How to control the hot meal

Pyroprocessing

PR-PYR P06-11 V1

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Introduction
Every plant should determine the boundaries of their own process by taking regular samples of hot meal,
measuring its Cl&SO3% and asking the operators in charge of tower cleaning, the type of build-up they
encountered.

Prerequisites
Combustion optimization
Hot meal sampling procedure

1 How to sample hot meal

Time frame
Sampling & analysis should be done on a daily basis (3/day recommended).

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Procedure Template developed by

How to control the hot meal

Pyroprocessing

PR-PYR P06-11

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Action Steps
1.

Sample & analyse

Sample hot meal and perform analysis on a daily basis (3/day recommended).
Keep record of the chemical analysis for investigation purposes.
If available, SO2 gas analysis give the fastest indication for sulphur volatilisation level

2.

Set the limits

Set the limit based on plant characteristic.
Chlorine and SO3 maximum content can be different from plant to plant depending also on the
existence of a bypass installation

Set plant limits for main fuel sulphur and make sure the purchasing department respect these limits.
Establish limits for chlorine content in raw mix or alternative raw materials as well as in waste fuels

1 Example in the annex

3.

Develop a control chart

Develop a chart of different quantities of volatile components and mark clearly on the chart, different
zones of build up conditions.

With the above performance monitoring tools, adjust on appropriate levers discussed later in the
document to achieve optimum conditions of operation.

1 Example of chart below

Graph 1: for hot meal sulphur & chlorine versus area of no build-ups, minor build-ups, heavy build-ups etc

Limits of coating tendency is based on general experience can be used as first indication of plant situation.

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Pyroprocessing

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PR-PYR P06-11

Action Steps
Graph 2: Specific example of Sugar Creek Control chart.

With this graph Sugar Creek (USA) is following their own kiln specific coating tendency.

Last 7 Days of 5th Stage Samples

1,75

Chlorine (%)

Heavy Coating

Acceptable
Coating

1,50

1,25

1,00

0,75

Known plugging
zones!!!!

0,50

No Coating
0,25

0,00
00
3,

80
2,

60
2,

40
2,

20
2,

00
2,

80
1,

60
1,

40
1,

20
1,

00
1,

80
0,

60
0,

40
0,

20
0,

00
0,

Sulfur (%)
Heavy Coating

4.

No Coating

2/16 to 2/24

Average

Optimisation of combustion
Make sure the position of burner is optimized (align with kiln axis recommended but it depend on
impulse level). Also make sure burner settings are adjusted for the type of fuel used.

5.

Optimise the location of waste fuel injection to avoid fuel drop out
Check the burning condition O2 level
Reduce coarse fuels with poor combustion properties
Change on fuel or raw material promoting volatile cycles (if possible)

Build a plant procedure for Hot Meal

Create a plant procedure for hot meal SO3 and Cl control that the operators should know how to react
in case of limit exceeded.

Procedure Template developed by

How to control the hot meal

Pyroprocessing

PR-PYR P06-11

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Appendix
1.

Example of a Plant Procedure for Hot Meal

Cl > limit value :
increase by pass rate
change on fuel input or raw materials promoting Cl cycles
increase cleaning cycle and inspection frequency on the preheater

SO3 > limit value :

2.

check the burning condition O2 level

reduce coarse fuels with poor combustion properties
change on fuel or raw material promoting volatile cycles (if possible)
increase cleaning cycle and inspection frequency on the preheater

Levers to adjust volatile content in hot meal

If volatile content in hot meal exceeded the limit value, it is important to react promptly to determine the
promoter of the volatile cycle and then to eliminate the source.

While for SO3 volatilisation there are levers to reduce the level of the phenomena (by adjusting the O2
level or flame), for Chlorine volatilisation there is nothing to do except removing the source. You have to
react quickly because Chlorine-related problems often lead to plugging up of the cyclones.

Check for modification on raw mix composition (SO3, Cl, alkali) and try to adjust
Check for main fuel sulphur. Alert purchasing department in case of sulphur exceeding plant limit.
In both cases it can take a little time to adjust the volatile input. Meanwhile try to run with more
oxidised atmosphere to reduce the volatilisation and , very important, intensify the cleaning cycle and
the inspections on the preheater to remove as much as possible the build ups .

Check your combustion indicators (adjust O2 level properly, no CO, fuel dosing stability, raw mix
uniformity).

In case of shredded materials fed to the back end, riser duct or precalciner, check the size of the
shredded pieces and reduce the dimension if necessary, in order to eliminate local reducing conditions.

Evaluate the sulphur/chlorine input via fuels and try to reduce the one who is promoting SO3/Cl cycles.
Poor fuel burnout in case of precalciner kiln can also cause high kiln inlet SO2. Try to optimise
combustion in the calciner

1 How to optimise a precalciner.

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