C.

Chemical transformation

Temperature < 100 100 - 400 400 - 750 600 - 900 900 - 1000 800 - 1300

Process
Drying elimination of free water. Elimination of physical absorbed water. Decomposition of clay with formation of metakaolinite. Removal of structural H2O. Decomposition of metakaolinite to mixture of free reactive oxides. Dissociation of limestone and formation of intermidiate products CS and CA. Binding of lime by CS and CA with formation of C2S, C3A and C4AF. Formation of belite and liquid phase (aluminate and ferrite melt).

1250 - 1450

Further binding of lime by C2S to Form C3S. Completion of reaction and re-crystallization of alite and belite.

1300 - 1240

Crystallization of liquid phase into mainly Aluminate and ferrite.

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TABLE OF CONTENTS

Clinker burning Process

1- The Process related to the preheater tower and the kiln zones. 2- Burning behavior. 3- Chemical reactions leading to refractory damage. 1

PROCESS
Outlines

123456789-

Fuel flow. Material flow. Gases flow. Grate cooler. Firing hood. Pressure & temperatures. Main drives torque. Sintering zone temperature. CO gas percentage.

OPERATION
Action & reactions

12345-

Kiln feed. Kiln speed. Preheater fans speed. Fuel. Auxiliary parameters - Grate speed. - Cooler fans. - Gravel fans dampers. - By pass fan & damper. - Fresh air fans damper.

CALCULATIONS
Process Chemistry Grate cooler Cooler fans Kiln refractory

CHARTS & DRAWINGS

Clinker burning process

I. The process related to the preheater tower and the kiln zones

A. Introduction
- Generally part of chemical processes start to take place in the preheater tower cyclones as the material is heated to 820 C by the hot kiln gas. This is includes the evaporation of free and absorbed water, the initial decomposition of the clay and a decomposition of a part of the carbonates. - The chemical processes taking place at higher temperature after the decomposition of the carbonates are different and more time consuming. They are also accompanied by the melting of apart of material that transforms the dry particles into clinker nodules. - The chemical and physical reactions takes place in the kiln are described in the following from an operational point of view, and relates the various reactions taking place to the zones inside the kiln and production parameters. - In order to obtain a steady flow of clinker with uniform and predictable properties, with minimum energy consumption, and fully utilizing the capacity of the kiln system, it is indispensable to understand the production parameters which influence process. - The chemical reaction determine the formation of the hydraulic minerals alite( C3S) belite (C2S), aluminates (C3A) and ferrite (C4AF). The properties of the cement depends not only on the potential contents of these minerals in the clinker which are determined by the chemical composition of the kiln feed, but also on the degree to which the synthesis of these completed in the kiln. - The clinker formation refers to the physical agglomeration processes which under favorable conditions, result in clinker nodules with diameters of 2-20 mm. - This nodule size is adequate for treatment in the cooler and normally indicates a satisfactory grind ability. - Problems in controlling the clinker formation do not necessarily influence the quality of the final cement, but frequently result in difficulties of kiln and cooler operation and may also result in a product that is difficult to grind.

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B. The kiln model

- The practical experience shows that the hot part of the kiln model can be divided into five zones. These zones of course are not distinguished by sharb boundaries but instead the dominant physical and chemical processes occurring to the material in each zone characterize them. - These zones are commonly denoted as the calcinig zone (CZ), heating zone (HZ), liquid zone (LZ), sintering zone (SZ) and cooling zone (AZ).

1. Calcinig zone
- Generally the calcinations takes place in the preheater tower 90 % and the result happens in the kiln. - It is in the calcining zone (CZ) that the decarbonation of the carbonates in the raw meal takes place. This may also be considerable formation of C2S taking place here. - Carbon dioxide dissociates from the kiln feed and is carried a way by the kiln gases. Kiln feed that is not completelycalcined before it enters the burning zone is difficult to burn and is a major cause of kiln disturbances. Thus a complete calcinations of the kiln feed before it enters the burning zone is required for proper kiln operation. - The overall process of decarbonization requires a great quantity of heat and consequently, the material temperature rises only slowly along the zone in the range 820 - 900 C. However as soon as all the CO2 has been expelled, the temperature rises rapidly.

2. Heating zone
- AT the end of calcining zone the material temperature is a above 900 C. - The heating zone is characterized by a sudden rise in the temperature of the kiln charge, as the calcinations processes comes to completion and formation of the interterm-phases takes place. - Thus, the reactions between CaO and Al2O3 and between CaO and Fe2O3 of the lime and clay particles continue in the heating zone with the formation of several intermediate minerals. Which are stable only within narrow temperature limits. - Since no heat consuming reactions take place, the temperature rises rapidly in this zone. Upon a sufficient increase in temperature normally 1300 -1350 C a significant

amount of liquid phase is suddenly formed a short distance in the kiln thus terminating the heating zone.

