How to warm up / cool down the kiln

Refractory 1/15
PR RFR P06-21 V1.0

Introduction
This document is intended to give production managers a working frame to design their own specific warm-up
or cool down procedure, adapted to each case: type of kiln, extend of repairs done on this kiln, etc…:
ƒ Procedure for kiln start-up after a major turnaround, defined for each type of kiln:
ƒ Preheating curve and kiln turning schedule
ƒ Adjustment to the above guidelines, depending on refractory work completed
ƒ Start-up procedure and strategy to reach full production
ƒ Record Keeping
ƒ Modifications to this Procedure for kiln start-up after shutdowns shorter than 48 hours
ƒ Additional information required to customize procedures for a specific kiln
ƒ Indicators required for process monitoring
ƒ This procedure details the following actions:
ƒ Warming up program
ƒ Tyre creep
ƒ Cooling down program
ƒ Warming after kiln breakdown
Result indicators
ƒ The indicators which need to be recorded to show progress should be
ƒ Number of incidents within 2 weeks after start-up
ƒ Number of bricks replaced between 2 major shut-downs
ƒ Brick consumption in the burning zone in Kg/T/KK/m of kiln length
ƒ Amount of time it takes to reach full production
Objectives
ƒ Develop master procedures for heating up the pyro-line in a standard, safe and efficient manner
(minimum transition periods, no aborted start-ups) while assuring the integrity of the equipment and of
the refractory and staying in environmental compliance. The procedures will address the quick
compliance with clinker quality objectives.
ƒ Then, each plant would customize these master procedures to the specific characteristics of their
equipment and develop more detailed checklists and SOPs.

Safety aspects
ƒ Ensure that the whole start-up process is supervised by an experienced kiln coach, burner or production
engineer.
ƒ Complete a thorough inspection to check if all doors are closed without anybody left behind, if all safety
protection devices are in place (pull cords, safety guards, limit switches…), and if analyzers and inerting
systems are in operating conditions.
ƒ Ensure that safety SOPs are known from the operators and applied (i.e. start-up of electrical motors, of
fuel feeding systems
ƒ Maintain a permanent radio contact between start-up team and kiln control operator.
 How to warm up / cool down the kiln
Refractory 2/15
PR RFR P06-21 V1.0

Prerequisites
ƒ Proper installation of refractory cannot be over emphasized as it plays a key role in the longevity of the
lining. During a major turnaround it would be good for plants to consider hiring an experienced
refractory installation specialist to supervise the ongoing lining replacement or ensure that the installer is
familiar with the various installation techniques that are available.
ƒ Each plant should consult and insist on having a representative from the refractory supplier on hand
during the installation and curing of the material chosen. This process is included in the purchasing
agreement set up by a group buying team established through Lafarge in 1998.

In this procedure you may find references to other information (calculation tools, other procedures, knowledge
documents, etc) which are available from the Refractory domain of the Web Cement Portal (standard &
procedures, job aid sections) or from the BRS database (indicators).
 How to warm up / cool down the kiln
Refractory 3/15
PR RFR P06-21 V1.0

Action Steps

A. Kiln warm-up
1. Prepare for kiln warm up: Pre-start checks
Check Kiln feed system
The kiln feed system should be run in a recirculation operation and calibrated, if allowed by the system. If
the system does not allow for a complete run, then a way to determine the readiness of the system should
be developed.
ƒ If no recirculation system is in place, then the feed system should be run for few minutes, checking for
proper operation and system leaks.
ƒ Test run the dust evacuation system including elevators, screws, pumps etc. Continue to run this system
throughout the warm up.

