FLSmidth Cement Services

Solving Operational Issues

Kiln Back Spillage in Dry Process Applications
by
William M. Lewis– General Manager of Cement Services
Sathish Krishnamoorthy- Manager of Commissioning Services
Cement Services Division
F.L.Smidth Inc.

ABSTRACT
As Cement Plants strive for ever higher production rates, a trend has developed where as kilns are seeing
higher degrees of kiln inlet loading or filling. Due to increased kiln inlet loading and coupled with an
increased use of cheaper (higher sulfur content) fuels, the sensitivity to kiln feed end spillage is increasing.
This problem has been experienced regardless of the kiln geometry and can adversely affect both the
production rate and the pyro-process availability. In this paper we will examine case studies in which
moderate to severe kiln back spillage was encountered. Presented will be several causes for kiln back
spillage and the resulting solutions.

In resolving these problems, FLSmidth gained specific experience which can be shared with our valued
customers.

INTRODUCTION
Kiln Back spillage is a very serious problem that normally results in the reduction of the kiln feed rate (or
even kiln shut down) due to severe fugitive emissions and creation of a personnel safety hazard. In addition
to this, kiln back spillage can cause damage, wear and premature failure of the kiln inlet seal and kiln
support tire / roller surfaces.

In troubleshooting a number of kilns with moderate to severe back spillage, it has been found that the major
causes can be categorized into five basic areas:

1. Running the kiln too slow for a given feed rate - exceeding the Maximum Inlet Volumetric Loading
2. Kiln ring development / Feed Shelf build-up
3. Pre-heater feed shelf or kiln tail ring refractory failure
4. Improper kiln tail ring casting position in relation to the preheater tower
5. Material skew in the feed pipe from the bottom stage cyclone
Noticeably not listed above is failure of the kiln inlet seal. The kiln inlet seal’s primary function is to
minimize false air entrainment into the back end of the kiln. It also acts to prevent fugitive emissions of
dust from this area. Under normal operating conditions the seal will only see fugitive dust (from the
process) during those times when the process goes to a slight positive pressure. Any material that spills
back into the seal housing (inlet cone on older kiln systems) is directed back to the kiln via the lifters in the
seal housing, before exiting the seal area.

The difficulty in trying to apply a complete material seal in this area comes from the various movements
associated with the kiln. On a standard two pier kiln, the inlet end will expand axially ~ 50mm, on a 5 pier
kiln this can be as much as 150mm. In addition to this, the kiln can float up and down hill 10-20mm total.
Along with this axial movement, a certain amount of radial run out is expected. When combining these
movements with the temperature and abrasiveness of the material entering the kiln, the most logical
approach from a design stand point then becomes engineering the interface of the kiln and preheater to
prevent material back spillage into the seal area.

Figure 1 and 2 are examples of two inlet seal configurations

Figure 1 Figure 2

Spillage from the seal can be classified into two groups:

1. Minor or transient spillage which occurs either because the floating section of the kiln seal hangs up
on the PH feed hood neck allowing the small amount of ever present dust to escape through the gap
(pneumatic seals) or due to overpressure (positive pressure) blowing dust though any crack or
crevice.
• If the inlet seal is gapping then we must look into the alignment of the seal and integrity of the
mechanical parts.

2. Major spillage of material occurs when the amount of material entering seal lifter area exceeds that
which can be transported via the lifters back into the kiln inlet.
• On pneumatic seals- Material floods the seal, material gets trapped in the space between the
seal housing (inlet cone) and the plate that makes up the floating section on the PH feed hood
 neck and due to minor axial run out of the kiln (acting as a kind of pump) the floating section is
forced “hydraulically” away from the kiln, opening the seal.
• On the newer lamella type seals- Material flows directly into a hopper and feed pipe to a
concrete containment area.
Material then spills in a constant stream, the temperature and abrasiveness of the material act
together to prematurely wear all the seal components. When pneumatic seals are utilized, the flex
hose providing air to the seal cylinders is damaged at the lower cylinders, which cuts the air
pressure disabling the seal.

In almost all cases of major spillage, the issue is not really whether the seal failed causing spillage but
rather that the spillage occurred and damaged the seal.

In certain worst case scenarios an enclosed hopper with induction system has been used to contain and
redirect the material back to the process, due to the severity of material spillage.

Kiln Volumetric Loading

In order to understand the fundamental causes of kiln back spillage, we should look into the basics
regarding volumetric loading of a kiln.

From a design and process stand point, kiln volumetric loading is normally expressed as a function of total
material load over the total available kiln volume, for example: Metric Tons per Day per Cubic Meter
(MTPD/M3).

However, in order to understand the cause and remediation of kiln back spillage, it becomes necessary to
look at the maximum inlet volumetric loading as a percent of the available volume.

For all practical purposes the kiln is just a rotating cylinder with a restriction at the feed end. The cylinder
is placed horizontally on a fixed inclination (slope). The amount of allowable volumetric loading (before
experiencing back spillage) is then determined by the size (diameter) of the feed end restriction and the
angle of inclination that the kiln is set to. Considering that the slope of the kiln is fairly minute (3.5 % to
4%) then, the Maximum (or achievable) Volumetric Loading of the kiln prior to back spilling is most
dependent on the kiln inlet restriction.

The difference between the inside diameter of the kiln and the inside diameter of the kiln inlet restriction
thus determines the maximum percent volumetric loading of a kiln at the inlet.

A basic calculation can be made to define this in the same manner that we calculate the % charge in a ball
mill:
% Maximum Volumetric Loading = A / (PI * D2 / 4)
Where as:
A (Area of load in- meters2) = 0.5 * (D / 2 * L – C *(D / 2-h))
D (effective inside kiln diameter in- meters) = Diameter inside kiln refractory
d (effective inside diameter of kiln inlet restriction in- meters) = Diameter inside inlet refractory
H (Free height to inlet restriction in- meters) = (h / D + 1/2) * D
h (center distance to inlet restriction in- meters) = (D – d) / 2
L (length of arc in- meters) = 0.01745* D * Q
C (chord width in- meters) = 2 * ((D / 2)2 - h2)0.5
Q (Load Angle in- degrees) = ACOS (2 * h/D) * 180 / PI
PI =3.142

H
D
d
Q h

A (area
of load)

D Kiln Volumetric
d
Loading

Kiln Inlet

Figure 3
The next step to understanding at what point the kiln will back spill, is to calculate the Actual Inlet
Volumetric Loading for a given feed rate and kiln rotational speed (The volume occupied by the material
divided by the total volume available).

