ilc kiln manual ed1

5/19/2018 ILC Kiln Manual Ed1

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OPERATING INSTRUCTIONS

AND REFERENCE MANUAL

FOR

ILC PREHEATER SYSTEM

CUSTOMER : RAIN INDUSTRIES LTD.,(3800 TPD NEW LINE)

PLANT LOCATION : KURNOOL, ANDHRA PRADESH, INDIA

FLSMIDTH LIMITEDWORK ORDER NO. : PRJ06-009-000

Prepared by: A.SRINIVASAN Date: 21.04.2008

Checked by: N.SIVAKUMAR Rev.: 0

Approved by: S.SARAVANAN


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TABLE OF CONTENTS

1. GENERAL NOTES

2. CONSTRUCTION AND OPERATING PRINCIPLE

3. DRYING AND HEATING OF LINING PRIOR TO START-UP OFKILN

4. STARTING OF THE KILN PLANT

5. STOPPAGE OF THE KILN PLANT

6. OPERATION OF THE KILN PLANT

7. INTERLOCKINGS, PROGRAMMING AND CONTROL CIRCUITS

8. PREVENTION OF FIRES AND EXPLOSIONS

9. BARRING

10. CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERSAND ALARM LIMITS.


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NOTE!

The present instruction manual is dealing with the

situations which, according to the experience ofFLS, are the most likely to occur. An exhaustive

enumeration of all conceivable situations which

ay occur during the

erection/operation/maintenance of the kiln

plant/machine/equipment cannot be provided.

Consequently, if a situation should arise, the

occurrence of which is not foreseen in the in-

struction manual, and which the operator is/or

feels unable to handle, we would recommend thatFLS is contacted without undue delay for advice on

appropriate action.


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1 GENERAL NOTES

This manual is intended as a reference guide, which can

be used in connection with the start-up, normal

operation and shutdown of the plant.

The majority of the directions given in the manual are

of a generalized character given that a range of

relevant factors of a specific or localized nature are

involved, and it would be impossible to provide adetailed evaluation of all these factors in this manual

without sacrifice of clarity.

The manual must be regarded as a tool for optimization

of the kiln plant, and it can also be used to support

judgements made by the operator in a given operating

situation.

In this manual it is a foregone conclusion that the

control panel equipment has been installed, tested andmade fully operational.

This manual should be thoroughly studied prior to

start-up, so as to permit detailed planning of this

phase.

Several separate instruction manuals related to the

plant under review in this manual; these manuals

contain detailed information about the single machines

or arrangements.

These manuals must also be studied very carefully

before the plant is put into operation.


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2 CONSTRUCTION AND OPERATING PRINCIPLE

2.1 Construction of Main Elements

The kiln plant construction is schematically shown in

enclosures.

The clinker producing plant is a FLS-ILC (In-LineCalciner, Low NOx type) installation incorporating the

following elements:

Kiln tube

Diameter 3.95meters

Length 61.0 meters

No of supports 3

Inclination 4.0%

Size of Kiln Drive & max. Speed 493 kW, 5.00 rpm

No. of Preheater Strings and Stage Single stringwith 5 Stages

Size of Cyclones in Kiln String Stage III: 7.8 m

Stage III-V: 8.0 m

Size of Calciner 6.9 m x35.2m Long

Grate Cooler Type SF CROSS BAR- 3x5F

Burner Type Duoflex

Kiln Feed System Bucket Elevator

2.2 Operating Principle

The ILC Calciner kiln system is installed. The Calciner

is placed in-line with the kiln riser duct.

The combustion gas for the Calciner is hot atmospheric


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air drawn from the SF CROSS BAR COOLER through tertiary

air duct mixed with the combustion gas from the kiln.

The Calciner is dimensioned for a gas retention time of

approximately 4.5 seconds.

The kiln and Calciner is provided with a preheater. The

cyclones are of the proven FLS LP-type, which ensures a

very low pressure loss of the preheater.

The kiln main burner is the new Duoflex burner. Theprimary air consumption of this burner is lower as

compared with traditional burners.

The burner is provided with an oil burner for start-up.

The raw meal feed i.e. the kiln feed is extracted from

the homogenizing raw meal silo into a kiln feed bin.

The raw meal is then transported to the preheater inlet

by the Bucket Elevator.

The preheater is operating as a counter current heat

exchanger with the raw meal passing downwards through

the preheater stages by gravity, and the hot gas moving

upwards drawn by the ID-fan.

Having passed 4 or 5 preheater stages - depending where

to the feed is directed - then the raw meal passes a

splitter gate, where the raw meal flow can be diverted

into two positions in variable amounts, one to the

calciner vessel, and two to the riser pipe from the

kiln. This splitting and the amount of material being

guided to one way or the other is depending very much

on the fuel used, and the tendency of coating formation

in the riser pipe.


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Approximately 55 - 60% of the fuel can be fired in the

Calciner. The raw meal will be calcined to a degree of

about 90-94%. The Calciner can be operated at high

temperatures of more than 1000 C., which increases the

combustion rate. The excess air at the top of the

Calciner is foreseen to be approximately 20%

corresponding to an oxygen level of 3% in the outlet

gas duct of the Calciner. These measures should ensure

complete combustion of the fuel applied.

The combustion air used in the Calciner is a mixture of

hot air (875-925 C.) drawn from the SF cooler through

the tertiary air duct and the kiln gases from the

rotary kiln.

The material is leaving the top of the Calciner and is

then passing onwards to the 5thpreheater stage.

From this last preheater stage the material slides to

the rotary kiln inlet.

Due to the inclination and rotation of the kiln, the

raw meal is transported downstream through the kiln.

Simultaneously, the raw meal is gradually heated up and

fully calcined by the heat supplied to the kiln.

Clinkerization - clinker formation - takes place when

the raw meal passes through the burning zone of the

kiln.

The clinker formed enters the grate cooler for cooling.

2.2.1 SF CROSS-BAR COOLER


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The cooler is the well proven SF (Smidth-Fuller) crossbar cooler. This cooler type comprises a number ofunique features:

Cross bar, separate conveying clinker device.

All grate plates are stationary.

Low energy grate plates with mechanical flowregulators.

Modular concept.

The SF cooler has a modular design. The coolernomenclature describes the number of modules the coolerconsists of (width x length). Before each row of coolermodules there is an inlet module without cross bars,serving as impact zone for the clinker leaving thekiln.

Each cooler module has a width of 1.3 m and a length of4.2 m and comprises 4 x 14 grate plates. The module hasan inclination of 4degrees.

The inlet modules, 1.3 m wide and 2.0 m long, has an

inclination of 15 and consist of 4 x 5 grate plates.The outer corners of the two outer inlet modules arecovered with refractory. Each row of cooler module andthe inlet modules has their own cooler fan.

The grate plates in the cooler modules as well as inthe inlet modules are stationary. The transport of theclinker is made by reciprocating crossbars locatedabout 50 mm above the grate line. Each cooler modulehas 12 cross bars, 6 stationary and 6 moveable. Themoveable crossbars are connected to two longitudinalprofiles, which are driven by a hydraulic cylinder

below the grate, one for each module. The drive systemin a module is connected to the drive systems in theprevious and subsequent modules. The right set and theleft set of modules can then be moved independent ofeach other for optimum distribution and transport ofthe clinker.


