ATC REPORT

Activity: AUDIT/PROCESS
China / Huaibei Plant
KILN AUDIT
by: ATC P&E Team
04~08Dec2007

Distribution:
Region
BU
Plant
ATC
Other
Codification

Rosy Wang /Wang ZhiHonh( for plant distribution)

Renaud de Belmont // G.Benveniste
TSP/HUA400/NQI/20080205/HUA kiln audit

Table of Content
A.

Executive Summary............................................................................................................... 2

B. Main Report............................................................................................................................ 4
B.1. Introduction......................................................................................................................... 4
B.2. Work Done:........................................................................................................................ 4
B.3. Analysis / Argument / Conclusions.....................................................................................5
B.3.1
Safety alert.................................................................................................................5
B.3.2
Plant information.........................................................................................................5
B.3.3
Heat and mass balance..............................................................................................8
B.3.4
Cooler performance..................................................................................................10
B.3.5
Preheater and precalciner inspection........................................................................12
B.3.6
Gas analyzer and false air........................................................................................15
B.3.7
NOx and SO2........................................................................................................... 18
B.3.8
Burner audit.............................................................................................................. 19
B.3.9
Volatile balance.........................................................................................................22
B.3.10 Fan efficiency............................................................................................................ 24
B.3.11
Operation.................................................................................................................. 25
B.3.12 Quality and Sample analysis.....................................................................................26
B.4. Recommendations............................................................................................................ 27
B.5. Acknowledgements.......................................................................................................... 29
B.6. References....................................................................................................................... 29
B.7. Appendices....................................................................................................................... 29

A.

Executive Summary

Objectives
Training of Lafarge ATC P&E engineers
Make an extensive kiln heat and mass balance
Run tests of general interest for technical assistance in LSO
NOx abatement Environmental protection standards
A 7 day report was sent after the audit based on the [presentation given to the plant (see
attachment)
Results and Findings
Global heat consumption was 777kcal/kg-ck @ clinker production 1145.5tpd. Main KPIs are as
following:
Kiln parameters:
actual
target
clinker production
1145.5 tpd
Clinker C3S & clinker CaOl
777kcal/kg-k
specific heat consumption
730
efficiency of top cyclones
94.9%
>92%
ID fan power consumption
12.45kWh/t-k
ID fan efficiency
53%
>70%
kiln/calciner ratio
38.6 : 62.4
>40% at kiln
Decarbonation
90~95%
primary air ratio
16%
12%
total false air (based C1
18.31%
<10%
outlet)efficiency
Cooler
recovery ratio:
0.67
0.70
cooling efficiency:
0.94
0.95
k-factor:
1.39
1.30
138kcal/kgck
Cooler loss:
<120
45.82t/m2.d
cooler load
<45
2.19N3/kg-k
cooling air specific
~2.2
The kiln operates at full capacity. The bottlenecks are ID fan (PH pressure drop), precalciner size
(1.4s residence time), EP Fan (false air).
Improvement Opportunities
Through implementation of following actions about 44kcal/kg-ck heat loss could be saved.
Table of actions:
No.

Action

Priority

Light the blower room of coal workshop

Fix the air cannon inlet valve at kiln inlet chamber

Reduce NOx and increase free lime by reducing overburning

Changing the TAD refractory

Reduce primary air of kiln burner, apply new burner

Arrest false air along the kiln, preheater and raw mill line.

Optimize cooler operation

ID fan optimize

prepare SOP for operators

10

10 rules of kiln operation

1
Page 2 of 31

Based these recommendations, the plant should establish a detailed action plan going through
priority level, actions, and expected results, starting and finishing dates, resources/ responsibilities.
In report recommendation chapter, one page indicates for each action ATC point of view regarding
objectives, way to implement, reference documents, persons in charge, cost and expected results.
Emergency Actions
None
Further Work
As part of the de-bottlenecking project, it is recommended to use the de-bottlenecking tool.
As ARL analysis could not be sent on time, an addendum will be written later taking into
account the finding of the analysis.
Miscellaneous topics
The plant has stated that one of their bottlenecks is the kiln drive capacity. We thus suggest testing
increasing the kiln filling rate (thus reducing the ratio kiln speed/kiln feed) to reduce the torque
induced by the materials.
Mainly due to limited residence time in the precalciner, the plant has got high CO at preheater
outlet, thus negatively impacting heat consumption. We have to consider increasing the coal feed at
kiln (thus decreasing coal feed at precal), although this is linked to various other issues (IDfan
capacity, pressure drop in the preheater).

Page 3 of 31

B.

Main Report

B.1. Introduction
The Huaibei plant kiln audit was carried out during 3-7Dec, 2007. ATC & Plant process team, DJY
process manager, and Shunfa process engineers participated. This report focuses only the HUA
plant related results.
Objectives of audit
- Training of Lafarge ATC P&E engineers

Make an extensive kiln heat and mass balance, including:

Dust weigh-check, clinker drop test
Volatile balance
Clinker temperature using calorimetric box
Secondary air temperature mapping in the kiln hood
Preheater survey
Run tests of general interest for technical assistance in LSO:
Test Chinese-made gas analyzer
Challenge ATC BO Process measurement techniques and equipment
Get data for on-going plant issues:
Preheater survey Preheater modification
NOx abatement Environmental protection standards
ID fan efficiency De-bottlenecking

Agenda of audit
- Monday (preparation)
-

Tuesday (heat and mass balance)

Wednesday (PH survey, Dust sampling perturbated because kiln condition)