Check Cooler and Clinker handling

Test run all cooler drives and inspect for loose grates after running. Check the alignment of the cooler while
running. Continue to run the system for at least 12 hours to ensure its mechanical integrity.
ƒ The following equipment should also be run and checked: Clinker Cooler Breaker, Vent Fan, Cooler Fans,
and all downstream clinker handling equipment. (I.e.: drag conveyors, belts, pan conveyors, gates etc.)
All equipment must be checked for alignment, motor direction and automated control. Ensure that fan
dampers or variable speed motors can operate at full range.
ƒ Test the operation of all of the cooler Plattco valves and check for a good seal.
ƒ Ensure the calibration of all pressure transmitters for the cooler fans.

Check I.D. Fan

Test run the I.D. fan and test for proper rotation, controls from the field and computer as well as check for
leaks

Check Coal conveying system:

ƒ Test run the coal mill circuit and fans. Ensure that all damper controls are working properly.
ƒ Test run the coal mill feed system as early as possible. If the system has been calibrated, keep track of
weight changes.
ƒ The entire coal mill circuit should be run as early as possible so that checks can be made for leaks. If leaks
are present, they can be corrected prior to start up so that it will not be delayed

Check Kiln Baghouse or ESP :

ƒ Follow the established start-up procedures (Process or Maintenance) for new bag installations. This will
include any pre-coating procedures, leak tests or air load testing.
ƒ Ensure that the dust removal equipment is running.
 How to warm up / cool down the kiln
Refractory 4/15
PR RFR P06-21 V1.0

Action Steps

Check Preheat system

The following items have to be done well before needed:
ƒ Ensure all locks are removed from the system
ƒ Verify all hoses and connections are in place for the fuel and air supply systems
ƒ All valves in their proper positions for operation
ƒ Ignition source ready and available at kiln hood
ƒ Test run burner axial, swirl and transport air systems and check filters

Check Material flow (for pre-heater kiln)

ƒ Verify all tower chutes are clear by dropping mill ball through cyclone and chutes
ƒ Verify all tower tipping valves are working properly. Open and close manually.

Check Common equipment

ƒ Ensure the proper direction or rotation of all fans, screws, conveyors, clinker breaker etc.
ƒ Checks should be made on:
ƒ Oil in reducers
ƒ Equipment properly closed up
ƒ Locks removed and switches in
ƒ Auxiliary kiln drive motor function
ƒ Check airflows on all fans that have been altered during the turnaround.

Align the burner pipe

1 How to align the kiln burner

In order to ensure the complete check, it is recommended to fill an "equipment check sheet" for
every equipment and have it signed.

To adjust ID fan draft, backend gas analyzer must be available and used all along the warming up
program.
 How to warm up / cool down the kiln
Refractory 5/15
PR RFR P06-21 V1.0

2. Preheating phase
The objective of preparing the kiln refractory for start-up is to:
ƒ Dry the burner pipe lining refractory if not already dried.
1 How to line the burner pipe
ƒ Dry the castable installed inside the kiln
ƒ Preheat the kiln refractory brick linings up to temperature where feed can be introduced into the kiln

It is essential that plants have a preheating schedule determined prior to the start up. The start-up
program, which mainly determines the kiln temperature increase per unit time and the timing of the
introduction of raw feed, must consider a number of factors such as the type of refractory material,
design of the kiln system, mechanical systems etc.
It is recommended to use a real-time report during the kiln start-up, in order to facilitate the post-
audit phase.

Inspection before preheating

ƒ Kiln must be left clean without scrap material left behind (metal shims, bricks, etc...).
ƒ Cooler must be left clean as well; no welding rods and no pieces of metal, etc.
ƒ Alignment of the burner pipe needs to be done and rechecked (see section “pre-start checks”).
ƒ Make one last inspection of kiln prior to flame on for bricking irregularities.