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As the grate plates are protected by a stationary layerof clinker they will, contrary to other modern coolers,not wear down and deteriorate the air distribution witha lot of sealing air.

The grate plate is made with labyrinth air path forelimination of through fall of clinker. Transportequipment below the grate is then completelyeliminated. The grate plate proper has a low pressuredrop. In order to ensure an optimal air distributionevery grate plate is provided with a mechanical flow

regulator (MFR). The MFR maintains a constant airflowthrough the grate and clinker bed irrespective ofclinker bed height, particle size distribution,temperature, etc; i.e. separate flow control for eachgrate plate. The MFRs allow use of one fan forrelative large areas and completely eliminates the useof under-grate ducts and dampers seen in other moderncoolers.

The modular concept of the SF cooler allows shopassembling of large part and very fast erection. Due tothe cross bar system the number of wear parts are

minimized and replacement of these parts are fast andeasy to perform.

The kiln hood is common for the kiln and the tertiary

air duct. The hood is made so large, that minimum

clinker dust is recirculated to the kiln and Calciner.

2.2.2 Gas treatment and distribution

Whenever the kiln is in normal operation, the preheater

exhaust gases or part of these can be utilizeddepending on the raw mill or coal mill is in operation

or it is stopped. When the mill is in operation, part

of the gases is used for drying raw material in raw

mill or coal in coal mill.


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The dust precipitated in the kiln/raw mill filter

installation is returned to either

the raw meal silo

or the kiln feed.

The cooler excess air is treated in a separate ESP -

designed especially for clinker dust. The recuperated

dust is returned to the clinker transport system.

2.2.3 Separate Instruction Manuals

A number of other instruction manuals for the

individual machines or arrangements are available for

the plant concerned.

STUDY THESE MANUALS BEFORE THE PLANT IS STARTED

It is not all machines or equipment in this instruction

manual, that are supplied by FLS.

The FLS delivery range can be read in the order

acknowledgement and the order list.

3 DRYING AND HEAT-UP OF LINING PRIOR TO START-UP

OF KILN

3.1. Preconditions and Criteria for start-up

This section must be compared with the graphical form

given section 9, which provides information about

heating and start-up procedures.

3.1.1 Personnel

Operators and operating personnel must be fully


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familiarized with the instruments and functions of the

control panel.

Furthermore, the personnel must be well informed about

the layout and operating principle of the motor control

system, especially all interlocking diagrams indicating

protective, safety and operational interlocking.

3.1.2 Raw Materials

Prior to start-up, raw materials must be available in

sufficient quantities and with a well known quality in

order to ensure continuous, stable kiln operation.

3.1.3 Preparations

The following activities must be carried out prior to

the initial start-up:

1. All kiln plant machinery should be subjected to no-

load testing and, where possible testing under load.

The trial run of the kiln should comprise only of the

kiln motor, with the coupling bolts removed.

Trial run of machines loaded with material should be

performed over a prolonged period. For instance 24

hours, with the kiln feed in circulation.

Water and/or air must be available where necessary.

2. The entire electrical and electronic control system

must be tested to ensure that all interlockings i.e.

safety, protective and operational interlockings are

active and that they function properly.


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3. Ensure that all alarm limits have been set. (Refer

section 10 in this instruction manual).

4. The raw meal must be recirculated to sustain the

operation of the feed arrangement and for calibration

of the load cells.

5. Prior to the production of clinker an appropriate

amount of correct quality raw meal must be available.At least 3 days consumption must be available.

6. Where possible, the oil in the firing installation

should be recirculated to check the function ability of

the installation.

7. Ignition burner and burner equipment must have been

prepared for start-up.

8. The chemical laboratory at the plant should be onstandby to perform the necessary analyses of the kiln

feed and clinker, particularly to determine the content

of free lime, the litre weight of the clinker, and the

kiln feed analysis.

9. In order to optimize the regulation of the primary

air volume in the kiln, for optimization of the flame

structure, it is advisable to measure the airflow

supplied to the burner by the primary air fan at

different valve openings and pressures. Hence it is

possible to ascertain what valve position should be

used during operation.


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NOTE!

Where specific demands for initial drying procedure of

the concrete are stipulated by the supplier of the

castable for the grate cooler, account must be taken of

such criteria during the start-up phase, or, if this is

not possible, it may be necessary to dry out the cooler

on a separate basis.

3.1.4 Preparations Prior to Heating

Before the below mentioned start-up sequence is

followed and any machines are put into operation, the

description in section 7 of the interlockings, the

programming and the control should be read through.

CHECK

- That all tools and all alien objects have been

removed from all kiln plant machines.

- That potential coatings have been removed from

cyclones, flue ducts and riser ducts.

- that all doors and clean-out hatches are closed.

- that the motorized dampers function properly

- that the barring device, with brake , is ready

to be operated.

- that all plant machinery has been lubricated in

strict accordance with directions given in


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separate instruction manuals.

- oil must be applied to the journals of the

supporting rollers to ensure that they are

covered by oil when barring operation is

started.

- the water supply to kiln bearings and gas

analyzer is functioning.

- that all instruments in the control system are

functioning.

- that all alarm limits have been set.

Start the compressed-air supply and check that

compressed air is present at the points of consumption

at the correct pressure.

Place the gas analyzer equipment in the kiln system inthe state of readiness.

Check that the thrust roller device and the spray

lubrication for gear rim are ready with sufficient oil

and grease. Refer separate instruction manual.

Mount the light-up nozzle on the burner installation of

the kiln and prepare the ignition burner for operation.

Prepare the cooler and the clinker transportation

system. Place about 300 - 400 mm layer of cold clinker

on the Fixed Inlet section of the cooler.

See separate instruction manual for cooler.


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If special requirements for the initial drying of the

castable are stipulated by the supplier of the castable

for the grate cooler, these requirements must either be

met during the start-up procedure or, if this is not

possible, the grate cooler must be dried out

separately.

Once these checks and activities have been completed,

both the electrical and the mechanical department must

ensure that the installation is reported ready forstart-up.

3.2 Drying-out procedure

3.2.1 Kiln & Preheater

The heating and drying-out of the refractory lining

must be performed very slowly and gradually in order toavoid cracking and spalling. This applies especially in

places where large zones are lined with castable and

are to be dried out.

The initial heat-up/drying-out operation should stretch

NOTE

The given heat-up schedule is applicable for

refractory supplied by FLS only. It may be necessary

to modify the outlined drying out procedure in case a

different code of practice is recommended by thebrick supplier. However, consultations between the

plant management and FLS are needed before any

modifications are introduced.


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over a time period of approximately 72 hours as shown

in the diagram given in section 9.

In connection with subsequent kiln starts, the heating

period can normally be reduced to 24 hours, though it

depends on the type of lining repairs conducted during

the intervening periods.

As mentioned previously, it is recommended to extend

the heat-up period if concrete castable has been used

for casting operations inside the kiln system.

3.3 Initiation of Heat-up Operation

See also the separate instruction manuals related to

the individual equipment mentioned.

Heat-up operation is started as follows:

3.3.1 Kiln and Preheater

Checkthat the dampers in the ducts to all the mills,which will be supplied with drying gas, are closed.

Start the oil circulation to the burner.

Checkthe pressure and temperature of the oil.

Start the hydraulic pump of the thrust device.

Start the spray lubrication system for the kiln drive.

Start the kiln bag house -fan with closed damper.

