Professional Documents
Culture Documents
Kiln Control Variables
Kiln Control Variables
Before explaining the control variables one has to understand first the
meaning of a variable and a controller.
So what is the meaning of a variable?
A variable is a physical quantity that can be measured and /or
changed; like weight, pressure, temperature, speed, level, flow, etc.
What is a process control?
A process control is the regulation of the physical variables to
obtain a desired end result.
Then the following question should also be answered
What are the goals of process control?
Process controls are for Optimizing operation conditions in the kiln
1- to maximize production.
2-to achieve maximum energy efficiency.
1. BURNING ZONE CONTROL
•
•Whenever the flame is shortened the dark feed will move in the direction of the
kiln outlet.
• When the kiln feed is harder to burn than usual and the flame is shortened and
when kiln material loading is higher, then the dark bed moves toward the kilns
outlet because the burning zone is cooling down
• When the flame is made longer but still strong enough and there is enough heat to
raise the temperature of the feed so the dark feed can move toward the kiln inlet
area.
• When the feed is easier to burn than usual this dark feed will move in the direction
of the inlet area because the feed will need less heat than usual to arrive to the
temperature that give it the bright red whitish color.
Color of the coating
Color of coating tells a great deal about the condition in the burning zone. The color of
the coating in the intense heat area should be whitish yellow.
When the color changes to red or orange red the burning zone is cooling down.
If it starts to change into white then it is heating up and if the color becomes dazzling
the burning zone is over heated.
The coating can be considered as heat storage in the burning zone. But the coating with
its temperature stored in, will not be able to do much if material lumps rush into the
burning zone.
So we can say it is the obligation of the kiln operator look after the changes in the
following items since any change in any one of them will surely indicate a change in
burning zone temperature.
1- Clinker color
2- Clinker size
3- Type of cascading movement of the clinker under the 4-
flame itself.
4- Feed bed before the directly before the flame area
5- Dark feed position
6- Appearance of secondary air coming from the cooler and the
quantity of dust in it
7- Coating condition
8- Flame shape and color
2- KILN EXIT GAS ANALYSIS CONTROL
Oxygen, Carbon monoxide, Carbon di-oxide and NOx measurements are made round the
clock in any rotary kiln. The instruments used in determining these compounds must work
as long as the kiln is in operation i.e. fuel is fired in the kiln system.
Now the rotary dry kiln works with very high production that normally not less than
4200t/day and any disturbance can represent considerable loss.
Does he work with combusting gas at the inlet? Does he get the correct oxygen content in
the kiln-inlet area?
Oxygen should be in the range of not less than 0.7 and that represents the border of
insufficient oxygen level in the kiln and not more than 3.5% in the kiln inlet and that
represents the border of high excess air in the kiln. for optimum operation the advisable
oxygen level should be between 1and 1.5% Same values can be applied to precalciner.
Now if a kiln works steady at maximum production yet with more than 3% oxygen or the
kiln works with deficiency of oxygen of 0.7% then in such condition the kiln works in a
stable condition, therefore there is no point in introducing any major changes because
this may upset the kiln.
The moves in such condition should be delicate and in a slow but steady way, so the
balance of the kiln would not be disturbed.
The strategy in such condition is to think first what to do, then starts the process of fine-
tuning in a way not disturbing the stability of the kiln in any way. The time between each
small change and another should be not less than one hour.
The whole process of fine-tuning should take from 10 to -16 hrs.
With the other control variables in consideration the, following are the basic steps to
follow as regards exit gas control:
• Secure sufficient oxygen and no carbon monoxide in the kiln atmosphere.
• Stabilize the kiln oxygen and make it level off and stay within a definite narrow range.
• Optimize by fine-tuning the oxygen in the kiln in small steps to bring the oxygen level
to the range of 1-1.5% for optimum kiln efficiency.
There is a relation between the burning zone temperature and the
concentration of NOx in the kiln atmosphere.
• When the temperature of the flame of the main burner changes in the burning
zone.
• Also when the Oxygen in the main burner increases in the burning zone, the
NOx concentration increases.
In any rotary cement kiln it is nice to work in an efficient way by making the kiln work
with as short burning zone as possible i.e. short flame and high flame temperature
that in turn means high NOx content. Therefore as a general rule if the kiln work with
say 1500ppm of NOx then start to be 2000ppm then the kiln tends to:
• have more draft i.e. excess Oxygen.
• may starts to have higher burning zone temperature.
