Kiln Operation

Pioneer Cement
22-28 July 2006

Prepared by Hatsachai prahanph

Siam cement (Ta-Luang) Co.,ltd
Training for Pioneer Cement Operation

Content
Quality of Clinker
Kiln Operation Parameter
Cooler Operation
Burner Operation

Training for Pioneer Cement Operation

Clinker quality
Clinker
Component
SiO2 22.8%
Al2O35.98%
Fe2O3
3.42%
CaO 63.95%

Compound in
Clinker

3.CaO.SiO2 , C3S
2.CaO.SiO2 , C2S
3.CaO.Al2O3 , C3A
4.CaO.Al2O3.Fe2O
3 ,C4AF

Training for Pioneer Cement Operation

Clinker Quality
C3S (Give initial strength of concrete)
= 4.07CaO - 7.6SiO2 - 6.72Al2O3 - 1.43Fe2O3
= 42.0%
C2S (Give late strength of concrete
= 8.6SiO2 + 5.07Al2O3 + 1.08Fe2O3 - 3.07CaO
= 33.8%
C3A (Give some initial strength and give the
plasticity of mortar)
= 2.65Al2O3 - 1.69Fe2O3
= 10.06%
C4AF
= 3.04Fe2O3 =10.4%
Training for Pioneer Cement Operation

Quality concern Kiln

operation
LSF
CaO / (2.8SiO2+1.18Al2O3+0.65Fe2O3)
( LSF <90 easy burn , >98 hard burn)
Higher LSF ,
- Harder burn clinker
- Use higher fuel consumption
- Higher C3S
Normal fluctuation = Setpoint +/- 1.5
Pioneer cement LSF-Cli = 88% (expect 90%)
Training for Pioneer Cement Operation

Quality concern Kiln

operation
Ms
SiO2 / (Al2O3 + Fe2O3)
(Ms <2.0 easy burn , >3.0 hard burn)
Higher Ms = Higher Silica
- Harder burn clinker
- Higher Fuel cons
Normal fluctuation = setpoint +/- 0.1

Training for Pioneer Cement Operation

Quality concern Kiln

operation
Ma
Al2O3 / Fe2O3
(Ma <1.3 easy burn , >2.5 hard burn)
Fe2O3 is better fluxing agent than Al2O3
Higher Ma = Harder burn clinker
Normal Fluctuation = setpoint +/- 0.1

Training for Pioneer Cement Operation

Quality concern Kiln

operation
FCaO
Remain CaO from incomplete reactivity
of clinkering process
High FCaO = Dusty Clinker
FCaO > 1.5%
Lead to expansion of mortar and
concrete

Training for Pioneer Cement Operation

Kiln Operation Parameter

Input

Operation

-Rawmeal Quality ( R90u, R200u, LSF ,Ms ,Ma

-Coal Quality ( R90u , LHV)
-Kiln feed , Filling Degree
-Fuel Feed rate , Fuel Ratio
-Burning Zone Temp
-Kiln Torque (Amp of Motor)
-Calciner Temperature
-O2 , CO at K-line , C-line
-Degree of Calcinations
-Clinker Cooler Operation

-FCaO
-LSF
Output
-Ms
-Ma
-Liter weight
Training for Pioneer Cement Operation

Kiln Input
Kiln feed
Fineness of Kiln feed : Residue on 200u
sieve should less than 1.0%
Quality of kiln feed (LSF , Ms ,Ma) are
according to clinker quality

Training for Pioneer Cement Operation

Kiln Input
Fuel
Fineness of fuel
0.5 -0.8* VM(dry ash free)
Coal Analysis in As fired basis
VM 39.46% , Ash 13.9% ,Moist 1.0%
VM(dry ash free)
= 39.46*100/(100-13.9-1)
= 46.3

Fineness of Coal
0.5 x 46.3

= 23%

Training for Pioneer Cement Operation

Kiln Operation
Filling Degree
F = 3.2 x P
D3 x H x N
F = 3.2 x 4000
4.23x3.5x2.8
F = 17.6%

