at its upper end which communicates with a mixing chamber 29 at the lower end of calcining combustor 12. Part of the hot air from cooler 14 leaving casing 25 is passed through kiln 10 where the oxygen therein nourishes combustion of fuel blown into kiln 10 through a burner pipe 30 provided at the clinker discharge end 24 of kiln 10. The hot exhaust gases pass through kiln 10 countercurrent to the preheated, substantially completely calcined cement meal which is fed from outlet meal pipe 18 of calcination stage V into meal inlet end 20 of kiln 10. The cement meal moves down through kiln 10 where it is chemically and physically changed under the influence of the heat in kiln 10. The hot exhaust gases leave kiln 10 through end 20 and enter hood 23 and then exit from hood 23 through restricted furnace gas exhaust throat conduit 27 which increases the velocity of exhaust gases flowing into mixing chamber 29. Hot air from clinker cooler 14 enters casing 25 and passes through an air duct 32 into mixing chamber 29. Preheated cement meal from inertial separator 15IV of stage IV is introduced into mixing chamber 29 through meal pipe 16, i.e., into the preheated cement inlet to the calcining combustor 12, and is entrained in the hot kiln-off gases rising through furnace gas exhaust conduit 27. A splash plate (not shown) is disposed within mixing chamber 29 opposite the lower end of meal pipe 76 to distribute the meal into the hot kiln-off gases, rising through conduit 27 which mix with air from cooler 14 introduced into mixing pipe 29 through duct 32. Fuel is also injected through burners 34 into the air/meal mixture within combustion chamber 35 of calcining furnace 12 where it burns to heat and calcine the raw cement material so suspended in the hot gas before the meal is introduced into kiln 10. Combustion within combustion chamber 35 is nourished by oxygen contained in the heated air from cooler 14 introduced through duct 32.

Gas/meal helical duct inertial separator 15III of stage III is shown in detail in FIGS. 2, 3 and 4 and includes a hollow elongated continuous duct 40 of rectangular transverse cross section having its longitudinal axis disposed generally along a generally spiral path, i.e., more specifically, along a portion of a turn of a helix whose axis is vertical. Elongated continuous duct 40 is preferably approximately U-shaped in longitudinal cross section with its outlet end 41 disposed at a vertically lower elevation than its inlet end 42. Duct 40 has a vertically facing inlet opening 44 adjacent inlet end 42 for receiving a generally horizontal current, or stream of hot gas with raw cement meal entrained, or suspended therein. The horizontal gas current flowing into inlet opening 44 comprises hot kiln-off gases from the stage below flowing upward through a heat exchange elbow conduit 45' of generally inverted-L configuration (See FIG. 5) and rectangular transverse cross section having the cross bar portion 46 thereof registering with inlet opening 44 and the downwardly inclined leg portion 48 registering with the gas exhaust opening of the helical duct separator 15IV of the stage below.

Inlet opening 44 is in a vertical plane and is partially defined by horizontal top and bottom walls and a curvate vertical side wall 50 of a first transition portion 51 of helical duct 40. Curvate vertical side wall 50 is in the path of the horizontal gas stream and directs the gas stream and suspended meal horizontally and at an acute angle from the inlet direction into a downwardly inclined generally arcuate-in-longitudinal-cross-section portion 53 of duct 40 which registers with first transition portion 51. Arcuate portion 53 is of rectangular transverse cross section and has a downwardly inclined upper wall 54 and a vertical, concave, outer side wall 56 both of which are in the path of the horizontal gas current from first transition portion 51 and together with side wall 50 comprise means to deflect the gas stream and suspended meal into a downwardly inclined helical path within duct 40 so that they are acted upon by radially outward directed centrifugal force and tangentially directed inertial force.

At its downstream end arcuate portion 53 of duct 40 registers with a second transition portion 58 having a horizontal top wall, a horizontal bottom wall 60 and a curvate vertical side wall 59. Bottom wall 60 and curvate side wall 59 of second transition portion 58 are in the path of the helically downward directed gas stream and suspended meal which are being acted upon by centrifugal and inertial forces. Curvate side wall 59 changes the direction of the gas stream and suspended meal particles into a path approximately the reverse of the direction of the horizontal current received by inlet opening 44, and horizontal bottom wall 60 deflects the gas stream upward and redirects the downwardly urged heavier meal particles horizontally so that they precipitate from the gas stream and flow under the centrifugal and inertial forces along bottom wall 60.

