kiln heat-up, optimun kiln operation
DESCRIPTION
kiln heat-up guidanceTRANSCRIPT
ONODA ENGINEERING CO., LTD.
ENGINEERING JAN. 0 6. i9.97
PROJECT
C o
KILN HEATING UP TIME oitte-17 '2- 1/-Q-
At the time of kiln heating up, it is necessary to pay attention to the following items.
(1) To avoid mechanical troubles of kiln shell, tyre, roller metal bearings,
etc.
(2) To avoid refractory troubles (The refractories protect directly or indirectly the above components against heat).
1 DETERMINATION OF HEATING UP TIME
The heating up time is determined taking into account the environment in vicinity of refractory.
(1) For new kiln, it is necessary to consider the drying time for castable,
burning down time for cardboard spacer (installed for expansion
allowance), thermal expansion of refractory, balance of kiln revolution by 180°, etc.
(2) Kiln inside temperature at the beginning of start-up (e.g. ambient temperature, high and medium temperature at shut down).
(3) Others such as flame pattern, whether or not there is refractory lining in top cyclone, etc.
Notwithstanding the above, it is most important to comply with the following.
(1) Burning Section (Preheater - Kiln)
The heating up should be carried out to achieve the target
temperature at outlet of top cyclone, kiln inlet hood and burning zone
- 1 -
ONODA ENGINEERING CO., LTD.
as well as balance among these temperatures. The raw meal feeding
is started once the temperature of gas at kiln inlet hood reaches the
target temperature. Nonetheless, the temperature at burning zone during heating up should not exceed the target temperature to avoid damage to refractory.
(2) The heating up time should be decided so as to prevent melting down of refractory as well as to avoid damage of refractory due to thermal stress inside refractory.
The non-compliance with the above two items during heating up will lead to refractory troubles and some other troubles (such as unstable condition inside the kiln, raw meal flushing, overheating, clogging of cyclones, etc.) which may occur after raw meal feeding. Even if there
is no apparent refractory trouble during heating up, there is always a danger of causing serious damage to refractory.
If heating up time is too long (24-36 hours) or too short (8 hours), in
either case, it is practically difficult to achieve a continuous balance
among the three temperatures mentioned above both during heating up and after raw meal feeding. If heating up time is too long, the
above troubles will be experienced repeatedly but too short heating time is worse.
Accordingly, the most optimum heating up time is 12-15 hours
which has been decided considering the mechanism of causing damage to refractory (described hereafter) and to achieve a stable kiln operation after raw meal feeding.
2
•
ONODA ENGINEERING CO., LTD.
2. MECHANISM OF CAUSING DAMAGE TO REFRACTORY
DURING HEATING UP
(1) High temperature of burning zone, highest temperature point, causing melting down of refractory.
- Too short flame causing overheating locally.
- Also, it is not possible to achieve a balance among three temperatures i.e. temperature at outlet of top cyclone, kiln inlet hood and burning zone. For example, the burning zone temperature may be high while other two temperature are low.
(2) When the heating up time is too short, sudden increase in temperature will cause excessive thermal stress inside refractory, thus damaging it.
(3) When there is rapid rise in temperature during short time, the newly lined refractory (without coating), particularly the refractory in burning zone will be damaged due to thermal shock, thus leading to unstable operation condition of burning section.
(4) Others •
ONODA ENGINEERING CO., LTD.
3. HEAT DISTRIBUTION DURING HEATING UP
Even if the total heating up time is optimum, the improper speed of raising the temperature will give rise to troubles mentioned at 2(2) and 2(3) above.
The bending strength of refractory decreases with increase in temperature. If the difference in temperature rise between loaded face and inside of refractory is large (i.e. rapid rate of raising the temperature), the thermal stress in refractory will increase. If this thermal stress at a particular temperature, exceeds the bending strength of refractory at that temperature, then refractory will be damaged.
(According to laboratory tests conducted by Asahi Glass Co., Ltd., Japan for basic refractory bricks, if half of the thermal stress
developed at particular temperature exceeds the bending strength at that temperature, the inside of refractory is damaged.)
Considering the above, the rate of raising the temperature at least up
to about 800°C should be kept as slow as possible (actually it is decided by stable burning condition achieved at minimum fuel feed
rate corresponding to burner design). In our opinion, the rate of raising the temperature up to about 800°C during heating up can be
kept as 80--i 00°C per hour. Above 800°C, the rate of raising the
temperature is determined by dividing 1,500-800 = 700°C temperature by remaining heating up time.
For example,
Normal temperature to 800°C : 9Q°C/hour, heating up time 8.5 hours 800 to 1,500°C : 700/(15-8.5)=110°C/hour, heating up time 6.5 hours
Instructions for Optimization of Kiln and Cooler Operation Doc. No : UT - KLCL - 01 Date : 7 Jan. 1998
1. Purpose of this document
UBE invited Mr. Kimura and Mr. Ujikawa ( Chichibu Onoda Cement Co., ) to CHC site from 15 — 25 Dec.1997 in order to check and optimize the kiln and cooler operation.
During their stay, Mr. Kimura explained much important and useful] matter for kiln and cooler operation, and also prepared reports. The purpose of this document is to record Mr. Kimura's various explanation during meetings ( which were written and explained on white board ) to keep as technical document in CHG.
