units

Environment

Emmissions
GCT pressure
Precip Inlet east
Precip Inlet west
GCT Inlet
GCT Outlet
GCT Inlet
Precipitator (E) Inlet
Precipitator (W) Inlet
Precip Fan Inlet

mg/Nm3
bar
C
C
C
C
mmWG
mmWG
mmWG
mmWG

Coal Shop

Mill Inlet
Mill Outlet
Mill Differential
Mill Rejects
Fine Coal 90m residue
Classifier Setting
Fine Coal Slide
P. A. Pressure
Moisture

C
C
mmWG
WB/DAY
%

Preheater Temperatures

Kiln Inlet
Material East
Material West
Stage 4 East
Stage 4 West
Stage 3
Stage 2 East
Stage 2 West
Stage 1 North
Stage 1 South
ID Fan Inlet

C
C
C
C
C
C
C
C
C
C
C

Preheater Pressures

Kiln Inlet
Stage 4 East
Stage 4 West
Stage 3
Stage 2 East
Stage 2 West
Satge 1 North
Stage 1 South
ID Fan Inlet

mmWG
mmWG
mmWG
mmWG
mmWG
mmWG
mmWG
mmWG
mmWG

Kiln Feed

LSF
Silica Ratio

mm
mmWG
%

Alumina Ratio

Burning and Combustion

NOx
Kiln Drive current
Backend CO
Backend O2
Hot meal SO3 East
Litre Weight
Free Lime

ppm
amperes
%
%
%
%
g/dm3
%

ID Fan current
North Firing Fan current
South Firing Fan current
Coal Mill Drive current
Kiln Speed
Coal Feed
Kiln Feed
ID Fan Speed
Precip Fan Damper

amperes
amperes
amperes
amperes
rpm
tph
tph
rpm
%

West

Kiln Drives and Levers

PROBLEM
High Back End CO
Low S4W Temperature
Low precip west inlet temperature
Low coal mill inlet temperature

ACTION
Increase draft
Calibrate the backend analyser
Clean Stage 4 bridge
Check fallout hopper
Close kiln door

BEST RUN
H

TOLERANCE
H

80
37
105
105
300
140
-30
-90
-90
-140

180
300
8
9.5
210
600

125
125
325
150
-80
-80
-130

230
85
400
8
9

DAY

87.9
38
117
98
290.6
125.7
-6.5
-33.7
-38.2
-88.7

Precipitation

300
90
400
10 14

142.9
54.4
350

Coal Mill

210
600

190
640.8

90
30
105
105
300
126
-30
-90
-80
-140

250
60
300
10
9.5
180
500

TRENDS

125
125
335
150
-80
-90
-130

13.87
11

840
800
800
810
805

865
805
805
820
815

840
790
800
800
800

900
810
820
830
830

305

335

300

340

849.1
798.3
742
806.8
749.4
553.9
548.2
549
342
330
303.6

-40

-30

-50

-500

-400

-550

-450

-35.8
-71.2
-88
-144
-210
-194
-345
-335
-445.7

98
2.4

102
2.6

102
2.57

Preheater Temperatures

Preheater Pressures

Kiln Feed

1000
250
2

1150
1

1250
135
145
120

0.8

1.2

1.19

700
250
0
2

1240
190
0.25
3.59
2.37
2.79
1207
1.45

Combustion State

209.9
139
128.7
139
2.1
5.7
68.5
822
50

Kiln Drives Levers

1200
500
0
3
2.5
2.5
1250
1.5

1100
1

1500
500
0.01
3
3
3
1300
2.5

1280
165
175
175
2.4

1250
135
145
120
0.1

1280
165
175
175
2.4

88

800
50

930
100

880

WHO
CRO
Instruments Technician
Instruments Technician
Plant Assistant
Maintenance

STATUS
Done

KSD

COMMENT

Checkout the fall out hopper (Verify the reading)

Affected
Affected
Affected
Affected

by
by
by
by

kiln
kiln
kiln
kiln

start
start
start
start

up
up
up
up

Blue dotted circle: Plant start up

mperatures
Clean the Stage 4 bridge
Clean the Stage 4 bridge

Blue dotted circle: Plant start up

Red dotted circle: S1 opened during oygen mapping exerc

Calibrate the backend anlyser

r (Verify the reading)

d during oygen mapping exercise