CEMENT KILN DUST (CKD)

MEI'HODS FOR REDUCTION A N D CONTROL

w
GRANT KESSLER

LAFARGE CORPORATION
Montreal, Quebec, Canada

for presentation at the

36TH IEEE CEMENT INDUSTRY TECHNICAL CONFERENCE
May 1994
Seattle, Washington

0-7803-1766-1194 $4.00 01994 IEEE 159

 Cement Kiln Dust (CKD)Methods for Reduction and Control

--Cement kiln dust (CKD) is a waste product generated during the

manufacture of Portland Cement. Volatile compound buildup in cement
kilns results in the need to purge the system which stabilizes the process or
brings the product quality within specifications. This paper outlines a
stepwise approach for reducing CKD generation. The present cost penalties
for generating CKD along with potential future liabilities of stored dust
should make CKD reduction a main priority. Many cement plants have gone
through similar investigations in the past, however most could benefit from
re examining their present dust wasting situation and applying new testing
programs now available. This investigative process can be relatively simple
and should be a high priority on any cement plant's agenda. Following a
stepwise, organized approach can often result in large reductions in dust
wasting. Today's technology allows the improved sampling and rapid
chemical analysis needed for each plant to establish and follow a volatile
management program resulting in the reduction of CKD generation.

161
 INTRODUCXION

Cement kiln dust (CKD) "is particulate matter that is collected from
kiln exhaust gases and consists of entrained particles of clinker, raw materials,
and partially calcined raw materials." [l] Increased concerns about the storage
of CKD, should motivate plants to investigate the reasons why dust is wasted
in their plant and follow up with a comprehensive dust control program.

In 1990 the national average was 9 tons of CKD generated for every 100
tons of clinker produced (9% of clinker). The US cement plant average CKD
rate for wet kilns is 11.5%of clinker, 10.5% of cliriker for long dry kilns and
4% of clinker for Preheater/Precalciner kilns, [2]. The present cost penalties
for generating CKD along with potential future liabilities of stored dust
should make CKD reduction a high priority. Control of dust wasting should
also be considered when selecting fuels, researching new raw materials,
introducing new product lines (low alkali), and/or investigating plant
optimization.

The process described within this paper can be relatively simple and
should be a high priority on any cement plant's agenda. In nearly every
situation the implementation of a short study will yield immediate
improvements in plant awareness of dust wasting and will result in some
reduction with a minimum of investment. Following a stepwise, organized
approach can often result in large reductions in dust wasting. However, the
complete elimination of CKD may require large capital expenditures.

Concerns over the generation of cement kiln dust, or CKD, have

increased quite dramatically over the last few years. There are direct costs
associated with producing CKD and furthermore, government agencies are
scrutinizing cement plant operations more and more closely. CKD consists of
fine raw material (kiln feed), partially heated (calcined) feed, clinker and
condensed volatile compounds like sulfur, alkalis and chlorides. These
materials are swept up in the counter flow gas stream of the kiln system and
can vary widely in chemical composition from plant to plant.

163
 Since the installation of kiln stack dust collection systems North
American cement plant operators have had to deal with the dust that is
generated from their cement kilns. Most of the dust produced is suitable for
return to the cement kiln as feed. According to data from the US Bureau of
Mines, over half of the total dust carried out of the cement kilns (Gross CKD),
is returned to the kilns as feed, (Recycled CKD). The remainder,
approximately 4.6 million Metric tons per year of CKD, is still removed from
the system 131. Most of this dust is disposed of through onsite or offsite
dumping and storage.

Figure 1 demonstrates the pathway taken by material through a typical

cement manufacturing process. [4] This schematic also serves to outline the
scope of this paper including inputs, outputs and material nomenclature.
Hereafter the term 'CKD' by itself refers to the net CKD, or waste product,
leaving the kiln system.

t
Cleaned
Stack
Gas

Dust
Net CKD Collector
(Waste 4 Fuels
Product) Kiln

Fig 1 . Typical Material Behavior in a Cement Kiln System

164
 The reasons for disposing of CKD range from mechanical limitations
to cement product quality necessity. A cement plant may waste an excess
portion of dust solely for the purpose of achieving smooth kiln operation
showing little concern over the short term costs and the long term CKD
liabilities.

Some plants have very good control of their dust wasting, using the
dust wasting rate to tightly control the sulfur, alkali or chlorine in their
process or products thus achieving kiln operational stability or the desired
product quality with good cost control and minimized environmental
impact.

