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ATC REPORT

Activity:

AUDIT/PROCESS

CHINA / QUJIANG
3# KILN AUDIT
by Jean Luc Josse & Looi Wan Leong & Wang Xiaohui

ATC, (16~20 July 2007)

Distribution
Region
BU
Plant
ATC

S. Urhan, JS Lee, RdeBelmont

Other
Codification

TSP/QJP400GENERAL/Kiln Audit /20-08-07

TABLE OF CONTENTS
A.

B.

EXECUTIVE SUMMARY..................................................................................3
A.1.

Safety issues.............................................................................................................3

A.2.

Main Operating Parameters......................................................................................3

A.3.

High False air inleakage...........................................................................................4

A.4.

High fluctuation in Kiln slurry feed rate.....................................................................5

A.5.

High CO formation....................................................................................................5

A.6.

Poor cooler performance..........................................................................................6

A.7.

High Heat consumption.............................................................................................6

MAIN REPORT..............................................................................................9
B.1.

Introduction...............................................................................................................9

B.2.

Work Done................................................................................................................9

B.3.

Analysis / Argument / Conclusions.........................................................................10

B.3.1.

Safety issues...................................................................................................10

B.3.2.

High fluctuation in Kiln slurry feeding rate.......................................................10

B.3.3.

High False air inleakage..................................................................................14

B.3.4.

High CO formation...........................................................................................18

B.3.5.

Poor cooler performances...............................................................................22

B.3.6.

High heat consumption....................................................................................24

B.4.

Ways to Implement.................................................................................................27

B.5.

Acknowledgements.................................................................................................30

B.6.

References..............................................................................................................30

B.7.

Appendices.............................................................................................................31

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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

Important fluctuations (+/-17tph)

Clinker Production

45.9 tph or 1100 tpd

not checked, PLC data

% false air at stack (C2


outlet to Kiln EP outlet)

55.7 % of stack flow is


false air

30 % false air

Specific heat consumption


(SHC)

1063 kCal /kgck (not


checked: based on PLC)

976 kCal
/kgck

- 87 kCal/kg ck reduction expected


from the differents actions

KWh/ton ck (kiln line only)

66.8 kWh/tck

50 kWh/t ck

Reduction of 25.7 % inleakage.


Increasing fan efficiencies to 65%

Average free lime

0.46 %

Clinker C3S average

49.29

Cooler k factor

0.9

1.5 %
60
1.15

Page 3 of 37

17kcal/kgck
and
reduction expected.

@8kWh/tck

25 kCal / kgck reduction


Higher SHC but better quality ck
39.9 kCal/kgck reduction

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

False air (%, based on


equipment outlet)

8 % O2

False air (Nm3/h, based


on calculation value)

PH C2 cyclone

Outlet Gas flow (Nm3/h,


based on calculation value)
82522

PH C1 cyclone

0.5%

440

82962

Dry-crusher inlet

27.5%

22851

105813

Dryer crusher outlet

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.

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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

Cooler recovery k factor

0.9

>1.15

Clinker temperature (assume)

1460 deg C (not checked)

Cold Clinker temperature

210 deg C

Cooling fan air flow

2.53 Nm3/kg cl

Tertiary
air
temperature

duct

inlet 730 deg C (up to 100 deg 850 deg C


C difference at outlet)

Secondary air temperature

730 deg C

Tertiary air flow

0.65 Nm3/kg cl

Exhaust air flow

1.54 Nm3/kg cl

Secondary air flow

0.27 Nm3/kg cl

Hot gas to coal mill

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).

Elimination of false air from C2 cyclone to


SO 2 cyclone outlet (ref: 30 % system
inleakage)
Cooler efficiency
Elimination of 21.1 % PA in Kiln burner pipe
(ref: 15 % PA)

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 %

High PH exit temperature due to fluctuation


Reduction of moisture content
Free lime

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

Prevent safety accident

Safety

To quickly repair kiln EP inlet gas analyzer in order to restore


the CO gas safety interlocking.
2

To reduce false air from 55.7 to 30% of EP outlet to


reduce SHC by 14.6 kCal/kg cl and 8.16 kWh/ton cl
To reduce primary air from 36% to 15% as to reduce SHC by
17.6 kCal /kg cl by adjusting axial and radial air dampers.

