KilnLine Operation

Page 1 Training THALOFA
Operation of the kiln line

Training
Klaus Grittner
Polysius Services
Polysius Headquarters / Germany
19. May 13. June 2008
SilzR 13 Jun 2008 S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt Page 2
Heating Up
Starting Sequence
Start Up
Increasing Performance
Normal Operation
Optimisation
Main Control Loops
Normal Shut Down
Emergency Power Consumers
Operation of the Kiln Line
Rotary kiln
Clinker cooler
P
r
e

h
e
a
t
e
r
C
a
l
c
i
n
e
r
Tertiary Air Duct
1400 C
Clinker Production Line Clinker Production Line
1700 C 280 C; to EP
900 C
340 C; to raw mill
and / or EP
80 C
fuel
55 60 %
fuel
40 45 %
860 C
80 - 100 C
Ambient air temp.
350 C
Heating up the kiln line
The fuel burns with the smallest possible amount of combustion air.
There is no CO, or only slightly formation of CO at the kiln inlet
Most of the heat remains in the clinkering zone
The flame is short and compact.
for the new kiln heating up takes approx.
-- 48 hrs. (with new brick lining)
-- 30 36 hrs. (after normal maintenance shut down)
Example for 1st heating up the kiln line
Continuous turning
or heavy fuel oil
Tilting and turning the kiln
During the heating up the kiln should be continuously inched and turned,
the guide values for a new kiln are :
0 12 h: 1/3 revolution with auxiliary drive every 30 minutes
12- 24 h: 1/3 revolution with auxiliary drive every 20 minutes
46 - 46 h: continuous rotation with auxiliary drive 0,1 rpm
from 48 h: turn kiln with main drive app. 0,6 rpm
and start feed
Starting-up Sequence of the Kiln Line
Filter dust transport
De-dusting plant
De-dusting filter fan
Kiln waste gas fan (ID-fan)
Remarks:
Control air compressors,
cooling water system.
Auxiliaries of the kiln line
with closed damper
with closed damper
rapping system
Remarks:
Clinker transport
Cooler waste air filter dust transport
Bull Nose cooling fan
Fuel supply (fuel oil or coal)
CO < min.
- analyser behind cyclone 2
- analyser before bag house
Primary air fan for MB
With damper closed
cooler roof protection
Cooling for roller crusher
Remarks:
Cooler exhaust air fan
Cooler de-dusting filter
Roller crusher
Cooling air fans for
recuperation zone
With damper closed
With damper closed
Remarks:
Cooler grates
Kiln main drive
Cooling fans for kiln outlet
Cooling fans for kiln shell
Main burner many preconditions (CO, T.)
slow speed 0.6 rpm
only if main drive is running
Kiln feed
Remarks:
Pre-heater cleaning systems
Open tertiary air dampers
Calciner burners
Cooling tower
app. 20 %
Fuel MIN
Start of the Kiln Line / Kiln Feed
For kiln feed start sufficient personnel has to be in the
pre-heater to watch the function of the pendulum flaps
and material flow!!!
1. Cooler Grates: ~ 3 - 5 stroke/min, (minimum speed)
2. Kiln main drive : 0,6 0,8 rpm
3. Cooler Fans : ~ 30% of the nominal quantity
kiln hood pressure: -1 to -2 mm WG (Automatic control)
4. Main burner fuel: Heavy oil: ~1.000 Nm/h
Coal / Pet coke: ~ 6.000 kg/h
5. Start Kiln Feed : ~30 to 35% of nominal feed rate (new kiln, no coating)
att.: there is a time delay between kiln feed group start
and real kiln feed.
6. Adjust draft after : - 12 to -15 mbar by ID-fan/ dampers exhaust gas duct.
cyclone pre-heater
!
Start of the Kiln Line / Kiln Feed
7. Main burner : Increasing of the fuel quantity to specific
heat consumption 1300 ...1500 kcal/kg clinker
Att. ! : Its only a guide value!!!
8. Start PC-burner : Sufficient Oxygen - after cyclone stage 2: > 2,5 %
- after DOPOL: > 4,0 %
Fuel distribution: MB ~70-75%, PC ~25-30%.
Kiln inlet : ~ 1050 C,
After stage I: ~ 860 C,
Hot meal 1: ~ 840 C
9. Adjustment of according to kiln feed ( ~ 2,0 Nm/kg clinker)!!!
cooling air:
10. Observing clinker visual check, kiln camera, pyrometer,
