Training OHORONGOFA

Pyroprocessing components and operation

Polysius Academy
Neubeckum, June 2010

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
1 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line

OHORONGOFA 24.05.2010
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
2 Polysius
Overview - production sequence in a cement plant

... from raw material through raw meal and clinker to cement ...

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
3 Polysius
Overview - production sequence in a cement plant

6
10
5
1 2
6
3 4 7 8 9 11 12

1. Crushing
7. Preheating and calcining
2. Material analysis
8. Burning
3. Intermediate storage and
9. Cooling
blending
10. Storage
4. Proportioning
11. Grinding
5. Grinding
12. Storage, packing and loading
6. Homogenising
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
4 Polysius
Overview - process functions of plant sections
•Déshydration de l’eau et évaporation
•Préchauffage de la farine crue
•Refroidissement des gaz à la cheminée
•Décarbonatation partielle de la matière

•Chauffage de la matière
•Combustion
•Decarbonatation

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
5 Polysius
Overview - basic temperatures and flows
80 °C 340 °C; To raw mill
and / or EP

Pre heater
Calciner
900 °C
Tertiary Air Duct
Fuel
55 – 60 %

1700 °C Fuel 280 °C; to EP

860 °C Rotary kiln
40 – 45 %

350 °C
1400 °C
Clinker cooler
80 - 100 °C

Pyroprocessing components and operation

11.09.20
Ambient air temp.
Training OHORONGOFA, Träder, Kai
6 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / Calciner

Rotary kiln

Cooler

Operation of the kiln line

OHORONGOFA 24.05.2010
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
7 Polysius
Preheater / calciner - topics

Gas and material flow

Cyclon functioning

Double rotary airlock feeder

Pneumatic flat slide gate

Hot meal pendulum flap

Calciner types

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
8 Polysius
Gas and material flow

Meal

Gas
Material Gas

Secondary firing

Gas
Meal
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
9 Polysius
Cyclone functioning

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
10 Polysius
Cyclone functioning

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
11 Polysius
Cyclone functioning

= 85 micra

= 71 micra

= 57 micra

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
12 Polysius
Double rotary airlock feeder

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
13 Polysius
Pneumatic flat slide gate

Pneumatic
cylinder

Valve

Air supply
system

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
14 Polysius
Hot meal pendulum flap

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
15 Polysius
Calciner types

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
16 Polysius
PREPOL MSC

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
17 Polysius
Cyclone preheater DOPOL 90 & PREPOL calcinator

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
18 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line OHORONGOFA 24.05.2010

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
19 Polysius
Rotary kiln - topics

Kiln types and tertiary air duct

Kiln shell

Reactions and mineral formations

Technological kiln design

Low dust kiln inlet

Examples

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
20 Polysius
Rotary kiln

Gas
Meal
Fuel

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
21 Polysius
Rotary kiln development

5 - support kiln

3 - support kiln

2 - support kiln

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
22 Polysius
3-support kiln vs. 2-support kiln

3-support kiln 2-support kiln

Statically undefined Statically defined

• possibility of • constant support loading

- extreme overload
- plastic deformation • elastic deformation only

• requirement for • no sensitivity to misalignment

- extra safety margin
- regular adjustment
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
23 Polysius
Tertiary air duct

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
24 Polysius
Functions of the kiln shell

• Conveys material
• Guides gas from cooler to kiln
• Creates a constant moving material bed
• Allows heat exchange between gas
and material
• Holds the brick lining

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
25 Polysius
Reactions and mineral formations

Preheater Kiln

Calciner
Raw meal

Clinker
Clay minerals

Temperature [°C]

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
26 Polysius
Technological kiln design - rotary kiln zones

Calcination

Transition

Sintering

Cooling
Preheater

Calciner

2 6 6 1
Calciner kiln
Preheater

7 3 4 1
Preheater kiln
0 Kiln length in D 15
Pyroprocessing components and operation
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Training OHORONGOFA, Träder, Kai
27 Polysius
Technological kiln design
Test procedure
representative raw material sample
test in gradient furnace
analysis of test results