To consider redesigning the burner if adjusting axial air and


radial air flow is unsuccessful.

Improve kiln slurry feeding stdev from 5tph to 1tph to


stabilize operation and increase production
To make the two slurry feeders vacuum filters to discharge
slurry separately according to timing.
To allow the weighting belt speed changeable.
To revive the automatic control of the kiln feeding system.
To consider installing an intermediate bin to better control the
kiln slurry feed : strongly recommended option. Refer to
Holcim India plant : MADUKKARAI Plant
ATC to investigate if other installations in the world have
similar problems.

1
1
1
1
2

To eliminate CO gas formation in precalciner


To re-activate the calciner coal feeder automatic control.

To reactivate the pressure meter of coal conveying system.

ATC engineers will investigate the calciner coal burner, coal


injection and the design of calciner. Plant to investigate coal
quality fluctuation

Reduce overburning

To train Operator in kiln operations+ proper instrumentation.

Page 7 of 37

Optimize cooler operation by increasing recovery k:


factor from 0.9 to 1.15 as to reduce SHC 39.9 kCal/kgck.
To optimize secondary air and tertiary air temperature to 850
deg C by increasing the theoretical clinker bed thickness
from 350 mm to 450 mm. This can be done by reducing
cooler grate speed from 9 stroke/min to 7 stroke/min.

To consider installing fixed cooler plate.

To reset kiln hood pressure to -0.1mbar and to re-activate


automatic control between kiln hood pressure and cooler EP
fan.

To install a clinker temperature monitoring system so that kiln


operator can monitor the clinker temperature.

To adjust blowing profile according to recommended pattern


7

Reduce water content


Other similar dewatering system plant manage to reduce
water content down to 10% . To be investigated. Refer to
Holcim India plant : MADUKKARAI Plant.

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.

B.2. Work Done


In the mission we carried out measurements such as air flow volume, static and dynamic
pressure, temperature and gas compositions of the kiln system. We also measured the
surface temperatures of kiln, cyclones and cooler for heat balance calculation. We also
visited CCR control room to collect some operating data. In the control room, we
downloaded some of these data for trend analysis. We also obtained the kiln feed slurry
moisture content and LOI analysis for kiln feed slurry and raw meal dust at the bottom of
cyclone C2. We were not able to perform fan efficiency test due to the plant Electrical
Departments power-meter was malfunctioned.
The semi-wet kiln was designed by FLS to produce 1000 tons of clinker per day. However,
from our calculation based on the moisture contents of 20 % and LOI of 35.5 % retrieved
from the lab analysis, the kiln was supposed to produce 1100 t/h, theoretically. Due to the
high fluctuation of the kiln feed at the slurry feeder, we were not able to obtain a constant
kiln slurry feed rate. The determination of the kiln feed rate was based on the average value
of the data collected from the PLC. To obtain a precise clinker production, it is advisable for
the plant to carry out the weighing of clinker and kiln slurry feed. However, since the
objectives of the mission are to determine the bottleneck of the kiln system, the weighing
has not been carried during the mission as this was not the #1 priority (as discussed with
RD before going). Nevertheless, we were still managed to conduct a heat balance starting
from cooler to ID fan inlet based on the following assumptions.
1. Kiln feed rate was 89 tph abstracted from the average value of PLC data.
2. Clinker factor was 1.94.
3. Kiln and calciner coal feed rate were 2.6 tph and 6.0 tph, respectively, abstracted from
the average values of PLC data.
4. Coal LHV was 5757 kCal/kg coal (given by the plant).
5. Minimum combustion air rate was 1.1631 Nm3/1000 kCal of coal combustion.
6. Minimum combustion air rate at kiln and calciner were 0.379 Nm3/kg clinker and 0.875
Nm3/kg clinker.
7. Coal combustion products:

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

There were some critical safety issues with the plant.


