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Kiln Area Learning Report

This document provides an overview of the major systems and safety considerations for a cement production plant. It describes the key processes involved including kiln feed extraction, preheating, pyroprocessing in the kiln, cooling, and transport of materials. It also outlines common hazards like hot surfaces, fire, and gases, as well as required personal protective equipment and safety procedures to mitigate risks.

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Abasiemeka
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440 views

Kiln Area Learning Report

This document provides an overview of the major systems and safety considerations for a cement production plant. It describes the key processes involved including kiln feed extraction, preheating, pyroprocessing in the kiln, cooling, and transport of materials. It also outlines common hazards like hot surfaces, fire, and gases, as well as required personal protective equipment and safety procedures to mitigate risks.

Uploaded by

Abasiemeka
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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LEARNING REPORT

Safety Considerations
Mass Flow
Major Systems
Kiln Feed Extraction
Dedusting
Preheating/Pre-Calcining
Pyro-processing
Cooling
Insulation
Fuel
Blowers
Transport
Plant Air
Auxiliaries
Kiln Camera
Gas Analyzers
Air blasters

Interlocks
Routine Activities
Inspections
Housekeeping
De-blocking
Cleaning kiln camera
Emptying pan conveyor dust tray
Poking (kiln backend, burner rhino
horn)



PRESENTATION OUTLINE

Hazards:
Hot surfaces/environment
Fire
Heights
Gas handling
Oil handling
Noise
Others
Mitigation:
PPE: Hard hat, coverall, safety
shoes, hand gloves, eye goggles
are standard PPE in UniCem. Area
specific requirements include
thermal suit, ear muff.
Equipment: Fire extinguishers,
Housekeeping.
Safety Considerations
Safety Procedures:
Risk assessment, hot work permit, work at height & fall hazard risk assessment,
confined space permit, scaffold request

Mass Flow
Material, Gas, Dust
Material Flow
X X X X X X X
2
3
4
5
CF Silo
K K
L.O.W.
Bin
B B
Mixing
Vessel
Kiln
G
C
a
l
c
i
n
e
r

Cooler
X
Clinker
Silo
Gas Flow
X X X X X X X
2
3
4
5
CF Silo
K K
L.O.W.
Bin
B B
Mixing
Vessel
Kiln
G
C
a
l
c
i
n
e
r

Cooler
X
Clinker
Silo
Dust Reclamation Flow
X X X X X X X
2
3
4
5
CF Silo
K K
L.O.W.
Bin
B B
Mixing
Vessel
Kiln
G
C
a
l
c
i
n
e
r

Cooler
X
Clinker
Silo

Major Systems
Kiln Feed Extraction, Preheating/Pre-Calcining, Pyro-processing, Cooling,
Insulation, Fuel, Blowers, Transport, Plant Air & Water
Kiln Feed System
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1. Extraction gates:
- 7 in number
- Operate according to a predetermined sequence to extract material from
the CF-Silo at different rates. This is key to CF-Silo homogenization
- Pneumatically actuated
2. Extraction air-slides
3. Aeration system & patches:
- Responsible for fluidization of material
- 42 aeration patches
- Fed by blowers 341BL300, 305, 310 (for extraction) and 351BL110, 111 (for
LOW)
4. Mixing tank
5. Butterfly valves
6. Loss-of-Weight bin:
- Allows for accurate metering of kiln feed flow
- 3 load cells
- Operates by using control parameters to open/close the Kiln feed flow
control gates to achieve flow set-point
7. Kiln feed control gates
8. Air-slide 300
9. Air-lift 351AL340:
- Powered by 6 blowers 351BL342 to 347
- Operating pressure range (420 480)mbar
Dedusting
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1.
- 7 in number
- Operate according to a predetermined sequence to extract material from
the CF-Silo at different rates. This is key to CF-Silo homogenization
- Pneumatically actuated
2. Extraction air-slides
3. Aeration system & patches:
- Responsible for fluidization of material
- 42 aeration patches
- Fed by blowers 341BL300, 305, 310 (for extraction) and 351BL110, 111 (for
LOW)
4. Mixing tank
5. Butterfly valves
6. Loss-of-Weight bin:
- Allows for accurate metering of kiln feed flow
- 3 load cells
- Operates by using control parameters to open/close the Kiln feed flow
control gates to achieve flow set-point
7. Kiln feed control gates
8. Air-slide 300
9. Air-lift 351AL340:
- Powered by 6 blowers 351BL342 to 347
- Operating pressure range (420 480)mbar
Kiln Feed System
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1. Extraction gates
2. Extraction air-slides
3. Mixing tank
4. Butterfly valves
5. Loss-of-Weight bin
6. Kiln feed control gates
7. Air-slide 300
8. Air-lift

Refractories
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1. Extraction gates
2. Extraction air-slides
3. Mixing tank
4. Butterfly valves
5. Loss-of-Weight bin
6. Kiln feed control gates
7. Air-slide 300
8. Air-lift

Refractories
1. Exist as shaped and castable
2. Insulate vessel walls from thermal mechanical and chemical shock
1. Bricks
- Used exclusively in the kiln.
- Kiln process zones determine required properties
Refractories

Auxiliaries
Kiln Camera, Gas Analyzers, Air blasters
Kiln Main Burner System
Operation
Oil lance
Material Transport
Transport Process Diagram

Considerations
Material
Kiln feed; Fine, Sometimes moist (GCT outlet)
Clinker; Coarse lumps, hot.



Kiln Area Transport Equipment
Air Slides
Air Lift
Screw Conveyors
Drag Chains
Pan Conveyor
Bucket elevator

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