• For the purpose of these investigations the material characteristics through out the kiln are used.
This means that we calculate the % volumetric inlet loading (with regards to density) and kiln
retention time considering the entire clinkering process.
• This approach does not take into account the fact that the material is not completely fluid like. The
material at the kiln inlet will tend to spread out of the normal “area of load” when subjected to
kiln rotation. This gives some safety with regards to the actual point where back spillage occurs
although, experience has shown that this safety is counteracted by the fact that the material is
normally at a lower density right at the inlet.
• With this understanding, the below calculation gives a viable mathematical model to
understanding the fundamental principal of Actual Inlet Volumetric Loading.

To calculate the Actual Kiln Inlet Loading we use the following:

% Actual Kiln Inlet Loading = Tmly / (PI * D / 4)2
Where as:
Tmlv (Total Material Load Volume- m3/m) = Tml / MD
Tml (Total Material Load per meter- kg/m) = ML / KL
MD (Material Density- kg /m3) = Approx. 1400 (or 1.4 t / m3) for pre-calciner
ML (Material Load- kg) = PR * RT
KL (Kiln Length in meters) = Total Kiln Length
RT (Retention Time- minutes) = (23* KL) / (R * D * S)
PR (Production Rate- kg / minute) = (Metric tons per day *1000) / 24 / 60 * (1+ (1-%CL))
R (Kiln speed- RPM) = actual kiln rotational speed
S (Kiln Slope- %) = actual kiln slope in percent- Normal 3.5% 2 pier kilns and 4% three pier kilns.
%CL = Calcination degree of kiln inlet material

Utilizing these equations we can then compare the % Maximum Volumetric Inlet Loading with the %
Actual Volumetric Inlet Loading to determine:
1) Whether the kiln is rotating fast enough for the given feed rate?
2) What effect wear or refractory failure at the kiln tail ring can have regarding spillage?
3) What effect ring development can have both in terms of thickness and placement of ring?
4) Along with studying the throat and riser gas velocities, a determination of what modifications to the
inlet to achieve higher loading prior to spillage can be made.

Case Study One

Plant A Improper kiln tail casting position in relation to the preheater tower.

1) Investigation into kiln back spillage-At Plant A, severe kiln back spillage was experienced
during start-up of the pyro process. The kiln was a standard three pier kiln with a twin string separate
line precalciner preheater tower. The kiln would spill until 80% of the full rotational speed was
reached.
a) As the kiln started back spilling from the very first start-up, ring development was ruled out as a
potential cause.
b) The speed to feed ratio played an important role in the back spillage as the kiln was hyper
sensitive to conditions seen at start-up in regards to both the lower speed to feed ratios and the kiln
expansion.
c) The process was stopped and an inspection of the inlet area was made.
2) Cause-It was found that the Kiln position in relation to the preheater tower (in particularly the kiln
riser feed shelf) was incorrectly placed 100 mm down hill of its normal position. This reduced the
normal 150mm overlap of the PH inlet feed shelf castings to the kiln tail ring castings. It is this overlap
that ensures material is dropped into the kiln rather then the kiln seal. See figure 4.
 Overlap: minimum 150 mm

Figure 4
3) Solution- The kiln feed shelf castings were extended 100 mm with a second set of modified castings
welded to the first. The inlet refractory was recast at a slightly lower inclination to accommodate the
longer castings.
a) The back spillage was completely eliminated with out need of major modification.

Case Study Two

Plant B Kiln ring development.

1) Investigation into kiln back spillage-At Plant B severe kiln back spillage was experienced 3
months after start-up. The pyro process incorporated a standard 3 pier kiln with a two string inline
precalciner preheater process. A kiln gas bypass system was utilized due to a high input of pyretic
sulfur in the raw materials.
a) Both the Preheater feed shelf and kiln tail ring castings had been recently checked for both proper
height and overlap. Refractory failure was ruled out. In addition to this, the kiln position was
checked in relation to the PH and found to be unchanged and correct.
b) Changing the kiln feed to speed ratio made little difference in the amount of spillage seen. The
kiln speed was taken to the maximum 3.8 rpm and the feed rate was reduced to 60% of full
production with out reducing the amount of spillage.
c) Material flow into the feed shelf area was checked and found to be positioned correctly at bottom
dead center of the feed pipe.
d) The feed shelf area was checked for build up that could direct feed improperly toward the sides of
the feed shelf. Although this area experienced build up, removing the build up had no effect on the
spillage.
e) Temperature profiles of the kiln shell were taken and compared to previous measurements, a
decrease in temperature (40-500 C) was found at the very end of the kiln.
f) It was suspected that a ring had formed in the kiln. In order to do an inspection, the kiln was crash
stopped and the draft was adjusted to give a clear view of the entire kiln (while still glowing red)
 from the discharge end. A ring was seen near the inlet but, the actual location and size could not
be ascertained from so far away. In order to get a better view of the ring, the kiln riser inspection
doors were opened and wood pallets thrown into the kiln inlet. As the wood pallet would ignite
and burn, a clear view of the kiln ring could be seen. This method works much better than spot
lights as it allows lighting from inside the kiln, giving a much better perspective of size and
location. The ring was located at the kiln inlet restriction and had formed a dam forcing material
into the seal. See figure 5

