Silo Installation and Kiln Feed Control System For Raw Meal: Operating Manual en-D000091-3K-4E-A

Operating manual
en-D000091-3K-4E-A
Silo installation and kiln feed control system for raw meal
Code word
SAMANFA
Order number
D000091
POLYSIUS Order Code (POC)

3K - 4E
Operating manual Contents
Silo installation and kiln feed control system for raw meal
Contents
1 Technical Data......................................................................................... 1-1

1.1 Technical data of the plant........................................................................ 1-1
1.2 List of machines ........................................................................................ 1-2
2 Safety ....................................................................................................... 2-1
3 Components and mode of functioning ................................................. 3-1
3.1 Functions of the silo installation ................................................................ 3-1
3.2 Conveyance to the silo.............................................................................. 3-1
3.3 Diagram of a blending silo ........................................................................ 3-2
3.4 Components of a BL silo........................................................................... 3-3
3.5 Mode of functioning of the silo .................................................................. 3-4
3.6 Material conveyance from the silo ............................................................ 3-8
3.7 Control system structure ........................................................................... 3-9
3.8 Control loops of the installation................................................................. 3-9
3.9 Operating modes .................................................................................... 3-10
3.10 Electrical interlocking system.................................................................. 3-10
4 Commissioning ....................................................................................... 4-1
4.1 Checking the mechanical equipment........................................................ 4-1
4.2 Checking the electrical equipment ............................................................ 4-2
4.3 Settings prior to commissioning ................................................................ 4-2
4.4 Settings after test runs with raw meal ....................................................... 4-2
5 Starting the plant..................................................................................... 5-1
5.1 Operation of the blending silo (discharge from the silo) ........................... 5-1
5.2 Start-up ..................................................................................................... 5-2
6 Shutting down the plant ......................................................................... 6-1
6.1 Switch-off sequence for the silo ................................................................ 6-1
6.2 Shutting down the raw meal feed system ................................................. 6-3
7 Operation ................................................................................................. 7-1
7.1 Continuous operation................................................................................ 7-1
7.2 Calibrating the flowmeter downstream of the mixing chamber................. 7-3
7.3 Operating mode during kiln stoppage....................................................... 7-4
8 Trouble shooting..................................................................................... 8-1
8.1 Procedure in the case of operating troubles ............................................. 8-1
9 Records of measured data..................................................................... 9-1
10 Appendix................................................................................................ 10-1
en-D000091-3K-4E-A
Operating manual Technical Data
Silo installation and kiln feed control system for raw meal 1-1
1 Technical Data
NOTE
For the technical data of the individual machines, refer to the machine manuals
or operating instructions of the respective machines. The machines are listed
with their item designations at the end of this section. For the documentation for
an individual machine, refer to the Table of contents in the first folder of the
overall documentation. The table of contents lists the machines and units in
accordance with their positioning in the plant. However, the table of contents
does not contain all sub-items that are in the flowsheets. For information on the
sub-items, refer to the respective main items.
For the technical data of machines not supplied by POLYSIUS AG Beckum,
refer to the technical documentation of the respective manufacturer or supplier.
Instructions for the control of the plant are included in the process functional
diagrams of POLYSIUS AG and in the documentation of the control system.
1.1 Technical data of the plant
NOTE
All data and values given in this operating manual are to be regarded as
recommended values only. They are not to be understood as warranty figures.
The relevant warranty data is contained in the contractual documents.
Information regarding the compilation of records and notes, as well as the
performance of analyses, is to be regarded as a recommendation only. The
information must not be understood as a basis for the preparation of
acceptance reports for a performance rating.
Basic data
Type of silo installation .................................................................................. BL16.0

Quantity .................................................................................................................. 2
Interior height of the silo ................................................................................... 66 m
Diameter........................................................................................................... 16 m
Effective volume .......................................................................................... 15 000 t
Year of construction ......................................................................................... 2009
Number of inlets (including central feed)................................................................ 7
Number of main silo compartment outlet apparatuses to the mixing chamber...... 8
Number of mixing chamber outlet apparatuses .................................................... 2
en-D000091-3K-4E-A
Technical Data Operating manual
1-2 Silo installation and kiln feed control system for raw meal
Specifications of the intended use
Conveying material.....................................................................................raw meal

