Activity:
AUDIT/PROCESS
CHINA / QUJIANG
3# KILN AUDIT
by Jean Luc Josse & Looi Wan Leong & Wang Xiaohui
Distribution
Region
BU
Plant
ATC
Other
Codification
TABLE OF CONTENTS
A.
B.
EXECUTIVE SUMMARY..................................................................................3
A.1.
Safety issues.............................................................................................................3
A.2.
A.3.
A.4.
A.5.
High CO formation....................................................................................................5
A.6.
A.7.
MAIN REPORT..............................................................................................9
B.1.
Introduction...............................................................................................................9
B.2.
Work Done................................................................................................................9
B.3.
B.3.1.
Safety issues...................................................................................................10
B.3.2.
B.3.3.
B.3.4.
High CO formation...........................................................................................18
B.3.5.
B.3.6.
B.4.
Ways to Implement.................................................................................................27
B.5.
Acknowledgements.................................................................................................30
B.6.
References..............................................................................................................30
B.7.
Appendices.............................................................................................................31
Page 2 of 37
A. EXECUTIVE SUMMARY
Objective(s)
QJP kiln 3# audit was conducted from 16~20 July 2007 by three ATC process engineers, JL
Josse, WXH and LWL. The objectives of the kiln audit are to determine the baffling factors
and to identify the bottlenecks in kiln system.
Results / Findings
There is a lot of room for improvement. We recommend a WR to be signed for 2008 to
address all the opportunities reported below.
The main process issues are : kiln feeding instability, high inleakage, poor cooler
performance, overburning (low free lime) and high CO in precalciner.
Four main recommendations are : reduce inleakage and primary air, install 30t
capacity surge bin to feed the kiln, increase clinker bed depth and increase fan
efficiency from @40% to 65%. Dewatering should be further investigated.
A.1. Safety issues
1. There was no CO safety interlocking for kiln EP due to the gas analyzer at the kiln
inlet EP was malfunctioned. The risk of EP explosion is high (CO @ 2375 ppm).
2. Electric cables lying on the ground floor beside the kiln shell cooling fans.
3. No safety protection screens on cooler bleed air damper, hot gas to coal mill gas duct
and on the cooling fan 2 dampers.
A.2. Main Operating Parameters
Main parameters
Current
Expected
Remark
Kiln feed
89 tph
Clinker Production
30 % false air
976 kCal
/kgck
66.8 kWh/tck
50 kWh/t ck
0.46 %
49.29
Cooler k factor
0.9
1.5 %
60
1.15
Page 3 of 37
17kcal/kgck
and
reduction expected.
@8kWh/tck
The plant can not increase production because the EP fan operates at 100% because of
high false air inleakage (more than 55% of the gas at EP outlet). ID fan already operates at
positive pressure at its outlet. Kiln is operating with high CO gas.
High fluctuation of kiln feed was also a bottleneck as it affects the margin operator shall
take to control operation during push of feeding. High CO formation was a big concern in
the kiln system.
All the bottlenecks/bafflings identified in the kiln system are described below:
A.3. High False air inleakage
Main false air inleakage are shown on the schematic diagram below:
1.9% false
air
8.3%
O2
SO2
27.5%
false
air
11.9 %
O2
0.5%
false
air
29.6%
false
air
3 % O2
2.9 % O2
11.7 %
O2
1.9 %
false
air
Location: Outlet
7 % O2
30.7% false
air
8 % O2
PH C2 cyclone
PH C1 cyclone
0.5%
440
82962
Dry-crusher inlet
27.5%
22851
105813
30.7%
32540
138353
PH SO 2 outlet
1.9%
2624
140977
Kiln EP inlet
29.6%
41692
182669
Kiln EP outlet
1.9%
3431
186100
Total
55.7%
103578
186100
For every 1 % of false air reduction, the savings of EP fan and ID fan power consumption
were estimated to be approximately 3.16 kWh and 18.9 kWh. These figures are equivalent
to a saving of 0.48 kWh/ton of clinker. By targeting only 30 % false air (based on EP
Page 4 of 37
outlet), the savings would be as high as >8kWh/tck. This would help reduce the very
excessive power consumption of the burning line 9>66kWh/tck according to MMP). In 2006,
ID Fan outlet O2 was only 9.0% to 9.6% vs. 11.6% in 2007. The situation has worsened.
