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Before explaining the control variables one has to understand first the meaning of a variable and a controller. So what is the meaning of a variable? A variable is a physical quantity that can be measured and /or changed; like weight, pressure, temperature, speed, level, flow, etc. What is a process control? A process control is the regulation of the physical variables to obtain a desired end result.
1- to maximize production.
2-to achieve maximum energy efficiency.
Apart from this the kiln operator should be trained also to make visual inspection of the burning zone The interference of dust coming from the grate cooler with the secondary air, shifting of the burning zone caused by change in burnability of the raw mix or change flame
characteristics, may affect the reading of the pyrometer without any real significant
change in the burning zone condition and temperature. T.V cameras in the kiln hood are there to help the operator to see part of the burning zone, However kiln interior after the flame area, color of the clinker and its granulation size, intensity and momentum of the flame, the type of coat in the burning zone etc, are not revealed by the cameras.
Viewing kiln from the kiln-hood It is quite dangerous to look at it without protective glass Appearance of clinker The visual inspection of the kiln hood can give an indication of the quality of the clinker by the size and color of the hot clinker If the clinker is overburned, it is burned in a hotter atmosphere, the cascading movement of the clinker bed in the burning zone
Whenever the flame is shortened the dark feed will move in the direction of the kiln outlet. When the kiln feed is harder to burn than usual and the flame is shortened and when kiln material loading is higher, then the dark bed moves toward the kilns outlet
1- Clinker color
2- Clinker size 3- Type of cascading movement of the clinker under the 4- flame itself. 4- Feed bed before the directly before the flame area 5- Dark feed position 6- Appearance of secondary air coming from the cooler and the quantity of dust in it 7- Coating condition
Now if a kiln works steady at maximum production yet with more than 3% oxygen or the
kiln works with deficiency of oxygen of 0.7% then in such condition the kiln works in a stable condition, therefore there is no point in introducing any major changes because this may upset the kiln.
The moves in such condition should be delicate and in a slow but steady way, so the balance of the kiln would not be disturbed. The strategy in such condition is to think first what to do, then starts the process of fine-
tuning in a way not disturbing the stability of the kiln in any way. The time between each
small change and another should be not less than one hour. The whole process of fine-tuning should take from 10 to -16 hrs. With the other control variables in consideration the, following are the basic steps to follow as regards exit gas control: Secure sufficient oxygen and no carbon monoxide in the kiln atmosphere. Stabilize the kiln oxygen and make it level off and stay within a definite narrow range.
Optimize by fine-tuning the oxygen in the kiln in small steps to bring the oxygen level
to the range of 1-1.5% for optimum kiln efficiency.
There is a relation between the burning zone temperature and the concentration of NOx in the kiln atmosphere. When the temperature of the flame of the main burner changes in the burning
zone.
Also when the Oxygen in the main burner increases in the burning zone, the NOx concentration increases. In any rotary cement kiln it is nice to work in an efficient way by making the kiln work with as short burning zone as possible i.e. short flame and high flame temperature that in turn means high NOx content. Therefore as a general rule if the kiln work with say 1500ppm of NOx then start to be 2000ppm then the kiln tends to: have more draft i.e. excess Oxygen. may starts to have higher burning zone temperature.
If a kiln works normally with 1600ppm of NOx concentration in the kiln out
let, then the concentration goes down to 600ppm so that indicates the following: - there is loss of oxygen in the burning-zone. - the burning-zone temperature is lowering and starts to cool down. -the operator should not wait until reduction condition prevails in the burning zone but when the concentration of the NOx starts to decrease he should stop that
It is the duty of the kiln operator to stabilize the oxygen percent after lit- up
of the kiln at a level below 5% Oxygen at the kiln inlet gas analyzer.