Thursday (PH survey, Preca Efficiency, Volatile Balance, False Air, Analysers benchmark)

Friday (quick report and debriefing)

B.2. Work Done:

Field measurement
Fan efficiency
Preheater survey
Temperature, pressure, and gas flow of the pyro-system
Cooler survey
Sample analyses
Raw mix (raw mill outlet)
K1450 (burnability)
Various chemical analyses (pyretic S, C, alkalis, Cl)
Preheater feed
C5 outlet material (hot meal dry // wet)
SO3, alkalis, Cl, unburnt C
Clinker
Microscopy
DX-Rietweld method
BB10 (grind ability)
Page 4 of 31

Various chemical analyses

Coal
Ultimate analysis
Remarks
Possibility to benchmark plan lab and ARL on some analyses
Opportunity for the plant to get some non-frequently carried out analyses results (pyretic
sulfur)
More comprehensive result interpretation can be done once results are received

B.3. Analysis / Argument / Conclusions

B.3.1 Safety alert
Safety alert 1
Theres no lamp in the blower section of coal mill workshop. During the day, its dark
inside the room.
Recommendation: Identify the reason, and then take corresponding measures to make
the room with sufficient light. Since it is in a coal grinding shop, we must have the
appropriate sealed light.
Safety alert 2
At the kiln inlet chamber, compressed air inlet
valve of air cannon cant be locked (see photo
on the right)
Recommendation:
Improve
LOTOTO
according to Lafarges Safety Regulation.

B.3.2 Plant information

Main equipments of Huaibei plant pyro system
Table 3.2.1: main equipments of pyro system

Equipments
ID fan
Preheater
Kiln
Cooler
Cooler EP fan

Specification
Flow 168000 170000m /h, Pressure 7840Pa, Temp.340C , gas density
1.4kg/Nm3, Motor YR4504, 560KW, 1500r/min
TC F7 type // 5 stage preheater: C1(x2): 3400mm, C2&3: 4500mm,
C4&5: 4800mm
PC: 4400mm, TAD: 1800mm
=3m, L=48M // Slope: 3.5 // speed 0.696~4.8rpm // auxiliary speed
0.2189rpm
2.13m (width) 13.5m (length) // 3.41~13.64strokes/min // moving distance
127mm // eff. Area 25m2 // Tinlet=13001400C, Toutlet=70Cambient
Fan: Y47311, NO18D // anti.45C, 145000m3/htotal pressure 1529Pa
Motor Y315M28
3

Page 5 of 31

Production during the audit days (plant information)

- Monday
Operation as normal, clinker output was 1180 t.
during kiln audit, decrease wind power out of the 5th cooler fan
- Tuesday
Operation as normal, clinker output was 1192t [Note: drop test:1145.5tpd].
During kiln audit, decrease wind power out of the 5th cooler fan
- Wednesday
Kiln main motor halted at 10:36; renewed feed in kiln at 11:43.
Decreased feed in kiln, from 14:00 to 16:30 (coal mill main motor)
Kiln feed get back 75t at 19:00.
Clinker output: 0:00-8:00 400t; 8:00-16:00 204t; 16:00-24:00 316t
Variation of operation was observed when shift changing.
- Thursday
Operation as normal, clinker output was1154t
During kiln audit, decrease wind power out of the 5th cooler fan.
Variation of operation was observed when shift changing
Notes:
- Raw material stagnate at preheater tube stack, air blaster was not opened to clean it for
auditors safety. (abnormal)
Fig 3.2.1: Kiln operation trends on 3 Dec

Page 6 of 31

Fig 3.2.2: Kiln operation trends on 4 Dec

Fig 3.2.3 : Kiln operation trends on 5 Dec

Page 7 of 31

Fig 3.2.4: Kiln operation trends on 6 Dec

We can see that Dec 3rd and 4th production was steady, but a stoppage of kiln happened in
Dec 5th. Hence, it is consider that the conditions of operation were representative on Tuesday
4th during the heat and mass balance.
B.3.3 Heat and mass balance
The production of Dec 4th is 1192tpd as recorded. But, by drop testing, the kiln production during the
audit (Dec 4th) was 1145.5tpd. Discrepancy is 4%.
The global heat balance was 777kcal/kg-ck during the audit (to be updated till the coal ultimate
analysis will be carried out). And it is higher for a 5-stage precalciner kiln.
Coal feed was 127 kg/t-ck during the audit and fuel split was 38.6% to the kiln and 62.4% to the
calciner.
Table 3.3.1: Mass and Heat Balance
Global Balance
input
cooling air
raw feed
wet content
coal feed
wet content
primary air
false air
SHC
Sum

Nm3/kg-k
2.196

0.070
0.275

kg/kg-k
2.839
1.645
0.003
0.122
0.005
0.091
0.356

kcal/kg.C kcal/kg-k output

0.240
6.82
clinker
0.192
18.95 vent air
1.001
0.21
ph exit gas
0.263
0.87
ph fly dust
0.999
0.14
wall loss
0.240
0.59
vaporisation
0.240
0.86
clinkerisation
777.1
805.56 Sum

10
60
60
27
27
27
10

5.061

Nm3/kg-k
1.397
1.479

kg/kg-k
1.000
1.806
2.140
0.115

120
260
315
315

0.003

5.061

kcal/kg.C kcal/kg-k
0.190
22.84
0.243
114.03
0.253
170.56
0.229
8.27
71.50
596
2.06
418.63
807.90