Characteristic data of raw material

••Fuel
Fuelproperties
properties Computer
••Product
Productquality
Results
quality simulation
••Concept kiln dimensions
Conceptofofkiln
kiln of
line
line kiln speed
burning process

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
28 Polysius
Rotary kiln dimensioning

Kiln length (m)

L/D = ~ 12-17 (15,2)
Kiln diameter (m)

Clinker production (t/d)

Spec. volumetric load = ~ 4.0-4.5 (4.12)
Kiln volume (m³)

Energy flow (kJ/h)

Sintering zone load = ~ 12-25*106
Kiln cross section (m²)
(18.8*106)

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
29 Polysius
Rotary kiln design
Process - technological dimensions

Kiln with calciner

Kiln with preheater

10 12 14 15 17
L/D ratio

Number of stations and L / D ratio

2 - Stations

3 - Stations
3 - Stations

10 12 14 17
L/D ratio

OHORONGOFA L / D = 54 m / 3,8 m = 14,2

Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
30 Polysius
Gas velocity in rotary kiln

14
Gas velocity [m/s]

12

10

6 4,0 tpd/m³ 4,5 tpd/m³ 5,0 tpd/m³

2 3 4 5 6 7 8
Kiln diameter [ m ]
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
31 Polysius
Low dust kiln inlet

• Controlled inflow of hot meal

• Minimized dust intake into calciner
• Reduction of internal re-circulation

Meal

Gas

Pyroprocessing components and operation

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Training OHORONGOFA, Träder, Kai
32 Polysius
Examples

DO NOT COPY THESE EXAMPLES

Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
33 Polysius
Examples

DO NOT COPY THESE EXAMPLES

Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
34 Polysius
Pyroprocessing components and operation - topics

Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line

OHORONGOFA 24.05.2010
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
35 Polysius
Cooler - topics

POLYTRACK clinker cooler

Aeration and air distributors

Cooler parameters

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
36 Polysius
Cooler

Meal Gas
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
37 Polysius
POLYTRACK

Air blast unit

Socket for Upper housing
Bull-nose
cooling

Static Movable grate

grate

Inspection ports Grate equipment

Drive and Lower housing
Grate sub-structure thermo couples
unit

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
38 Polysius
POLYTRACK
Clinker
Tetiäry air Waste air
(1400 °C)
(900 °C) (280 °C)
Secondary
air (950 °C)

Static grate

Cooling air Clinker

(25 °C) (80 °C)
Pyroprocessing components and operation
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Training OHORONGOFA, Träder, Kai
39 Polysius
POLYTRACK

POLYTRACK 5 tracks
2 modules

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
40 Polysius
POLYTRACK - mode of working

Example of a POLYTRACK® with 5 transport tracks

M Material flow direction
V Forward stroke
1. 1st return stroke
2. 2nd return stroke
3. 3rd return stroke
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
41 Polysius
POLYTRACK - Aeration arrangement

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
42 Polysius
POLYTRACK - Air distributors in chambers 1 - 3

Pyroprocessing components and operation

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POLYTRACK - Air distributors in chambers 1 - 3

To replace a pendulum
counterweight, first
remove one of the spring
cotters and then pull out
the pin. Then the
pendulum counterweight
can be removed.
Install analogously in
reverse order.

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
44 Polysius
Clinker temperature as function of crushed clinker

Clinker 350
temp.
[°C] 300
250
200
150
100
50
0 10 20 30 40
Amount of crushed clinker [%]

crushed clinker at 400°C crushed clinker at 600 °C

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
45 Polysius
Cooler efficiency

Cooler efficiency [%]

82

80

78

76

74

72
Referring to 20 °C ambient air and
70 1400 °C clinker temperature

68
0,75 0,8 0,85 0,9 0,95
Secondary- and tertiary air [Nm³/Kg Cl.]
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
46 Polysius
Pyroprocessing components and operation - Topics

Overview

Preheater / calciner

Rotary kiln

Cooler

Operation of the kiln line

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
47 Polysius
Operation of the kiln line - Topics
Heating up
Starting sequence
Starting up / kiln feed
Increasing performance
Normal operation
Optimisation
Main control loops

NOx reduction

Normal shut down

Emergency power consumers
Interlocks Deviation from normal operation
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
48 Polysius
Heating up the kiln line

• The fuel burns with the smallest possible amount of combustion air

• There is no CO

• Most of the heat remains in the clinkering zone

• The flame is short and compact and steady

• Kiln heating up takes approximately:

(!! Always according to the directions of the supplier of the bricks !!)