Open the filter fan damper gradually, so that a

negative pressure of 1-2 mmwg is maintained in the gas

duct just after the ID-fan.


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The damper for the ID-fan are opened 10-15% so that

there is created a slight negative pressure in the kiln

hood.

Start the primary air fan and close the primary air

damper to 10%.

Start the ignition burner.

Start the oil burner by opening the oil valve for the

light-up nozzle.

Checkthat the oil is ignited; if necessary adjust the

primary air valve to facilitate the flame formation.

Adjust the draught in the kiln by means of the exhaust

gas damper, the filter fan speed and the damper.

Start the barring of the kiln in accordance with thebarring programme outlined in section 9.

Check lubrication of supporting rollers. The journals

must not become dry. During barring it may be required

to pour additional oil directly on the journals.

The specified barring program must be adhered to;

however, if the thrust device equipment for indication

of kiln position gives alarm, barring must be

continuous until the alarm can be cancelled.

Continuous barring is also required if the kiln is

subjected to cooling, for instance due to heavy rain.

Soon after the start of the burner, the gas analyzer in


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the riser duct should be put into operation.

Start the fans for the cooler inclusive the nose ring

fan (it is the fan at the kiln outlet).

Start the Bag house-fan for excess air from the cooler

with closed damper.

Setthe automatic negative pressure control in the kiln

hood to a set point of -0.5 mmwg.

Openthe hoisting damper in the tertiary air pipe 50%.

Start the burner in the kiln hood, if supplied, the oil

volume is set to 10-20% of full capacity. Over heating

of the lining in the TA duct is thus avoided.

Regulate the kiln string exhaust fan damper to get

oxygen content of 8-10% in the kiln inlet. When thekiln has become hotter after some hours this level can

be reduced to 3-4%.

The ignition burner can be extinguished after

approximately 8 hours or as soon as the lining is hot

enough to support the ignition of the oil.

3.3.2Air Supply during the Heat-up Phase

During the heat-up period, the maximum amount of the

heat input should be utilized for heating of the kiln,

i.e. only the necessary air volume should be drawn

through the kiln.

However, an adequate air surplus must be present for


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the complete combustion process.

It could be necessary to start 2-3 cooling air fans and

to start the excess air fan to be able to control the

negative pressure in the kiln outlet.

The oil flame must not cause sooting.

Often, this would require that the oxygen content

indicated by exit gas analysis in the riser duct is8-10%. When the kiln has become hotter after a couple

of hours, then the oxygen content can be reduced to

about 3-4%. An oxygen content smaller than this might

cause a sooting flame.

An exit gas analyser after the preheater is not of much

use during the heat-up phase, since air infiltration

from the preheater system would influence the analysis.

3.4 Inspection during heat-up period

The programme for heat-up period is graphical indicated

in section 9.

Following major lining repairs, a heat-up period of

approximately 72 hours is recommended, whereas for

normal starting of cold-state kiln the period should be

approximately 24 hours.

It is very important that no attempt is made to speed

up the programme.

In case of interruptions during the heat-up period

compensation is needed by extending the time period, so

that the actual heating period has the stipulated


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duration.

The heat-up speed, as measured at the kiln inlet and

the outlet from the preheater tower, should very

closely follow the curves as indicated in section 9.

It is advisable to record operational experience gained

during initial heat-up periods, so that the curves in

the enclosure can be adjusted in accordance with the

local conditions.

A regulation of fuel rate, draught level and oxygen

level is needed to ensure strict adherence to the

curves for the temperature rise.

Overall, the prime aim is, as previously mentioned, to

ensure retention of the supplied heat inside the kiln.

Any increase in the draught level will rapidly cause

the temperature in the cyclone tower to rise at the

expense of the temperature in the kiln, and this is notdesirable.

The following inspection and check-up must be made

during the heat-up period:

Kiln Lining

Inspect the kiln lining at regular intervals. The

lining in the burning zone must not be exposed to fast

and local overheating.

The lining temperature must not exceed 1000 C.

If the lining temperature rises too quickly and/or

becomes too high, reduce the amount of fuel.


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Kiln Shell Temperature

Check the kiln shell temperature. Special attention

must be focused on the burning zone where high surface

temperatures may occur. Temperatures of up to 350 C.

will be acceptable.

If the kiln should become too hot in the burning zone,

and the temperature after the preheater is relativelylow, i.e. it permits that surplus heat is drawn from

the kiln upstream to the preheater by increasing the

draught.

Alternatively the flame shape must be adjusted by

regulating the air volume to the main burner.

Bearings for supporting rollers

Check the lubrication. Dry running of the bearingjournals must not occur. When the kiln is barred, it

may be necessary to apply additional oil directly to

the bearing journals.

Barring

Strict observance of the specified barring programme is

needed, but in the event that an alarm is tripped by

the thrust device equipment indicating the position of

the kiln, then the kiln must be barred continuously

until the alarm can be cancelled.

Continuous barring is also needed if the kiln is

subjected to cooling, for example due to heavy

rainfall.


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Clearance between kiln shell and live ring

The clearance between the kiln shell and the kiln tires

must be checked at regular intervals during heat-up and

start-up phase, especially at piers I and II.

Clinker transport

If the kiln has been filled with raw materials, it may,from time to time, be necessary to start the grate

cooler and the clinker conveying system in order to

transport away the materials, however, do not empty the

cooler. To ensure effective cooling at the cooler

inlet, it may as previously stated be necessary to

start the first fans of the cooler.

4 STARTING THE KILN PLANT

4.1 Getting Ready for Operation

Operational status must be prepared approximately 3

hours in advance of the anticipated time for start-up

with feed.

At this stage the temperature of the kiln lining is

sufficiently high to ensure ignition of the coal from

the burner, which is put into operation as follows:

- Reduce the oil flow to the burner.

- Start coal firing with minimum coal.

- Finally stop the oil & continue heating with

necessary coal until the desired temperature profiles

have been achieved, as indicated below.


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Start the transport lines for dust and clinker after

the kiln.

Start the recirculation of raw meal if the equipment

has been out of operation over a prolonged period of

time.

Start the burner in the kiln hood, if installed, unless

it is already in operation. The oil quantity isadjusted so the lining temperature does not exceed 1000

C.

Start the dust conveyance system after the kiln bag

house, and the cooler ESP.

Check that the dividing or splitter gate after the 2nd

lower most cyclones is adjusted so all the raw meal is

directed to the riser pipe.

4.2 Starting of kiln Feed

When the temperature at the top of the 2nd lower most

cyclone stage is about 750 C., and assuming compliance

with the heating programme as outlined in enclosure,

the kiln is ready to accept feed material.

Personnel must be stationed in the cyclone tower in

order to watch the raw meal as it passes through the

cyclone preheater.

Supervision is performed at the sluice flaps under each

cyclone. The flaps must move freely. This is done to

ascertain that the raw meal is passing through. The

risk of jamming in the cyclones is particularly high


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during start-up.

The control room must have the possibility to contact

the supervising personnel via mobile communication

equipment, radio or telephone; so that early warning

can be given from the supervising personnel to the

control room in event of jamming symptoms in cyclones

are observed.

4.3 Starting of Kiln Main Motor

Stop the barring motor, disengage the barring gear and

start the kiln main motor at the lowest speed.

Start the exhaust gas fan with closed damper. Sometimes

it is necessary to stop the burner if it takes a long

time to establish the draught as the fan is started

with closed damper. However, it should be possible to

operate the burner at minimum rate.