Main reasons for high SHC include:

- Higher wall losses
Especially the TAD surface temperature got 174C, which leads 7.22 kcal/kg-ck increase of heat
loss offsetting that at the surface temperature being 90C. ATC will provide a short note on this
issue.
Table 3.3.2: TAD surface temperature
C1

C2

C3

C4

C5

PC

TAD

Kiln

cooler

Wall losses

HUA

63

58

67

98

94

94

174

251

68

8.85%

HCN

102

52

66

74

80

90

90

265

65

4.58%

Page 8 of 31

Table 3.3.3: Heat loss of the TAD

Diameter

Length

Surface

Shell surface

Ambient t

Wind velocity

Heat loss

kcal/kgCk

1.70m

53m

283m2

174C

8C

2.5m/s

686159kcal/h

14.28

53m

90C

8C

2.5m/s

338946 kcal/h

7.06

1.70m

283m

- High CO at preheater outlet

Higher CO reflects an incomplete combustion until top cyclones of the preheater. 2400ppm CO
would cause more heat loss of about 10.7kcal/kgCk. As stated at table 3.3.5, CO at PH outlet was
higher than C5, is related to the precalciner combustion condition due to less resident time(1.4sec),
and maybe due to carbon content in the raw mix (to be checked by raw mix chemical analyze).
However, C5 CO is high because low residence time in precalciner.
Table 3.3.4: Gas analysis at Dec 4
Huabei Audit
Heat lost with CO
Dec-07
CO Dunbar
ppm
% v/v
Nm3/h CO kcal/h CO
CO PH
2400
0.24%
168.8
509817
CO Kiln
500
0.050%
10.0
30200
PH Nm3/h
70339
Kiln Nm3/h
20000
Pkcal/Nm3 CO
3020
CO + 1/2O2 --> CO2 + 67.6kcal/mol
kg/h ck
47708.33

kcal/kgck
10.69
0.63

Table 3.3.5: Gas analysis at Dec 4

Measurement at 4th Dec

Content

O2 %

CO ppm

NOx ppm

Kiln back end

3.15

500

2650

C5 outlet

3.37

1280

850

ID fan inlet

4.67

2400

800

- High O2 at preheater outlet

Also more oxygen (4.7%) in the exhaust gas, it is well known that the more the excessive air, the
more the heat loss. If the oxygen density be less (3%), the heat loss would be reduced by about
10kcal/kg-ck. One reason of the high O2 concentration is theres too much false air along the kiln
and preheater (18.6% based on preheater outlet gas). And about 7.2% comes from the preheater,
and 11.4% comes from kiln back end and kiln hood.
It was observed that O2 at preheat exit reduced to about 3.5% in the last two days of the audit,
since ID fan speed slow down a little from 13971388rpm.
Table 3.3.6: Total input air volume to kiln and preheater
items

flow

unit

Comments

Kiln Primary air

0.055

Nm3/kg-ck

15.85% based on PA & SA

Secondary air

0.292

Nm3/kg-ck

Calciner Primary
air

0.016

Nm3/kg-ck

Tertiary air

0.506

Nm3/kg-ck

False air of PH

0.106

Nm3/kg-ck

7.2% based on PH gas flow 1.479Nm3/kg-ck

False air of kiln

0.169

Nm3/kg-ck

11.4% based on PH gas flow1.479Nm3/kg-ck

- Higher cooler vent air temperature

Cooler vent air temperature was 260C. Its higher than normal figure (<240C). Thus the excessive
heat loss would be about 9kcal/kgck. Causes to be discussed later in cooler performance.
Page 9 of 31

Table 3.3.7: Heat loss due to vent air

Nm3/kg-k

kg/kg-k

kcal/kg.C

kcal/kg-k

vent air

1.396

1.805

260

0.243

113.94

vent air

1.396

1.805

240

0.242

105.01
8.93

- Higher clinker temperature

Clinker temperature at the bucket conveyer was measured ranging between 61~111C, average
85C, but the clinker pile temperature at silo side was 120C. In the calculation of heat balance we
took the 120C, and If we took 85C, the heat saving would be about 7.01kcal/kg-ck.
Recommendation
Based on the above analyze, total heat loss could be saved by about 44 kcal/kg-ck, and thus SHC
would be 730~735kcal/kg-ck, if following recommendations were implemented:
Reduce the TAD surface temperature to 90C through changing the TAD refractory with
Calcium Silicate Board + refractory brick.
Reduce O2: match the ID fan speed with raw feed so that reducing the O2 at PH top (~3%),
and false air as stated in the Gas analyzer and false air.
Reduce CO through: precalciner size to be checked to make sure resident time is enough
(>3.5sec)also debottlenecking project, and carbon content in raw mix to be valuated to
see if it is have relation with high CO.
Reduce cooler vent air temperature to below 240C, through optimizing operation.
Reduce clinker temperature to 70C + ambient. To be discussed following in cooler
performance.
B.3.4 Cooler performance
Findings:
Overall cooler heat loss is high 138kcal/kg-ck (see table 1.3.4.1). The heat loss that oversteps
average level comes from high clinker temperature (120C vs 85C), cooler vent air high
temperature. Other parameters see table 1.3.4.2.
Table 3.4.1: Cooler heat and mass balance

Table 3.4.2: Cooler efficiency:

Items

actual

Standard

recovery ratio

0.67

0.70

cooling efficiency

0.94

0.95

k-factor

1.39

Cooler loss

138.3

cooler load

45.8

cooling air specific

2.19

1.30

Comments
High PA to be reduced and
blowing
density
to
be
optimized

kcal/kg-ck

<120

t/m2.d

<45

OK

N3/kg-k

~2.2

OK

Reasons for the heat loss could be:

Too much blowing density in the cooling side of cooler which is related to the high
temperature of vent air, and less blowing density in the recuperating side of cooler. Cooler
blowing density is as table 3.4.3.
Page 10 of 31

High clinker temperature 120C is the silo side, but at bucket conveyer it ranged between
61~111C, average 85C.
And meanwhile, too much kiln primary air is related to the heat loss in cooler: much primary
air less secondary air much vent airmuch heat loss.