- 48 hrs. (with new brick lining)

- 30 – 36 hrs. (after normal maintenance shut down)

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
49 Polysius
Example for first heating up

Continuous turning
or heavy fuel oil

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
50 Polysius
Tilting and turning the kiln
During the heating up the kiln should be continuously inched and turned,
the guide values for a new kiln are :

After approx. 2 h: 180 °

2 – 12 h: 1/3 revolution with auxiliary drive every 30 minutes

13 – 26 h: 1/3 revolution with auxiliary drive every 20 minutes

27 – 40 h: 1/3 revolution with auxiliary drive every 15 minutes

41 – 46 h: 1/3 revolution with auxiliary drive every 10 minutes

47 - 48 h: continuous rotation with auxiliary drive  0,1 rpm

from 49 h: turn kiln with main drive app. 0,6 rpm

and start feed
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
51 Polysius
Starting sequence

Remarks:

Auxiliaries of the kiln line Control air compressors,

cooling water system.

Filter dust transport

De-dusting plant rapping system

De-dusting filter fan with closed damper

Kiln waste gas fan (ID fan) with closed damper

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
52 Polysius
Starting sequence

Remarks:

Primary air fan for MB with closed damper

CO < min.
Fuel supply (fuel oil or coal) - analyser behind cyclone 2
- analyser before bag house

Clinker transport

Cooler waste air filter dust transport

„Bull Nose“ cooling fan Cooler roof protection

Pyroprocessing components and operation

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53 Polysius
Starting sequence

Remarks:

Kiln sealing in-/outlet

Cooling fans for kiln
tertiary air

Cooling for roller crusher

Roller crusher

Cooling air fans for

recuperation zone with closed damper

Cooler exhaust air fan with closed damper

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
54 Polysius
Starting sequence

Cooler de-dusting filter Remarks:

Main burner many preconditions (CO, T….)

Cooler fans recuperation zone already running

Cooler grates

Kiln main drive slow speed  0.6 rpm

only if main drive is running

Cooling fans for kiln shell and if nessasary acc. to kiln
shell temperature
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Training OHORONGOFA, Träder, Kai
55 Polysius
Starting sequence

Remarks:

Kiln feed

Cooling tower

Preheater cleaning systems

Open tertiary air dampers app. 20 %

Calciner burners Fuel MIN

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
56 Polysius
Starting up / kiln feed

! For kiln feed start sufficient personnel has to be in the

Preheater to watch the function of the pendulum flaps
and material flow!!!

1. Cooler grates: ~ 3 - 5 stroke/min, (minimum speed, manual mode)

2. Kiln main drive : 0,6 – 0,8 rpm

3. Cooler fans : ~ 30% of the nominal quantity

kiln hood pressure: -0,1 to -0,3 mbar (automatic control)

4. Main burner fuel: Light fuel oil: ~ 1.500 kg/h

Coal / pet coke: ~ 6.000 kg/h

5. Start kiln feed : ~30 to 35% of nominal feed rate (new kiln, no coating)
att.: there is a time delay between kiln feed group start
and real kiln feed

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
57 Polysius
Starting up / kiln feed

6. Adjust draft after - 12 to -15 mbar by ID fan/ dampers exhaust gas duct
cyclone Preheater:

7. Main burner : Increasing of the fuel quantity to specific

heat consumption  1300 ...1500 kcal/kg clinker

Att. ! : It’s only a guide value!!!

8. Start PC-burner : Sufficient oxygen - after cyclone stage 2: > 2,5 %

(before starting burner ~ 4,5%)
- after DOPOL: > 4,0 %

Fuel distribution: MB ~70-75%, PC ~25-30%.

