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Kiln Start Procedure (Wonder Cement LTD)

1. The document outlines the start up and shut down procedures for a cement kiln, including starting various equipment like compressors, fans, pumps, and firing systems in a specific sequence to safely bring the kiln online. 2. It provides details on heating the kiln according to a schedule, starting additional equipment once certain temperature thresholds are reached, and regulating dampers and fans to control temperatures. 3. The procedure describes initiating the kiln feed and achieving full production rates once the kiln is up to temperature and operating properly, and then similarly shutting down equipment in reverse order to safely take the kiln offline.

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Satish Kumar
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175 views3 pages

Kiln Start Procedure (Wonder Cement LTD)

1. The document outlines the start up and shut down procedures for a cement kiln, including starting various equipment like compressors, fans, pumps, and firing systems in a specific sequence to safely bring the kiln online. 2. It provides details on heating the kiln according to a schedule, starting additional equipment once certain temperature thresholds are reached, and regulating dampers and fans to control temperatures. 3. The procedure describes initiating the kiln feed and achieving full production rates once the kiln is up to temperature and operating properly, and then similarly shutting down equipment in reverse order to safely take the kiln offline.

Uploaded by

Satish Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Kiln Start Procedure(Wonder cement Ltd)

1 Start the compressors and water pumps


2 Open the PH O/L fresh air dampers (20% each or if only one 40%)
3 Start the PA blower (Starting Pressure 800-1000 mmwg) and PA fan
(600-700 RPM)
4 Start the Diesel Firing
5 Start Kiln GB, Girth Gear pump, Roller pumps and thruster pump
6 Rotate the Kiln according to schedule
7 Kiln heating should be done according to the 'Heating schedule' and
increase the temp. as per the schedule
(Maintain the Kiln I/L temp by regulating the PH O/L fresh air
dampers(Check kiln I/L temp. regularly)
8 No need to open the PH fan I/L dampers while heating the kiln until
there is a margin in fresh air dampers
9 After achieving temp 350, Start the Bag House fan before the coal
firing and maintain the Junction Draught between -20 mmwg and
-30 mmwg
10 Open the PH Fan I/L damper 5 to 10%
11 Start the Coal Firing as per the 'Heating schedule' (Also increase the
PA blower pressure)
12 Rotate Kiln on 'aux drive' continuously
13 Regulate the TAD dampers to increase the kiln I/L temp and PC temp
14 After achieving temp 500'C, start the Nose ring fans, kiln I/L cooling
fan(tongue plate cooling fan) and TAD cooling fan and Bull Nose
cooling fan
15 Start the two or three fans of CIS after achieving temp 500 (If need
start before)
16 Take all the trials of listed below during the 'Heating schedule'-
(a)Cooler fans,(b)Cooler drives(grates),(c)PH fans(I/L dampers
should be closed),(d)Kiln main drive and its cooling blowers
(e)Cooler ESP fan,(f)DPC and Cooler crusher,(g)KF rotary air locks
and slide grates (h) Calciner firing blower (i) Kiln feed Elevator
(j)Cooler ESP transport group,(k)Mixing bin Group

Open TAD damper > 75% before taking feed


After achieving the desired Kiln I/L temperature and Kiln is ready to
start
1 Start the PH fan(I/L damper should be closed)
2 Start the Kiln Feed group except SFM
3 Start Cooler fans(Ist grate fans should be between 50 and 60%, Rest
will be 30 to 40%)
4 Open the PH fan damper 100%
5 Start ESP fan and maintain the hood draught between -5 and -7 mmwg
6 Start cooler grates at minimum speed(3 SPM)
7 Stop auxiliary drive and start main drive (0.8 RPM)
8 Start the thruster pump group
9 Start shell cooling fans
10 Increase the PH fans RPM (585 for 160TPH,)
11 Close the PH Fresh air dampers(one damper can be about 30% to
control PH fan I/L temp)
(All the cone draught should be > -30 mmwg)
12 Start the feed(SFM with 160 TPH)
13 Start the Calciner coal firing
14 Maintain the calciner O/L temperature between 860 to 880
15 Increase the feed and RPM according to kiln condition

After starting the kiln-


Maintain the hood draught between -5 and -7 mmwg
Maintain the junction draught between -25 and -35 mmwg
Try to maintain PH O/L O2 4 to 5%(Initially 7%)
Increase PA blower pressure up to 4000 mmwg
Maintain the cooler bed height 75 to 80 cm
Maintain Calciner O/L temp as per kiln condition

Kiln Stop Procedure


Stop the feed
Stop the calciner firing
Reduce the Kiln RPM
Close the PH fans dampers and reduce the PH fans speed(minimum)
and open the fresh air dampers.(But be careful to maintain the hood
draught by regulating the cooler fans and cooler ESP fan)
Stop or reduce kiln firing as per schedule
Reduce the PA fan pressure
Stop main drive and start auxiliary drive
Stop shell cooling fans
Reduce the cooler SPM ( minimum)
After some time stop the cooler
Reduce the cooler fans speed(minimum)
After some time stop the cooler fans (except starting 4 fans)
Cool down the kiln as per schedule by regulating the PH fresh air
dampers

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