Room of improvement
As showing of the blowing density, blowing density need improving through enlarging the
fans in chamber 1# and 2# as table 3.4.3 indicated.
And re-adjust the blowing density as recommendation curve to be close to the
recommendation curve.
Reduce kiln primary air as stated in section Burner audit.
Table 3.4.4: Cooler blowing density

Table 3.4.3: Cooler fans measurement and recommendation

Items
Measurement
Recommenda
tion

Flow [m3/h]

Fan 1#

Fan 2#

Fan 3#

Fan 4#

Fan 5#

Sum

15319

17524

22943

24658

24393

104836

3664

3340

2800

1778

28771

20814

18823

17022

Pressure [Pa]
Flow [m3/h]

19575

Pressure [Pa]

Page 11 of 31

105004

B.3.5 Preheater and precalciner inspection

Preheater survey
Very high pressure loss, preheater top 818mmWG. below is the pressure drop for each
stage of the cyclones. C3, C4and C5 have high pressure drop in the cyclones.
Table 3.5.1: Preheater pressure drop

C1

C2

C3

C4

C5

Cyclone (mmWG)

58

61

100

101

94

Riser duct (mmWG)

81

83

73

65

72

Very high cyclone loading ~110 tpd/m2 (shall be <90)

False Air Control in the PH itself is very good sealing. Total false air 8.4%. But between
C4~C5 4.2%, see also the kiln inlet dust hopper connected to dust reclaiming system without
flaps (see photo Gas analyzer and false air)
No by-passes (material or gas) were detected (high velocities and very tight flaps. See table
3.5.5
De-bottlenecking to be done but only C3 is easily possible. For C3, roof can be risen by 1m;
For other cyclones, because of beam, it is not possible to rise the position of the splash box
and as a result rising the cyclone roof is difficult
Very High CO in gas - Calciner volume too small: <1.4 s (to be calculated).
Kiln outlet CO:170~555ppm. Good
C5 outlet CO: 390~3400ppm. High variability of CO.
It can be observed carbon burning in the hot meal (C5)
Raw mix carbon to be done by ARL.
Table 3.5.2: Preheater gasflow (to be updated)
Gasflow Tempe.

Cyclone 1
Cyclone 2
Cyclone 3
Cyclone 4
Cyclone 5
Calciner
TAD
kiln

Gasflow

Pressure

Size (m2)

velocity (m/s)

Nm3/kg-ck

mmWG

m3/h

m3/s

inlet

cyclone

outlet

inlet

cyclone

outlet

1.479
1.442
1.410
1.391
1.256
1.256
0.506
0.447

318
460
583
739
878
850
945
969

-818
-717
-507
-377
-226
-170
-112
-20

168726
202030
225623
259787
262552
254728
110703
98817

47
56
63
72
73
71
31
27

2.00
2.52
2.52
2.86
2.86
100.00m3
1.33
4.51

13.20
12.56
12.56
14.51
14.51

2.40
2.77
2.77
3.14
3.14

23.43
22.27
24.87
25.23
25.50
1.41sec
23.18
6.09

3.55
4.47
4.99
4.97
5.02

19.50
20.23
22.59
22.98
23.23

Precalciner Efficiency
Poor temperature profile in the riser duct; one side goes high to 950C, and the other side
just stays less than 800C.
The hot core touches the refractory in the front of the burner. To be further investigated
(transport air velocity, position ) :
Temperature profile OK in the vortex
Samples analyze to be done by ARL.
Precalciner efficiency & mapping still waiting for un-burnt carbon measurement
Decarbonation of hot meal is between 90~95%. And SO3 is steady.
Table 3.5.3: hot meal
Hours
11:00
13:00
15:00
17:00
19:00

SO3
1.73
1.64
1.67
1.68
1.68

LOI
4.83
4.14
5.2
3.74
2.58

Page 12 of 31

Decarbonation
90.78%
92.2%
90.0%
92.9%
95.2%

Table 3.5.4: Preheater survey

Page 13 of 31

Table 3.5.5: Gas by-pass and meal by-pass checking

Page 14 of 31

Fig 3.5.1: Riser Duct Mapping

Fig 3.5.2: Vertex chamber mapping

B.3.6 Gas analyzer and false air

During the kiln audit, we measured the preheater and stack gas analysis. And below is the result:

Page 15 of 31

Table 3.6.1: Gas analysis at 6th Dec. with the TESTO350pro analyzer
Content

O2

CO

NOx

Unit

ppm

ppm

Kiln back end

2.5

353

2770

C5 outlet

2.18

1380

850

ID fan inlet

3.65

2400

810

raw mill bagfilter inlet

8.97

1500

570

Bagfilter fan inlet

10.9

1570

465

Findings
False air was 7.8%in preheater above C5 outlet. Its OK.
False air was 42% between ID fan and bag filter fan. It is high, and O2 should be less than
7.5%~8.5% at bag filter fan inlet.
False air in the bagfilter was 16%. And before it 30.7% in the raw mill system.
Hence, the power consumption of EP fan to be reduced by 44kW, thats 0.94kwh/t-ck.
Table 3.6.2: power saving by reducing false air
O2

