7 Most Common Problem in Pyro Processing

for Kiln and Cooler

Cyclone Blockage

Kiln inlet Blockage

Big clinker ball formation

kiln Coating

Feed rushes and dusty kiln

Cooler Snow Man

Red river in clinker cooler

Main Reasons for Cyclone Blockage

Insufficient suction due to low rpm in PH fan.
Flap valve failure & blockage in material pipe.
Refractory failure.
High Iron % in Raw mix.
High Sulfur % in fuel(i.e- coal)

Main Reasons for Kiln Inlet Blockage

High Iron % in Raw mix.
High Sulfur % in fuel(i.e- coal)

Main Reasons for big size clinker ball formation

 High Iron % in Raw mix.
High Sulfur (S)% in fuel(i.e- coal).
Kiln running with slow rpm & % filling is more.
High BZ temperature.
% liquid is more.
Higher % of Magnesia (MgO).

Main Reason for heavy coating formation in kiln

High Iron % in Raw m
High Sulfur (S)% in fuel(i.e- coal).
Kiln running with slow rpm & % filling is m
% liquid is m
Higher % of Magnesia (MgO).

Main Reason for Feed rushes and dust kiln

High lime in Raw mix or high LSF.
Very less % of liqui
High A
Less iron% in raw m
Blockage of hot meal due to clinker ball occasion

SNOWMAN FORMATION IN COOLER

Higher % of liquid, may be iron % is more in raw mix so hot meal will be
sticky and viscous.
Shorter cooling zone; so may be shortage of adequate quenching .
Higher BZ temperature, may be due to short flame.
Failure of air blaster in cooler 1st grate if any.
RED RIVER IN COOLER
Uneven distribution of cooling air
Misalignment of kiln & cooler

10 Difficult Problems about Raw Grinding with Vertical

Roller Mill Systems and their solutions
First : High vibrations
Potential causes:
Too many fines in mill feed
Material bed on grinding table not stable
Proposed solutions:
Increase feed size
Adjust crushers
Maybe eliminate a crusher

Expected results:
Less vibrations
Less fine fractions in mill feed
Lower crushing costs (energy, wear, maintenance)

Estimated costs:
Minimal

Implementation time:
Short-term

High amount of false air

Potential causes:
Defects on external seals

Proposed solutions:
Improve maintenance

Expected results:
Improved drying of mill product
Reduced specific power consumption (fans)

Estimated costs:
Minimal
Implementation time:
Short-term

Dynamic seal not working effectively

Potential causes:
Seal space too big
Possible damages on seal

Proposed solutions:
Improve maintenance (check status of seal more frequently)
Repair damages

Expected results:
Less coarse mill product
Reduced specific power consumption

Estimated costs:
Minimal

Implementation time:
Short-term

Mill exit temperature too low

Potential causes:
False air
Damper positions

Proposed solutions:
Reduce damper between conditioning tower and filter
Reduce damper of re-circulation air flow
Expected results:
Less humidity in mill product
Lower temperature in filter

Estimated costs:
Minimal

Implementation time:
Short-term

Roller pressure too low

Potential causes:
High vibrations
Pressure adjustment does not follow wear

Proposed solutions:
Train mill operators
Adjust pressure periodically

Expected results:
Increased feed rate and higher production
Reduced specific power consumption

Estimated costs:
Minimal

Implementation time:
Short-term

Air speed variations in mill

Potential causes:
Cone design
Inclination of nozzles

Proposed solutions:
Redesign cone
Adjust inclination of nozzles (35 to 60)

Expected results:
More uniform speed increase
Less material falling through nozzle ring
Reduced specific power consumption

Estimated costs:
Minimal

Implementation time:Mid-term

Material distribution on grinding table not optimal

Potential causes:
Feed chute too short

Proposed solutions:
Prolong feed chute

Expected results:
More stable material bed
Less vibrations

Estimated costs:
Minimal

Implementation time:Mid-term
Grinding tools with high wear
Potential causes:
Recommendation of equipment supplier

Proposed solutions:
Investigate alternative (better) grinding tools

Expected results:
Prolonged lifetime of grinding tools
Reduced specific grinding costs

Estimated costs:
Medium

Implementation time:Mid-term

Manual operation
Potential causes:
Original installation not improved

Proposed solutions:
Investigate possible automation

Expected results:
More stable operation
Reduced specific costs of milling

Estimated costs:
High

Implementation time:Long-term
Material falling through nozzle ring
Potential causes:
Original installation not improved

Proposed solutions:
Install external material circulation

Expected results:
Less cleaning necessary
Environmental aspects improved

Estimated costs:
High

Implementation time:Long-term