Using process parameters to assess refractory materials performance

REFRA-Training 2015
Hugo Ordóñez
What is performance?

The manner in which or the efficiency

with which something reacts or fulfills its
intended purpose.

What is the intended purpose of

refractory materials?

To enable production by protecting the

equipment from damaging temperatures
What is performance?

The manner in which or the efficiency

with which something reacts or fulfills its
intended purpose.

What is the intended purpose of

refractory materials?

To enable production by protecting the

equipment from damaging temperatures
What is performance?

The manner in which or the efficiency

with which something reacts or fulfills its
intended purpose.

What is the intended purpose of

refractory materials?

To enable production by protecting the

equipment from damaging temperatures
What is performance?

The manner in which or the efficiency

with which something reacts or fulfills its
intended purpose.

What is the intended purpose of

refractory materials?

To enable production by protecting the

equipment from damaging temperatures
What is performance?

The manner in which or the efficiency

with which something reacts or fulfills its
intended purpose.

What is the intended purpose of

refractory materials?

To enable production by protecting the

equipment from damaging temperatures
Refractory Lining Chart
How do we measure refractory material performance?

• Lifetime
(years, months, weeks)

• Specific Refractory Consumption

(Kilogram of refractory/Metric Ton of clinker)

• Wear rate:

– mm/month
– cm/month
– mm/Metric ton of clinker
Lifetime calculation

Lifetime = date of removal-date of instalation (days, months years)

Lifetime alone does not inform about:

• The state of the lining by removal.

• The reasons for the removal.
• If the kiln produced during all the period.
• Relevant aspects for lifetime.
Residual thickness measurements
HISTORIA DE CATEOS DEL HORNO 5

FECHA OCT 14/2002 SEP 10/2003 DIC 22/2003 OCT 14/2004 DIC 21 2004 31.03.2005
METRO 0° 180° ZR 0° 180° ZR 0 90° 180° 270° Z.R. 0° 180° ZR 0° 180 ° ZR 0 90° Z.R.
1 5 5 4 4 1/4 4 1/2 4 6 1/2 5 1/2 51/2 6
2 4 4 2 1/2 2 1/2 3 2 3/4 5 3/4 5 5 5
3 5 6 3 1/2 3 3 3/4 3 1/2 6 6 5 5
4 7 6 1/2 5 5 1/2 5 5 6 1/2 6 51/2 41/2
5 7 3/4 7 3 1/2 4 1/2 4 3/4 5 8 8 71/2 63/4 6 1/2 5
6 7 7 4 4 1/2 5 3 1/2 5 1/2 5 1/2 6 61/2 5 3/4 5
7 6 1/2 7 1/2 5 4 3 1/2 5 1/2 6 4 3/4 41/2 5 4 1/2 5
8 5 1/2 6 3/4 4 4 4 3 1/2 5 1/4 5 1/2 5 43/4 5 4
9 7 1/4 4 3/4 4 4 1/2 4 1/2 4 1/2 5 8 41/2 41/2 4 4 1/4
10 7 1/2 4 3/4 4 3 1/2 4 1/2 4 6 1/4 6 1/2 41/2 41/2 5 1/4 6
11 4 4 1/2 5 3 1/4 4 3 1/2 6 6 5 51/4 4 3/4 3 1/4
12 4 6 1/2 6 4 4 1/2 4 1/2 6 6 5 61/4 6 1/4 6 1/2
13 4 1/2 6 1/2 4 4 1/2 5 3 1/2 5 5 2 31/2 5 3/4 6
14 5 1/2 6 4 1/2 3 1/2 4 1/2 5 1/2 3 3 6 51/2
15 3 2 1/2 6 3 5 1/2 5 1/2 1 1 6 6 5
16 3 1/2 2 4 1/2 4 1/2 6 6 1/2 2 3 5 51/4 6 5 3/4
17 3 1/2 5 6 1/2 6 1/2 6 5 1/2 2 2 1/2 5 61/8 5 1/4 5
18 3 1/2 5 5 1/2 6 6 5 1/2 4 2 41/2 41/2 4 3/4 3 1/2
 Wear rate (WR) calulation

WR=Wear/time

Initial thickness= T1 (mm) Thickness

Final thickness= T2 (mm)

Wear = (T2- T1) mm inicial

WR = (T2- T1) /time

Time [months] RELEVANT WEAR
final
1/3 hi

WR [ mm/month] Instalación time Replacement

date date
Specific refractory consumption (Kg/Metric Ton of clinker)
Is calculated from:
• Wear rate
• Brick density
• Kiln dimensions
• Klinker production
SRC= Kg refractories/Metric tonn clinker
• Is the most frequently used measurement of performance.
• Different production systems have different typical values
• Values fluctuate a lot.
Factors related to refractory material performance
Influences on the part of the cement producer