O2

False air
coefficient

ID fan -- Bagfilter outlet

3.65

10.9

41.8%

ID fan Bagfilter inlet

3.65

8.97

30.66%

Bagfilter inlet--outlet

8.97

10.9

16.04%

Future

3.65

25.1%

Power
consumption
(kW)
199

155

Recommendation
Inspect along the kiln, preheater and raw mill system and make mark of the false air when the kiln
and raw mill starting, and repair them when shutting down. See Fig 3.6.2 and fig 3.6.3
Fig 3.6.1: False air survey

Page 16 of 31

Fig 3.6.3: False in raw mill system

Page 17 of 31

Fig 3.6.2: False Air in PH

To be added flap
damper to seal fasle
air to KBE

B.3.7 NOx and SO2

Findings
NOx at kiln back end is high, 2707ppm.
Looking to NOx concentration figures, it looks as though there is post-combustion in
precalciner. Actually, the NOx reduction from kiln back-end to precalciner outlet is due to gas
dilution (more gas at precalciner outlet than at kiln back-end). In terms of kg of NOx per kg of
clinker, it does not change. CO in precalciner does not contribute to NOx reduction because
of too low residence time in the precalciner.
NOx concentration in the stack is 1108mg/Nm3 vs. 500mg/Nm3 as per Chinese standard
SO2 was not detected from KBE and preheater. Low SO2 at KBE is difficult to explain. It can
be explained by the fact that SO3/alk ratio is low. It has to be highlighted that TESTO
supplier participated to the audit with brand new equipment and still could not detect SO2
neither. This measurement shall be further confirmed once ATC gets accurate SO2
monitoring equipment.
Room for improvement
Reduce NOx at kiln BE by avoiding over-burning.
Include multistage combustion in new de-bottle necking project.
Investigate SNCR in the future.

SNCR-- Selective Non-Catalytic Reduction

Page 18 of 31

Table 1.3.6.9: NOx concentration mapping

Figure 1.3.6.1: NOx Mapping in ppm

B.3.8 Burner audit

Finding
Now the burner stands for 3 months of life time with its tip. Reason was due to wearing from
high transport air tip velocity (67 m/s).
High clinker temperature at kiln discharge (1488C) and High NOx (2770ppm KBE) was also
detected. The cause could be the high burner Specific Impulse (7.67Nh/Gcal) due to high air
velocity at burner tip. Also the high burning zone temperature resulted in high Sulfur
Volatilization factor (85%).
Table3.8.1: Kiln primary air
axial air :

0.019Nm3/kg-k

5.52%

radial :

0.013Nm3/kg-k

3.69%

transport :

0.023Nm3/kg-k

6.65%

Total :

0.055Nm3/kg-k

15.86%

Table3.8.2: gas analysis at KBE

Gas Analyzing
Kiln back end

O2

CO

NOx

ppm

ppm

2.5

353

2770

Recommendation
A new burner is suggested and the design has been done.
Page 19 of 31

The coal transportation air velocity will be reduced to 26 m/s. This will reduce the wear
degree of burner tip dramatically.
The coal transportation pipe diameter will be 105 mm.
The coal transportation air content will be reduced from 9 % to 3.5 %. This will also
contribute to SHC, NOx and Is reduction.
Fig 3.8.1: Kiln main burner calculation present operation

IMPULSION AND SWIRL CALCULATION

Plant : Huabei
Date : 04.12.2007
Name : ATCBOTeam/Yang J inBiao / Qian Feng

IMPULSION - Version on 10/04/95

CLV / Stphane THIERS

COMMENTS :

Actual Operation
OUTLET SURFACES

diameter
(mm)
198
182

AXIAL AIR
856

surface reduction %

Ext.diam. : 245
thIckness 9

227

273 m/s

210 m/s

mm2
152
120

COAL AIR
6836

180

39 m/s

67 m/s

mm2

121

100
82

78 m/s

Waste fuel
1. J acket Tube/Waste pipe
2. J acket Tube/Waste pipe

Name
Solid waste

Dia (mm)
80

Pipe speed (m/s)

0

DETAIL OF THE NOZZLE

Swirl
angle ()
35

Fins
number
12

Orifices
width
16.2
16.2

RADIAL AIR

76 m/s

15.3 (head)
10.9 (base)

Axial (if holes)

Number of holes :

Base data
Kiln system :

Fins
width
9.7 (head)
5.3 (base)
10.6
10.6

10

Fins radial
gap (mm)
0.5

Diameter :

AS

SP : no calciner, AT : air through, AS : separated air.