Each plant should analyze their own situations. Often, a review of the
present status can start a plant on the road to controlling and reducing CKD
generation.

165
 COSTS ASSOCIATED WITH CKD

Table 2 below outlines and compares some typical costs associated with
CKD generation and disposal. It can be concluded that the cost of landfilled
CKD can be similar to the bin cost of clinker.

-
LOW -
Ave High
Raw Material Costs $1.50 $4.00 $5.50

Raw Feed Costs

Crushing, Conveying, Drying and Grinding $3.00 $4.50 $6.00

Fuel Costs
Dust Calcination and Sensible Heat $1 .oo $1.50 $2.00

CKD Transport
Conveying, Hauling and Dedusting $0.50 $1.oo $1.50

Landfill Maintenance
Monitoring, Pile Maintenance and Closing $1 .oo $3.00 $5.00

Totals, $/short ton of CKD Landfilled $7.00 $14.00 $20.00

Table 2 . Typical Costs Associated With C K D Disposal, $/short ton

Any plant that is wasting dust experiences a major cost attributable to

CKD and its' disposal. In many cases the cost is hidden or unaccounted for,
but it is obvious that benefits will be realized for every ton of CKD not
generated.

CKD causes lost clinker production revenue in addition to the total

costs associated with dust wasting. Typically each percent of dust wasted
increases specific heat consumption by approximately 0.7% and decreases
clinker production by 0.5%.

166
 BENEFICIAL USES OF CKD

This paper describes methods of reducing the amount of CKD

produced. However, it must be stated that CKD can have many beneficial
uses. The list below is taken from ASTM D-5050-90,the American Society for
Testing and Materials, Uses of CKD. [51.

Structural Purposes - Additions in the manufacture of glass, brick,

block and other materials.

-
Stabilization Purposes With soils to modify plastic limit or moisture,
and to provide stabilized properties to solid and other waste
construction products.

-
Fixation Purposes For neutralization with other materials, both
hazardous and non hazardous.

Solidification Purposes - For dewatering waste materials to provide

structural and handling properties, for economic and environmental
use, and disposal.

pH Control Purposes - For use with sludges to reduce pathogens and to

enable sludges to be safely and economically applied to the land.

Flocculation Purposes - For use to separate solids from liquids and in

multi-purpose processes to treat, dispose, and utilize industrial,
municipal, and utility wastes.

Agricultural Purposes - A soil conditioner and nutrient source to meet

the needs of the agricultural industry.

The sale or disposal of residual CKD for one or more of these purposes
may be a better solution than landfilling while avoiding the associated costs
and liabilities.

167
 REASONS FOR CKD GENERATION

Since CKD generation carries such a large cost penalty why is it

produced in so many of our plants? The reasons can be summarized in three
main categories:

Mechanical Limitations

Operating Stability

Product Quality Considerations

Mechanical Limitations.

In the distant past it was common to waste all of the dust carried out
with the kiln gases. The situation was different, however, because the CKD
was not collected prior to going out of the stacks. Today we are able to collect
the CKD and return it to the kiln when practical, but there are still plants that
do not return CKD for process or mechanical reasons. In some cases
additional equipment would allow the return of only the wanted portions of
the dust collected in an electrostatic precipitator or baghouse. Some processes
are able to use the CKD as feed but do not because of inadequate CKD
handling systems or reintroduction equipment.

Operation Stabilitv.

CKD consists mainly of raw materials contaminated with volatile

compounds consisting primarily of sulfur, alkalis and chlorides. If the
concentrations get too high they can cause plugs in the kiln system, process
instability and frequent, unscheduled kiln shut downs.

Not returning enough dust is costly, however returning too much dust
can contribute to system instability or shutdowns. The proper balance can be
calculated and monitored by investigating the chemistries of the clinker and
of the intermediate process materials.

168
Product oualitv Considerations.
The production of low alkali clinker from high alkali raw materials,
can today only be accomplished through the wasting of dust. A plant could
accomplish this by monitoring the alkali concentration in the clinker and
adjusting the CKD rate to achieve the low alkali target in the clinker.