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 very high as based on our
measurement; the CO content at the kiln EP inlet has reached up to 2375 ppm.
2. It was seen that there were a lot of electric cables lying on the ground floor beside the
kiln shell cooling fans. The cables were actually exposed to rain. The cables pose very
high risk of electric shocks at the site.
3. There was no safety railing around the measuring point at the kiln outlet EP.
4. There were no safety protection screens on the bleed air dampers of cooler exhaust
gas duct and hot gas to coal mill gas duct.
5. There was no safety protection screen on the cooling fan 2 dampers.
B.3.2.

High fluctuation in Kiln slurry feeding rate

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

1. High fluctuation in cyclone C2 bottom temperature (after pre-calciner). Temperature was


fluctuating from 812 deg C to 879 deg C.
2. High fluctuation in cyclone C2 outlet gas temperature (after pre-calciner). Temperature
was fluctuating from 850 deg C to 952 deg C.
3. Big variation in C1 outlet CO gas (based on fixed coal feed). Please refer to Table 2.
4. High fluctuation in cyclone SO2 outlet gas pressure. Pressure was fluctuating from 55
mbar to -59 mbar.
5. Big variation in calcination degree at the C2 cyclone bottom. The variation was from
57.37 % to 87.35 %.
Chart 2 shows the variation of the material temperature.
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. It was
dangerous to operate the kiln this way.
It was also observed that the big fluctuation in cyclone C2 bottom temperature was also due
to high variation in tertiary air temperature. From our measurement, the temperature
difference between the tertiary air duct inlet and outlet was up to 100 deg C. The big drop in
temperature was due to high false air inleakage in tertiary air duct which would be
discussed later.
Chart 1Kiln slurry feed fluctuation

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

Chart 4 Slurry feeding rate with time

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.

High False air inleakage

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

PH IDF inlet ~ Kiln EP


inlet
Kiln EP inlet

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

Kiln IDF inlet

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

Chart 10Cyclone C1 outlet CO

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.

PC upper is higher than middle and bottom; huge


variations--- Max 98 between two points at
same level.

Bad

Stable 5

Max. 24

Bad

CO kiln exit

<100ppm

Unknown in 2006, In 2007, seems to be 0

OK

O2 kiln exit

3-5%

Unknown in 2006 and 2007

Unknown

500ppm

Normal 2014~6250ppm Seldom 500ppm

Bad

2~3%

0.8~3.2%

Poor

Stable

Unstable Max. variations 45

Bad

No sparkle at
outlet

Many sparkles was found in different section

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

Stable fuel splitting


PC

Kiln/PC=40:60

Around 60%

OK

Reminder of 2006 temperature measurements in the precalciner :


Kiln Feed: 60t/h (R/C=1.87) Decarbonation Degree: 91-95%
1

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

17-July-2006 14:50 - 16:15

O2 (%)

CO ppm

No indication

> 10000

1.4-2.0

3500-6250

C2 Cyclone exit

1.7-2.2

3264-3816

The Dry-crusher exit

7.9-8.1

2824-3004

The ID fan inlet

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

The Dry-crusher exit

7.1-7.2

4012-4612

The ID fan inlet

8.4-8.5

4882-5771

PC exit

Kiln Feed: 75-80t/h (R/C=1.87) 20-July-2006 9:30 - 10:40


1

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

The Dry-crusher exit

8.7-9.2

288-292

The ID fan inlet

9.1-9.3

2535-2378

Poor cooler performances

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.

High heat consumption

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

Prevent safety accident

Safety

To quickly repair kiln EP inlet gas analyzer in order to restore the


CO gas safety interlocking.

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

To reduce false air from 55.7 to 30% of EP outlet to reduce SHC


by 14.6 kCal/kg cl and 8.16 kWh/ton cl

To repair and seal the false air inleakage at the 2 inspection


doors on dedusting cyclone SO2.
To further investigate the cause of high false air inleakage at the
duct of C1 to dry-crusher inlet during shutdown.
To further investigate the cause of high false air at dryer crusher.
To further investigate the cause of high false air inleakage from
SO2 cyclone outlet to Kiln EP inlet.
To repair and seal the gap of the kiln hood main door.
To reduce primary air from 36% to 15% as to reduce SHC by 17.6
kCal /kg cl by adjusting axial and radial air dampers.
To consider redesigning the burner if adjusting axial air and radial
air flow is unsuccessful.
3