Heat consumption th/T KK :

1175
0.96

Inside kiln shell diameter (m) :

LCV
Kcal/kg
6100
0

Therm.energy
Gcal/h
15.27
0.00
0.00
0.00

Total (Gcal/h) :
AERAULIC MEASUREMENTS
Stat. press. in the burner (mmWG)
T in the burner (C)
Theoretical flow (Nm3/h)
Adopted flow (Nm3/h)
Bias coefficient :
Atmospheric pressure (mmWG)
Inlet air temperature
Inlet flow (m3/h)

Axial
4500
100
655
655
1.00
10204
20
703

10

PRODUCTION (T CK /j) :
% of fuel to the pre-heater :

Flow
kg/h
2503
0

rayon
raccord.
1

Total neutral combustion air (Nm3/kg CK) :

780

Heat consumption
to the main burner
Petcoke
Solid waste

194
7
133
6

16 m/s
Ext.diam. : 76
thIckness 8

1476
mm2
(surface area normal to the flow)

Radial (constant width for orifices)

Radial (constant width for orifices)
Radial (constant width for fins)
Radial (constant width for fins)

16 m/s
Ext.diam. :
thIckness
Ext.diam. :
thIckness

60
3.00

Recalculated heat consumption :

780
OK

th/T KK

15.27

Radial
400
30
379
360
0.95

Transport
2000
50
1638

Solid waste
2000
50

20
387

20
1758

20
0

RESULTS
SPEEDS
Type of flow

Axial

Radial

Transport air

subsonic

subsonic

speed

273

78

39.4

Outlet speed (m/s)

MAP/MAS
2.87

Is
N.h/Gcal
7.67

Table3.8.3: Burner air suggestion

Content of axial air

4.6%

radial
3.9%
Page 20 of 31

transport
3.7%

Total
12.2%

Swirl
0.024

Fig 3.8.2: Kiln main burner calculation New burner Design

IMPULSION AND SWIRL CALCULATION

Plant : Huaibei
Date : 16.05.2007
Name : Chandrasekar J ayaraman

IMPULSION - Version on 10/04/95

CLV / Stphane THIERS

COMMENTS :

New Lafarge Burner - Coal

OUTLET SURFACES

diameter
(mm)

surface reduction %

Ext.diam. : 295
thIckness 9

277

AXIAL AIR
223 m/s
1810

188 m/s

mm2
215
180

COAL AIR
10858

215

26 m/s

26 m/s

mm2

160

156
136

150 m/s

Waste fuel
1. J acket Tube/Waste pipe
2. J acket Tube/Waste pipe

Name
Solid waste

Dia (mm)
80

Pipe speed (m/s)

0

DETAIL OF THE NOZZLE

Swirl
angle ()
35

Fins
number
17

Orifices
width
14
14

RADIAL AIR

133 m/s

15.8 (head)
12.3 (base)

Axial (if holes)

Base data
Kiln system :

Number of holes :

Heat consumption th/T KK :

Fins
width
14.6 (head)
11.1 (base)
12.8
12.8

16

Fins radial
gap (mm)
0.5

12.00

PRODUCTION (T CK /j) :

1300

Total neutral combustion air (Nm3/kg CK) :

0.95

770

% of fuel to the pre-heater :

Inside kiln shell diameter (m) :

Heat consumption
to the main burner
Coal
Solid waste

Flow
kg/h
3077
0

LCV
Kcal/kg
6100
0

Total (Gcal/h) :
AERAULIC MEASUREMENTS
Stat. press. in the burner (mmWG)
T in the burner (C)
Theoretical flow (Nm3/h)
Adopted flow (Nm3/h)
Bias coefficient :
Atmospheric pressure (mmWG)
Inlet air temperature
Inlet flow (m3/h)

Axial
2700
100
1070
1070
1.00
10000
20
1149

rayon
raccord.
1

Diameter :

AS

SP : no calciner, AT : air through, AS : separated air.

245
15
180
10

31 m/s
Ext.diam. : 121
thIckness 8

2045
mm2
(surface area normal to the flow)

Radial (constant width for orifices)

Radial (constant width for orifices)
Radial (constant width for fins)
Radial (constant width for fins)

25 m/s
Ext.diam. :
thIckness
Ext.diam. :
thIckness

Therm.energy
Gcal/h
18.77
0.00
0.00
0.00

55
3.00

Recalculated heat consumption :

770
OK

th/T KK

18.77

Radial
1800
60
1048
891
0.85

Transport
600
60
850

Solid waste
0
50

20
956

20
912

20
0

RESULTS
SPEEDS
Type of flow
Outlet speed (m/s)

Axial

Radial

Transport air

subsonic

subsonic

speed

223

150

25.8

Objectives
to
obtain:

Fuel-Oil
Coal
Petrol coke

Content of axial air : 4.63%

radial : 3.85%
transport : 3.68%
J acket Tubes/Waste pipes 0.00%
Content of primary air 12.16%

Page 21 of 31

MAP/MAS
2.07

Is
N.h/Gcal
7.11
5
6
>7

Swirl
0.155
0.15
0.15
0.15

B.3.9 Volatile balance

Main finding
The Volatilization Factor is high 85% comparing with normal Volatilization Factor 55% of
Precalciner kiln. However, this high ratio comes from high SO3 content I the dust escaping
the kiln.
SO3 content in clinker is only 0.3% due to low SO3 in the raw meal.
The NOx in kiln backend gas is very high (average 2400ppm, max 3600 ppm). These results
indicate a high temperature in burning zone. This is confirmed by the low free lime (0.5 to
0.7%).
And sometimes material rings and clinker balls appeared in kiln from plant report, which
means plant needs take some actions to reduce volatile re-circulating in kiln. See fig 3 hereafter.
The plant reports build up in riser duct as well as seldom ring/ball formation. This can be
caused by cold false air entering through the dust reclaiming system, carbon content in C5
meal, burner flame adjustment (see November 2007 ring formation) or high alkali.
Recommendations
For short term steps, keep proper O2 content (2.5-3%) at the kiln backend, and adjust the
burner, so that decrease kiln burning zone temperature (step by step following the clinker
quality).
Try to control a short flame by new burner design and primary air adjustment through new
burner design.
Further investigations at kiln back end (iso kinetic sampling and SO2 measurement) to cross
check the information.
Table 3.9.1: The HuaiBei plant sampler data in Volatile balance 20071207 1