2. Contents
Explanation by Mr. Kimura ( Chichibu ()noda) about kiln cooler operation
No. 1 : on 16 Dec.'97 at 9 . 30 — 12:00
No. 2 : on 18 Dec.'97 at 10 00 — 11:45
No. 3 : on 19 Dec.'97 at 14:00 — 15:00
No. 4 : on 22 Dec.'97 at 14: 45 — 16: 30
No. 5 : on 25 Dec.'97 at 14'00 ,,, 16:30
(Explained with above mentioned report "Report concerning damaged grate plates, 25 Dec.'97")
3. Reference documents
Refer to the following documents which were submitted to CHC together with this document.
0.) Report concerning damaged grate plates ( 25 Dec.'97 by Mr. Kimura, Mr.Ujikawa )
(Z Modification proposal during kiln shut-down from 21 Dec.'97 to beginning of Jan. '98
( UBE letter ; A/N - 234 on 24 Dec. '97 )
- New grate narrowing
- Installation of kiln burning zone thermometer at the side of kiln hood
- 2 sets of new inspection hole for cooler inside
- Change of location for grate thermometers
- Installation of guide vane for cooler 1st chamber cooling air
(a) Reference training text
(Prepared by Mr. Kimura for a training text book of cement plant in Taiwan )
t)C\wu&O.,A (1 4 47
tit
Explanation of Kiln, Cooler Operation by Mr. Kimura on16 Dec.'97 No. 1 : Present operating condition
on 16 Dec. '97 at 9:30 — 12: 00
I. Status of the meeting
- To explain the present operating condition
- To explain some important matter for kiln Operation
2. Kiln torque and kiln speed
Kiln torque Kiln power (kW) Kiln speed (rpm)
Kiln power (kW)
Kiln speed (rpm)
Kiln torque shoidd be observed to monitor the kiln burning condition.
3. Problem of the present kiln operation condition
The most problem of the present kiln operation is that the kiln burner flame is " too short ". In this case, the following problem occur.
(1) Kiln brick trouble around 7m-12m from kiln discharge end
© Clinker telrnperature at the kiln discharge becomes high, then it causes the grate damage.
OO The quality of clinker becomes worse
- Free Ca0 increase (1/41 c
- Voltnetric weight (V.W) of clinker increase AAL
Kiln length (m) Om 7m (Kiln out let)
freSerit" C ond 111'011 0 CHC
(VI -t- ern )
Max. tem retoch,o- e ■ Temp.
1420°C
1250°C
mi- v€
3
• Burning time is short Free CaO increase
Maximum temprature high Volmetric weight (V.W) of clinker is high.
The present operating condition of CFIC kiln is "the short flame condition of kiln burner" and "the high max;mum temperature".
(Show in line in above graph)
In this case, free CaO is high and the volmetric weight ( V.W. ) of clinker is high The brick problem ( about 7m) is caused by the short fl.nie condition.
4. Operat ng condition of yesterday (15 Dec.'97 )
Due to the leakage at the pulverized coal transport piping, kiln fuel was changed to 100% heavy oil conbustion.
The kiln torque was high after changing to 100% heavy oil, then red river was not observed in cooler.
15 Dec Kiln power Kiln speed Kiln burning zone 12nip.
Kiln torque Red river
14 : 00 221 kW 2.44 rpm 1459 "C 221/2.44 = 90 NO
15 :00 231 kW 2.51 rpm 1491°C 231/2.51 = 92 NO
Tool-et IS In _til 15 cir€q•
f5; 00 on /590
r N4
7 7/"'\
/
\_ %I/ r ftd---- 1-z 00 on i C. -t)
Buthing zone
Temp.
1500°C
1450
1400
ec.
Kiln tol que Vs temperature of kiln burning zone
Kiln torque 80
90
100 ( kiln power/ kiln rpm )
6. Calculation of liquid phase of clinker
at 1340°C 6.1 Fe 203 + MgO R20 = 6.1X 3.16 + 0.87 + 0.47 = 20.6%
at 1400°C 2.95 Ae 203 2.2Fe2 O 3 + MgO 1- R 20 = 2.95 x 5.34 +2.2 x 3.16 +0.87 -4-0.47
= 24.1 %
at 1450°C 3.0 A(. 203 + 2.25 Fe203 + MgO + R20 = 3.0 x 5.34 + 2.25 x 3.16 + 0.87 +0.47 7 24.47 %
Normally, 24_5% of liquid phase id desirable figure.
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CooQer
° 4thie
jh Co.se of S‘/tort fame, di'iiker teinrerafore
is 191A 1 akic( &Ae ic'ttiki'o( rAase ineveAcec,
T4E/i, cooffria r( _.,_ r
efi-Ec I. o i- Cx irl ker becomes
wors- e. pier lore , v-a-te olan-,75 eas,1/
occukv-s,
'7. Heat Flux 5
Heat flux means quantity of heat trasfer,
171- ;ek incide L "Pi A 4-f CoGr6in
V = calorific value of Fuel ( kcal/kg )
m = amount of fuel ( kg/sec )
Heat flux Ilfr , V x m (kcal / sec.m 2 )
ixTcxD
0 In case that the length of coatingt is around 15m — 16m, Free - Ca0 is high, or Free - Ca0 fluctuate ( high, low, high, low ).
In this occasion, kiln operation becomes quite difficult. The present kiln operation is in such conditions caused by short flame.
Free— CAO -OtAc -Evcs -tes,
© About 22 —,25m of coating length ( ) is desirahble for this size of kiln.
© The coating length can be observed by kiln shell temperature scanner.