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3. Liquid zone
- This zone begins at temperatures 1300 - 1350 C where the liquid phase is formed. - The liquid phase content depends on the chemical composition and increase very little as the temperature increases. Normally the liquid phase properties do not change as the temperature increases, even though the viscosity decreases a little. - The liquid zone is the most important zone with respect to the nodulization of clinker. The formation of nodules and their size depends on the quantity and the properties of the liquid phase the size distribution of the solid particles in the feed and the residence time of the material in the liquid zone. - Nodulization starts by capillary bounding in which the individual particles are held together by the liquid. As the clinker grows in the size capillary bounding is very quickly succeeded by crystal bounding in all cases where two particles have different chemical composition. Such as one rich in lime (CaO) and one rich in silica C2S. In this process the particles form a solid union by diffusion and crystallization through the fluid bridge which is they replaced by a solid bridge consisting of C3S. - In order to secure a good nodulization, it is of importance that the liquid zone is sufficiently long. The relative length of the zones can be changed by modification of the temperature profile or by changing the characteristics of the raw mix with respect to its burnability.

4. Sintering zone
- At the point where the amount of C3S has reached its highest value, the nodulization stops and the sintering zone (SZ) begins. In this zone which is directly under the illuminated part of flame, the dominant processes are the formation and growth of individual C3S particles and their bounding to each other. - Essentially, this mean that the chemical reactions are limited by diffusion velocity of the reactants in the liquid phase.

5. Cooling zone

- The cooling zone (AZ) begins when the material start to solidify. - The chemical reactions also occur here in the last section of the kiln. The proportion of C3S mineral will always decrease during cooling and the slower the cooling the greater the decrease. Some of this mineral will be converted to C2S with the release of CaO which immediately combines with the unstable C-A minerals form C3S. - The conversion from to C3S to C2S certainly will affect clinker grinding as C2S is more difficult to grind than C3S.
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II. Burning behavior

- During the burning process we may have different behavior resulting from burning the raw mix having concentration of elements higher in their limits than the permissible range. It is therefore necessary to distinguish between the following :

1. Coating
In the cement kiln is the desired protective layer on the refractory lining. Which is formed during the kiln operation under the influence of high temperature from the traveling material on the refractory lining in the transition and sintering zones.

2. Ring Formation
Is an undesired degree of growth coating.

3. Incrustations
Referred to as build ups, are coatings which are formed below 1100 C by alkali salt and which occur particularly in the preheater tower.

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A. Significance of coating
Coating has the following functions to fulfill :
1. Protection of the refractory brick against over heating. 2. Protection of refractory lining against the abrasive effect of the moving clinker bed and dust. 3. Protection of the refractory lining against the chemical attack of clinker constituents, fuel Ash and Gas atmosphere. 4. Reduction of heat radiation and protection of the kiln shell against thermal overloading. 5. Augmenting the mixing effect, improvement of the blending effect of the clinker due to the unevenness of the coating surface. 6. Increasing the retention time inside the kiln.

B. Formation of Coating
Two basic hypothesis are plausible as to the mechanism of coating formation :
1. Formation of clinker melts ( above 1280 C ) and their sticking together with the refractory lining with simultaneous cementing to solid particles. 2. Adhesion of solid crystalline phases on the refractory lining. - In both cases, chemical and / or physical reactions (impregnation / infiltration ) with the upper zone of the brick strengthen the adhesion of the coating.

C. Thickness of Coating
- Usually, the following classification is applied as to the thickness of coating : 30 - 50 cm 20 - 30 cm 0 - 10 cm thick coating normal coating thin coating

- Coating thicker than 50 cm is classified as ring formation.

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III. Chemical Reactions Leading to Refractory Damage

A. SO3 attack on castables

- The bounding agent of many refractory castable is monocalcium aluminates ( CA ) which exhibits both hydraulic properties ( high alumina cement ) and high melting point ( 1600 C ). - At service temperature in the range 800 - 1000 C, CA reacts with sulphates from the kiln gases. - During shutdowns a further reaction with moisture can occur. - As consequence of these reaction their occurs. 1. A destruction of the bounding agent and a change of structure. 2. A loss of strength.

B. Alkali bursting of alumina refractories

- The most well known by which high alumina bricks are damaged is the socalled " Alkali bursting " or " Alkali spalling ". - By the pick up of alkalis, the formation of feldspathoids take place which is a direct cause of the volume increasing a disruption of the brick at a given depth below the hot face. - The ensuing cracking over a large area causes the heads of the bricks to spall-off.

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Process
Outlines

1.