Therefore the draught and fuel rate must be reset tolevels applicable prior to the starting of the exhaust

gas fan. Please make sure that the filter fan speed is

adjusted to maintain sufficient suction after the kiln

exhaust gas fan.

Start the clinker transport system, with clinker

breaker, and the cooler drives and fans (refer to

separate manual for the SF-cooler).

4.4 Establishing Normal Production Rate

Perform the following operations in RAPID but PROPER,

sequence:

- Start the raw meal feed to the preheater.


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- Increase the draught level by opening the damper for

the exhaust gas fan as well as the speed of the fan.

- Increase the fuel rate accordingly.

- Increase the feed rate to 55-60% of full production,

with simultaneous increase in kiln speed to 1.4-1.6

rpm.

- Start the fuel supply to the Calciner at minimum

rate. As soon as the kiln feed has reached the lower

most cyclone stage, then increase the fuel rate in

order to maintain the temperature of this lower most

stage of about 860 C.

- Set the draught level and fuel rate so the fuel

supply rate is 5-10 % in excess of the normal

operational level at the same production rate. The

reason is that the kiln system is colder at start-up ascompared with normal operation.

The draught must always be increased prior to any

increase in the fuel rate in order to avoid CO-

formations. Also remember to regulate the damper in the

tertiary air duct for the Calciner.

The temperature after the preheater must not exceed

400 C.

The gas analyzer after the preheater will typically

indicate an oxygen level of 6-8% during start-up.

However, the oxygen level should be in the range of 3-

4% at the kiln inlet.

When it has been ascertained that the clinker in the


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burning zone is well-burned, the kiln speed can

gradually be increased to match the production level.

The kiln feed rate and the kiln speed rpm should be

synchronized to maintain constant material level, for

instance 4.0 rpm corresponds to 100% production level.

It is of critical importancethat the first material is

well burned in order to avoid circulation of dust

between kiln and cooler. Dust circulation may cause

cooling of the burning zone so more time is needed tostabilize the kiln operation.

Since, as mentioned above, the heat input to the kiln

at the beginning exceeds the amount required for

clinker formation, the kiln system will gradually be

heated.

When there is solid evidence of satisfactory clinker

formation at low free lime levels, the kiln output can

gradually be increased with simultaneous increase ofdraught level, feed rate and fuel rate.

Especially the kiln torque and visual inspection of the

clinker are useful parameters to use in order to judge

whether the clinker are well burned. Further analyses

of the clinker litre weight and content of free lime

are useful for judgment of the clinker quality.

The duration of the period from starting of the kiln

feed to full production level is reached, will normally

be 5 - 8 hours.

4.5 Starting and Operation of the Cooler


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See also separate instruction manual.

4.6 Preparations for Calciner Operation

As mentioned above the firing in the Calciner must be

started at the same time as feed taken to the

preheater. However, the following interlockings must be

fulfilled:

- Kiln main burner in operation with ID-fan inOperation.

- Kiln main drive in operation.

- The temperature in the lower most cyclone stage must

be higher than minimum (750 C.) and lower than max

I (920 C).

- The feed to the preheater is on.

- CO content in the gases after the preheater must not

be higher than max II (0.9%) for more than 10

seconds, and then the fuel rate to the Calciner

must automatically be reduced by minimum 20%. Theburner is then automatically changed to manual

control mode.

The combustion gas/air to the Calciner is controlled

both by adjustment of the ID-fan speed and by changing

the position of the damper in the tertiary air duct.

The draught adjustment should maintain 3-4% oxygen at

the preheater outlet with CO content lower than 0.05%

and an oxygen level between 3-4.5% at the kiln inlet.

Always increase draught before fuel rate is increased

to prevent formation of explosive gases.

4.6.1 Achieving Nominal Capacity


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During the first couple of hours after the production

has been started the feed rate is increased gradually,

however, only concurrently with production of well

burnt clinker.

Adapt feed and fuel so the temperature in the lower

most cyclone stage is maintained at approximately 880 -

890 C., which would correspond to a degree of

calcination of 90-94%. This calcining temperatureshould be maintained automatically by the CCR-control

system.

Consequently the kiln production is increased as

follows:

- Increase the draught

- Increase the feed. (Synchronously with the kiln

Speed).

- Increase the fuel supply to the Calciner(possibly automatically).

- Check whether a change of the kiln fuel is

needed. (Depending of free lime level, litre weight

and torque).

The temperature of the hot air from the cooler to the

Calciner through the tertiary air duct will increase

progressively as the clinker volume is increased.

Therefore the fuel rate to the Calciner will be

reduced.

5 SHUTDOWN

5.1 Normal shutdown of the plant


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It is advisable to shutdown the kiln plant in a

controlled manner by following the sequence outlined

below:

- Reduce the total air-flow to the cooler.

- Stop the fuel to the Calciner.

- Stop the exhaust gas fan and close the

damper (automatically)

This automatically involves that:

- The kiln burner is stopped

- The kiln feed is stopped or switched over to

recirculation back to the CF silo.

- Stop the kiln motor.

- Stop the filter fan and close the motorized

damper ahead of the fan.

- Reduce the amount of primary air to a minimum.

However, a certain amount of primary air is needed tocool down the burner pipe, if the burner remains in the

kiln.

- Reduce the cooler grate speed. After a few

minutes they can be stopped.

- The cooling air fans can be stopped one by one

gradually.

Start barring operation as outlined in section 9.

BARRING.

Where the shutdown period of the kiln extends over a

prolonged period of time, then all machinery not

required for barring of the kiln and cooling of the


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burner pipe must be stopped. i.e.:

- Stop the dust conveyance system when the system

is empty.

- Withdraw the gas analyzer from the riser duct.

- Stop the compressors.

- Draw up plans for subsequent clean-up operation

in the cyclones, flue ducts and riser ducts.

- Make sure that the cooling water supply for the

kiln bearings is functioning as long as the kilnis barred.

After the kiln has cooled off:

- Stop the primary air fan and retract the burner.

- Stop the clinker conveying system.

- Inspect the kiln, the cooler, the hot gas ducts

and the preheater.

- Planning of the maintenance- and repair work

required prior to renewed start-up.

NOTE!

The kiln must always be cooled off slowly to prevent

too rapid cooling of the lining in relation to the kiln

shell. Otherwise, the lining may become loose,

involving risk of twisting and drop-out of bricks.


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5.2 Unscheduled shutdowns

In the following a description is given of the most

common types of operational disorders.

5.2.1 Total Power failure

All machines and motors are stopped.

The emergency power generator must be started making it

possible to bar the kiln, to close the fan dampers, to

cool down the burner pipe, to start the nose-ring fan

and to start the first 3 fans of the cooler. Cooling

water for cooling of the support roller bearings must

be available as long as the kiln is barred.

5.2.2 The kiln main burner stops functioning.

If operational status cannot be restored immediately,

the exhaust gas fan must be stopped; thereafter the

shutdown procedure outlined in subsection 5.1 must be

initiated.

5.2.3 The Calciner burner stops functioning

If the Calciner burner can be restarted immediately,

then there is a possibility of restoring stable

operation. Otherwise, the kiln may have to be stopped.

Until the burner can be restarted the kiln feed as well

as the draught should be reduced. The draught in the

Calciner and the preheater is likely to be too low

causing drop-through of material from one preheater


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stage to another. So if the Calciner burner is not

restarted fairly quickly then kiln operation must stop,

and the shutdown procedure outlined in subsection 5.1

must be initiated.

