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