Kiln inlet : ~ 1050 °C,
After stage I: ~ 860 °C,
Hot meal 1: ~ 840 °C

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
58 Polysius
Starting up / kiln feed

9. Adjustment of according to kiln feed (~ 2,0 Nm³/kg clinker)!!!

cooling air:

10. Observing clinker visual check, kiln camera, pyrometer

formation: observe the power consumption of the kiln drive

11. Checks during - Meal chutes flap valves

operation: - T, p and gas analyses in operating conditions
- Check indicated values
- Check clearance, inlet and outlet kiln seal
- Kiln bearing temperature

Pyroprocessing components and operation

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Training OHORONGOFA, Träder, Kai
59 Polysius
Gas analyser

Gas analyser behind calciner

-- CO (max-max. 0,8 %; calciner burner)
-- O2 normal value app. 2,5 %

CO > 0,4 % alarm

CO > 0,8 % shut off the calciner burners
CO > 1,2 % stop the main burner

Gas analyser before bag house

-- CO (max-max 1,2 %; main burner) Gas analyser behind kiln
-- O2 normal value app. 4,0 % -- CO (max 0,8 %, alarm)
-- O2 (min 1,0 %, alarm)

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11.09.20
Training OHORONGOFA, Träder, Kai
60 Polysius
Increasing the kiln performance

Precondition: granulated clinker in the sintering zone and in the clinker cooler

1. Increasing the gas flow through via damper or speed of ID-fan- / filter-fan
the cyclone preheater oxygen content behind cyclone
stage 5 > 4,0 % before increasing fuel
After ID fan: keep - 5 mbar (by EP fan)

2. Stepwise opening of the oxygen at kiln inlet adjust to ~2 – 3 %

tertiary air flaps

3. Increasing of clinker keep kiln hood pressure - 0,1 to - 0,3 mbar

cooler air quantity (control loop by cooler exhaust gas fan)

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61 Polysius
Increasing the kiln performance

4. increase of fuel and kiln feed target of fuel distribution:

- MB ~ 45%,
- PC ~ 55%

5. increase of kiln speed according to the kiln feed and power

consumption of the main drive

6. close fresh air flap (if open) depends on temperature after preheater

7. operate clinker cooler with until a clinker bed dept ~ 500 mm

slow speed pressure in aeration chamber 1 ~ 70 mbar

Same above mentioned steps for further increasing of the kiln feed!

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Increasing the kiln performance

Cooler grate velocity (watch the pressure!!!) and cooling air

quantities have to be adapted
(1,8 …2 Nm³/kg clinker)!

Att.: Secondary air and tertiary air temperatures will rise! The specific heat
consumption will reduce!!! Prevent overheating the sintering zone!!!

Take attention to: the kiln inlet temperature (max. 1150°C),

the hot meal temperature (max 880°C),
the temperature after preheater
(normal 340°C, max. 450°C):

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Normal operation

Preconditions of trouble-free operation:

- most homogeneous raw meal (LSF, SR, AR)

- constant kiln feed (variation < 1 % / minute)

- constant fuel rates (variation < 1 % / minute)

- constant gas flows, cooling air flows

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Optimisation of the plant

Process parameters

Typical operating parameters

Burner-/ flame adjustments

Reactivity of fuels

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
65 Polysius
Process parameters

1. Kiln feed rate tons / h

2. Specific heat consumption kcal / kgClinker (calculated)

3. Total fuel rate tons / h

4. Proportion of fuel to precalciner / riser %
5. Secondary air temperature degree C
6. ID fan draft mbar
7. Preheater exhaust gas temperature degree C

8. Kiln inlet gas analyser O2 %, CO %, NOx mg (ppm)

9. Cyclone stage II gas analyser O2 %, CO %, NOx mg (ppm)

10. After ID fan gas analyser O2 %, CO %, NOx mg (ppm)

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Process parameters

11. Kiln feed material (meal chute 1) SO3 %, LoI. %, (Lab. results)

12. Kiln drive power kW, Amps

13. Primary air pressure (burners) mbar
14. Primary air flow (burners) Nm3 / h
15. Clinker cooler ventilators air volume Nm3 / h
16. Preheater profile (temperatures, pressures) degree C, mbar
17. Specific calculations kcal/kg clinker
- Specific kiln volume loading, tons / m³day
- Gas velocity in burning zone, m / sec
- Specific heat loading of burning zone, Mcal / h per m2

