Cement kilns are 60-100 m rotating cylinders that form clinker at 1450 °C. They burn 500-3000 t/day of coke, tire chips, refuse-derived fuel (RDF) and solvent waste. NFPA 85 provides calorimetric calculations and fuel-management rules.
Cement Process
- Calcination: 900 °C CaCO3 -> CaO
- Clinker: 1450 °C C3S C2S formation
- Cooler: Grate 100 °C cooling
- Kiln rotation: 2-4 rpm
- Capacity: 3000-10000 t/day
Alternative Fuels
- RDF: 15-20 MJ/kg
- Tire chip: 32 MJ/kg
- Solvent: 25-35 MJ/kg
- Biomass: 14-18 MJ/kg
- Petcoke: 32 MJ/kg, the traditional reference fuel
NFPA 85 Fuel Management
- Feed interlock: Flame scanner required
- Purge: 5 volume changes before re-ignition
- CO monitor: 2 percent alarm
- Pressure control: kept at about -5 mmWg (negative)
- Trip: High temperature 1550 °C
Downstream Fire Protection
- Cable tray: Sprinkler 12.2 L/min/m2
- Fuel feed silo: Spark detection
- Coal mill: CO monitor + inert
- ESP (electrostatic precipitator): fly ash and CO buildup create an explosion risk
- Bag filter: hot-gas risk; refractory protection
Turkish Cement Sector
- Large plant: 7.5 Mt/y
- Another plant: 2.3 Mt/y
- Large cement groups: 10 plants
- One plant: White cement
- Total: 70+ Mt/y Turkey capacity
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Download SprinkCalc on the App StoreNFPA 85, NFPA 664, NFPA 654, EN 197, CEN TC 51. NFPA 85 Boiler and Combustion Systems.