Bulk density acc. to EN 459-2 ...................................................................... 1.0 t/m3
Compaction factor ............................................................................................... 1.2
Temperature........................................................................................... max. 90 °C
Surface moisture content ..................................................................... < 1.0 % H2O
1.2 List of machines
NOTE
For a correct description of the plant and of the plant operation it is also
necessary to consider plant components and machines not included in the
scope of supply of POLYSIUS AG.
NOTE
The following descriptions refer to the first silo installation (position number
3K1). However, they equally apply to the identical second silo installation
(position number 3K2). The machine lists apply accordingly to both
installations.
en-D000091-3K-4E-A
Figure 1 Raw meal silo
POLYSIUS
Qty. Designation
Order Code
1 Raw meal silo 3K1
1 Bag filter 3K1.BF01
1 Tangential blending silo 3K1.BL01
1 Bin weighing device 3K1.BN01
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Figure 2 Kiln feed control system
en-D000091-3K-4E-A
POLYSIUS
Qty. Designation
Order Code
Raw meal conveying equipment and kiln feed con-
1 trol system 4C1
1 AEROPOL vertical conveyor 4C1.AC01
1 Bucket elevator 4C1.BE01
4 Bag filter 4C1.BF01 - BF04
1 Continuous feeder 4C1.CD01
1 Diverter gate 4C1.CF01
1 Compressor 4C1.CP01
2 Outlet apparatuses 4C1.DD01 - DD02
1 Monorail trolley 4C1.MC01
1 Sampling system 4C1.QS01
4 Rotary blowers 4C1.RB01 - RB04
1 Pneumatic screw pump 4C1.SP01
3 Fluidor pneumatic trough conveyors 4C1.TC01 + TC03
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Figure 3 Dedusting and connection system
POLYSIUS
Qty. Designation
Order Code
1 Dedusting and connection system 4E1
1 Electrostatic precipitator 4E1.EL01
1 Evaporation cooling tower 4E1.ET01
1 Fan 4E1.FN01
1 Stack 4E1.SK01
en-D000091-3K-4E-A
Figure 4 Connection system dust conveying system
POLYSIUS
Qty. Designation
Order Code
1 Connection system dust conveying system 4F1
1 Bucket elevator 4F1.BE01
1 Bag filter 4F1.BF01
1 Bin weighing device 4F1.BN01
1 Continuous feeder 4F1.CD01
1 Diverter gate 4F1.CF01
1 Dust hopper 4F1.DH01
2 Flat slide valves 4F1.FG01 - FG02
1 Rotary blowers 4F1.RB01
1 Rotary airlock 4F1.RF01
3 Trough screw conveyors 4F1.SC01 - SC03
en-D000091-3K-4E-A
Operating manual Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
• The plant is exclusively intended for the storage, conveyance and metered
feeding of dry bulk materials, ranging from pulverised materials up to fine-
grained and fluidisable materials.
Be sure to comply with the specifications for the maximum permissible
temperature and the permissible moisture content indicated in the section
Technical Data.
• Any use other than the intended use (e.g. storage of flammable or explosive
bulk materials) is forbidden. POLYSIUS AG is not responsible for damage
resulting from any use other than the intended use. All other use is at the
user's own risk.
• The intended use also includes compliance with the instructions in the
operating manual, the machine manuals, and the operating instructions.
Operation
• Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
• If changes in the plant or its operating behaviour relevant to safety occur, shut
the plant down immediately.
• All silo doors and silo access openings must be closed and secured with
padlocks.
en-D000091-3K-4E-A
Safety Operating manual
Inspection
• Be sure to comply with all warning signs and safety instructions on and around
the machines, as well as in the machine manuals and operating instructions.
• Ensure that all machines and motors whose operation might endanger
persons or equipment are switched off and safeguarded against restarting for
the entire duration of the inspection work.
• Ensure that all rotating parts of the machines have come to a complete
standstill before you remove any protection devices or open any covers.
• Remount all protection devices and properly close all inspection and service
covers after inspection work has been finished.
en-D000091-3K-4E-A
Operating manual Components and mode of functioning
3 Components and mode of functioning
3.1 Functions of the silo installation

The silo installation performs three different functions:
• storing the raw meal
• homogenising the raw meal chemistry and fineness
• dosing the raw meal for the material feed.
3.2 Conveyance to the silo

The raw meal generated in the raw meal grinding plant is conveyed via the
pneumatic trough conveyors 3J1.TC01 and TC02 to the Aeropol 3J1.AC01, the
pneumatic trough conveyor TC03 and the material distributor 3K1.BL01.MDS01
that feeds the raw meal silo 3K1.BL01.
en-D000091-3K-4E-A
Components and mode of functioning Operating manual
3.3 Diagram of a blending silo
Figure 5 Diagram of the silo installation
No. Designation Item no.

1 Material distributor 3K1.BL01.MDS01
2 Main silo compartment 3K1.BL01
3 Mixing chamber 3K1.BL01.MXB01
4 Flowmeter 4C1.CD01
5 1 rotary blower for aeration of the 3K1.RB01
mixing chamber
6 2 rotary blowers for aeration of the silo 3K1.RB02
floor
3K1.RB03
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3.4 Components of a BL silo
Figure 6 Example of a silo with 6 outlets
1.1 Material distributor 1.10 Silo access door

1.2 Silo roof 1.11 Silo outlet frame
1.3 Silo cone 1.12 Silo outlet trough
1.4 Pressure relief hood 1.13 Aeration box
1.5 Silo inlet 2.2 Rotary flow-regulating valve
1.6 Manhole 2.3 Trough conveyor section
(FLUIDOR® pneumatic trough
conveyor)
1.7 Radar sensor 3 Mixing chamber
1.8 Filling level limit switch 4 Outlet apparatus
1.9 Overpressure / negative pressure
relief device
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3.5 Mode of functioning of the silo