Improve kiln slurry feeding stdev from 5tph to 1tph to stabilize

Page 25 of 37

operation and increase production and reduce SHC


To make the two slurry feeders vacuum filters to discharge slurry
separately according to timing.
To allow the weighting belt speed changeable.
To revive the automatic control of the kiln feeding system.
To regularly clean up the accumulation of materials on the belt
weigher.
To install a chain scraper under the belt conveyor to clean up the
spillage before the rotary feeder.
To consider installing an intermediate bin to better control the kiln
slurry feed: strongly recommended option
To install measuring point at the SO 2 bottom discharge point.
ATC to investigate if other installation in the world have similar
problems.
4

To eliminate CO gas formation.

To re-activate the calciner coal feeder automatic control.


To further investigate on how to eliminate the sudden increase of
differential pressure inside dryer crusher during shutdown.
To increase cooler efficiency to recovery k factor of 1.15.
To reactivate the pressure meter of coal conveying system.
Trial with coal fineness @10%
ATC engineers will investigate the calciner coal burner, coal
injection and the design of calciner.
5

Reduce overburning

To train Operator in kiln operations.


To reduce kiln feed fluctuation
To get proper instrumentation
6

Optimize cooler operation by increasing recovery k: factor from


0.9 to 1.15 as to reduce SHC 39.9 kCal/kg cl.
To optimize secondary air and tertiary air temperature to 850 deg
C by increasing the theoretical clinker bed thickness from 350
mm to 450 mm. This can be done by reducing cooler grate speed
from 9 stroke/min to 7 stroke/min.
To consider installing fixed cooler plate.
Plant has to try to obtain an optimum undergrate pressure

Page 26 of 37

To reset kiln hood pressure to -0.2mbar.


To re-activate automatic control between kiln hood pressure and
cooler EP fan.
To install a clinker temperature monitoring system so that kiln
operator can monitor the clinker temperature.
To repair or check the availability of the kiln hood pressure gauge.
To adjust blowing profile according to recommended pattern
To train Operator in kiln operations.

B.4. Ways to Implement


No. 1 Action
Prevent safety accident
Way to implement : Followed up by Safety Manager and ATC engineers

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

Way to implement: Weekly followed up of gas measurement after optimization. To further


investigate the design of calciner coal burner, conducting a precise mapping of O2 and CO
in the precalciner. To be confirmed by trial: fine coal too fine of 8.8 % at 80 micron resulting
into injection fluctuation. ATC can help to define the trial protocole. After installation of the
pressure gauge and connection to CCR, further investigation could be carried out on the
injection system. Plant to provide drawing of the precalciner burner to ATC for further study.
No. 5 of action
To reduce overburning.
Way to implement: reducing kiln feed fluctuation is the first step. In addition, install proper
instrumentation, train operator using 10 golden rules of kiln operation and post sevilla
combustion concepts. An attempt wit higher C3S could e also an option to validate the
impact of clinker quality. The optimum kiln speed to feed ratio should be further
investigated and a representative clinker microscopy should be completed to see the size
of the remaining free lime as well as of belite and alite.
Instrument