CKD REDUCIlON STRATEGIES

This section will outline an organized strategy for reducing CKD

generation in a cement plant. The relative costs and benefits will be described
along with step by step approaches toward improving the CKD situation. The
following methods will be described:

A) Monitoring and Control

B) Optimization of Current Raw Materials and Fuels

C) Burning Zone and Fuel Combustion Improvements

D)Raw Material Changes

E) CKD Reprocessing

Figure 3, compares the capital costs associated with the various CKD
reduction options listed above [61. The slope of the line is an indicator of the
relative cost. As the methods become more involved and technically
complex the capital cost goes up. The net cost and benefit of each step will
vary from plant to plant depending on the materials available, transportation
costs, fuel pricing and the market for byproducts among other things. A
similar curve can be constructed for each plant of interest highlighting the
most efficient procedure to follow. It is recommended to implement the
lower cost solutions first since these will often give the best results per dollar
invested.

169
 - -

Raw Material Change

/
pt--.#
Combustion Improvements

1 1 Improved Mining Plan

4 Monitoring and Control- :
0 10 20 30 40 50 60 70 80 90 100
% Reduction in CKD Generation

Fig 3 . CKD Reduction Methods Vs Cost

A) Monitoring and Control.

It can be seen from Figure 3 that monitoring and control of the process
is the most cost effective method toward CKD reduction. CKD consists mainly
of raw materials which contain volatile compounds, therefore the tracking
and control of the volatiles throughout the system often allows for CKD
reduction.

170
 Plan

Establish a New Target

Observe the Process

Document the Results

Reduce CKD on of the Element

a Trial Basis

Fig 4. CKD Monitor and Control of the Process

Step 1) Plan.

The process of monitoring and controlling CKD is cyclic. An organized

plan is the first step in this process. Success of this procedure relies on the
concept of following the steps listed below repeatedly until the process is
optimized and the CKD rate is minimized.

Step 2) Measure the CKD Generation Rate and Chemistry.

The initial step in your plan toward CKD reduction is to identify the
amount and chemistry of the CKD. Direct weighing of CKD is the only
acceptable method of documenting CKD production. Indirect measurement
by using kiln feed rates and LOI's are only valid for short term comparisons
and must be done in conjunction with the direct weighing of dust and clinker
to obtain values for long term use.

171
 Step 3) Pinpoint the Problem Element Causing Dust Wasting.

If there is a mechanical reason for generating CKD then one must begin
there. However if there are high levels of any volatile in the total feed to the
kiln, buildup material or in the CKD this could be the cause of dust wasting.
The sulfur/alkali ratio is a good indication of a possible imbalance. This ratio
is calculated as the molar ratio of S03/(K20+Na20) in the CKD. This ratio
should be between 0.5 and 1.5 in either the CKD or the kiln load material.
The kiln load material can be sampled through a port in the kiln shell,
toward the end of the calcining zone where the volatile content of the
material is the highest. The following table shows an example from a system
that has out-of-balance (molar balance) CKD.

Volatile YO Analysis (As Received Basis) Molecular Weight

NaX) 0.20% 62
Kx) 3.30% 94.2
c12 0.40% 71
SO3 16.70% 80

Table 5 : CKD Volatile Analysis

In this example it is apparent that there is an overabundance of sulfur

in the net CKD. Calculating the molar ratio of S03/(K20+Na20) will help
confirm this.

% SO3 80i -
- 16.7 + 80 = 5.5
(%K20+94.2) + (%Na20+62) (3.3 + 94.2) + (0.2 i 62)

This molar ratio of 5.5 indicates an imbalance with an excess of sulfur

being taken out in the waste dust. This can be confirmed by performing a
similar analysis on other materials in the kiln system.

172
Step 4) Find the Source of the Element.

List all of the chemistries of the system inputs and find which one is
the largest contributor. Try to minimize the input of the problem element.
Once you understand why you are wasting dust and have established a good
mass balance, you can move on to the next step.

Step 5) Increase the Amount of CKD Returned to the Kiln on a Trial Basis.

This step is best accomplished as a team effort. The greatest return with
the minimum of investment nearly always occurs in this stage of a CKD
reduction study. The more people that are involved and the more levels of
the plant organization that they represent, the better the chances are for a real
reduction in net CKD.

