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OPERATING INSTRUCTIONS

AND REFERENCE MANUAL

FOR

ILC PREHEATER SYSTEM








CUSTOMER : RAIN INDUSTRIES LTD.,
(3800 TPD NEW LINE)

PLANT LOCATION : KURNOOL, ANDHRA PRADESH, INDIA

FLSMIDTH LIMITED
WORK ORDER NO. : PRJ06-009-000





Prepared by: A.SRINIVASAN Date: 21.04.2008
Checked by: N.SIVAKUMAR Rev.: 0
Approved by: S.SARAVANAN






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TABLE OF CONTENTS


1. GENERAL NOTES


2. CONSTRUCTION AND OPERATING PRINCIPLE


3. DRYING AND HEATING OF LINING PRIOR TO START-UP OF
KILN


4. STARTING OF THE KILN PLANT


5. STOPPAGE OF THE KILN PLANT


6. OPERATION OF THE KILN PLANT


7. INTERLOCKINGS, PROGRAMMING AND CONTROL CIRCUITS


8. PREVENTION OF FIRES AND EXPLOSIONS


9. BARRING


10. CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS
AND ALARM LIMITS.












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NOTE!

The present instruction manual is dealing with the
situations which, according to the experience of
FLS, are the most likely to occur. An exhaustive
enumeration of all conceivable situations which
may occur during the
erection/operation/maintenance of the kiln
plant/machine/equipment cannot be provided.

Consequently, if a situation should arise, the
occurrence of which is not foreseen in the in-
struction manual, and which the operator is/or
feels unable to handle, we would recommend that
FLS is contacted without undue delay for advice on
appropriate action.







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1 GENERAL NOTES

This manual is intended as a reference guide, which can
be used in connection with the start-up, normal
operation and shutdown of the plant.

The majority of the directions given in the manual are
of a generalized character given that a range of
relevant factors of a specific or localized nature are
involved, and it would be impossible to provide a
detailed evaluation of all these factors in this manual
without sacrifice of clarity.

The manual must be regarded as a tool for optimization
of the kiln plant, and it can also be used to support
judgements made by the operator in a given operating
situation.

In this manual it is a foregone conclusion that the
control panel equipment has been installed, tested and
made fully operational.

This manual should be thoroughly studied prior to
start-up, so as to permit detailed planning of this
phase.

Several separate instruction manuals related to the
plant under review in this manual; these manuals
contain detailed information about the single machines
or arrangements.

These manuals must also be studied very carefully
before the plant is put into operation.








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2 CONSTRUCTION AND OPERATING PRINCIPLE

2.1 Construction of Main Elements

The kiln plant construction is schematically shown in
enclosures.

The clinker producing plant is a FLS-ILC (In-Line
Calciner, Low NOx type) installation incorporating the
following elements:

Kiln tube
Diameter 3.95 meters
Length 61.0 meters
No of supports 3
Inclination 4.0%
Size of Kiln Drive & max. Speed 493 kW, 5.00 rpm
No. of Preheater Strings and Stage Single string
with 5 Stages

Size of Cyclones in Kiln String Stage III: 7.8 m
Stage III-V: 8.0 m
Size of Calciner 6.9 m x35.2m Long
Grate Cooler Type SF CROSS BAR- 3x5F
Burner Type Duoflex
Kiln Feed System Bucket Elevator

2.2 Operating Principle

The ILC Calciner kiln system is installed. The Calciner
is placed in-line with the kiln riser duct.

The combustion gas for the Calciner is hot atmospheric






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air drawn from the SF CROSS BAR COOLER through tertiary
air duct mixed with the combustion gas from the kiln.
The Calciner is dimensioned for a gas retention time of
approximately 4.5 seconds.

The kiln and Calciner is provided with a preheater. The
cyclones are of the proven FLS LP-type, which ensures a
very low pressure loss of the preheater.

The kiln main burner is the new Duoflex burner. The
primary air consumption of this burner is lower as
compared with traditional burners.

The burner is provided with an oil burner for start-up.

The raw meal feed i.e. the kiln feed is extracted from
the homogenizing raw meal silo into a kiln feed bin.
The raw meal is then transported to the preheater inlet
by the Bucket Elevator.

The preheater is operating as a counter current heat
exchanger with the raw meal passing downwards through
the preheater stages by gravity, and the hot gas moving
upwards drawn by the ID-fan.

Having passed 4 or 5 preheater stages - depending where
to the feed is directed - then the raw meal passes a
splitter gate, where the raw meal flow can be diverted
into two positions in variable amounts, one to the
calciner vessel, and two to the riser pipe from the
kiln. This splitting and the amount of material being
guided to one way or the other is depending very much
on the fuel used, and the tendency of coating formation
in the riser pipe.







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Approximately 55 - 60% of the fuel can be fired in the
Calciner. The raw meal will be calcined to a degree of
about 90-94%. The Calciner can be operated at high
temperatures of more than 1000 C., which increases the
combustion rate. The excess air at the top of the
Calciner is foreseen to be approximately 20%
corresponding to an oxygen level of 3% in the outlet
gas duct of the Calciner. These measures should ensure
complete combustion of the fuel applied.

The combustion air used in the Calciner is a mixture of
hot air (875-925 C.) drawn from the SF cooler through
the tertiary air duct and the kiln gases from the
rotary kiln.

The material is leaving the top of the Calciner and is
then passing onwards to the 5
th
preheater stage.
From this last preheater stage the material slides to
the rotary kiln inlet.

Due to the inclination and rotation of the kiln, the
raw meal is transported downstream through the kiln.
Simultaneously, the raw meal is gradually heated up and
fully calcined by the heat supplied to the kiln.

Clinkerization - clinker formation - takes place when
the raw meal passes through the burning zone of the
kiln.

The clinker formed enters the grate cooler for cooling.


2.2.1 SF CROSS-BAR COOLER







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The cooler is the well proven SF (Smidth-Fuller) cross
bar cooler. This cooler type comprises a number of
unique features:
Cross bar, separate conveying clinker device.
All grate plates are stationary.
Low energy grate plates with mechanical flow
regulators.
Modular concept.

The SF cooler has a modular design. The cooler
nomenclature describes the number of modules the cooler
consists of (width x length). Before each row of cooler
modules there is an inlet module without cross bars,
serving as impact zone for the clinker leaving the
kiln.
Each cooler module has a width of 1.3 m and a length of
4.2 m and comprises 4 x 14 grate plates. The module has
an inclination of 4 degrees.
The inlet modules, 1.3 m wide and 2.0 m long, has an
inclination of 15 and consist of 4 x 5 grate plates.
The outer corners of the two outer inlet modules are
covered with refractory. Each row of cooler module and
the inlet modules has their own cooler fan.
The grate plates in the cooler modules as well as in
the inlet modules are stationary. The transport of the
clinker is made by reciprocating crossbars located
about 50 mm above the grate line. Each cooler module
has 12 cross bars, 6 stationary and 6 moveable. The
moveable crossbars are connected to two longitudinal
profiles, which are driven by a hydraulic cylinder
below the grate, one for each module. The drive system
in a module is connected to the drive systems in the
previous and subsequent modules. The right set and the
left set of modules can then be moved independent of
each other for optimum distribution and transport of
the clinker.