Start up conditions recording

ƒ Record the following points :
Preheater / Precalciner kilns Long wet / Long dry kilns
Stage #1 exit oxygen Feed shelf oxygen
Stage #4 or Precalciner temperature Feed shelf temperature
Feed shelf Temperature/kiln exit temperature Chain temperature
Feed shelf or kiln exit oxygen Burning zone temperature (shell scanner)
Burning zone temperature (shell scanner) Kiln turning schedule
1 Job aid > "24h-preheat schedule”
Tire Creep Tire Creep
1 See section “Tire creep monitoring” 1 See section “Tire creep monitoring”
Tire temperature and the bearing temperatures Tire temperature and bearing temperatures
Kiln hood pressure Kiln hood pressure
Fuel consumption Fuel Consumption
Kiln turning schedule Thermal expansion of the kiln
1 Job aid > "24h-preheat schedule”
Thermal expansion of the kiln Monitor ESP/Baghouse - turn on as soon as possible
Monitor ESP/Baghouse - turn on as soon as possible

1 Job aid > 24h pre-heat schedule

 How to warm up / cool down the kiln
Refractory 6/15
PR RFR P06-21 V1.0

Kiln turning schedule

The purpose of a turning schedule is to ensure slow, uniform heating of the kiln and its refractory lining.
Turning schedules are based on an increase in temperature over time. A good schedule will allow for the
expansion of the refractory and kiln shell so that the brick remain in place and the shell expands uniformly
along its longitudinal axis.
ƒ Turning Schedule
Too Slow Too Fast

Overheating of the refractory and the kiln shell Poor heat distribution

Duck-nesting of the refractory Longer preheat time due to poor transfer of heat

Shell and refractory damage Potential for spiralling of brick

ƒ Expected range or values

An example of the turning schedules for a kiln is shown below:
TEMPERATURE OF EXIT GAS KILN TURNING PROCEDURE
AT KILN INLET WITH AUXILIARY DRIVE
UP TO 120°C KEEP THE KILN STOPPED
120°C TO 210°C TURN 90° TO 120° EVERY 45 MINUTES
210°C TO 450°C TURN 90° TO 120° EVERY 30 MINUTES
450°C TO 600°C TURN 90° TO 120° EVERY 15 MINUTES
600°C TO 750°C TURN 90° TO 120° EVERY 10 MINUTES
750°C UP TO FEEDING CONTINUOUS TURNING

As a compromise, the kiln should be periodically turned i.e.: rotated a fraction of a turn during the initial
phase until the sintering zone temperature reaches approximately 900 degrees "C" (1650F). After this
phase, the kiln can be rotated continuously in a normal manner through the auxiliary drive.
 How to warm up / cool down the kiln
Refractory 7/15
PR RFR P06-21 V1.0

Heating up guidelines
ƒ Below you will find general guidelines for heating up the kiln before start-up but you should draw a
specific preheat schedule depending on your kiln characteristics and length of stop.
The following information has been collected from a large number of refractory suppliers used by
Lafarge. This information should be used only as a guideline for proper refractory management. In all
cases the plants should review the intended operating procedures with the refractory suppliers as the
amount of refractory types and materials vary extensively.
Most suppliers of refractory materials recommend for the start up of kilns after major turnarounds
with monolithic linings, a maximum heating-up rate of approximately 25°C /h in the sintering zone up
to a temperature of 900°C. After reaching 900°C, heating up can continue at a rate of 50°C up to
the working temperature.
After a minor shutdown (less than 24 hours) where no major lining is replaced, refractory suppliers
recommend a heating-up rate of 50°C/h.
What is not shown in the graph above is a stepped approach to the heat up schedule. What this
means is that there should be a holding pattern on the temperatures in the kiln system in at least two
separate temperature ranges. The first holding pattern should be made in the initial stages of the
heat up procedure. This means that when the sintering zone temperature reaches approximately
300°C, the temperature should be held constant for approximately 3 hours. This procedure should be
repeated again once the sintering zone temperature reaches approximately 500 to 550°C. This
procedure allows the refractory material to "catch up" with the gas temperature. The heat penetrates
the refractory material as well as the metal casings and reduces the possibility of non-uniform
expansion and tyre creep problems. This procedure can of course be modified based on the amount
of refractory work that has been completed during the shutdown.
 How to warm up / cool down the kiln
Refractory 8/15
PR RFR P06-21 V1.0

Avoid quick heat up program

Quick heat up program must be avoided.