Fuel Flow
1. Fuel oil should be hot 70 C at least, to make sure the fuel oil is not viscous, but meanwhile the fuel oil temperature should not exceed 130 C to prevent the fluctuation of the fuel oil high pressure pump. 2.The calorific value of the fuel oil. The calorific value of the fuel oil is the energy that we can get from burning one Kilogram of fuel oil with the needed Oxygen this value is 9600 Kcal / Kg. 3.The heat consumption. It is the quantity of heat that you need to get one kilogram clinker That value is = 850 Kcal / kg clinker. 4.Excess air. It is the air more than the air needed for making sure that you have complete combustion. 5.Excess Fuel. It is phenomena happen when you do not enough air for burning this fuel.

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2.

Material Flow

1. Material flow through the preheater tower.

- The material goes through the feeding pipes to the riser duct of the second cyclone. Then gets to the first cyclone and makes its cycle in the cyclones. Then goes down to the riser duct of the third stage through the meal shuts, and from the third stage to the calciner, and then fourth stage. The material takes its cycle into fourth cyclone and goes down to kiln inlet by gravity, and hot gases goes up by the preheater fans suction. - Calcinations CaCo3 ----------- Cao + Co2 This action is mostly done in the preheater tower about 90- 92 % ( should not exceed this value to prevent making clinker inside the preheater tower the other 8 - 10 % of the material calcinations happens in the first zone in kiln.

2. Material flow through the kiln ( Clinkerization - Cooling ).

- The material after calcinations get into the kiln and it is temperature get higher more and more till the material reaches the liquid phase in the clinkerization zone which should not exceed 27 %. - After the last phase the material makes granules ( the normal form of clinker ) and then it goes to the cooling zone down to the cooler. N.B : - Kind of heat transfer : 1. By Conduction. 2. By Convection. 3. By Radiation.

By Pass system
- This system is made to get rid of alkalis from material, these alkalis concentrates as a solid in 900 C, if these alkalis gets into kiln its temperature gets higher than turns from solid state immediately to gases state this phenomena called " Circulation phenomena " - To prevent any circulation in kiln inlet, we take these alkalis out of system and dilute it with fresh air to decrease its temperature. But we do not take all of these alkalis to prevent loosing heat material we take what just make the quantity of the alkalis is stable.

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N.B : - If we do not take these alkalis after a while it will block the kiln inlet ( the narrow cross section ). < 900 C Alkalis is in solid state, acts like material action and goes in the same direction. Alkalis is in gaseous state, acts like gases action and turn back into the preheater tower.

1000 C

- Then the new material got its alkalis with the old ones so, the concentration of alkalis gets higher and blocks kiln inlet and mixing chamber.

3.

Gases Flow

Sources of fresh air :

1. Cooler Fans. 2. Primary air fans ( Main burner - Precalciner burners ). 3. Air blower of airlift. 4. Nose ring fans. 5. Fresh air fans of by - pass. 6. False air ( refer to calcinations section ).

Flow direction 1. The cooler fans.

The air produced by the cooler fans goes into the cooler through the grates making cooling to the clinker ( heat transfer by convection ) this is the main task of the air from cooler fans. Then the hot air goes either the preheater fans or excess air fan depending on where is this hot air inside the cooler. If it goes to the direction of excess air fan all the happens that air goes through the filter then to the fan. But if it goes to direction of preheater fans the hot air goes either to the tertiary air ducts or to the kiln as a secondary air for all burners then it goes to the preheater fans.

2. The primary air fans.

This air produced by these fns is the source of Oxygen needed to burn the fuel either in the main burner or in precalciner burners but in main burner this air mainly used to make control on the flame shape.

3. The air blower of the airlift.

This air is only used to take material from feeding bins of kiln up to feeding pipes in the second stage. On the other hand this air is not hot so we loose some temperature we put it in the system , and we consider it as a load on the preheater fans.

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4.

Grate Cooler

Cooler Hoppers
These hoppers are made to prevent loosing air given by cooler fans, these hoppers have plates from inside like stiffener to prevent the abrasive effect of the fine clinker collected by these hoppers. And on the other hand we never let these hoppers get empty because the fine clinker make a seal to prevent any pressure drop under the grate cooler chambers.

Rules :
1. Pressure reversely proportion to Velocity. 2. Pressure reversely proportion to Volume flow rate. 3. Flow direction. negative pressure more negative pressure 4. Under the grate is the only place in the system that has a positive pressure. 5. Retention Time : time needed for heat transfer 6. Bernoulli equation.
2 2

P1 y Elevation head Velocity head Pressure head

V1 2g

Z1

P2 y

V2 2g

Z2

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A. First Case
Thick Clinker Bed : 1. The retention time will be longer so the air passing through the clinker bed takes longer time for heat transfer ( by conviction ), so the hot air in cooler will have higher heat. 2. When the bed of clinker gets higher the air under the grate that wants to pass through that clinker bed will face bigger resistance to pass through. That mean that if we made a set point of 55000 m3 / hr in the fan 1 not all this air will pass. So : a. Air pressure inside the cooler ( P1 ) will be lower. b. The volume flow rate ( Q1 ) of air in the cooler will be smaller. c. Air pressure under the grate ( P2 ) will be higher. d. The volume flow rate ( Q2 ) of air under the grate will be smaller. Then after that, the flowmeter of this fan will feel that and gives a command to open a little more the damper of that fan to give more air to achieve the set point.

