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GUIDE LINES
Our objectives
To produce more
To produce with regularity
To produce cheaper
Rules
R1 - Constant kiln volume load
R2 - Constant cooler clinker bed depth
R3 - Predefined tables for cooler fans
R4 - Constant slightly negative kiln hood
pressure
R5 - Constant Oxygen and in excess at kiln back
end
R6 - Oxygen in excess at tower exit
R7 - Constant ID fan outlet pressure
R8 - Fuel amount proportional of to kiln feed
rate Production ramp up
R9 - Constant calcination
R10 - Maximize production to minimize heat
consumption
Indicators
The kiln speed is proportional to the kiln feed
Recommended value
Kiln speed/kiln feed ratio has
to be calculated by the process engineer
Takes into account kiln dimensions, process, clinker reactivity.
Wet kiln
Grate preheater
Preheater
Precalciner
1.2 rpm
1.2 rpm
2 rpm
3.5 rpm
Indicators
Constant bed depth
=
constant under grate pressure measured in the first chambers
=
Adjust cooler grate speed and never change the fan volume that impacts this
under grate pressure
Recommended values
Cooler bed depth must be maximized.
On new cooler generations, the clinker bed depth measured on the first grate
can range from 500 to 800 mm.
Indicators
Air flows
Outlet cooler clinker temperature
Recommended values
In the first chambers
fluidized clinker bed
fixed fan volume, air flow density must be constant
Chamber#
Air flow density (Nm3/m2/.s)
1,5
1,3
If hood pressure is
too negative
Impact
Risk of
Secondary air
CO
Levers
Controlled by cooler exhaust fan which extracts excess air from the cooler
Recommended values
Kiln hood pressure setting point
2 to 7 mmWG.
depends on its stability: the more stable the pressure, the closer to zero it can
be.
Levers
Kiln back end O2
Increase Kiln back end O2 set point
If
> 2,5 %
Recommended values
For Precalciner kiln, the O2 set point ranges from 3 to 5%
Standard deviation measured by 1-minute average values over 24 hours
4,5
4
Very good if
O < 0.2%
2
3,5
3
2,5
2
1
11
13
15
17
mi nutes
Very bad if
O > 0.4%
2
19
21
23
25
27
29
31
4,5
4
3,5
3
2,5
2
1
11
13
15
17
19
21
31
minut es
Indicators
Tower exit O2 value
Also Take into account
Carbon included in the raw material
False air
Recommended values
Indicators
ID fan outlet pressure must be controlled by the EP fan damper or variable
speed drive.
Recommended values
Depend on stability
ID fan outlet pressure must be slightly negative but as close to zero as possible
(-10 mmWG).
If ID fan at the maximum limit with margin on EP fan, ID fan outlet pressure set
point can be more negative.
10
Fuel t/h
8,00
7,00
6,00
5,00
4,00
3,00
2,00
1,00
0,00
0
10
20
30
40
50
60
70
80
90
100
Ratio
Kiln Speed
Feed rate
Ratio
Burner Fuel
Draft
Ratio
Indicators
Kiln specific heat
consumption (SHC)
1200
1175
1150
1125
1100
1075
1050
1025
1000
975
950
925
900
875
850
825
800
18
Recommended values
Create operation table for kiln feed
to fuel rate taking in consideration
Kiln specific heat consumption
Heat wall losses
Fuel calorific value
23
28
33
38
43
48
53
58
Clinker t/h
R9 Constant Calcination
Why?
To avoid a shift of the burning zone.
Calcination
Calcination
Indicators
Bottom cyclones and riser duct temperatures
Calcination level of bottom cyclones hot meal
Recommended values
Calcination level is controlled by temperature probe considered as
representative (bottom cyclones, riser duct) with a control loop acting on
secondary burner fuel rate. Set point around 850C
The main burner / secondary burner ratio must be mastered on continuous basis
to detect any drift (probe build-ups). The main burner / secondary burner ratio
does not vary too much (example: Precalciner kiln main burner = 40%, secondary
= 60%)
Type of kiln
% calcination
Preheater AT
55 - 70%
Preheater AS
90 92%
12
1200
1175
1150
1125
1100
1075
1050
1025
1000
975
950
925
900
875
850
825
800
18
23
28
33
38
43
48
53
58
Indicators
If the ID fan is at nominal ventilation : the only actuator to maintain kiln
condition is the feed rate
If the ID fan is below nominal ventilation, give priority to feed rate and use fuel
and ID fan to control combustion
Recommended values
13
Prerequisites
P1 - Raw mix preparation
P2 - Fuel preparation
P3 - Burner adjustment
P4 - Reliable sensors
P5 - Free lime follow-up
14
100m
10%
200m
1%
Lime saturation
100C
LSF =
2.8S + 1.18 A + 0.65 F
15
with (a + b) = 1
%Ash fuel
SHC .
100
b=
Ratio (feed/clinker) . PCI fuel
Fuel
Kiln
Calorific Value
(PCI)
ash
Heat Cons.
(SHC)
J/g
J/g kk
24000
20,0
3500
Feed / kk
1,54
b = 0.019 a = 0.981
C3Sclinker b.C3Sashes
C3Sraw mix =
a
65 0.019(-258)
C3Sraw mix =
= 71.2
0.981
16
Silica ratio
S
A+ F
SR =
SR
Burning
Liquid phase
Coating
Clinker
Cement
strength
Low
Easy
Excessive,
attack to bricks
Too thick,
unstable
Balling, hard
Low
High
Hard
Low, high
thermal load
No
Dusty, high
free lime
High
Alumina ratio
AR =
AR
A
F
Liquid phase
Clinker
Cement strength
Low
Fluid
If AR<0,64 No
C3A in clinker
High
17
KFUI
1
N
i=1
(C 3 S i C 3 S T ) 2
Combustion regularity
Heat consumption
Kiln stability
Brick life
Clinker output
Volatilization of SO3
Effects on
PROCESS
Equipment life
Grindability (kWh/t)
KILN FEED
UNIFORMITY
Effects on
PRODUCT
Prehomogenization
Mining
KILN FEED
UNIFORMITY
Blockages
Analyser
P2 - Fuel preparation
Solid fuel residues
Target
S fuel < 4%
200 m
0%
< (0.5VM*) %
S fuel > 4%
90 m
63 m
19
P3 Burner adjustment
Line up the burner with the kiln axis using laser beam
To avoid that the flame licks:
Either the material in the zone with the risk of local formation of CO and
thus volatilization of sulphates
Either the walls with the risk of destroying coating and refractories
Sharp
Narrow
Strong
Attached to the burner (30 cm black plume)
Such that flame licks neither the bricks nor the clinker bed
Lafarge burner
Influence of the rotational and Axial air on the flame
Impulse
Swirl
Liquid
fuel
0,1
Coal
0,1
Coke
0,1
Gas
0,05
20
P4 - Reliable sensors
Sensors
Scales
Comments
O2
0 /10%
CO
0 / 3000 ppm
NOx
0 / 2000 ppm
SO2
0 / 30000 ppm
BZ temperature
0 / 2000C
Calcination
temperature
0 / 1000C
+ 5 / - 10 mmWG
Kiln amps
ID fan outlet
pressure
+ 10 / - 50 mmWG
0 / 100 mbar
Clinker temperature
0 / 500C
Free lime
0 / 5%
21
BZT
NOx
F-CaO
GLW
Gamma
Advance 15 mn
NOx
Advance 25 mn
T Zone
Advance 35 mn
Amps
Advance 46 mn
FLUI =
free lime
0.2 free lime + 0.1
<1
22