The following are main structural units
• the material distribution system on the silo top
• the silo shell with silo cone (displacement cone)
• the mixing chamber below the silo cone
Material distribution system
The material is distributed, i.e. fed into the silo, by alternate operation of the outer
inlets and the central inlet. During operation, a flap of the respective inlet is
continuously opened for 3 minutes, then closed again for 12 minutes, and so on.
Silo aeration
The floors of the BL silo and of the mixing chamber are designed with aeration
systems in order to fluidise the raw meal and make it free-flowing. The
compressed air required for this is generated by three rotary blowers which are
allocated as follows.
• Floor aeration system of the main silo compartments.
• Aeration system of the mixing chamber.
• A redundant rotary blower is intended for stand-by operation and can be used
to aerate the main silo compartment or the mixing chamber.
Due to the inclined floor, the fluidised material from the BL silo flows into the
mixing chamber via outlet apparatuses and short pneumatic trough conveyors . A
filling level measuring device using radar sensors and a maximum filling level
indication with capacitive measuring probes are provided for the silo.
Venting and dedusting
The silo is vented by means of individually allocated bag filters

• for the fluidisation air
• for dedusting the silo cone (mixing chamber)
• for dedusting the bucket elevator and the pneumatic trough conveyors.
The dust collected in the bag filters is returned to the system.
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Mixing chamber
The function of the mixing chamber is to further blend the material discharged
from the different layers in the silo in order to achieve a uniform quality. On the
one hand, mixing of the material takes place through formation of a completely
fluid layer above the aerated surfaces. On the other hand, the necessary cross-
mixing occurs between aerated sections (as density decreases, the material
starts rising) and non-aerated sections (density higher compared to fluidised
material, material falls from the sides onto the aerated surfaces and forces
fluidised material upwards).
The mixing chamber is continuously operated. For this purpose, a constant filling
level is maintained.
The mixing chamber is only filled via one silo outlet at a time (operating mode 1).
The control loop for the filling level consists of load cells and the respective rotary
flow-regulating valve. The filling level is calculated through the density and the
fluidisation factor of the material from the weight of the material. The position of
the rotary drum feeder of the rotary flow-regulating valve that is currently in
operation is controlled in accordance with the determined filling level and its
variation.
The aeration floor of the mixing chamber is divided into aeration surfaces which
are aerated independently from one another. Aeration is performed exclusively
via a blower specifically installed for this purpose.
The mixing chamber is aerated independently of the main silo compartment. The
central area is permanently aerated. The remaining areas are divided into two
rings. On the inner and on the outer ring, two opposite segment surfaces are
always aerated simultaneously.
The aeration of the aeration surfaces is activated through valves. The air flow rate
is set by dampers.
The surfaces on the two annular sections are aerated in clockwise rotation at
predefined intervals overlapping with one another for 15 seconds, time during
which the previous and the currently activated segment are simultaneously
aerated.
Figure 7 Outlet zone with sectors
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The raw meal is continuously discharged from the main silo compartment to the
mixing chamber via one of the outlet zones .
A, B = floor sectors
Figure 8 Diagram of a silo outlet with 10 outlet zones to the mixing chamber
A= Outlet zone of the

mixing chamber
B
B= Mixing chamber,
outer area with aeration
sectors
A
Figure 9 Floor of the mixing chamber
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Discharge of material from the silo
The raw meal is extracted via an outlet apparatus. The second outlet apparatus is
intended for stand-by operation. In the process flow downstream of the outlet
apparatus, flowmeters are installed to record the discharged quantity of raw meal.
By controlling the aperture angle of the rotary flow-regulating valves in the outlet
apparatuses, the flowmeters allow for the dosing of a continuous flow of bulk
material.
Multiple outlets are arranged all-around below the main silo compartment. Each
outlet is equipped with an outlet apparatus. The outlet apparatus consists of a
manual shut-off valve, a pneumatically controllable rotary flow-regulating valve
and a subsequently arranged FLUIDOR® pneumatic trough conveyor.
In the main silo compartment, multiple independently aerated aeration surfaces
are allocated to each outlet.
The central aeration surfaces have the function of conveying the material to the
outlet. The outer aeration surfaces form the actual aeration sector. The material
accumulated above this sector is activated (fluidised) and vertical exit flow
funnels form. This vertical blending effect constitutes the most important factor of
the silo's homogenisation effect.
The central aeration surfaces are exclusively aerated by one blower. The outer
aeration surfaces are aerated by a second blower.
Only one outlet is open at a time (operating mode 1). Furthermore, only one
aeration sector is activated at a time. Thus, for instance, only individual aeration
surfaces are simultaneously aerated in the silo.
The duration of the discharge from an outlet is previously calculated on the basis
of the silo data and then permanently set. The initial setting of the discharge time
(period of time that starts with the signal "Rotary flow-regulating valve open" and
ends with the signal "Close rotary flow-regulating valve") should be 15 minutes.
The next aeration sector to be activated must be the sector that fulfils the
condition "angle of rotation > 90°". However, the selected sector must be 3, 5 or 7
sectors further because otherwise not all the sectors can be activated during a
cycle. The information on this switching cycle is contained in the process
functional diagrams.
The individual aeration surfaces are activated by valves. The air flow rates are set
in percent by means of throttle valves.
Two rotary blowers are allocated to the main silo compartment.
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3.6 Material conveyance from the silo