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Typical operation parameters
Preheater / kiln: Temperatures:
- Gas duct 1 860….... 880 °C
- Meal chute 1 840….... 860 °C
- Tertiary air 850….... 950 °C
- After preheater 320….... 340 °C
Pressures:
- Kiln hood - 0,1……- 0,3 mbar
- Kiln Inlet - 4…. ….- 6 mbar
- Gas duct 1 -14…….- 16 mbar
- After preheater - 50…….- 60 mbar

Clinker cooler: - Chamber 1 pressure 50…..…. 60 mbar

- Secondary air temperature 900….... 1000 °C
- Cooler exhaust air temperature 250….... 300 °C
- Clinker temperature 80……... 100 °C
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Burner- / flame adjustment

- To burn a good clinker quality, but prevent damages in the refractory

(nozzle relative to kiln axle)

- To build and to keep good coating formation

as protection of kiln bricks and reduced kiln shell temperature,
but also to avoid coatings rings etc.

- Good heat transfer to the material by radiation and convection

- Far enough into kiln to ensure last section to be cooling zone

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Burner- / flame adjustment

Main burner fuel: - Temperature of sintering zone

- Kiln inlet temperature
- Kiln main drive power (A or kW)
- Free lime (CaO) in the clinker

Total fuel: - Specific heat consumption (kcal/kg clinker)

- Temperatures of meal and gas in the preheater

Fuel calcinator: - Hot meal temperature

- Degree of calcination (92...95%)

Attention: Orientation only! Parameters/Results may overlap!!!

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Reactivity of fuels

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Optimal operation

Gas conditions: CO -> to be prevented!!!

min. of oxygen is required!

Oxygen after Preheater: ~4% by damper or fan speed

Oxygen after stage II ~2-3% by damper or fan speed

Kiln inlet: ~2-3% by tertiary air flaps

- more open:
Oxygen stage II up / kiln inlet down!!!

- more closed:
Oxygen stage II down / kiln inlet up!!!

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Main control loops of a kiln plant
- Kiln hood pressure Target:  -0.1 mbar
- Actuator: Cooler exhaust fan speed or damper

- Cooler clinker bed Target: constant at set point

- (undergrate p., Actuator: hydraulic drive for grates
- and/or hydraulic p.)

- Cooler air flow Target: constant at set point

- (at inlet nozzle) Actuator: Cooler fan speed or damper position

- P. after kiln ID fan Target:  - 2 mbar

- (Raw mill stopped) Actuator: Filter fan speed or damper position

- P. before main filter Target:  - 2 mbar

- (Raw mill running) Actuator: Filter fan speed or damper position
- (P. after ID fan controlled by return air
flap position at raw mill)
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NOx reduction

Pyroprocessing components and operation

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NOx reduction Mealsplit

-Split feeding of meal and air into the calciner

-Tertiary air is supplied to the lower part of the
calciner
-Top air is supplied to the upper part of the
calciner Top air

-Air distribution can be individually adjusted

-Tertiary air is kept constant when the flap
position is changed (flowmeter)
Tertiary air
-It ensures that also the gas flow volume
through the kiln is constant
-Content of O2 in the kiln inlet is constant

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Training OHORONGOFA, Träder, Kai
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NOx reduction

-The top air reduces the combustion air volume for the fuel supplied to the lower part
of the calciner (reducing conditions)
-The other necessary combustion air comes from the top air supplied later
-Simplified equation:
-NO + CO  1/2N2 + CO2

-For effective minimisation of the NOx emissions:

-Reducing gas atmosphere in the lower calciner section
-An adequate temperature (between the meal infeed points  950 to 1150 °C)
-Lower temperatures will not have any effect on the NOx content
-Higher temperatures may have a negative effect on operating reliability

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Training OHORONGOFA, Träder, Kai
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Normal shut-down of the kiln plant

Generally
- Reducing of the kiln feed in steps of app. 5%
- Minimal kiln feed is about 40…50%
- An empty kiln can be easier heated-up and re-started!