B. Second Case
Thin Clinker Bed : 1. The retention time will be shorter so the air passing through clinker bed takes shorter time for heat transfer so the hot air over the grate will have less heat. 2. When the air is passing through the thin clinker bed it will face less resistance, then the volume flow rate ( Q1- Q2 ) will be over and under the grate bigger. The pressure over the grate ( P1 ) will be over the normal. The pressure under the grate ( P2 ) will be lower. N.B : The clinker bed has another task to protect cooler plates from the heat and abrasion.

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5.

Firing hood

Reasons of making firing hood pressure in this place

1. Intermediate place between the kiln and the cooler. 2. In this point the pressure should be always negative to make sure that the flame should always be inside the kiln. 3. To control the heading of the gases ( flow direction ).

Firing hood pressure have action on :

1. All pressure in all the system. 2. Volume flow rate direction of gases.

Firing hood pressure is effected by :

1. Cooler fans. 2. Clinker bed ( grate speed ). 3. Preheater fans speed. 4. By - pass fan damper or speed. 5. Fresh air fans damper of the by - pass system. 6. Gravel bed filter fans dampers.

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6.

Pressures and Temperatures

A. Pressure in the third stage

Effected by : 1. Preheater fans speed. 2. Feed : the material decreases the cross section of the riser duct ( Throttling ) then velocity goes up and the pressure goes down. Effected in : Retention time in the feeding start is long in the kiln, but generally the retention time in the steady state in stable and do not vary by anything only the kiln speed.

B. Temperature of the raw meal ( fourth stage ).

- Indication of the temperature of raw meal only. - Indication of the heat transfer efficiency. Effected by : 1. Feed rate. 2. Preheater fans speed. 3. Heat transfer efficiency. 4. Retention time. 5. Fuel of precalciner burners. 6. Gases temperature in the system. Effected in : 1. Gases temperature. 2. Fuel consumption.

3. Retention time inside the kiln.

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The relation between the calciner temperature and the Pressure inside the preheater tower
1. When the temperature gets higher, the pressure also goes up then the velocity of gases goes down so, the quantity of material carried by gases is less than ever. 2. The material now is less so, the volume flow rate of gases is low so, the pressure goes down and velocity of gases now is higher so, the gases carries more material. This circulation is going on and till temperature in the preheater tower goes down. # When the material ( not carried by gases ) goes down so, the heat transfer of this material is not completed. So , the calination degree is less than ever so, the material needs a lot of heat to be clinker. So the kiln gets cold. # The decrease of preheater fans speed can help in this case.

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7.

Main Drives Torque

Kind of stresses on the kiln main drives :

1. Bending stress ( on the radial direction ). 2. Thermal stress.

N.B :
KA of main drives is not actually the torque but it is the power consumption of these drives.

Kiln speed has an effect on :

1. Bending stress : Speed 2. Thermal stress : Speed Retention time Heat Material level Weight

Torque performance
At the steady state, nothing have be changed nothing have be increased or decreased

First Case :
Bending stress Thermal stress This case is rare ( PPM of kiln not suitable to feed ) ( heat consumed by raw meal inside kiln )

heat for this quantity of material is big but we have not increase the fuel so the heat remaining inside the kiln will be distributed on the material so, the material is not hot enough so, we can see that the sintering zone will decrease. When the thermal stress is higher due to the heat content of material inside the kiln. The material is well calcined and the heat needed to complete the calcinations is available and more so the material got what it wants and more the figure of heat content so, the kiln heat is higher. The sintering zone will increase. Bending S. and Thermal S. S.Z and S.Z equal ??

We know that any stress beat the other by the difference of S.Z temperature but the torque will increase any way. Tq
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Second Case :
Bending stress Thermal stress This case is the contrary of the last one. S.Z Tq ?

Third Case :
Bending stress Thermal stress S.Z Tq This case level of material is higher than should be.

Fourth Case :
Bending stress Thermal stress S.z Tq

Case no. Five :

Bending stress Thermal stress S.Z Tq This case as third case.

Case no. Six :

Bending stress Thermal stress S.Z Tq This case as fourth case.

Because of :
1. Hard to burn material. 2. Coarse material. 3. High Silica content. 4. LSF high.

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Case no. Seven :

Bending stress Thermal stress S.Z Tq The sintering zone will decrease sharply but the torque will ( or will not ) change according to the percentage of each one of them. N.B : The torque would be stable when B.S 50 % T.S 50 %

Case no. (8) :

Bending stress Thermal stress S.Z Tq The sintering zone temperature will increase sharply and the torque will have

the same action like the last case.