Fan Efficiency:
The Fans efficiency of #3 Kiln ID Fan, ESP Fan is 44%, 41%. The Impact would be 8-9
kW/tck by rising to standard 65% figure. The analysis of the Fan Efficiency and
Mechanical check on the Fans should be given in order to formulate an action plan to
improve the performance to reduce the overall power consumption of the plant (see QJP
PC investigation study in 2006).
Positive pressure at Kiln ID fan outlet
ID fan was running at 45 % 5 years ago. Currently, ID fan operates at 58 %. As the result of
this, EP fan has to run at 100 % speed. When the ID fan speed was 45 %, the kiln might be
operating at only 25.7 % of system false air inleakage 5 years ago. Therefore, it is
recommended to the plant to reduce the false air inleakage to 30 %. The positive pressure
at the ID fan outlet can then be eliminated, helping also for CO control (see below).
A.4. High fluctuation in Kiln slurry feed rate
It was observed the kiln slurry feed was fluctuating from 70 tph to 104 tph. Because of the
high fluctuation in kiln feed rate, the kiln has been operating with:
1. C2 cyclone bottom temperature fluctuating from 812 deg C to 879 deg C.
2. C2 cyclone outlet temperature fluctuating from 850 deg C to 952 deg C.
3. Big variation in C1 outlet CO gas. Please refer to Table 2.
4. SO2 dedusting cyclone outlet gas pressure fluctuating from 55 mbar to -59 mbar.
5. C2 cyclone bottom calcination degree fluctuating from 57.37 % to 87.35 %.
It was observed that the calciner coal feeder automatic control loop could not be used to
control the high fluctuation of C2 outlet gas and material temperature and high fluctuation of
CO gas. The plant have been operating with fixed coal feed rate most of the time.
A.5. High CO formation
CO gas came from preheater tower although residence time is 2.6s. The most probable
causes of high CO formation in the kiln system were (burner design yet to be checked):
1. High variation of the kiln feed resulting into sudden increase of differential pressure in
dryer crusher. Both affecting the O2 content in the precalciner.
2. High usage of pre-calciner coal fuel rate at 6 tph due to low tertiary air temperature and
high false air inleakage and important variation in the precalciner temperature.
Page 5 of 37
3. The fine coal is already fine (8.8 % at 90 microns. VM is 25%). It may result into
injection fluctuation. It also dangerous from a risk fire point of view in coal mill circuit
trials are recommended with coarser coal (10-12%).
4. Low tertiary air temperature (730C dropped down by -100C to 630C across the TA
duct)
A.6. Poor cooler performance
Main Parameter
Operating
Expected
Cooler Efficiency
55 %
65
0.9
>1.15
210 deg C
2.53 Nm3/kg cl
Tertiary
air
temperature
duct
730 deg C
0.65 Nm3/kg cl
1.54 Nm3/kg cl
0.27 Nm3/kg cl
0.08 Nm3/kg cl
>850 deg C
The overall efficiency of the cooler was considered very poor (standard grate cooler).
A.7. High Heat consumption
Due to high false air, high primary air, CO formation, overburning, excessive fluctuation in
the kiln system, kiln is currently operating at high heat consumption (1068 kCal/kg cl).
Current
Expected
SHC reduction
55.7 %
30 %
14.6 kCal/kg cl
0.9
1.15
39.9 kcal/kgck
36.1 %
15 %
17.6 kcal/kg
20%
10% ?
0.46 %
1.5 %
Page 6 of 37
15 kcal/kgck
Emergency Actions
To quickly install back the CO safety interlocking system for Kiln EP.
Table of actions
This table of actions lists recommendations that have been identified by plant and ATC
representatives during the audit (See more-detailed one with ways for implementation at
the end of the document)
No.
Action
Priority
Safety
1
1
1
1
2
Reduce overburning
Page 7 of 37
Page 8 of 37
1
2
B. MAIN REPORT
B.1. Introduction
QJP kiln 3# audit was conducted from 16~20 July 2007 by three ATC process engineers, JL Josse,
WXH and LWL. The objectives of the kiln audit are to determine the baffling factors and to identify
the bottlenecks in kiln system. The one-week mission was carried out with the great co-operation &
enthusiasm from the plant management and the plant team.
Page 9 of 37
a) Carbon dioxide gas produced was 0.2077 Nm3 / 1000 kCal of coal combustion
b) H2O gas produced was 0.0695 Nm3 / 1000 kCal of coal combustion
c) Nitrogen gas was 0.9235 Nm3 / 1000 kCal of coal combustion
8. Hot Clinker temperature was 1460 deg C.
9. Preheater exit dust load was 0.1 kg / kg clinker
10. Kiln backend false air inlekage was 0.07 Nm3/kg clinker.
11. Water spray inside dryer crusher was 2 tph.
In Appendix, Table 3 shows the description of main equipment and its design data. Table 4
shows the main kiln operating data during the mission and Figure 1 shows the process data
of the kiln system.