Kiln riser inspection door

Kiln Ring

Figure 5
g) The ring was removed utilizing a 12 gauge shot gun and the kiln was put back into service with
out spillage, but this was only a temporary solution as the mechanism behind the ring formation
had yet to be found.
2) Cause- To understand the specific mechanism for ring development and its effect on back spillage,
location is extremely important. The location of this ring was right at the kiln inlet prior to the normal
area of formation of the liquid phase and clinker minerals. A sample of the ring material was taken and
no significant chemical differences were found between it and the material that accumulates in the kiln
riser area. That is to say that the ring chemical composition was similar to the kiln feed with elevated
levels of potassium (2%) and sulfur (7-9%). Several theories exist regarding the mechanisms for kiln
ring formation, which we will explore in a little more detail further in this paper. As for this particular
ring, due to the proximity of the ring to the inlet and the excess sulfur content of the raw material
(causing an extreme sulfur/ alkali in balance) it was deduced that the ring development was a result of
forming excess Calcium Sulfate (CaSO4). As mentioned above, the build up location will depend on
the specific temperature, oxidizing conditions and presence of dust in the process. In essence the point
at which sulfur related build up forms can move from the riser into the kiln as was the case here.
a) Build up in a pre-calciner system that occurs in the riser or smoke chamber is often the result of
formation of excess calcium sulfite (CaSO3) or calcium sulfate (CaSO4). Both calcium sulfite and
sulfate are very volatile and have low evaporation temperatures (high evaporation factors). When
formed in the pyro-process they tend to significantly increase the volatiles (in this case sulfur) in a
continuous loop (cycle) thus accumulating in the system. As mentioned above, a kiln bypass was
incorporated in the system to act as a valve to release a certain amount of the sulfur. The %
bypass was run at its highest level (approximately 30%) to lessen severity of the sulfur cycle. But,
 due to higher amounts of sulfur input to the system, coupled with a harder burning kiln feed (high
presence of insoluble silica + 45 microns, quartz) it became very important to maximize the
amount of sulfur exiting the kiln as Potassium and Sodium sulfates (K2SO4, Na2SO4). These alkali
sulfates have a high evaporation temperature (low evaporation factors) and once bound with the
alkalis; the sulfur then exits the system with the clinker.
b) In order to combine the highest levels of Potassium and Sodium with Sulfur a strong oxidizing
condition must exist. As the amount of excess air at the kiln inlet (expressed in % excess oxygen)
drops, the content of Sulfur Dioxide (SO2) in the kiln gases increases. The rate of increase for the
SO2 in kiln gases is extremely sharp in the 1%-3% excess O2 range due to the tendency to form
CaSO4 rather then the alkali sulphates K2SO4, and Na2SO4. As the content of SO2 increased in the
kiln exit gases, so too did the content of Sulfur in the lowest stage meal seen as SO3.

CaO(s) + ½ O2 (g) + SO2 (g)
K2O(s) + ½ O2 (g) + SO2 (g)
kiln
Na2O(s) + ½ O2 (g) + SO2 (g)
kiln
CaSO4 (s) Decomposes in the kiln burning zone
K2SO4 (s) reverts back at higher temperature exits
Na2SO4 (s) reverts back at higher temperature exits

3) Plant B was equipped with a SO2 channel at the kiln inlet gas analyzer. This coupled with empirical
data gathering showed that when the SO2 was greater then 50% of the analyzers full range in the kiln
gases, the % SO3 of the bottom stage material would increase. It was proven that should the SO3
content of the bottom stage material exceed 3.2% for 24 hours a ring would develop. See figure 6 SO3
ring correlation
Plant B
Correlation between SO3 in PH cyclone-4 and kiln inlet ring