Thermal shock:
brick split like spallings
in 2 – 3 cm layers

24 hours warming up program

ƒ Valid for minor castable repair
Backend T°
(°C)
1000
900
800
700
Continuous rotation 600
1/3 revolution every 10 min 500
1/3 revolution every 15 min
400
1/3 revolution every 30 min
1/3 revolution every 45 min 300
200
100
0
0

8
10

12

14

16

18

20

22

24

Hours
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Refractory 9/15
PR RFR P06-21 V1.0

36 hours warming up program

ƒ Valid for significant castable repair

Backend T°
(°C)
1000
900
Continuous rotation 800
1/3 revolution every 10 min
1/3 revolution every 15 min
700
1/3 revolution every 30 min 600
1/3 revolution every 45 min 500
400
300
200
100
0
0

9
12

15

18

21

24

27

30

33

36
Hours
 How to warm up / cool down the kiln
Refractory 10/15
PR RFR P06-21 V1.0

Tyre creep monitoring

Quick heat up program must be avoided.

ƒ The kiln shell will heat up faster than tyres.

ƒ Too rapid heat up can result in a constriction of the kiln shell, which will cause permanent deformation if
the yield strength of the kiln shell material is exceeded.

ƒ This will contribute to excessive refractory lining wear.

ƒ If the tyre creep is too low or non-existent, the

heating-up process should be slowed down or
interrupted until a measurable amount of
relative movement is established.

1 How to measure the gap between shell & tyre (Maintenance)

ƒ The combination of tyre/shell temperature differences and slippage is extremely valuable information.
Temperature or Slippage alone is meaningless. Both parameters must be recorded for proper assessment.
ƒ Consider external means of heating or cooling to assist with reduced or excessive slippage.

Tyre temperature is determined by taking the measurement on each side of the tyre. The recorded
temperature should be the average of the two. Tyre creep could be monitored by a shell scanner if
available and, in addition, should be measured every 2 hours during the critical period when tyre
creep is below 8 mm/rev.
 How to warm up / cool down the kiln
Refractory 11/15
PR RFR P06-21 V1.0

ƒ The temperature difference between the tyre and the shell must be less than 125°C all times during
the warming up program. (To be checked at the plant with the hypothesis taken for shim calculations)
ƒ The minimum tyre slippage per kiln revolution is 8mm.
ƒ If the kiln tyre slippage falls below 8mm/rev, hold the kiln heat input until the tyre slippage reaches
8mm/rev. At 8mm / rev, resume the preheating schedule.
ƒ If the kiln tyre slippage falls below 5mm / rev decrease kiln heat input until the tyre slippage reaches
5mm / rev. Ensure that the shell and the tyre temperature are rising at the same rate. At 5mm +, hold
the kiln heat input until the slippage reaches 8mm +, at this point, resume preheating schedule.
ƒ If there is no measurable slippage, follow the instructions for slippage below 5mm/rev with
aggressive moves on heat decrease. If slippage has not returned in ½ hour, shut down.
ƒ If tyre slippage is in excess of 25mm,
shimming of the tyre must be considered.
Excess slippage of the tyre can cause problems
with kiln ovality which may result in shell,
refractory and nose ring damage.