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8.

Sintering Zone Temperature

The temperature is a result of all what happens in the system and it may tell us what to do to prevent any damage. This indication has an effect on properties of the product ( clinker ). This indication mainly is an indication of heat transfer. The range of this temperature is 1300 C - 1400 C with an optimum of 1350 C.

9.

CO % ( Carbon monoxide )

The gas analyzer that give us this value is between the preheater fan and the preheater tower. Tells us the quantity of CO in the whole system. If this gas was from preheater tower when us increase the fuel in the precalciner burners only the CO will increase but if it was from the kiln when you increase the precalciner fuel the calciner temperature and the CO % will both increase.

How to decrease the CO % ?

1. Preheater fans speed increasing. 2. Clinker bed increasing. 3. By - Pass fresh air damper opening decreasing ( increase the temperature of conditioning inlet tower Max. 450 C ). 4. Firing hood pressure decreasing ( not recommended ). 5. Easy material from the silo increasing after making analysis.

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Operation
Actions & Reactions

1.

Kiln Feed
Cases of increasing kiln feed :

A. At the kiln feed starting :

The kiln feed starting rate is high, starting from the set point that gives about 120 t / hr and according temperatures. The increasing rate should be kept above 10 - 20 t /hr but this increase value decreases upon reaching higher values to be 10 t / hr and less. Generally the feed increasing is according to the preheater temperature and the kiln main drives torque. The sintering zone temperature appears above 1100 C indicating the temperature of the clinkering of coming material.

The preheater temperature should preferably be higher than the usual temperature about 20 C. The cooler fans dampers should be as usual state of operation to prevent any thermal shocks on the grate cooler plates. At the cooler, as there is no clinker bed so there is no heat transfer between air from cooler fans and clinker, the air going to the tertiary air duct and to the kiln ( as secondary air for burners ) will be cold, so we must increase fuel more than the normal case. The kiln speed should be more than the usual speed according to the kiln feed because we want to sure that thermal stresses is the main increasing stresses on the main drives torque not bending stresses. The preheater fans speed should be more than normal speed according to the kiln feed to prevent the appearance of CO % gas inside the system, and to have higher suction than normal to prevent any accumulation to material inside the preheater tower ( narrow ducts ). Generally preheater fans speed should be 75 - 80 %.

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B. At the steady state :

1. Decision by Operator of increasing the feed
First of all actions we prepare preheater tower 1. Temperature - fuel increasing in case of not having CO % high. 2. CO % - CO decreasing by : a) Preheater fan speed increasing. b) Clinker bed increasing. We increase it in the limit of not getting gases temperature inside the cooler high than 250 C and in the opposite side this thick bed will increase the power consumed by the grates motors, which is not recommended. c) By - Pass fresh air fans. In this action the temperature of the conditioning tower inlet is limited ( 450 C max. ) to prevent the sticky material of alkalis at ( 500 C ) which may make blockages inside the system.

d) Easy to burn material. We can use this way by using the easy material from the storage silo, but this may make an unbalanced state inside the kiln like heating it up which may cause the case of the fallen coat so it is not preferred in several cases and this material is not always available. e) Firing hood pressure increasing. We can increase the firing hood pressure that gives you big response in system at the smallest change this way is not preferred when the system is not very balanced. # Sintering zone temperature - we prefer that this temperature would be in it is upper range 1400 - 1450 C. if it is in the lower range ( 1350 - 1400 C ) So, no way to increase the kiln feed. # Main drives torque # Level of material : should be stable should not fall down by thermal stresses. this step should be the first one in the way of increasing the kiln feed to make any problem from this increasing action, it should be checked up visually first . ( should not exceed 17 % ).

# Increasing the feed must be proportional to gained conditions inside the system.

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2. Kiln needs more feed

In the common condition, we have all the parameters that we make to increase the feed happens by itself like preheater tower temperatures increasing, torque increasing sintering zone temperature increasing, CO % decreasing and the level of material inside the kiln is in the lower range, this case happens when the material burned is easier than ever or when the coat is falling down. The kiln feed increasing should be corresponding to the quantity of change of parameters inside the system whenever, we want to increase feed more than these parameters after increasing the feed to make complete control on the temperatures in

in the preheater tower and the kiln. In the rate condition, sintering zone temperature is getting high and the torque getting down which means that the level of the material is getting lower, the preheater tower temperatures must be stable.

Action :
First : increasing the feed by certain amount corresponding the changing of conditions inside the kiln. Second : controlling preheater temperature ( fuel - preheater fan speed ). # When the litter weight gets over 1250 - 1300 g / Lt. then there is availability to increase the kiln feed.