• Stop of PC-burners and kiln feed

• Reduce fuel at the main burner

• Reduce preheater draft

• Close the tertiary air sliders / flaps

• Stop of main burner

primary fans to be kept in operation (for cooling!!!)

• Close the DOPOL-flaps to 10 - 15%; open fresh air flaps

Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
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Normal shut-down of the kiln plant
• DOPOL-fan: dampers to be closed

• Clinker cooler fans: dampers to be closed

• Cooler exhaust air fan: controlled by kiln hood pressure measurement,

or set to minimum value

• Kiln to be tilted! - during cooling down

- if raining continuously with auxiliary drive
- 1st and 2nd hour each 10 min 120°
- 3rd hour each 15 min 120°
- 4th hour each 20 min 120°
- 5th till 8th hour each 25 min 120°
- then... each 30 min 120°

...till a kiln shell temperature (sintering zone) of about 100°C is reached

• Cooler track units: to be operated in intervals

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Training OHORONGOFA, Träder, Kai
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Emergency power consumers
- Emergency lighting
- Communication systems
- UPS unit for computer and process automation equipment
- Control voltage for the total kiln plant and control cabinets
- Cooling water supply system
- Dampers in DOPOL exhaust gas duct and fresh air
- Kiln auxiliary drive
- Oil pumps for circulation lubrication system for kiln roller bearings
- Primary air fans for all burners including actuators
- Protective air fan for sintering zone pyrometer
- Actuators for damper in tertiary air duct
- Fan for kiln outlet cooling
- Cooling air fans for roller crusher
- Cooling air fans for recuperation section
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
79 Polysius
Interlocks

Implemented in By own control system

central control system FIS (Firing Interlocking System)

- Protective Machine - FIS is a control system for the

Interlocks (PMI) safety interlocks of burner and
E-filter in a kiln plant

- Operation interlocks - FIS automation systems are

used in plants with increased
requirements regarding safety

- The FIS system is the highest

possible protection against
explosion

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
80 Polysius
Interlocks

FIS:
- CO measurements:
- Downstream of cyclone stage 2
- Downstream of DOPOL waste gas fan (ID-fan)

- CO limit values (example BAZIFA site Irak):

- MAX1 = 0.4 % by volume (purging condition kiln plant, start condition
MB / PC / E-filter)
- MAX2 = 0.5 % by volume (operation condition PC, shut-off PC-burner)
- MAX3 = 0.8 % by volume (operation condition MB, shut-off main
burner)
- MAX4 = 1.2 % by volume (operation condition E-filter, grounding of E-
filter, shut-off high voltage E-filter)

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Training OHORONGOFA, Träder, Kai
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Interlocks

FIS:
- Pressure values:
- Kiln hood
- Downstream ID fan

- Operating signals:
- ID fan
- Main filter fan
- Primary air fans
- Cooler fans (recuperation zone clinker cooler)

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Training OHORONGOFA, Träder, Kai
82 Polysius
Interlocks FILTER FAN STOP Temperature
Preheater > Max Max

STOP

CO
KILN ID-FAN

Main Plant Interlocks

Preheater > Max Max

STOP PRIMARY AIR FAN

Temperature
MAIN BURNER STOP Preheater > Max Max
STOP
Stop Timer Filter dust transport
0,5 hour

CALCINER CO
KILN FEED STOP STOP
BURNER Stage 2 > Max Max

Stop
STOP STOP Timer
CLINKER Transport
STOP

MAIN DRIVE 5 min Grate 1 Grate 2

Stop
STOP Timer 5 min

CLINKER CLINKER CLINKER

COOLER COOLER COOLER
Exhaust air
failure of 2 or failure of one fan
more air fans fan

Stop Timer
15 min

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11.09.20
Training OHORONGOFA, Träder, Kai
83 Polysius
Deviation from normal operation

Cyclone/preheater blockage
Mostly pressure and temperature change
suddenly and drastically