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As the grate plates are protected by a stationary layer
of clinker they will, contrary to other modern coolers,
not wear down and deteriorate the air distribution with
a lot of sealing air.
The grate plate is made with labyrinth air path for
elimination of through fall of clinker. Transport
equipment below the grate is then completely
eliminated. The grate plate proper has a low pressure
drop. In order to ensure an optimal air distribution
every grate plate is provided with a mechanical flow
regulator (MFR). The MFR maintains a constant airflow
through the grate and clinker bed irrespective of
clinker bed height, particle size distribution,
temperature, etc; i.e. separate flow control for each
grate plate. The MFRs allow use of one fan for
relative large areas and completely eliminates the use
of under-grate ducts and dampers seen in other modern
coolers.
The modular concept of the SF cooler allows shop
assembling of large part and very fast erection. Due to
the cross bar system the number of wear parts are
minimized and replacement of these parts are fast and
easy to perform.
The kiln hood is common for the kiln and the tertiary
air duct. The hood is made so large, that minimum
clinker dust is recirculated to the kiln and Calciner.

2.2.2 Gas treatment and distribution

Whenever the kiln is in normal operation, the preheater
exhaust gases or part of these can be utilized
depending on the raw mill or coal mill is in operation
or it is stopped. When the mill is in operation, part
of the gases is used for drying raw material in raw
mill or coal in coal mill.







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The dust precipitated in the kiln/raw mill filter
installation is returned to either
the raw meal silo
or the kiln feed.
The cooler excess air is treated in a separate ESP -
designed especially for clinker dust. The recuperated
dust is returned to the clinker transport system.


2.2.3 Separate Instruction Manuals

A number of other instruction manuals for the
individual machines or arrangements are available for
the plant concerned.

STUDY THESE MANUALS BEFORE THE PLANT IS STARTED

It is not all machines or equipment in this instruction
manual, that are supplied by FLS.

The FLS delivery range can be read in the order
acknowledgement and the order list.

3 DRYING AND HEAT-UP OF LINING PRIOR TO START-UP
OF KILN

3.1. Preconditions and Criteria for start-up

This section must be compared with the graphical form
given section 9, which provides information about
heating and start-up procedures.

3.1.1 Personnel

Operators and operating personnel must be fully






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familiarized with the instruments and functions of the
control panel.

Furthermore, the personnel must be well informed about
the layout and operating principle of the motor control
system, especially all interlocking diagrams indicating
protective, safety and operational interlocking.


3.1.2 Raw Materials

Prior to start-up, raw materials must be available in
sufficient quantities and with a well known quality in
order to ensure continuous, stable kiln operation.

3.1.3 Preparations

The following activities must be carried out prior to
the initial start-up:

1. All kiln plant machinery should be subjected to no-
load testing and, where possible testing under load.

The trial run of the kiln should comprise only of the
kiln motor, with the coupling bolts removed.
Trial run of machines loaded with material should be
performed over a prolonged period. For instance 24
hours, with the kiln feed in circulation.

Water and/or air must be available where necessary.

2. The entire electrical and electronic control system
must be tested to ensure that all interlockings i.e.
safety, protective and operational interlockings are
active and that they function properly.






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3. Ensure that all alarm limits have been set. (Refer
section 10 in this instruction manual).

4. The raw meal must be recirculated to sustain the
operation of the feed arrangement and for calibration
of the load cells.

5. Prior to the production of clinker an appropriate
amount of correct quality raw meal must be available.
At least 3 days consumption must be available.

6. Where possible, the oil in the firing installation
should be recirculated to check the function ability of
the installation.

7. Ignition burner and burner equipment must have been
prepared for start-up.

8. The chemical laboratory at the plant should be on
standby to perform the necessary analyses of the kiln
feed and clinker, particularly to determine the content
of free lime, the litre weight of the clinker, and the
kiln feed analysis.

9. In order to optimize the regulation of the primary
air volume in the kiln, for optimization of the flame
structure, it is advisable to measure the airflow
supplied to the burner by the primary air fan at
different valve openings and pressures. Hence it is
possible to ascertain what valve position should be
used during operation.









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NOTE!

Where specific demands for initial drying procedure of
the concrete are stipulated by the supplier of the
castable for the grate cooler, account must be taken of
such criteria during the start-up phase, or, if this is
not possible, it may be necessary to dry out the cooler
on a separate basis.


3.1.4 Preparations Prior to Heating

Before the below mentioned start-up sequence is
followed and any machines are put into operation, the
description in section 7 of the interlockings, the
programming and the control should be read through.

CHECK

- That all tools and all alien objects have been
removed from all kiln plant machines.

- That potential coatings have been removed from
cyclones, flue ducts and riser ducts.

- that all doors and clean-out hatches are closed.

- that the motorized dampers function properly

- that the barring device, with brake , is ready
to be operated.

- that all plant machinery has been lubricated in
strict accordance with directions given in






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separate instruction manuals.

- oil must be applied to the journals of the
supporting rollers to ensure that they are
covered by oil when barring operation is
started.

- the water supply to kiln bearings and gas
analyzer is functioning.

- that all instruments in the control system are
functioning.

- that all alarm limits have been set.

Start the compressed-air supply and check that
compressed air is present at the points of consumption
at the correct pressure.

Place the gas analyzer equipment in the kiln system in
the state of readiness.

Check that the thrust roller device and the spray
lubrication for gear rim are ready with sufficient oil
and grease. Refer separate instruction manual.

Mount the light-up nozzle on the burner installation of
the kiln and prepare the ignition burner for operation.

Prepare the cooler and the clinker transportation
system. Place about 300 - 400 mm layer of cold clinker
on the Fixed Inlet section of the cooler.

See separate instruction manual for cooler.







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If special requirements for the initial drying of the
castable are stipulated by the supplier of the castable
for the grate cooler, these requirements must either be
met during the start-up procedure or, if this is not
possible, the grate cooler must be dried out
separately.

Once these checks and activities have been completed,
both the electrical and the mechanical department must
ensure that the installation is reported ready for
start-up.


3.2 Drying-out procedure

3.2.1 Kiln & Preheater


The heating and drying-out of the refractory lining
must be performed very slowly and gradually in order to
avoid cracking and spalling. This applies especially in
places where large zones are lined with castable and
are to be dried out.


The initial heat-up/drying-out operation should stretch
NOTE

The given heat-up schedule is applicable for
refractory supplied by FLS only. It may be necessary
to modify the outlined drying out procedure in case a
different code of practice is recommended by the
brick supplier. However, consultations between the
plant management and FLS are needed before any
modifications are introduced.






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over a time period of approximately 72 hours as shown
in the diagram given in section 9.
In connection with subsequent kiln starts, the heating
period can normally be reduced to 24 hours, though it
depends on the type of lining repairs conducted during
the intervening periods.

As mentioned previously, it is recommended to extend
the heat-up period if concrete castable has been used
for casting operations inside the kiln system.

3.3 Initiation of Heat-up Operation

See also the separate instruction manuals related to
the individual equipment mentioned.
Heat-up operation is started as follows:

3.3.1 Kiln and Preheater

Check that the dampers in the ducts to all the mills,
which will be supplied with drying gas, are closed.

Start the oil circulation to the burner.

Check the pressure and temperature of the oil.

Start the hydraulic pump of the thrust device.

Start the spray lubrication system for the kiln drive.

Start the kiln bag house -fan with closed damper.

Open the filter fan damper gradually, so that a
negative pressure of 1-2 mmwg is maintained in the gas
duct just after the ID-fan.






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The damper for the ID-fan are opened 10-15% so that
there is created a slight negative pressure in the kiln
hood.

Start the primary air fan and close the primary air
damper to 10%.

Start the ignition burner.

Start the oil burner by opening the oil valve for the
light-up nozzle.

Check that the oil is ignited; if necessary adjust the
primary air valve to facilitate the flame formation.

Adjust the draught in the kiln by means of the exhaust
gas damper, the filter fan speed and the damper.

Start the barring of the kiln in accordance with the
barring programme outlined in section 9.

Check lubrication of supporting rollers. The journals
must not become dry. During barring it may be required
to pour additional oil directly on the journals.

