FROM WOIDA PHONE NO. 

"RECENT DtSIGN tH~ROVEMZNIS IN 

THE CUrE-KILN SYSTEM" 

by 

Geo~ge J •. S~o~onski 

Se~~or Applica~ioa E~sineer 

Le.o11aJ:cl J. 1-lGicl.a · Senior Applica~ioa ingincer 

of the 

Allia-Chalmer$ eo~oracion 

P. 0. Box SU · 

Milwaukee,; Yiscousia 53201 

(4.l4) 475-4$!)1 

!At~oductioa 

'1"he ecottOII:lics of peUae ph.u~: operac:iou, ia 

tettu of f,.l •nd. ~~\" co.usWEp_t.iou, ·flexibility 

in the &electi~u of the cheapest ful!!l source, sya~ availability, maiutea&nce coats, aad the 

e impli.cicy of pJ:ocesa deaisll; .coa.tribute . t.o the 

determination of buil~ius and p~ofitabty ope~ating a pellet plant. nesisn innovations, supported by act~l field da,a, h~e beell initiated 

i11to the GlAtE-KtLN System 4a~iga co poaicively 

add.r••• these f~eora, 

!his pape~ ~eseats che recaac sca~e of tbe ar~ dasig~ concepts Which h~e helped tbe 'GiAIE-

!ILN Syacea assume worldwide acceptance status. 

1. 

Precess Desisa Improvements 

Reac ·Recuperatiou Sratea 

a. Cauventioaal Pl~nt Design 

The Cl4Tt-klL• System has changed aig- ~ific~atlY i~ de~ig~ coucepc aiuce the 

fi~st systens uere ·. commia4ioa.ed for 

Clavelaad Cliffs Iron CCIIlpany ia· the 

early · 19601s through ~ru. · ·110ac nct~llt 

• c:ar1:up of ·: t:he LJCAa U-79 ph.at. LL'l 

Xi~~-. s~edea LC 1981. 

Iaiti.al .GUU•tCIJ.~ ph11ts were designed vi·th no heat re~pU4tion 'yst e1u and, typically cousi.sc:1d '4f a two 

pass. 4ovnc!=-dc ·. drying · aad downdraft 

_preh•ar: , ·nee cYcle. .a. preheat byp.su· .• )'Stlllll Va& .iusr:i!.lllld to c-p.LeJDe.nt• ebe 

preheat • of~gas au.pply so t.hat tl\ese 

tvo .-creams · delivered: the· r~qui.red · 

cl~draft . cleyiug heat supph>~ . 

FigUTe 1 deJiicts ' . coli.VeDtio'cal pl.sa.t 

clesi.gn e~~pl.oyiag , a• tvo paaa c)1'ele. · 

1~0.. c:he ·cvo p~&a c!QUUd_nft cy~ le > the ucxc irmov•tion of the proceu eyclo! ~ppe-ue<;t .wicb an vp4raft clryilic •one •.. 

This 1.1pdt:aft cleyiag ~ne vas .i.oiti&teci.' 

co c::i.=-Q.~:~~~vent problaills usociated' with 

collapse of the pellet bed ea.co~a~e~cd 

with . c:er.~ain type a of steec bal b. 

l 

7705177753 APR. 16 2001 02:41PM P3 

83- 355. 

The updraft drying ~one was foll~ed 

by a ~borter clovndrafr dry\~8 zo~e 

Vhieb prepare• ~he pelloc bed for 

•=try into the bot~ei pr~beat zoae. 

b. Inch11:ef! Heat llec:up<tratioa · 

Ihe first GlATE-XILN Syttem ~ith heat 

rec:uperario~ was supplied to Sydvaraa-

~er ~~ i3 li~~eGet, No~~Y· Ihis facility .,u commiuione~· 'iu 1972. The 

beat rec:~ps~atioa deai&n conaisted of 

a d~JC c fro.a ch•. ·annular cooler Jib ich 

~aa introduced into eAch pr~heat fan 

~ia cbe ·outlet chamber of ~he . preheat 

cyclone duat coLlectors~ The late~t 

of tbia deai.g~:~. waa to replace the process sa. ao~~ly ~ypaased fro. the 

preheat furisace . which, wbea c~iued 

wit~ Che prebeat off-gas -streams, ~a=~ 

prised the deyiug require.aept. The 

plant voutd ttart up . ia che bypass 

1110de. ar:d once· che coole-r was t illed 

uitb a hot pellet 4:h•r;e, the r~coup. 

nov. "~' inc::r811lentally introduced to 

replace che bypa&s flow. Ia. the ~-- · 

C:OQP mgde, the total drying heat aud 

•aaa requiremeata we~e thea. coaDQ$ed 

of recoup. gaa &nd p~eh•at off-g~$es. Th~ recoup ~~peeatu~e vas adjusted to 

IUintaiB a mad111t= dry{.~ "C:earperatura 

c~pattble Yicn the preheat · fan const~ctioa aud with the green h4ll c:b~a~teristics. 

Figure 2 depicts * preheat fan Lnduced 

type heat ~ecuper~tion system. 

Tb.i.s type of r.cou" deaiga. i.ndueu tile requ~rea procata gas· flo~ via t~e 

pr~suze head ~ailable at the ~e~~t 

f~ inlet duct•· Since Sydvar4nger, th~s type of hea~ recu~r~tiou ayata~~~ 

vaa inatalled Oil three aev plants and aa a retrofit on oae aachiae. 

c. Dedicated Fan Heat leeu~e:racioa 

A conservative approach co hea~ re-.. 

euperation daaigu·came about ~i~h the 

install.acioa of a declica·ted heat re-

;up!lr&tion fan. this. ~an induces How 

fiom tiLe snnu.lar cooler into 1;1\e 

recoup fall a.ncl suhac~uel\tly ~lllllps 

process gas directly t-o· ,a pro.:eu 

zone of · the grat&o Procaas · · . gas 

flow represl!nte4 by tbio· re~oup . faa 

COI!lpli!llleD.ted .· the ' pntiea-t-· off-gaS .s~reiiiD . · to delive~ 1:he · required =.:tu 

a.nd heat . c.o the deyiog . zone. Ill spccifi!!. c:i .. rcumatecea, -t.hi:.t · l'eoou-p fan 

cie"livet:ed procua a•• to ·an air heat- e-r, for. ·use in a · dehyd1:acion J:Onl!.· 

Til~ clHic.:atc4 ian approach · vaa. ias taltecl 'i.n cl\ne mal:latite · plants ·ancl 

si,x hematite plants· both . .as ·odgind 

desisn 1114 recrofit equi~eat. 

Figu~• 3 depicts a dedicated fsn type 

heat rec:uperction liyste~. 
FROM WOIDA PHONE NO. 

d. !Ugh Te.moeraeure I:nclueacJ !ieac 

!teeup~ution. 

Aila.lysia "f boc:b e;he induced. and dedi.., 

cactil4 fan·&pproac:nes to heat rer::uper-

·atioa. revealed devi..:~tic.:Ls betlleel.\ ·des isn. eoadi·d.oe~s lla.d. aet~al··field. ctae:. P&ramou~t amons tbe ·cieYiatioa.s ~as the 

ce=~er~t~re of· the heac·recuper~~ioa. 

sa.s- Ct.leulatioc teehfti.que a.t .the 

t~e of the &foreaeotionecl · ~esiga.• 

precliet·ed ·a a.Oiilio.d t..oo•c recoup aas ~;esaperatu'C'e. -Field · ~perienc:e· ~onsilltencly prod~~·~ ~ source c~peratu.re in the range ·of SOO to 8LS•.c. .u 5 result· !lf ·this difference. the rec:oup · ·gaa raquirad. tempe riDS "ith ·ambient' air-'especially ia. .thou plants 

vith ciedic:ated ~:ecoup f:fts.· Thh t.empe·dng· prMise e~.u · recogni.:cec! as i.Gef• 

ti:eiel'lt 11 inca the hot gas hs<l to be 

eoo Le<l, and. iu c:en:a.in inst:&ncee: !:'e-

'bear::e<! ·in· pla!U:s · e<tuipt:~.ed with ait' 

heacers for dehydr~cion. In pl~ncs 

u c:iliz.iag t:he induc:ed. eo de of hear: ucuperacioll inr::o r::b.e '·!)rehear: fans, ~r:: 

. "'"'* found ~hat <Jqe cc a · lo-r cnan ex• peeteci avnage prehuc o.ff-gu etmp&r· 

at(lre pred.ict:ed h·cm caJ.culacion anci 

te$t ~ata, tne recoup ga~ cemperac~re 

had. to be nigher 'than design level to 

pro~uce·a dOwnliCream olen4 at t~e ~esired dryi~ r::emperature. 