B.3. Analysis / Argument / Conclusions
In the mission, we were able to identify the bottlenecks of the kiln system. The bottlenecks
are described below:
B.3.1.
Safety issues
It was observed the kiln slurry feed was fluctuating from 70 tph to 104 tph. The fluctuation
was confirmed from the data we have collected from the PLC. The trend curve of the kiln
slurry feed against time is shown in Chart 1. Using statistical analysis method on the data
from PLC, the average and standard deviation of the kiln slurry feed were 89 tph and 5 tph,
respectively. The feeder precision only reached 21% (dry lines recommended figure should
be<1%).
Because of the high fluctuation in kiln feed rate, the kiln has been operating with:
Page 10 of 37
Because of the high fluctuation in kiln feed, there was a big variation in cyclone C2 bottom
temperature (after pre-calciner). Chart 2 shows the variation of the material temperature.
Chart 2 Cyclone C2 bottom temperature variation
Page 11 of 37
At the site, were able to identify some of the causes of the fluctuation:
1. It was observed that the timing of the two vacuum filters was not synchronized. The two
paratactic vacuum filters were not consistently supplying kiln slurry feed. Due to the
inconsistent of the vacuum filters, the amount of material on the belt conveyor was
sometimes less and sometime more. This was due to the two vacuum filters were
sometimes discharging slurry at the same time, and sometimes discharging one at a
time.
Chart 3 Inconsistent slurry feed on belt conveyor
Less material
More material
2. It was observed that there was material accumulating on the load cell of the belt
conveyor weigher.
3. It was observed that there was a lot of spillage underneath the belt conveyor before the
rotary valve. The cleaning of the spillage was done once a shift by worker.
Page 12 of 37
Spillage
4. It was observed there was a sudden peak increase in dryer crusher differential
pressure. The increase of this differential pressure affects the outlet pressure of cyclone
SO2 and hence, CO formation was observed immediately after this phenomenon. It
was also observed that this phenomenon happened in a time cycle of about 40 minutes
or longer. The phenomenon was maybe caused:
a) By falling coating inside the dryer crusher.
b) High fluctuation of feed in to dryer.
Chart 5 Dry-crusher difference pressure with time
Falling
coating
Decrease
of feed
However, we do not think that the previous mentioned improvement will definitively improve
the kiln feed stability. Therefore, it is strongly recommended to apply the FLS design of this
kind of circuit (see Holcim, ACC LTD Madukkarai plant in India). Indeed the design includes
Page 13 of 37
a surge bin at cyclone discharge with rotary valve and weigh feeder. The capacity of the
bin is small (20min : 30t in our case). The main objective is to eliminate fluctuation coming
from the hammer mill system. This is option is strongly recommended.
Chart 6 CO content variation with pressure at PH outlet
B.3.3.
Based on our oxygen gas measurement, we have calculated the false air inleakage in the
kiln system starting from C2 outlet to Kiln EP outlet. The amount of false air inleakages are
shown in Table 1. We are confident that our gas measurement was quite accurate as the
difference between the calculated and measured air flow was within 4 %.
Table 1 System false air
Item
PH C2 outlet
O2
content
(%,
Actual
measure
ment
value)
Gas flow
volume
(Nm3/h, based
on calculation
value)
82522
0.5%
440
PH C1 Dry-crusher
Dry-crusher inlet
False air
(Nm3/h,
based on
calculation
value)
2.9
PH C2 C1
PH C1 outlet
False air
(%,
based on
equipme
nt inlet)
82962
27.5%
22851
105813
Page 14 of 37
Gas flow
volume
(Nm3/h,
actual
measureme
nt value)
Difference
(%, based
on
calculation
value)
Dry-crusher
30.7%
Dry-crusher outlet
Dry-crusher PH IDF
inlet
PH IDF inlet
1.9%
29.6%
Kiln EP outlet
Total
1.9%
-2.7%
140977
138733
-1.6%
182669
190106
4.1%
186100
190305
2.2%
186100
190305
2.2%
3431
11.9
55.7%
134617
41692
11.7
Kiln EP
138353
2624
8.3
32540
103578
From our analysis, the most false air inleakages were found at:
1. Between cyclone C1 outlet gas duct and dryer crusher inlet. The % of false air
inleakage was 32 %. This is far to high.