CO up down down
CO2 down up up
NOx down up up
Decreases
Flame Temp. Feed rate Calcine Decreases Increases Increases Decreases
down
down up
up
-
down
up down
down
up down -
increases
decreases increased Decreases
B.Z. is heating up
B.Z. is cooling down B.Z. is heating up B.Z. is cooling down B.Z is heating up B.Z is cooling down B.Z is cooling down
Decreased
Higher than normal Lower than normal
B.Z is heating up
heating up cooling down
The kiln operator should control the fuel rate on the basis of the following variables: First: the burning zone temperature
Since the kiln speed in this condition is greatly reduced and since the visibility is
greatly reduced, the operator will think that the burning zone is of very low in temperature and he will leave the fuel rate very high for a long time in the kiln without alteration, waiting for the burning zone to clear. In most cases the kiln will be very hot in the burning zone and the burning zone will be in an overheated condition. The following are to be considered during such condition
Change in the homogeneity of the kiln feed and change in the standard deviation of
say L.S.F. or silica modulus. Change in the fuel chemical composition or in its temperature in case of fuel oil. Change in calcination degree coming from the precalciner.
Kiln inlet temperature will start to increase, but this is undesirable, since
this temperature should be held within 20C. Reducing the I.D. fan speed will help reducing this increase in temperature of the kiln inlet. Reducing kiln draft resulting from I.D. fan speed decrease, will make the oxygen content less in the kiln exit gas and there will not be enough oxygen for fuel to complete combustion
What is the effect of slower kiln speed on the cooler and secondary and tertiary air temperature?
when the operator decreases kiln speed, less material will enter the cooler. The direct result will be lower secondary and tertiary air temperatures and the under grates pressure will decrease
When should the operator decide to increase the kiln speed again in the time of upset periods in the kiln?
Never increase kiln speed before there is definite sign of burning zone
warming up, due to less feed coming to the kiln burning zone. The
behavior of the operator during this period should be as follows: Never hold the kiln on very low speed until the kiln reaches normal clinkering temperature. Start increasing the speed as soon as there is a sign of warming up of the burning zone. The more the kiln speed increases, the smaller should be the increments
and the longer the time intervals between each speed increase.
The operator should remember that: The way the kiln speed is increased is the most important factor in getting the kiln into stable conditions again
1- EXAMPLE
An operator started to increase the kiln speed in large steps at a time of 15rph i.e 0.25rpm, until the kiln reached 150rph i.e.2.5rpm, then he extended the time between each speed increment and also he carried out the increase in smaller steps. The rate was 9rph i.e.0.15rpm from150 to186rph
i.e.3.1rpm, 6rph from 186 to 198rph i.e. 3.3rpm and 3i.e.0.055rph from 198 to
210rph.i.e 3.5rpm. Time interval is irrelevant here because it depends on many factors we cant put into consideration during explaining this example.
EXAMPLE 2:
In the last example if the kiln operator started to increases the speed say at 0.5 rpm for a short period, then he went at 1rpm then quickly jumped to 2 rpm then to 3rpm and finally to 3.5 rpm then surly he will be obliged to backup on the kiln speed since the burning zone was not ready for these speeds. Since every time he increases the speed the kiln inlet temperature will drop, he therefore has to start reheating the kiln-burning zone all over
again.
EXAMPLE 3:
Here in this example the condition is opposite to what the second example showed: The operator waited too long to increase kiln speed. The result he suddenly
found that the burning zone gained heat very rapidly, forcing him to
increase kiln speed in large increments and in short time intervals. In such case full kiln speed can be maintained but very soon the kiln would be overloaded and the operator had to slow the kiln speed and eventually decreased feed
requiring increasing fuel rate to the kiln. Any increase in the fuel rate will require an
adjustment in kiln fuel rate and an increase I.D. fan speed. Both should be increase in a manner equal to that practiced in increasing kiln speed.
To keep the cooler controlling parameters in such a way that protect the cooler
components from overheating.
higher the resistance and require more pressure and force from the fan to
push the air through this bed.
obtain and maintain a constant clinker bed depth by keeping the under grate
pressure constant regulating coolers grate speed.
stage.
