Kiln Operations Guide lines

PB:Ghassan AL-Abbadi

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 Kiln Operations Guide lines

Our objectives

• To produce more
• To produce with regularity
• To produce cheaper

Stable kiln operations are the key to achieve our objectives

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 Kiln Operations Guide lines

Prerequisites

P1 - Raw mix preparation

P2 - Fuel preparation
P3 - Burner adjustment
P4 - Reliable sensors
P5 - Free lime follow-up

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Rules

R1 - Constant kiln volume load

R2 - Constant cooler clinker bed depth
R3 - Cooler fans blowing according to predefine table
R4 - Constant kiln hood pressure
R5 - Constant Oxygen and in excess at kiln back end
R6 - Oxygen in excess at tower exit
R7 - Constant ID fan outlet pressure
R8 - Proportional amount of fuel to kiln feed rate –
Production ramp up
R9 - Constant calcinations
R10 - Maximize production to minimize heat consumption

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P1 – Raw mix preparation

100m 10%
• Raw mix residues target
200m 1%

• Lime saturation
100C
LSF  Between 90 and 98
2.8S  1.18 A  0.65F

100(2.8S  1.65 A  0.35F  C )

bc  Between –4 and +4
S  A F C

Potential C3S content of

C3S  4.07C  (7.6Ssol  6.72A  1.43F) clinker when the free lime is
zero and calculation LOI=0.

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P1 – Raw mix preparation

C3S Raw Mix Sensitivity

% SiO2 % Al2O3 % Fe 2O3 % CaO % LOI LSF C3S
Team 1 15.0 2.9 2.1 44.6 35.0 99.6 69.4
Team 2 15.2 2.9 2.1 44.4 34.9 99.5 65.6
Team 3 15.4 2.9 2.1 44.2 34.7 99.3 61.9
Team 4 15.6 2.9 2.1 44.0 34.6 99.2 58.2

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P1 – Raw mix preparation

S
• Silica ratio SR 
A F
SR: 2.3 to 3.0 constant at ± 0.1

SR Burning Liquid phase Coating Clinker Cement

strength
Low Easy Excessive, Too Balling, Low
attack to thick, hard
bricks unstable
High Hard Low, high No Dusty, High
thermal load high free
lime

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P1 – Raw mix preparation

A
• Alumina ratio AR 
F
AR: 1.3 to 2.0 constant at ± 0.1

AR Liquid phase Clinker Cement strength

Low Fluid If AR<0,64 No Low early

C3A in clinker strength

High With low F, High early

insufficient liquid strength
phase is formed
(Viscous liquid
phase)

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P1 – Raw mix preparation

• KFUI = Kiln Feed Uniformity Index

• KFUI is the index to monitor the kiln feed chemistry

uniformity, it is used in all plants and all technical
centres of Lafarge

• Kiln Feed Uniformity Index <14

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P1 – Raw mix preparation

• The chemistry uniformity is monitored through C3S

(main clinker phase) and an associated target

• “Average of the squared difference between an

instantaneous kiln feed sample C3S value and the
C3S target, on a daily basis”

1 N
KFUI 
N
 (C S
i 1
3 i  C3 S T ) 2

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P1 – Raw mix preparation: Effect of bad KFUI

Combustion regularity
Calorific consumption
Kiln stability
Brick life
Clinker output
Effects on Volatilization of SO3
PROCESS Equipment life (cooler)
Grindability (kWh/t)
Cement mill output
KILN FEED
Clinker quality
UNIFORMITY Regular clinker quality
 C 3S
 f-CaO

Effects on
 mechanical strengths
Mechanical strength
PRODUCT
Cost
CC/CK ratio
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P1 – Raw mix preparation: Reasons for bad KFUI

PREHOMOGENIZATION

MINING VARAIBLE MATERIALS

KILN FEED RAW MILL FEDDERS

ACCURACY
UNIFORMITY

BLOCKAGES
HOMOGENIZATION

ANALYZER KILN DUST MANAGEMENT

KFUI > 30 Emergency action plan

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P2 – Fuel preparation: solid fuel

• Solid fuel residues

Target S fuel < 4% S fuel > 4%

0% 200 µm

< (0.5×VM*) % 90 µm 63 µm

*VM: volatile matter

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P2 – Fuel preparation: Liquid fuel

• Keep a viscosity of 17 cST to obtain satisfactory

atomization
• Viscosity decreases with higher fuel temperature
• Fuel heating temperature to achieve required viscosity
depends on fuel oil type
• Example: 120°C minimum for a bunker C fuel oil (n° 6)

• Filter at 125 µm to protect pumps and nozzles

injectors

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P2 – Fuel preparation: Fuel atomizer MY

The flow is adjusted by the fuel pressure and

operates adequately for a flow
ranging between 80 and 100% of the
fuel scale. If the flow differs, the orifice plate
and atomizer must be replaced.
On stabilized operations, pressure
nozzle range around 40 bars
The primary / secondary pressure differential
allows the adjustment of the divergence
angle of the streams jet (optimization)

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P3 – Burner adjustment

• Be lined up with the kiln axis using laser beam to avoid

that the flame licks:
• Either the material in the zone with the risk of local formation of
CO and thus volatilization of sulphates
• Either the walls with the risk of refractories or coating destruction
• Flow rate at the burner must be constant at ± 1%
• Flame must be:   
• a. Sharp
• b. Narrow
• c. Strong
• d. Attached to the burner
• e. Avoid the flame to impinge the bricks or the clinker bed.