Refractory
Thermal
installation Chemical
Kiln
Storage burning
conditions
Lifetime Mechanical
of
Refractor refractories
y
selection
Raw
Installation Production-
material
draw quality
quality

Influences on the part of the producer

We are going to focus on the influences being controlled
by the technical management!
Influences on the part of the cement producer

Thermal
Chemical
Kiln
burning
conditions
Lifetime Mechanical
of
refractories
Process parameters and process goals

Process parameters: Process goals:

Mass flows
Temperatures Quantity
Pressures Quality
Management/control
Chemical compositions
Mineralogical compositions Cost
Fineness
Heating values
Etc.
Basic control loop

set desired value

measure value

take control action

Is the difference
between measured
YES and desired values NO
acceptable?
Schewhart control chart
Old analog instruments
Modern process control
 Clinker chemical composition report
(1 analysis/hour = 24 analyses/day = 720 analyses/month = 8.000 analyses/year

SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O K2O C3S C2S C3A C3S C2S C4AF CaO
Fecha Hora Operador LSF (%) F.L. M.F M.H. M.S P/L
(%) (%) (%) (%) (%) (%) (%) (%) (FRX) (FRX) (FRX) (DRX) (DRX) (FRX) libre, %
00:00 Lourdes Calla 22,12 4,31 3,96 65,38 2,63 0,60 0,11 0,79 95,26 59,32 18,67 4,72 12,04 58,05 21,90 25,95 1,09 2,15 2,68 0,59 1182
01:00 Lourdes Calla 22,11 4,29 4,40 64,84 2,60 0,66 0,11 0,87 94,17 56,74 20,58 3,92 13,38 63,82 14,46 26,99 0,98 2,11 2,55 0,55 1340
02:00 Lourdes Calla 22,13 4,32 4,38 64,98 2,60 0,54 0,11 0,78 94,23 57,27 20,25 4,05 13,31 66,00 16,05 26,84 0,99 2,11 2,54 0,54 1408
03:00 Lourdes Calla 22,12 4,23 4,23 65,05 2,58 0,67 0,11 0,89 94,64 58,06 19,61 4,06 12,86 61,63 17,98 26,45 1,00 2,13 2,62 0,56 1258
04:00 Lourdes Calla 22,13 4,21 4,23 64,71 2,61 0,75 0,11 0,96 94,18 56,52 20,81 4,00 12,86 63,53 15,65 26,56 1,00 2,12 2,62 0,56 1212
05:00 Lourdes Calla 22,12 4,21 4,22 64,72 2,60 0,76 0,11 0,98 94,24 56,64 20,70 4,01 12,83 63,73 14,30 26,56 1,00 2,12 2,63 0,56 1397
06:00 Yorgan Llerena 22,05 4,16 4,21 63,99 2,54 0,87 0,12 1,16 93,47 54,07 22,43 3,91 12,81 62,29 17,25 26,66 0,99 2,10 2,63 0,58 1188
08:00 Yorgan Llerena 22,23 4,25 4,25 64,30 2,55 0,76 0,13 0,99 93,08 53,80 23,15 4,06 12,94 62,60 16,74 26,75 1,00 2,09 2,61 0,55 1214
26.09.2011 10:00 Yorgan Llerena 22,20 4,13 3,95 64,88 2,52 0,65 0,11 0,95 94,41 58,01 19,89 4,27 12,01 62,61 17,90 25,51 1,05 2,14 2,75 0,52 1202
12:00 Yorgan Llerena 22,32 4,35 4,17 63,56 2,58 0,90 0,14 1,11 91,67 49,00 27,01 4,46 12,70 61,85 16,99 27,16 1,04 2,06 2,62 0,59 1235
14:00 Yorgan Llerena 22,11 4,26 4,00 64,27 2,56 0,88 0,12 1,14 93,68 54,11 22,58 4,52 12,17 60,85 19,29 26,48 1,07 2,12 2,68 0,64 1198
16:00 Yorgan Llerena 22,11 4,20 4,15 63,80 2,57 0,98 0,12 1,21 92,99 51,99 24,18 4,12 12,63 58,15 21,69 26,84 1,01 2,09 2,65 0,66 1232
18:00 Dianne Paco 21,98 4,14 3,98 63,92 2,53 0,80 0,11 1,06 93,86 53,45 22,70 4,25 12,10 67,44 12,95 25,87 1,04 2,12 2,71 0,96 1189
20:00 Dianne Paco 22,00 4,21 4,03 63,83 2,60 0,93 0,12 1,19 93,60 53,63 22,61 4,33 12,27 61,71 16,87 26,53 1,04 2,11 2,67 0,58 1205
22:00 Dianne Paco 22,19 4,20 4,13 65,02 2,58 0,51 0,11 0,84 94,44 58,28 19,67 4,15 12,57 66,99 11,73 25,94 1,02 2,13 2,66 0,53 1225
Promedio 22,13 4,23 4,15 64,48 2,58 0,75 0,12 1,00 93,86 55,39 21,66 4,19 12,63 62,75 16,78 26,47 0,60 1246
Desviacion Estandar 0,09 0,06 0,14 0,56 0,03 0,14 0,01 0,14 0,85 2,82 2,17 0,24 0,44 2,72 2,84 0,46 0,11 74,45
00:00
02:00 Dianne Paco 22,01 4,14 3,64 64,02 2,75 1,02 0,12 1,52 94,44 49,48 25,77 4,81 11,08 48,17 25,33 26,02 1,14 2,15 2,83 1,96 920
04:00 Dianne Paco 22,04 4,19 3,81 65,50 2,65 0,58 0,11 0,93 96,07 61,33 16,93 4,67 11,59 66,66 15,49 25,42 1,10 2,18 2,75 0,62 1194
06:00 Yorgan Llerena 22,10 4,56 3,94 62,84 2,58 0,99 0,12 1,65 91,33 46,34 28,39 5,43 11,97 67,05 14,98 27,88 1,16 2,05 2,60 0,60 1224
08:00 Yorgan Llerena 22,18 4,08 4,14 64,25 2,44 0,78 0,11 1,15 93,43 55,41 21,79 3,81 12,60 60,21 16,79 26,04 0,99 2,11 2,70 0,49 1207
10:00 Yorgan Llerena 21,91 4,11 4,15 63,39 2,41 0,86 0,11 1,24 93,16 53,16 22,70 3,88 12,62 62,43 16,46 26,29 0,99 2,10 2,65 0,59 1204
12:00 Yorgan Llerena 22,15 4,16 4,00 64,45 2,46 0,85 0,12 1,19 93,84 55,72 21,48 4,25 12,18 61,93 18,38 26,10 1,04 2,13 2,71 0,54 1206
27.09.2011
14:00 Yorgan Llerena 22,16 4,05 3,95 64,06 2,39 0,94 0,12 1,31 93,41 54,66 22,30 4,03 12,03 62,59 16,68 25,80 1,02 2,12 2,77 0,54 1154
16:00 Yorgan Llerena PARO HORNO
18:00
20:00
22:00
Promedio 22,08 4,18 3,95 64,07 2,53 0,86 0,12 1,28 93,67 53,73 22,77 4,41 12,01 61,29 17,73 26,22 0,76 1158
Desviacion Estandar 0,10 0,17 0,18 0,84 0,14 0,15 0,01 0,24 1,43 4,80 3,60 0,59 0,55 6,31 3,52 0,78 0,53 107
We need to use statistical methods
to manage the data
Statistical analysis options

