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ATC
SMO / 02/09/2008 - 1
Review
Production
Heat Consumption
Power Consumption
Efficiency
Benchmark
Past performance
Supplier guarantees
Type of equipment / system
Anticipated performance
SMO / 4-Jun-2007 - 2
Calculation tools
Data from other plant audits
Result Interpretations.
Report writing
Reference documents
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No. of stages
No. of strings
Whether In line calciner / separate calciner / AS / AT
Type of calciner: Low NOx / hot point etc.
Cyclone sizes
Calciner dimensions with sketch (showing firing / feed /Tertiary air entry point locations)
Feeding arrangement (air lift / bucket elevator)
Kiln
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Supplier
Supplier product code (e.g. FLS COOLAX 1284)
Type (Conventional chamber aerated / Beam aeration etc.)
Type of inlet (e.g. Fixed)
No. of Grates
Dimensions (width x Length)
Effective Grate area
No. of compartments
No. of fans (Specify v-belt / direct drive, variable / fixed speed)
Enclose sketch showing grate plate layout with aeration arrangement
Vent air de-dusting arrangement (ESP, Heat exchanger + Bag filter)
Emergency cooling arrangements (fresh air / water spray)
Cooling air & Vent air fan specifications
Tertiary air take-off point (through kiln hood / separate)
Dust Settling Chamber in tertiary air line?
Any hot air tapping (for raw / coal / cement mill)
Under-grate dust collection arrangement (drag chain / hoppers with
pneumatic gates)
SMO / 4-Jun-2007 - 5
Miscellaneous
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Inputs
Kiln Feed
Fuel, as fired
Moisture
Fineness (Residues on 90 and 212)
Temperature
Heat value
Proximate analysis
Ultimate analysis
SMO / 4-Jun-2007 - 7
Outputs
Clinker
Temperature
Sieve analysis
Free lime
Liter weight
LOI
Chemical analysis (incl. Minor oxides)
Microscopy
With in Process
Bottom stage exit material
LOI
Temperature
Chemical analysis (incl. minor oxides)
Un-burnt Carbon
SMO / 4-Jun-2007 - 8
Sample
Kiln Feed
Fuel
Clinker
Dust from Preheater
PH bottom stage cyclone exit material
collection frequency
Every 2 hour
Every 2 hour
Hourly
2 samples
2 samples
Temperature
Static Pressure
Flow
Gas analysis (O2, CO, CO2, SO2, NOx)
Dust concentration
Calciner exit
Temperature
Static Pressure
Gas analysis (O2, CO, CO2, SO2, NOx)
Kiln
Kiln inlet
Temperature
Static Pressure
Gas analysis (O2, CO, CO2, SO2, NOx)
Cooler
Cooling air
Flow
Temperature
Pressure (at fan outlet, for each individual duct after flap damper)
Secondary air
Temperature
Kiln hood
Pressure
SMO / 4-Jun-2007 - 12
Mass flows
Power
Kiln Feed
Clinker (by drop test)
Preheater exit dust (by drop test)
Fuel to Kiln
Fuel to calciner
Kiln main drive
Preheater fan
Cooler vent fan
Individual cooling air fan
Total shop
Surface temperatures
Kiln shell
All components of preheater (cyclones incl. risers, material pipes, smoke chamber,
kiln riser pipe, calciner vessel)
Tertiary air duct
Kiln hood
Cooler walls
Remember! Always specify emissivity set in pyrometer for temperature measurement
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Remember!
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Kiln Speed
Preheater fan speed & damper opening
Tertiary air duct damper position
Cooler grate speeds
Cooler under-grate pressure (way of calculation)
Ratios used for grate-2, 3 speed w.r.t. grate-1 speed
Individual cooler fan speed, damper opening
Cooler vent fan speed, damper opening
If SLC kiln, feed dividing gate (at PH Top) position
Material dividing gate position for material diverted to kiln riser
Primary air fan speed, damper opening
Any other relevant parameter
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SMO / 4-Jun-2007 - 17
Air Distribution
Compare cooler flows w.r.t. recommended
K factor
Recovery ratio
Cooling efficiency
Cooler loss
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380oC
330oC
300oC
<14
< 0.11
8% of Kiln feed
80 mmWG
60 mmWG
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760 - 780
720 - 730
690 - 700
Power Consumption
kWh/t cli.
Preheater fan
Cooling air fans
Cooler vent fan
6.5
5 5.2 (beam aeration w/ fixed speed fans)
0.6 0.8
Cooler Performance
Conventional
K-Factor
Recovery ratio
Sp. cooling air (Kg/Kg cli.)
3.0
Beam aeration
> 1.5
> 70
2.5 2.6
2.3
SMO / 4-Jun-2007 - 20