Date Time East West average Report on kiln inlet ring

SO3 SO3 SO3 6/25/01 4:24 97.8% 2.79 96.9% 2.45
Calcination Calcination
6/26/01 14:01 97.8% 3.06 98.0% 3.07
5/04/01 10:40 96.2% 2.12 97.2% 2.02 6/26/01 2:14 91.4% 2.90 95.2% 2.83
5/10/01 15:44 97.6% 3.02 97.1% 2.96 6/27/01 13:49 96.9% 2.70 98.2% 2.43
6/27/01 2:04 94.4% 2.51 98.7% 2.61 2.72 SO3 Is controlled < than 3 until 27 June
5/15/01 14:06 97.9% 3.78 98.6% 3.78
6/28/01 13:27 98.4% 3.01 96.9% 2.72
5/16/01 15:58 97.6% 3.94 97.6% 3.60 6/28/01 1:57 98.1% 3.50 97.1% 3.26
5/16/01 1:35 99.4% 3.53 98.4% 3.36 6/29/01 1:54 96.5% 3.31 94.7% 3.04 3.07 Knocked out kiln ring at 10:10hrs on
5/17/01 16:56 96.0% 3.88 95.1% 3.54 6/30/01 9:10 93.9% 3.44 95.9% 3.39 29-June-01 during kiln stoppage
7/01/01 8:10 94.5% 3.21 93.6% 3.24
5/17/01 1:30 96.9% 3.41 96.2% 3.61 7/01/01 4:00 98.2% 3.29 99.2% 3.28
5/18/01 19:00 95.8% 3.82 96.1% 3.96 7/01/01 23:10 95.7% 4.10 98.3% 3.87 3.39 Kiln stoppedat 9:15 hrs on 2-July-01
5/18/01 3:09 96.6% 3.44 95.5% 3.23 7/02/01 23:22 98.6% 3.54 98.2% 3.19 due to ring at kiln inlet.
7/03/01 11:40 97.9% 3.16 95.4% 2.85
5/21/01 14:07 98.9% 2.75 99.8% 2.65
7/03/01 18:49 98.3% 3.14 96.4% 2.80
5/21/01 2:40 98.8% 3.86 95.6% 3.79 7/03/01 2:41 98.1% 3.29 98.1% 3.08
5/23/01 13:50 99.0% 1.56 99.2% 1.79 7/04/01 13:32 97.3% 3.48 94.0% 3.05
7/04/01 23:00 98.0% 3.70 98.0% 3.42 3.22 Knocked ot kiln ring at 14:05 hrs on
5/23/01 1:22 99.4% 2.25 99.2% 2.19
7/06/01 13:50 98.7% 1.84 98.1% 1.84 5-July-01 during kiln stoppage
5/24/01 13:03 97.8% 2.70 97.8% 2.53 7/08/01 8:22 99.2% 1.95 96.8% 1.91
5/25/01 16:09 98.5% 2.83 98.9% 2.52 7/08/01 3:03 99.0% 2.08 98.9% 1.93
5/25/01 3:36 99.2% 3.19 98.6% 3.06 7/09/01 15:20 98.2% 2.07 98.3% 2.01
7/09/01 20:46 97.6% 2.08 97.4% 2.08
5/27/01 4:00 97.5% 3.73 98.5% 3.67 7/09/01 3:48 97.1% 2.09 98.5% 1.92
5/28/01 20:00 98.0% 3.53 97.9% 3.10 7/10/01 4:06 97.1% 2.09 98.5% 1.92
5/29/01 3:10 98.3% 2.31 98.6% 2.42 7/11/01 10:45 97.7% 2.37 98.3% 2.40
7/11/01 22:18 93.8% 2.22 98.1% 2.36
5/30/01 18:00 98.7% 2.88 99.0% 2.75 7/11/01 2:56 97.2% 2.16 97.2% 2.67
5/30/01 3:00 98.3% 3.14 95.0% 2.92 7/12/01 14:00 98.1% 1.89 98.4% 1.97
5/31/01 4:00 98.8% 4.16 98.8% 3.71 7/12/01 20:55 98.0% 2.16 97.0% 2.03
7/12/01 2:14 97.7% 2.27 98.5% 2.21
6/03/01 17:17 98.3% 4.22 97.5% 3.57
7/13/01 11:00 97.6% 2.13 96.7% 1.94
6/05/01 0:55 97.6% 4.20 97.6% 4.19 7/13/01 3:00 97.5% 2.45 98.9% 2.33
6/08/01 8:51 97.9% 4.22 98.0% 3.96 3.21 Kiln stopped at 1:55 hrs on 10-June-01 7/14/01 9:30 98.6% 3.02 98.6% 3.22
7/15/01 13:37 97.0% 2.73 98.5% 2.58
6/16/01 10:23 94.6% 3.23 98.2% 2.88 due to ring at kiln inlet.
7/15/01 2:16 95.1% 2.65 94.7% 2.54
6/16/01 2:11 98.8% 3.08 98.9% 2.86 7/16/01 15:35 98.2% 2.15 98.7% 2.07
6/16/01 5:59 96.9% 2.62 97.7% 2.45 7/16/01 4:34 97.0% 2.58 94.4% 2.58
6/17/01 11:35 98.3% 3.08 99.1% 2.86 7/17/01 13:25 97.5% 2.87 98.7% 2.66
7/18/01 10:49 98.6% 2.48 98.5% 2.41
6/17/01 18:20 97.2% 2.60 98.3% 2.48 7/18/01 17:13 99.5% 2.51 98.8% 2.44
6/18/01 10:46 95.8% 2.37 97.2% 2.36 7/18/01 1:53 95.2% 3.42 97.2% 3.39
6/18/01 1:15 99.7% 2.28 94.1% 2.29 7/19/01 1:57 98.7% 2.89 98.8% 2.79
7/20/01 10:26 97.0% 2.95 98.3% 3.02
6/19/01 4:21 97.7% 3.41 97.2% 3.15 7/20/01 23:03 98.5% 3.20 96.6% 2.79
6/20/01 15:00 98.6% 3.38 90.6% 3.68 7/21/01 23:00 98.7% 3.12 98.0% 2.90
6/21/01 20:00 97.1% 2.57 97.3% 2.46 7/21/01 6:00 98.3% 2.76 98.3% 2.55
7/22/01 13:00 97.3% 2.58 97.9% 2.54
6/21/01 3:25 98.4% 3.11 98.1% 2.93 2.83 SO3 Is controlled < than 3 until 21 June 7/22/01 1:44 98.6% 2.71 98.2% 2.67
6/22/01 8:26 96.7% 3.33 96.7% 3.05 7/23/01 14:00 98.6% 2.57 98.4% 2.41
6/22/01 17:35 98.4% 3.51 98.4% 3.37 7/23/01 2:00 98.6% 2.07 99.1% 1.95
7/24/01 22:33 97.9% 2.24 98.2% 2.17
6/22/01 21:42 98.3% 3.34 97.2% 3.21 7/24/01 3:58 97.2% 2.95 97.7% 2.80
6/22/01 2:50 98.3% 3.16 98.2% 3.12 7/25/01 15:30 97.9% 2.68 96.8% 2.68
6/23/01 9:07 97.1% 2.61 97.5% 2.55 7/25/01 22:24 98.4% 3.39 98.1% 3.18
7/25/01 3:20 99.3% 3.18 98.6% 3.16
6/23/01 23:42 98.8% 3.53 98.5% 3.26 7/26/01 11:50 97.6% 2.99 97.1% 3.07 2.48 NO KILN INLET RING SINCE 6TH JULY.
6/23/01 3:27 98.5% 3.45 98.2% 3.23 Conclusion :
6/24/01 9:06 97.7% 3.70 98.5% 3.40 3.24 Kiln stopped at 21:11 24-June-01 due to ring Observed formation of kiln inlet ring if SO3 in cyclone-4 material is more than 3.3% for extended period.