Searching for adequate tools for

statistical analysis can be a very
frustrating experience because:

• Our knowledge of statistics is normally

not very developed.
• The amount of available resources is
huge and their use require special
knowledge.
• Most of the frequently used models
are not suitable for the analysis of
parameters at the cement plants.
Exploratory Data Analysis

Exploratory Data Analysis (EDA) is an approach/philosophy for data analysis that

employs a variety of techniques (mostly graphical) to maximize insight into a
data set to:
• Uncover underlying structure;
• Extract important variables;
• Detect outliers and anomalies;
• Test underlying assumptions;
• Develop parsimonious models (based on as few as possible parameters)
• Determine optimal factor settings.
There are a number of tools that are useful for EDA, but EDA is characterized more by
the attitude taken than by particular techniques.[
How does exploratory data analysis differ from classical data analysis?
Three popular data analysis approaches are:

• Classical
• Exploratory (EDA)
• Bayesian

These three approaches are similar in that they all start with a general
science/engineering problem and all yield science/engineering conclusions. The
difference is the sequence and focus of the intermediate steps.
Common to all approaches is:
There are models
There is data available
There is a problem!

We want to reach Suported by the analyses

conclusions of the data
The difference is the sequence and focus of the
intermediate steps.
For classical analysis, the sequence is
• Problem => Data => Model => Analysis => Conclusions

For Bayesian, the sequence is

• Problem => Data => Model => Prior Distribution => Analysis => Conclusions

For EDA, the sequence is

• Problem => Data => Analysis => Model => Conclusions
Italian Example
Analisi chimica farina calda e clinker

Normal distribution for the parameters is assumed, a typical statistical approach

based on bayesian models. Is the assumption right?
Is the normality assumption correct?