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P3 – Burner adjustment: Lafarge burner

Influence of the rotational and Axial air on the flame

Impulse Swirl
Liquid 5,0 N.h. GCal-1 0,1
fuel
Coal 6,0 N.h. GCal-1 0,1
Coke 7,5 N.h. GCal-1 0,1

Gas 7,5 N.h. GCal-1 0,05

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P4 – Reliable sensors
Sensors Scales Comments
O2 0 /10% Measured inside the kiln (50 to 80
cm in the Kiln), ¼ superior
opposite kiln bed depth
CO 0 / 3000 ppm “
NOx 0 / 2000 ppm “
SO2 0 / 30000 ppm Mandatory if usage of fuel with
high S content
BZ temperature 0 / 2000°C Measured with pyrometric camera

Calcination 0 / 1000°C Measured with thermocouple

temperature probe representative and well
placed (far from buildups)

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P4 – Reliable sensors

Sensors Scales Comments

Kiln hood + 5 / - 10 Measured in 3 points, using big diameter pipe
pressure mmWG tubes with easy cleaning facilities
Kiln amps
ID fan outlet + 10 / - 50
pressure mmWG

Cooler under 0 / 100 mbar Immediate chamber after fixed part (kids) or 2nd
grate pressure chamber
Clinker 0 / 500°C Measured with pyrometer
temperature
Free lime 0 / 5%

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P5 – Qualifier Sensors for free lime

• The free lime content is an indicator of the state of

the burning
• Setting time is a function of the free lime content

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P5 – Qualifier Sensors for free lime

Free lime analyzer = the last direct indicator of the quality for clinker
burning.
Amps F-CaO
NOx
BZT
GLW

Gamma
Advance 15 mn
NOx
Advance 25 mn
T Zone
Advance 35 mn
Amps
Advance 46 mn

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P5 – Qualifier Sensors for free lime

• Take into account trends and not only values

• Free lime signification for well proportioned raw

material
• Free CaO > 2.0% under burning
• 0.5% < Free CaO < 2.0% well burnt
• Free CaO < 0.5% over burning

• Free lime stability


FLUI  free lime
1
0.2  free lime  0.1
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R1 - Constant kiln load volume: Why?

• Because Operating the kiln with an irregular bed

depth
• Makes the clinker pour irregularly into the cooler
• Influences heat exchanges between gases and material
• Impacts on the state of combustion in the burning zone
• Makes the kiln torque signal to be less representative to
kiln state anymore

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R1 - Constant kiln load volume: Indicator

• The kiln speed is proportional to the kiln feed

Kiln speed = k ∙ kiln feed

The k factor characterizes each kiln

• In general, maximum kiln speed is reached at maximum

kiln feed

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R1 - Constant kiln load volume: Recommended values

• Kiln speed/kiln ratio feed has to be calculated by

the process engineer

• Takes into account kiln dimensions, process,

clinker reactivity

Wet kiln Grate preheater Preheater Precalciner

1.2 rpm 1.2 rpm 2 rpm 3.5 rpm

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R2 - Constant cooler clinker bed depth: Why?

To maximise & regularise heat recuperation

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R2 - Constant cooler clinker bed depth

• Indicators Constant bed depth

=
Constant under grate pressure measured in the first
chambers
=
Adjust cooler grate speed and never change the fan
volume that impacts this under grate pressure…

• Recommended values
• Cooler bed depth must be maximized.
• On new cooler generations range from 500 to 800 mm high, measured
in the first grate can be reached.

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R3 – Cooler fans predefine tables

• Why?
• To maximise heat recovery
• To supply secondary and tertiary air
• To cool enough the clinker and avoid clinker transport
problems and maintain cement mills operation efficiency

• Indicators
• Air flows
• Outlet cooler clinker temperature

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R3 – Cooler fans predefine tables: Recommended values

• On the first chambers Chamber# 1 2 3

• fluidized clinker bed Air flow density (Nm3/m2/.s) 1,5 1,3 1
• fixed fan volume, air flow density must be constant
• On the last chambers Average air flow : 1,8 – 2,5 Nm3/kg clinker
• non-fluidized bed
• cooler fan volume proportional to clinker production rate, do
specific air flow (Nm3/kg clinker) adjustments on the last
chambers to maintain a constant Air flow/Clinker ratio
• Clinker temperature at the cooler outlet
• Good performance = 100°C
• Unacceptable > 150°C (cement false set…)
• Conversely, too cold clinker must be avoided, the temperature
inside the cement mill may not be sufficient to form enough semi-
hydrate in the cement.