If a kiln works normally with 1600ppm of NOx concentration in the kiln out
let, then the concentration goes down to 600ppm so that indicates the
following:
- there is loss of oxygen in the burning-zone.
- the burning-zone temperature is lowering and starts to cool down.
-the operator should not wait until reduction condition prevails in the burning zone
but when the concentration of the NOx starts to decrease he should stop that
O2 CO CO2 NOx
down
Decreased B.Z is heating up
Kiln inlet temp*. Higher than normal heating up
Lower than normal cooling down
The kiln operator should control the fuel rate on
•The cooler grate speed determines the clinker bed depth and its residence time
in the cooler.
•The quantity of air delivered by cooler fans to the different grate compartments
and the way of distributing it on these compartments.
5.2 Under-grate pressure and air flow rate
Under-grate pressure is governed by:
•Depth of the clinker bed over the grate
•Average particle size of the clinker in the cooler
•Temperature of the clinker in the cooler
•Amount of air introduced into the cooler
The thicker the clinker bed over the grate plates in any cooler stage, the
higher the resistance and require more pressure and force from the fan to
push the air through this bed.
:Control of the clinker bed thickness
The clinker bed thickness is controlled by the speed of cooler grates. A deeper
bed can be obtained by slowing of the grate speed. Therefore, it is logical to
obtain and maintain a constant clinker bed depth by keeping the under grate
pressure constant regulating cooler’s grate speed.
Air low rate:
Sometimes the kiln suddenly starts to discharge high amount of clinker due to
the falling down of a coat in the kiln-burning zone. The reaction of the cooler
control is to speed up the grate to maintain the under-grate pressure constant.
This will result in reducing the residence time of the clinker in the cooler resulting
hotter clinker leaving the cooler.
6. Secondary and tertiary air temperature control
The source of both of the secondary and tertiary air is the grate cooler first
stage.
Both of them are drawn form either the kiln hood or in some cases the
tertiary air is drawn form the middle of the roof of the first stage of the
grate cooler. This ensure that the temperature of the secondary air to be
higher than the tertiary air.
Secondary air temperature has a direct influence on the shape of the flame
and the point of ignition of the fuel; therefore irregular secondary air
temperature can cause irregular flame characteristics that can cause
shifting in the burning zone.
Control of the secondary air temperature during normal kiln
operation:
Every kiln operator understands that he must maintain the secondary air
temperature as high as possible because it contains the maximum amount of
heat that can be recovered from the clinker.
The second advantage of higher secondary air temperature is that it gives the
operator the chance and therefore the advantage of burning the clinker nearer to
the nose ring of the kiln.
Tertiary air temperature, should not be more than 900ºC since the temperature
in the precalciner should not exceed this limit.
Factors affecting secondary and tertiary air temperature:
•The speed of the clinker bed on the grate cooler in relation to the volume
and temperature of air introduced into the cooler to cool that bed of
clinker.
•The grain size distribution of the clinker and the temperature of that
clinker discharged from the kiln to the cooler.
The rule of thump in secondary air temperature is that
1.The higher the speed of the grate the less bed clinker thickness will
be and the lower the secondary and tertiary air temperatures.
2.The lower the speed of the grate the higher bed clinker thickness
will be and the higher the secondary and tertiary air temperature.
This can simply be explained if all other factors are remained unchanged
as follows:
• When the grate cooler speed is reduced the clinker speed is lowered,
the direct result will be higher clinker bed thickness and the air will find
more chance to absorb more heat from the clinker in the cooler and visa
versa.
• When the cooler speed is increased the clinker bed is lowered and the
chance of cooling air to absorb heat will decrease resulting in lower
secondary and tertiary air temperature.
Clinker grain size and its effect on secondary and tertiary air
temperature:
For example consider a kiln in an upset condition and the clinker
produced was either small nodules, or in worst case condition is dust. The
operator in this condition would reduce kiln speed; so amount of clinker
discharged to the kiln is reduced. This would lead to lower secondary air
temperature.
The operator should never attempt to hold the
secondary air temperature
At its normal operating level in an upset
condition in the kiln
And the clinker is dusty or having lower liter
weight
Temperature of clinker discharged from and its effect on secondary
and tertiary air temperatures
By changing the character of the main burner flame, the burning zone can be
shifted very near to kiln nose ring outlet, thus the clinker can be discharged to the
cooler very hot, and so the secondary air temperature will be higher.