The specified barring program must be adhered to;
however, if the thrust device equipment for indication
of kiln position gives alarm, barring must be
continuous until the alarm can be cancelled.

Continuous barring is also required if the kiln is
subjected to cooling, for instance due to heavy rain.

Soon after the start of the burner, the gas analyzer in






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the riser duct should be put into operation.

Start the fans for the cooler inclusive the nose ring
fan (it is the fan at the kiln outlet).

Start the Bag house-fan for excess air from the cooler
with closed damper.

Set the automatic negative pressure control in the kiln
hood to a set point of -0.5 mmwg.

Open the hoisting damper in the tertiary air pipe 50%.


Start the burner in the kiln hood, if supplied, the oil
volume is set to 10-20% of full capacity. Over heating
of the lining in the TA duct is thus avoided.

Regulate the kiln string exhaust fan damper to get
oxygen content of 8-10% in the kiln inlet. When the
kiln has become hotter after some hours this level can
be reduced to 3-4%.

The ignition burner can be extinguished after
approximately 8 hours or as soon as the lining is hot
enough to support the ignition of the oil.

3.3.2 Air Supply during the Heat-up Phase

During the heat-up period, the maximum amount of the
heat input should be utilized for heating of the kiln,
i.e. only the necessary air volume should be drawn
through the kiln.

However, an adequate air surplus must be present for






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the complete combustion process.

It could be necessary to start 2-3 cooling air fans and
to start the excess air fan to be able to control the
negative pressure in the kiln outlet.

The oil flame must not cause sooting.

Often, this would require that the oxygen content
indicated by exit gas analysis in the riser duct is
8-10%. When the kiln has become hotter after a couple
of hours, then the oxygen content can be reduced to
about 3-4%. An oxygen content smaller than this might
cause a sooting flame.

An exit gas analyser after the preheater is not of much
use during the heat-up phase, since air infiltration
from the preheater system would influence the analysis.

3.4 Inspection during heat-up period

The programme for heat-up period is graphical indicated
in section 9.

Following major lining repairs, a heat-up period of
approximately 72 hours is recommended, whereas for
normal starting of cold-state kiln the period should be
approximately 24 hours.

It is very important that no attempt is made to speed
up the programme.

In case of interruptions during the heat-up period
compensation is needed by extending the time period, so
that the actual heating period has the stipulated






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duration.

The heat-up speed, as measured at the kiln inlet and
the outlet from the preheater tower, should very
closely follow the curves as indicated in section 9.

It is advisable to record operational experience gained
during initial heat-up periods, so that the curves in
the enclosure can be adjusted in accordance with the
local conditions.

A regulation of fuel rate, draught level and oxygen
level is needed to ensure strict adherence to the
curves for the temperature rise.

Overall, the prime aim is, as previously mentioned, to
ensure retention of the supplied heat inside the kiln.
Any increase in the draught level will rapidly cause
the temperature in the cyclone tower to rise at the
expense of the temperature in the kiln, and this is not
desirable.

The following inspection and check-up must be made
during the heat-up period:

Kiln Lining

Inspect the kiln lining at regular intervals. The
lining in the burning zone must not be exposed to fast
and local overheating.

The lining temperature must not exceed 1000 C.

If the lining temperature rises too quickly and/or
becomes too high, reduce the amount of fuel.






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Kiln Shell Temperature

Check the kiln shell temperature. Special attention
must be focused on the burning zone where high surface
temperatures may occur. Temperatures of up to 350 C.
will be acceptable.

If the kiln should become too hot in the burning zone,
and the temperature after the preheater is relatively
low, i.e. it permits that surplus heat is drawn from
the kiln upstream to the preheater by increasing the
draught.

Alternatively the flame shape must be adjusted by
regulating the air volume to the main burner.

Bearings for supporting rollers

Check the lubrication. Dry running of the bearing
journals must not occur. When the kiln is barred, it
may be necessary to apply additional oil directly to
the bearing journals.

Barring

Strict observance of the specified barring programme is
needed, but in the event that an alarm is tripped by
the thrust device equipment indicating the position of
the kiln, then the kiln must be barred continuously
until the alarm can be cancelled.

Continuous barring is also needed if the kiln is
subjected to cooling, for example due to heavy
rainfall.






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Clearance between kiln shell and live ring

The clearance between the kiln shell and the kiln tires
must be checked at regular intervals during heat-up and
start-up phase, especially at piers I and II.

Clinker transport

If the kiln has been filled with raw materials, it may,
from time to time, be necessary to start the grate
cooler and the clinker conveying system in order to
transport away the materials, however, do not empty the
cooler. To ensure effective cooling at the cooler
inlet, it may as previously stated be necessary to
start the first fans of the cooler.


4 STARTING THE KILN PLANT

4.1 Getting Ready for Operation

Operational status must be prepared approximately 3
hours in advance of the anticipated time for start-up
with feed.

At this stage the temperature of the kiln lining is
sufficiently high to ensure ignition of the coal from
the burner, which is put into operation as follows:

- Reduce the oil flow to the burner.
- Start coal firing with minimum coal.
- Finally stop the oil & continue heating with
necessary coal until the desired temperature profiles
have been achieved, as indicated below.






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Start the transport lines for dust and clinker after
the kiln.

Start the recirculation of raw meal if the equipment
has been out of operation over a prolonged period of
time.

Start the burner in the kiln hood, if installed, unless
it is already in operation. The oil quantity is
adjusted so the lining temperature does not exceed 1000
C.

Start the dust conveyance system after the kiln bag
house, and the cooler ESP.

Check that the dividing or splitter gate after the 2nd
lower most cyclones is adjusted so all the raw meal is
directed to the riser pipe.

4.2 Starting of kiln Feed

When the temperature at the top of the 2nd lower most
cyclone stage is about 750 C., and assuming compliance
with the heating programme as outlined in enclosure,
the kiln is ready to accept feed material.

Personnel must be stationed in the cyclone tower in
order to watch the raw meal as it passes through the
cyclone preheater.

Supervision is performed at the sluice flaps under each
cyclone. The flaps must move freely. This is done to
ascertain that the raw meal is passing through. The
risk of jamming in the cyclones is particularly high






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during start-up.

The control room must have the possibility to contact
the supervising personnel via mobile communication
equipment, radio or telephone; so that early warning
can be given from the supervising personnel to the
control room in event of jamming symptoms in cyclones
are observed.

4.3 Starting of Kiln Main Motor

Stop the barring motor, disengage the barring gear and
start the kiln main motor at the lowest speed.

Start the exhaust gas fan with closed damper. Sometimes
it is necessary to stop the burner if it takes a long
time to establish the draught as the fan is started
with closed damper. However, it should be possible to
operate the burner at minimum rate.
Therefore the draught and fuel rate must be reset to
levels applicable prior to the starting of the exhaust
gas fan. Please make sure that the filter fan speed is
adjusted to maintain sufficient suction after the kiln
exhaust gas fan.

Start the clinker transport system, with clinker
breaker, and the cooler drives and fans (refer to
separate manual for the SF-cooler).

4.4 Establishing Normal Production Rate

Perform the following operations in RAPID but PROPER,
sequence:

- Start the raw meal feed to the preheater.






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- Increase the draught level by opening the damper for
the exhaust gas fan as well as the speed of the fan.

- Increase the fuel rate accordingly.

- Increase the feed rate to 55-60% of full production,
with simultaneous increase in kiln speed to 1.4-1.6
rpm.

- Start the fuel supply to the Calciner at minimum
rate. As soon as the kiln feed has reached the lower
most cyclone stage, then increase the fuel rate in
order to maintain the temperature of this lower most
stage of about 860 C.

