Cyclone 5 blockage report

Before kiln stopped due to cyclone 5 blockage at 23:55 pm .there was another stoppage for
kiln at 17:17pm – 17:48 pm due to main burner coal dosing system tripped.kiln start feed
with heavy oil in main burner and coal in precalciner . As appear in following trend
After kiln feeding cyclone 5 gas temperature was in the range from 860 celecius to 900
celecius until shift end as appear in trend
Main reason for cyclone 5 blockage
First: no problem in material chemistry as appear in lab analysis
 Kiln feed analysis
 Clinker analysis
 Hotmeal c5
 Bypass analysis
At 22/2/2019 I sent report about kiln optimization in which I take in details about
preheater situation. At 24/2/2019 sent another report about ID fan situation. In both report
I mention the following

1. Degree of Calcination
Degree of calcination of hot meal samples maintained at C5 was very high at 98 -99 %
against the normal range 95-96 % gas temperature.

2. Material flushing:
It was observed from CCR that there are fluctuations in cyclones cone draft It indicates the
material may be accumulation in cyclone 5 duct resulting in flushing of material in kiln-
cooler system. This may be one of the reasons for dusty kiln condition.

3. CYCLON 5 FLAP GATE

Always C5 flap gate found stack and feed pipe above and under flap is coated this is may
be fixed flap make some kiln inlet gas take direction of C5feed pipe may let to coating and
high C.D

4. ID FAN SPPED
ID fan ampere is reaches max ampere with sharp fan speed foll down without any change
in fan speed set point which effect cyclone material pressure as it appear in following
trend this happen 5:09 pm
 5. Calciner coal dosing system
Feeding rate t/h for calciner dose have fluctuated which make cyclone 5 gas temperature
fluctuated the evidence for this calciner coal blower ampere which changed without
change of coal federate set point it need online calibration after as schenck supplying
company recommended o .the following trend appear that from one month ago kiln
running with cyclone 5 gas temperature out of range