5.2.4 Kiln Feed Failure

If the kiln feed cannot be restarted immediately, it

will be necessary to shut down the kiln. Stop the

exhaust gas fan and follow the shutdown procedureoutlined in subsection 5.1.

5.2.5 Blockage of Cyclones

Blockage symptoms are normally indicated by a drop in

the negative pressure at the bottom of the cyclone or a

drop in the temperature of the material after the

cyclone.

If blockage is ascertained in a cyclone, it isessential, that the kiln is brought to immediate

standstill in order to avoid overfilling.

Stop the exhaust gas fan and the kiln motor. The feed

is stopped by interlocking.

Then follow the shutdown procedure outlined in

subsection 5.1.

Before the clean-up operation is started, a negative

pressure can be generated by means of the filter fan.

5.2.6 Hot spots on the kiln shell

A shutdown of the kiln will normally be required if the


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kiln shell temperature is higher than 400 C.

An attempt can be made to maintain the kiln in

operation to postpone the shutdown to a more

appropriate time, provided the temperature can be

lowered by means of cooling fans with concentrated

cooling at the hot spot(s).

It is prudent practice to keep the kiln motor running

on minimum speed until the temperature of the hot spothas been substantially reduced.

If, however, it is not possible to cool the hot spot,

then a kiln shutdown for repairs of the lining is

described in subsection 5.1.

It may be advantageous to make a partial discharge of

material from the kiln by prolonged barring before the

repair of the lining is initiated.

5.2.7 Failure of Clinker Transport

In event of clinker transport failure, the kiln can

normally be maintained in operation for a couple of

minutes before it must be shutdown.

During this period of time an attempt to restart the

clinker transport must be made, but if operation cannot

be resumed, it will be necessary to shutdown the kiln

in accordance with the procedure outlined in subsection

5.1.

5.2.8 Failure of the Cross bar Cooler


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In this case, the precautionary measures which should

be taken are identical to those outlined in subsection

5.2.7.

5.2.9 Failure of dust handling system

Normally, kiln operation may continue for a short

period (if some accumulation of material in the dust

transport system is found to be acceptable, and if the

authorities will allow short periods of kiln operationwithout dedusting). If it is not possible to restart

the dust conveyance in this short period, the kiln must

be stopped in accordance with procedure outlined in

subsection 5.1.

6 OPERATION

6.1 General Notes

The kiln performance is optimized by ensuring that

operational kiln adjustments are restricted to an

absolute minimum. The necessary adjustments must be

phased in gradually.

Once all control loops are active, these will ensure

maintenance of:

- the pressure after the exhaust gas fan for

stabilization of the draught.

- the outlet temperature from the Calciner, ensuring

a constant degree of calcination.

- the pressure at the kiln outlet, this contributes


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towards stable cooler operation, and stable

secondary and tertiary air conditions.

- the operation of the cooler, with a battery of

regulators providing uniform cooling by adjustment

of air flows and grate speeds.

The fuel supply rate to the kiln installation is

determined on the basis of an evaluation of the clinker

quality, i.e. the litre weight, free lime content andthe general appearance of the clinker.

Another determinant is the current status of the kiln,

i.e. the trend of the torque curve, the potential

presence of coating formation or other operational

disorders recently encountered.

6.2 Specific Conditions related to kiln operation

In the following a review is made of a range of

specific factors affecting the kiln operation.

6.2.1 Exit Gas Analysis

The exit gas analysis constitutes the most important

source of information for the evaluation of the

combustion process. Therefore, it is of crucial

importance to ensure that the analysis equipment is

functioning properly.

The smoke gases must not contain any unburnt substances

i.e. C (Carbon) or CO (Carbon Monoxide).


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Presence of such gases may, under adverse

circumstances, cause fires or explosions and further,

the loss incurred by wasting the latent heat of the

unburnt part of the gases may be quite substantial.

A CO level of more than 0.1% in the smoke gases may

entail added calorie consumption in the kiln.

Any presence of unburnt substances would indicate

inadequacy of air for the combustion of the fuel. Evenwith an adequate air volume, the smoke may contain

unburnt substances due to the fact that the mixture of

fuel and air is not ideal. Therefore, a certain air

surplus should be applied during the combustion

process.

As previously mentioned, the exit gases from the

preheater should contain 3-4% of oxygen. It is possible

to set a lower alarm limit for the oxygen level. For

example, a limit of 2% can be applied. This alarm willinform the operator about the risk of unburnt

substances in the exit gases.

After the preheater the gas analyser will continuously

monitor the CO level in the exit gases.

The alarm limits should be set as follows:

MAX I : 0.5% CO

MAX II : 0.9% CO

MAX I will signal alarm. Then the operator must make

the necessary adjustments to the combustion process.


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MAX II will signal alarm and after 10 seconds

automatically reduce the fuel rate to the Calciner by

minimum 20%. The Calciner burner is then in manual

control mode.

6.2.2 Primary Air Volume

The primary air is supplied through the burner pipe,

ensuring an effective mixture of air and fuel.

Normally the primary air volume supplied by the fanconstitutes 5-6% of the air volume needed for

combustion.

6.2.3 Temperatures after Cyclone Preheater.

The exhaust gas fan is designed to withstand operating

temperatures up to 400 C. However, short term

temperature rises up to 450 C. can be tolerated.

The following alarm limits should be set:

MAX I : Giving alarm which is 400 C.

MAX II : Causing alarm tripping and

Stoppage of the exhaust gas fan

at a temperature level which is

450 C.

but never higher than 450 C.

Note:

Also one bleed air damper is provided in the downcomer

duct to cool the preheater hot gases whenever the

temperature rises beyond 450 oC.

6.2.4 Bearing Temperatures


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An excessive temperature in any fan bearing will cause

alarm tripping and automatic switch the fan off. This

applies to the exhaust gas fan, the filter fan and the

grate cooler excess air fan.

An excessive temperature in any supporting roller

bearing will only cause alarm indication, but the

operator must ensure, that immediate action is taken

for the remedy of the situation, if kiln operation iscontinued.

6.2.5 Bag-Filter

The operating temperature of the filter must never

exceed the maximum temperature specified by the

supplier.

The thermocouples at the inlet and the outlet of the

Bag-filter casing are connected to electricalinterlockings that will stop the filter fan in case of

elevated temperature.

6.2.6 Blockage in the Cyclones

Changes in the temperatures of the material at the

discharge point from the cyclones, may be signs of

incipient - the beginning stages of a - blockage in the

cyclones.

Negative pressure meters are installed at the bottom of

all the cyclones. If the negative pressure drops during

normal operation, this is, combined with a possible


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change in temperature, confirms a sure sign of

blockage. The pressure gauges will cause alarm

indication, if the negative pressure should drop below

the set minimum value. It is then up to the operator to

assess, on a case by case basis, whether a kiln

shutdown is required.

A drilled hole, with a diameter of about 2 mm must be

present in the connecting bushings for the negative

pressure meters, and it is very important to keep thishole clean. In case of blockage in the cyclones, the

pressure measurement will gradually move towards zero

as the tube is filled with atmospheric air.

Once blockage in a cyclone has been ascertained, the

operator must ensure that the kiln is shutdown,

thereafter the blockage is removed manually.