The homogenised raw meal is either fed into the preheater string or circulated
back to the silo.
Discharge of raw meal from the silo and feed into the kiln line
Via the pneumatic trough conveyor 4C1.TC01, the raw meal is conveyed to the
flowmeter 4C1.CD01 that serves to determine the mass flows of raw meal
discharged from the silo.
Upstream of the subsequent bucket elevator, there is the screw sampler
4C1.QS01. The screw sampler serves to regularly take samples of the
homogenised raw meal that is fed into the preheater strings.
The bucket elevator 4C1.BE01 further conveys the raw meal and discharges it
into the diverter gate 4C1.CF01. In the first position, the flap transfers the raw
meal to the screw pump 4C1.SP01 that conveys the meal to the kiln line II silo. In
the second position, the diverter flap controls the standard raw meal conveying
route to the vertical conveyor AEROPOL 4C1.AC01.
Downstream of the vertical conveyor, a diverter with two flat slide valves
4C1.VP01.FGJ01 and 4C1.VP01.FGJ02 is installed in the piping 4C1.VP01 to
control the conveyed raw meal flow to the preheater or the raw meal recirculation
to the silo.
If the homogenised raw meal is fed to the kiln, it is conveyed to the preheater
string of the kiln plant (cf. the relevant manual of the kiln plant).
Recirculation mode
Depending on the environmental conditions and the plant operating conditions,

consolidations of the raw meal may occur which make the subsequent discharge
of the raw meal more difficult. In order to prevent this, the silo is regularly
operated in the circulation mode. During kiln stoppage, the raw meal can also be
recirculated into the silo. This facility is used for calibrating the dosing system or,
when heating up the kiln plant, for adding the filter dust collected from the filter
cone to the raw meal. To this purpose, set the flat slide valves 4C1.VP01.FJG01
and 4C1.VP01.FJG02 so that the raw meal recirculates back to the silo feeding
system via the pneumatic trough conveyor 4C1.TC02.
Once a week, a complete cycle (i.e. discharge from all sectors) should be
performed in accordance with the specified discharge times during a stoppage of
the installation. The discharge capacity can be reduced accordingly.
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3.7 Control system structure

Almost all the control and monitoring functions of the silo and raw meal feed
system group are implemented by the decentralised host computer. Basically,
these functions are:
• monitoring the filling level in the mixing chamber (load cells and filling level
limit switches)
• activating the dedusting system of the mixing chamber, the bucket elevator
boot and the bucket elevator head
• activating the discharge from the silo and the associated aeration sectors
• activating and monitoring the conveyors of the raw meal conveying equipment
(speed monitor, temperature switch, power consumption and check-back
signals)
• controlling the shut-off valves and the diverter gates and position indication
and monitoring in the raw meal conveying equipment
• activating the blowers for the aeration of the silo and the mixing chamber
Raw meal dosing system
The raw meal dosing is performed via a flowmeter and the respective rotary flow-
regulating valve of the two outlet apparatuses that are provided with a separate
subordinate control system. The subordinate control system receives a start
command (or stop command) and a setpoint for the intended conveying rate from
the decentral host computer. The subordinate control system transmits status
information (e.g. operation signal, current conveying rate, alarm messages) to the
host computer. The subordinate control system records the conveying rate and
controls the rotor speed and thus, the rotary flow-regulating valve in the outlet
apparatus to the conveyor scale.
3.8 Control loops of the installation

To obtain the homogenous raw meal required for stable kiln operation, the mixing
chambers and the outlet zones of the silo are operated in an exactly defined
cycle. A detailed description is contained in section 3.5.
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3.9 Operating modes
BL silo
Mode 1: meal discharge by means of outlet apparatus 1 or 2

This operating mode is used for normal feeding of raw meal into the preheater
and comprises the start and stop of the machines and units (compressors, trough
conveyors, gate valves and rotary flow-regulating valves, filters, etc.) installed in
the area of the silo.
Mode 2: residue discharge by means of outlet apparatus 1 or 2

The silo must be largely emptied for inspection and maintenance purposes.
Raw meal feed system
Mode 1
Mode 1 is the normal operation. The raw meal is fed into stage 5 of the
preheater.
Mode 2
Mode 2 is the circulation operation during kiln stoppage.
Silo aeration (circulation operation during kiln stoppage)

The operation in this mode is comparable to the normal preheater feeding
process, but the raw meal is returned to the silo.
3.10 Electrical interlocking system

The drives of the machines in the installation or in a installation component are
interlocked with one another. If one machine fails (e.g. due to overloading), then
all the drives in the process sequence upstream of the failed machine are
switched off automatically.
This arrangement prevents blockages and machine damage.
The sequence for switching the individual drives on and off is stated in the
process functional diagrams.
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Operating manual Commissioning
4 Commissioning
NOTE
Be sure to also perform the checks specified in the machine manuals of
POLYSIUS AG and in the operating instructions of the respective
manufacturers.
Perform a test run of all machines belonging to this functional group or the
subsequent functional group.
Set all machines of the functional group in accordance with the specifications
contained in the machine manuals.
4.1 Checking the mechanical equipment

After having completed the assembly work and prior to the first test run, be sure
to remove all material remnants, tools and assembly appliances and check and/or
adjust the plant components. Be sure to carry out the following particularly
important checks and actions:
Prepare measurement records as specified in the machine manuals.