Possible reasons:
-Jammed flap valves
-Chemical properties of raw meal
-Overheating
-Inadequate cleaning
Reactions of operator:
-Stop PC burner
-Immediately stop kiln feed
-Stop MB
-Adjust all flaps in and after preheater to make the system save
When cleaning blockages wear safety clothes and take care of hot material coming out
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
84 Polysius
Deviation from normal operation

Cyclone/preheater blockage
Mostly pressure and temperature change
suddenly and drastically

When cleaning blockages wear safety clothes and take care of hot material coming out
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
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Deviation from normal operation

Temperature downstream Preheater very high

Possible reasons:
-Not enough raw material
coming to the kiln
-Change over flap not
correct
-Airslide (partially) blocked
-Fault with calibration of
feeding scale

Wet material in the airslide

Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
86 Polysius
Deviation from normal operation

Weak kiln

Condition of burning process

-Inadequate raw meal
temperature
-Poor granulation
-Poor clinker quality
-Dusty kiln atmosphere

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Training OHORONGOFA, Träder, Kai
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Deviation from normal operation

Meal flush
Reactions of operator:
-Kiln speed drastically down
-Increase fuel SZ-burner
-Reduce kiln feed by approx.
20 to 25%
-Reduce PC burner (keep
temperature meal chute 1)
-Close tertiary air dampers
(keep O2 kiln inlet)
-Adapt pressure downstream preheater
-Reduce control pressure first grate from 60 – 70 mbar to ~ 55 mbar
-Increase air flow first cooler fans if undergrate temperature > 400 °C
If not getting kiln back after 20 min reduce again OR stop kiln and heat up
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Training OHORONGOFA, Träder, Kai
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Deviation from normal operation

Hot spot at kiln shell

Reactions of operator:
-Start shell cooling fans (if not already
running)

-Reduce fuel at SZ-burner (get kiln

weaker but without flushing!!!)

-Reduce kiln speed (by 0,2 … 0,4 rpm)

-Change burner- / flame adjustment

Coating over will take time BUT if temperature

don‘t stop to rise and/or spot gets drastically
bigger THAN kiln needs to be stopped and
inspected
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11.09.20
Training OHORONGOFA, Träder, Kai
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Deviation from normal operation

Homogeneous
coating formation
inside kiln

Ring formation

Lost coating at kiln

outlet section

Clinker bed in kiln

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11.09.20
Training OHORONGOFA, Träder, Kai
90 Polysius
Deviation from normal operation

Homogeneous
coating formation
inside kiln

Ring formation

Clinker bed in kiln

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11.09.20
Training OHORONGOFA, Träder, Kai
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Deviation from normal operation

Red river
Possible reason:
-Fine and coarse material separate when falling into cooler
-No uniform flow of cooling air (different flow resistence)
-Insufficient or no cooling air at some sectors
-Usually occur on one side at the edge of the aeration floor.

Solving the problem:

-Adjust cooling air distribution
-Adjust stroke length (take care of clinker discharge
conditions of kiln)
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
92 Polysius
Deviation from normal operation

Red river
on first grate

Big coating pieces

on roller crusher

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11.09.20
Training OHORONGOFA, Träder, Kai
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Deviation from normal operation

Snowmen formation in
clinker cooler

Possible reasons:
Static grate
-Material has tendendcy to
stick together (temporary
overheating due to chemical Snowmen
fluctuations,
raw material <> fuel)
-Build up at static grate and
forms snowmen
First grate

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
94 Polysius
Deviation from normal operation

Snowmen formation in
clinker cooler

How to avoid:
Static grate
-Avoid chemical fluctuations
-Push the burner pipe more in
the kiln (kiln as pre-cooler) Snowmen
-Change air distribution
-Improve initial cooling
-Check air blasters (sequenz,
pressure)
First grate
-install additional air blasters
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
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Deviation from normal operation
Cooler fan without flow

Possible reasons:
-Material in front of inlet nozzle
(platics, bird, etc.)
-Flap not in position (broken shaft,
AUMA drive not working)

Pyroprocessing components and operation

11.09.20
Training OHORONGOFA, Träder, Kai
96 Polysius
Pyroprocessing components and operation
11.09.20
Training OHORONGOFA, Träder, Kai
97 Polysius