Sine.e tl\e lliib. l'ie•t .vdu~ ·of clle 

reeuperaei.ort gases vas c:ousisi::encly 

8Vid.ent in cu~. G~ti-~1~~ p&llecizing 

pla1u:s 1 ~o~aiag · these. gu;es. d.i::-aecly 

into the proc:esa evolved. · Thia·iciea 

vu i.1npleaen1:ed by Cltivebnd Cliffs 

l::roQ Company in t:heir ~mpi.re XU ullh. 

This u.uir:: ori.gi,!la.Uy ·n4d · a dedicated 

faa. o.uilt .!or 4zs•c· operacion. In 

.!.ieu of installin.$ "-faa. r::o . operate at 

·6.00QC,· the origitt.sl' roco-t va6 rcmoved, 

a refuc·coq lining iust.sl.le~ whe'C'e 

-e<eq ... ired,, ;a11cl che r11coup s•• U"lls ..... cl 

din~;tl.y an th~ grate b)' f.tr.d\J~ i.ng flo-• 

~ie~ · cl1e existing vasce gas fan~ 

Figure 4 ·dapi.~u · ~ big~; te!llper~cure 

h.ea!: reeu.pera.~3.on :y~C6m· v:.a. a sJ.c·;:le. 

duct frOUt· the c:ool~r'· · 

:tke t.J:.AB g.p.-79 plant of£ere.d. 1u1ot.he1: 

-=e!inaaent to . ne":: roecuperadou vi t.ti 

fcyr duces frgm cbe .cooler which feed 

u-pcl.raft: dr-}'io.g, dovrui::-af.t. <1:,-ine. ceaaperecl prehe,st:.- and . pn~eat v;.a ~he 

tr;.iln respecdvaly. The obJective of. 

r::h'is c:Les~n vaa to provide the minimum quanr::ic:y of hiJh, qv.di~y h.•ac for. 

;:·acn ·_aw-... vw .;:h,a:_c~•v!iil.i.~~ ira~e • . a~­

slilu ot -thi-s dl!!.si.lft ·vet-e. reflected• i11 · lov. fuel· coDSUI!Ipti.on ,t.nd.· low ~~:oc:.,.ss.: 

tiilt\ power coniSu.pdott• 

Figu~e ! depict:a ~ha sehematic o£ ~ 

h ign r.empersrure' heac ncuperadon 

sysw:ea> "'ich mult:i!)le .duc:cs frOUL the 

coo},ar. 

2 

7705177753 APR. 16 2001 02:45PM Pll 

e.·. 

Variat-ions s teDIIILing frolll ~he bas i.e 

high tnt~erac:ure heat :ec'!-lpnaation 

syst:a!D. ar.e conciageat ~.~~a. ~.he e--

peutur'e .dbt.db~£tioa. of gase~· luvit\a 

r.h.e bed of ~ellecs i.ft .. ·r.he coolec-. 

Fig~~e ~ sho ... e a cyp~~~l ~."rve: of ~ffsas tota~pU'.clture vcu .... s · 11\US fl.ov ·of 

c:ooliag A~r. 'A dee~ease ia l:~e amov~t 

of ga'$ flowing into cne kiln 

inc:rea5es the g;u; ccmpe:rol.ture .ali.gilcly. · Such a <:bange, h~ar ,. causes a 

~a distinct i11c~ease in the recoup 

gaa temperat::ure. As a ~:esult, de• 

creuing the flC)'II of gas1u1 hota tht~ 

eoole!'/ltila./p:reb.ear:: ,~:~ce ·t'oute ·c,.ft. ln• 

Cl'USI! the oveull h~llt effi.ci.eRcy of 

t:be P't'ae.e••· 

~AvczntaJaS of Cligh Te:mpe:.:u:ura Heat 

ltecll-pen.cion 

1ha high tempe~at~re recoup syscea offers the following advanta~es over 

earlier recoup d.e10igna: 

1. SigQi;ficaut fuel reduetioa by 

2. 

taking acl.vantase of ti:.~J ·heat 

l:~anafer cs.pabili t)' of r.ecoup 

nigh t-.peratul:'e s••es. 

Fan poile.r 

nation · of 

fan. 

%ed\lc:t:iou by a dedicated 

3. · Faa · paver and ai~e .reduc:r::iou in 

the l)reheat. f.a.u by eliminat:ing 

the re~ai~~ent for ~heee f~n• to 

ha~le the·~ncire dr;in& heat anQ 

.U$~ ·load requb·_.,,.t. · 

· li.. A &hort:er kilo. d~e ·.to the in"" 

c reaaed. lltrel\,th lave 1 of pell~ts 

e ntel:ing the kill.\ nsul t.in.g f't'·CIID 

im!'raved thei'TIIal proc•uin;s in 

~he gul:e. 

S. ~p~o:~~:ililar.:ely 90% ol!id.atl.on· rate 

Oft che g1:u:e. fo~ ·1114cncti~e. ~iel:l 

illi.p~cc:s positively ou pro~e:n 

fue:l coi\O~~ap.c:i.on anli .. Preheat fau 

power ciuw~ 

6. 

7. 

a. 

Lowet'iQg the cooler sass . ratio 

req4.lh'CIIIenc: for magne'r.i.te plant:a 

~hich re4ucea cooli~ · fan·pawer 

~O:UI.UIIIpt:iOI1. 

COIIlplete ;~roeus ~e~overy of ~u 

••aaible he•e in t:b.e c:oo .. h!r. 

RedW::.ed. proea•• i;-~ts flo" i;n cbe. 

vu t.a · ca• sr:t:e:a~ d.ue to che t, £c'n 

gaS· .tftpet'£1:\l.~e/lOW• I. US4 . l'•U:io 

r-elatia.nship tor .a ·required !<.ilocaloJ:~e i.a.put level. 

~. Min:i:D.UIIl A~mbel:'. o£ l)rocess f;tns 

.. for ii11t iM\I.I:'&Cio~ IY8Cetll. · 

tO. A very 'simpie. proeess · du ign for 

ebe operatol' to u.ad.eucand.. · 
FROM • WOJDA 

\ 

PHONE NO. 7705177753 APR. 16 2001 02:42PM P4 

3 S3-3SS 

f. &esul ts of- Ileac Rec~peraciol\ J)evel.opent on Fuel CousumJit:iou 

Plaai: I) liS ig11. 

No Recoup • Magnaeit~ 

No Recoup - Bema~ite 

r~s~ced lecc~p - Magnetite 

tddu.cecl R.ec011p - JiA!mad.c:~ 

i'uel Coalilw:ptic~t 

137-162,000 ~CAL/Hl 

ZZ.S-275.000 KCAL/KI 

sa-us.ooo KCIJ./'I!II 

2.00-225,000 'LcAL/!fi 

lliS!I 'rempel:'atul:'e lztcluced leci)Up ~ Magaetite SQ-7S ;ooO . lJ;AJ./'!rr 

Higb te.pel:'atul:'e tad~ed .lecou?. • He=atice 175-lOO,QOO KCAL/wt 

Fuel Consumption b~sed on gross besting value of fuel. 

g ~ llesul t;~ of Heat: R.ecapera.t:ion Dev.lotnttei:tt on Fen Power Consumption 

Plant 'Design 

No Recoup - Magnetite 

Ind~c: ed Recoup - Magnetite 

Fau Power Cousumntion 

liiih ·remp•r.i.c~e Il\d~&cecl Recoup '- Magnetite 

10 ... 14 li'JJ-HR/Ml' 

8-12 Dl-Hl/trt 

6-8 IGI·Hl/:t'I 

One liiU.St bear ill 111.iud tbac a varie~:y 

of factors ca~ affect fuel consumption 

fi:'OIII. !!L4CU: eo plane: even though the 

cu eype is sie.ilaZ". · IQ .Nd.i.ti.ol\ to 

che in• e v~ ~• oi· !:he he.!t re- eupe~atioa. sysr;~~ such tacC:oc-• ••~ 

L . cusnedte cont$~c o5 the. ore,. 

2. L.o.r. conte~t of t~e ore, 

3. graeu ball moiatu~e aud temperature, 

(1.. 

5. 

gree~ ball quality as 

co reeoveiy rate, 

it.relatc• 

gl'.ei!n bd1 bad de.ptl\ a~ it re-, .. 

latas to reeea.ci0n ti~~.e on tb• 

·grace, 

6. pla~t pro4uctiou rate, 

7. pC'esen~e .of ,additi:ve:S. or era·. cons tiC1.1eu.c~; which c~eo:aca . eudochen&.i.o or ezccbe=ic ·reac:tioa.s• 

iZl che process.. · 

s. general physical .conditio~t of tbe 

operating· plane ia teras. ·of air 

se.-1 eonclit.ion Oil tha .· srar.a an.c~ , kila., Ye.:lt' , o;Qnc:ition of grate 

c:osponencs, aact cooler· pallet al.is=ccu:. 

9- 'kiln burner s to icl:u:=• ~.~i.e air 

d.eaiga, 

1. 