8. Important factors of kiln operation
Et) Following factors are very important for kiln operation,
- Volmetric weight ( V.W ) of clinker
- Free-CaO
- kiln power ( kW) and torque
- TBZ ( temperature of kiln burning zone )
- Length of kiln coating
6
the prfseht rocitiur,
(2) Especially, the monitoring of kiln burning zone temp. ( TBZ) is quite important. 7
In the most of ONODA cement factories, the temperature of discharged clinker from the kiln end is monitored. Then, such modification is recommended.
(;3) Average temperature of discharged clinker at kiln end in ONODA factories is 1350°C.
9. Brown color clinker
The reason of" Brown color clinker /1 is low MgO content in clinker.
( MgO content is 0.74% in CHC clinker. )
Mr. Kimura experienced " Brown color clinker" in a cement factory in China.
Finally, this factory decided to feed dolomite ( as adding MgO) in raw material.
Ae203 Fe20, MgO SO3 A p n /p,a -2.,3, . ‘...2%-, 3
C3S : Ordinary clinker 0.83 0.53 1.04 0.08 1.57
Brown clinker 0.97 0.72 1.08 0.15 1.35
C 2 S : Ordinary clinker 1.71 0.92 0.47 0.89 1.85
Brown clinker 2.14 1.2S 1.75 1.24 1.71
GAF : Ordinary clinker 24.81 15.45 4.94 0.07
Brown clinker 31.82 5.07 0.54 0.00
The color of cement is effected by C4AF.
Cement color is indicated " b value " in Japan
High
(Brown r)
b value
low
(blue)
1.0
20
3.0
MgO.
In case of low MgO content in clinker, Fe-2.03 goes to C 3 S and C2 S, and Fe2O3 in C4AF becomes low.
If MgO content increase by 0.1%, b value degrease 0.5%. ( Cement color becomes blue. )
10. Actual method for change of kiln operation
Or Following procedures shall be done,
- Change of the length of kiln burner flame ( from short flame to long flame )
- Change of fuel combustion ratio of SC / kiln ( Increase of kiln burner fuel )
Howere, a high temperature position of kiln shell ( 440°C) is observed at 7.6m from discharge end. Therefore, change of operation should be done very carefully.
© The fuel combustion ratio of SC/ kiln is decided by a de-carbonation ratio of raw meal ( at the inlet of kiln ) and free - CaO content in clinker.
The target value is ;
De-carbonation ratio of raw meal = more than 90%
Free-CaO in clinker= less than 0.8 vo
The present. de-carbonation ratio is reported about 85%, but sometimes it decrease to 70-75%.
© In case of the consideration of fuel ratio of SC / kiln and De-carbonation ratio of raw meal , not only the . SC fuel, but also the tertiary air temp. shall be taken into account.
Total heat value of SC = SC (fuel) + ( tertiary air temp. x tertiary air volume x Cp ( specific heat air ) )
In case of low temperature of tertiary air, fuel amount increases.
OD Relation between the vonietric weight ( V.W ) of clinker and tertiary air temperature
V.W of clinker increase -4 Tertiary air temp. decrease
V.W of clinker decrease Tertiary air temp. increase
8 11. Cooler width control and operation
Reference of cooler width control
CHC China 1 China 2 Japan 1
Clinker Production
( t/d )
4,000 4,300 4,100 4,000
Kiln D 4.55 4 4.64) 4.64) 4.24
Brick thickiless(T)
0.2 0.2 0.2 0.2
Non width ! control e I (m)
2,7
2.7/4.15-0.65
2.4
2.4/4.2 = 0.57
2.4
2.4/4.2 = 0.57
2.1
0.55 e ti D
(0 The cooler width control in ONODA plant is done by blind grate, not by castable like CIIC.
(.4 In case of width control by castable, cooling air leakage occurs between the clinker bed and the castable (r41,1- t 0 nett- r--,9.e•)
[A.r1
Ctoier Co4er- w 04 Cory( r-4 04: Non vtid-til Coerti-oY
,6/ = Q. s- O. 6 (3) Control of cooler
The following matters are important factors for cooler operation.
- Setting of suitable thickness of clinker bed, and keep this thickness
- Control of red hot area of clinker
In orderix) know the thickness of clinker bed, the following method is recommendable.
In order to look inside of cooler of 1st — 4th chamber, installation of additional inspection hole is recommended .
/ / r
Air ct;r
-
/j7 / / T.
Cas-ta e
Cooler Narrowin
ithn4
In ONODA's plant, narrowing is made by blind grate.
In case of narrowing by castable ( as present CHC cooler ), air goes through between the castable and clinket bed.
Confirmation of the clinker bed thickness
71
'',,I —,--,—...
/
h.-
, --,
In order to check the clinker bed thickness, it is recommended to install the marking brick.
i / ,
0,8m
0.6p,
dinkr iro9rstribt"tior, of
Coo -re r tr, °meter --
riird e
(11) Cooler efficiency
(J) Cooler efficiency vs Thickness of clinker bed
/ 0
Cooler
Efficiency
0.6 0.8 clinker bed thickness (m)
- In case that the thickness of clinker bed is too thick, the secondary sintering occurs on the surface of clinker bed.
- The target of clinker bed thickness is about 600mm.
(.5) Heat consumption vs tertiary air temp.
Heat Consumption Kcal / kg.c1
To goo Ro O
Tertiary air temp. ( °C )
(0) Monitoring of grate plate temperature
Cnventional cooler : Normal 55% — 60%
In case of good width control 60% — 65%
Mulden type cooler = 70% — 75%
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Requirements max. max.