Hystogram for AR (1.213 analyses) Gauss Distribution F(avg, s)

Gauss´s normal distribution does not correctly describe the
behaviour of most parameters at a Cement Plant!

Because the assumption of normality

might lead to false judgments, we
prefer tu use EDA (exploratory data
analysis)
Some graphical techniques employed in EDA
• Plotting the raw data (such as time series, histograms, probability plots, lag plots etc.)
• Plotting control charts for the relevant parameters.
• Plotting simple statistics such as mean plots, standard deviation plots, box plots and
main effects plots of the raw data.
• Positioning such plots so as to maximize our natural pattern-recognition abilities,
such as using multiple plots per page.
• Using graphic methods that enhance the visualization of the behaviour of the
parameter or parameters in relation with the property we want to measure.
THE POWER OF VISUALISATION (GRAPHICAL REPRESENTATION)
Example: we want to analyse 4 data sets by means of clasical statistical analysis (lineal regression)

Data Set 1 D ata Set 2 Data Set 3 Data Set 4

Obs. X1 Y1 X2 Y2 X3 Y3 X4 Y4
1 10 8,04 10 9,14 10 7,46 8 6,58
2 8 6,95 8 8,14 8 6,77 8 5,76
3 13 7,58 13 8,74 13 12,7 8 7,71
4 9 8,81 9 8,77 9 7,11 8 8,84
5 11 8,33 11 9,26 11 7,81 8 8,47
6 14 9,96 14 8,1 14 8,84 8 7,04
7 6 7,24 6 6,13 6 6,08 8 5,25
8 4 4,26 4 3,1 4 5,39 19 12,5
9 12 10,8 12 9,13 12 8,15 8 5,56
10 7 4,82 7 7,26 7 6,42 8 7,91
11 5 5,6 5 4,74 5 5,73 8 6,89
n 11 11 11 11 11 11 11 11
mean 9 7,5 9 7,5 9 7,5 9 7,5
in terc ept 3 3 3 3
slope 0,5 0,5 0,5 0,5
c orrelation 0,67 0,67 0,67 0,67
Graphical Representation
D ata Set 1 D ata Set 2

D ata Set 3 Data Set 4

OUTLIER x
Some relevant parameters related to refractory material
performance:
Lime Saturation Factor (LSF)
Burnability, coating behaviour
Silica Ratio (SR)

Alumina Ratio (AR) Coating behavior, burnability

Liquid Phase Quantity (LP)
Circulation Phenomena
Alkalies-Sulphur Ratio (ASR) infiltration tendency

Thermal shock behaviour,

Temp. & Thermal load in burning zone
coating behaviour
%O2 & %CO2 in combustion gas Redox behaviour
One parsimonial model for burnability based on LSF and SR.

Lime Saturation Factor (LSF)

Silica Ratio (SR) Burnability, coating behaviour

• The underlying assumption for this model is that the burnability of the raw mix is
strongly dependent on these two parameters.

• We know of course that this is a simplification, as burnability does not depend solely of
these parameters, however, it is a useful simplification that enables us to better
understand the influences of these two parameters on both, burnability and refractory
material performance in the burning zone of the rotary kiln.
Lime saturation factor

100CaO 1.Stoichiometric relationship.

LSF =
2,8SiO2+1,18Al2O3+,65Fe2O3 2.Burnability of raw mix

Change in theorethical Sintering Temperature in

dependence with LSF

1510
1500
1490
T °C 1480
1470
1460
∆T = 48 °C
1450 ∆ LSF=6
1440
89 90 91 92 93 94 95 96 97 98
LSF
Silica ratio
SiO2 Solid
SR = Al2O3 + Fe2O3 Liquid

High SR values decrease burnability due to

•Increased probability of having big SiO2 particles in raw meal
•Decreased amount of clinker melt
•A tendency for decreased homogeneity of raw meal (segregation)
Burnability

EASY
If less energy is required (T<1450°C)

~1450 °C
NORMAL
RAW MIX + ENERGY CLINKER
Free lime MAX 2%

If more energy is required (T>1450°C) HARD

Clinker burnability chart

more difficult to burn

normal burnability

easier to burn
 How chemical changes affect burnability?
Clinker Burnability Acc. Peyre

115

110 From LSF 93, AR 2,5 to LSF 95; AR 3

105
Lime Saturation Factor

100

95
Extrem hard

Very hard
90
Hard

Normal
85
0,5 1 1,5 2 2,5 3 3,5 4 4,5
Silica Modul
Insufficient raw meal preparation
Burnability graph

4
3
2
1 5
Burnability graph

4
3
2
T
1 5
Of course, burnability also depends on other parameters:

• Particle size distribution of the kiln feed

• Fineness of kiln feed
• Degree of mixing (homogeneity) of kiln feed
• Mineralogical composition of raw materials
• Segregation, which may happen after homogeneization
• Mixing partially calcined dust with fresh meal

The influence of these parameters on burnability shall be also understood and should
be investigated using additional methods, which in no way diminish the contribution
of our parsimonial model based on LSF and SR to UNDERSTANDING AND SEEING
WHATS GOING ON
Raw meal: we grind to develop surface, required to promote
chemical reactions among the components.