Training for Pioneer Cement Operation

Kiln Operation
Kiln in hot condition
Kiln amp increase
Burning Zone temp increase
Clinker has a good quality
FCaO Low
Liter weight high
At this condition O/P can increase feed
5-10 t/h in each 15-30min
Training for Pioneer Cement Operation

Kiln Operation
Kiln in cold condition
Kiln amp decrease
Burning Zone temp decrease
Clinker has a poor quality
FCaO higher
Liter weight lower
At this condition O/P have to carefully
observe the kiln
Decrease Kiln speed
Decrease feed if necessary
Training for Pioneer Cement Operation

Kiln Operation
Calciner Control
Control the temperature of Calciner constant
(as possible) in range 860-880 C
Check Degree of Calcinations
DOC =

( LOI[KF] LOI[C4] )x100

(100 LOI[C4])x(LOI[KF] /100)
-LOI[KF] : Loss on ignition of Kiln feed
-LOI[C4] : Loss on ignition of C4 Material

- DOC should control in range 90-95%

Training for Pioneer Cement Operation

Kiln Operation
Degree Of Calcination

Training for Pioneer Cement Operation

Kiln Operation
Free Lime, FCaO
Control Range 0.5-1.5%
FCaO < 0.5
Hard burn clinker
Lead to snowman at Cooler
Use higher heat consumption
Harmful to brick life

Training for Pioneer Cement Operation

Kiln Operation
Free Lime, FCaO
FCaO > 1.5
Low quality of clinker
Dusty clinker

Training for Pioneer Cement Operation

Kiln Operation
O2 at Kiln and Calciner
Control >2.0%
Keep complete combustion in kiln and
Calciner
C + O2 -> 2CO : E = 2500 kcal/kg-C
C + O2 -> CO2 : E = 8060 kcal/kg-C
Heat loss 69% with CO condition

Training for Pioneer Cement Operation

Clinker Bed
Higher clinker bed can increase heat
recuperation from clinker cooler
Clinker Bed
1.15xT/Dx1000
(1.2x24x60)x (WxLxst)

W = Grate width 3.6m

L = Stroke length 150mm
St = Stroke/min or rpm
Training for Pioneer Cement Operation

Clinker Cooler Operation

Combustion Air
0.85 Nm3/kg.cli
Use from Fan K11 K30

Heat Recuperation
Secondary Air temp > higher than 960
C
Tertiary Air temp > higher than 960 C

Training for Pioneer Cement Operation

Existing Clinker Cooler

Operation
Too much air at K11-K23
Control this value in range 0.85 Nm3/kg.cli

Training for PioneerControl

Cement
Operation
this
value in range 2.1 Nm3/kg.cli

Clinker Cooler Operation

Training for Pioneer Cement Operation

Clinker Bed
At 2,800 t/d ,G1 = 10.5 ,G2 = 11.5 stk/min
Clinker bed G1
1.15 x 2800 x 1000
= 330 mm
(1.2 x 24 x 60) x (3.6 x 0.15 x 10.5 )

Clinker bed G2
1.15 x 2800 x 1000
= 300 mm
(1.2 x 24 x 60) x (3.6 x 0.15 x 11.5 )

Recommend Clinker bed > 500mm

Training for Pioneer Cement Operation

Burner Operation
Flame Momentum
Primary Air (% of A) x Velocity (%.m/s)

Stoichiometric air require

Ao = 1.01x(LHV+550)/1000 Nm3/kg.fuel
m = excess air 10-20%
A = (1+m)xAo

Training for Pioneer Cement Operation

Burner Operation
Velocity
V = 4.4 x sqrt(10.2 x P)
P = Fan Pressure 20

Flame Momentum
1500 1700 %xm/s

Training for Pioneer Cement Operation

Burner Operation

Training for Pioneer Cement Operation