- Set the draught level and fuel rate so the fuel
supply rate is 5-10 % in excess of the normal
operational level at the same production rate. The
reason is that the kiln system is colder at start-up as
compared with normal operation.
The draught must always be increased prior to any
increase in the fuel rate in order to avoid CO-
formations. Also remember to regulate the damper in the
tertiary air duct for the Calciner.

The temperature after the preheater must not exceed
400 C.

The gas analyzer after the preheater will typically
indicate an oxygen level of 6-8% during start-up.
However, the oxygen level should be in the range of 3-
4% at the kiln inlet.

When it has been ascertained that the clinker in the






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burning zone is well-burned, the kiln speed can
gradually be increased to match the production level.
The kiln feed rate and the kiln speed rpm should be
synchronized to maintain constant material level, for
instance 4.0 rpm corresponds to 100% production level.

It is of critical importance that the first material is
well burned in order to avoid circulation of dust
between kiln and cooler. Dust circulation may cause
cooling of the burning zone so more time is needed to
stabilize the kiln operation.

Since, as mentioned above, the heat input to the kiln
at the beginning exceeds the amount required for
clinker formation, the kiln system will gradually be
heated.

When there is solid evidence of satisfactory clinker
formation at low free lime levels, the kiln output can
gradually be increased with simultaneous increase of
draught level, feed rate and fuel rate.

Especially the kiln torque and visual inspection of the
clinker are useful parameters to use in order to judge
whether the clinker are well burned. Further analyses
of the clinker litre weight and content of free lime
are useful for judgment of the clinker quality.
The duration of the period from starting of the kiln
feed to full production level is reached, will normally
be 5 - 8 hours.



4.5 Starting and Operation of the Cooler







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See also separate instruction manual.

4.6 Preparations for Calciner Operation

As mentioned above the firing in the Calciner must be
started at the same time as feed taken to the
preheater. However, the following interlockings must be
fulfilled:

- Kiln main burner in operation with ID-fan in
Operation.
- Kiln main drive in operation.
- The temperature in the lower most cyclone stage must
be higher than minimum (750 C.) and lower than max
I (920 C).
- The feed to the preheater is on.
- CO content in the gases after the preheater must not
be higher than max II (0.9%) for more than 10
seconds, and then the fuel rate to the Calciner
must automatically be reduced by minimum 20%. The
burner is then automatically changed to manual
control mode.

The combustion gas/air to the Calciner is controlled
both by adjustment of the ID-fan speed and by changing
the position of the damper in the tertiary air duct.

The draught adjustment should maintain 3-4% oxygen at
the preheater outlet with CO content lower than 0.05%
and an oxygen level between 3-4.5% at the kiln inlet.

Always increase draught before fuel rate is increased
to prevent formation of explosive gases.

4.6.1 Achieving Nominal Capacity






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During the first couple of hours after the production
has been started the feed rate is increased gradually,
however, only concurrently with production of well
burnt clinker.

Adapt feed and fuel so the temperature in the lower
most cyclone stage is maintained at approximately 880 -
890 C., which would correspond to a degree of
calcination of 90-94%. This calcining temperature
should be maintained automatically by the CCR-control
system.

Consequently the kiln production is increased as
follows:

- Increase the draught
- Increase the feed. (Synchronously with the kiln
Speed).
- Increase the fuel supply to the Calciner
(possibly automatically).
- Check whether a change of the kiln fuel is
needed. (Depending of free lime level, litre weight
and torque).

The temperature of the hot air from the cooler to the
Calciner through the tertiary air duct will increase
progressively as the clinker volume is increased.
Therefore the fuel rate to the Calciner will be
reduced.


5 SHUTDOWN

5.1 Normal shutdown of the plant






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It is advisable to shutdown the kiln plant in a
controlled manner by following the sequence outlined
below:

- Reduce the total air-flow to the cooler.
- Stop the fuel to the Calciner.
- Stop the exhaust gas fan and close the
damper (automatically)
This automatically involves that:

- The kiln burner is stopped
- The kiln feed is stopped or switched over to
recirculation back to the CF silo.
- Stop the kiln motor.
- Stop the filter fan and close the motorized
damper ahead of the fan.
- Reduce the amount of primary air to a minimum.

However, a certain amount of primary air is needed to
cool down the burner pipe, if the burner remains in the
kiln.

- Reduce the cooler grate speed. After a few
minutes they can be stopped.

- The cooling air fans can be stopped one by one
gradually.

Start barring operation as outlined in section 9.
BARRING.

Where the shutdown period of the kiln extends over a
prolonged period of time, then all machinery not
required for barring of the kiln and cooling of the






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burner pipe must be stopped. i.e.:

- Stop the dust conveyance system when the system
is empty.
- Withdraw the gas analyzer from the riser duct.
- Stop the compressors.
- Draw up plans for subsequent clean-up operation
in the cyclones, flue ducts and riser ducts.
- Make sure that the cooling water supply for the
kiln bearings is functioning as long as the kiln
is barred.

After the kiln has cooled off:

- Stop the primary air fan and retract the burner.

- Stop the clinker conveying system.

- Inspect the kiln, the cooler, the hot gas ducts
and the preheater.

- Planning of the maintenance- and repair work
required prior to renewed start-up.





NOTE!

The kiln must always be cooled off slowly to prevent
too rapid cooling of the lining in relation to the kiln
shell. Otherwise, the lining may become loose,
involving risk of twisting and drop-out of bricks.







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5.2 Unscheduled shutdowns

In the following a description is given of the most
common types of operational disorders.

5.2.1 Total Power failure

All machines and motors are stopped.

The emergency power generator must be started making it
possible to bar the kiln, to close the fan dampers, to
cool down the burner pipe, to start the nose-ring fan
and to start the first 3 fans of the cooler. Cooling
water for cooling of the support roller bearings must
be available as long as the kiln is barred.

5.2.2 The kiln main burner stops functioning.

If operational status cannot be restored immediately,
the exhaust gas fan must be stopped; thereafter the
shutdown procedure outlined in subsection 5.1 must be
initiated.

5.2.3 The Calciner burner stops functioning

If the Calciner burner can be restarted immediately,
then there is a possibility of restoring stable
operation. Otherwise, the kiln may have to be stopped.

Until the burner can be restarted the kiln feed as well
as the draught should be reduced. The draught in the
Calciner and the preheater is likely to be too low
causing drop-through of material from one preheater






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stage to another. So if the Calciner burner is not
restarted fairly quickly then kiln operation must stop,
and the shutdown procedure outlined in subsection 5.1
must be initiated.

5.2.4 Kiln Feed Failure

If the kiln feed cannot be restarted immediately, it
will be necessary to shut down the kiln. Stop the
exhaust gas fan and follow the shutdown procedure
outlined in subsection 5.1.

5.2.5 Blockage of Cyclones

Blockage symptoms are normally indicated by a drop in
the negative pressure at the bottom of the cyclone or a
drop in the temperature of the material after the
cyclone.

If blockage is ascertained in a cyclone, it is
essential, that the kiln is brought to immediate
standstill in order to avoid overfilling.

Stop the exhaust gas fan and the kiln motor. The feed
is stopped by interlocking.

Then follow the shutdown procedure outlined in
subsection 5.1.

Before the clean-up operation is started, a negative
pressure can be generated by means of the filter fan.

5.2.6 Hot spots on the kiln shell

A shutdown of the kiln will normally be required if the






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kiln shell temperature is higher than 400 C.

An attempt can be made to maintain the kiln in
operation to postpone the shutdown to a more
appropriate time, provided the temperature can be
lowered by means of cooling fans with concentrated
cooling at the hot spot(s).