Kaolin; picture width 200 micrometer (µ) Quartz grain; Average Ø 200 µ
Big quartz grains (sourronded by belite ring) do not let sintering to C3S to
proceed due to lower reaction rate (low surface area).

1620
Alite crystals
A parsimonial model for coating behaviour based on Liquid Phase
Quantity and AR.
Alumina Ratio (AR)
Coating behavior, burnability
Liquid Phase Quantity (LP)

Current practice shows us that coating behaviour is strongly dependent on these two
parameters.

We also know that this is a simplification, as other parameters also influence coating
behaviour, however; this is a useful simplification that enables us to better understand
the influences of chemical conditions on refractory material performance in the burning
zone of the rotary kiln.
 Al2O3 viscous
Alumina ratio AR = =
Fe2O3 fluid

SOME STATEMENTS RELATED TO AR

• AR values are relevant for the viscosity of the clinker melt.
• Melt viscosity is relevant for the sinter rate.
• Alkalies and MgO can lower the viscosity of the clinker melt.
• At AR=1,38 clinker melt achieves optimun properties to
promote
• sintering at lowest possible temperatures (1280-1340 °C)
% Liquid Phase at 1450 °C Acc. To Lea& Parker:
3Al2O3+2,25Fe2O3+MgO+K2O+Na2O
 Coating conditions

thin coating thick coating

dusty clinker nodular clinker
low melt quantity high melt quantity
high melt viscosity high melt viscosity

AR good
coating
thin coating thin coating
dusty clinker high melt quantity
low melt quantity low melt viscosity
low melt viscosity high infiltration of
high infiltration of refractories refractories
Changing coating conditions

AR
 Coating conditions

thin coating thick coating

dusty clinker nodular clinker
low melt quantity high melt quantity
high melt viscosity high melt viscosity

AR good
coating
thin coating thin coating
dusty clinker high melt quantity
low melt quantity low melt viscosity
low melt viscosity high infiltration of
high infiltration of refractories refractories
 Coating conditions

thin coating thick coating

dusty clinker nodular clinker
low melt quantity high melt quantity
high melt viscosity high melt viscosity

AR good Period 2
coating
Period 1
thin coating thin coating
dusty clinker high melt quantity
low melt quantity low melt viscosity
low melt viscosity high infiltration of
high infiltration of refractories refractories
Accelerated wear of refractories in lower transition zone
due to concurring action of various factors
Combustion conditions
Redox conditions

These reactions are associated

with volume changes
Chemical Composition and AFR Feed
1. Plants invest a great deal of effort (and
money) to bring the chemical
composition of raw meal fed to the kiln RM
within narrow fluctuation ranges for
chemical and physical properties: Pre-
homo, blending and homogeneizing
installations, on line analizers etc.
2. They destroy it by uncontrolled
feeding of AFR AFR
Main burner running with 6 different fuels

Solid:
Coal
Pet Coke
Wood
Plastic/Fabric/paper
Liquid:
Waste Solvent
Waste oil
Disturbances in LSF due to introduction of AFR
Disturbances in AR due to introduction of AFR
Disturbances in SR due to introduction of AFR
Disturbances in ASR due to introduction of AFR
A reminder: ASR = Alkaly Sulfur Ratio