10. refr~tory m:a.x syate.a, throughout the 

11. cir~laciou of va~ ai~ · inco·;he ,r~ary cecli~s fa~ i~lac, 

l~. operator ua4er•eand.i.ng 

p1'0CIUIJ 1 

of the 

all coabia.e co enhance or detract fro~ 

a plant:'s fuel COftSWilfH.iOO. 

Mec:tumic&l lluiso l111.p~oveme.uts 

travelina Gr:~.te 

'Iheilia:in pu.~pollet of the design improve-

!RilD.t.e on. the ~raveling graee were: 

a.· 

b. 

c. 

tO C:OU.C:r~l tlle ·t1'&D.SYe'l:'$e Y&~etU:: and 

~ha. gapping .of tbe Ch.ai:ll ColnpOfteEU:II, 

to improve sealiftg co lllinillliz.e ·aebi.;!.!lc· a i.r i:nleakase, and. 

to iatprov• mac:hine avaibbi.lic;y and. 

the. e<~sa ;;,f maint.enaac:a. · 

a. Control. of tr~!varsc ~ncl ·Axial 

GaDoin~ ift tl'le Couv.evor Chain 

CoD.tl!'ol of ;he transverse and axial 

aapping vas gained by close concrol of 

colerances on the vario~o~s · grate plate 

.t'II.Ci cbdn· link .ca...s.Ha.ss •hich c:gg~pri.n 

a ~itch AGi~bly. Control of the 

geppina: is .. i'llll:lorcant l:lecause mia.imu111 
FROM WO;IDA 

' \ 

PHONE NO. . : 7705177753 APR. 16 2001 02:46PM P12 

_4 

sappicg miniai&es saeariat fall 

t:br4Ngh. bacveen adja.ceuc g-:;u:e p1.aces · 

and batvee'll eboiu CQS ti.!lgS .and ~~ate 

~1•~es. !y «l~i~tius siguificaa~ 

fall tbr~sh of ~terial. veisht re- eoveey ia the proce.u i.l iapr_oved and. 

less· dvat 4_114 cllipe are haudl<!cS in · ;tua 

recyc-le ·syacem. 

Another important: 11dvauc.age of .minimiz-:i.a.s uter!aL hll through ou the 

~~·=· ' is chat abi=ua aapa j)I!'O&Ote 

vcif~~ ~eatill& of th~ pellet bed and 

• ~n - e.v~.E\ : tea.pel'atu.re. ar~ien:t 

chr-~gh the ~Qnveyc:~r c;l'lain. .My sa~s 

vl\ich .foEIII · on tb.e chain allOY -. Cbaa1\elirig· of- nocainal !ooo•c proc:•n g4se_:t 

~hich can ~er~a; ~pecific a~aas ·~~~ 

a.eeessi.t:ate,. freq~Jen;- p.art:s repl&c:ciiieM 

and r!l!cluce· pL4U:lt: availabilicy. _ 

Cha~ling of hOt .. process gas .can alao at~Aelt ia.tarior pa.r~a cf tbe. c!ld: .!lo 

chat - the i.ed-u.c~:iall .h..ardoecd. areas of 

the chai~ link a~ci tnrough ~od - are 

:e.'!'e~ed &44 bec.o.e. soft. Ollctt -this 

softe:lliq .a~do11 . ~CC\Ior8, c.~ea-c betve-tn 

the cbain lillk/through roci- interface 

ac::a_le:ratea · vll.ich requires 1110re f:r:equen~ replacemaac of -theae c~apo~~ta. 

The. induction ha~deaed area of r::~e 

chain lillkbore .tnd throush rod vhieh 

~ncarhc:e ill 600 !lri=ell. Maintainina _the . illteg:rity of the ve~rillS ~u·ts 

of che -chdu b ~lleref!)~e very i.mpo-.:·eant ' fol- C:bain· u::e, ' plant avail-_ 

·ability, • .aQd_ citi~ .'llaincena_uce.-

As . me'Cit:i.on•ct- abo-i~, priD·ary eo~r::ro fif_ 

th~ · .&ial •apping. i8 con~rolle4 by 

close · casti-ag tolerauce of the_ chai:~. U.tslu- al\cl ~race platee. · If 411 eh&in 

cas.:tca~ aull gn,ce place.e are IDOY•d · co 

fOl!l ;a.·. ai.ngle gli,P acro$1 thf:l- vidtil of 

th•- chain, r::he total ace~laced gap 

vottl4 -be only_ 1).2 ailli.111t1t~n ou a 

4.6 ~eter wide sra~e. I" ~4~i: ~u t~ 

ut:iug tolerance concrol, tne' ~ipe' 

5p.&!OII!!r Qich fits or di4es on the 

. chrougb ro_d is u~v a thicker wall_ 

pipe; the p~eaene Qe•igu bas • ?7% 

i~~reAse. in ~onc&ct· area beeveeA ~ho

pipe ·s-pAcer aud. c:haiu Unlc. ove~ :he 

-previous_ 4uiln• _ this l.u'ger c:oacac;t 

as-a& prevenca .... anreo'>llli-·1\1 of the pi.pe 

,tpacar vall . .!IO ~ha.r:: ?reclecaminad. gaps 

i a · che _pitch aase.ahl.y , a~~ 111a inuin&d. 

~ainr::ainin;. ~;he il\t:egricy of tha Jlipe 

apace~ -- el_i.ciua_cas· i.r::a 'c:haa.ce c.o tDOVe 

or _slide on· ·che tbraugh rod ao ~:.hat 

g~pa eaan~c acc;umulata ia oc• •~•~ 

~hich ia t~~n ~~oca~ -leakage of pel• 

lets th1:ou_gb '. the c~aiu, ancl the ~e6Ult~nr:: _ p~oblems vich over~eaci:tg a.ru.l 

z:e1>L ac:ecae"~ ~l ~he affec:~ted paz:t:s. 

tre~ l:hrouth rod' · are t:l\reac!ad ·_an 

_eithel' encS so that the' axia.l IIIOV-en.t 

i.e lilet.tl!r coatroll.ac!. aia<!e a ' ftut r•- · 

places cl'l.e od~lnal clip 4e&ig!1. 

b- ·-

c. 

Transverse gapping i• im~rovad ~y s~pplying a larger di.smet:er c.hrough rod 

whi~ -increases tb~ oearing area of 

the. througll- 'rod/ c:h-.!i11. li'llk iln:erface: 

by 18% over the previou4 de.cJiga. ~b. 

feo.~~re dot~g t~\th i~duc::iotl. ba.:-d.eD1n~ 

of- tb.e coni:~ct areaa chu_ll c:on.tro.ls che 

tTauave.-ae_ ga.ppi(lg -'110\"C: c:ffec:tivaly. 

the ~et result of the improvsmeats to 

chain· design is ta iuoreaae cbaiu 1i fe 

toa p&-ojected 44 to S2- mon1:b -sch:edule 

vers·vs tbe 22 to 26 montlla acb.edule of 

th~ origical _desisn· 

S~al I~rovem•uc.s of :he Traveling 

~ 

Ambient air iuleakage i.nto -~:he proce:~~ 

gaa e 'r:re- h -unde&irs.ble bec•u.se ambie~at: .air de-p~e:~~.aes the system temperatuTe~~ Lover proces.a 8&5 

t:empe~ilturea re<l1.1~e 'ileac transfer effectiveness which · can promote ~igher 

fuel -·rat~ .an.d highe.r procea~ fan 

· pow.~ clue to the. l.araoe.r quant:Ll:Y of 

denser :proc:e&s gas ~o be handled. 

Tvo areas of grate aealing have beeu 

improved to ~educe cbe de~~LD*ftt:&l effect of lealt.ase• ~e upper Sui'p0~4: 

_s.b.afU (i.e~, . th-ose wic:h h.a1fC C&l.'~

i~& 'C'ollers wbicn accually support cbe 

::onveyor c:hain} nov nave . double ri'lig. 

carbon seals o~ ei~her ai~e ~bic~ re- place. · :.he.- od&i.D.a4 1111e~e:al l• by"C"i.t\~h 

-seals. Tbe ea~bon rings are i~lit · 

i.A!:Q : 1110• -•cgmeu'o ucl are .held - in 

~Lace ·by eiroular spring• ao ~C:bat eoot"~ b~tvc:eu the silaf: and ~;ul i.a . alvay• _-illai~tai.nad. . !bi& poa itive - ses!. 

be~en · '_t:he -windbox- allci aea.ospbcre 

_lliilU.bcs: teak~agc • 

Si.da eallr::iuga have an' improved gr:a,ity 

typ~ ab' l!e.al llhieh . floats on ~h.~ upper-eur:ac:e of the side caH i.ng. The 

'eal.vidth has been i.ncreuecl c:o allav 

aOCIIe 111ov•en~ of .the &ide cutio.s • The seal &tU! i.l:s housing n-.zva fadlity 

to IIIOVe in tbe vertieal aa4 hor:i~ontal 

otiz:ect:ion - 10 t.hat p:"O!'I!I!' COAtact be• 

tween the sed bar a:ld aaovins • ide 

~~C:in1 h !!1!!i!l'!:a.itl4ci. 'this dde 

:::an;ug- seal reciu<:es· air -i.Q.fi.l.;ruion 

be~een · the acaosphe~e Aftd fuc na~e 

(o;,erbed c:h.-ber) ,_ AM betveeu · the 

furnace and the vindDOX - (un4erbed 

cbaaber>•- 1ft acloic:iou, tne aide un- ing. · has-a - vaar ·shoe" actached to -tile 