It is prudent practice to keep the kiln motor running
on minimum speed until the temperature of the hot spot
has been substantially reduced.

If, however, it is not possible to cool the hot spot,
then a kiln shutdown for repairs of the lining is
described in subsection 5.1.

It may be advantageous to make a partial discharge of
material from the kiln by prolonged barring before the
repair of the lining is initiated.


5.2.7 Failure of Clinker Transport

In event of clinker transport failure, the kiln can
normally be maintained in operation for a couple of
minutes before it must be shutdown.

During this period of time an attempt to restart the
clinker transport must be made, but if operation cannot
be resumed, it will be necessary to shutdown the kiln
in accordance with the procedure outlined in subsection
5.1.

5.2.8 Failure of the Cross bar Cooler







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In this case, the precautionary measures which should
be taken are identical to those outlined in subsection
5.2.7.

5.2.9 Failure of dust handling system

Normally, kiln operation may continue for a short
period (if some accumulation of material in the dust
transport system is found to be acceptable, and if the
authorities will allow short periods of kiln operation
without dedusting). If it is not possible to restart
the dust conveyance in this short period, the kiln must
be stopped in accordance with procedure outlined in
subsection 5.1.


6 OPERATION

6.1 General Notes

The kiln performance is optimized by ensuring that
operational kiln adjustments are restricted to an
absolute minimum. The necessary adjustments must be
phased in gradually.

Once all control loops are active, these will ensure
maintenance of:

- the pressure after the exhaust gas fan for
stabilization of the draught.

- the outlet temperature from the Calciner, ensuring
a constant degree of calcination.

- the pressure at the kiln outlet, this contributes






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towards stable cooler operation, and stable
secondary and tertiary air conditions.

- the operation of the cooler, with a battery of
regulators providing uniform cooling by adjustment
of air flows and grate speeds.

The fuel supply rate to the kiln installation is
determined on the basis of an evaluation of the clinker
quality, i.e. the litre weight, free lime content and
the general appearance of the clinker.

Another determinant is the current status of the kiln,
i.e. the trend of the torque curve, the potential
presence of coating formation or other operational
disorders recently encountered.


6.2 Specific Conditions related to kiln operation

In the following a review is made of a range of
specific factors affecting the kiln operation.


6.2.1 Exit Gas Analysis

The exit gas analysis constitutes the most important
source of information for the evaluation of the
combustion process. Therefore, it is of crucial
importance to ensure that the analysis equipment is
functioning properly.

The smoke gases must not contain any unburnt substances
i.e. C (Carbon) or CO (Carbon Monoxide).







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Presence of such gases may, under adverse
circumstances, cause fires or explosions and further,
the loss incurred by wasting the latent heat of the
unburnt part of the gases may be quite substantial.

A CO level of more than 0.1% in the smoke gases may
entail added calorie consumption in the kiln.

Any presence of unburnt substances would indicate
inadequacy of air for the combustion of the fuel. Even
with an adequate air volume, the smoke may contain
unburnt substances due to the fact that the mixture of
fuel and air is not ideal. Therefore, a certain air
surplus should be applied during the combustion
process.

As previously mentioned, the exit gases from the
preheater should contain 3-4% of oxygen. It is possible
to set a lower alarm limit for the oxygen level. For
example, a limit of 2% can be applied. This alarm will
inform the operator about the risk of unburnt
substances in the exit gases.

After the preheater the gas analyser will continuously
monitor the CO level in the exit gases.

The alarm limits should be set as follows:

MAX I : 0.5% CO

MAX II : 0.9% CO

MAX I will signal alarm. Then the operator must make
the necessary adjustments to the combustion process.







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MAX II will signal alarm and after 10 seconds
automatically reduce the fuel rate to the Calciner by
minimum 20%. The Calciner burner is then in manual
control mode.

6.2.2 Primary Air Volume

The primary air is supplied through the burner pipe,
ensuring an effective mixture of air and fuel.
Normally the primary air volume supplied by the fan
constitutes 5-6% of the air volume needed for
combustion.

6.2.3 Temperatures after Cyclone Preheater.

The exhaust gas fan is designed to withstand operating
temperatures up to 400 C. However, short term
temperature rises up to 450 C. can be tolerated.

The following alarm limits should be set:

MAX I : Giving alarm which is 400 C.

MAX II : Causing alarm tripping and
Stoppage of the exhaust gas fan
at a temperature level which is
450 C.
but never higher than 450 C.

Note:
Also one bleed air damper is provided in the downcomer
duct to cool the preheater hot gases whenever the
temperature rises beyond 450
o
C.

6.2.4 Bearing Temperatures






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An excessive temperature in any fan bearing will cause
alarm tripping and automatic switch the fan off. This
applies to the exhaust gas fan, the filter fan and the
grate cooler excess air fan.

An excessive temperature in any supporting roller
bearing will only cause alarm indication, but the
operator must ensure, that immediate action is taken
for the remedy of the situation, if kiln operation is
continued.

6.2.5 Bag-Filter

The operating temperature of the filter must never
exceed the maximum temperature specified by the
supplier.

The thermocouples at the inlet and the outlet of the
Bag-filter casing are connected to electrical
interlockings that will stop the filter fan in case of
elevated temperature.



6.2.6 Blockage in the Cyclones

Changes in the temperatures of the material at the
discharge point from the cyclones, may be signs of
incipient - the beginning stages of a - blockage in the
cyclones.

Negative pressure meters are installed at the bottom of
all the cyclones. If the negative pressure drops during
normal operation, this is, combined with a possible






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change in temperature, confirms a sure sign of
blockage. The pressure gauges will cause alarm
indication, if the negative pressure should drop below
the set minimum value. It is then up to the operator to
assess, on a case by case basis, whether a kiln
shutdown is required.

A drilled hole, with a diameter of about 2 mm must be
present in the connecting bushings for the negative
pressure meters, and it is very important to keep this
hole clean. In case of blockage in the cyclones, the
pressure measurement will gradually move towards zero
as the tube is filled with atmospheric air.

Once blockage in a cyclone has been ascertained, the
operator must ensure that the kiln is shutdown,
thereafter the blockage is removed manually.

Normally, air lances in appropriate lengths are
effective tools. Extreme caution must be exercised
during the clean-out operation.


NOTE!

The temperature of the material cakings may be as high
as 800 C., with attendant risk of sudden outflow of
hot raw meal, flowing as if it were a liquid.

Therefore, it is essential that extreme caution and
care is being exercised during the operation, and it is
advisable that the operators involved are equipped with
heat-insulated protective suits during the clean-out
operation.







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A number of precautionary measures to be taken in a
cement plant are outlined in a separate instruction
manual.

6.2.7 Cakings in the Riser Duct and kiln Inlet

It is possible to detect major cakings in the riser
duct and kiln inlet by checking the difference between
the negative pressures at the kiln outlet and at the
lower most cyclone.

The safety precautions which must be taken during the
clean-up operation are similar to those stipulated for
the cyclones.

Operational experience will show whether the extent and
locations of potential cakings would make it
appropriate to equip the installation with additional
clean-out hatches.

Also it may be practical to install air shock blasters
at appropriate locations.

6.2.8 Kiln Position

The axial position of the kiln on the supporting
rollers is monitored by the thrust device. The alarm
limits must be set as directed in the instruction
manual for the thrust device.

The MAX I alarm is a signal instructing the operator to
undertake inspection of the thrust device and/or the
position of the supporting rollers.







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The MAX II alarm automatically stops the kiln drive for
prevention of damage to the smoke chamber seal, kiln
hood seal or thrust roller.

It may be necessary to check the thrust direction of
the supporting rollers. See separate instruction
manual.