Na2O K2O Cl
+ -
62 94 71
ASR =
SO3
80
Disturbances in ASR due to introduction of AFR
Alkali spalling in the upper transition zone
Is the ASR in kiln feed “under control”?
After the coffe brake we sill look at some „case studies“ using EDA to draw
useful conclusions from data analyses.
 CASE STUDIE 1
BURNABILITY AND COATING BEHAVIOUR
 3 different data sets were
distributed
Liquid
NUM Datum LSF () SR () AR () Phase
1450°C (%)
1 1.1.12 0:00 95,9 2,04 1,26 30,1
2 1.1.12 1:00 95,8 2,05 1,26 29,9
3 1.1.12 2:00 95,7 2,06 1,26 29,9
4 1.1.12 3:00 96,5 2,09 1,25 29,6
5 1.1.12 4:00 96,2 2,06 1,26 29,6
6 1.1.12 5:00 96,0 2,08 1,27 29,7
7 1.1.12 6:00 96,3 2,07 1,26 29,7
8 1.1.12 7:00 96,1 2,07 1,26 29,6
9 1.1.12 8:00 95,1 2,04 1,29 30,5
10 1.1.12 9:00 96,5 2,07 1,25 29,6
11 1.1.12 10:00 96,3 2,06 1,26 29,7
12 1.1.12 11:00 96,3 2,08 1,25 29,8
13 1.1.12 12:00 96,5 2,10 1,26 29,3
14 1.1.12 13:00 95,9 2,07 1,27 29,6
15 1.1.12 14:00 95,4 2,05 1,26 30,0
16 1.1.12 15:00 96,4 2,10 1,27 29,2
17 1.1.12 16:00 96,1 2,07 1,27 29,6
18 1.1.12 17:00 95,6 2,09 1,28 29,6
19 1.1.12 18:00 96,2 2,09 1,28 29,5
20 1.1.12 19:00 95,0 2,03 1,29 30,6
21 1.1.12 20:00 96,5 2,11 1,28 29,2
22 1.1.12 21:00 95,8 2,08 1,29 29,6
23 1.1.12 22:00 96,5 2,11 1,29 29,2
24 1.1.12 23:00 95,2 2,09 1,31 29,8

AVERAGE 95,99 2,07 1, 27 29, 70

Maximun 96,50 2,11 1, 31 30, 63
Minimum 94,95 2,03 1, 25 29, 19
S T A NDA RD DEVIA T ION 0,455 0,020 0, 015 0, 349
The LSF and SR data are to be
ploted in the burnability chart

DATA SET 1
Liquid
NUM Datum LSF () SR () AR () Phase
1450°C (%)
1 1.1.12 0:00 95,9 2,04 1,26 30,1
2 1.1.12 1:00 95,8 2,05 1,26 29,9
3 1.1.12 2:00 95,7 2,06 1,26 29,9
4 1.1.12 3:00 96,5 2,09 1,25 29,6
5 1.1.12 4:00 96,2 2,06 1,26 29,6
6 1.1.12 5:00 96,0 2,08 1,27 29,7
7 1.1.12 6:00 96,3 2,07 1,26 29,7
8 1.1.12 7:00 96,1 2,07 1,26 29,6
9 1.1.12 8:00 95,1 2,04 1,29 30,5
10 1.1.12 9:00 96,5 2,07 1,25 29,6
11 1.1.12 10:00 96,3 2,06 1,26 29,7
12 1.1.12 11:00 96,3 2,08 1,25 29,8
13 1.1.12 12:00 96,5 2,10 1,26 29,3
14 1.1.12 13:00 95,9 2,07 1,27 29,6
15 1.1.12 14:00 95,4 2,05 1,26 30,0
16 1.1.12 15:00 96,4 2,10 1,27 29,2
17 1.1.12 16:00 96,1 2,07 1,27 29,6
18 1.1.12 17:00 95,6 2,09 1,28 29,6
19 1.1.12 18:00 96,2 2,09 1,28 29,5
20 1.1.12 19:00 95,0 2,03 1,29 30,6
21 1.1.12 20:00 96,5 2,11 1,28 29,2
22 1.1.12 21:00 95,8 2,08 1,29 29,6
23 1.1.12 22:00 96,5 2,11 1,29 29,2
24 1.1.12 23:00 95,2 2,09 1,31 29,8

AV ER AGE 95,99 2,07 1,27 29, 70

Maxi m un 96,50 2,11 1,31 30, 63
M i ni m um 94,95 2,03 1,25 29, 19
S T A NDA RD DEVIA T ION 0, 455 0,020 0,015 0, 349
 DATA SET 1

LSF () SR () AR ()
The first point Point for example
95,9 2,04 1,26

95,9

2,04
 For the coating behaviour we plot
the points in the same way on the
coating conditions grap
DATA SET 1
Liquid
NUM Datum LSF () SR () AR () Phase
1450°C (%)
1 1.1.12 0:00 95,9 2,04 1,26 30,1
2 1.1.12 1:00 95,8 2,05 1,26 29,9
3 1.1.12 2:00 95,7 2,06 1,26 29,9
4 1.1.12 3:00 96,5 2,09 1,25 29,6
5 1.1.12 4:00 96,2 2,06 1,26 29,6
6 1.1.12 5:00 96,0 2,08 1,27 29,7
7 1.1.12 6:00 96,3 2,07 1,26 29,7
8 1.1.12 7:00 96,1 2,07 1,26 29,6
9 1.1.12 8:00 95,1 2,04 1,29 30,5
10 1.1.12 9:00 96,5 2,07 1,25 29,6
11 1.1.12 10:00 96,3 2,06 1,26 29,7
12 1.1.12 11:00 96,3 2,08 1,25 29,8
13 1.1.12 12:00 96,5 2,10 1,26 29,3
14 1.1.12 13:00 95,9 2,07 1,27 29,6
15 1.1.12 14:00 95,4 2,05 1,26 30,0
16 1.1.12 15:00 96,4 2,10 1,27 29,2
17 1.1.12 16:00 96,1 2,07 1,27 29,6
18 1.1.12 17:00 95,6 2,09 1,28 29,6
19 1.1.12 18:00 96,2 2,09 1,28 29,5
20 1.1.12 19:00 95,0 2,03 1,29 30,6
21 1.1.12 20:00 96,5 2,11 1,28 29,2
22 1.1.12 21:00 95,8 2,08 1,29 29,6
23 1.1.12 22:00 96,5 2,11 1,29 29,2
24 1.1.12 23:00 95,2 2,09 1,31 29,8