Normally, air lances in appropriate lengths are

effective tools. Extreme caution must be exercisedduring the clean-out operation.

NOTE!

The temperature of the material cakings may be as high

as 800 C., with attendant risk of sudden outflow of

hot raw meal, flowing as if it were a liquid.

Therefore, it is essential that extreme caution andcare is being exercised during the operation, and it is

advisable that the operators involved are equipped with

heat-insulated protective suits during the clean-out

operation.


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A number of precautionary measures to be taken in a

cement plant are outlined in a separate instruction

manual.

6.2.7 Cakings in the Riser Duct and kiln Inlet

It is possible to detect major cakings in the riser

duct and kiln inlet by checking the difference between

the negative pressures at the kiln outlet and at thelower most cyclone.

The safety precautions which must be taken during the

clean-up operation are similar to those stipulated for

the cyclones.

Operational experience will show whether the extent and

locations of potential cakings would make it

appropriate to equip the installation with additional

clean-out hatches.

Also it may be practical to install air shock blasters

at appropriate locations.

6.2.8 Kiln Position

The axial position of the kiln on the supporting

rollers is monitored by the thrust device. The alarm

limits must be set as directed in the instruction

manual for the thrust device.

The MAX I alarm is a signal instructing the operator to

undertake inspection of the thrust device and/or the

position of the supporting rollers.


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The MAX II alarm automatically stops the kiln drive for

prevention of damage to the smoke chamber seal, kiln

hood seal or thrust roller.

It may be necessary to check the thrust direction of

the supporting rollers. See separate instruction

manual.

In a critical situation, it may be necessary to apply

oil directly to the supporting rollers if the rollerstend to thrust the kiln upwards, but it is very

important to ensure that the oil is removed as soon as

possible following the re-alignment of the supporting

rollers.

The lubrication between the supporting rollers and the

kiln tyre must be provided by means of dry graphite

lubrication. See separate instruction manual.

6.2.9 Kiln Lining

The temperatures in the kiln system are so high that

most of the system is protected by means of a lining

which consists of bricks and castable.

It is a prerequisite for smooth kiln operation that the

kiln lining is intact. Consequently, proper maintenance

of the lining is of paramount importance.

Normally, the lining in the preheater, hot-air duct and

in most parts of the cooler will have a lifetime of

several years with no need for replacements.

However, especially the lining installed in the burning

zone of the kiln will require more frequent replacement


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of bricks.

The exact frequency depends on a range of factors, but,

generally, replacement is recommended in case the

thickness of bricks has been reduced to half the

original size owing to wear.

Any damage to the lining involves risk that the kiln

shell will be overheated. Particularly the kiln burning

zone should be kept under continuous supervision.

If the kiln shell temperature should rise to 380-400

C, the affected area must be cooled by means of fans.

In event of a further rise in temperature, the kiln

must be shutdown for repair of the lining.

During operation the condition of the kiln lining can

be checked by installing a radiation pyrometer

(scanner) for monitoring of the kiln shell temperature.This alarm level should not exceed 400 C.

Whenever access to the kiln is possible during a

shutdown period the opportunity should be taken to

inspect the lining, so appropriate time schedules for

replacement or repair can be worked out.

7.0 INTERLOCKINGS, PROGRAMMING AND CONTROL

CIRCUITS

The various motors, machines, dampers and other

equipment are operated and controlled by the central

control system. In the following the proposed structure

of the control system is described seen from the


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operational and process point of view. A proposal for

grouping of the motors is given below. The general and

special rules of interlockings are listed. A survey of

all process related measurements and their treatment is

given in section 10.

Finally the list of control loops is presented.

7.1 Interlockings

The detailed interlockings, as programmed, are

described in the interlocking diagrams, however, main

philosophy is given below.

The general rule of operational interlockings is that

no machine can be started before the subsequent machine

has been started. Inversely, stop of any machine will

cause the stop of the machine ahead. This follows the

process order.

Protection interlockings like

- bearing temperature

- vibrations

- winding temperature

- minimum oil level

- speed monitors

- skew running

- maximum material level, etc.

will stop the machine in question immediately.

Examples:

- If the speed monitor of an air sluice does not

indicate any rotations, then the motor for this air


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sluice will stop.

- If the vibration level of the kiln exhaust gas fan is

high, then the motor of this fan will stop.

- If the bearing temperature of the clinker breaker is

above the maximum temperature allowed, then this

breaker will stop.

Special interlockings

The special interlockings will be described in the

section of programming as well as in the diagrams

giving the process instrumentation (CAUSE/EFFECT

DIAGRAMS as described in section 10.).

In the control system the various motors and machines

will be arranged in a number of groups for common start

and stop.

7.2 Programming

From the central control room the kiln department can

be operated by selection of a number of programs and a

number of direct functions.

The programs installed in the control system will

perform the start and stop procedures for the machines

divided into groups. Further the operation is

automatically supervised, checking constantly all

interlockings for operation, protection and safety.

The direct functions consist of opening and closing the

dampers and speed control of motors.


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The following programs are proposed. (Please note that

the groupings of machines may be carried out

differently to the proposal, but the main ideas should

be kept).

The following programs are proposed:

1. Blending silo

2. Kiln feed

3. Filter fan4. Dust transport

5. Bag House control

6. Kiln exhaust gas fan

7. Gas analyzers

8. Kiln auxiliaries

9. Kiln drive

10. Kiln barring

11. Kiln burner fans

12. Kiln burner

13. Calciner burner14. Clinker transport system

15. Cooler excess air fan

16. Cooler drives

17. Cooler fans

19. Scanners and cameras

The following equipment can be operated individually:

Fan dampers

Changeover gates and dividing gates

Position of valves - oil valves and feed valves

Motors with speed regulation, such as kiln drive and

grate drives.

7.3 Comments to Programs


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For the details of the programming reference is made to

the separate documentation for the PLC system, however,

in the following some important notes are pointed out

in relation to each program. In general all bag filters

should stop with a minimum delay of 15 minutes to empty

the system.

1. Blending Silo

Machines:

Blending silo extraction system

Blower for aeration

Gate

Filter

Conditions to be fulfilled before start:

The filter, the blowers and the silo extraction

sequence can be started at any time.

Conditions to be fulfilled in order to produce:

No conditions. The extraction sequence will be stopped

whenever the kiln feed hopper reaches maximum level.

2. Kiln feed

Machines:

Air slide

Dosing valve

Bottom Gate, dividing gate

Blower for aeration of feed bin

Bucket Elevator

Bag filter


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Sampler


Filter on top of the homogenizing silo is in operation.

The dividing gates are in the correct position

directing the kiln feed or in recirculation mode back

to the Inverted cone-homogenizing silo.


Same as for start:

However, once the program is running, the operator can

change the gates so the raw meal is transported towards

the kiln and Calciner - becoming kiln feed - provided

the exhaust gas fan are operational.

If the feed stops (program 2) for more than 30 seconds,

then the exhaust gas fan must be stopped to prevent

overheating of the preheater. This interlock can be

bypassed during heating up before feeding the kiln.

3. Bag Filter fan

Machines:

Filter fan with damper


Damper to be closed, and filter inlet temperature lower

than the maximum allowed.

Dust transport operational.


Filter inlet temperature below the maximum allowed for

the filter.

Once program 4 is in operation a certain allowed stop


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time of program 5 can be allowed before the filter fan

program 3 will have to be stopped.