11D.ders-ide, 'ftl.ia ."'S~ shoe rid.ea. On . 4 

lubdcat.ed atatio"ary· sed bar to fom an ~ir edl. this seal elilllift:a~o• -.-

. b i.e_nr. a~r · lu'-&&:e _ into ~he process 

~asca. 

t~vro~e ~chi~e Avsilabili5y and ~·•• 

of l'lai.!lte!\ae.ce 

'Ibe i&por~al\1,\ feat ~es \lb.ich eoa.-

r::rib~te co t-:ansversa gap.~ina c:o~c:rol 
FROM WOIDA PHONE t-[1. 

h. ave llollell duc:ribad above. A& previously aael\ti.omeil, tb.e inere,as.e _in ~he 

~hr~~,~an 1:'04 rli.auer coupled wuh J.ociuction ha~eoiug of the throush r~d 

~tiain link .i,oCef'face lli.ll be the priae £a~1:or• for· a 1onge'E' chain life~ I\\e 

1 ife i• no¥ . project:ed to · be in the 

r .ange . of 44 . to .. s-z 'IIIOil~hs. 'Ihi.• pl"ojecdoU: ·.i·a band on clac.a obtained .from 

operadna planca · vith similar de~ign 

ialpr~vesen cs. 

Grar::e plates · supp_lie.d on the traveli.aa 

gr~te ·are one piece. cast, high ar~e 

acainle•• s1:eel units. These uftl.t~ 

are · utrl!lllely. heat resistall.t. aad replaeeaen.t is. ·usually .ticcaeec!. Oillj if 

oue should ~reSk ~r become ~os6~ to 

a c!.i:rec·t f.lOOt ot ho~; prcbeae z:olie ongas. 

Sicle c·aacin.as are aqui.ppell wit!\ cut 

iron tht\lst: &uE:tons .'1111i.cb are UBed in 

eotljucctioa Vi,th tllruat bracket• co 

con.eetly track. or guide the grate 

chain.· 'Ihruat brackets au locacac:l o·a; 

each furnace .steel col- · aad . are 

e:cily · · acc:esaible aod ad.juo;a.bla 

sllould the grate. ebain requirli!l tracking ad:jullflaet~t. . Ud=g this tbruat. 

bracket/thru~t · button approach ~o 

suide th,e~bai.o., the re~uiremeat. fer 

J\d.de .!lp;-~e~cu ~n the :upper. sup~on 

a:ooller tt\afu auci fot:' chru•t 'C'ol.lers 

oft cbe r'etvnl a~••b'ly are· elicci.Aat~d. 

Lei a har~vi&-ct ao.d .leu· ui~te~tance. is 

1;e~ub·~· 

Si.cia .. ~aacings ·uve, a · "t"eplaceable wear 

•hoe. on the bottom ~f Cha caseins. 

Tbie a-.411 sboe t!li.111inal:l!ls cha need to 

replace t~e· eAtire loYer c~atiaa of 

che aide casciag assembly and · this 

pie~e.Je . -ceplaced .very ea!lily i.l\ tbc 

repair· ao!le. Ihh ·feature agai11 saves 

.h.sr<lwac-e and c:i•e uquired for repair versus ·the previo~e .desil=· 

The .dri.ve for the· t:c...,eling grace is 

i11 a haad.sb.aft oouct" unit wherein 

ai.salig11111ent betveen a bullge.sr an<l 

pinion is el\ln.i.l'ULCed, ·'!hill new, drive 

anem'bly i.s ulf•contained and h.as a 

built b c:irc:uhting lube s)'sce., th.ua 

elimia.adl!-$ the ~cviou• .sprily lubr icatioa tyscam for. ~he gear aad 

pi.Zlion.. 

Meads haf~ .. sprockets o! .the trave:ling 

sr•:e uow ··· .have . z.oeplaceable sr::elli.te 

;l.Dseri:s in a&eh tooth. On che preYi.OUI · dadgn ,, ell.- ·eAt ire. sprocket ·bad 

co be replaced when word as ouly ·a 

welded hardened overlap oA t~e coot~ 

va:t p-resent: to take · the wear action 

beeveea.· tooth' ~t ~liai.a.. The !lev de• 

Ji&ued ·inserts are repl&ced vicho~t 

•prociket .. rl!llloval &Ad. i.o. a fr.acci.oa of 

the ~ime versus the previous de9ian. 

7705177753 APR. 16 2001 02:42PM P5 

83-3SS 

A hydravlic cailsbaft takeup aasaably 

is 11.011 c:le.dgned iato ::be traveling 

srate • . ih• tail.rbaft ·waa historically 

fixaci to che ·frame of: · the ~ate. 

· WheneVer. the . grate chain requirad c 4;hteuirig, clue ~o Pl:'.ogz.oessioa. of wear 

vich .d.lle. the srace b·ad to be shut 

4owa for tai$ p~rpo••· Nov pitch -rellloval. · vbel\ reqQir.ad ~ ~an · t·hell be per:-

fo'C'IIIO<:l liuring a · scheduled cuiatenac.ee 

ll&riod. 

The ticru>eli11.g Jt'&te b.l<aed.er scaclt cap. 

.hall been reliesicnii<l ·auch tl!..at a. pi.voc 

pd.11cipl.e is ·uov eiaployed •. !he praYious· · stack c.sp ~6a~bly reqnired a 

••~ie~ of ch&ins A~~ noac ahielcla to 

lift th.e cap. · the new de.sisa. l:l_sa tbe 

pi•oe paine away from tbe hear; ao"rce and fever paru are :-equi-red to lif::. 

tbe cap itself. 

Haac:lshaft beat'Lag.s .on th~ traveliag 

grate have . oeen e:!Ctea.dflc! to the out-

·OO&rd sUa o.f . the 1\udsbaft • . this 

•ove=ecc . peraiu · easi.er IIIS.intecsftet of· 

thes• bearill89, ~ile tne cooler e~~ 

vho11111ea.t -p_rolollgs· oe4ring tife. 

the Get I:'&Sult of .the abOVB descz.o\bed 

deaign impf'ovneilts on the traveling 

grar;e · is co. provide·: longer· wachine 

·life, easier _. mainte'll4DCe, fe11er replacemeu~ parts, aftd' Unprovec process 

thera~~ effieiedcy. · 

Kiln feed and discharge end air aeals ha~e 

bee11. i.mprovad to further min~iEe ~bient 

~i.e- inlukaa~ to che kil11. 

t~ or4er to ~P,rove the k~ln faed an4 a~r 

seal, tile d'isc:harge h4)"sil'lg of the gnce, 

u!)On IIIlich th•. feel! elll.d.·. ;ai r $e«·l u:=bly 

is .loc~ted, vi.ll g~- canted so that its fae~ 

i.s· paral.iel to th.e . .l&.lopi.l!-1 face of the 

ltilu. the .sul assembl7 seedns agai~st 

the ·ent.i.re c;ircwafere.ace of the 't'Ot~tLng 

fla11ge of the kl~~ viti, therefore, be improve4 •. In. orde.r ~o in.sure tontac.c; bec11e.tl'l 

~:ne sc:aei.oa•ry ao.cl rotal:it~J:. seal faces ; air 

eylia.dn• will . be. ·utili.l:ed co · assi$t. . io 

l>ositioft.i:~g · tile . atati.O"nery seal face agai~~.tll: ~he; 'kilO:. A~r c:ylin.c!ers wi).l 'be. 

loc:a~td. . i.n each 90• quadrant·· of tl:le ~11al. 

Th-is ~esi.cn laprove.,e~:~t &long with . l."'b~ic:aced, eaellioeil •urfaees of t.he · aeal fac:es,· 

vill fur~~~•~ re.4uce -bioat air l,!,•k~,.:• 

into the l(ila~ tb.••• .4esian ~hangee c:O!n• 

bia.e to. fu~the~ U.prove.tne already" ~pr~s8 ive fu.el · efficiency of tile GRAT!:•.UL.N 

Sy$11:CIIo 
' ' 

FROM WOlD~ PHONE NO. 7705177753 APR. 16 2001 02::47PM P13 

Azlnular Cooler 

l'be __ ~imary pu~potes of the duigA eh:u1gu 

in the &4n~l~r cooler are: 

a. minimize ambiecu~: .air ialeakalie r;o the 

p1:'0QI!88 ~ . . . ··. . . 

b. improve !dchioe jvai~abil"it)" •M. ease_ 

o( aa_i.ncecau_c:e. 