AV ERAG E 95,99 2,07 1,27 29,70

M axim un 96,50 2,11 1,31 30,63
Mi ni m um 94,95 2,03 1,25 29,19
S T A NDA RD DEVIA T ION 0, 455 0,020 0,015 0,349
COUNT 24 24 24 24
Plot the two graphs with the information on your data sets

Please use the next 10 minutes for doing so

Burnability Chart Data Set 1
Burnability Chart Data Set 1, average point
BURNABILITY CHART DATA SET 1
Variable N Mean Minimum Maximum
LSF 24 95,99 94,95 96,50
SR 24 2,07 2,03 2,11

LSF MAX
LSF MIN
SR MAX
SR MIN
BURNABILITY CHART DATA SET 1

POINTS WITHIN THE REGION OF

DIFFICULT BURNABILITY
EASY-NORMAL DIFFICULT TOTAL
24 0 24
100% 0% 100%

Variable Max-Min Area

LSF 1,54833
0,12
SR 0,07667
Burnability Chart Data Set 2
Variable N Mean Minimum Maximum Std Dev Max-Min Area
LFS 24 88,75 85,82 93,08 1,48534624 7,254565822
1,3
MS 24 2,05 1,94 2,13 0,05425465 0,185349066
Variable N Mean Minimum Maximum Std Dev Max-Min Area
LFS 24 98,45 94,50 101,00 1,59907639 6,5
7,2
MS 24 3,94 3,40 4,50 0,44298761 1,1
 OPC clinker white cement clinker

These 3 clinker types were produced by a Cement type II clinker

single rotaty kiln in a cement plant. Due (astm)
to current low market demand for OPC in
the region, they produce special clinker
types to use the installed production
capacity of the kiln!
Can this „visualization“ help us in judging what kind of
refractory bricks we need in the kiln?

Burnability bevaviour Coating behaviour

ADDITIONAL EXAMPLES
Clinker samples each hour, chemical analysis every 8 hours.

Physical Average
(MIX)

1 Analysis per shift

Enero 2013
FEBRERO 2013
Marzo 2013
Abril 2014
Mayo 2013
Junio 2013
Julio 2013
Agosto 2014
septiembre 2013
Octubre 2013
Noviembre 2013
Diciembre 2013
Enero-diciembre 2013 (all analyses)
 Enero-diciembre 2013
All data Average (1 point)

Variable N Variable Mean

LFS 1004 LFS 92,4
MS 1004 MS 2,6

By looking at the average, we miss the information that all data contains. We can
not see it! We make it invisible!
But unlike clinker, raw meal fed to the kiln is analized each hour!

1
2
How does it look like if we use
HOUR DATE

1.1.14
1.1.14
0:00
0:01
Sample

1
2
LSF () SR ()

complete
complete
AR ()

chemical analysis
chemical analysis
Liquid Phase
1450°C (%)

all these data for our

3 1.1.14 0:02 3 complete chemical analysis
4
5
6
7
1.1.14
1.1.14
1.1.14
1.1.14
0:03
0:04
0:05
0:06
4
5
6
7
It means complete
complete
complete
complete
chemical analysis
chemical analysis
chemical analysis
chemical analysis

24
8 1.1.14 0:07 8 complete chemical analysis

burnability analysis?
9 1.1.14 0:08 9 complete chemical analysis
10 1.1.14 0:09 10 complete chemical analysis
11 1.1.14 0:10 11 complete chemical analysis
12 complete chemical analysis

chemical
1.1.14 0:11 12
13 1.1.14 0:12 13 complete chemical analysis
14 1.1.14 0:13 14 complete chemical analysis
15 1.1.14 0:14 15 complete chemical analysis
16 1.1.14 0:15 16 complete chemical analysis
17
18
19
20
1.1.14
1.1.14
1.1.14
1.1.14
0:16
0:17
0:18
0:19
17
18
19
20
complete
complete
complete
complete
chemical analysis
chemical analysis
chemical analysis
chemical analysis
analysis
21
22
23
24
1.1.14
1.1.14
1.1.14
1.1.14
0:20
0:21
0:22
0:23
21
22
23
24
complete
complete
complete
complete
chemical analysis
chemical analysis
chemical analysis
chemical analysis
per day
Kiln feed burnability enero -diciembre 2013

a
v
g
Why is the picture so different?