2 ways of dust collecting in gas was taken: one is suction pump and another is scoop.
Obviously, the SO3 content is too low in kiln dust by scoop method, maybe some material from
C5 mixed in the sample. So we discarded the sample results by scoop method.
Page 22 of 31

Table 3.9.2: The calculation of HuaiBei kiln sulphur balance 20071207

The ratio 0.15kgdust/kgck is a standard figure (see vademecum, considering that the kiln is closed
to its max capacity. Velocity was ~16m/s).
Photo 3.9.1: The volatile check area in HuaiBei kiln audit 20071207

Photo 3.9.2: The kiln backend gas dust sampling method in HuaiBei plant 20071207

Page 23 of 31

Photo 3.9.3: The Volatilization and its consequences

B.3.10Fan efficiency
Findings
The efficiency of ID fan and EP fan was inspected during the audit. And findings are:
The ID fan efficiency is too low around 53%.
To increase the efficiency to be 75%, power consumption can be reduced by 174kW, or
3.65kWh/t-ck.
As a result, specific power consumption of the ID fan is high12.5kWh/tck;
ID Fan is current kiln bottleneck.
The EP fan efficiency is ok 74%.
False air is relatively controlled in PH outlet.
Actual fan rpm was 1420 rpm compare with 1394 rpm at CCR.
The pressure drop at fan inlet damper was ~ 50 mm H2O.
Fan power was 594 kW. Motor rated power was 630 kW.
Improvement actions
Junction box at ID fan outlet tapping to coal and raw mill from this box
Supplier to check why internal recirculation (ATC can support)
Check diffuser at outlet
Remove the damper or at least one by one damper blades (check electrical and mechanical
aspect of it): potential saving 5mbar.
Fill and send Flackt fan questionnary (see in annex)
Fig 3.10.1: ID fan and EP fan measurement

Page 24 of 31

Table 3.9.1: Quick Win Fan Efficiency Calculations (ID fan)

Items

Measured,
actual

Fan speed

1420

rpm

Fan Inlet Static Pressure

-877

mmWg

Fan Outlet Static Pressure

-270

mmWg

Fan Inlet Volume

169119

m3/hr

Gas Temperature

315

Motor Power Consumed

594

Total Loss

10%

Shaft Power (calculated)

534.6

Static Pressure Difference across Fan

607

Power output

314.8

314.8

kW

Fan Efficiency (Static - Calculated)

53%

75%

To be

unit

419.8

kW
%

377.8

kW
mmWg

Table 3.9.2: Quick Win Fan Efficiency Calculations (EP fan)

Items

Measured, actual

Fan rpm

1082

rpm

Fan Inlet Static Pressure

-465

mmWg

Fan Outlet Static Pressure

-97

mmWg

Fan Inlet Volume

183250

m3/hr

Gas Temperature

151

OC

Motor Power Consumed

280

kW

Total Loss

10%

SPRS Recovery (Power Recovery)

kW

Shaft Power (calculated)

252

kW

Static Pressure Difference across Fan

367.98

mmWg

Fan Efficiency (Static - Calculated)

74%

B.3.11 Operation
SOP
-

Finding:
The plant said that they have hot kiln feeding SOP and follow it. But there is not SOP
manuals on operating desk in CCR.
The plant claims (see WXH monthly report) that it follows 6 SOPs.
- Recommendation:
Prepare SOPs and set on operating desk for operators reference by Plant kiln coach.

10 rules
- Finding:
Kiln load volume----there is not operating table between kiln speed and feeding.
Cooler clinker bed depth----O.K. is controlled through under grate pressure by manual.
Cooler cooling fan predefined table----? there is no air flow indicator on operating screen.
Kiln hood slightly negative pressure----? there is slightly positive pressure by manual
Constant oxygen in kiln back end----O.K. is between 2~4% by manual.
Constant oxygen in PH outlet----O.K. it is between 3~5% by manual.
Page 25 of 31

Constant ID fan outlet pressure----O.K. it is 150~300Pa by manual.

Fuel amount proportional to kiln feeding----? They have implemented but there is no
operating table.
Constant calcinations----O.K. Temperature on pre-calciner outlet is controlled by coal
feeding to pre-calciner manually.
Maximize production and minimize heat consumption----O.K. Maximization production is
80 t/h of raw meal.
The kiln filling rate is 12.4% (see table 3.11.1).
Table 3.11.1: kiln filling rate

Recommendation
Prepare an operation table of kiln and cooler on CCR.
Try to keep kiln hood under slight negative pressure about 0.2mbar and to observe which
changes.
Install 3 auto controlling PID loops between kiln hood pressure and cooler venting fan
speed, cooler grate speed and under grate pressure of 2nd chamber, PH ID fan outlet
pressure and EP ID fan speed. Recovery using PID loop between precalciner coal
feeding and precalciner outlet temperature.
B.3.12Quality and Sample analysis
All the samples taken for the audit were analyzed at the plant laboratory (where possible) and Asian
Regional Laboratory(to be analyzed), including some specific analyses such as Organic carbon on
raw mix and ultimate analyses of fuel.
- Clinker and raw mix chemical analysis
Clinker f-CaO mostly between 0.5%~0.7%.
Steady burning in the kiln
Over burning in the kiln
- SO3/(K2O+Na2O) of Clinker
S/K is low
Contribute to ring formation in kiln and build-ups at KBE.
- C5 hot meal
SO3 between 1.6~1.7%
LOI and decarbonation is steady
Table 3.12.1: chemical analyses of clinker and raw feed