•· Minimil'.a · Ambient: Al.:r: Inle4k~!!'je to the 

l'ro~esa 

Il\e $41ld. seal · be eve eo· "t;he rou~:i.nc and 

a car:i.onary -11411 hat bee11. ·re.pl.accc1 by " 

va en· _ aeal..- ·-'l:b.e vater C"'Cilt is ·atca~~d to the ro~acio.s vall vi til the 

aeal s>lai:e ;bei.cr part of che .~;atioAary assebly above- the ::otatia.t atruc:-

tu:re. Desiga.Uia a · 11aal vida mi:nimulll 

Nbte-:i:i::.ca ;mci cp~ra.ti.r.g loaaeviey 1s 

i•-porac:ive ft<0111 r:he s.tand.pouu: .of llro- cesa efficiency_. - 'Ihe.· water - seal allows the prima,ry and .. fi.aal cooling 

fall4 t.o d.aliver· the required. g~$ flov t 0 - the pro~o~a . Vi tho"c- any detri:illencal 

effects to che eq~iPQCnt. The ~acure 

of the coqliug- ~oeaas imparu· : -ll · 

dist::ty p~.aiti'lte~ preu.ure dightly 

po&~tive pt>es'Jur~J '· abcmt the pel_lec: bed 

nea-r che .irea of tll.e _ seal.- Tba ual 

desisft intenc · is co. prevent c:he flov 

of .e~ieuc air· inc:o ~he proeess, ~ic~ 

dilu=~$ prOF.~iM ' sa$ emperac:ures aAd re~tri.<:ca .the flov-_ of cool,ieg air 

c~ourh the .pellec ·bcc. lastricr::ing 

the fla. of i:ocling . air chro~igh ~he 

be~ rec:ards tbe coap_letion ~f oxida• 

tio1;1. .&a.d &~hievem~Q!: · of - requisict 

product .•tnngth for · a~aguatite. orcs·. 

bee ~f: proeeu_ 3a• fl~v ·chrough the 

cooler be4 bu. beell d.CIIIOoatr.sud eo 

afffitct Lov Tem.per&J:ul:'e -areakd.CIY'O characr::aristica ·of certain pellet:•· The 

wat:er soeal; ~o-taiel\ pr9motes ee!!C·I:"cl of 

thilil _ flew race_, c~. - th.eref-o.ee _imp4t:t 

fav-orabl.y oo 1:lli.1 --•ta-Uurgic:al eha:--: 

ACI:~I:'i&t:lc:. . 

i.ate ot .process . ;a$ _fl0'4 · through the 

-c:ooler bed. 'h.as · 1>111111. . <iaftl0t~I5Crated to . 

affect Low Tempera~Ure B~etkdown ~bar­

·aoceristics ·of· ·c:eruin _ pdlett. The 

watel' ·a eat,· Which prollfoc:ee connol of 

cltil fl.ow t'-'illte',', can' :here .fore illl.p4~t 

E~vorabl)' oc ~b.i'a · aetallllra:ical cll.aE"'-

acceri s de. ·. 

tt• Imvtove !f&c:li:L~• AvdbbUity and E.,:=a_ 

_of Kain.telt~Cee 

-the v&tu •••l ~sia,. _("· 444icioa. co i tl proi:eu · me_l'i ta .as. ou c:lill1!4 .above, 

luu also !aprovad. -eool.•r jvai.labHicy. 

~ ·autamatie_ czoougb ,fi-ll '· ayu.- -ill-· _cains ·vaia!- level co- co.pa<~GO!te · fol' · evaporative. loases. tu ··a<iditioR,- "' 

· p.-,muic czoo.,sh :PU!IP h ~ph1yed · c:o 

6 

rcm.ove pellec b~ildup in tile ~rough 

tank.. 

Ccioler p~lle ts . are now f4bricsted 

in;eel. p1.ec:es · 111hi·ch _replace·· - the 

ol'i,ii-aal cast il'on pallet·•· - Fabricat~ 

e4 palleu are easily - repaired in 

place ~;~Qich haa reclueed maintenance 

cim.e and ell:pause. 

Coai Firing_ 

l'!te· caAtJt-lit.N Syst:eqa 5.iguificancly redllces 

~ellec: produccioa. _coats by utilicing ~oal ~u 

pl.ac:e of IIIQU expensive. liquid o't' gauo•u t~ell. 

Co ~l. is ~irectly fired. i.tl the GlA'ti·KILN Systa, el~Lu&tLng need fe~ ;x:e~al ~ombuatioA. ~hmDl>~rs, . sbg - ~apholes, awci~i.ary b..:rners or specl.al hi;h prt.ced. ~e.fractorLea. · 

Faulkner, Lo$iO, and· Cna~e (1977) presented a 

h iscorical ilceteh .of coal fir~11r ia the GUn:-

ULS- System t:llae elated back to a 1962 e01111111e~d.41 

·teal a · teat. - They also presea.ted l.4boratoty cOli- . bus_cor . cut results thac· rel.sted -c-oaL ·al1d coal 

·,&slfpropertiu. :v plcii~ pe~fota~ance. 

Ccab•:a~or tec:vo:k. ancl cOI!Iiaerc:i.al caa1 -fir-ing 

hllY'e _ eoftcl.~ed prov1d1.ns a .cranser 5Catistieal 

beae -fat' coal el:araccerizaeion. the tt\llllb-er of 

coue tenecl ~Q~proadl.e• ·. fifty. At leut ceu 

GlAI!-!CII.N pl-llliCO: an aow ~v.ip_ped to fire .:cal 

typically· •c. 'lOO% of ~he fual. requireeeiLC c!urin~ no~l operation. _ Pr~se~taciona by: Murr ~19~2); Job.asou {19_82); ·Itrollmaa <l98l);" l.op~z. 

aollkoneu, .aud. Poe c.& -( 1982) llave ducrib,ed coal 

flriug a_yst.OQa ac tiad.ou• GRATE-~!!.l'r !:,•st;:ma in. 

~onside~aole depth. · 

. TypiC..l •ue · •nd llKiistun rol . of·. kill\ 

bur_ner .eoal: feed . i.s. 50 . to 90% pas~ ing zoo· ~esh 

at one -to tW'O percenc free. tioiet-ure. Bura.er .tip 

v-elocicy ranae.s frO.. 27SO . to , 457.!) 1D8Cers per 

•in~te. - - ._,:,_ :': · '-:·:_-,.-,· · .~·. ~· . 

StS.t.isr:ical . Ait.llysis of · LaboratO!jY Ruulu 

·r.ab le. ·1. ehot~s ·· ~he ral~r:ionships OQtVefln vari0\.1$ ·c:oal·a:nd -coa1'.-.i.sh va(L~blaa and.- ~abor~tory 

depos_idOQ _ -~ac:.es · at: three · tesparat~" levels. 

!hit· .ral.:.tiouhipa · an ex-p-rcaae4 . :i.n· =u!lls· of 

correlation coe_Uici61lts · .ella~ deac;-ribe . the 

· stathcieal" - ·sls&\i.HceC:11 of a.: gi.ven· .,ariable 

rda.Civc .~o t~e . c!e.posic:iaD.-'rate obt~i.i'led at a 

.a~r:ic:\llar -c:e~~perature. the .clos-er the eoercht i.on c:oeffi.~ienc h to oa.e.; -the bau-er tba fit 

_of ~lata r:o ll str..aight line plot. . 

The IIIO.!It ~ si.cuificaar: _v.iriabl.u a:ce coal heating _villua, anct· "fixed ear-boa ·and.. -ash eont-elllcs. 

~.t ShQ!Il~ be ·noced, -~hat eacb of. :!lese v-ari.aillea 

u icu:err~ !':tee! co ~he other. Basically_, u. ash ~o~cenc n.e .. -·tb.a fl.Xad c&;-boa. coD.te~c .all¢ 'heat•· 

tnt valr.te - deereae_lh _ . Coal- lte&ti!IJ "a lue ia.• 

c-rease& _di,nctll' vi.cb ~ILcua .. ln fi>.:ed ._.-rboA 

c:oateot._ - Ccnrelaci.on coaffi~iencs ' !o-r as~ co 

heatias- _VIllt.Ui -&114 li,ce4 c::&rboD. ~!"- na.atins v,;~l~:a 

vn~ · fo1.1il.cl to. · ~ in tb.oe· 0 ~ 7,J ~o Q .n-rant e.. 1J1n~ ash ~eyoa iti.OI\ ~·~~~i.er ,_ t:ben.fnc.; b -de• 
FROM WOIDf=l PHONE NO. 7705177753 APR. 16 2001 02:43PM P6 

p~ndent -Oft _cbese incerrelate4 coal ~baracceristi~s. The ee~ · Coal Cbaraceerization Value, or .CCV, bu. ·therefore. _·been dav~ losre<l ·to exprel!ls . cni.a =elati~as'!lip 'l'alacivc . to de pol icion 

rates.- n i.• <!ef~~ed u; · 

. (Coal Ash Co~tefl.t. in· Percent . 