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N.B : A. Silica This component have nothing to do with calcinations degree which is CaCo3 Silica ratio CaO + CO2

= Ease material to burn at the clinkerization zone and vise versa

SR

= Al2O3

SiO2 +

( should not exceed 2.5 ) Fe2O3

B. Aluminum This component make the burnability higher but on the other hand more ( AR ) make balls and rings inside the kiln.

AR

Al2O3 Fe2O3

( should not exceed 1.7 )

C. Lime Saturation Factor This value gives a figure of the entire composition of the kiln feed.

LSF

CaO 2.8 SiO2 + 1.18 Al2O3 + 0.65 Fe2O3

123-

Range 90 - 105 Less than 90 gives us C3S % low More than 105 gives us less burnability

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Cases of decreasing kiln feed

A. At the steady state When we have material hard to burn ( LSF - SR ) any or of them we may decrease feed if we can not increase heat. When the level of material gets higher in the kiln we should decrease kiln feed. B. At the unsteady state The unsteady state is : " Unsteady running for some / all parameters but more than tow parameters ".

The Special Case ( overheated kiln )

- Mainly it is a dangerous state gases carry more heat than it should. - Parameters changes : Firing hood pressure, Sintering zone temperature and the under grate pressure fluctuation a lot. In this case, we might have high or low litter weight, according to the kiln speed and the kiln feed rate.

Action :
1. Decrease fuel in the main burner. 2. Decrease preheater fan speed. 3. Making the firing hood pressure more negative. 4. Increase the flow of V1 - V2 - V3

Normally the overheated case happens after starting the feeding of kiln.

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The Common Case

Reasons of the unsteady state in common case A. In the preheater tower
1. Fluctuation of the raw mix. Composition ( LSF ). 2. Accumulation of material in narrow places. 3. By - Pass accumulation of material. 4. Gases heat content is higher than it should.

5. Fluctuation of kiln speed is higher than it should. - Electrical problem ( dosing schenck ). - Production problem : Air left ( Aeration ). 6. Fluctuation of precalciner fuel higher than it should.

B. In the kiln
1. High fluctuation in fuel of main burner. 2. Main burner position and the flame shape ( Axial air - Radial air ). 3. Firing hood pressure. 4. Under grate pressure. 5. High fluctuation of kiln feed. 6. Fluctuation of raw mix. Composition ( LSF ).

Action :
1. Decrease kiln feed. 2. Decrease preheater fans speed. 3. Decrease kiln speed. 4. Decrease cooler fans speed. 5. Preheater tower check up and cleaning ( Cyclones - Tipping flaps ). 6. By - Pass system check up and cleaning ( kiln inlet - mixing chamber ). 7. Kiln check up visually ( level of material ).

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Firing hood pressure fluctuation

When gases temperature is high then pressure inside kiln gets high also. that would cause lower volume flow rate of gases, then the retention time gets longer then the heat transfer is good this will cause that the material took heat from gases, gases have less heat than the last case so, the pressure inside the kiln will decrease this cause that

the volume flow rate of gases gets higher so the retention time will be shorter than the last case so, the transfer will be bad ( material do not take from gases ). The firing hood pressure fluctuate, Sintering zone temperature fluctuate and the under grate pressure also fluctuate.

The under grate pressure fluctuation

When the under grate pressure indicate high pressure the grates work faster to achieve the set point of the controller so the clinker bed in the cooler gets thicker. As a result of that the produced by the cooler fans penetrates through that bed and producing lower heat hot gases which is used as a secondary air for all burners so the heat produced will be lower. Finally we have clinker with low litter weight. When the under grate pressure indicates low pressure then happens the contrary. When the circulation of action inside the kiln happens ( firing hood pressure and the sintering zone temperature ) the heat content of clinker produced from kiln going to the cooler differs ( good heat transfer bad heat transfer etc. So, the litter weight of this clinker have difference for example : 1000 1200 1000 etc.

So, the under grate every time acts a different action caused by the weight of this clinker so the under grate pressure fluctuates.

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2.

Kiln Speed

A. At the kiln start up

The minimum speed should be at the start up is 1 RPM. The kiln speed increasing must be related to the feed increasing and the main drives torque direction with a factor of safety to prevent filling the kiln.

B. At the kiln shut down

Short stop : We decrease the speed as well as the material level inside kiln in its half-normal. Long stop ( overhaul ) : We must decrease speed slowly to guarantee emptying of kiln. Sometimes after cutting the feed we let the speed 1 RPM for one hour or more to empty the kiln but we must let the main burner on.

I.

Increasing the kiln speed

A. Steady state : 1. When the litter weight is high. 2. When the kiln is getting hot. 3. When we have heavy coat. 4. When the level of material is getting high. 5. When the coat is falling. 6. When we have a ball ( in steady state ). B. Unsteady state : 1. When the kiln is filled. 2. When we have a ball. 3. When we have a ring.