CHINFON HAIPHUNG CEMENT CORP. TRANGKENI I - MINHDUC - 1111, )/NIGUYEN -11A1PlIONG - VIETNAM
TEL: (84.31) 875 ) FAX (84.31) 875 478
—441, ❑ Poi Hand Cement
Conlract,l40.
Type .
Qu Inlay
Lot Ito. i
CHEMICAL COMPOSITION & MINF,LAL CONS'ITIVENT
M a X.
Los on ignition (W' )
In s~lilhl¢~IZ~si~luc (%)
SiO z I y';',
Al z03 (`;"(), 13&:*.y. 81; X. ((70
MgO (rg,) SO3 (VC') K2 0 Nai9 C;f0)' Total alkalies (as Na 2 0) ' Fro Ca()I
C3 5 I (:)c(:)) e2S
C3 A (To) C4 A (%)
Results* 0.47
22.06 5.32 3.36
64.97 0.74
0.38 0.63 0.19 0.61 0.76
55.21 21.60 8.41
. 10.22
mar. .
111 a X.
l i
PITYSICAI., PROPERTIES
Con tires 1tC strenglli
3(tiys
7days I .
28days
Setting tiMe: (Vicat lest)
set Final set
Soul' lness: (Le Chatelicr)
Fineness:
Sieve 0.08 nun
• Plaine
*Tet TCVN
(N/n), ,
) min.
(min)
(min) max.
(`ro) max.
(%)
(cin'j); I min.
Oft lion Clung - SI Hung
Chief - ()wilily Mgt Sec.
Explanation of Kiln, Cooler Operation by Mr. Kimur No 2 : Change of kiln speed and burner position, Kiln passage time
on 18 Dec.'97 at 10:00 11:45
1. Status c f the meeting
After checking of the present operating conditions, the following matters are proposed.
- Change of kiln speed
- Change of burnner position ( for long flame )
- Consideration of passage time of raw material in the kiln
2. Present operating condition
•CO The present kiln speed 2.60 rpm at 260 t/h Kiln feed rate is too fast.
According to the attached graph, the target of material filling rate in the kiln shall be 6%, then the target of kiln speed is 2.34 rpm at 260 t/h kiln feed.
Kiln
torque
kiln burning zone
Temp. ( TI;Z )
Passage time
in kiln
Kiln speed
17 Dec. 75 1550°C 22 min 2.60 rpm
5 Dec. 85 1450°C 27 min 2.60 rpm
In case that the material filling ratio in the kiln Is changed, the condition of falling down clinker on the cooler is also changed.
3. Importantfactors for kiln operation
Factors
The present condition of CHC
(-0 Kiln torque Low
W Temperature of burning zone ( TBZ ) High
.r) End of kiln coating 15m ( short ) 2 ,, 1, ,....,
(4 ) Material passage time in the kiln 22 min. ( short ) ...-s. - I.:, %.." ■■•• ,
V Volmen ic weight of kiln
©
High
Free - Ca0 High
(-7) Temp. Of kiln inlet end Low
V Temp. of tertiary air OK
- 0A -feed zoo 270 2-2 9 230 .240 2 SO _aeo 270 280 E_-`71,3
f.-)00 T +A1.3 icrrdtwfioil,
raw wts.r.ot,/ / t- cAin,4e-
3 00 > 600 •
in.5icke r-Q,lorcutvvi
1%.t,t froAi 0 tA. 49
kt 0 rn bet w e.e ,n Fateal feed tune om ty,
2 (
Yir)6° ;. 1 6
147 207
2. c) — 22
185 3 0
/. 77
2 16
2_, cg — 2.6
1. 20
1.54-
/.62 7 a
a. 6
(. 6
1 .4
4. Operation data on 17 Dec.'97
Sift
Kiln speed
( rpm )
Kiln
torque
TBZ
( Kiln burning zone)
Kiln
passage time
1st : 2.60 75 1435 — 1576 25 min.
2nd 2.60 73 1400 — 1597 25 min.
3rd 2.55 80 1407 — 1598 28 min.
5. Raw material passage time in kiln
Kiln passage time Kiln condition
Less than 25 min. Kiln condition becomes unstable.
30 min, Kiln condition is stable, and clinker quality is good.
More than 40 min. Kiln condition becomes dusty. Red river occurs.
(t) The red river of CHC occurs in the condition of the passage time of less than'25 min, and high temperature of clinker discharged from kiln.
The red river of CHC is not the case of long passage time of more than 40 min.
The target of the passage time is 28 min — 3 0 min.
6. Target of kiln speed, kiln torque and the burning zone temperature ( TBZ )
Target of kiln torque 80 — 90
Target of TBZ 1400 — 1500 °C
Target of kiln speed is 2.50 rpm as a first step.
Present kiln speed 2.60 x 60 = 156 rph
First target 2.50 x 60 = 150 rph
17
Kiln length 15m 20m
Tc nip.
142.0°C
1250°C
Theorei ic ally, final target is 2.34 rpm x 60 = 140 rph
/8.
7. Kiln burner position and adjustment of burner flame
A / Present- cbnd4isot PrRseht et,pet (0,Feco
cAcie / /b(aveh)
Under the area of 1420°C
is a cooling zone.
The current operating condition is show in " " line, and it means high burning zone temperature and short burning time ( short flame ).
© The operating condition shown in " " line is desirable, and the current condition should be changed to " " line .
After change of operation
Condition
B < A Free - CaO is high.
Volmetric weight of clinker is low .
Then, kiln fuel shall be increased from 42% to 43%.