Figure 6
4) Solution- In order to prevent the formation of the inlet ring the kiln excess oxygen was maintained
above 3 %. This would prevent a high content of SO2, thus also controlling the % SO3 in the bottom
stage material. As burning zone conditions and sulfur input to the system were never constant the most
useful tool in combating the ring formation became the kiln inlet analyzer. The difficulty though was
that the inlet analyzer probe was very susceptible to plugging and deformation making its availability
very poor. As the kiln inlet gas analysis system was not working consistently the solution for this plant
was to constantly sample the bottom stage material and monitor the SO3 content.
a) Control – To obtain a better and more direct online process control of the kiln excess oxygen
level a reliable kiln inlet gas analysis system most be applied. To monitor the potential ring
formation in the kiln the SO2 can be directly analyzed and directly controlled by the oxygen level.
As the gas analysis is to be performed in the very difficult environment of a kiln inlet the question
of availability is not based on IF the probe eventually will get plugged but more on how often it
gets plugged and how easy it is cleaned out and up running again. Gas analysis system availability
will always be a function of the process conditions. Meaning; that in upsetting conditions with
periods of high SO2 concentrations plugging of a gas analysis probe is more likely. These periods
can however only be monitored with an operating gas analysis system. The gas analysis system in
that respect becomes the key to eliminating periods with upsetting conditions which can result in
kiln ring formations and plugging of the gas analysis probe system. A new FLSmidth KilnLoq
probe is made with this situation in mind, realizing that if no kiln inlet system can be maintenance
free it has to be maintenance easy. This is obtained through the introduction a new patent pending
probe design named “One Pipe” which provide extremely powerful cleaning very much like an air
blaster and easy manual cleanout in the entire length of the probe in a couple of minutes.
 Figure:7
The KilnLoq “One Pipe” design is very efficient in cleaning the probe during most conditions.
The straight pipe inside the probe is having no pressure drops or areas were material can get
stocked. Through a quick connector in the back of the KilnLoq probe a rod can be entered to
manually correct the problem in a couple of minutes.
5) Application of build up resistant refractory -To make the system less sensitive to ring
development, Plant B installed a silicon carbide refractory in the tail ring area and 2 meters down hill.
This worked to some extent in preventing the ring at the inlet but in reality moved the formation to the
end of the SC refractory.
6) Applying volumetric loading – This case also illustrated how critical the actual location of a
kiln ring can be on the severity of back spillage. When applying the calculations for both Maximum
Kiln Inlet Loading with Actual Kiln Inlet Loading and inputting a ring as a dam, we find that the
possibility of spillage increases greatly, the closer the ring is to the inlet. Depending on the kiln size,
configuration, feed rate and rotational speed it has been shown that a ring of 150-250mm thickness can
cause back spillage when located close enough to the inlet. This can be seen graphically in the
following chart (figure 8). The chart assumes a standard base width (of a potential ring) of one meter.
At each point in the kiln, the height of the ring is calculated to achieve Maximum Kiln Inlet Loading
(the point at which the kiln can potentially back spill). What can be seen is that the height of a ring at
the inlet can be relatively low and still cause spillage, where as the tolerance to a ring is much higher
as it moves further into the kiln.
 COATING THICKNESS VS KILN LENGTH FOR DESIGN %FILL

1400 28

1200 24

MATERIAL RETENTION TIME, mins

COATING THICKNESS, mms

1000 20

800 16

600 12

400 8

200 4

0 0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0

FROM FEED INLET, Meter

Coating thickness - mms Retention time - min

Figure 8

Case Studies Three and Four

Plants C and D Pre-heater feed shelf or kiln tail ring refractory failure.

1) Investigation into Back Spillage- Plants C and D experienced back spillage long after each
plant was commissioned. Plant C experienced back spillage 10 months after startup where as plant D
experienced back spillage 5 years after commissioning. Both plants incorporated standard single string
inline precalciner preheater processes. Plant C utilizes a two pier kiln and Plant D utilizes a three pier
kiln.
a) Plant C- The five before mentioned possibilities were investigated to explain the material
leakage. The feed to speed ratio was maintained correctly ruling this out as a possible contributor
i) As sulfur content had recently been intentionally raised and about the same time the kiln seal
began experiencing leakage, the possibility of ring formation or build up was investigated. A
kiln temperature profile was made, but no clear evidence of ring formation in the back
end of the kiln could be found. The shell temperature was generally even from the second
tire to the inlet of the kiln. Temperatures averaged 5000 F + or – 200 F. The plant reported that
during a short outage for power loss, the back end of the kiln was inspected through the kiln
feed shelf inspection doors, but no ring could be seen. Figure 9 is a chart showing the shell
temperature profile comparisons from a period of no spillage against a period of spillage.
 Refractory type Kiln Shell Temp
changed
900
800

Temperature Deg F
700
600
temp on 10-10
500
400 temp on 5-23
300
200
100
0
1
0
0
0
0
0
0

10 0
11 0
13 0
14 0
15 0
17 0
60
.2
.4
.6
.8
.0
.2
.4

6
8
0
2
4
6.
9.
3.
6.
9.
2.
14
27
40
53
67
80
93
Feet from feed end

Figure 9
ii) This lead to the possibility of riser build up directing material into the seal. Plant C reported
an increase in build up through out the kiln riser although, cleaning the material made no
impact on the spillage. A preliminary sulfur/alkali balance was made to understand if a
condition existed that would promote excess CaSO4 formation. The sulfur was found to be in
balance with the alkalis, the S/A ratio was 1.2 on clinker basis with 77.5 grams/100Kg clinker
excess sulfur as SO3. Problems do not normally develop until the excess sulfur is above 300
grams/100kg clinker.
Sulfur/Alkali Balance
Kiln Feed Clinker
Loss Free
% SO3 0.280 0.470 From lab
% Na 0.130 0.120 From lab
%K 0.540 0.370 From lab

Heat Consumption: 733 kcal/kg Clk from operating screen data

Coal LHV: 7254 kcal/kg Coal calculated from proximate analysis
Coal S: 1.42 % from proximate analysis
Fuel LHV: mix 7254 kcal/kg Fuel
Fuel Fired: 0.101 kg Fuel/kg Clk calculated
Sulfur Input w/Fuel As SO3: 0.359 % Clk calculated
Total Expected SO3 in Clk: 0.639 % Clk calculated
Clinker S/A Ratio: 1.20 (Normally 0.8 to 1.1) calculated