83-355 

for any singular variable or any of the cen 

other p.uuzete'!'s e~tu.diecl.. This vu true 9ver 

tb.e range ot tempera.turas ill•estigated. 

A coal .baving ·a CCV of o.a or lea• ia x:ec:oarmer.aded for GRAti-lr;ILN 5Y·Iteats ope-ratiu; . wfth 

fuel c:ons\llllpcio'llA of 115 .ooo ll:eal/tOCll\e or· 'les•• . Reccameo.dec!. · CGV . increases· or decl'eatet' depe'llding 

COl ~ 

by Dry WOeigbd X (11.,6 X .197) . 

(p-ry Coal Heat:. Co!1CatlC 1.Q J~ltg) (Coal Fixec!. · Ca't'bof\ Cauten~ ~n :Perce.a-.; 'by·.' Dr7 'Weigl\ d . 

· on the p.ardc:\&lar· ·ph.nt fuel·· ratiZil• · · Fo-.:. example·, a ~oal vitb -a O.SS CCV BhO~Jlcl ~t'll very 

ve~l i11 ·.:~. plur; pt"oeeiJsing lllailll·tice a~ 7:i ,000 

kc:al/ con.M, but its r.elac:ive · pcu:fol'lll&a.ee ruy 

vell be expeoted. · co c!.ec:'l'4UU1 e in a similar plane 

proc:~s'•in& ncar.il.tito e.t 200,000 lu:al/c:onue. 

. : . . . ~ ' . ' . 

Correlation coefficient$ obt4ined vben relat~ 

ing CCV- to aJh depoaition rates are. hi;he-r :h•n 

TABLE 1 

CO&a!LAttOM COtFliCIENTS 'i!LAIING COAL ANn 

COAl. A.Stl COtfPOIIIE.KtS TO LABORATORY D~l'OSttiOtl _11,.\T!SCoal Kelated _Variables 

-Fixed Carbon Content 

Volatile Content 

lle.a tias ,Value 

.Uh Couc:azu: 

S~:Lph~o~r Ce~nte\\t 

Ash Related Variables 

Ash eao ·coatellt 

.Ub. HgO Co\\teftt 

Asb ~a20 COntent 

Alb :K10. Conteut 

Ash S:r.Qz Co_ntenc 

Ash Al201 Content 

Ash Ti02 ~oncenc 

Ash Je10] Con~eut 

AAh Fusion Levels. 

b.'itial . Defomad.on Tesperuur'e (IT) 

Soft:e~:~i.ng Tempe~at~o~re ( St) 

!ltlllbpher:i.c:d tempez:oacure (\IT) 

Fl"'id 't'aw.ii~;.i:."':t~ . ( fT) 

· .l!'arameter 

TABLE 2 

ns•c 

0.62 

0.11 

o. 7S 

0.57 

0.31 

0.67 

Q,)io 

0 •. 31 

O.JS 

0.15 

0.43 

0.21 

0.12 

0.20 

0.21 

0_.2:3 

o.-26 

0.79 

THE E.FFECT OF DOST LEVEL AND 

1040"C 

0.69 

0.17 

o.u 

0.78 

0~35 

0.56 

0 • .19 

0.07 

o •. 3_2 

0.02. 

0~40 

0.04 

0.04 

o.so 

0.46 

0;.48 

"' "' U•:.L\1 

0 •. 86 

'lYP.E ON . ~IIHZINc; ASH FUS~ON 'l:EMPEMTQES, '( •c) . 

11.50"<: 

0.7l 

0.17 

0.81 

o.ao 

0.37 

0.46 

o.n 

o.os 

0.23 

.o.u 

0.40. 

0.07 

o.os 

0.44· 

0.43 

0.43 

o.oz. 

o.sa 

Aab. Fu~ ion .1\51\. . - .t.8h . P l.as Ash- Pl~a ASh Pl\ls ·. ·. Ash Pl~l; 

Level Al oue S% .P!l Out t ;z Pellet l>ust 2S% P!l O..,st . ZS% Pella~: · Ou$C 

IT 

ST 

Ht' 

.FT 

l:Zl8 

1285 

1307 

1346 

1l71 

1371 

llolO 

1482• 

1182 

1447 

1460 

l482• 

1442+ 

l4U•· 1482-to 

l<o82~ 

1481• 

1482• 

1482+ 

14~2· 
FROM WOIDA PHONE NO. 

Sirnificance of Coal Ash rvs ~o.:L 'l'eti.p~nt:U'r'e 

CCV also describes plant pe;fo~~ee -~ath~r 

r.Je 11. 'l'be .sole · U:cepdon · co i ct inc!i~~cor 

statv.S is a --1~7-' ceaJ: · ni.a in- ~ich the coal 

r.ea.t:ed was found to. be. col'l.tilminated vi th 111i1L~ 

scale aad ocher debl'ia. . Suc)l LLD.o:rid i:z.eci iron . i ir 

kco~~~:t to depreu "COal · ash ·.fusion r.e~~peratures 

ch·amaci.cal1y thereby· .eoctd~.t.izt~t to ub buildutl 

potencial. Oil cne · o:b.el" ha'CI·c!. =d:i.ti.olls. of .u 

Lirtle aa Hve pereant ·•preha~tcci. ~·~ t'irod. pellet 

ciuat. to coal ash C:Jlll• raisa c:ba ••h .fl~i.cf '~per:.. 

atu~e as much as us·c·. The effect of prc\\c.:at:ecl 

#M tired pellet 4uats 011. ash fusion tmpeuoo 

Cli'C'e• i8 sll.oW!l- _i.u table 2;· D.is efhet i$. >~er:y 

im.poru.nc as the :eb.dve coal .ash t:o irou ore 

maeer:i.al in n~o.t b t)'pically at rhe o~t:enth or· 

one per:~eq.c or loc;re&' ·level. Airbc:)'i<ne pell•c 

dusc. conc;ant'l:atioc.a a.re es ti.mateil to be at-less-t 

twenty-five percent ~,l--ch.e .. coa.l ash ;oaunc. It 

icl, tbe~efore,· ·d.oubcful i.£ puZ:.<Il coal. ·ash fusion 

cl,a1:3 b44t'S .any .. aigni.fic:ance · i.o. terms· of nr, .. t.; '"":-

ins bu:Ud.up cende!!._eiu. 

When eoals ~tl'l I!.J.&I!. CCV terms !lust be lf,4;e<! 

as Ga.\U: .. K1.LN Sya teas · ·f~.~el.S, it is po·aa ible co 

u.tilize e. coe.l c~eaning ~it'clai.~ t.o t~pgrade ~hat 

coaL to ;nl accept~b1e level. 

DEPOSITION 

FIATE 

(Mg/Min) ' 20 

10 

Coat 

Component As Fie<=eived 

77121517775:;3 APR. 16 21211211 02:47PM P14 

S3-3SS 

Taji le 3 . a hew a. how laboratory · ub d.epoGi.t_ioc 

rat<ea c:an be lOYered :,y. utilizing coal cleani..ng 

ci:eocuics. CCV has been cut: by m.ore. than. half 

·aM. uh. . flloliQ ce~~~peu.tu.re inct"eased by abo11t 135~c. Iha ;hauge. i01 bull~. uh hsl.oo. te.pen .. 

tu.re ·is e.xplaiced .by coa.id.eriail: ·that cod al!he.t 

contain a variety of .m.inerah, sc111e . mora easily 

removed by <:.leaning chan ocher:o. Ihi5 f'llrC:b.er 

.itldicates that PU'l::·e coal uh. fusiein. ·data cannot 

ot · r•lied U.pc!Q. to ~edict coal· pet"fon~&nce .in 

tne ·GlAT!~KIL~ Sys;aa. 

'i:hO!!re have been cases where coals wi.s:b. ash 

i.t~iti.:l.l <ieformstion.· temperatures of nso~c have 

lower deposid.on r.s.J:ea than coals . vit:h graacer 

~h.an ·tG.ao•c .a.-.h in:.r.ial clefor:ia.ation tempera1:\l.l'ts· Ce#l!t vi.;l'l ash f11.1id CeWpl}ratut'ea ~n exceu .of 14so•c lla11'c b..aoii follr. l:i.mes the <lepo~ ition. ·rates of c:oalll vith a:sh fluid. temparacurn 

less cha~.l370ac. · 

Auxiliary Equio111cuc ·ul:i.lincio~ ~.ad l)c!li!i" 

Im2-rovement 

.u~-t -ft¢::. t.-h:e -p-:!:&.~y tb:u~t.. ef i::::.o~.:.-~iQ:l 

f·ll.to basic · proc;:ese a~ ~c~an:ic:al design 

~prove=en~a, a~cRntion has also been ditecced. 

toward updating puiph!!-ral equi,pmenc which illlpacta in pl.aut effidenc~. 

Cleaned 

Asti 

CCV 

11.50 

1.21 

WI. pc:t, s.oo 

0.54 . 