Page 26 of 31

LOI

SiO2

AL2O3

Fe2O3

CaO

MgO

K2O

Na2O

SO3

SUM

fCaO

clinker

22.77

4.12

2.87

66.47

1.85

0.84

0.13

0.25

99.29

0.65

raw feed

35.55

14.32

2.64

1.78

43.14

1.26

0.56

0.08

0.06

99.38

35.61

Table 3.12.2: Clinker S/K

%

kgmol

Mol

K2O

0.84

94.20

0.0089

Na2O

0.13

62.00

0.0021

SO3

0.25

80.00

0.0031

SO3/(K2O+Na2O)

0.2785

Table 3.12.3: C5 hotmeal analysis

C5 hot meal

SO3

LOI

2007-12-4 10:00

1.68

2.24

2007-12-4 11:00
2007-12-4 13:00

1.73
1.64

4.83
4.14

90.76%
92.16%

2007-12-4 15:00
2007-12-4 17:00

1.67
1.68

5.2
3.74

90.03%
92.94%

2007-12-4 19:00

1.68

2.58

95.21%

2007-12-6 10:00

1.27

4.65

91.18%

2007-12-6 13:00
Average

1.59

3.26

1.62

3.83

93.91%
92.31%

Decatbonation rate

B.4. Recommendations
Action N1: light the blower room of coal workshop
Objective: work in the room with sufficient brightness
Way to implement: inspect electricity line and fix bright lamps
Reference documents: No
Plant or BU responsible: Plant maintenance team
Expected result: work with sufficient brightness.
Action N2: fix the air cannon inlet valve at kiln inlet chamber
Objective: avoid hazard to people when operating there
Way to implement: check the valve and change it with new one.
Reference documents: no
Plant or BU responsible: plant maintenance team
Expected result: the valve can be shut down completely
Action N3: Reduce NOx at kiln back end.
Objective: avoid hazard to environment regulation and overburning
Way to implement: replace new kiln burner and operate according to 10 rules
Reference documents: None
Plant or BU responsible: ATC & Plant
Expected result: Reduce NOx at KBE by 50% and meet demand of environment
regulation.
Action N4: heat preservation of the TAD
Objective: reduce the TAD surface temperature to below 100C
Way to implement: to be see further in separate report.
Reference documents: none
Page 27 of 31

Plant or BU responsible: plant process and production team

Expected result: save ~7 kcal/kg-ck of heat loss

Action N5: Reduce primary air of kiln burner and apply new lafarge burner
Objective: reduce primary air
Way to implement: new burner design
Reference documents:

PR-PYR P06-02 How

to optimize a burner final.pdf

Plant or BU responsible: ATC & Plant

Expected result: Primary air decrease to 12%

Action N6: arrest false air along the kiln, preheater and raw mill line.
Objective: reduce false air in kiln hood and backend to be <15% and false air in the raw
mill system to be <40%.
Way to implement: identify the false air source (refer to fig 3.6.1 and 3.6.2), and make
action plan. After action re-measure the false air to check the results.
Reference documents:

PR-PYR P06-09 How R-PYR 0P06-10 How

to control false air
to in
measure
the preheater.pdf
false air.pdf

Plant or BU responsible: Plant

Expected result: to reduce heat loss 10.7kcal/kg-ck and power consumption 0.94kWh/t-ck

Action N7: Optimize cooler operation

Objective: to reduce vent air temperature to <240C and clinker temperature
<70C+ambient temperature
Way to implement: install piezo ring, adjust the cooling fans ventilation and clinker depth
according to cooling air blowing density
Reference documents:

PR-PYR P06-08 How

to adjust cooling air level & distribution.pdf

Plant or BU responsible: plant

Expected result: save heat loss for 15.94kcal/kg-ck

Action N8: ID fan optimize

Objective: to increase the ID fan efficiency >75%, and save 500Pa pressure drop.
Way to implement: check the internal recirculation and diffuser at outlet and damper at
inlet.( refer to FLAKT questionnaire)
Reference documents: no
Plant or BU responsible: Plant (ATC can help)
Expected result: reduce power consumption by 3.65kWh/t-ck
Action N9: SOP prepare
Objective: uniform the kiln operation
Way to implement: prepare SOPs and place them in the CCR
Reference documents: no
Plant or BU responsible: kiln coach
Expected result: keep the kiln stable
Page 28 of 31

Action N10: 10 rules of kiln operation

Objective: stably operation of kiln
Way to implement: set kiln operation sheets for operator references.
Reference documents: SOP & 10 rules of kiln operation
Plant or BU responsible: kiln coach
Expected result: make the kiln operation stably.

B.5. Acknowledgements
Great thanks of the HUA process team, esp. Mr Wang ZhiHong and Mr Han Li, for their great
support in the kiln audit and organization.
And thanks also to the Plant manager Mrs. Wang, for her kindly help.

B.6. References

analysis for
Mass & heat
0712klin demarcate.xls
balance 0201.xls

B.7. Appendices

Fan FLAKT.doc

Flaktwoods fan
data A.jpg

Page 29 of 31