Fill the machines and installation components with the required consumables
(e. g. oils, greases).
The qualities and quantities are specified in the respective machine manuals.
Visually inspect all pipings and screwed pipe joints for leaks and check all
weld seams.
Check all drive motors for correct direction of rotation.
Check that all the necessary protection devices (e. g. guards) and warning
signs have been properly mounted.
Check all flaps, dampers and discharge devices for proper functioning and
adjust them if necessary.
Check the compressed air supply system (e.g. water separator, lubricator).
Check the anti-runback devices for correct installation (blocking direction).
Check that all manholes, inspection doors and covers are correctly closed.
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Commissioning Operating manual
4.2 Checking the electrical equipment
Signal check
Check the monitoring devices (e. g. speed monitors, true-run switches, filling
level monitors) for proper functioning.
Check and adjust all measuring points (e. g. pressures, temperatures, speed).
4.3 Settings prior to commissioning

All necessary checks before commissioning are described in the machine manual
for the tangential blending silo and must be performed accordingly. The checklist
for commissioning must be strictly complied with, also regarding the sequence of
actions to be performed, and each item must be initialed after been performed.
When all checks have been realised successfully, all dampers must be set for the
first warm start.
Completely open all maintenance slide gates at the silo outlets.

Completely open all maintenance slide gates at the mixing chamber outlets.
Completely open all dampers in the ducts of the air supply system.
Set the material distributor, i.e. set the time for switching between the central
outlet and the trough conveyors. During operation, the valve is consecutively
opened for 3 minutes, then closed again for 12 minutes, and so on.
Damper positions
4.4 Settings after test runs with raw meal

After the test runs with raw meal, the settings of the aeration system must be
optimised. The settings should allow for aerating the discharge devices of the
main silo compartment in such a way that the discharge into the mixing chamber
is realised at minimum aeration. Thus maximum aeration of the floor sectors in
the main silo compartment and good thorough mixing of the raw meal are
achieved. The aeration system is set by means of manually operated dampers.
Discharge from the mixing chamber

The cross-sections of all air-conveying ducts are dimensioned in such a way that
the previously calculated air volumes reach the individual sectors.
The throttle devices for aerating the mixing chamber are set to ensure that
homogenisation is performed in the following way. The raw meal in the outer
area of the mixing chamber is highly fluidised and carried upwards. The outlet
zone is set so that continuous discharge is possible (cf. Fig. 9).
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Operating manual Starting the plant
5 Starting the plant
NOTE
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
NOTE
The conveyance of raw meal and filter dust to the silo is started when the whole
raw grinding plant is started. For information on the start-up of the raw grinding
plant and about direct operation bypassing the raw grinding plant, refer to the
operating manuals of the raw grinding plant and the rotary kiln plant.
5.1 Operation of the blending silo (discharge from the silo)

The operating modes "Start-up", "Continuous operation" and "Shutdown" proceed
in chronological order (cf. the corresponding sections). If any faults occur, follow
the instructions in section 4.
During continuous operation, it is necessary to regularly calibrate the measuring
device downstream of the mixing chamber. The procedure is described in section
7.2.
If the rotary kiln is not in operation, it is necessary to keep moving the material
that is stored in the silo. This prevents local consolidations of the raw meal, which
would make the subsequent discharge more difficult. The procedure is described
in section 7.3.
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Starting the plant Operating manual
5.2 Start-up
Start the subsequent conveyors leading to the kiln feed system:
No. Unit Comments

1 Start the dust collection filter All valves are closed
2 Start the fan of the aeration system
3 Start the fan of the venting system
4 Start the filter fan on top of the mixing
chamber
5 Open the aeration valves of one mixing
chamber outlet and one mixing chamber
sector
6 Start the blower for the mixing chamber
7 Query 1: Filling level in the mixing chamber
>50% (by means of the load cells)
8 No: The filling level must be further The filling level can only be raised when
increased. Repeat query 1 constantly until the discharge from the silo has begun.
the filling level >50 % is reached.
7 Yes: Open one rotary valve Conveyance to the kiln is started. Initial
setting is 25% until the control loop is
active
8 Open the valves for aeration of one outlet
zone of the main silo compartment
9 Start the blower for aeration of the outlet Waiting time: 5 seconds (timer)
zone
10 Open the valve for sector aeration
11 Start the second blower for sector aeration Waiting time: 5 seconds
12 Set the first rotary flow-regulating valve to Discharge from the silo starts.
the position "50% open"
The position of the rotary drum of the rotary flow-regulating valve must now be
controlled by means of the control loop "Rotary flow-regulating valve and load
cell".
The start-up process is completed.
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Operating manual Shutting down the plant
6 Shutting down the plant
6.1 Switch-off sequence for the silo
Normal shutting down
The silo can be switched off, no matter what sector the raw meal is being
discharged from.
No. Unit Comments

