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Process Problem Trouble Shooting

This document discusses common process problems that occur in cement production plants. In pyroprocessing, issues include cyclone and kiln inlet jamming, large clinker balls forming, coatings in the kiln, and dusty or rushed feed. In grinding, mills can jam and there can be residue or Blaine problems. The document then provides more details on the main causes of several key problems, such as high iron or sulfur content causing jamming, coatings, or clinker balls, and process imbalances leading to issues like feed rushes or snowman formation in coolers.

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Min Zayar
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
560 views

Process Problem Trouble Shooting

This document discusses common process problems that occur in cement production plants. In pyroprocessing, issues include cyclone and kiln inlet jamming, large clinker balls forming, coatings in the kiln, and dusty or rushed feed. In grinding, mills can jam and there can be residue or Blaine problems. The document then provides more details on the main causes of several key problems, such as high iron or sulfur content causing jamming, coatings, or clinker balls, and process imbalances leading to issues like feed rushes or snowman formation in coolers.

Uploaded by

Min Zayar
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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RNB CEMENTS (P) LIMITED

DEPARTMENT- PROCESS
Presented By-
Akshay Kumar Si
01/15/16 DGM (Process) 1
01/15/16 2
WHAT ARE THE MAIN PROCESS PROBLEMS
IN CEMENT PLANT?
In Pyroprocessing-
 Cyclone Jamming
 Kiln inlet jamming
 Big clinker ball formation
 Coating formation in kiln
 Feed rushes and dusty kiln
 Snow man formation in cooler
 Red river in clinker cooler

01/15/16 3
PROCESS PROBLEMS IN GRINDING
 Mill jamming
 Residue problems
 Blaine problems

01/15/16 4
Cyclone Jamming
Why cyclone jamming happens in Preheater?

Main Reasons-
 Insufficient suction due to low rpm in PH fan.
 Flap valve failure & blockage in material pipe.
 Refractory failure.
 High Iron % in Raw mix.
 High Sulfur % in fuel(i.e- coal)

01/15/16 5
KILN INLET JAMMING
Why kiln inlet jamming happens?

Main Reasons-
 High Iron % in Raw mix.
 High Sulfur % in fuel(i.e- coal)

01/15/16 6
BIG CLINKER BALL FORMATION
Why big size clinker ball formation happens?

Main Reasons-
 High Iron % in Raw mix.
 High Sulfur (S)% in fuel(i.e- coal).
 Kiln running with slow rpm & % filling is more.
 High BZ temperature.
 % liquid is more.
 Higher % of Magnesia (MgO).

01/15/16 7
HEAVY COATING FORMATION IN
KILN
Why heavy coating formation in kiln?

Main Reasons-
 High Iron % in Raw mix.
 High Sulfur (S)% in fuel(i.e- coal).
 Kiln running with slow rpm & % filling is more.
 % liquid is more.
 Higher % of Magnesia (MgO).

01/15/16 8
FEED RUSHES & DUST KILN

Why Feed rushes and dust kiln happens?


Main Reasons-
 High lime in Raw mix or high LSF.
 Very less % of liquid.
 High AR.
 Less iron% in raw mix.
 Blockage of hot meal due to clinker ball occasionally.

01/15/16 9
SNOWMAN FORMATION IN COOLER
Why snowman is formed in cooler?
Main reasons-
 Higher % of liquid, may be iron % is more in raw mix
so hot meal will be sticky and viscous.
 Shorter cooling zone; so may be shortage of adequate
quenching .
 Higher BZ temperature, may be due to short flame.
 Failure of air blaster in cooler 1st grate if any.

01/15/16 10
RED RIVER IN COOLER
Why red river is shown in cooler?
Main reasons-
 Uneven distribution of cooling air.
 Mis alignment of kiln & cooler.

01/15/16 11
RED RIVER

01/15/16 12
THANK YOU

01/15/16 13

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