Example of kiln warming up process data

Date: _________ Flame On

Preheat Schedule: _____ Hours
Hour Tyre Tyre Tyre #1 Fuel Rate Feed End Swirl Air Axial Air Feed End I.D. Fan
of the Creep #1 Creep #2 shell T° Oxygen Setting Setting Temp Speed
Preheat
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Refractory 12/15
PR RFR P06-21 V1.0

3. Feed on phase
Preheaters / Precalciners :
ƒ Raw material feed can be started when the temperature curve in the kiln system approaches operational
conditions or as soon as the precalciner and preheat temperatures profile is ready for feed.
ƒ The period between the start of the kiln feed and its arrival at the sintering zone is the most critical with
respect to tire creep because the fuel supply must be increased rapidly to compensate for the heat
absorbed by the processing of the raw material. Close attention must be made at this phase so that slip
is continuously present. If slip of the tire ceases, countermeasures must be taken to correct the situation.
ƒ Feed may be introduced into the kiln system prior to arriving at optimal temperature as a measure to
coat the refractory linings. Only small amounts can be introduced so that there is not a deterioration of
the heat gradient.

Long wet and dry kilns :

ƒ Kiln chains or other heat exchange systems should not be exposed to excessive heat prior to the
introduction of feed. Excessive heat can damage and potentially cause fires in the metallic systems. For
this reason, material feed is usually started after the sintering zone temperature reaches 950 degrees C
and the kiln is rotated continuously by using a feed rate of 10% of the nominal throughput.
ƒ The feed rate is then continuously increased depending on the kiln exit gas temperature, the specific heat
consumption and the burning conditions. The kiln speed is increased proportionally to the feed rate.
ƒ Graph the specific heat consumption versus the feed rate, oxygen, kiln amps and kiln speed.

4. Stabilisation period
ƒ This is the time where we are building the protective coating on the bricks.
ƒ We should avoid over-heating
ƒ Feed-rate should be increased by small increments to maintain the back-end temperature while avoiding
flushing in the burning zone.

5. Post audit
A post audit of the start-up to analyze deviations from the planned schedule should be systematically
done between the production coordinator and the kiln operators.
Reasons for deviations should be identified and recommendations to improve the next kiln start-up
should be drafted and when necessary, incorporated into the SOP. Control room operators’
involvement is essential to the success of proper kiln start ups.

Review Items
ƒ Preheat temperatures and oxygen control-actual vs. plan
ƒ Timing of preheat-actual vs plan
ƒ Specific heat consumption / NOx values
ƒ Tire Creep report
ƒ Axial and swirl settings
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Refractory 13/15
PR RFR P06-21 V1.0

ƒ Review of check-sheets - explanation of variances

ƒ Review of problems incurred during preheat
ƒ # of incidents within two weeks after start-up
ƒ Amount of time to full production

Develop the above into a table that shows the variances and explanations for the
variances.
1 See proposal to build a post-audit report in Annex.
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PR RFR P06-21 V1.0

B. Kiln cooling down program

Fast cooling program must be avoided.

ƒ Dilatation between bricks and shell must be respected

Brick hanging
Especially for Alumina brick area

24 hours cooling down program

Backend T°
(°C)
1000
900
800
700
600
500
400
300
200
100
0
0

8
10

12

14

16

18

20

22

24

Hours
Continuous rotation
1/3 revolution every 10 min
1/3 revolution every 15 min
1/3 revolution every 30 min
1/3 revolution every 45 min
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Refractory 15/15
PR RFR P06-21 V1.0

Appendix

1. Example of Post Audit Report for kiln start-up

Post Audit Report for the kiln start-up dated from ____________________

Reference:___________________

Plant :_______________________ Kiln # ____________ Kiln type: ______________________

The Post-Audit Report will be split in 3 parts :

- The first one includes the data recorded during the audited kiln start-up. This data are automatically
gathered from the kiln start-up report.
- The second one has to be filled with the indicator values for progress monitoring. These indicators are
the following :
- Number of incidents within 2 weeks after start-up
- Number of bricks replaced between 2 major shut-downs
- Brick consumption in the burning zone in Kg/T/KK/m of kiln length
- Amount of time it takes to reach full production
- The third one is the conclusion of the post-audit group for the audited kiln start-up: assessment, what
to do in order to improve the next kiln start-up, ...

Validation Responsible for this post audit Signature