1 Switch off the blower for sector
aeration
2 Close the valve for sector
aeration
3 Close the rotary flow-regulating
valve currently in operation
4 Switch off the blower for aeration
of the outlet zone from the main
silo compartment
5 Close the valves for aeration of
the outlet
valve downstream of the mixing
chamber
7 Switch off the blower for aeration
of the mixing chamber
8 Close all valves of the mixing
chamber
The aeration and venting system of the silo cone should remain in operation in
order to maintain a constant temperature below the cone.
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Shutting down the plant Operating manual
Interruption of operation
• If malfunctions of the sensor system or the conveyors occurs, shut the silo
down as described above.
• In the event of a power failure, all rotary flow-regulating valves of the silo
(main silo compartment and mixing chamber) must unconditionally be closed.
The valve position for the "Close" procedure must be open when de-
energised.
• If the aeration and venting systems fail partially or completely, a message will
be sent to the control panel. 30 minutes later, the silo will be shut down. If one
of the two systems (e. g. the aeration system) fails, the other system (in this
case the venting system) will be shut down, too, in order to prevent
overpressure or negative pressure in the compartment below the main silo
compartment (there are no openings in the silo wall to let in fresh air). If the
aeration and venting systems fail, the temperature under the silo cone slowly
rises to the temperature of the raw meal. In this case, functioning of the
equipment can no longer be guaranteed.
en-D000091-3K-4E-A
Operating manual Shutting down the plant
6.2 Shutting down the raw meal feed system
Normal shutting down
The discharge of raw meal from the silos is finished. All conveyors between silo
and preheater, e.g. pneumatic trough conveyors and bucket elevators, are run
until no residual raw meal is left inside.
No. Unit Function Comments

1 Raw meal conveyors to the Leave running After-running
preheater time: approx.
5 minutes
2 Raw meal conveyors to the Switch off
preheater
3 Drive of the double rotary Switch off
airlock
4 Pneumatically operated flat Close
slide valve
Shortened, controlled stop
The stop mode controlled stop is the fast reduction of the raw meal feed rate to
the preheater to zero (stop).
No. Unit Function Comments

1 Rotary flow-regulating valve in Close
the outlet apparatus of the
mixing chamber
2 Raw meal conveyors to the Leave running After-running
preheater time: approx. 1
minute
3 Raw meal conveyors to the Switch off
preheater
4 Drives of the double rotary Switch off
airlock
5 Pneumatically operated flat Close
slide valve
Uncontrolled stop
An uncontrolled stop corresponds to an emergency-off stop. All drives fail

simultaneously.
en-D000091-3K-4E-A
Operating manual Operation
7 Operation
7.1 Continuous operation
Continuous control cycle in case of interruptions
If the discharge of raw meal from the mixing chamber is stopped by means of the
relevant stop function "End of discharge" or by "Emergency off", the control
system will store the data specifying which aeration sector of the silo was the last
active one.
When the silo aeration system is started again, the control system activates the
aeration sector that follows the last active sector as if the silo operation had not
been interrupted.
During continuous operation, the mixing chamber and the main silo compartment
are operated separately. There is no mutual effect on the respective operating
modes.
Operation of the mixing chamber (aeration system)
The central area must be permanently aerated during operation. This is assured
because no shut-off valve is installed there.
Next to the central aeration surface, the aeration system of the mixing chamber is
divided into two aeration rings, each of which is subdivided into 8 segments.
Opposite segments are aerated simultaneously. This results in 4 aeration cycles.
No. Unit Comments

1 The valve for aeration cycle 1 is The remaining valves of the mixing
open (taken over from start-up chamber are closed
process)
2 Inner ring area: 2 x 1/8 =
1/4 of the surface (in opposite
locations) is permanently aerated
3 Outer ring area: 2 x 1/8 = When the next sector is activated,
1/4 of the surface (sectors always the aeration of the two sectors
adjacent to inner sectors, which is overlaps
assured by piping) is permanently
aerated
4 Waiting time: 3 minutes (i.e. every 3
minutes changeover to the next
sector in clockwise direction)
5 Open the valve for aeration cycle 2 Waiting time: 15 seconds
en-D000091-3K-4E-A
Operation Operating manual
No. Unit Comments

6 Close the valve for aeration cycle 1 Waiting time: 3 minutes
11 One cycle (4 x 3 minutes) has been
completed. A new cycle starts.
13 Further procedure as above.
Operation of the main silo compartment
The following settings have been taken over from the start-up process:
No. Unit Comments