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II.

Decreasing the kiln speed

A. Steady state : 1. The litter weight is low. 2. The kiln is getting cold. 3. Hard to burn material. B. Unsteady state : 1. When the under grate pressure fluctuating we decreases the kiln speed to extend the time needed to regulate the clinker bed on the grate. 2. When the kiln is getting cold we decrease the speed to increase the retention time and decrease the flow rate of material.

3.

Preheater Fans Speed

A. Increasing the preheater fans speed

1. To decrease the CO % in the preheater. 2. To crease the retention time in the kiln. 3. To increase the preheater temperatures. 4. To decrease the calcinations degree. 5. To prepare the preheater for more feed.

B. Decreasing the preheater fans speed

Generally the decrease of preheater fans speed is not recommended either in the steady state or in unsteady state but we do it when we decrease the feed a lot ( To prevent any damage in the preheater tower bricks ). We may decrease it when we have vibration in preheater fans. When the pressure of preheater fluctuates, the decrease of the perheater fan speed may help in this case with decreasing the calciner fuel.

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Kiln Start up :
The minimum speed should be 75 - 80 % to prevent any blockage in the cyclones and we increase the preheater fans speed according to the appearance of the CO %.

Kiln Shut Down :

A. Short Stop If we do not have work in the kiln : Preheater fan damper 15 - 20 % Slide damper close to minimum If we have work in the kiln : Perheater fan damper 40 - 50 % Slide damper 50 % B. Long Stop If we do not have any work inside kiln ( work in shell or roller or tiers ) : Preheater fan damper 35 - 40 % Slide damper 100 % If we have work inside kiln : Perheater fan damper open gradually Slide damper 100 % Preheater fan speed Main burner OFF 40 - 50 % Preheater fan speed 35 - 40 % Main burner OFF Preheater fan speed 40 - 50 % Main burner OFF Preheater fan speed 20 % Main burner ON

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4.

Fuel
Main burner fuel

1. Increasing the fuel

Usually we increase the preheater tower temperature by increasing fuel in the calciner burners. A. Steady state : To increase the coat thickness. To increase the litter weight. If the material hard to burn. To heat up the kiln. B. Unsteady state : According to the kiln state unless we have fallen coat we must increase the main burner fuel. If the kiln is getting cold we must also increase fuel.

2. Decreasing the fuel

A. Steady state : To decrease the coat thickness. To decrease the litter weight. To decrease the kiln temperature. If the material easy to burn. B. Unsteady state : If we want to cool the kiln preheater. To keep the hot gases in kiln to heat it up.

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Flame Shape

Flame Shape Adjustment by Air

1. Radial Air :
Open : Wide Flame Close : Narrow Flame

2. Axial Air :
Open : Long Flame Close : Short Flame

Flame Shape Adjustment by Fuel

1. Primary Fuel :
Open : Wide short Flame Close : Narrow Long Flame

2. Secondary Fuel :
Open : Narrow Long Flame Close : Wide Short Flame

N.B :
Adjustment by air is more effective than the fuel. Adjustment by by fuel is for fine tuning. Primary fuel is proportional to the secondary fuel.

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Main burner and Flame Adjustment

Main Burner :
The burner is centered to get the burner to material to make sintering zone and to prevent any damage in the kiln refractory.

Main Burner Carriage :

The carriage is adjusted to make the entire inside kiln. We control the burner from the carriage within need.

Flame Shape
1. When we make the flame wide and short ?
a) If we want to make coat in first 10 meter in the kiln. b) If we want to heat up kiln hood. c) If we want to loose the coat inside the kiln 20 m. d) If we want to decrease the main drives torque.

2. When we make the flame narrow and long ?

a) If we want to elongate the sintering zone and the coat area. b) If we want to heat up the inside of kiln and cool down the firing hood. c) If we want to decrease the coat thickness.

N.B :
We never want to loose the kiln hood coat because its unstable coat. For the fine adjustment we might use the secondary and primary fuel. Also, we can remove the sintering zone by changing the carriage position ( not recommended ).

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Precalciner Fuel
A. Increasing the fuel
At the steady / unsteady state : 1. To heat up the preheater. 2. To increase the calcinations degree. 3. To increase the main drive torque.

B. Decreasing the fuel

At the steady / unsteady state : 1. To cool down the preheater. 2. To decrease the calcinations degree. 3. To decrease the CO %. 4. To decrease the preheater pressure fluctuation.

N.B :
Calciner temperature should not exceed 850 C.

page (33)

5.

Auxiliary Parameters

1. Grates Speed
We control it as a set point of the under grate pressure. The normal cases to have an automatic control on the grates speed.