B = A Free CaO is low
Volmetric weight of clinker is low
Then,this condition is OK
A,B is each area above 1420°C ( A is current condition, B is the condition after change of kiln flame. )
(i) Length of kiln cooling zone
Desirable length of kiln cooling zone = ( 1.5 ) x D = 4.15 — 6.2m
D = kiln inside brick dia. ( m )
The present cooling zone length seems to bey about 2m only.
Karl feed ( t/h )
C4 material temp.
Burning zone temp. ( TBZ ) •
IM=111/11•11111■
V When the bUrner position is changed, operating condition should be monitored for minimum 4 hours until situation changes. ( Due to large heat capacity of kiln )
8. Raw material passage time in the kiln
T= K x L T = Passage time min. )
DxNx0 K : constant value
L : Kiln length ( 76 m )
D = Kiln inside bri&k dia. 4.15 in )
N = Kiln speed ( rpm )
0 = Kiln inclination ( 4/ 100 )
The theoretical value of K is 0.142.
In CHC kiln, T is measured as 22 min by trend chart graph.
K is caliculated by using T = 22, then K is 0.13.
)te kr 110 "Xo
Method of determination T by trend chart geduce -Peel to -6A
-Soy. 5 ^- 10 m in.
Actual passage tinn e Time
Lictec.ot fr, ate r itd tethrev.0-6- 01-e,
-tto cool be vsed or cd,ove
/et hoot
Explanation_of Kiln,Cooler OperationbyMr,Kimura No. 3 : Condilion_after 100mm insert_of kiln burn=
_on Mice. '97 al 14:00 — 15:00
1. Status of meeting
(1) Kiln burner was inserted into kiln by 100rum on 18 Dec. at 14 : 30.
The burner position before insert was just the kiln end at hot condition. After insert
of burner, the burner front end is 100mm inside of kiln in hot condition.
2. Condition after inserting kiln burner ( 100m n
The condition after inserting burner is the case B < A. ( Refer to the explanation of 18
Dec.'97)
That is, Free - Ca0 is high and Volumetric weight of clinker is low.
3. Analysints by the concept of Heat Flux ( refer to explanation on 16 Dec.'97 )
Hf = 7200 kcal/kg / 3600 x 7400 kg/h = 73.7 kcal/m2
x D x-e
D = 4.15 m (;kiln inside brick dia. )
e = 15 in ( Coating length )
Le rie A ,e Coating length was changed from 15m to 16m. Hf ( at = 16m ) = 75.7 x 15 = 71.0 kcal/m 2
If Hf is kept constant, fuel shall be increased as follow.
7400 x 75.7 = 7890 kg/h
71.0
7890 - 7400 = 490 = 0.5 ton coal/h
Z2
23 Therefore, fuel of kiln and SC ( calciner) shall be changed as follow.
Kiln fuel 7.4 -1- 0.5 = 7.9 t/h
SC ( calciner ) 10.5 - 0.5 = 10.0 t/h
4. Kiln Coating monitored by kiln shell temp. Scanner
When the butter position is changed or burner flame shape is changed, the most import
check points are above mentioned coating end position ( coating length ) and the
position or coating ring .
5. Fluctuation of ELM in the kiln feed raw mul
If H.NI fluctuates as 2.15 ± 0.04, kiln operator can not control the operation.
In case ,of fluctuation as 2.15 ± 0.02 which has continued from yesterday, it is very
difficult to keep good operation.
In the worst case, it may cause the melting of kiln brick.
(Ii) Kiln heat load of cross section heat load is calculated of follow.
Heat load = 7,200 kcal/kg x 7,400 kg/h 3.9 x 10 6 kcal/m2 h
7C / 4 x D 2 t 1 3,0)
D = kiln inside brick dia = 4.15m
The average figure of kiln heat load in Japanese cement fectories is 5.0 — 5.2 x 10 6 kcal/m2 h.
The, figure. of CHC is lower than the average of kiln in Japan, thus even if ELM
flactotes, there is not concern about melting of kiln brick.
But, low heat load cause high Free-CaO in general. Thus, the heat load is
recommended to be increased more. If the kiln fuel is increased from 7,400 kcal/h to
7,900 kcal/h, the kiln heat load is increased from 3.9 x 10 6 to 4.2 x 106 kcal/m2 h.
711100•IMII■
21- The kiln heat load about 4.2 x 106 kcal/111 2h is recommended to keep Free-CaO in a
target range.
(E)) In Tsukumi plant, the target value of ITN; deviation ( clinker basis ) is ± 0.02.
0 The kiln heat load is depended on burnability of raw material.
In case of low burnability material, kiln heat load should be higher.
(4) Whtn R. 1W mill is stopped, kiln dust collected by EP ( high HM dust ) should be
stored in kiln dust bin.
After Raw mill start, the kiln dust is gradually discharged, and is mixed to raw meal.
(After finish of this day's meeting, it is confirmed that kiln dust is stored in the kiln
dust bin from 2 months ago. Operator forgot this action only on 18 Dec. )
6. The next action for operation
If the lbllowing conditions are fulfilled,
> 2.17
Kiln torque > 70
Kiln burning zone temp. < 1550 ° C
( TBZ )
Change fuel by the step of 0.1t/h at avery 30 minutes.
7. Mater* filling ratio in kiln
For rough visual checking method is described in Cement Data Book. ( It is attached to
this report. )
8. When S.M is decreased, the burnability of raw meal becomes good. ( It becomes easy
burning. )
9. Kiln heat load vs Free-CaO the normal relation is as follows.
Free
CaO
4.2
Kiln heat load
5.0 x 106 kcal/m2 h
2 5- 10. Action of operation on 19 Dec.'97.