1 The valve for sector aeration of The remaining valves of the main
cycle 1 is open, the valves of the silo compartment are closed
respective outlet zone of the main
silo compartment are open
2 The respective drive of the rotary Waiting time: 15 minutes (basic
flow-regulating valve is open setting for discharge from one outlet
of a sector)
3 Start of 2nd cycle:
4 Open the valves for aeration of the Waiting time: 3 seconds
outlet zone for the next cycle
5 Open the valve for sector aeration
of the 2nd cycle
valve of discharge cycle 1
7 Open the rotary flow-regulating (is moved into the same position as
valve for discharge cycle 2 the last rotary flow-regulating valve
at the end position)
8 Close the valves for aeration of the
outlet zone of cycle 1
9 Close the valve for sector aeration Waiting time: 15 minutes
of cycle 1
10 Start of 3rd cycle Cf. the table describing the
sequence of the following cycles
below
en-D000091-3K-4E-A
Operating manual Operation
For information on the switching cycles, i.e. on the sequence of sector aeration,
refer to the respective process functional diagrams.
This control cycle ensures that even in the case of many single starts and
intermediate stops the raw meal is discharged from different sectors of the silo
and does not always start at the same sector. Homogeneous discharging of the
silo is therefore ensured.
7.2 Calibrating the flowmeter downstream of the mixing chamber

During continuous operation of the silo, it is necessary to calibrate the flowmeter
downstream of the mixing chamber at regular intervals. The calibration is
performed by means of the load cells of the mixing chamber. The following
procedure is carried out:
No. Unit Comments

1 Switch off the blower for sector
aeration
2 Close the valve for sector aeration
3 Close the respective rotary flow-
regulating valve
4 Switch off the blower for aeration of
the outlet zone of the main silo
compartment
5 Close the valves for aeration of the
outlet zone
With this, the filling of the mixing chamber is stopped. The weight decrease per
unit of time can then be read off by means of the load cells.
en-D000091-3K-4E-A
Operation Operating manual
Capacity of the mixing chamber
The mixing chamber is operated with a nominal filling level of 5.4 m relating to its
cylindrical section. That is equal to 155 m³. Relating to a bulk density of 1 t/m³
and a fluidisation factor of 0.75, the resulting theoretical nominal filling weight is
116 t (plus the dead weight of the mixing chamber which must be determined
during commissioning). The maximum filling volume of the mixing chamber,
which is reached when the capacitive MAX measurement is triggered, is 165 m³.
After the calibration, the filling process of the mixing chamber is activated as
follows:
No. Unit Comments

1 Open the valves for aeration of this
outlet zone of the last active main
silo compartment
2 Start the blower for aeration of the Waiting time: 3 seconds (timer)
outlet zone
3 Open the valve for aeration of the
previously active sector
4 Start the blower for sector aeration
5 Set the rotary flow-regulating valve in order to quickly reach the nominal
to the position "Before calibration + filling level of the mixing chamber
20%" (or to position MAX) again
7.3 Operating mode during kiln stoppage

Depending on the environmental conditions and the plant operating conditions,
consolidations of the raw meal may occur during a stoppage, making the
subsequent discharge of the raw meal more difficult. Therefore it is advisable to
recirculate the raw meal of the silo. To do so, the same operating modes ("Start-
up", "Continuous operation" and "Shutdown") as for the kiln feeding process are
used. The material, however, is returned to the silo.
Once a week, a complete cycle (i.e. discharge from all sectors) should be
performed in accordance with the specified discharge times. The discharge
capacity can be reduced accordingly.
en-D000091-3K-4E-A
Operating manual Trouble shooting
8 Trouble shooting
Provided that maintenance work is properly carried out and that the plant is
correctly operated, faults should not occur. However, if operating trouble does
occur, its cause must be determined and eliminated immediately.
NOTE
For trouble shooting at the individual machines and units, consult the machine
manuals or operating instructions of the respective machines. The trouble
shooting instructions below refer to faults that affect the entire installation
described in this operating manual.
8.1 Procedure in the case of operating troubles

If the sensor system or the conveyor system fails, the installation should always
be shut down according to the normal procedure described in section 7.1.
In the event of a power failure, all rotary flow-regulating valves of the silo (main
silo compartment and mixing chamber) must be closed.
The respective valve position for the "Close" procedure must be open and de-
energised.
If the aeration and venting systems fail partially or completely, a message will be
sent to the control panel, and 30 minutes later the silo will be shut down.
Otherwise the temperature below the silo cone would slowly rise to the
temperature of raw meal and then the functioning of the equipment could no
longer be guaranteed.
If one system fails, the other will also be shut down. This prevents overpressure
or negative pressure.
Fault Cause Elimination

Piston-controlled valves Control air pressure too Increase the air pressure
close too slowly low to at least 4 bar
(e.g. at the rotary flow-
Filter in the control air Clean the filter
regulating valve)
piping is clogged
(compressed air
conditioner)
Seals of the 5/2-way Replace all seals.
solenoid valves and
compressed air Rinse the control air
cylinders are damaged piping.
5/2-way solenoid valves do False activation Check the solenoid

not vent properly or (e. g. voltage) valves.
switching errors
(e.g. false activation)
en-D000091-3K-4E-A
Operating manual Records of measured data
9 Records of measured data
Sampling
Take samples as follows to check the correct mode of functioning of the silo
installation.
• The period for sampling is 24 hours.
• Every 30 minutes, 5 random samples are taken from the silo inlet at time
intervals of 6 minutes.
• Within the same period of time, samples are also taken every 30 minutes
downstream of the mixing vessel, the sampling downstream of the mixing
vessel being started after 1.5 hours at the earliest and 2 hours at the latest.
• The 5 samples are carefully mixed and subsequently divided into 2 samples.
Sample analysis
All samples are pressed to tablets and analysed in an X-ray analyser. The mean
value of the two sub-samples is the analysis value.
The analysis values are compiled in a table.
Determination of measurement errors

