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5.
TABLE OF CONTENTS
5.1
5.2
Operation target.......................................................................................4
5.3
5.4
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5.5
15
.6
C.T.S
Technical Training
5-1
5.
5.1
Kiln is operated according to general principles but there are no absolute rules.
Operating the kiln means attaining 3 goals by setting the controls and checking
the variables.
A)
Quality
B)
Stability
Kiln system must be kept stable. Stay aware of the variables that will
affect the system's stability.
C)
Optimization
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5.2
5.3
Operation target
Clinker temperature.
- under 110C as it could promote quality problems (false set) the
during grinding process.
Chemical
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B.
Physical
Good spray injects into gas stream, not into the material load.
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5.3.4
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5.3.7
Upper limit.
-
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5.4
With the use of a water spray in the back end, the water volume
will slow reactions of the back end temperature.
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NOx analyzer:
NOx level has been measured in the range between 500 and
2000 PPM in the Lafarge group kilns.
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NOx correlates better with clinker liter weight than free lime.
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Hood pressure:
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Undergrate pressure:
The value varies with the cooler bed depth and with the clinker
size. It must be held constant in order to achieve a constant
secondary air temperature. Also, only a constant air flow can
allow the relationship between undergrate pressure, bed depth,
and secondary air temperature to be valid.
Oxygen analyzer:
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Kiln amps:
NOX analyzer:
Nitrogen
oxide
related
to
temperature.
level
can
burning
be
zone
Gas temperature:
Oxygen level:
Hood pressure:
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5.5
Fuel flow:
Kiln speed:
Draft fan:
Undergrate pressure:
OK
too low
too high
OK
too low
too high
c. oxygen level
OK
too low
too high
Because any of these conditions can be within the allowable range, below
the minimum allowable value or above the maximum value.
In most conditions, except for emergencies or upset conditions, the
operator will find that these 3 variables can be maintained within
reasonable limits by means of adjustments of one or more of 3 basic
controls, which are:
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As operator:
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The kiln speed (slowing down or speeding up the kiln can move
the burning zone front)
Playing with draft and/or fuel will affect the burning zone state.
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Cooler control:
The cooler is an amplifier of the kiln instability.
Hot Clinker
Controller:
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5.5.3
5.6
B)
C)
Find the optimum production level of the kiln and keep this level of
production as a permanent operation setpoint.
D)
E)
F)
Corrections for the draft through the kiln should be small and
should principally be made to keep the temperature constant.
G)
H)
Watch the kiln burning zone of possible and the kiln panel
instruments constantly, and react immediately.
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constant mix.
All fans should be maintained well within their rated capacity, and
attention should be given to the operating position on the fan curves.
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5.6.1
Diameter of kiln
-
Cooler capacity
-
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Warning:
Action to take:
First and foremost - do not wait until raw feed is in the cooler, act when the
first signs of impending problems are visible in the burning zone.
1.
2.
3.
4.
5.
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Action to take:
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5.6.4
Possible actions:
1. Reduce fuel flow rate to minimum until sausaging stops.
2. Increase kiln speed approximately 5-10 RPH until sausage is
broken.
3. Provide maximum possible air in cooler (without hood pressure
going positive).
4. Reduce primary air flow.
Then, as soon as the primary objective of breaking the
agglomeration is accomplished.
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Preventive measures:
5.6.5 Emergency
temperature
condition
4:
Sudden,
sharp
rise
in
back-end
Possible reasons:
Feed shortage.
Chain "fire"
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Possible actions:
1. Immediately de-energize electrostatic precipitator.
2. Immediately reduce fuel flow rate and I.D. fan speed to obtain
less than 0.3% oxygen in exit gas.
Warning: Do not cut off fuel flow rate completely as this could
trigger an explosion.
3. Increase kiln speed and feed rate.
4. Warn personnel to stay clear of kiln back end.
5. Do not open any doors in kiln back end.
Then, as soon as the primary objective of bringing the back-end
temperature under control is accomplished:
6. Return kiln control variables to normal to restore normal
operating conditions.
7. Check out back end to determine if thermal damage has
occurred.
Preventive measures:
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5.6.6
Possible actions:
1. Immediately make a visual check of the cooler to determine
reason for red-clinker discharge:
-
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Preventive measures:
A) On frequent grate failures:
of
stalagmite
Slow kiln speed down before raw feed enters cooler or cooler
can become overloaded (make your corrective moves before
things get out of control).
By visual observation
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Possible actions:
Warning: Under no circumstances should there be water added at the
feed end.
1. Immediately, reduce fuel rate to minimum (but don't shut fuel off
completely!!!). At he same time, reduce I.D. fan speed to obtain
zero combustibles and less then 0.3% oxygen.
2. Increase kiln speed and feed rate to maximum until the backend temperature is under control.
3. On wet-process kilns: Clear all personnel from firing floor.
Preventive measures:
Avoid operating the kiln for more then 10 min. when there is a
feed shortage.
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Possible reasons:
Possible actions:
1. Immediately, clear all personnel from firing floor.
2. Immediately, reduce fuel rate to minimum and increase I.D. fan
speed.
3. Reduce cooler air-flow rates into undergrate compartments.
4. Open cooler excess air damper manually.
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