Excess Sulfur in Clinker (S/A>1.1): 77.50 gSO3/100 kgClk (Normal Maximum up to 300)
Molar ratio 1.56
iii) Cause-Refractory failure at the tail ring castings caused the problems- The possibility
of refractory failure was deemed most likely. The kiln seal did not leak for the first 6 months
of operation. Barring the sulfur increase, a change in the system had occurred. If a refractory
failure occurs at the kiln inlet restriction, then the maximum allowable kiln loading is greatly
reduced. If the feed shelf castings have failed then kiln feed will be directed into the seal. The
kiln was eventually stopped and a major refractory failure was found at the kiln inlet
tail castings.
b) Plant D – Plant D had recently seen the amount of dust in the kiln bypass double and excess dust
spillage at the kiln inlet seal, because of this the plant operators were forced to run with high firing
hood draft to maintain the inlet area as negative as possible. An internal inspection of the kiln inlet
area was conducted to ascertain those factors contributing to high kiln bypass dust loss and excess
 kiln back spillage. The feed to speed ratio was maintained correctly ruling this out as a possible
contributor. During the internal inspection the following items were found:
i) A large “Ski Slope” at the point where the lowest stage meal pipe meets the feed hood, was
created by refractory installed over an existing splash plate disturbing the material flow.
ii) Material build-up was found (partially due to failure of the right hand kiln feed shelf air
cannon) restricting the lowest stage meal pipe and worsened the disturbance of the material
flow.
iii) Wear of the feed shelf refractory, creating an uneven surface for the meal to flow into the kiln.
iv) Cause- An excessive gap between the feed shelf castings and the kiln feed inlet
restriction was found, resulting in spillage into the seal area. The kiln feed end tail
casting’s refractory had recently been cast with an inside diameter too large, thus lowering the
% loading the kiln was capable of sustaining before experiencing spill back into the seal and
lifters
v) Evidence of the presence of sulfur rings at the feed end of the kiln was found, exacerbating
the spillage into the seal area.

Excess gap (230mm) between FS castings and kiln inlet refractory Tail casting w/proper gap(50 mm)
2) Solution- In both cases the kiln inlet tail ring refractory was incorrect. In one case a failure of the
refractory had taken place. In the other case, the refractory had been cast with the incorrect dimensions.
Both cases were solved by casting the refractory to the correct dimension eliminating all spillage.
3) Applying volumetric loading- When a failure at the tail ring castings of the kiln has taken
place, a significant reduction in the degree of volumetric loading the kiln can have before back spilling
occurs. Plant D was originally designed to have 6.5% kiln inlet volumetric loading with 9” brick. To
illustrate the effects of worn tail ring castings, if the tail ring casting is reduced by 25 mm the
Maximum Inlet Volumetric Loading reduces to 6.4%, 230 mm resulted in a Maximum Volumetric
Inlet Loading of only 3.7%.

Case Study Five

Investigation into kiln back spillage - At Plant E, severe kiln back spillage was experienced two
months after startup and after two years of operation. In the interim period, the back spillage was evident
occasionally. The kiln was the new two pier kiln with a single string inline calciner preheater tower.

Kiln back spillage after two months of startup

a) As the kiln started to back spill only after two months of operation and as the feed to speed ratio
was also maintained correctly at 13.5% fill (corresponding to 6.15% inlet material load), the kiln
inlet profile (castable on the feed shelf and tail ring section) and geometry / position (kiln position
 in relation to preheater tower) was ruled out as a possibility. Further before startup, the overlap
and gap were measured physically at the kiln inlet (tail ring area) and are as expected.

b) The raw meal and coal has low sulfur and alkali content in the clinker yielding S/A ratio less than
1.1. Even with 20% pet coke firing in the calciner and with increased sulfur content, the
calculated S/A ratio is within acceptable range and so the presence of chemical impurities was
ruled out.

Sulfur/Alkali Balance Sulfur/Alkali Balance

Kiln Feed Clinker Kiln Feed Clinker

% SO3 0.072 0.420 % SO3 0.018 0.540

% Na 0.170 0.100 % Na 0.110 0.100
%K 0.431 0.540 %K 0.440 0.560

Heat Consumption: 794 kcal/kg Clk Heat Consumption: 792.3 kcal/kg Clk
Coal LHV: 6495 kcal/kg Coal Fuel LHV: 6311 kcal/kg Coal
Coal S: 1.34 % Fuel S: 1.42 %

Fuel Fired: 0.122 kg Fuel/kg Clk Fuel Fired: 0.126 kg Fuel/kg Clk
Sulfur Input w/Fuel As SO3: 0.408 % Clk Sulfur Input w/Fuel As SO3: 0.446 % Clk
%Sulfur in feed leaving stage I 0% %Sulfur in feed leaving stage I 0%
Total Expected SO3 in Clk: 0.480 % Clk Total Expected SO3 in Clk: 0.464 % Clk

Clinker S/A Ratio: 0.80 (Normal 0.8 to 1.1) Clinker S/A Ratio: 1.00 (Normal 0.8 to 1.1)
Excess Sulfur in Clinker (S/A>1.1): 0.0 gSO3/100kgClk Excess Sulfur in Clinker (S/A>1.1): 0.0 gSO3/100kgClk

S/A ratio with 100% coal S/A ratio with 20% coke in the Calciner
The coating thickness was not measured but based
c) Temperature measurements of the kiln on the spreadsheet to determine the thickness at
shell were taken during the back spillage, which this location for back spillage it is back calculated
confirmed the presence of the ring 8 – 10 meters ~ 650 mms.
from the kiln inlet @ lower transition zone. The
kiln surface temperature dropped as much as 80 oC
before tire 2 when compared to previous
measurements. The kiln back spillage was
temporarily suspended when operated at higher
speeds and lower production yielding a fill degree
of 9% – 10% (corresponding to 4.15% – 4.63%
inlet material load) facilitate diminishing the ring
thickness after prolong operation. The kiln was
inspected when it was hot and confirmed the ring
presence. Refer figure 10 and 11 for kiln shell
temperature profile and ring formation in the kiln. Figure 10
 Kiln Shell Temperature

350

300

250
Temperature, celcius

200

150

100

50

0
0 5 10 15 20 25 30 35 40 45 50
Kiln Length, meters

25-Nov 17-Dec

Figure 11

Cause – When the kiln was stopped to cast the feed shelf (damaged during the removal process of coating
in the lower transition zone) the sample of the ring material was taken and no significant chemical
differences were found between it and the clinker that is produced. This particular plant had historic
problems of ring formation in their existing kilns. The ring formation was suspected mainly due to non-
homogeneous kiln feed and complete change in chemistry when switching bays. It was also believed that
the over burning of material in combination with low C3S feed causing ring formation in the lower
transition zone. In an attempt to prevent the occurrence of ring formation and kiln inlet back spillage, the
kiln inlet temperature was also dropped below 1100 C (2010 F). With revised operating practice, no ring
coating formation was experienced for the next 3 months. An auto control of kiln feed rate with kiln speed
was used for 14% loading until the problems with ring formation in lower transition zone was experienced.
The kiln loading was decreased to 9% – 10% in steps before the coating / ring in the lower transition zone
of kiln start to strip. Since then the percent loading in the kiln was maintained at 13% to minimize the ring
formations in the kiln. The chart below (figure 12) indicates the C3S variation in clinker based on daily
averages when the coating occurred in the lower transition zone.
 C3S [Clk]

70

68

66

64

62

60

58

56
0 5 10 15 20 25 30

Figure 12

A few theories exist regarding the mechanisms for middle kiln ring formation, which we will discuss in a
little more detail. An unsuitable raw meal composition will result in middle or sinter ring formation before
the burning zone. Low C3S, high liquid content and high coating index are factors that determine the
fusion-based adhesion of these rings.