Ash.FT. 1346 1482+ . 

1150 1100 '1040 985 

DEF'OSITION TEMPERATURE (°C) 

Table 3. Labo_~r?ry Deposition Rates For l.ow 'AGh Fl~o~id Temperature Coal 
. .. 

FROM WOIDA PHONE NO. 7705177753 APR .. 16 2001 02:43PM P7 

Blen4·iq 

· Bigh iutenai,r:y mixi.ns by m,ullen or cylindrical sb&ft ~nd. plow eype lllixers lu.s. bee-n .shavo. to 

~ecl'aa&l3 the .amoun~ ·of b.inder .. raq~i~ed fo-. 

p~:.o~er greet'lball strenst:h development. l)ecre2sed binder ad.dicion rnu te.tld to u.duc• 

g:teenball ph.sticicy aDd:,. the-refore, i.'!Lcre~se 

pemeabiliey of the t~avell.~ grate b~4 .lead1'!1S 

to· :l.mprovecl £ua 1 and powar .coa.suaptl.Oll rates. 

Pellet iron con.t:ent. favo~ably iri.~reases. Pellet: 

a lk.ali and silica le-veb · ue d.ec:nased in plal\t!l 

~sing beu~oaite bindaT5• 

):i.la. Burners 

· '!he mgsc siJnificant ·<l,esi.S" . improve.near;: rda-'-

;ive c" lf;iln bu.rners has bee'!l. tl!.e re4~ctioa. in 

stoLchiometric air requ~~e4. ~or combustion in 

on: &nd gas burners. fr'ete!lt designs . .,;·eni•a 4 

co 6 percen~ c0111buadon air l:'elat:ive ·.co 25 ·to 30 

pel:'cent i.n previoll• .. .,p1ic4tions. this ciesigrt 

i.m-p:-ovel!lenc d.ecreues -bie11c· •i.r- ··iiip<tt: ~.;; ~b~ 

~illi aAd allows &ubl;titud.oti of b.igh · :::er.a~erac.ura 

•ecoa.dary air il\t~ the prQC:a~a. · lleducti()n ia· 

1:-.1 coa.aQIIi-ptiou aucl i.~~oc~eaaed · fl•e 

c emperature, vh i.ch (I~OIIlOtas im.pro-te<l h.ii!!&C traa.s• 

fer:, result frOa. this .-desi.su i.la;!rovement. 

i'ee~oleum coke, viti\ .:1. n~iual 11 p<lr:ce:nt vola-

~i.ie conun.e·, h~s beea: sW:cessfully i.unod.ui:ed co bu~n. ,;..ultaiWci~Jal.t vith co.al in aa ~puac:ins 

place. Burner suppli.ers eonte'll<i "that $tate of 

cbe at"t. burners can 1\0W effectively · l.ici.lize lOO . 

peJ:"cel\t low volatile $OJi.d. fuels. This d.esian 

illlprove!llCRt opena up IOI'lr~et.s for more cost effi• 

cient f~l :elative to Eaa~e~n t~pe coal~ ~st 

c=manly u.sed ac c:he present: tiM. 

Elubbe.r li·aed ~.alU.i:lg d.ruiiUI u·a .being ,.sed. in 

at l.east ·.even pellet plaa~ .r,ri.t:h so-~h.~t 'lllilted-· te~ults i11 tar:ms of pe:-foiE'IIl&.cc:e. Thue .vessels 

operace vi.thout cuu.-e;- ban. 

Ihe d.'C't.llll iru:erior b ·lincG >lith a .s.eriea of 

parallel, loi:leitu4i.nal, ~bber belts which lire 

snehored co-.:he shell .along th.e. belc e.dlfia.a '7'i"th 

eeta.l strips. Flexing or "droop".·-of cbe belt 

during dnn11 roocation purges c.onc:.cucl"'ll-.:e !rom o~~.ccul!ltil-acion Ol\ the. lining. . 

B.enefit:s derived froaa a 1:ubber' tined ·drum. · 

circ:.~:~i,ii; ne lower drum . por.rer co!ii1DipC:iOl'l, decrea•e6 mai!).ten.aa.c:e c:oa r: and .lower capital c:ost 

expenditvra. "the veE'clict oti. bautonic:e eotts~o~apt:ioll ancl graanbaU qt.Lality .ia not yet :defidi.tely 

eatab liahed. · . · · 

Efficienc gree11.bd 1 screening, novev4U', is ao~e. c!iffiC\ilt in a Nb'ber tiDed . i!.ru111 circuit 

due to the lower drulll &peeo;l,.· l.ltlieh .affect• di•'" 

tr.il:lution of the clru11 4iseh&1:'8e c)ff thEi ·acr~:~ll 

octo the screen. Soae operators. report cha' 

!llOre sc:reea.ing area 'c pre~erred . in a rubber 

lia.ed dJ:Um circuit. -eoapared c:o ~ ·convenHo11al. 

drum c:ircuic, co maiat~iu· aaxi~wa e•pac:ity. 

.Pros-ammable Ce~nC'C'olleu 

SoliG IJt.atll programmable ·con.trol technology 

is b~J:;~ .-pLoye.d in peller:.t~ing .planes .and :ic 

ha~ the following s~vaa.tas••.ov•r the ~elay type 

sys tC~D:s 1 

B3-35S 

1. red.uc.ed cablio.g and assodated labor 

eosts; 

2. simple-z: logic ona~eou.r::; 

3. bighe;o ope.ut:ing reli.abili:y; 

4. ~ower pove:- coJU-pdon; 

5. ftreamlined tro~bleshooci~ eapability; 

!i. rupplicadon potential; and 

' 7 .• reliuc~ O'C'ea 'Z'eq_uiremanra. 

tmproveri process stabilicy, ln · ccnas of a 

tightsr · J:.Snge of sysC8111. 11.&t":i.&t:ion, cal\ bo 

acllieve<i vich t'nis. type of iusr::nam.eo.ution vhich 

eoa·tri'buu:s to improved oveJ;d l fuel conaump-

~ion, especially at lower plaa.c capacity and. in. 

periods of process upse~-

!Jt i.Li.a~ci.ot:t of variable a peed f~ns i.n place· 

of eocstant apee.d d.a&~penci fans resW.ea · in 

· se-~n·al ope~ati~:~g a.:ivantqea. The5e. incl~Jd~; 

r-.:!u.ced pO"'er. coi\Suaa!ldon, .. louer fm. liuer and 

. wheel ve•r, 11:'Ver noiee levels, softer st.arr::s 

ltith les•· scre!ia on associated equipment, anli.aaitad motor etart.a, and no ayecem voltage d;rop 

problems· on mor::or startin!• 

these eysr::e=a have ~igher.inar::alled. coat& iu 

· eom;~.athot\ to the e.on.s:tattt spead dampered. fan. 

•yHc=s. Cecrease in ·plant p"toc:us f.an power 

~oll8umptioa. however. can develop a "ayback in 

addidonal invested ea~ir::al of less than two 

yea~:s in a ,eypically sbed pellet: plant •. 

Ne.w Allpl!.cuions 

One of the moac interesc:ing poc:enc:u.u for 

tbtl CllATE-r.ILN ·sy!lti!Dl is the. abili·r:y ; ·c·o pro;;luce 

reduced. pe"i le ~~~ u.sing the oxide grate . in c:ottjunC:r:.i.on, vi,r;h a r~duetion kiln. 

Co'CIV'en.Ci.<n\z~ di.IC'ecc nduc:d.oa. :f~~oadstocic. pelleu are· pr!)duced by high· cempel:'ature i.ncllii"JS• 

don, . ;r.t ;r.bou.r:: lJOO"c, .followed . by ii cooling 

·s c:e.p that ioVer!!l pellet tE!IIIp~racuies to near am-· 

bieftt •. 'nlese pellets are then rehea.ted.in the 

sUbseituent: rotary .:educ ciot1 kiln at temPeratures. 

near ~he JOOo•c level. By ·~::oupling ·an oltide 

~raveli.ne :race ~retleate: to .s. d:irect nducti.oa. 

kiln. thi.a .s.tc:u.ac:ioa c,aiL\ be averted. Also; tb.e 

oXide peU•ac: kiln and &l'.nuhr cooler are ri!II\Oved 

·all lfl4nd4Cor:y ectuipcaellt0 ruk,ia,g .this c:.oupl ing 

<~e't;l· attracr:ive ac:onomically • 

Allis-ChsliiiE!Z'.!I has parfon~lld axt;1lna ive rese.s"teh 0111. this ·p~:o~:oesa c:ouce.pt. Cue of the 1110s c 

beo.efic:ial r.uults of ·this ·re&8iirc:h .was th.at 

preheated ,peller::s survived tra11.sport through raciuc c i.e~.n \ti.lft s ~ulation• .n. th aqtul. or Len 

des~adAtion cnan fully indurated pellets. This 

"as true for three <li.fferent feed IIICII:et"iab .;a$ 

s~oqn·in Table 4. Redaction ctlancc~ii.sti;$ of 

~C"eheaud. :~eUe~:.s val."st fo~&~d to be v·ar"J :ailllilar to. chOse of fully indurated pellets.· 
/ ..-·---,,\ 