2. Between dryer crusher inlet and outlet. The % of false air inleakage was 9 %.
3. Between dryer crusher outlet and kiln EP inlet. The false air inleakage was 11 %.
4. Between kiln EP inlet and EP outlet. The false air inleakage was 10 %.
The amount of false air inleakage from C2 to kiln EP outlet was 103,578 Nm3/h which was
55.7 % of the total airflow at the EP fan (starting from C2 gas duct exit, excluding
precalciner inleakage). The amount of false air inleakage from C2 to SO2 cyclone outlet
was 58,455 Nm3/hr. This high false air inleakage has obviously caused high losses in
electricity and heat consumption and high instability in kiln operation.
Using the Fan Law Theory, we are able to estimate EP fan and ID fan power reduction for
every 1 % reduction in the preheater false air. For every 1 % of false air reduction, the
savings of EP fan and ID fan power consumption were estimated to be approximately 3.16
kWh and 18.9 kWh. These figures are equivalent to a saving of 0.481 kWh/ton of clinker. If
the plant is targeted to reduce the false air inleakage to 30 %, that means a reduction of
25.7 % false air, the savings for EP fan and ID fan power consumption would be 71 kWh
and 407 kWh. The saving in specific power consumption of EP fan and ID fan for 25.7% of
false air reduction would be 8.16 kWh/ton of clinker. Please refer to Chart 7 for the
determination of fan power reduction and saving against false air reduction.
Chart 7 Reduction in ID fan and EP fan Power Consumption
Page 15 of 37
High false air inleakage supplies the necessary O2 for the precalciner combustion (see
below) : our calculation shows that the minimum combustion air required for calciner
complete coal combustion at 6 tph was 0.875 Nm3/kg clinker. It was calculated that the total
neutral air flow to calciner was 1.009 Nm3/kg clinker. The excess neutral air flow was 15 %
of the minimum combustion air flow which is a standard value. However, the combustion
would be improved if this O2 was provided by hot gas from the cooler instead of cold
inleakage gas that have to be heated (requiring more fuel).
Beside false air inleakage in preheater tower, we also managed to determine other false air
inleakage in the kiln system.
False air in tertiary air duct was calculated to be 1238 Nm3/hr or 0.027 Nm3/kg cl. From our
measurement, it was found that the tertiary air temperature at its outlet was 100 deg C
lower than its inlet due to the false air inleakage and also radiation loss. It was observed
that the tertiary air duct temperature was not consistent. This could explain why the
fluctuation of C2 outlet gas temperature was also due to high variation of the tertiary air
duct temperature.
The % of primary air at kiln burner pipe was calculated at 36.1 % which was 21.1 % higher
than the 15 % (maximum) primary air recommended by Lafarge Process Guidelines. The
additional 21.1 % primary air was actually additional false air inleakage of 3668 Nm3/hr.
At the site, we were able to identify some of the cause of the false air inleakages:
Page 16 of 37
1. It was observed that there was false air inleakage at the inspection door of cyclone SO2
gas duct. Please refer to Chart 8.
Chart 8 False air inleakage at Cyclone SO2 inlet gas duct
Air leakage
2. The area between Cyclone C 1and dryer crusher inlet, we were not able to observe the
false air inleakages.
3. At the dryer crusher, we were not able to observe the false air inleakage.
4. At the kiln EP inlet and outlet, we were not able to observe false air inleakages.
5. It was observed that there was false air inleakage at the kiln main door. Please refer to
Chart 9.
Chart 9 False air inleakage at kiln main door
Big
gap
around
kiln burner
pipe
Page 17 of 37
B.3.4.
High CO formation
From our gas analysis measurement, we have detected high CO composition in Cyclone
C2 outlet gas duct, cyclone C1 outlet gas duct and kiln EP inlet. The CO gas compositions
are shown in Table 2. The high fluctuation of CO gas at cyclone C1 outlet gas duct was
confirmed from the CO gas data collected from the PLC. Chart 10 shows the high
fluctuation of CO inside cyclone C1 outlet gas duct. We did not detect CO at kiln exit.