In a critical situation, it may be necessary to apply
oil directly to the supporting rollers if the rollers
tend to thrust the kiln upwards, but it is very
important to ensure that the oil is removed as soon as
possible following the re-alignment of the supporting
rollers.

The lubrication between the supporting rollers and the
kiln tyre must be provided by means of dry graphite
lubrication. See separate instruction manual.

6.2.9 Kiln Lining

The temperatures in the kiln system are so high that
most of the system is protected by means of a lining
which consists of bricks and castable.

It is a prerequisite for smooth kiln operation that the
kiln lining is intact. Consequently, proper maintenance
of the lining is of paramount importance.

Normally, the lining in the preheater, hot-air duct and
in most parts of the cooler will have a lifetime of
several years with no need for replacements.

However, especially the lining installed in the burning
zone of the kiln will require more frequent replacement






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of bricks.

The exact frequency depends on a range of factors, but,
generally, replacement is recommended in case the
thickness of bricks has been reduced to half the
original size owing to wear.

Any damage to the lining involves risk that the kiln
shell will be overheated. Particularly the kiln burning
zone should be kept under continuous supervision.

If the kiln shell temperature should rise to 380-400
C, the affected area must be cooled by means of fans.

In event of a further rise in temperature, the kiln
must be shutdown for repair of the lining.

During operation the condition of the kiln lining can
be checked by installing a radiation pyrometer
(scanner) for monitoring of the kiln shell temperature.
This alarm level should not exceed 400 C.

Whenever access to the kiln is possible during a
shutdown period the opportunity should be taken to
inspect the lining, so appropriate time schedules for
replacement or repair can be worked out.


7.0 INTERLOCKINGS, PROGRAMMING AND CONTROL
CIRCUITS

The various motors, machines, dampers and other
equipment are operated and controlled by the central
control system. In the following the proposed structure
of the control system is described seen from the






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operational and process point of view. A proposal for
grouping of the motors is given below. The general and
special rules of interlockings are listed. A survey of
all process related measurements and their treatment is
given in section 10.

Finally the list of control loops is presented.

7.1 Interlockings

The detailed interlockings, as programmed, are
described in the interlocking diagrams, however, main
philosophy is given below.

The general rule of operational interlockings is that
no machine can be started before the subsequent machine
has been started. Inversely, stop of any machine will
cause the stop of the machine ahead. This follows the
process order.

Protection interlockings like

- bearing temperature
- vibrations
- winding temperature
- minimum oil level
- speed monitors
- skew running
- maximum material level, etc.

will stop the machine in question immediately.
Examples:

- If the speed monitor of an air sluice does not
indicate any rotations, then the motor for this air






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sluice will stop.

- If the vibration level of the kiln exhaust gas fan is
high, then the motor of this fan will stop.

- If the bearing temperature of the clinker breaker is
above the maximum temperature allowed, then this
breaker will stop.

Special interlockings

The special interlockings will be described in the
section of programming as well as in the diagrams
giving the process instrumentation (CAUSE/EFFECT
DIAGRAMS as described in section 10.).

In the control system the various motors and machines
will be arranged in a number of groups for common start
and stop.

7.2 Programming

From the central control room the kiln department can
be operated by selection of a number of programs and a
number of direct functions.

The programs installed in the control system will
perform the start and stop procedures for the machines
divided into groups. Further the operation is
automatically supervised, checking constantly all
interlockings for operation, protection and safety.

The direct functions consist of opening and closing the
dampers and speed control of motors.







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The following programs are proposed. (Please note that
the groupings of machines may be carried out
differently to the proposal, but the main ideas should
be kept).

The following programs are proposed:

1. Blending silo
2. Kiln feed
3. Filter fan
4. Dust transport
5. Bag House control
6. Kiln exhaust gas fan
7. Gas analyzers
8. Kiln auxiliaries
9. Kiln drive
10. Kiln barring
11. Kiln burner fans
12. Kiln burner
13. Calciner burner
14. Clinker transport system
15. Cooler excess air fan
16. Cooler drives
17. Cooler fans
19. Scanners and cameras

The following equipment can be operated individually:

Fan dampers
Changeover gates and dividing gates
Position of valves - oil valves and feed valves
Motors with speed regulation, such as kiln drive and
grate drives.

7.3 Comments to Programs






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For the details of the programming reference is made to
the separate documentation for the PLC system, however,
in the following some important notes are pointed out
in relation to each program. In general all bag filters
should stop with a minimum delay of 15 minutes to empty
the system.

1. Blending Silo

Machines:

Blending silo extraction system
Blower for aeration
Gate
Filter

Conditions to be fulfilled before start:
The filter, the blowers and the silo extraction
sequence can be started at any time.

Conditions to be fulfilled in order to produce:
No conditions. The extraction sequence will be stopped
whenever the kiln feed hopper reaches maximum level.

2. Kiln feed

Machines:

Air slide
Dosing valve
Bottom Gate, dividing gate
Blower for aeration of feed bin
Bucket Elevator
Bag filter






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Sampler

Conditions to be fulfilled before start:
Filter on top of the homogenizing silo is in operation.
The dividing gates are in the correct position
directing the kiln feed or in recirculation mode back
to the Inverted cone-homogenizing silo.

Conditions to be fulfilled in order to produce:
Same as for start:

However, once the program is running, the operator can
change the gates so the raw meal is transported towards
the kiln and Calciner - becoming kiln feed - provided
the exhaust gas fan are operational.
If the feed stops (program 2) for more than 30 seconds,
then the exhaust gas fan must be stopped to prevent
overheating of the preheater. This interlock can be
bypassed during heating up before feeding the kiln.

3. Bag Filter fan

Machines:

Filter fan with damper

Conditions to be fulfilled before start:
Damper to be closed, and filter inlet temperature lower
than the maximum allowed.
Dust transport operational.

Conditions to be fulfilled in order to produce:
Filter inlet temperature below the maximum allowed for
the filter.
Once program 4 is in operation a certain allowed stop






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time of program 5 can be allowed before the filter fan
program 3 will have to be stopped.

4.Dust transport

Selection of which way to send the dust:

1. dust to Blending silo
2. dust to kiln feed

Machines:

Screw conveyor
Air slide
Bucket Elevator
Filter
Gate

Conditions to be fulfilled before start:

For all possible selections, the subsequent transport
equipment must be in operation and the silo level must
not have maximum level alarm.

Conditions to be fulfilled in order to produce:
Same as for start.
NOTE, delayed stop for emptying.

5. Bag filter control

Machines:

Filter fan
Damper







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Conditions to be fulfilled before start:
Damper to be closed.

Conditions to be fulfilled in order to produce.
None.

6. Kiln exhaust gas fan

Machines:

Fan
Damper

Conditions to be fulfilled before start:
Bag filter fan in operation.
Preheater outlet temperature lower than MAX I.
Damper to be closed

Conditions to be fulfilled in order to produce:
Bag filter fan in operation.
Preheater outlet temperature lower than MAX II.
The kiln feed - program 2 - has not been stopped for
more than 30 sec. after having run simultaneously with
the kiln exhaust fan.

7. Gas analyzers

Machines:

Analyzer
Pump

Conditions to be fulfilled before start:
availability of compressed air and cooling water.







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Conditions to be fulfilled in order to produce:
Same as for start.


8. Kiln Auxiliaries

Machines:

Grease pump
Thrust device
Spray lubrication
Cooling fan
Outlet seal fan

Conditions to be fulfilled before start:
None.

Conditions to be fulfilled in order to produce:
None.

9. Kiln Drive

Machines:

Main drive with oil pumps

Conditions to be fulfilled before start:
Barring disconnected.
No alarm for kiln position.
Cooler grate in operation.
Cooler fans in operation.
(These interlockings can be bypassed during kiln start-
up).