After finish of above explanation, kiln condition is as follows.
Kiln torque = 140kW/ 2.51rpm = 56 ( very low )
TBZ = 1600° C ( very high )
Therefore, the damper of kiln primary air +An ( 24FN5 ) is reduced in order to make
burner flame longer.
Before
action
16 : 15
19 Dec.
16 : 49
19 Dec.
Kiln prim. Air
fan damper
26.8 °A 18.1 % 14.6 % Keep
continuously
Pressure of circulation
flow of kiln burner
1150mm H2 O 1050mm H2 O 950mm H2 O
Afer above action, kiln power was going high.
11. Operating condition on 20 Dec.'97
After the action on 19 Dec. ( making kiln burner flame longer ), kiln condition became
stable and the following points were observed.
(I) Free CaO keeps less than 0.8 %.
Kiln torque became high
13e1bre Action Action for
long flame
19 Dec 16:00
After Action
19 Dec
10 :00 12 :00 14 :00
19 Dec.
22 :00
20 Dec.
2:00 6:00 10 :00 14 :00
Free-CEO
( % )
1.69 0.86 0.38 0.49 0.86 0.47
Kilit Torque
' 61 60 62 79 77 75 77 74
( Refer to attached " TY'end after action. )
(,3.) Grate plates of 2nd row in 1st chamber was heated to red color before action.
( was observed from inspection window under grate. )
Hoverer, after above action was taken, rcd color heat was disapeared.
It meanS that the clinker temperature at kiln discharge end was rather decreased.
(4) The color of red river ( which is observed from the tertiary duct on 4th chamber of
cooler ) became dark.
According to the identification sample (color vs temperature), the color of red river
was changed from " light orange red : about 950 ° C " to "orange red = about 850°C).
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19. Der Otehofun
schen C'fensch issen. Die Ausmauerung on 1Ther-gangsz Lien ist kompliziert, arbeitsaufwendi und verlam t Spe7dalforinsteine. Eine besonders
F)rmgebung, die mehrfach angetroffen wind, ist lie Ve -engung der Auslaufzone des Drelic.fens ; dies (Wart z •t teil .veisen Ktahlung des Klinkers in, Olen und zu; schnellen Abnutzung des Ofenfutters ,n die-sem At schnitt_
Sowohl praktische Erfahrungen als auch theorctische Cfherlegungen ftihren zur Erkenntnis, dad der Dreh-ofen ohne Einschniirungen bz-w. Erweiterungen die derzeit g , instigste Ofenform darstellt. Die Dreiirohre der mr dernen WarrnetauscherOfen weisea hereits durchwe.gs einheitliche Querschnitte auf. Schtechte Erfahrungen mit Drehofen verschiedener Quer-schnitte veranla3ten die Zementindustrie der Sowjet-union, rur noch Olen mit einheitlichem Durchmesser zu bauen,.
19.1.1. Of.mfdlIungcgraci
Die Ma:erialftilleng ina Drehofen bildet einen Kreis-abschni t des Ofnquerschnittes. Das Flachenv rhalt-nis diesel Kreisabschnittes zum gesainten Ofenquer-schnitt 'a Prozent ausgedriickt wird als OfehfUllungs-grad f bezeichnet (siehe Fig. 193.).
Ofenfrillungsgrade schwanken in den Grenze i von etwa 5— UnebbAngig vora Ofenclurchnies er ist der Fulliulgsgrail hit- die verschiedenen Wertz des Zentriwinkels rc wie
19. The rotary kiln
highly labor consuming, job, requiring specially shaped refractory bricks. A kiln shell shaping which is particularly disadvantageous, Is the narrowing of the kiln's discharge end; this results in partial cooling of the clinker in the kiln and in a rapid wear of the refractory in this section. I
Practical experience as well as theoretical delibera-tions lead to the observation that rotary kilns without constrictions or enlargements represent currently the most useful kiln construction. The ;hells of modern preheater kilns already sh'c)w uniformity throughout the cross-sections. Unfavorable experience with rotary kilns of different cross-sections, prompted the cement industry of the SOviet Unio). to build rotary kilns with an invariable diameter exclusively.
19.1.1. Degree of kiln
The feed forms a segment of the rotary 1- iln's cross-: ection. The area ratio of this segment to the area of the kiln's cross-section expressed in percent is called the kiln's degree or percent of filling f, (see Fig. 19.3.).
Fig 19.3. Scheinatische Darstellung des OfenInflungsgra- des
Fig 19.3. Schematic of the de g ree of kiln filling
Kiln filling degrees fluctuate within the limits of about 5-17 go. Independent from Ulf- kiln's diameter, the percent of filling for the different values of the centric angle a is as follows;
Zq
Zentrk\a inkel Centric angle cc
r -tfenfrillungsgrad 0/0 010 of kiln filling
11C ' 15.65 o/o 105 ' 13.75 (lib 100 ' 12.10 0/0 95' 10.70 0/0 90' 9.09 0/0
7.75 0/o BO' 6.52 oio 75' 5.40 0/0 70' 4.50 nio
Der Einflu3 des Dfenhillungsgrades auf den Derch-satz des Drehofen; ist in Fig. 19.4. dargestellt. Drei Kurven reprasentieren FCillungsgrzele von 7, 1‘' und 13 Vo, wit den dazugeharigen Durchsatzen in t, h (dr Drehofen rift Durchmessern von 2 his 3.5 m.