4.Dust transport

Selection of which way to send the dust:

1. dust to Blending silo

2. dust to kiln feed

Machines:

Screw conveyor

Air slide

Bucket Elevator

Filter

Gate


For all possible selections, the subsequent transport

equipment must be in operation and the silo level must

not have maximum level alarm.


Same as for start.

NOTE, delayed stop for emptying.

5. Bag filter control

Machines:

Filter fan

Damper


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Damper to be closed.

Conditions to be fulfilled in order to produce.

None.

6. Kiln exhaust gas fan

Machines:

Fan

Damper


Bag filter fan in operation.

Preheater outlet temperature lower than MAX I.

Damper to be closed


Bag filter fan in operation.Preheater outlet temperature lower than MAX II.

The kiln feed - program 2 - has not been stopped for

more than 30 sec. after having run simultaneously with

the kiln exhaust fan.

7. Gas analyzers

Machines:

Analyzer

Pump


availability of compressed air and cooling water.


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Same as for start.

8. Kiln Auxiliaries

Machines:

Grease pump

Thrust deviceSpray lubrication

Cooling fan

Outlet seal fan


None.


None.

9. Kiln Drive

Machines:

Main drive with oil pumps


Barring disconnected.

No alarm for kiln position.

Cooler grate in operation.

Cooler fans in operation.

(These interlockings can be bypassed during kiln start-

up).



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Barring disconnected.

No MAX II alarm for kiln position.

Cooler grate in operation or not stopped for more than

3 minute.

Cooler fans in operation.

10. Barring

Machines:

Barring drive


Main kiln drive stopped.


Main kiln drive stopped.

11. Kiln burner fans

Machines:

Primary air fan

Emergency air fan


None


Once the kiln burner - program 12 - has been put into

operation, then the emergency fan must start

automatically when the primary air fan stops.

12. Kiln burner


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Machines:

Oil/Coal supply:

Pump Station


bag filter fan - program 3 - is in operation.

Kiln exhaust fan - program 6 - are in operation, during

heating up of the kiln a special interlock permissioncan be given, that a start-up of the burner without

fans in operation is allowed, however, when the fan

have been started this special interlocking is

automatically cancelled.

Primary air fan in operation - program 11 -.


Same as for start up.

13. Calciner Burner

Machines:

Oil/coal supply:

Pump

Station


Kiln burner in operation - program 12

Kiln fan in operation - program 6

Calciner outlet temperature must be above minimum level

and below MAX II level.

Kiln feed is on - program 2


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Same as for start, however, if the Calciner temperature

rises above MAX II or the CO level after the preheater

has been above MAX II (0.9%) for more than 10 seconds,

then the fuel rate is reduced to minimum level.

14. Clinker transport system

Selection to clinker silo

De-dusting of clinker transport and dust transport

Machines:

Deep pan conveyor

Hammer Crusher

Air sluices below ESP

Screw conveyor


Clinker storage area must not be full.


Same as for start.

15. Cooler Excess Air Fan

Machines:

Fan

Damper


Clinker transport group and cooler dust transport

should run


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Same as for start.

16. Cooler dedusting unit

Machines:

ESP Charging


Clinker transport group and cooler dust transport

should run

ESP fan in operation.


Same as for start.

17. Cooler drives

(Please also refer to cooler instruction manual)

18. Cooler Fans

(Please also refer to cooler instruction manual)

19. Scanners and cameras

Television cameras, monitors and kiln shell scanner can

be operated separately.

7.3 Control Loops

The following control Loops are foreseen.


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1. The kiln feed is synchronized with the kiln speed.

2. The Bag-filter fan speed controls the pressure

measured just after the exhaust gas fan.

3. The temperature in the top of the lower most cyclone

controls the fuel supply to the Calciner burner.

4. The pressure in the kiln firing hood is maintainedby the speed of the cooler excess air fan.

5. The operator can select between the modes of cross

bar control

6. For all cooler fans the measured air flow will be

controlled by the Fan speed.

7.4 Cause/effect diagram

In section 10. cause and effect diagrams are shown. All

instrumentation related to process parameters are

listed. The handling and the use of these signals are

presented.

8. PREVENTION OF FIRES AND EXPLOSIONS

8.1 General Precautions

On no account must, soot non-combustible, unburned exit

gases be allowed to accumulate in the kiln, the

cyclones, the flue ducts etc., since this would involve

a serious risk of explosion or fire.

Therefore strict adherence to the following rules is


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needed:

1) In connection with renewed light-up of the kiln,

following a temporary shutdown, it must be firmly

established that the kiln heat (material surface

temperature) is sufficient to ignite the fuel.

If the kiln is too cold, the kiln must be lit in the

normal manner, using the light-up equipment, and, if

necessary, the light-up nozzle, under procedure similarto that applied during normal heat-up phase prior to

start-up.

2) Always ensure that the burner is not operating with

an air deficiency.

3) Inject the fuel at sufficient primary air velocity,

i.e. with a nozzle velocity for the primary air of

about 180-200 m/s.

4) Never increase the fuel supply rate too suddenly or

excessively at any one time. In any case, the draught

must always be increased first, and the upward

adjustment of the fuel supply must take place evenly

and slowly.

8.2 Precautionary measures relating to the burners

In the following the interlockings for the burners and

the gas analyzers are summarised. The main purpose of

the interlockings is to reduce the risk of any fire or

explosion. Whenever working with fuels, these risks are

present. Although measures are taken to prevent the

dangers, the operator should always observe and act


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carefully when working with fuels and firing equipment.

It is therefore an important interlocking, that a

burner can only operate, if at least one of the gas

analyzers after the preheater is in operation without

any unit alarms or without analyzer fault on the CO

channel.

Further it is conditional for the calciner burner

operation that the CO level has not been over MAX II(0.9% CO) for more than a few seconds (less than 10

seconds). In this case the fuel rate must be reduced to

minimum automatically.

If the CO level is above MAX I (0.5% CO) or MAX II

(0.9% CO), then the operator must take actions to

reduce this immediately. Depending on the circumstances

these actions could be either to reduce fuel rate or

increase draught.

PROCEDURE FOR GAS ANALYZER TEST MODE

The analyzer has a digital input for permission to test

mode. This input must be set before any local test can

be performed.

The test permission is selected by the operator in the

central control room and is automatically deselected

whenever the analyzer is put into test mode, or if not,

is deselected after 10 minutes by a timer.

The test permission for analyzers must be separated in

three test permissions, one for each analyzer. The test


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mode must always be clearly indicated to the operator.

For further safety, test permission should only be

possible for one analyzer at a time.

8.3 Fuels

For precautionary measures to be taken when using fuel

oil, see separate instruction manual.

Reference is also made to the regulations of the local

authorities.

9 BARRING

9.1 General Instructions

If the kiln is stopped while hot, barring of the kiln

is required to avoid kiln shell deformation.

Normally, barring should always be restricted to an

absolute minimum to prevent damage to the lining.

The hydraulic thrust device and the spray lubrication

system of the kiln drive must be in operation while

barring operation is being performed.

The following guidelines apply to a situation where the

kiln is stopped in a hot condition and is to be barred:

1) As long as the kiln is hot, the barring operation

must not be stopped for more than 10 minutes.

2) If the axial position of the kiln should cause the


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alarm to be tripped, then barring must be

continued until the correct position has been re-

established.