Conditions to be fulfilled in order to produce:






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Barring disconnected.
No MAX II alarm for kiln position.
Cooler grate in operation or not stopped for more than
3 minute.
Cooler fans in operation.

10. Barring

Machines:

Barring drive

Conditions to be fulfilled before start:
Main kiln drive stopped.

Conditions to be fulfilled in order to produce:
Main kiln drive stopped.


11. Kiln burner fans

Machines:

Primary air fan
Emergency air fan

Conditions to be fulfilled before start:
None

Conditions to be fulfilled in order to produce:
Once the kiln burner - program 12 - has been put into
operation, then the emergency fan must start
automatically when the primary air fan stops.

12. Kiln burner






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Machines:

Oil/Coal supply:
Pump Station

Conditions to be fulfilled before start:
bag filter fan - program 3 - is in operation.
Kiln exhaust fan - program 6 - are in operation, during
heating up of the kiln a special interlock permission
can be given, that a start-up of the burner without
fans in operation is allowed, however, when the fan
have been started this special interlocking is
automatically cancelled.

Primary air fan in operation - program 11 -.

Conditions to be fulfilled in order to produce:
Same as for start up.

13. Calciner Burner

Machines:

Oil/coal supply:
Pump
Station

Conditions to be fulfilled before start:
Kiln burner in operation - program 12
Kiln fan in operation - program 6
Calciner outlet temperature must be above minimum level
and below MAX II level.
Kiln feed is on - program 2







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Conditions to be fulfilled in order to produce:
Same as for start, however, if the Calciner temperature
rises above MAX II or the CO level after the preheater
has been above MAX II (0.9%) for more than 10 seconds,
then the fuel rate is reduced to minimum level.

14. Clinker transport system

Selection to clinker silo
De-dusting of clinker transport and dust transport

Machines:

Deep pan conveyor
Hammer Crusher
Air sluices below ESP
Screw conveyor

Conditions to be fulfilled before start:
Clinker storage area must not be full.

Conditions to be fulfilled in order to produce:
Same as for start.


15. Cooler Excess Air Fan

Machines:

Fan
Damper

Conditions to be fulfilled before start:
Clinker transport group and cooler dust transport
should run






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Conditions to be fulfilled in order to produce:
Same as for start.

16. Cooler dedusting unit

Machines:

ESP Charging

Conditions to be fulfilled before start:
Clinker transport group and cooler dust transport
should run
ESP fan in operation.

Conditions to be fulfilled in order to produce:
Same as for start.

17. Cooler drives

(Please also refer to cooler instruction manual)

18. Cooler Fans

(Please also refer to cooler instruction manual)

19. Scanners and cameras

Television cameras, monitors and kiln shell scanner can
be operated separately.


7.3 Control Loops

The following control Loops are foreseen.






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1. The kiln feed is synchronized with the kiln speed.

2. The Bag-filter fan speed controls the pressure
measured just after the exhaust gas fan.

3. The temperature in the top of the lower most cyclone
controls the fuel supply to the Calciner burner.

4. The pressure in the kiln firing hood is maintained
by the speed of the cooler excess air fan.

5. The operator can select between the modes of cross
bar control

6. For all cooler fans the measured air flow will be
controlled by the Fan speed.

7.4 Cause/effect diagram

In section 10. cause and effect diagrams are shown. All
instrumentation related to process parameters are
listed. The handling and the use of these signals are
presented.

8. PREVENTION OF FIRES AND EXPLOSIONS

8.1 General Precautions

On no account must, soot non-combustible, unburned exit
gases be allowed to accumulate in the kiln, the
cyclones, the flue ducts etc., since this would involve
a serious risk of explosion or fire.

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needed:

1) In connection with renewed light-up of the kiln,
following a temporary shutdown, it must be firmly
established that the kiln heat (material surface
temperature) is sufficient to ignite the fuel.

If the kiln is too cold, the kiln must be lit in the
normal manner, using the light-up equipment, and, if
necessary, the light-up nozzle, under procedure similar
to that applied during normal heat-up phase prior to
start-up.

2) Always ensure that the burner is not operating with
an air deficiency.

3) Inject the fuel at sufficient primary air velocity,
i.e. with a nozzle velocity for the primary air of
about 180-200 m/s.

4) Never increase the fuel supply rate too suddenly or
excessively at any one time. In any case, the draught
must always be increased first, and the upward
adjustment of the fuel supply must take place evenly
and slowly.


8.2 Precautionary measures relating to the burners

In the following the interlockings for the burners and
the gas analyzers are summarised. The main purpose of
the interlockings is to reduce the risk of any fire or
explosion. Whenever working with fuels, these risks are
present. Although measures are taken to prevent the
dangers, the operator should always observe and act






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carefully when working with fuels and firing equipment.

It is therefore an important interlocking, that a
burner can only operate, if at least one of the gas
analyzers after the preheater is in operation without
any unit alarms or without analyzer fault on the CO
channel.

Further it is conditional for the calciner burner
operation that the CO level has not been over MAX II
(0.9% CO) for more than a few seconds (less than 10
seconds). In this case the fuel rate must be reduced to
minimum automatically.

If the CO level is above MAX I (0.5% CO) or MAX II
(0.9% CO), then the operator must take actions to
reduce this immediately. Depending on the circumstances
these actions could be either to reduce fuel rate or
increase draught.



PROCEDURE FOR GAS ANALYZER TEST MODE

The analyzer has a digital input for permission to test
mode. This input must be set before any local test can
be performed.

The test permission is selected by the operator in the
central control room and is automatically deselected
whenever the analyzer is put into test mode, or if not,
is deselected after 10 minutes by a timer.

The test permission for analyzers must be separated in
three test permissions, one for each analyzer. The test






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mode must always be clearly indicated to the operator.

For further safety, test permission should only be
possible for one analyzer at a time.

8.3 Fuels

For precautionary measures to be taken when using fuel
oil, see separate instruction manual.

Reference is also made to the regulations of the local
authorities.


9 BARRING

9.1 General Instructions

If the kiln is stopped while hot, barring of the kiln
is required to avoid kiln shell deformation.

Normally, barring should always be restricted to an
absolute minimum to prevent damage to the lining.

The hydraulic thrust device and the spray lubrication
system of the kiln drive must be in operation while
barring operation is being performed.

The following guidelines apply to a situation where the
kiln is stopped in a hot condition and is to be barred:

1) As long as the kiln is hot, the barring operation
must not be stopped for more than 10 minutes.

2) If the axial position of the kiln should cause the






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alarm to be tripped, then barring must be
continued until the correct position has been re-
established.

3) If the kiln shell is exposed to strong external
cooling, for example due to heavy rainfall,
then continuous barring is required.

9.2 Barring programmes

The barring programmes are divided into stages of 100
deg. rotation. This is done to ensure variations in the
position of the kiln during standstill.


9.2.1 Barring during drying of the lining before
initial start-up.

0 - 24 hours: About 100 degrees every 30 minutes
24 - 64 hours: About 100 degrees every 15 minutes
64 - 72 hours: Continuous barring.

Keep a close check on the longitudinal expansion of the
kiln and its position on the supporting rollers during
the entire period.

See separate instruction manual for thrust device.

9.2.2 Barring during normal start of cold-state kiln

0 - 8 hours: About 100 degrees every 30 minutes
8 - 16 hours: About 100 degrees every 15 minutes
16 - 24 hours: Continuous barring.

Keep a close check on the longitudinal expansion of the






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kiln and its position on the supporting rollers during
the entire period.

See separate instruction manual for thrust device.