Tile influence of the degree (.1 filling to the rotary kiln's capacity is shown in Fig. 19.1. Three curves represent filling degrees of 7, 10, and 13 0/o, with the corresponding capacities in t/h for rotary kilns with di imeter from 2 to 3.5 m.
19.1.2_ 0'?;ineigun;
Es gibt k eitie allgemein giiitige Regal fur (lie richtige Neigung von Dreil5fen. Neigungen von Drehofen lie-
/P./.2. Kiln slope
No generally valid rule exists for the proper slope of rotary kilns. Rotary kilns shpv slopes from 2 to 6 0/o.
384
Drehoienneigung and Ofenifinungsvad Rotary kiln slope ver as .11n load
Ofenneigung No Kiln slope No
4.5 ',la 4.0 0/o 3.5 No 3.0 wo 2.5 No
Entsprechender Ofentullungsgrail an Corresponding kiln load 0/
9 a/o 10 0/s II Vo 12 No 13 0/
19.1. Ausfri nrungsformen uas Drehofens
.1
19.1. Types of rotary kAns
11'6 -
11 0"
10'0'
Fig 19.4. OfeuRillung.tgrail end Drehofendurchsatz
Fig. 19 4. Degree of filling versus rotary kiln capacity
.7. In
sid
e k
iln
d
ia
me
ter
10 Drenolendurchsotx
20 30 35 lin
60 120 Rotary kiln capacil y
1150 210 Win
gen zwi ir- hea 2 und 6 Vo. Meistens triff:, man jr loch Ofen mit Neigungen von etwa 2-4 Wo znr Hod? )rita-ln an. Eirsprunglich hatten Drehofen qn56ere 1‘fei-g , ingen lei niedrigen Umdrehungszahlon von -,tv a 05-0.75 LUrnin. Geringere OfennuiguLrg erk dert e i ne ho'wre Drehzahl ; dies hat den Vo;teil, dad das Ofenmaterial besser gemischt und eLrem intensi-veren Warmeaustausch ausgesetzt wird. Nlan erreicht auch mit geringerer Neigung hohere )(en-hillungs grade. Aus praktischer Erfahrung resuliert, daft den folgenden Ofenneigungen im prakti; :hen Ofenbetri!b optimal erreichhare Ofenhillungs; rade entsprechen; siehe Tabelle 19.1.
Tabelle 19.1.
Most kiln slopes are between 2 and 4 olo to the hori-zontal. Originally, rotary kilns had higher slopes with lower revolutions ranging (rola 0.5 to 0.75 rpm. Lower kiln slopes require higher numbers of revolutions; this has the benefit of better mixing of the kiln feed, together with a more intensive heat exchange. Lower slopes also permit higher degrees of kiln filling or of kiln load. Practical experie'r, :e resulting from kiln operation shows that the following kiln slopes yield the corresponding average kiln loads; see table 19.1.
Table 19.1.
:kndererseits wird behauptet, dab der Clenfrillv ngs-grad vorn Verhaltnis der Lange (L) zum 1,?nrc:hrn sser (D) des ()fens abhangt. NaBdrehofen mit 'einem './D-Verhaltr is von 40 und darriber weisen Fullungst•rade his zu 11 0/o auf [1761 dedenfalls bestim nt die lei-gong des Drehofens in erster Linie den ngs-g[ad, wobei ein steigendes L/D-Verhaltnis den Fril-lungsg -ad noch erhohen kann.
fm praktischen Ofenbetrieb soil ein Frillungsgrar' von 1:1 °A) nicht uberschritten werden, da 1rohere ['CIL tungsgrade den Warmelibergang versddr chtern.
On the other hand, it is said that the kiln load depends on the length (L) to diameter (D) ratio of the kiln. Wet process rotary kilns with an LID-ratio of 40 and more, show kiln loads of tip to 17 % 0761. In any case it is the rotary kiln's slo'pe which determines the kiln's load in the first place; in addition to this Is an increasing L/D - ratio a factor, v-hich can contribute to the kiln's higher load!
In practical kiln operation the kiln load should not exceed 13 ,/o, since higher kiln loads impair the heat transfer.
385
EN')lac ation of Kiln, Cooler Operation by Mr. Kimura No.4 : Modification plaA during Kiln stoppage
on 22 Dec. '97 at 14:45 — 16 :30
1. Status of this meeting
cooler was stopped on 21 Dec. at 20:00 by falling down of 2 pieces of nose
ring of kiln discharge end.
0 In this meeting, proposal of next cooler narrowing and necessary modification plans
were explained to CHC.
2. New narrowing idea of cooler
Tis narrowin4 plan comes from much experiences of ONODA.
3. Installation of kiln burning zone pyro meter ( 24T72 ) at the side of kiln firing hood
4. New installation of 2 inspection holes at cooler
5. Relocation of grate plate thermometers to check the clinker bed conditions properly.
6. Guide vanes for cooler 1st chamber cooling air duct
These modification items are officially proposed by UBE's letter. ( Ref. No. A/N-234
dated 2.4 Dec.'97 )
3l
•
•
Explanation of Kiln, Cooler Operation by Mr. KitniAVok
No.5 : Summary of Instructions from 16 Dec. And
Instruction for Next Kiln, Cooler Operation on 25 Dee. '97 at 14: 00 — 16 - 30
1. Status cf this meeting
CO Mr. Kimura and Mr. Ujikawa prepared a report " Report Concerning damaged grate
plates, dated on 25 Dec.'97 " and submitted it to CHC.