Under grate pressure adjustment

Increasing and decreasing the under grate pressure Increasing is not heat up the kiln gases and tertiary air gases and vice versa. To decrease fuel consumption and vice versa. Decreasing is to give more cooling to the clinker and vice versa.

2. Cooler Fans
Generally we increase the cooler fans to cool the clinker. V1 , V2 , V3 These fans are quenching fans and have a direct effect on the under grate pressure and the quality of clinker ( C3S % ). The increase of the flow of these fans increases the under grate pressure and vice versa. End fans in cooler for cooling clinker only.

N.B :
How to slow down the speed of grates without changing the set point of the under grate pressure ?

We can decrease the first cooler fan V1 , V2 , V3 then the under grate pressure decreases ( actual value ) so, the grates speed slow down.

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3. Gravel Fans Dampers ( Excess Fan )

Usually the gravel fans dampers is controlled by the set point of the firing hood pressure. We can control the firing hood pressure manually by to mean : 1- The controller of the firing hood ( manual mode ). 2- The tow controllers of the gravel fans dampers ( manual mode ). The controllers of the gravel fans dampers are installed to mange the flow of every separate fan within need.

N.B :
The main task of the gravel fans is to get rid of the not needed air and to make the negative pressure in the system. The gravel filter is installed to collect the fine dust of clinker going with the air of the cooler fans.

4. By-Pass Fan Speed or Damper

Mainly the flow of the by-pass fan is controlled by the manual mode. The opening of by-pass fan damper or speed must be as minimum as possible to prevent loosing raw meal and heat, we should not change this opening in short times and according to analysis. The by-pass damper or speed is only to control the circulating elements not

to change the suction inside the kiln. The conditioning tower inlet temperature should not exceed 450 C.

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5. Fresh Air Fans Damper

These dampers its only task is to control the temperature of the conditioning tower inlet. It is also effecting in the CO % inside the kiln but not controlling it except in a narrow range according to the temperature of the conditioning tower inlet. The minimum temperature of the conditioning tower inlet must be according to the minimum suction of the circulating element in the kiln inlet.

By-Pass flow

= fresh air + circulating element flow ( as a hot gases ).

By-Pass gases= Cooling air flow.[T mixing chamber- Tambient] / [Tkiln inlet- Tmixing chamber]

Rate of By-Pass

= 100. By-Pass gases / Kiln gases

Eng:Elwathig Ahmed

page (36)

filling degree
feed 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 speed 1.341 1.49 1.639 1.788 1.937 2.086 2.235 2.384 2.533 2.682 2.831 2.98 3.129 3.278 3.427 3.576 3.725 3.874 4.023 fillingspeed/feed ratio 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298 12 0.0298

1)

2)

feed 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115

speed 1.287 1.43 1.573 1.716 1.859 2.002 2.145 2.288 2.431 2.574 2.717 2.86 3.003 3.146 3.289

filling 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5

ratio 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286 0.0286

120 125 130 135

3.432 3.575 3.718 3.861

12.5 12.5 12.5 12.5

0.0286 0.0286 0.0286 0.0286

3)

feed 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135

speed 1.2375 1.375 1.5125 1.65 1.7875 1.925 2.0625 2.2 2.3375 2.475 2.6125 2.75 2.8875 3.025 3.1625 3.3 3.4375 3.575 3.7125

filling 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13

ratio 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275 0.0275

4)

feed 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135

speed 1.1925 1.325 1.4575 1.59 1.7225 1.855 1.9875 2.12 2.2525 2.385 2.5175 2.65 2.7825 2.915 3.0475 3.18 3.3125 3.445 3.5775

filling 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5

ratio 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265 0.0265

5)

feed 45 50 55 60 65 70 75 80 85 90 95 100

speed 1.1475 1.275 1.4025 1.53 1.6575 1.785 1.9125 2.04 2.1675 2.295 2.4225 2.55

filling 14 14 14 14 14 14 14 14 14 14 14 14

ratio 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255

105 110 115 120 125 130 135

2.6775 2.805 2.9325 3.06 3.1875 3.315 3.4425

14 14 14 14 14 14 14

0.0255 0.0255 0.0255 0.0255 0.0255 0.0255 0.0255

6)

feed 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135

speed 1.4625 1.625 1.7875 1.95 2.1125 2.275 2.4375 2.6 2.7625 2.925 3.0875 3.25 3.4125 3.575 3.7375 3.9 4.0625 4.225 4.3875

filling% 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11

ratio 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325 0.0325

6)

feed 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135

speed 1.395 1.55 1.705 1.86 2.015 2.17 2.325 2.48 2.635 2.79 2.945 3.1 3.255 3.41 3.565 3.72 3.875 4.03 4.185

filling% 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5

ratio 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031

Note: 1) effective internal diam inclination clinker factor

3.4 3.50% 1.54

we found the optimum filling2) degree for our kiln between the range (13-14%) by operations experiments