9.2.3 Barring during stoppage and shutdown of the kiln

0 - 1 hour : About 100 degrees every 10 minutes
1 - 24 hours: About 100 degrees every 15 minutes
24 - 48 hours: About 100 degrees every 30 minutes
48 - hours: Barring as required, if some of the
conditions mentioned in subsection 9.1 makes it
necessary.

During the final period the kiln must be barred for a
few minutes, if the axial migration of the kiln exceeds
the maximum value for normal kiln operation.

This barring operation is required to prevent damaging
or possibly rupturing of the thrust roller shaft during
the kiln tube contraction which still may take place up
to the 72nd hour.

Proper graphite lubrication of the supporting roller
surfaces must be ensured. The graphite blocks must rest
loosely in their holders so that the pressure against
the supporting roller surfaces is not hampered.

To protect the surfaces of the supporting rollers and
live-rings against damage as the live-ring slides over
the supporting rollers during the axial movement of the
kiln, it is essential that the mentioned dry matter
lubrication is in order.








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Refractory Dryout Schedule
0
100
200
300
400
500
600
700
800
900
73 69 65 61 57 53 49 45 41 37 33 29 25 21 17 13 9 5 1
Hours
T
e
m
p
e
r
a
t
u
r
e

D
e
g
.
C
Top Cyclone
Bottom Cyclon
24 hr. Preheat Schedule
0
100
200
300
400
500
600
700
800
900
25 23 22 20 19 18 16 15 14 12 11 10 9 7 6 5 3 2 1
Hours
T
e
m
p
e
r
a
t
u
r
e

D
e
g
.
C
Top Cyclone
Bottom Cyclon






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9.3 Braking


If the barring operation is stopped, the kiln is
automatically braked and maintained in an arbitrary
position. Therefore, the kiln may be side heavy; this
fact must be taken into account when the brake is
slackened.

Reference is also made to the instruction manual for
the barring device.


10 CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS AND
ALARM LIMITS.

The following tables are a survey of the expected
normal operating parameters and the normal alarm
limits.

The operating parameters stated are for guidance only
and apply to the normal, stable operating situation.
The operating limits stated are meant as guidance for
start-up. It will be possible to adjust many of these
with advantage later on in order to make them more
suitable for the actual operation. Concerning many of
the alarm limits they too will have to be adjusted
according to local conditions as factors like the
lubrication oil selected, the ambient temperature,
etc., will affect the values.

The mechanical and/or the electrical departments must,
in every single case, approve the change and fixing of
the alarm limits for protection of the machines.






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Normally, the alarm limits for the operating parameters
will be the responsibility of the production
management.

SEE ALSO INSTRUMENTATION INSTRUCTION MANUAL AS WELL AS
FLOWSHEET FOR CODES AND INSTRUMENTATION.

The following process instrumentation/indications are
required:
Notes used in the instrument and alarm table:
a: Refer to mechanical and electrical documentation for
the equipment.
b: To be set empirically at a level not activating the
alarm under normal operating conditions.
x: To be evaluated during commissioning.
Kiln feed
Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Raw meal
feed
t/h
0-
307
256
kW of
elevator
kW
a

Preheater
Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts






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Page 64 of 68

Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Temperatu
re of
gases in
the down
comer
duct
C
0-
600

332 380 450
Pressure
in the
down
comer
duct
mmw
g
-
700
to
0
-
446

Temperatu
re of
gases in
the duct
after the
1
st

cyclone
C
0-
600
334 380

450


Temperatu
re of
material
from 1
st

cyclone
C
0-
600
329
Pressure
in the
duct
after the
1
st

cyclone
mmw
g
-
700
to
0
-
420

Pressure
in bottom
of 1
st

cyclone
mmw
g
-
700
to
0
-
420







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Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Temperatu
re of
gases in
top of 2
nd

cyclone
C
0-
600
527
Temperatu
re of
material
from 2
nd

cyclone
C
0-
600
522
Pressure
in the
duct
after the
2
nd

cyclone
mmw
g
-
600
to
0
-
340

Pressure
in bottom
of 2
nd

cyclone
mmw
g
-
600
to
0
-
340
150
Temperatu
re of
gases in
top of 3
rd

cyclone
C
0-
100
0
690
Temperatu
re of
material
from 3
rd

cyclone
C
0-
100
0
685
Pressure
in top of
3
rd

cyclone
mmw
g
-
600
to
0
-
295







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Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Pressure
in bottom
of 3
rd

cyclone
mmw
g
-
600
to
0
-
295
120
Temperatu
re of
gases in
top of 4
th

cyclone
C
0-
100
0
821
Temperatu
re of
material
from 4
th

cyclone
C
0-
100
0
811
Pressure
in top of
4
th

cyclone
mmw
g
-
400
to
0
-
250

Pressure
in bottom
of 4
th

cyclone
mmw
g
-
400
to
0
-
250
80
Temperatu
re of
gases in
top of 5
th

cyclone
C
0-
120
0
890 750 920

980


Temperatu
re of
material
from 5
th

cyclone
C
0-
120
0
870
Pressure
in top of
5
th

cyclone
mmw
g
-
400
to
0
-
200







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Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Pressure
in bottom
of 5
th

cyclone
mmw
g
-
400
to
0
-
200
60
Position
of
divider
gate
after 4
th

cyclone
%
0-
100


O
2
out of
5
th

cyclone
%
0-
10
3.0

CO out of
5
th

cyclone.
ppm
0
to
200
00
0
Max.
1
5000
Max.
2
9000
Max.
3
1200
0

O
2
out of
cyclone
preheater
%
0-
10
3.9

CO out of
cyclone
preheater
ppm
0
to
200
00
0 Max
.1
500
0
Max
. 2
900
0
Max
. 3
120
00

Calciner
Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Temperatu
re of
tertiary
air
C
0-
120
0
950







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Page 68 of 68

Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Temperatu
re in the
reduction
zone
C
0-
120
0


Temperatu
re in
exit of
calciner
C
0-
120
0
895 750 820

Pressure
in
tertiary
air duct
mmw
g
-
200
to
0
-
100

Position
of
hoisting
damper
%
0-
100


Coal flow
to
calciner
burner
t/h
2.0
-20
1.4
-
14.
7


Kiln
Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Kiln
torque
Amp


Kiln
speed
rpm
0-5 3.6

Axial
movement
of the
kiln
mm
-30
-
+30
a
a






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Page 69 of 68

Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Pressure
in kiln
inlet
mmw
g

-
100
to
0
-30

Temperatu
re in
kiln
inlet
C
0
to
120
0
108
0


O
2
in kiln
inlet
%
0-
10
4.2 1

CO in
kiln
inlet
ppm 0-
200
00
0 Max
.1
500
0
Max
. 2
900
0
Max
. 3
120
00

NO
x
in
kiln
inlet
ppm 0-
200
0

Kiln Burner
Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Coal feed
to kiln
t/h
1.3
-
13.
5
1.0
-
10.
8


Primary
air fan
speed
%
0-
100


Power for
primary
air fan
kW
a

Primary
air
pressure
mmw
g
a







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Page 70 of 68

Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Primary
air flow
m3/
min
a

Damper
position
for
emergency
cooling
of
burner
ope
n /
clo
sed
clo
sed


ID Fan
Uni
t
Ran
ge
Exp
.
Val
ue
Min
. 2
Min
. 1
Max
. 1
Max
. 2
Comme
nts
Position
of ID fan
damper
%
0-
100
100

Motor
power for
ID fan
kW
0-
1700
1072

Pressure
after ID
fan
mmw
g
*)
-30
to
+30
-20 0 +20

ID fan
speed
%
0-
100


*) + indicate pressure above the atmosphere, - indicate
pressure below the atmosphere.