Before an evaluation is carried out, the stability and reproducibility of the results is
checked by means of a test in the X-ray unit.
For this purpose, 2 kg of raw meal are carefully mixed and, after repeated piling
up of material cones, divided into 16 individual samples. The 16 individual
samples are pressed to tablets and analysed in the X-ray unit.
The last tablet is analysed 20 times in succession to test the stability and
reliability of the X-ray unit.
en-D000091-3K-4E-A
Records of measured data Operating manual
Recording of the individual process sequences

During the total sampling time, the following data is read off and recorded.
Reclaiming from blending bed stockpile no..............................................................
Extracted quantity................................................................................................ tph

Throughput of conveyor scale no........................................................................ tph
Filling level of silo .................................................................................................. m
Furthermore, all irregularities of the operational sequence are recorded.
Evaluation
Based on the series of measured values, the mean values and standard
deviations are calculated for the individual components of the raw meal.
Calculation of the standard deviation may only be made after the Gaussian
distribution has been verified for the series of measured values.
en-D000091-3K-4E-A
Operating results – silo inlet

page 1
Date h min SiO2 Al2O3 Fe2O3 CaO LSt
en-D000091-3K-4E-A
Operating results – silo inlet

page 2
max.
min.
Average x
s=
Warranty:
Standard
deviation s =
en-D000091-3K-4E-A
Operating results – silo outlet

page 1
en-D000091-3K-4E-A
Operating results – silo outlet

page 2
max.
min.
Average x
s=
Warranty:
Standard
deviation s =
en-D000091-3K-4E-A
Operating manual Appendix
10 Appendix
Designation Drawing No. Register
Flowsheet 65000414,
Sheet 3K1 - 4E2
Flowsheet BL silo Ø20 65001486
en-D000091-3K-4E-A

Silo Installation and Kiln Feed Control System For Raw Meal: Operating Manual en-D000091-3K-4E-A

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Silo Installation and Kiln Feed Control System For Raw Meal: Operating Manual en-D000091-3K-4E-A

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Operating manual

POLYSIUS Order Code (POC)

1 Technical Data......................................................................................... 1-1

1.1 Technical data of the plant

Type of silo installation .................................................................................. BL16.0

Specifications of the intended use

Conveying material.....................................................................................raw meal

1.2 List of machines

Figure 1 Raw meal silo

Figure 2 Kiln feed control system

Figure 3 Dedusting and connection system

Figure 4 Connection system dust conveying system

3 Components and mode of functioning

3.1 Functions of the silo installation

3.2 Conveyance to the silo

3.3 Diagram of a blending silo

Figure 5 Diagram of the silo installation

No. Designation Item no.

3.4 Components of a BL silo

Figure 6 Example of a silo with 6 outlets

1.1 Material distributor 1.10 Silo access door

3.5 Mode of functioning of the silo

Material distribution system

Venting and dedusting

The silo is vented by means of individually allocated bag filters

Figure 7 Outlet zone with sectors

A= Outlet zone of the

Figure 9 Floor of the mixing chamber

Discharge of material from the silo

3.6 Material conveyance from the silo

Depending on the environmental conditions and the plant operating conditions,

3.7 Control system structure

3.8 Control loops of the installation

3.9 Operating modes

Mode 1: meal discharge by means of outlet apparatus 1 or 2

Mode 2: residue discharge by means of outlet apparatus 1 or 2

Raw meal feed system

Silo aeration (circulation operation during kiln stoppage)

3.10 Electrical interlocking system

4.1 Checking the mechanical equipment

 Prepare measurement records as specified in the machine manuals.

4.2 Checking the electrical equipment

4.3 Settings prior to commissioning

 Completely open all maintenance slide gates at the silo outlets.

4.4 Settings after test runs with raw meal

Discharge from the mixing chamber

5 Starting the plant

5.1 Operation of the blending silo (discharge from the silo)

No. Unit Comments

6 Shutting down the plant

6.1 Switch-off sequence for the silo

Normal shutting down

No. Unit Comments

6.2 Shutting down the raw meal feed system

Normal shutting down

No. Unit Function Comments

Shortened, controlled stop

No. Unit Function Comments

An uncontrolled stop corresponds to an emergency-off stop. All drives fail

7.1 Continuous operation

Continuous control cycle in case of interruptions

Operation of the mixing chamber (aeration system)

No. Unit Comments

Prepare measurement records as specified in the machine manuals.

Completely open all maintenance slide gates at the silo outlets.