Both of them are drawn form either the kiln hood or in some cases the tertiary air is drawn form the middle of the roof of the first stage of the grate cooler. This ensure that the temperature of the secondary air to be higher than the tertiary air. Secondary air temperature has a direct influence on the shape of the flame and the point of ignition of the fuel; therefore irregular secondary air
This can simply be explained if all other factors are remained unchanged as follows: When the grate cooler speed is reduced the clinker speed is lowered, the
direct result will be higher clinker bed thickness and the air will find more
chance to absorb more heat from the clinker in the cooler and visa versa. When the cooler speed is increased the clinker bed is lowered and the chance of cooling air to absorb heat will decrease resulting in lower secondary and tertiary air temperature.
Clinker grain size and its effect on secondary and tertiary air
temperature:
For example consider a kiln in an upset condition and the clinker produced was either small nodules, or in worst case condition is dust. The operator in this condition would reduce kiln speed; so amount of clinker discharged to the kiln is reduced. This would lead to lower secondary air temperature.
The operator should never attempt to hold the secondary air temperature At its normal operating level in an upset condition in the kiln And the clinker is dusty or having lower liter weight
Temperature of clinker discharged from and its effect on secondary and tertiary air temperatures
By changing the character of the main burner flame, the burning zone can be shifted very near to kiln nose ring outlet, thus the clinker can be discharged to the
cooler very hot, and so the secondary air temperature will be higher.
Controls of secondary air and tertiary air tempera To raise secondary air temp Decrease cooler grate speed Increase clinker bed depth in cooler Increase size of clinker particles Increase amount of clinker Burn closer to the nose ring of the kiln to reduce secondary air temp increase cooler grate speed decrease clinker bed depth in cooler decrease size of clinker particles decrease amount of clinker burn further back in the kiln
Kiln speed
1- If all other factors remain stable without change and the operator increases the I.D. fan speed then the kiln inlet temperature increases. 2- If all other factors remain stable without change and the operator increases the fuel rate to the kiln main burner then the kiln inlet temperature increases. 3- If feed rate decreases then the kiln inlet temperature increases.
If the operator decreases I.D. fan speed, decreases fuel rate or increase feed
rate, the kiln inlet temperature increases.
changes at both the kiln inlet and the kiln out let i.e. burning zone.
the air in side the kiln either becomes higher or lower depend on the change in
the draft. The main cause of changing the draft in kiln inlet is changing the speed of the I.D. fan or the speed of the by-pass fan.
9.
One of the most important factor in the control of the feed into the kiln is the accuracy of the kiln raw meal feed weigh-feeder i.e the dosing system is reliable and working properly.
The factors which are determine the kiln feed rate are
Kiln speed Kiln cross-sectional feed loading or volumetric load Kiln cross sectional thermal loading What is the relation between kiln speed and the kiln feed rate? 1- If the feed rate changed but kiln speed is kept constant, the burning zone conditions is remains unchanged from 25 to30 minutes until the different feed rate
arrives to this zone. After a short time, the kiln inlet temperature will start to
change making it necessary to readjust the I.D. fan speed and fuel rate
2- If the feed rate held constant and kiln speed is changed, there will be an immediate reaction in the burning zone and the kiln inlet temperature and this will demand an adjustment in I.D. fan speed and fuel rate in the same time
But when the operator after achieving stable condition in the kiln try again to add
more feed and what are the criteria to be questioned before he takes such act? The operator or kiln manager can try to add extra tons to the kiln production when : He has additional grinding capacity in the raw grinding department to cover the additional kiln feed and/or enough raw meal in kiln feed storage silos. The kiln operates in stable condition over reasonably extended period of time
with stable burning zone temperature and kiln inlet temperature prior to the
intend feed increase. The oxygen reading in the kiln inlet is above 1.5 for at least one shift. The black feed in the burning zone, during the last shift is consistently located behind or directly under the end of the flame inside the kiln. In the addition to the excess oxygen the kiln has, it is preferably to have some reserve rpms in the I.D. fan speed to be utilized if needed.
It is necessary that the kiln department manager evaluate what effect the
proposed change will have on the overall prospects of kiln condition, fuel
efficiency, clinker size, burnability and adjustments that may have to be made to fuel rate, I.D. fan speed, kiln speed, and other variables.