Slowly increasing the CKD return to the kiln is crucial. It can be very
simple if the plant has the equipment required. If not, one can review the
dust return options listed in Figure 6 for a method suitable to their process.
The purpose of this exercise is to establish the chemical limits for the volatile
compounds by increasing the volatile cycle in the system. Each stepwise
increase in dust return must be followed by a stabilizing period of one to two
days. The longer the better except in the case of a chlorine cycle which
requires much less time due to its high volatilization rate and rapid cycling
ability. [A

173
 I REfuRNDUsT 1
L

RElUlW DUST I RETURNDUST 1 ADD DUST

E F
TO TO KILN TO FINISH
MID KILN PRODUCT

TI-KuGH - USER3R
TO RAW - KILN MASONRY

-
SHaL

7HRou(yI
I 1 ZCNE

INJECT
CEIuENr

ADD AT
WST PAST BURNING
SCOOPS

c
N
FEED/SLURRY SpH;IAL VELOCITY
. CONTAINERS SPRAY

-FUELMIXFORWITH
t
l
F l CATAPULT
PARTIAL
PREC.ALICINATDN
I
CATAPULT

RAME

PAST CHAINS
I ' euRNINGZONE J

I 1
I
I EXITINGKILN

ADD TO
PAST CHAINS CLINKER BED

I CIRCUIT

INJECT IN
SECONDARY
AIR STREAM

INJECT IN
COOLER VENT
AIR STREAM

Fig 6. Methods for Returning CKD to WetlLong Dry Process Kiln Systems

174
Step 6) Observe the Process and Document the Results.

The process should be continually monitored for indications of

plugging or material flowability problems. Document all observations
continuously through the test period. All materials must be accurately
sampled and chemically analyzed especially the CKD, Kiln Load material and
Clinker. The samples should be analyzed for sulfur, chlorine and alkalis with
emphasis on the suspect volatile. The test will be worthless if these values
are not well documented.

Step 7) Establish a Chemical Target.

Once the volatile levels in the system reach a maximum it will be

indicated by process instability, plugging or material flow problems. This
unstable process will continue until a sustainable volatile equilibrium is
reached. It is this point of control of the equilibrium that holds the key to the
reduction of waste dust generation. This is achieved by slightly reducing the
rate of CKD into the kiln until smooth operation is re-established. The level
of the problem element at this point in time establishes your operating
chemical target. At this point the CKD rate should be adjusted to maintain
the target. Typical operating targets for the volatiles in the kiln load are:

- so3,3%to 4%.

- C1, 1%to 1.8%.

- K20,2% to 3%.
This procedure should clearly define the problem elements in the kiln
system, the sources of those elements and the maximum amount tolerated by
the process. This test should be repeated after other CKD reduction measures
are taken, or any changes in materials or fuels.

After increasing the CKD recycled to the kiln as outlined above, the
plant should continue to reduce CKD by exploring other methods.

175
 . .
8) &tlnuza tion of Current Raw Materials and Fuels.

Once the problem element has been determined, identify all of its
possible sources. Explore ways to reduce its inputs. Typically, a raw material
is being quarried with the optimization of only one of the major components
in mind; i.e. CaC03. A change in chemical priorities in the quarry may allow
for an improved mining plan or the opening of a new area in the quarry that
results in CKD reductions. In the case of purchased materials, a study may be
needed to investigate the quarry or the source, or to possibly change sources.

Two plants with long dry kilns recently reduced CKD generation by
10% and 35%. One plant did it by opening up a previously unused limestone
bench and the other introduced lower sulfur silica and calcium additives.

Most plants have spent considerable effort selecting fuels that reduce
the overall addition of contaminants to the system. Fuel selection may need
to be re investigated to better optimize sulfur and chlorine inputs.

C) Fuel Combustion Imtxovements:

Modifications to the kiln fuel burning system can affect the amount of
sulfur, and alkalis in the clinker. For example, adequate fuel/air mixing in an
excess oxygen atmosphere will allow higher sulfur levels (and to some extent
alkali levels) in the clinker. This can be beneficial in cases where clinker
alkali is not being limited. Even in situations where low alkali clinker is
required a study should be conducted to insure that the kiln is operating at
the proper balance between dust wasting, optimized combustion and low
alkali clinker production.

Similar changes in volatilization can be achieved with a cooler burning

zone. A stable but elevated free lime level in clinker is favorable over lower
varying free lime. Kiln automation and kiln feed mix changes can enable the
control of a cooler burning zone.

176
D)Raw Material ChanFes.
Figure 7 outlines waste dust reduction options for a typical long dry
kiln with an excess sulfur problem. [8] If the less costly options for CKD
reduction have been exhausted, a change of raw material should be
considered. This change must be very well thought out with all of the
economics of the situation considered.

A very large investment is being made at a plant with high sulfur

input. After realizing only minimum CKD reductions, (8 - 10%) with minor
combustion improvements and current raw material optimization, it was
decided to replace the main silica source, which is also the main sulfur
source, with alternate low sulfur raw materials. The resulting sulfur cycle is
compared in Figure 8. The gray areas represent the flow of sulfur through the
system presently and with the revised raw materials. The width of the lines
of flow are proportional to the mass flow of sulfur. Many changes in the
sulfur flow were seen in recent trials. The amount of CKD was reduced by
80% and the reduced sulfur cycle resulted in smoother operation. With
longer term planned combustion improvements, an increase in clinker
sulfur should further improve the CKD control.