3) If the kiln shell is exposed to strong external

cooling, for example due to heavy rainfall,

then continuous barring is required.

9.2 Barring programmes

The barring programmes are divided into stages of 100

deg. rotation. This is done to ensure variations in the

position of the kiln during standstill.

9.2.1 Barring during drying of the lining before

initial start-up.

0 - 24 hours: About 100 degrees every 30 minutes

24 - 64 hours: About 100 degrees every 15 minutes64 - 72 hours: Continuous barring.

Keep a close check on the longitudinal expansion of the

kiln and its position on the supporting rollers during

the entire period.

See separate instruction manual for thrust device.

9.2.2 Barring during normal start of cold-state kiln



16 - 24 hours: Continuous barring.

Keep a close check on the longitudinal expansion of the


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kiln and its position on the supporting rollers during

the entire period.

See separate instruction manual for thrust device.

9.2.3 Barring during stoppage and shutdown of the kiln

0 - 1 hour : About 100 degrees every 10 minutes


24 - 48 hours: About 100 degrees every 30 minutes48 - hours: Barring as required, if some of the

conditions mentioned in subsection 9.1 makes it

necessary.

During the final period the kiln must be barred for a

few minutes, if the axial migration of the kiln exceeds

the maximum value for normal kiln operation.

This barring operation is required to prevent damaging

or possibly rupturing of the thrust roller shaft duringthe kiln tube contraction which still may take place up

to the 72nd hour.

Proper graphite lubrication of the supporting roller

surfaces must be ensured. The graphite blocks must rest

loosely in their holders so that the pressure against

the supporting roller surfaces is not hampered.

To protect the surfaces of the supporting rollers and

live-rings against damage as the live-ring slides over

the supporting rollers during the axial movement of the

kiln, it is essential that the mentioned dry matter

lubrication is in order.


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Refractory Dryout Schedule

0

100

200

300

400

500

600

700

800

900

73696561575349454137332925211713951

Hours

TemperatureDeg.C

Top Cyclone

Bottom Cyclon

24 hr. Preheat Schedule

0

100

200

300

400500

600

700

800

900

2523222019181615141211109765321

Hours

Temperatur

eDeg.C

Top Cyclone

Bottom Cyclon


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9.3 Braking

If the barring operation is stopped, the kiln is

automatically braked and maintained in an arbitrary

position. Therefore, the kiln may be side heavy; this

fact must be taken into account when the brake is

slackened.

Reference is also made to the instruction manual for

the barring device.

10 CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS AND

ALARM LIMITS.

The following tables are a survey of the expected

normal operating parameters and the normal alarm

limits.

The operating parameters stated are for guidance only

and apply to the normal, stable operating situation.

The operating limits stated are meant as guidance for

start-up. It will be possible to adjust many of these

with advantage later on in order to make them more

suitable for the actual operation. Concerning many of

the alarm limits they too will have to be adjusted

according to local conditions as factors like the

lubrication oil selected, the ambient temperature,

etc., will affect the values.

The mechanical and/or the electrical departments must,

in every single case, approve the change and fixing of

the alarm limits for protection of the machines.


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Normally, the alarm limits for the operating parameters

will be the responsibility of the production

management.

SEE ALSO INSTRUMENTATION INSTRUCTION MANUAL AS WELL AS

FLOWSHEET FOR CODES AND INSTRUMENTATION.

The following process instrumentation/indications arerequired:Notes used in the instrument and alarm table:a: Refer to mechanical and electrical documentation forthe equipment.b: To be set empirically at a level not activating thealarm under normal operating conditions.x: To be evaluated during commissioning.

Kiln feed

Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Raw mealfeed

t/h 0-307

256

kW ofelevator

kW a

Preheater

Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments


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Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Temperature ofgases inthe downcomerduct

C 0-600

332 380 450

Pressurein thedowncomerduct

mmwg-700to0

-446

Temperature ofgases inthe ductafter the1stcyclone

C 0-600

334 380 450

Temperature ofmaterialfrom 1stcyclone

C 0-600

329

Pressurein theductafter the1stcyclone

mmwg

-700to0

-420

Pressurein bottomof 1stcyclone

mmwg

-700to0

-420


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Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Temperature ofgases intop of 2ndcyclone

C 0-600

527

Temperatu

re ofmaterialfrom 2ndcyclone

C 0-600

522

Pressurein theductafter the2ndcyclone

mmwg

-600to0

-340

Pressurein bottom

of 2ndcyclone

mmwg

-600

to0

-340

150

Temperature ofgases intop of 3rdcyclone

C 0-1000

690

Temperature ofmaterialfrom 3rd

cyclone

C 0-1000

685

Pressurein top of3rdcyclone

mmwg

-600to0

-295


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Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Pressurein bottomof 3rdcyclone

mmwg

-600to0

-295

120

Temperature of

gases intop of 4thcyclone

C 0-1000

821

Temperature ofmaterialfrom 4thcyclone

C 0-1000

811

Pressurein top of4thcyclone

mmwg

-400to0

-250

Pressurein bottomof 4thcyclone

mmwg

-400to0

-250

80

Temperature ofgases intop of 5thcyclone

C 0-1200

890 750 920 980

Temperature of

materialfrom 5thcyclone

C 0-1200

870

Pressurein top of5thcyclone

mmwg

-400to0

-200


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Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Pressurein bottomof 5thcyclone

mmwg

-400to0

-200

60

Positionof

dividergateafter 4thcyclone

% 0-100

O2 out of5thcyclone

% 0-10

3.0

CO out of5thcyclone.

ppm 0to20000

0 Max.1

5000

Max.2

9000

Max.3

12000

O2 out of

cyclonepreheater

% 0-10

3.9

CO out ofcyclonepreheater

ppm 0to20000

0 Max.1

5000

Max. 2

9000

Max. 3

12000

Calciner

Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Temperature oftertiaryair

C 0-1200

950


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Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Temperature in thereductionzone

C 0-1200

Temperature in

exit ofcalciner

C 0-1200

895 750 820

Pressureintertiaryair duct

mmwg

-200to0

-100

Positionofhoistingdamper

% 0-100

Coal flowto

calcinerburner

t/h 2.0-20

1.4-

14.7

Kiln

Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Kilntorque

Amp

Kilnspeed rpm0-5 3.6

Axialmovementof thekiln

mm -30-+30

a a


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Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Pressurein kilninlet

mmwg

-100to0

-30

Temperature inkiln

inlet

C 0to1200

1080

O2in kilninlet

% 0-10

4.2 1

CO inkilninlet

ppm 0-20000

0 Max.1

5000

Max. 2

9000

Max. 3

12000

NOx inkilninlet

ppm 0-2000

Kiln Burner

Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Coal feedto kiln

t/h 1.3-13.5

1.0-10.8

Primaryair fanspeed

% 0-100

Power forprimaryair fan

kW a

Primaryairpressure

mmwg

a


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Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Primaryair flow

m3/min

a

Damperpositionforemergency

coolingofburner

open /closed

closed

ID Fan

Unit

Range

Exp.

Value

Min. 2

Min. 1

Max. 1

Max. 2

Comments

Positionof ID fan

damper

% 0-100

100

Motorpower forID fan

kW 0-1700

1072

Pressureafter IDfan

mmwg*)

-30to+30

-20 0 +20

ID fanspeed

% 0-100

*) + indicate pressure above the atmosphere, - indicatepressure below the atmosphere.

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