formation: observe the power consumption of the kiln drive.
Gas analyser / Alarm set points
Gas analyser behind kiln
-- CO (max 0,8 %, Alarm)
-- O
2
(min 1,0 %, Alarm)
Gas analyser behind Calciner
-- CO (max-max. 0,8 %; calciner burner)
-- O
2
normal value app. 2,5 %
Gas analyser before bag house
-- CO (max-max 1,1 %; main burner)
-- O
2
normal value app. 4,0 %
CO > 0.6 % alarm
CO > 0.8 % shut off the calciner burners
CO > 1,1 % stop the main burner
Increasing the kiln performance
Precondition: granulated clinker in the sintering zone and in the clinker cooler
1. Increasing the gas flow through via damper or speed of ID-fan- / filter-fan
the cyclone pre-heater Oxygen content behind cyclone
stage 5 > 4,0 % before increasing fuel.
After ID-fan: keep -50 mm WG (by EP-fan)
2. Stepwise opening of the (Oxygen at kiln inlet adjust to ~2 3 %)
tertiary flaps
3. Increasing of clinker keep kiln hood pressure -1 to -2 mm WG.
cooler air quantity (control loop)
Increasing performance
4. increase of kiln feed and fuel target of fuel distribution:
-- MB ~ 45%,
-- PC ~ 55%
5. increase of kiln speed according to the kiln feed
6. close fresh air flap (if open) depends on temp. after the pre-heater
7. operate clinker cooler with -- until a clinker bed dept ~ 500 mm
slow speed -- pressure in aeration chamber 1 ~ 40 mbar)
Same above mentioned steps for further increasing of the kiln feed!
Increasing performance
Cooler grate velocity (watch the pressure!!!) and cooling air
quantities have to be adapted
(1,8 2 Nm/kg Clinker)!
Att.: Secondary air and tertiary air temperatures will rise! The specific heat
consumption will reduce!!! Prevent overheating the sintering zone!!!
Take attention to: the kiln inlet temperature (max. 1150C),
the hot meal temperature (max 870C),
the temperature after pre-heater
(normal 340C, max. 450C):
Normal Operation
Preconditions of trouble-free operation:
- most homogeneous raw meal (LSF, SR, AR)
- constant kiln feed (variation < 1 % / minute)
- constant fuel rates (variation < 1 % / minute)
- constant gas flows, cooling air flows
Optimisation of the plant
-- Process parameters
-- Typical operating parameters
-- Burner-/ Flame adjustments
Process Parameters
1. kiln feed rate tons / h
2. Specific heat consumption, kcal / kg (calculated)
3. Total fuel rate , tons / h
4. Proportion of fuel to pre calciner / riser, %
5. Secondary air temperature , degree C
6. ID fan draft , mbar
7. Pre-heater exhaust gas temperature, degree C
8. Kiln inlet gas analyser O
2
%, CO %, NOx mg
9. Cyclone stage II gas analyser O
2
%, CO %, NOx mg
10. After ID.-fan gas analyser O
2
%, CO %, NOx mg
11. Water into the cooling tower l / h
12. Kiln feed material (meal chute 1) SO
3
%, LoI. %, (Lab. results)
13. Kiln drive power , kW, Amps
14. Primary air pressure mbar
15. Clinker cooler ventilators, air volume Nm
3
/ h
16. (Primary air, Nm
3
/ h)
17. Pre-heater profile (Temp. Pressure) C; mbar;
18. Specific Calculations kcal/kg clinker
-- Specific kiln volume loading, tons / mday
-- Gas velocity in burning zone, m / sec
-- Specific heat loading of burning zone, Mcal / h per m
2
Process Parameters
Typical Operation Parameters
Temp.: -- gas duct 1: 860.... 880 C
-- meal chute 1: 840.... 860 C
-- tertiary air: 850.... 950 C
-- after pre heater: 320.... 340 C
Press.: -- Kiln Hood: - 0,1- 0,3 mbar
-- Kiln Inlet: - 4. .- 6 mbar
-- Gas Duct 1: -14.- 16 mbar
-- after Pre heater: - 50.- 60 mbar
Clinker cooler: -- Chamber 1 pressure 50... 60 mbar
-- Secondary air temp. 900.... 1000 C
-- Cooler exhaust air temp. 250.... 300 C
-- Clinker temperature 80... 100 C
-- to burn a good clinker quality, but prevent damages in the refractory.
-- to build and to keep good coating formation.
as protection of kiln bricks and reduced kiln shell temperature,