E) CKD Reprocessing.

When CKD is generated due to product quality or process stability

considerations, it may not be possible to completely eliminate CKD wasting.
In these cases the remaining CKD can be landfilled or used beneficially as
described above. However, it can also be reprocessed and returned to the kiln.
In one such process the alkali sulfates can be leached out and the hydrated
dust can be returned to the kiln. In another process it is possible to sinter the
dust in a fluid bed reactor and recover the products. CKD can also be treated
with kiln exhaust gases in a recovery scrubber and returned as kiln feed. [9]
This option can be used at any level of dust generation but becomes less
capital intensive if the amount of CKD generated is first reduced to a
minimum by the other methods outlined above.

177
 I FlEMlcE 1
pr
l!?J 5-75%
INCLINKER

5 - 20 Oh I
GENERATION

5-15%

STABILIZE I REDu(=E
KILN EXIT GAS
I

KILN DIAMETER

MID KILN

I ’ INCUNKER ’
KILN FEED
I
I Ru)(IcE 1 . CREATEMORE
SULFUR IN - OXIDIZNG KILN FEED
ATMOSPHERE

- DUCREASE
KILN D I T
, OXYGENLEVEL IN SYSTEM

- MODIFY
CHAIN SYSTEM
DESGN

PREPARATlON

Fig 7. Options for CKD Reduction for an Over Sulfated Long Dry Kiln

178
 ORIGINAL RAW MATERIALS

STACKGAS

RAW MATERIALS CLINKER

REVISED RAW MATERIALS

STACKGAS

WASTE DUST

w
RAW MATERIALS CLINKER

Fig 8. Sulfur Balances Resulting From a Major Raw Material Change in an

Over Sulfated Long Dry Kiln

179
 SUMMARY

The recently released "Report to Congress on Cement Kiln Dust" Dec.

1993, has served as a mapr wake-up call for many cement plant operators. It
is believed that the challenge has been made and that the industry should
react responsibly to this challenge. The solutions can be very cost effective in
some cases and very costly in others, therefore requiring that some
courageous decisions be made in many operations.

This paper has presented an organized strategy for reducing CKD

generation in a cement plant consisting of the following components:

- Monitoring and Control

- Optimization of Current Raw Materials and Fuels
- Burning Zone and Fuel Combustion Improvements
- Raw Material Changes
- CKD Reprocessing
Obviously, not every method described is appropriate for every cement
plant, indeed some plants are blessed with high quality raw materials and do
not generate any CKD. It is these plants that will be setting the CKD standard
for the rest of the industry in the future. Today's technology allows the
improved sampling and rapid chemical analysis needed for each plant to
establish and follow a volatile management program for the reduction of
their CKD.

180
 References

D. Abeln, R. Hastings, R. Schreiber, and C. Yonley, "Detailed

Illustration of Contingent Management Practices for Cement Kiln
Dust", Portland Cement Association, Sept., 1993.

"Report to Congress on Cement Kiln Dust," United States

Environmental Protection Anencv, Office of Solid Wastes, Dec. 1993.
Ibid., 3.1.3, "Quantities and Fate of CKD Generated"

W. Kreft, "The interruption of material cycles, taking account of

integrated further utilization in the cement plant", Zement Kalk Gips
NO. 11/ 1987, pp. 257 - 259.

"Commercial Use of Lime Kiln Dusts and Portland Cement Kiln

Dusts," Annual Book of ASTM Standards, Vol. 04.04, Designation
5050-90 pp. 189-191,1993.
J. Melick, "Costs of Cement Kiln Dust Reduction", May 1992.
M. Rose, "Problems Related to Minor Volatile Components in the
Kiln", Training Course, C. L. F. - St. Concord, pp. 8, Oct.1977.
E. Hanson, "A Rich Man's Precalciner: Modification of a Conventional
Kiln with Bypass, Secondary Firing, and Tertiary Air", 29th
International Rock Products Cement Seminar, pp. 104110, Dec. 1993.

Garrett L. Morrison, "CKD Management Using a Passamaquoddy

Technology Recovery Scrubber", PCA Emerging Technologies For Kiln
Dust Management, Spring 1992.

181