Table 2 CO content in some equipments outlet
Item
CO(ppm, 18 July)
Kiln inlet
CO (ppm,19 July)
Precalciner outlet
4572
C2 outlet
4572
C1 outlet
7050
Dry-crusher inlet
1300
5000
Dry-crusher outlet
1450
3650
3700
1038
Kiln EP inlet
1042
1400~2375
Kiln EP outlet
2480
1740
Remark
Due to the
fluctuation
measuring data,
data
used
calculation
based
estimation.
big
of
the
for
are
on
The causes for CO formations are numereous : poor preparation and variability of fuel, poor
injection, poor mixing of O2 and coal or lack of O2, too cold or too short condition of burning
. Let us investigate those aspects :
Page 18 of 37
O2 quantity
From our air measurement and calculation, the tertiary air duct air flow was 0.6433 Nm3/kg
clinker, the kiln excess air flow was calculated to be 0.1424 Nm3/kg clinker, calciner primary
air flow was 0.123 Nm3/kg cl and the false air at kiln backend was 0.07 Nm3/kg cl. The total
amount of neutral air supplied to calciner was 1.009 Nm3/kg cl or 46,288 Nm3/h. The
minimum combustion air required for calciner was 0.875 Nm3/kg cl or 40,141 Nm3/hr. This
surplus air flow was 15 % excess of the minimum coal combustion air flow. The air flow
should be sufficient for complete combustion. However, it would be better to get the O2
using hot gas from the cooler.
Nevertheless, the main cause for CO formation is not overall lack of O2. However, it is
possible that locally, in the space or in the time, there is lack of O2 because of :
Fluctuation in the O2 content because of fluctuation in the draft (obvious kiln feed
fluctuation of fluctuation in amount of coal_ not observed for lack of pressure
gauge).
Poor location of the precalciner burner making the contact between available O2
and fuel difficult. This point has not bee investigated yet.
Precalciner residence time
Chart 11 Precalciner construction and measurement data
From our calculations, the coal residence time was estimated to be 2.6s which is sufficient
for complete combustion. The recommended residence time is >2s. Hence, too short
Page 19 of 37
residence time is not a direct cause for bad combustion. Obviously, less inleakage would
increase even more the residence time.
There are enough time and enough O2 for combustion. However, as already mentioned,
the fluctuating and low tertiary air temperature (@650C at precalciner inlet) affects the
quality and the speed of the ignition of the combustion.
Coal preparation and injection
Coal finely ground (8.8%R80, finer than the recommended figure for a 25% VM coal). Too
fine coal may create fluctuation in the injection. However it is not always the case.
The design of the precalciner burner has not been studied yet. The primary air seems to be
OK.
The quality of coal shall also be further investigated.
Impact of high inleakage
Although false air brings O2 for the combustion, it has an overall negative impact on the
combustion quality for the following reasons :
The O2 may not be located where it is required
The false air have to be heated, requiring more fuel and as a consequence more
O2, hence reducing the overall residence time in the precalciner.
Build up formation that affects the flow pattern
Overall instability of the system and IDFan outlet underpressure
Observing the trends and commun understanding indicate that CO generation is obviously
clearly affected by the huge fluctuation of the kiln feeding. However shall be the other
factors, important variation in the kiln feeding affects all the dynamics inside the precalciner
and as a result the combustion. Addressing these fluctuations is the main factor to reduce
CO.
A standard way to smooth those variation is to keep the IDFan outlet pressure under
control, slightly in succion (around -1mbar). This is not the case in QJP (see next topic).
Positive pressure at Kiln ID fan outlet
Based on our measurement, the static pressure at the kiln EP inlet was at positive 3.2 mbar
even though kiln EP fan damper and EP fan speed have run up to 100 %. It was observed
that the kiln ID fan speed was operating at 58 %. We were told by the plant personnel that
ID fan speed was normally at 40 to 45 % 5 years ago. The air flow at ID fan was measured
to be 140,985 Nm3/hr. The ID fan speed was set at 58 %.
Page 20 of 37
Using Fan Law Theory, ID fan at speed of 45 % would be operating at 109,394 Nm3/hr of
air flow. The reduction of air flow of 31,591 m3/hr is equivalent to 30.5 % reduction of total
system false air of 103,278 Nm3/hr. This could explain that the kiln might be operating at
only 25.7 % of system false air inleakage 5 years ago. Therefore, it is recommended to the
plant to reduce the false air inleakage to 30 % at this moment. The positive pressure at the
ID fan outlet can then be eliminated.
Other factor
It was also calculated that the kiln hood cross velocity was high at 11.7m/s. The
recommended figure was 6 m/s. This high velocity air might affect the stability of flame and
even might cause high refractory wear rate at kiln nosering and burner pipe.