In this meeting, Mr.Kimura explained this report, and summarized the optimization
of kiln and cooler operation.
And also, important items for next kiln operation was explained to CHC.
2. Page 4/12 of the report " Trend after action '
(.0 When Mr. Kimura came to CHC site, and checked operating condition, the kiln
passage time was short ( 22 min. ) and Frce-Ca0 was high. ( It fluctuated rapidly. )
The damper of kiln primary air fan was cb)sed from 26.8 % to 14.6 %, and tried to
make the kiln burner flame longer on 19 Dec. at 16:50.
(0) After this Ac tion was taken, kiln torque kept high, and Free —Ca0 was decreased.
This change of condition are obsered in the graph of " Trend after action " in page 4/12 of the report.
32
Kiln
torque
70
19 Dec.
16 : 50
I )ate and time
33
Free
CaO
19 Dec. Date and time
16 : 50
3. Kiln material filling ratio
S = 1.667 x T x M. x R = 7.2 %
AxLN9
T = Kiln passage time ( 28 min. )
M = Clinker production 3900/24 = 162.5 t/h
R = Average material in On R + 1.0 - 1. 055
R 1 = Material at kiln inlet
R j = 1 55 t/t x (1- 14)c ) 1- 1.0 t/t cl' x c 1.11 (q) c = Decarbonation ratio = 80% )
100 100
A = Kiln cross section area = 7" x ( 4.55 - 0.4) 2 = 13.52 m2
4
L = Kiln. length = 76m
G = Average bulk density = 0.9 + 1.27 = 1.085 Um'
2
In case of the calculation at the most recomn endable kiln passage time : T = 28 min the
filling ratio S = 7.2 %.
In case of the passage time T ( before the kiln burner shape adjustment )
S= 7,2 x 21 = 5.4 %. ( lt is too low. )
28
The target value of kiln passage time should be 28 min. — 30 min.
After fie action for the kiln burner long flame on 19 Dec.'97, the passage time is about
32 min ( 13y• the time difference of trend chart of kiln inlet temperature and burning
zone to trip.
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In casc of the present low heat load ( about 3,9 x 10 6 kcal/m2 h ), clinker quality ( Free-
Ca0 ) is not stable
C5 C/c2on(,
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4. Kiln heat load, Coating length and kiln inlet hood temperature
Kiln heat load
( kcal/ in2 h)
Coating length
( m )
Temperature of kiln
inlet hood ( °C )
4.2x 106 17 — 18 .950
5.0 x 106 22 1050
5.5 x 106 25 1150
Around 4.2 4.7 x 10 6 kcal/m2 h is a recommendable range of kiln heat load for CHC
kiln.
5. Kiln bi.irning 'zone temperature and kiln power
( Page 4/6 of the report " Report concerning daliaged grate plates" )
73X ( kArtitil
20rie teiT )
1c16*t livv"vw%
In case that 113Z increase and kiln power decrease ( as above mentioned trend ), it
means that the liquid phase of clinker is increasing. This case is a very dangerous
situation for ttrate plates, because it is easy to be damaged by incerased liquid phase,
In such case, operator must open the damper of cooler 1st chamber fan more for
preventing grate damage.
35
If the damper can not be opened more, kiln buring zone temperature should be
decreased.
Operator must consider such cases as emergency case, i.e. grate plates might be easily
damaged.
For decreasing kiln buring zone temperature following action shall be taken
- Decrease of kiln fuel
- Open of kiln primary air fan damper to make flame longer
6. Difference of clinker bed thickness between 1st and 2nd stage grate ( Page 5/6 of the
report " Report concerning damaged grate plates " )
The present difference of the pressure between 4th chamber and 5th chamber ( 1st
stage and 2nd stage of grate ) is 150 — 200mm H 2 O ( = 15 — 20mbar )
It seems that the thickness of 2nd stage grate is much thinner than 1st stage grate.
In this case, red river can easily flush from 1st stage to 2nd stage of grate, then grate damage occurs.
The thiekticsS of clinker bed of 2nd stage grate should be same as 1st stage, or thicker than 2nd stage.
This is a very important matter for cooler operation.
The suitable pressure difference of 4th chamber and 5th chamber can be considered as about 70mm 14,0 ( = 7mbar ). However, the situation of clinker bed should be well obsertkd.
7. Kiln torque vs kiln burning zone temperature.
( The graph in page 2/12 of " Report concerning damaged grate plates" )
The operation target is kiln torque 75 and burning zone temperature 1500 — 1550 °C.
8. Red river in case of too long burning time
Red river occur at the following 2 cases
- Too high temperature of kiln burning zone ( it is the case of CHC )
- Too long burning time
3t
Temp.
1450°C
1250°C
37
•
KjIii length (m)
The largeo(eause smaller A lite size ( large size clinker) :
The smallo(cause larger A lite size ( Dusty clinker ) then, red river easily occurs. ( But,
this case of red river is not CI-IC case. ) ; 4. 2
9. Countermeasure for the damage of castable at SC ( Swirl calciner) of RSP
In case of the tertiary air volume F I is less than F2, castable damage easily occurs.
Therefore, it is important to make tertiary air flow Fl and F2 equal flow rate. ( It can be
achie'ed by installing pressure gauge and making both pressure equal. )
Ak'fi2v4A,
0.3D (A 0
F2
11 if F1< F 2
roo----t- of- cas fade
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