The middle rings are usually dense and hard that forms at 7 – 9 kiln diameters from the kiln discharge.
They are clinker-like in appearance and composition. The mechanism of bonding is freezing of the clinker
phase when clinker dust is carried from the burning zone and deposited on a cooler refractory surface
(usually < 1250 C) behind the burning zone. The liquid phase freezes and binds the clinker particles
together. The kiln charge material is still too fine to break up the formation at that point, and it will
continue to grow.

The sinter rings establish at the point in the kiln where the liquid phase is beginning to form, when the kiln
turns; the melt comes into contact with cooler surface and solidifies. This process repeats until a ring
forms. The above two rings are most likely to develop where there is a long flame in the kiln along with
high dust laden burning zone gas velocities (dusty clinker is produced in the kiln with high clinker C3S).

Applying volumetric loading – This case also illustrated how critical the actual location of a kiln
ring can be on the severity of back spillage. When applying the calculations for Actual Kiln Inlet Loading
and inputting a ring as a dam, we find that the possibility of spillage increases greatly, the closer the ring is
to the inlet. For these given circumstances kiln size, configuration, feed rate and rotational speed it was
shown that a ring of ~ 650 mms thickness @ 8 – 10 m mark from the inlet can cause back spillage. This can
be seen graphically in the following chart (figure 13). The chart assumes a standard base width (of a
potential ring) of one meter. Again, at each point in the kiln, the height of the ring is calculated to achieve
Maximum Kiln Inlet Loading (the point at which the kiln can potentially back spill).
 COATING THICKNESS VS KILN LENGTH FOR DESIGN %FILL

1400 28

1200 24

MATERIAL RETENTION TIME, mins

COATING THICKNESS, mms

1000 20

800 16

600 12

400 8

200 4

0 0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0

FROM FEED INLET, Meter

Coating thickness - mms Retention time - min

Figure 13

Solution – To minimize the coating development in the lower transition zone, the following operating
practice was followed that prevented the kiln back spillage.
• The kiln inlet temperature was dropped below 1100 C (2010 F)
• The kiln feed rate to kiln speed was decreased to maintain 13% fill degree (corresponding to
4.15% – 4.63% inlet material load)
• The chemical composition of kiln feed was controlled to eliminate deviation making for stable
kiln operation.
• Maintain a strong and short flame – higher flame momentum
• Optimize chemistry and mineralogy of raw mix to fire an easier burning raw mix

Kiln back spillage after two years of Operation

The kiln back spillage was severe and continuous after two years of operation. The plant experienced a
total of 200 hours downtime (~ 23% of total downtime) in six months of operation. The kiln production
also had to be maintained much below the rated levels (~80% production) due to severity of back spillage.
a) As no raw material and fuel composition changed since the startup, the possibility of chemical
impurities in relation to back spillage was ruled out. The S / A ratio in the clinker was checked and
confirmed to be less than 1.2 on clinker basis with 104 grams/100Kg clinker excess sulfur as SO3.
b) There was also a relationship to back spillage with respect to kiln fill degree (feed to speed ratio) and
as well with the cleanliness of the kiln feed shelf (but not all the time). When operated at lower Feed
to Speed ratio (< 10% fill degree that corresponds to 5% kiln inlet loading), the back spillage decreased
or stopped but this limited the maximum production from the process. Further operating the process at
low production for prolonged periods would decrease the refractory life and as well posed threat to the
life of the equipment (increased wear and tear).
c) The feed shelf area was checked for build up that could direct feed improperly toward the sides of the
feed shelf. Although this area experienced build up, removing the build up was only effective ½ the
time, and only eliminated the back spillage temporarily.
d) The riser temperature measurements indicated that the gas temperatures were extremely low on the left
side (away from the material load - kiln turns counter clockwise) and with no material diverted to the
kiln riser. There was no material buildup in the riser and the cleaning frequency has declined
considerably compared to startup. The bottom stage meal enters from the left of the kiln and even with
a straight section of ~ 3 x the meal pipe diameter, the material is skewed towards the right, due to the
location of the pipe miter. The bed thickness in the meal pipe is determined to be as per figure 15.
Initially the material entering the kiln was skewed causing some material to become entrained in the
gases (on the load side). It was believed that this was also contributing to the back spillage problem.
However, temperature measurements of the riser (during this period) indicated the opposite to be true
(see figure 14). Later examination of feed shelf area with the kiln stopped, clarified that the material
skew had affected the temperature profile during the initial commissioning period but, at this time the
major cause of uneven temperatures was due to a kink at the inlet to the feed shelf that acts as a “ski
slope” like surface.