Hence the most probable causes of high CO formation in the kiln system were:
1. High variation of the kiln feed affecting all the gas flow of the line
2. High false air inleakage in preheater system which has been discussed earlier.
3. High usage of pre-calciner coal fuel rate due to low temperature tertiary air and high
inleakage.
4. Coal fineness of 8.8 % could be too fine.
5. The design of the installation should be checked with more details (inc. burner).
6. Lack of control of ID fan outlet pressure because of excessive inleakage
Reminder of 2006 observations :
Items
Target/Normal
Existing status
Evaluation
~ 2.0s
@3.0s
OK
Uniform and
reasonable.
Bad
Stable 5
Max. 24
Bad
CO kiln exit
<100ppm
OK
O2 kiln exit
3-5%
Unknown
500ppm
Bad
2~3%
0.8~3.2%
Poor
Stable
Bad
No sparkle at
outlet
Bad
Residence time
PC temperature
profile
PC
exit
temperature
gas
CO PC exit gas
O2 PC exit gas
Temperature In
main section
Burn condition by
visual inspection
Page 21 of 37
Kiln/PC=40:60
Around 60%
OK
A(PC Inlet)
798-850
815-828
B(PC Cone)
760-800
779-855
792-823
C(PC Middle)
872-885
820-828
801-855
D(PC Upside)
849-852
818-821
854-868
PC exit
881-905
O2 (%)
CO ppm
No indication
> 10000
1.4-2.0
3500-6250
C2 Cyclone exit
1.7-2.2
3264-3816
7.9-8.1
2824-3004
9.5-9.6
1587-2830
PC exit
C2 Cyclone exit
Kiln Feed: 65-70t/h (R/C=1.87) 18-July-2006 10:40 - 12:00
1
A(PC Inlet)
867-870
918-930
B(PC Cone)
790-806
808-818
813-817
C(PC Middle)
835-846
817-820
878-881
D(PC Upside)
835
875-886
894
PC exit
865-872
C2 Cyclone exit
861-904
O2 (%)
CO ppm
No indication
> 10000
0.8-1.2
275-1270
C2 Cyclone exit
0.5-0.9
2257-5171
7.1-7.2
4012-4612
8.4-8.5
4882-5771
PC exit
A(PC Inlet)
949
904
B(PC Cone)
891
833
C(PC Middle)
832
D(PC Upside)
838
PC exit
938
C2 Cyclone exit
839
B.3.5.
O2 (%)
CO ppm
Kiln inlet
0.3-0.4
5200-7800
797
PC exit
1.5-3.2
2203-2014
843
849
C2 Cyclone exit
2.8-4.2
2623-1892
936
886
8.7-9.2
288-292
9.1-9.3
2535-2378
The cooler outlet clinker temperature was 210 deg C and cooler cooling fan air flow was
2.53 Nm3/kg ck (28 deg C). Tertiary air flow was 0.6463 Nm3/kg ck (730 deg C). The
exhaust air flow (270 deg C) and hot gas to coal mill (490 deg C) air flow were 1.5427
Nm3/kg ck and 0.0772 Nm3/kg ck, respectively. The secondary air flow was calculated to
be 0.2698Nm3 / kg ck at 730 deg C.
Page 22 of 37
Based on the measurement above, the cooler efficiency and recovery k factor were
evaluated to be 56% and 0.9, respectively. The overall efficiency of the cooler was
considered poor.
We were not able to see the interior of cooler to check for the red river. However,
considering the high amount of cooling air volume and clinker outlet discharge temperature
of 210 deg C, there is a likelihood of red river inside the cooler. Further investigation to
install inspection door for inspection.
From our calculation, based on the same amount of cooling air flow, it was possible to
increase cooler efficiency to 65 % with heat recovery ratio of 1.15 by increasing tertiary air
and secondary air temperature to 850 deg C and reducing clinker outlet temperature to 110
deg C. This could be done by regulating the speed of cooler. We recommend that the plant
start by reducing the speed from 9 stroke / min to 7 stroke / min. Further optimization of
cooler is required to obtain good cooler efficiency.
It is also possible to increase the cooler efficiency by installing fixed plates at the cooler
inlet.
By increasing the temperature of secondary and tertiary air temperature from 730 deg C to
850 deg C (assuming with same air flow), it is possible to gain additional heat of 39.9
kCal/kg cl.
The chart of cooler cooling air blowing density along the cooler is shown in Chart 12.