Second transition portion 58 communicates with a meal collection box 62 which in its upper wall has a gas exhaust opening 63 in a horizontal plane and in its lower wall has a meal exit opening 64 in a horizontal plane. Gas exhaust opening 63 registers with the upwardly extending leg portion 48 of the generally inverted-L shaped heat exchanger elbow conduit 45" of stage II above. Meal exit opening 64 communicates with the open upper end of a meal hopper 70 which may be of generally inverted pyramidal configuration truncated at its apex, and at its lower end hopper 70 terminates in a vertical meal outlet pipe 71 that is closed by a meal valve 72 to prevent air or gas from entering meal outlet pipe 71 under vacuum operating conditions. As described hereinafter, meal outlet pipe 71 communicates with a meal pipe 76' (see FIG. 1) which feeds separated meal to the heat exchange elbow conduit 45 of stage IV below. The gas stream is deflected upwardly by horizontal bottom wall 60 of second transition portion 58 and drawn by suction from conduit 45" toward gas exhaust opening 63 while the heavier meal particles precipitate from the gas stream and flow under the centrifugal and inertial forces along horizontal bottom wall 60 and through meal exit opening 64 into hopper 70.

Helical duct 40 is thus defined by first transition portion 51, arcuate portion 53, second transition portion 58 and meal collection box 62 and preferably is of arcuate longitudinal cross section and preferably extends through approximately 180 degrees of arc, and inlet opening opening 44 and gas exhaust opening 63 are at approximately the same radial distance from the center of such arc. This configuration results in substantial reduction in pressure drop across inertial helical duct separator 40 in comparison to a conventional cyclone separator wherein a major portion of the gas pressure loss results from the energy required to draw the relatively low whirl velocity gas at the cyclone body outer diameter into the higher whirl velocity of the axial exit gas stream. It will be appreciated that such losses are substantially eliminated in helical duct inertial separator 40.

FIG. 6 plots the pressure drop (in inches of water) versus volume of ambient air flow per unit of time (in cubic feet per minute) through: (a) a conventional cyclone separator; and (b) a helical duct separator 15, and it will be noted that the pressure drop through helical duct separator 15 is only a minor fraction of the pressure loss in a cyclone separator for a given volume of gas flow per unit time. For example, FIG. 8 shows that the pressure drop in drawing 500 cubic feet per minute of ambient air through helical duct separator 15 is approximately 1.05 inches of water, whereas the pressure drop in moving the same volume through a conventional cyclone separator is approximately 6.1 inches of water. It will be appreciated that such difference in pressure loss greatly reduces the static pressure and power that a fan, such as induced draft fan 74 represented in FIG. 1, must develop to move the kiln-off gases through the multiple stages of the preheater string in comparison to a preheater of the cyclone separator type since power consumption in a preheater results principally from moving the gas against the differential pressure of the separator.

FIG. 5 illustrates a single heat exchanger and helical duct meal/gas separator stage of a suspension preheater embodying the invention, for example, stage III which include helical duct separator 15III, heat exchanger elbow conduit 45' which registers at its upper end with gas inlet opening 44 of separator 15III and at its lower end with gas exhaust opening 63 of separator 15IV of stage IV; separated meal pipe 76" whose upper end communicates with meal outlet pipe 71 from hopper 70 of stage II and at its lower end communicates with the interior of the leg portion 48 of heat exchanger elbow conduit 45'; and a splash plate 77 positioned within conduit 45' opposite the lower end of meal pipe 76' which distributes the meal from pipe 76 into the hot separated gases from stage IV rising through elbow conduit 45'. The cement meal separated in stage II and descending through pipe 76" is moved upward through substantially the entire length of elbow conduit 45' by the rising hot gases from gas exhaust opening 63 of stage IV to achieve maximum heat transfer and further preheat the meal before it is separated from the gases in separator 15III and then fed through meal pipe 76' into elbow conduit 45 of stage IV.