FIELD MEASUREMENTS TAKEN AT THE KILN RISER 06-Nov-06

1086 C 1185 C

1045 C 1219 C
8'above burners
1087 C 1145 C 1280 C

1061 1027 C 1229 C 1228

1060 C 1260 C

level with burners

1173 C

1080 1100 C 1270 C 1265

950 C 1065 C

950 C 1085 C
Kiln inlet
1018 C

Note With 1580 F at stage V exit and no calciner gas

Figure 14 Riser temperatures during severe back spillage
Figure 15: Measuring bed thickness in the meal pipe entering the kiln.

e) The kiln was stopped and a detail kiln inlet inspection was carried out to find the cause of the back
spillage.

i) A minor “Ski” like transition at the

point where the lowest stage meal
pipe meets the feed hood was created
by refractory when installed during a
repair, disturbing the material flow
and entraining feed in the air stream.
Refer Figure 16.

ii) The kiln feed shelf surface was

corrugated (maybe due to wear or
improper reinstallation) resulting in
material build-up, restricting the
material flow out of the lowest stage
meal pipe and worsened the
disturbance of the flow.
Figure 16: Stage V material inlet
 iii) The tail ring castable was worn badly resulting in an excessive gap ~ 290 mm between the feed shelf
castings and the kiln feed inlet, resulting in spillage into the seal area. The kiln tail ring castable was
installed before startup and had not been repaired since then. The wear in the castable thus lowered the
% loading resulting spill back into the seal and lifters. See pictures below for the condition of the kiln
inlet castable. (Figure 17)

Applying volumetric loading – This case also illustrated how critical it is to maintain the kiln inlet casting to
avoid severity of back spillage. When applying the calculation for Maximum Kiln Inlet Loading with worn opening
at the kiln inlet, we found that the possibility of spillage increased greatly when the kiln inlet loading was greater
than 4.8% percent load (corresponding to 10.5% process fill). With the operating condition then, the process is very
sensitive for ring formation in the kiln inlet area and can be seen graphically in the following chart Figure 19.

COATING THICKNESS VS KILN LENGTH FOR OPERATING 4.8%FILL

600 24

500 20
MATERIAL RETENTION TIME, mins
COATING THICKNESS, mms

400 16

300 12

200 8

100 4

0 0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0

FROM FEED INLET, Meter

Coating thickness - mms Retention time - min

Figure 19

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Solution – Several modifications were carried out during the shutdown to eliminate the back spillage completely.
All the modifications that were performed were listed below and the explanations given for the respective
modifications.
• The feed end air seal assembly showing the kiln throat ID was increased from standard 7.5% to 8.6% kiln
inlet load. The nominal gap of 75 mms between the kiln throat ID and the bottom of the feed shelf was also
revised to 50 mms gap to provide higher kiln inlet percent load. This modification will effectively allow
the process to operate at higher material fill degree and also be less susceptible for back spillage at higher
coating thickness both at the kiln inlet and in lower transition zone.
• Plant E revised the feed shelf castings with to be 100 mm longer and as well the configuration (refers figure
20) to facilitate installation of feed shelf castings without removal of castable over the kiln tail ring thereby
decreasing down time. The refractory on the feed shelf was recast at a slightly lower inclination to
accommodate the longer castings, changing the feed shelf slope ~ 2 degrees. This modification will
facilitate placing the material away from the kiln throat section and forward movement of flow.

Figure 20: Existing design and new design for the feed shelf casting

• The kiln feed hood section was also modified, extending the existing 143 degree castable shelf to ~ 160
degree castable shelf. This extension incorporated two feed shelf castings one on either sides. See figure
21. The modification was followed due to the tendency for the material to skew away from the center
when it exits the last stage meal pipe. Also, raising the side cheeks would guide the material further to the
kiln rather than allowing them to the seal / lifters etc.

Page 21 of 23
 Figure 21: Kiln feed shelf casting arrangement

• The complete refractory on the feed shelf and lower riser section was recast with THOR AZ during the
shutdown. The THOR AZ castable is dense, withstands high temperature and abrasion yielding smooth
surface of the feed shelf. This minimizes the kiln feed shelf buildups that direct the material flow towards
the seal (side cheeks).
• Since the above modifications, the plant is in operation for the past ½ year with little to no back spillage.
When ever the spillage scenario occurs, it was primarily due to a massive ring formation in the lower
transition zone. The current max kiln inlet loading is 8.6% (corresponding to process fill degree of 18.8%)
much higher than ever required to operate the kiln. With the modification performed, the kiln is
considerably less sensitive to back spillage even with max kiln production ~ 30% higher than the original
capacity. A trend for the coating thickness at given kiln length position at modified conditions is as shown
below. Figure 22
Figure 22
COATING THICKNESS VS KILN LENGTH FOR DESIGN MAX 8.6%FILL

1600 32

1400 28
MATERIAL RETENTION TIME, mins

1200 24
COATING THICKNESS, mms

1000 20

800 16

600 12

400 8

200 4

0 0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0

FROM FEED INLET, Meter

Coating thickness - mms Retention time - min

Page 22 of 23
Conclusion
When experiencing an operational problem first and foremost one should analyze and evaluate all the potential
causes. In dealing with the kiln back spillage problem, at times it seemed that there was no rhyme or reason to the
spilling. It is a fact that nothing happens miraculously and then disappears. For this reason, the investigation must be
made in a logical manner, in which all potential causes are identified. In a systematic manner we then eliminate
potential causes until we are left with the answer.
In dealing with this particular problem we have learned that
1) It is seldom that the problem originates from the kiln inlet seal assembly. The seal’s purpose is to prevent false
air in leakage and minor fugitive emissions. In most cases, the seal is destroyed by the severe material leakage.
This severe material leakage being caused by internal problems.
2) The integrity of the refractory and castings at the inlet are especially critical. The majority of spillage related
problems are caused by the failure or improper casting of refractory at the inlet.
3) The location of kiln ring development plays an important role in the problem. The closer the ring is to the inlet
the greater the chance of spillage, even with relatively small ring heights.
a) Ring development can be combated. Through understanding the specific mechanisms of ring development,
actions can be taken to minimize the occurrence and severity of the ring development.
b) Modifications can be successfully incorporated to make the process more tolerant of ring development. By
studying the design and understanding the gas velocities through this area, the kiln can be made less
sensitive to back spillage.
4) Geometry of the feed pipes into the feed shelf can affect the spillage issue. More importantly the amount of dust
entrainment in the gases exiting the kiln can be greatly affected by the condition of the feed shelf and lowest
stage meal pipe.

FLSmidth Cement Services works in all areas of Cement Manufacture in troubleshooting and resolving operational,
mechanical and electrical problems. As FLSmidth gains knowledge and experience we are pleased to share this with
our customers.

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