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R4 – Constant slightly negative kiln hood pressure

Why? For safety issues:

Positive pressure gas/material puffing, spillages

If hood pressure is too negative Impact Risk of

Hood air in leak  Discharge end ring

Secondary air  CO

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R4 – Constant slightly negative kiln hood pressure

• Lever: Controlled by cooler exhaust fan which extracts excess air

from the cooler

• Kiln hood pressure setting point

• –2 to –7 mmWG.
• depends on its stability: the more stable the pressure, the closer to
zero it can be.

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R5 – Constant oxygen & in excess at kiln back end:

Why?

• To avoid formation of CO which gives less energy where we

want it
C + O2 CO2 + 97.6 kcal C + ½ O2 CO + 29.4 kcal

• To minimize volatilization & cyclic operations

• To guarantee uniform clinker quality especially sulfate

fluctuations

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R5 – Constant oxygen & in excess at kiln back end:

Levers

• Kiln back end O2

Increase Kiln back end O2 set point If

CO level at kiln back end > 100 ppm
Hot meal analysis on stage 4
•SO3 > 2,5 %

• Kiln back end O2 Standard deviation

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R5 – Constant oxygen & in excess at kiln back end:

Recommended values

• For Precalciner kiln O2 set point from 3 to 5%

• Standard deviation measured by 1-minute average
values over 24 hours
4,5

• Very good if  O2  0.2% 3,5

2,5

2
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

mi nute s

4,5

 O2  0.4% 4

3,5

• Very bad if 3

2,5

2
1 3 5 7 9 11 13 15 17 19 21 2 2 2 2 31

minut e s

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R6 – Oxygen in excess at tower exit

• Why?
• Too low O2 level will drive to formation of CO in preheater
tower & possible explosion in the electrostatic precipitator:
When the CO produced finds some oxygen, it burns as
follows
• CO + ½ O2 CO2 + 68.2 kcal = Explosive
reaction if there is a spark!
• Too high O2 level will drive to possible loss of production
• Indicators
• O2 tower exit value
• Take also into account
• Carbon included in the raw material
• False airs
• Recommended value: Generally 3% < O2 < 5%
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R7 – Constant ID fan outlet pressure

Why? Stable pressure will avoid perturbations from

raw mill, GCT to the kiln

If ID fan outlet pressure

positive

Circuit head loss

ID fan volumetric flow 

 O2 

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R8 – Proportional amount of fuel to kiln

feed rate – Production ramp up: Why?
Kiln feed increase
Fuel t/h
8,00

7,00

6,00

B
more material to be burned 5,00

4,00

3,00

proportional fuel increase 2,00

A
1,00

Fuel = A ∙ kiln feed + B 0,00

0 10 20 30 40 50 60 70 80 90 100

Kiln feed t/h

B = constant function of heat wall losses

Ratio Kiln Speed

Feed rate

Ratio Burner Fuel Ratio Draft

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R8 – Proportional amount of fuel to kiln

feed rate – Production ramp up: Indicator

• Kiln specific heat consumption (SHC)

SHC Specific Heat

Consumption
kcal/k ck
1200
1175
1150
1125
1100
1075
1050
1025 A
1000
975
950
925
900
875 B
850
825
800
18 23 28 33 38 43 48 53 58

Clinker t/h

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R8 – Proportional amount of fuel to kiln

feed rate – Production ramp up

Recommended values
• Create operation table for • Questions to be raised in
kiln feed to fuel rate case of drift on SHC (A or
taking in consideration B)
• Kiln specific heat • Calibration of the feeders
consumption • Raw mix chemistry
• Heat wall losses • Raw mix uniformity
• Fuel calorific value • Fuel Calorific Value

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R9 – Constant calcination: Why?

• To avoid a shift of the burning zone

Ignition point = Start of liquid phase

Calcination 

Calcination 

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R9 – Constant calcination: Why?

• Indicators
• Bottom cyclones, riser duct temperatures
• Hot meal stage 4 calcination level
• Recommended values
• Calcination level controlled by temperature probe found to
be representative (bottom cyclones, riser duct) with a
control loop acting on secondary burner fuel rate.
• Set point around 850°C
• Ratio main burner / secondary burner almost constant &
mastered on continuous basis Type of kiln % calcination

Preheater AT 55 - 70%

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Preheater AS 90 – 92%
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R10 – Maximize production to minimize

Heat consumption

Why? Because the maximum production minimizes

the heat consumption:

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R10 – Maximize production to minimize

Heat consumption

• Indicators
• If the ID fan is at nominal ventilation : the only actuator to
maintain kiln condition is the feed rate
• If the ID fan is below nominal ventilation, give priority to
feed rate and use fuel and ID fan to control combustion
• Recommended values

ID fan draught margin

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