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Kiln Control Unicemfinal

This document provides training on kiln control for a cement production process. It discusses the objectives of kiln operation, key control parameters like back end temperature and burning zone temperature, control variables that can be adjusted like fuel rate and feed rate, maintaining stable operation, responding to upset conditions, and examples of issues like ring falls and their detection and resolution. The goal is to maintain consistent clinker quality, stable operation, and maximum efficiency through monitoring and adjusting these control points.

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OUSSAMA LAKHILI
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100% found this document useful (1 vote)
459 views26 pages

Kiln Control Unicemfinal

This document provides training on kiln control for a cement production process. It discusses the objectives of kiln operation, key control parameters like back end temperature and burning zone temperature, control variables that can be adjusted like fuel rate and feed rate, maintaining stable operation, responding to upset conditions, and examples of issues like ring falls and their detection and resolution. The goal is to maintain consistent clinker quality, stable operation, and maximum efficiency through monitoring and adjusting these control points.

Uploaded by

OUSSAMA LAKHILI
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 26

Manufacturing Workforce Training

PRODUCTION

Operation Area(s): Clinker Production


Category: Process Operation & Control
Module/Sub-Module: Kiln Control
Presentation Name: Kiln Control
Version: 1.1
Date: 09-07-03
General Considerations

Objectives of kiln operation:


▪ Protection of equipment and personnel
▪ Production of consistent clinker quality

▪ Smooth and stable process operation


▪ Maximum thermal efficiency

▪ Maximum production rate

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameters

Control parameters of a kiln system:


▪ Back End Temperature (BET)
▪ Burning Zone Temperature (BZT)

▪ Oxygen concentration of the combustion gases at


kiln inlet

Control parameters of a precalciner system:


▪ Precalciner outlet temperature
▪ Oxygen concentration of the combustion gases at
precalciner exit

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameters (BZT)

BZ
T
NO
x

Amp
s

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Kiln Amps (BZT)

x x

Hot kiln Cold kiln

Hot kiln = High torque ⇒ High kiln Amps

Cold kiln = Low torque ⇒ Low kiln Amps

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Variables
Control variables of a kiln system:
▪ Fuel rate to kiln
▪ Material feed rate to kiln
▪ Kiln draft (ID fan speed or damper position)
▪ Kiln speed
Control variables of a precalciner system:
▪ Fuel rate to precalciner
▪ Precalciner draft (ID fan speed or damper position /
tertiary air damper or kiln orifice)

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameters and Variables
Wet kiln

Oxygen (for coal)


1.5 –2 %
BZT BET
~800 °C
~1450 °C

Fuel rate Kiln speed Feed rate Kiln draft

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameters and Variables
Lepol kiln

Oxygen (for coal)


1.5 - 2.5 %
BET
~1000 °C
BZT
1450 °C

Fuel rate Kiln speed Feed rate Kiln draft


(H2O/RM)

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameters and Variables
Precalciner kiln

Oxygen after PC
1 - 1.5 %

Oxygen at KI
(for coal) 2.5
BZT BET - 3.5%
~1150 °C
1450 °C

Fuel rate Kiln speed Kiln draft Feed rate


and PC draft
Fuel rate PC

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameter Condition
Control parameters can be assigned to a certain
state, depending on the actual value.
Example for kiln with preheater (limits may vary):

BZT BET Oxygen

LOW <1430 °C <980 °C < 2.0 %

O.K. ~1450 °C ~1000 °C ~2.5 %

HIGH >1470 °C >1020 °C > 3.0 %

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameter Condition
Decision tree
27 states

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Objective of Kiln Control
▪ The objective is to maintain a stable kiln system,
i.e. close to case 14, which is:


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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Counter Action (1)
▪ Example 1: counteraction for case 18:

▪ Action: 1. Decrease kiln draft to decrease


oxygen and BET
2. Decrease fuel rate slightly to decrease
BET and to compensate BZT increase of step 1

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Control Parameters and Variables
Preheater kiln

Oxygen (for
BET coal) 1.5 - 2.5%
BZT ~1000 °C
1450 °C

Fuel rate Kiln speed Kiln draft Feed rate

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Counter Action (2)
▪ Example 2: counteraction for case 9:

▪ Action: 1. Decrease kiln speed to increase


BZT and decrease feed rate
2. Decrease fuel rate to increase oxygen
and to prepare for step 3
3. Decrease kiln draft to decrease BET

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Upset Conditions
▪ Upset conditions are abnormal process conditions which
disturb kiln operation and lead to loss of production
▪ The most common upset conditions are:
- Ring fall
- Coating fall
- Hot meal flush
- Red spot on the kiln shell
- Cyclone blockage
- ……..
- ……..

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Ring Fall

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Ring Fall
▪ Detection:
▪ Clinker ring: sharp increase of the grate cooler chamber pressures, increase
in secondary air temperature, smooth drop of the kiln amps, drop in the kiln
inlet pressure
▪ Sinter, ash and middle ring: cooling of burning zone, smooth drop in the kiln
amps and possible drop in the kiln inlet pressure

▪ Counter measures:

▪ Clinker ring: reduce kiln speed, increase cooler grate speed (if possible,
depending on clinker discharge temperature and cooler crusher power)
▪ Sinter ring, ash ring and middle ring: depending on general kiln condition
according counter action 1 - 9 (BZT low)

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Coating Fall

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Coating Fall
▪ Detection:
▪ Sharp increase and widening of amplitude in the kiln amps (if coating breaks
out uneven), increase in the grate cooler chamber pressures

▪Counter measures:
▪ Reduce kiln speed and decrease cooler grate speed (if required to protect the
clinker crusher or to avoid high clinker discharge temperatures)

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Cyclone Blockage
▪ Detection:
▪ Pressure decrease, measured in the cone of the cyclone (quickest
response)
▪ Radiation Detector

▪ Counter measures:
▪ Shut down kiln and clean blockage

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Hot Meal Flush

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Hot Meal Flush
▪ Detection:
▪ Drastic drop in the BZT, hot meal enters the cooler, kiln becomes dark, flame
hardly visible

▪Counter measures:
▪ Reduce kiln speed drastically, decrease feed rate, but less than the kiln speed
in order to avoid an excessive BET
▪ When BZT recovers: subsequent reduction of the kiln filling degree to normal,
emptying out of the kiln

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Red Spot on Kiln Shell

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Red Spot on Kiln Shell
▪ Detection:
▪ Red shining spot is visible, alarm of kiln shell scanner
▪Counter measures:
▪ Shut down kiln if:
▪ the affected area is bigger than 1 m²
▪ the affected area is in a zone where no coating formation is possible
▪ the affected area cannot be covered with coating within a certain time
(more than 4 h)
▪ the red spot is close to or under a tire

▪ Try to build coating on the affected area by shifting the reaction zones up and down
(moving the burner in and out of the kiln, kiln speed variation) if:
▪ the red spot is in the burning zone and smaller than ~1 m²
▪ shell is not extremely hot (cooling of the shell with fans help form coating)

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
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Cyclone Blockage

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Holcim Group Support Manufacturing Workforce Training - Kiln Control.ppt
Production

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