Chart 12Cooler Blowing Density
From the chart above, we can see that the cooling air flow at chamber 1 and 2 was too
high. This could explain why the tertiary air and secondary air temperature were low at 730
deg C. Hence this has affected good recuperation of heat from the cooler. From the chart,
Page 23 of 37
we can see that the most probable reason for high cooler outlet clinker temperature was
due to cooling air flow at chamber 3 and 4 were lower than recommended air flow.
In the mission, the grate speed was measured at 9 stroke/min. Theoretically the clinker bed
thickness is calculated to be 350 mm. In order to improve heat recuperation, the grate
speed should be reduced to 7 stroke/min. Theoretically, with this speed, the clinker bed
thickness would be at 450 mm.
It was also observed that the kiln hood pressure was always controlled at 0.0 mbar. From
the control room, it was understood that the operator was actually using the cooling air fan
volume flow rate to regulate the kiln hood pressure. This operating procedure is totally
against the Lafarge Kiln Operating Guidelines.
Furthermore the bottlenecks identified by the evaluation tool were included cooler EP and
EP fan which have deficient margin when upset.
B.3.6.
Due to high false air, CO formation in the kiln system, poor cooler performance, high
primary air, high fluctuation of the feed rate and low free lime (ove-rburning), kiln is currently
operating at high heat consumption.
From our calculation, the heat loss due to:
False air (from C2 to ID fan inlet) at 58,455 Nm3/hr was 2,602,825 kCal/hr or 56.7
kCal/kg clinker. The heat loss was equivalent to 452 kg Coal /hr of energy from
combustion. If the false air (from C2 to ID fan inlet), is reduced to 30 % false air, by
15,022 Nm3/hr which is 25.7 % reduction, then the heat loss would be 668,844 kCal /
hr or 14.6 kCal/kg clinker.
The reduction in primary air flow would increase the intake of secondary air flow. By
reducing the 21.1 % primary air would allow 3,673 Nm3/hr of secondary air intake. The
increase of 3,673 Nm3/hr of secondary air would supply 806,128 kCal/hr or 17.6
kCal/kg cl of energy to the kiln. This is equivalent to reduction of 140 kg coal/hr from the
kiln coal feed.
Improvement in SAT and TAT would reduce the SHC by 39.9kcal/kgck.
Stabilization of the feeding rate should help smooth the system outlet temperature
variation getting the averaged figure down by @20C, affecting the SHC by
Because of the huge variation of the system, lack of proper instrumentation and
process mastery, the plant produces clinker with very low free lime. In order to avoid
flushes, the operator has to overburn to be able to control the variation in the level of
preparation of the material entering the kiln. There are no other option at the time being.
Page 24 of 37
Hence, kiln feeding variation is really cause for overburning and in this aspect over
SHC.
In addition, the plant should investigate opportunity to reduce the cake water content.
For wet dry process, it has been reported reduction down to 10% of the moisture
content (see Holcim, ACC LTD Madukkarai plant in India).
Table of actions and recommendations
This table of actions lists recommendations that have been identified by plant and ATC
representatives during the audit.
This table of actions has to be considered as base document for further discussion.
No.
Action
Priority
Safety
To install safety railing at the kiln EP fan inlet and cyclone roofs
measurement point platform.
To install safety protection screens on the bleed air dampers of
cooler exhaust gas duct and hot gas to coal mill gas duct.
To reinstall cables which were found lying on the ground floor
beside the kiln shell cooling fan to above the ground with proper
electrical conduit.
2
Page 25 of 37
Reduce overburning
Page 26 of 37
No. 2 Action
To reduce false air from 55.7% to 30% at EP outlet.
Way to implement: Process inspection coordinated with maintenance. Weekly follow up of
oxygen measurement after optimization. Thorough inspection of dryer crusher, gas duct
expansion joints, and gas ducts from C1 cyclone to kiln EP inlet during shutdown. To install
scaffolding on preheater tower to inspect gas ducts conditions. To regulate axial and radial
air damper to reduce primary air flow. To consider redesigning the burner if adjusting
primary air flow is unsuccessful with ATC supports.
No. 3 Action
To Improve kiln slurry feeding as to stabilize operation
Way to implement: Apply the priority-1 actions. Install instrumentation to better
understand the causes of the lack of stability. To carry out weighing of kiln slurry feed
after optimization. To consider installing an intermediate bin to better control the kiln
slurry feed. To install sampling points at the SO 2 discharge point. ATC engineers will
refer to other installation for detail information from Lafarge plants. And also to refer to
other installation or supplier of the dryer crusher for detail information Weekly follow up of
temperature and gas measurement after optimization.