QJP Instrumentation
status

Recommendations

Kiln burning zone


pyrometer

No

To install pyrometer proper


maintenance and proper calibration
schedule

Kiln hood pressure


meter

Ok

To maintain the reliability of the


pressure meter proper calibration
schedule

Tertiary air duct inlet


temperature

Ok

To maintain the reliability of the


thermocouple proper calibration
schedule

Tertiary air duct outlet


temperature

No

To install thermocouple and to maintain


the reliability of the thermocouple
proper calibration schedule

Tertiary air duct


pressure meter

No

To install pressure meter

Tertiary air duct damper


position opening
indicator

No

To repair automatic control from PLC

Cooler clinker
temperature indicator

No

To install thermocouple and to maintain


the reliability of the thermocouple
proper calibration schedule

Undergrate pressure
meter

Ok

To maintain the reliability of the


pressure meter proper calibration
schedule

Cooler exhaut gas


temperature indicator

Ok

To maintain the reliability of the


thermocouple proper calibration
schedule

Hot gas to coal mill gas

No

To install thermocouple and to maintain

Page 28 of 37

temperature indicator

the reliability of the thermocouple


proper calibration schedule

Kiln shell temperature


scanner

Ok

To maintain the reliability of the scanner


proper maintenance and calibration
schedule

Kiln main motor current


indicator

Ok

To maintain the reliability of the


ammeter proper maintenance and
proper calibration schedule

Kiln speed indicator

Ok

To maintain the reliability proper


maintenance and calibration schedule

Kiln inlet temperature


indicator

Ok

To maintain the reliability of the


thermocouple proper calibration
schedule

Kiln inlet pressure meter

Ok

To maintain the reliability of the


pressure meter proper calibration
schedule

Kiln inlet gas analyzer

Ok

To maintain the reliability of the


analyzer proper maintenance and
calibration schedule

C2 cyclone bottom
temperature indicator

Ok

To maintain the reliability of the


thermocouple proper calibration
schedule

C2 cyclone outlet gas


temperature indicator

Ok

To maintain the reliability of the


thermocouple proper calibration
schedule

C1 cyclone outlet gas


analyzer

No

To repair oxygen gas analyzer

Kiln Pfister coal feeder


coal transport pressure
meter

No

To install a digital pressure meter and


link to PLC

Kiln Pfister motor


current indicator

Ok

To maintain the reliability of the


ammeter proper maintenance and
proper calibration schedule

Kiln Pfister weighting


system

Ok

To maintain the reliability of the


weighting system proper
maintenance and proper calibration
schedule

Calciner Pfister coal


feeder coal transport
pressure

No

To install a digital pressure meter and


link to PLC

Calciner Pfister motor


current indicator

Ok

To maintain the reliability of the


ammeter proper maintenance and
proper calibration schedule

Calciner Pfister
weighting system

Ok

To maintain the reliability of the


weighting system proper
maintenance and proper calibration

Page 29 of 37

schedule
Calciner automatic
control

No

To repair control system

Kiln primary air blower


pressure indicator

No

To install digital pressure meter and link


to PLC

Kiln primary air blower


motor current indicator

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

The Heat and Mass balance of 3# kiln

The cooler air distribution of 3# kiln.

The false air evaluation of 3# kiln

The plant update study of 3# kiln

Mass and Heat


Balance

Cooler air
distribution of QJP

PH False air
calculation

Plant update
study of QJP

2006 report on precalciner survey

The measurement data of 3# kiln

Page 30 of 37

Measurement data
of QJP

The cooler bed depth of 3# kiln..

Cooler bed depth


of QJP

B.7. Appendices
Table 3
Item

QJP 3# kiln main equipments basic data


Unit

Designed

operating

Kiln output

t/d

996

1100

Kiln speed

rpm

3.2

3.4

Kiln main motor

kw

160

97

Main burner coal rate

t/h

1.5~5

2.9

Precalciner burner coal rate

t/h

2~8

6.0

Vacuum filter output

t/h

402

89

Dry-crusher output

t/h

80

PH IDF volume flow rate

M3/h

220000

PH IDF pressure

Pa

9800

PH IDF inlet damper

95

PH IDF speed

57

PH IDF main motor

kw

1000

865

Kiln EP inlet volume rate

M3/h

250000

298345

Kiln EP fan volume rate

M3/h

233730

302714

Kiln EP fan pressure

Pa

1934

Kiln EP fan main motor

kw

220

Kiln EP fan inlet damper

100

Kiln EP fan speed

100

Cooler grates area

M2

26.7

1# chamber fan volume rate

M3/h

13270

1# chamber fan pressure

Pa

7540

1# chamber fan damper

2# chamber fan volume rate

M3/h

35000

2# chamber fan pressure

Pa

5370

2# chamber fan damper

3# chamber fan volume rate

M3/h

45300

3# chamber fan pressure

Pa

2597

Page 31 of 37

23780

195

15186
100
35498
100
27898

Remark
3.554m

160

160

3# chamber fan damper

90

4# chamber fan volume rate

M3/h

62400

4# chamber fan pressure

Pa

1715

4# chamber fan damper

Inlet clinker temperature

1371

Outlet clinker temperature

65+ambient

Cooler EP inlet temperature

200

Cooler EP inlet volume rate

M3/h

160000

Cooler EP fan inlet temperature

300max.