~ ~ 

·-

FROM WOIDR PHONE NO. 7705177753 RPR. 16 2001 02:48PM P15 

10 

With. . the advent of imp_roved burn~r · duigu hu 

CCIQ;Ie ctle oppon~ity ·to· uae _f~~,els pl:'evicusly not 

!uirable for the GUT!-Xltlf Sysc.-. Ofte e;c~111ple 

is.petroleu:a · eok• vi~h · a. fomeily:-probibit.iv.e 

l- vol.~eilc · eoru::-ent of a\tgut· •l~n p.erceru:. 

t'a.eae f~els, wri.tl!. ex.trccaei.y lgw ou;h lev.elJ. hold 

•.ia;n..l.ficanc prOCil:i.aa, at leaat as .a. part:ial (epb.c;eme;:it fo.r coal. Suc.ceaaful. ,iu•plaut: tucs 

have _been compl.eted using 2S aDd.. 30. perce11t 

pet:roleWII coic.e 4441 tl.otl co. tile .coal a~ill .ei,:::-

Cilic. tt\e limit of subs~i·cuc:ioa. wi1l1110st often 

be:por-ed.ieatsd on c:b.e s,~o~lphur level of ·.the particular- P•:tro.laull coke used. _li:c:oaoa.ie jusr!ificaeioa lor petroleum coke utilization · iJ -aigt~.:i.fi.e;aac. l)eUver•d fuel eoi.t 'at: tne burner cu. 

be reQuO:::eQ by. as ;nucb. as ·fort:y perceDt: ·nl.at:f.ve .. 

. t·o ·,.a:. E a • tern u.s. coal. A typical ccau,ariaoa · 

of pecrole111a coke and ~ot:h Eastern . .'.sl\4 Weste-rn 

u, s. · cype ·coals . is presuced, in' tab l.e h · 

!mpr1W1!d "Pellec" Shane for Blast FU:t'nace 

·Burdening 

Pellee~ cen4 eo migra~e coward ~he cancer of 

blast furnace burdlltftS d~e to relative. low. angle 

of repose i: ~Oalpa~ison to oeher charg~ 

Gla.:eri.&Ls, This oan be correct ad. · s_~vbu ~Y 

83-3$5 

ehu•glng IIM!Iehoda and proeedllres, but poEeoeio:al. 

for- o1ddi.t.ional'improvement. e;~;i.st•• 

OJ;~.e met.hod. of .i:t.~~ea$ing ·"pellet" ·. ansle .of 

r_~poae ·is ·to c.rush Luge pdleta irit.o &l!laller 

pl.eees as de~c~ibecl .. ily l'ag·uchi .et-· al (1SI83). 

.thJs azethc4 has ·cvo pocenti.al. problems asaoei.~tad vi eh it. . The· e.uergy required· to iftd~Jr.t.te 

. large diilllle.Ce'J' pdlet:a &il.ou.ld be ar.e;a.c:e·t' than 

fo~ 111ore typii::al. -15 +-6 111111 di.araece:l," pellets. 

o\bo • the C!:'UIIhe.d pellet: fi.11e11 rcq~i~· · aclditi~ 

ouai .. p-rocesaina. perhaplll u sint~r feed .or re-

~ycl~d pel-let feed ~~e!"i.al. 

An alternate .method.. of improving "pellet" 

an3le of repose i• to feed fonud nakes to the 

.pdliu: i.~ncioa process in :iooM. l~icad pro;.; 

por:.i.ott. F.lakes have beet:t. proecs&e<l in phospil.ac~t · GR.AT.!.:..·nLN S)l's tau for 11111.ny yea~s. They 

have .aLso.heett feci dir•ct.ly t.o. kilt:t.s processi.=~ 

ocher ·.feed materials sue b. as ·allllllio.a • 

l;t; is '·U dmated that ·Oill)" 10% Hakes· are req,uirad co :increa&e :lli.xture a~a: Le of . repose to 

tltat of .sint:er or coke. -No illCt'UU i~ in<:~uration energy is utictpned for flake· produe·doa.. 

In .fact, eneq1 .c:onsUQtptioll 111ighc · eve.n deere.ue 

ai11.ee· flakes cart ~e formed. wich c:oarser feed 

t.h.lln s:reefiD<llb. They also have Lover moiseu~e 

·~:ont:ezu:a, typically in the siz to seven. pe~c.eftt 

area. · A ve-ry slicht iac:reaae in ·pellet: recycle 

fh.es level ~" ancicip•ted. 

TABl.t 4 

I 

I 

I 

I 

Streqt:!i. (q) Scan I 

Ftn.d I 

Degradation (pc:c.· •3 mm)l 

Hecallization lBO m1n. I 

4SO mill. 

.Percent Fixed Carbon 

Percent Volati~es 

Pa;cenc .Ash 

P,_rC::ea.c ~.oisture 

Percent Sulpb.ur 

l!eaci.ag Vab.c J/'kg 

Delivar~d Cos~ $/109 J 

I Ka!jneti.c~:: I !lemacice u-nice 

l"rebe.ated Fired I Prehe•ted Find Preheated 

I J 

36 151. I ~I. 44S I 48 

41 59 I 68 39 I .33 

1•4 J.2 I 4.3 . 17.8 .I 0.6 

88 92 I 94 94 I 

:- ! 79.S 

::A.Bt.r; 5 

Pei:rci1Bum Coke !asc:er11, Coal Ye.ster11. .Coal 

82 • .8 

u.o 

0.2. 

6.0 

5.0 ~3.:3.x 106 . 1.58 

so.o 

33.0 

8.0 

9.0 

·1 ~o · 

211.1 " 106 . 2 .• 86 

36.0 

29.0 

9.0 

26.0 . 

1-0 • 19·~ lli lOS 

·l.27 

i'i.red 

41 

22 

0.6 

79•8 
/ 

I 

'· 

FROM 

·. 

WOIDA PHONE NO. 7705177753 APR. 16 2001 02:44PM 'P8 

11 

RE:F'E!U:IIC!S 

1.:- ·raulknet, B. _P._, Losin, t. 1'.~ an4 -Cn;a:r;:e,· 

a-. p •• ' l977. II A ' Study of Cod Fi.x·i_ng iii -Che 

Grate-JCilll Sya tem", -·. I'roct~ed il!,(s Annual 

Keeds of' the Minnesota Section. Ani!: a':ld _ 

.38th AntNal :iicins Sy!DOdum, - J)Ulut.h, -Jan. 

1971. ' -

2.. l+J~~. D. t., 1982,· "Coal Fhi11g fot-

·Pellediing-"ilu.cler 'Ia:11ouic:e", Proeeeclins• . 

AlU\u&l . liceting of the Minnesota Section · AIHE and ' 4Srd · · Annual Mi.ni1115 _ Stmoosium, 

Duluth, Jan._ 1982. · 

3. -- Johnson, -A. r.. ,· 1982,- "C<oal · Fhi128 foJ' _Pel-,. 

- l•~i~~n&-~i'~t~i.ence:l 01t CCt' s "!ilde&UliJL.e11 ; 

· l'roc:e'edinr,t Anu11al !1eeci.ns of' che :lfi11nesou 

Sa~tiou 6~ and. 43rci Annud ~ifli.nc SVIIIpo"' 

~· D!Jlucll, J'ari. 1982. 

4. Kroll.man,- c.·, l-9a2, "Co ill Yiriag & G~:a.:.eKiln· Sylitea at E'.v_elccb.:'Hiuu'', Proc:.eedinu 

Annual M•ecing of ' ~be · Min=~soca .Seeeioc 

Ailm ancf 43rd Annual Minin~ SY1!1g'o~ium , 

Duluth; Ja11,. 1982. -

s. Lope:r.:', _a • . D•, Ronk.onen, B.. c., and ,Pgtts,. 

R., 1982 , "Coa,l Firing at Minntac 1 u.s, 

Sted11, ProceecUnss. Ann~Jd Mtleting of the· 

Minnesota Section: ·AIME all!l 43rd Annu.d !tinLnS Syatponum, . Duluth, Jan.- 1982. 

6 0- l';a&uehi~ X~, tl'euakc; T., I11aba, S, .• halco, 

1\.:, ~iz11gucbi · :· I., ·ahd Uuji, ~. , 1983', 

"Development of Cruab.eo li'ell.ec:s i11 Kakogawa 

·wo;-ks", Slii-AIME Annual' Meeting. Atlan~a, 

Georgia, Kneb, · 19$3. 

n I , 

I I 

J 

Figure 1 - Grate-Kiln System· Pe~pecive Vlf.ith ~o , Aeeoup S~stem and Two·Pa$$ Grate_ Cycle