FIG. 1 schematically represents that suspension preheater string 11 includes upper stage I having cyclone separator 17 which removes the extra fine particles in the raw cement meal fed into meal inlet pipe 16; an induced draft fan 74 connected to the gas exhaust outlet of cyclone separator 17 drawing the kiln-off gases with cement meal entrained therein through the five stages of preheater 11; a heat exchanger elbow conduit 79 which registers at its upper end with the gas inlet to a cyclone separator 17 and at its lower end with gas exhaust opening 63 of separator 15II of stage II; meal inlet pipe 16 which registers with the interior of heat exchanger elbow conduit 79 and through which raw cement meal is fed to preheater 11 and carried upward through conduit 79 with the rising hot separated gases from helical duct separator 15II to preheat the cement meal; a meal pipe 76'" which registers at its upper end with the separated meal outlet from cyclone separator 17 and at its lower end with the interior of heat exchanger elbow conduit 45" of stage II so that the meal separated in cyclone separator 17 is further preheated by the gases separated in stage III rising within heat exchanger conduit 45"; meal pipe 76" which at its upper end registers with separated meal hopper 70 of helical duct separator 15II of stage II and at its lower end with the interior of heat exchanger elbow conduit 45' so that the meal separated in stage IV rising through conduit 45'; meal pipe 76 which at its upper end communicates with separated meal hopper 70 of helical duct separator 15III and at its lower end communicates with heat exchanger elbow conduit 45 to further preheat the separated meal from stage III by the gases separated from helical duct separator stage V rising within conduit 45; meal pipe 76 which at its upper end communicates with meal hopper 70 of helical duct separator 15IV of fourth stage IV and at its lower end with the preheated meal inlet into mixing chamber 29 of calcining combustor 12; preheater stage V having a helical duct separator 15V whose gas inlet opening 44 registers with a combustion gas and calcined meal outlet (not shown) from the upper portion of calcining combustor 12 so that stage V receives substantially completely calcined cement meal as an input and whose separated meal hopper 70 is connected by meal pipe conduit 18 to the meal inlet end 20 of kiln 10.

FIGS. 7 and 8 are front and top views respectively of a cement calcining plant dual preheater embodiment of the invention employing helical duct inertial separators 15 and having two suspension preheater strings 80L and 80R both of which are analogous to preheater string 11 of FIG. 1 embodiment with the exception that each string 80L or 80R comprises one cyclone type stage and only three helical duct separator stages. In effect, each preheater string 80L and 80R eliminates stage IV of the FIG. 1 embodiment. Both preheater strings 80L and 80R have an upper stage I provided with cyclone separator 17 whose gas inlet receives hot gases from an elbow conduit 79 which at its lower end communicates with the gas exhaust opening of helical duct inertial separator 15II of stage II. The gas exhaust openings of the cyclone separators 17 of both strings communicate with a duct 82 connected to a single induced draft fan 74 that draws the kiln off gases upwardly through the meal/gas separators and heat exchanger conduits of both strings by suction. The meal outlet from cyclone separator 17 of stage I registers with a meal pipe 76" which at its lower end communicates with the interior of an elbow conduit 45". At its upper end elbow conduit 45" registers with the gas inlet opening of helical duct separator 15II, and at its lower end conduit 45" registers with the gas exhaust opening of helical duct separator 15III of stage III. Meal hopper 70 of stage II registers with meal pipe 76" that communicates with the interior of elbow conduit 45' which at its upper end registers with the gas inlet opening of helical duct separator 15III of stage III and at its lower end communicates with the gas exhaust opening of helical duct separator 15IV of stage IV. Meal outlet pipe 83 from hopper 70 of separator 15III of strings 80L and 80R differs from the FIG. 1 embodiment in that at its lower end it communicates with the preheated meal inlet to mixing chamber 29' of a single calcining combustor 12' for both preheater strings 80L and 80R.

The fourth stage also differs from the FIG. 1 embodiment in that the gas inlet opening of helical duct separator 15IV of both strings 80L and 80R communicates with the combustion gas and calcined meal outlet of calcining combuster 12' adjacent the top thereof and also in that the meal hopper 70 of helical duct separator 15IV communicates with the upper end of a meal pipe 85 which at its lower end communicates with the meal inlet end of kiln 10. Two air inlet ducts 32 from the cooler (not shown in FIGS. 7 and 8) communicate with mixing chamber 29' of calciner 12'.

The height of each helical duct separator 15 is approximately 49 percent of the height of a typical cyclone separator. Inasmuch as preheater 11 of FIG. 1 embodiment includes one cyclone separator stage I, the overall stacking height of the five stages of preheater 11 of this embodiment will be approximately sixty percent of the height of the typical cyclone separator preheater tower. The height of a typical four stage dual preheater of the cyclone separator type with a single combustion chamber rated at 3000 standard tons per day capacity is approximately 190 feet from the top to the longitudinal axis of the kiln, whereas the height of the four dual preheater embodiment of the invention illustrated in FIGS. 7 and 8 using helical duct separators 15 in three stages thereof is only approximately 110 feet. Further, the pressure requirement of the induced draft fan for the dual preheater embodiment of the invention employing helical duct inertial separators illustrated in FIGS. 7 and 8 is less than one-half that of a conventional four stage preheater with cyclone separators.

Tests establish that collection efficiency of helical duct separators 15 for finely ground meal is in the range from 84 to 88 percent and is only slightly less that that of a standard cyclone separator. Helical duct separators 15 permit construction of a suspension preheater having more stages than a conventional four-stage cyclone separator type preheater without increase in height or pressure drop, thereby increasing preheating of the meal and reducing the fuel requirements.