Cooler EP fan inlet volume rate

M3/h

160800

Cooler EP fan pressure

Pa

2000

Cooler EP fan inlet damper

100

Cooler EP fan speed

74

Cooler EP fan main motor

kw

43258
75
110~210

150

155

123

Table 4 Main process operation data


Item

Operation data

Item

Operation data

Slurry moister (%)

19

Slurry feeding rate(t/h)

89

Coal fineness(%, 0.08mm sieve


residual)

8.8

Slurry
fineness(%,
sieve residual)

0.08mm

Coal fine moister (%)

1.1

Coal LHV (kcal/kg)

5726

kiln inlet temperature ()

996

Kiln inlet O2 (%)

Kiln inlet CO (ppm)

Kiln
inlet
decarbonisation (%)

Kiln inlet material temperature


()

843

Kiln inlet pressure (Pa)

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

C1 outlet pressure (Pa)

-2600

Dry-crusher
()

Dry-crusher outlet temperature


()

370

PH IDF inlet temperature ()

167

PH IDF inlet O2 (%)

10.6

PH IDF inlet CO (ppm)

1038

PH IDF inlet pressure (Pa)

-838

Kiln EP inlet temperature ()

169

Kiln EP inlet pressure (Pa)

320

Kiln EP inlet O2 (%)

9.6

Kiln EP inlet CO (ppm)

2375

Kiln EP fan inlet temperature ()

160

Kiln EP fan inlet O2 (%)

10.6

Kiln EP fan inlet CO (ppm)

1740

Page 32 of 37

inlet

material

temperature

79

543

Cooler outlet gas temperature


()

270

Clinker temperature in cooler


outlet ()

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%

Chart13 QJP Process Measurement

SO2 from crusher


T

200
C

CO

3836

Pst

-48

NOx

585

O2

C2 outlet gas duct

8.4%

832C

CO

4964

Pst

-13.9

NOx

855

O2

2.9%

C1 outlet gas duct


T

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

Tertiary air temp

Calciner to C2 gas duct

750 C

150 C

Pst

- 9.9

Cooler waste gas


To coal mill

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

Hot gas to coal mill

NOx

391

491 C

Pst

-10

210 C

Chart 14 Measurement flat without safety railing

Chart 15 No safety protection screen on bleed air damper of cooler exhaust gas duct

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Chart 16 No safety protection screen on bleed damper of hot gas to coal mill gas duct

Chart 17 The cables on floor

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Action table from 2006 audit

Table of actions

No.

Action

Priority

Proper step or ladder for the measurement points should be installed;


some handrails must be installed also.

Safety

Alarm marks should be fixed on the Preheater concrete beams


overhead the accesses

Safety

Gangways on the scaffolding optionally must be carried away to keep


from falling down.

Safety

The Kiln Feed Fluctuation has to be reduced to +/-1% from 40%.


4

Improve vacuum filter performance to reduce the feed material quantity


and quality deviation.

Install thermocouples at Precalciner bottom, middle, upper and kiln inlet.


Cross-check Preheater manometers and thermocouples regularly to
achieve more uniform combustion and decarbonatation

Increase O2 in preca by reducing inleakage and install proper


instrumentation

Improve drying crusher air sealing and weld or change duct to reduce
false air

Control KFUI <14

10

11

Calciner Coal fluctuations to PC to be studied in detail, after


stabilisation of Kiln Combustion (ATC) :Is Coal Transportation
Velocity OK, Is the fluctuation because of Calciner Temperature,
Burner design to be checked
Increase #3 ID Fan, EP Fans & #1 ID Fan from 45% to 65% in
consultation with the Fan experts to reduce 8-9 Kwh/t kk

2006 precalciner audit

QJP Preca July


2006

QJP July kiln


7 day report

7 day report : audit

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