CEMENT

Heat Consumption Mastery

Standard
Dec 2011
 Heat Consumption Mastery Standard

Systematic Optimisation of Heat Consumption

Basic Level
Implementation
by December 31st, 2012
10 Golden Action
Rules Plans
Full Implementation
by December 31st, 2014*

Tracking
Tool

*According to plant Priorities 2

Basic Level Implementation
by December 31st, 2012
 5 Golden Rules
 Prepare a consistent raw mix

 Control oxygen levels in kiln and pre-heater

 Optimize fuel combustion

 Master kiln stability

 Optimize cooler efficiency

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Full Implementation
According to plant Priorities
by December 31st, 2014
 10 Golden Rules
 Master pre-heater and calciner operation

 Optimize kiln throughput

 Maximize reliability factor

 Minimize wasted cement kiln dust and kiln dust

losses

 Apply operating procedures with skilled operators

4
Basic Level implementation
5 Golden Rules

5
 Golden Rules 1 – Prepare a Consistent Raw Mix

CONTROL ACTIONS SUPPORT

Review KFUI results monthly Training : Raw Mix Optimisation

Review burnability index at least once Technical Doctrine : Raw mix

every 3 years

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 Golden Rules 2 – Control Oxygen Levels in
Kiln and Pre-heater

CONTROL ACTIONS SUPPORT

Maintain Process Gas Analysers Procedures & Tools:

Availability and Accuracy
1) How to measure gas composition by
gas analyzer
Develop inspection plan for chasing false
air in pyro-line; conduct regular overall 2) How to control false air in the pre-
measurements & compare with targets; heater
inspections and repairs at least monthly
3) How to measure false air
(as per Power Standard)

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 Golden Rules 3 – Optimize Fuel Combustion

CONTROL ACTIONS SUPPORT

Align burner or flame with kiln axis Training : Pyro 1 Training

Procedures & Tools :

Process fuel to target fineness (target
defined with TC) 1. How to start up & optimise a burner

2. How to measure gas composition by

Kiln burning zone operating with oxidising gas analyser
atmosphere
3. Lafarge burner spreadsheet

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 Golden Rules 4 – Master Kiln Stability

CONTROL ACTIONS SUPPORT

Training : Pyro 1 Training

Free-lime target and control

Procedures & Tools :

1. Combustion Manual Post Sevilla

Keep constant bed depth in the kiln 2. TA Fuel Flexibility

3. LQTS - free lime analysis

4. Kiln operation guidelines 2006 (TCEA)

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 Golden Rules 5 – Optimize Cooler Efficiency

CONTROL ACTIONS SUPPORT

Stable Cooler Operation
Training : Pyro 1 Training
Optimise Airflow Distribution and Bed
Depth

Procedures & Tools :

1. How to check the calibration of

cooling fan airflows

Maintain Proper Mechanical Condition 2. 2) How to adjust the cooling air level
and airflows

3. 3) Airflow distribution calculation tool

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Full implementation
10 Golden Rules

1
 Golden Rules 6 – Master Pre-heater &
Precalciner Operation

CONTROL ACTIONS SUPPORT

Control calciner temperature Training : Pyro 1 & Pyro2 Training

Procedures & Tools :

Ensure proper condition of preheater
1. How to sample hot meal
components: thimbles (except for lower
cyclone), flap valves, splash boxes,
refractory, restrictor, etc 2. How to control hot meal

3. How to assess and optimise preheater

efficiency
Keep build ups under control
4. Technical Agenda -Fuel Flexibility

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 Golden Rules 7 – Optimize Kiln Throughput

CONTROL ACTIONS SUPPORT

Regularly Challenge Operators on Training : Pyro 1, Lucie, Cecil & KHD

Performance factor Simulator

Documents:
Ensure reliability and accuracy of critical
kiln system sensors 1. Technical agenda - De-bottlenecking

2. Kiln operation guidelines 2006 (TCEA)

Analyse all kiln feed reductions of greater 3. POM P2 - Instrument Quality

than 20% and define corrective actions Assurance

1
 Golden Rules 8 – Maximize Reliability Factor

CONTROL ACTIONS SUPPORT

Systematically analyze incidents resulting Training : RCA training

in most significant production losses with
the RCA tool (as per POM)
Documents: POM Toolkit

1
 Golden Rules 9 – Minimize Wasted CKD and
Kiln Dust Losses

CONTROL ACTIONS SUPPORT

Measure or estimate kiln dust loss

Training : Pyro 1
For long kilns determine effective control
levers that can be used to minimise dust Documents Easy+:
wasting. Optimise the kiln chain system by
monitoring chain density by zone and Cement kiln dust methods for reduction
replacement at least annually.

1
 Golden Rules 10 – Apply Operating
Procedures with Skilled Operators

CONTROL ACTIONS SUPPORT

Have at least one certified operator per
shift, implement POM C1

Have critical SOP Mgt system in place and Training : CRO training
used.

N.B. These 2 actions must be implemented Documents: POM Toolkit

as soon as possible – in any case
according to plant POM implementation
timeline.