Raw meal looks much more difficult to burn than clinker!

RAW MEAL CLINKER

There are other influences on the chemical composition of
clinker Filter
dust Coal Ash

Kiln
Feed
BURNER
 Chemical composition of clinker calculated from chemical
composicion of raw meal and coal ash (average values)

L
S
F

SR
How important is the influence of filter dust?
Filter
dust Coal Ash

Kiln
Feed
BURNER
How important is the influence of filter dust?
Filter
dust Coal Ash

Kiln
Feed
BURNER

SOURCE: HOLCIM
Options for kiln dust handling
To cement mill
Kiln
dust Sold as fertilizer
Other uses

X% A
Y %B HOMO
Z %C SILO
RAW MILL
RAW
MATERIALS
clinker
How does the burnability of the raw meal output looks like?

Did homogeneization improve the

burnability of the raw meal?
X% A HOMO
Y %B SILO
Z %C RAW MILL

clinker
How does the burnability of the raw meal output looks like?

How do we measure
homogeneization achieved?
X% A HOMO
Y %B SILO
Z %C RAW MILL

clinker
Homogenization degree

SD in SD out

X% A HOMO
Y %B SILO
Z %C RAW MILL

clinker
 SD in
Homogenization degree =
SD out
SD in SD out

X% A HOMO
Y %B SILO
Z %C RAW MILL

clinker
New definition for Homogeneization degree = A1/A2 ?

A1

A2
Coating conditions Coating conditions
kiln feed clinker

Coal ash influence is not visible Coal ash influence is visible

Clinker melt quantity

Source FLS
THERMAL LOAD
Definition
Thermal load is the heat flow throug a cross sectional area.
In metric units it is usually expressed in Gcal/m2-Hr

It can be calculated from:

1. Kiln output (MT/Hr)

2. Specific energy consumption of the kiln (Kcal/Kg clinker)
3. kiln diameter.
Or from
1. fuel input (Kg/Hr or m3/Hr)
2. the energy content of the fuel (Kcal/Kg or Kcal/m3)
3. kiln diameter
Thermal Load depends mostly from the clinker production
system.

Source FLS
Thermal load is normally calculated based on the AVERAGE
VALUES
Example: In a cement plant the thermal load at the burning zone was given as 3,12
Gcal/m2-Hr.

BASED ON
HEATING VALUE OF COAL 5.500 Kcal/Kg
COAL INYECTION RATE AT THE MAIN BURNER: 50% OF TOTAL COAL

These are average values on long term basis (1 year)

In real life however, flow rate adjustments are made almost on an
hourly basis!

HOUR FUEL RATE (TM/Hr) Meal rate (TM/Hr)

1 8 120
2 8,5 110
3 9 100
4 11 120
5 9 140
6 12 150
7 10 130
Mass flows into the kiln: raw meal and coal

KILN FEED
MT/HR
AVERAGE
128

TOTAL COAL FEED MT/HR AVERAGE

11,19
Does the average value inform us about the situation?

MT/HR
KILN FEED
AVERAGE
128

TOTAL COAL FEED MT/HR AVERAGE

11,19
Causes for this:

• 8 different local coal suppliers

• Every local supplier has his own mine
• The coal from each mine has ist own
characteristics: As a result the plant
• Ash content, Humidity, Calorific value operating personnel can
• 3 suppliers deliver imported coal (better quality but not control energy
more expensive) delivery to the kiln!
• The plant does not have coal blending installations
• Coal analyses are made once a week
 Energy content of 1 Kg of coal in dependence with moisture
and ash content

Kcal

%
water

% ash
Calorific value of 1 Kg/Hr of coal with changing ash and water
content. (Normal distribution assumed for coal parameters)

Coal mass folw rate constant = 1 Kg/Hr

Thermal load during one kiln turn

3 RPM = 1.5 million turns/year

coating

bricks Temperature on the internal surface °C

Kiln shell
Final remarks
• Try to develop your own „parsimonial models“ at your plants for the parameters you
would like to analize.
•
• Whenever possible, do not assume your data follow a model. Instead, use graphs to
uncover the behaviour pattern of this parameter IN YOUR PLANT

• When possible, use the original data (all) and use statistical models only in the cases
where you know the model fits.

thanks for your attention and…

enjoy your time at Refratechnik!