No. 4 of action
To eliminate CO formation
Page 27 of 37
QJP Instrumentation
status
Recommendations
No
Ok
Ok
No
No
No
Cooler clinker
temperature indicator
No
Undergrate pressure
meter
Ok
Ok
No
Page 28 of 37
temperature indicator
Ok
Ok
Ok
Ok
Ok
Ok
C2 cyclone bottom
temperature indicator
Ok
Ok
No
No
Ok
Ok
No
Ok
Calciner Pfister
weighting system
Ok
Page 29 of 37
schedule
Calciner automatic
control
No
No
No
To repair ammeter
No. 6 of action
To optimize cooler operation to reduce SHC.
Way to implement: To optimize cooler undergrate pressure by regulating the cooler speed.
A step by step approach is recommended. Weekly followed up of air flow and temperature
measurement of cooler system after optimization+ observation of red river. In case of red
river, ATC should make recommendations accordingly
B.5. Acknowledgements
The 3# kiln audit mission at QUJIANG had been successfully implemented with the help
and supports from the plant management especially Mr. Zhang Jinghong, Mr. Li Da Bing
and Mr. Zhang Zhe Ping.
B.6. References
Cooler air
distribution of QJP
PH False air
calculation
Plant update
study of QJP
Page 30 of 37
Measurement data
of QJP
B.7. Appendices
Table 3
Item
Designed
operating
Kiln output
t/d
996
1100
Kiln speed
rpm
3.2
3.4
kw
160
97
t/h
1.5~5
2.9
t/h
2~8
6.0
t/h
402
89
Dry-crusher output
t/h
80
M3/h
220000
PH IDF pressure
Pa
9800
95
PH IDF speed
57
kw
1000
865
M3/h
250000
298345
M3/h
233730
302714
Pa
1934
kw
220
100
100
M2
26.7
M3/h
13270
Pa
7540
M3/h
35000
Pa
5370
M3/h
45300
Pa
2597
Page 31 of 37
23780
195
15186
100
35498
100
27898
Remark
3.554m
160
160
90
M3/h
62400
Pa
1715
1371
65+ambient
200
M3/h
160000
300max.
M3/h
160800
Pa
2000
100
74
kw
43258
75
110~210
150
155
123
Operation data
Item
Operation data
19
89
8.8
Slurry
fineness(%,
sieve residual)
0.08mm
1.1
5726
996
Kiln
inlet
decarbonisation (%)
843
150
C2 outlet O2 (%)
2.85
C2 outlet temperature ()
832
C2 outlet CO (%)
4964
C1 outlet O2 (%)
2.3
C1 outlet temperature ()
591
C1 outlet CO (%)
1300
-2600
Dry-crusher
()
370
167
10.6
1038
-838
169
320
9.6
2375
160
10.6
1740
Page 32 of 37
inlet
material
temperature
79
543
270
Page 33 of 37
210
unit
SO2 to ID fan
C2 to C1 gas duct
Pst
mbar
161
C
CO
167
C
710
CC
CO
5300
CO
ppm
Pst
-60
NOx
167
C
Pst
-16.5
NOx
1013
NOx
ppm
O2
8.3%
O2
2.9%
200
C
CO
3836
Pst
-48
NOx
585
O2
8.4%
832C
CO
4964
Pst
-13.9
NOx
855
O2
2.9%
591
C
CO
1300
Pst
-26
NOx
850
O2
3%
Dust
return
EP outlet
161
C
CO
1740
Pst
- 8.38
NOx
456
O2
11.9%
970
C
CO
4572
Pst
-8
NOx
888
O2
3.34
%
EP outlet
750 C
150 C
Pst
- 9.9
270 C
Pst
-3.7
Clinker temperature
Crusher inlet
EP inlet
T
161
C
CO
2375
Pst
3.2
NOx
454
O2
11.7 %
543
C
Pst
O2
7%
Page 34 of 37
Crusher outlet
CO
5000
NOx
509
Pst
O2
370C
8%
T
CO
3650
NOx
391
491 C
Pst
-10
210 C
Chart 15 No safety protection screen on bleed air damper of cooler exhaust gas duct
Page 35 of 37
Chart 16 No safety protection screen on bleed damper of hot gas to coal mill gas duct
Page 36 of 37
Table of actions
No.
Action
Priority
Safety
Safety
Safety
Improve drying crusher air sealing and weld or change duct to reduce
false air
10
11
Page 37 of 37