but also to avoid coatings rings etc.
-- good heat transfer to the material by radiation and convection.
Burner- / Flame Adjustment
Burner- / Flame Adjustment
Main Burner Fuel: - Temperature of sintering zone
- Kiln inlet temperature
- Kiln main drive power (A or kW)
- Free lime (CaO) in the clinker
Total Fuel: - Specific heat consumption (kcal/kg clinker)
- Temperatures of meal and gas in the pre-heater
Fuel Calcinator: - Hot meal temperature
- Degree of calcination (92...95%)
Attention: Orientation only! Parameters/Results may overlap!!!
Gas conditions: CO ---> to be prevented!!!
min. of Oxygen is required!
Oxygen after pre-heater: ~ 4 % by damper or fan speed
Oxygen after stage II ~ 2 3 % by damper or fan speed
Kiln inlet: ~ 1,5 - 2 % by Tertiary Air Flaps
-- more open:
Oxygen stage II up / kiln inlet down!!!
-- more closed:
Oxygen stage II down / kiln inlet up!!!
Optimal Operation:
Kiln hood pressure Target: -0.1 mbar
Actuator: Cooler exhaust fan speed or damper
Under grate press. Target: constant at set point
(chamber 1 or 2) Actuator hydraulic drive for grates
Cooler air flow Target: constant at set point
Actuator: Cooler fan speed or damper position
Press. after kiln ID fan Target: - 5 mbar
Actuator: EP-fan speed or damper position
Temp. after Target: 160-190 C
Cooling tower Actuator: Water valve at the return line
Main control loops of a kiln plant
Normal shut-down of the kiln plant
Generally
-- reducing of the kiln feed in steps of app. 5%
-- minimal kiln feed is about 4050%
-- an empty kiln can be easier heated-up and re-started!
Stop of PC-Burners and kiln feed
Reduce fuel at the main burner
Reduce pre-heater draft
Close the Tertiary air sliders / flaps
Stop of main burner
primary fans to be kept in operation (for cooling!!!)
Close the DOPOL-flaps to 10-15%
Normal shut-down of the kiln plant
DOPOL-fan: dampers to be closed
Clinker cooler fans: dampers to be closed
Cooler exhaust air fan: controlled by kiln hood pressure measurement,
or set to minimum value
Kiln to be tilted! - during cooling down
- if raining continuously with auxiliary drive
- 1st and 2nd hour each 10 min 120
- 3rd hour each 15 min 120
- 4th hour each 20 min 120
- 5th till 8th hour each 25 min 120
- then... each 30 min 120
...till a kiln shell temperature (sintering zone) of about 100C is reached
cooler track units: to be operated in intervals
Emergency power consumers
-- Emergency lighting
-- Communication systems
-- UPS unit for computer and process automation equipment
-- Control voltage for the total kiln plant
-- Cooling water supply system
-- Dampers in DOPOL exhaust gas duct
-- Kiln auxiliary drive including lubrication)
-- Oil pumps for circulation lubrication system for roller bearings
-- Primary air fans for all burners including actuators
-- Protective air fan for sintering zone pyrometer
-- Actuators for damper in tertiary air duct
-- Fan for kiln outlet cooling
-- Cooling air fans for roller crusher
-- Cooling air fans for recuperation section
Stop
Timer
Filter dust transport
CLINKER Transport
5 min
Stop Timer
15 min
failure of 2 or
more air fans
failure of one fan
CALCINER
BURNER
Stop Timer
0,5 hour
FILTER FAN
KILN ID-FAN
STOP
STOP
STOP
STOP
STOP
STOP
STOP
STOP
STOP
MAIN DRIVE
KILN FEED
MAIN BURNER
PRIMARY AIR FAN
CO
Stage 2 > Max Max
Temperature
Preheater > Max Max
CO
Preheater > Max Max
Temperature
Preheater > Max Max
Grate 1
CLINKER
COOLER
CLINKER
COOLER
CLINKER
COOLER
Exhaust air
fan
STOP
STOP
Stop
Timer
5 min
M
a
i
n

P
l
a
n
t

I
n
t
e
r
l
o
c
k
Rotary Kiln
Grate 2

KilnLine Operation

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

KilnLine Operation

Uploaded by

Copyright:

Available Formats

Page 1 Training THALOFA

Operation of the kiln line

You might also like